Paper Mill Thermocouple Monitoring System using NI CompactRIO
The Challenge
Our customer wanted to measure the temperature of steam tubes located inside its utility boiler to make sure start-up conditions were met. The customer also needed to quantify and analyze temperature changes inside the boiler during normal operation so it could use that information to trigger the operation of other equipment and interlocks.
The Solution
To identify and quantify temperature conditions inside its boiler, the customer needed a system that could a) log temperature measurements, b) transfer these data files to a remote computer, c) perform complex measurements at high speeds and d) output results to a web page.
To accomplish this, ITM developed and installed a measurement and control system consisting of two cRIO-9046 Controllers and two NI 9144 EtherCAT chassis containing 19 NI 9214 thermocouple modules. This system could monitor signals from 280 thermocouples. We deployed a LabVIEW™ RT application that would determine if certain temperature conditions were met inside the boiler. When these events occurred, the system then used the NI 9485 relay module to control other equipment and interlocks.
The System
- NI Hardware: cRIO-9046 (x2), NI 9144 (x2), NI 9214 (x19) and NI 9485 (x2)
- Third-Party Hardware: Type K Thermocouples
- Software: Embedded LabVIEW™ RT Application
- DCS & PLC Communication Options: Modbus, OPC UA, PI UFL Connector & EthernetIP
Conclusions
The remote monitoring system ITM developed operates as a watchdog to ensure that the boiler is operating under normal conditions. It also works to reduce downtime and to reduce the risk of damaging the boiler systems during normal operation and start-up periods. The temperature measurement system was so effective that our customer plans to deploy this system on more of its utility boilers throughout the enterprise.
Author Information: For more information on this Case Study or ITM’s other monitoring solutions and testing services, contact: Mark Yeager – Integrated Test & Measurement (ITM), LLC – mark.yeager@itestsystem.com
Monitoring critical process temperatures? Our engineers can design a custom thermocouple or sensor network for your facility.
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