Research and Improvement of Water Heating Boiler Automation System
Students Name: Zheplinskyi Dmytro Ihorovych
Qualification Level: master (ESP)
Speciality: Automation and Computer-Integrated Technologies
Institute: Institute of Power Engineering and Control Systems
Mode of Study: full
Academic Year: 2022-2023 н.р.
Language of Defence: ukrainian
Abstract: Zheplinskyi, D.I., Lesovoi, L.V. (supervisor). Research and Improvement of the Automation System for a Water Heater Boiler. Master’s Thesis. Lviv Polytechnic National University, Lviv, 2023. Extended Abstract: In the modern world, issues of energy efficiency and operational safety are becoming increasingly relevant. One way to reduce energy costs is by using water heater boilers with an automated control system. However, existing automation systems do not always provide efficient and safe boiler operation. Ukraine is currently in the phase of the fourth industrial revolution, characterized by full automation of all production processes in real-time. The fourth industrial revolution is the latest and most advanced phase of industrial development, which started in the 2010s. It involves widespread use of digital technologies such as artificial intelligence, the Internet of Things, smart manufacturing technology, 3D printing, etc. These technologies enable process automation, the development of "smart" factories that can operate without direct human control, and help increase productivity, reduce production costs, improve product quality, and minimize environmental impact. The fourth industrial revolution also has a significant impact on the development and automation of water heater boilers. This master’s thesis is dedicated to the research and improvement of the automation system for a water heater boiler. The work analyzes and evaluates current issues related to the energy efficiency and safety of water heater boilers, and identifies the key requirements for automation systems of water heater boilers. Many existing automation systems for water heater boilers have limitations in regulation since the temperature profile of the boiler is not programmed into the boiler system, and operators constantly need to manually adjust the water temperature settings, resulting in gas overconsumption when changing the outdoor temperature or insufficient heating temperature for consumer needs. Another limitation is the lack of a modern SCADA system and a human-machine interface for visualizing all boiler parameters and quickly changing boiler operation modes. Therefore, this master’s thesis includes the modernization of the automated control system for a water heater boiler. During the examination of the boiler installed at the enterprise KP "Borislavteploenergo," several drawbacks were identified, namely the use of an unreliable controller from the company OVEN and the absence of an HMI panel for a computer-integrated automation and monitoring system of the water heater boiler. To improve the boiler, a freely programmable controller Siemens SIMATIC S7-1500 was utilized, allowing for real-time adjustment of the regulation process based on demand. As a result, a new operating algorithm was proposed, an SCADA system was developed, and an HMI panel was implemented for a computer-integrated automation and monitoring system of the water heater boiler. Such a system enables real-time monitoring of the boiler’s condition and prompt response to any deviations in operation. The research object is a water heater boiler used for centralized heating supply to the population. The research subject is the improvement of the automated control system for a water heater boiler used for centralized heating supply to the population. The goal of the research is to develop and implement effective measures for improving the control systems of water heater boilers, ensuring optimal use of thermal energy and creating a modern process control system. This work selects and analyzes the chosen technical means of automation, and a program for the functioning of the Siemens S7-1500 controller was developed. The functional diagram of the automation process, the electrical connection switching diagram, the SCADA system, and a specification of the technical means of automation were developed. Calculation and modeling of the automatic temperature control system for the water leaving the water heater boiler were performed. A conclusion is made for the Master’s Thesis (MT). Keywords: water heater boiler, automated control system, monitoring