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Monitoring and Control Solution - Worcester Polytechnic Institute

1. 6 1 2 Configuration 6 1 3 Monitor 6 1 4 Alarms 6 2 Web Page 6 3 Historic Web Site 6 4 Building a Test Environment Chapter 7 Conclusion 7 1 Possibilities amp Limitations of Change 7 2 MQP Experience References Glossary Appendix located in confidential folder Appendix A Bill of Materials Excel Appendix B Panel Infrastructure Diagram PDF Appendix C Panel Ladder Diagram 1 PDF Appendix D Panel Ladder Diagram 2 PDF Appendix E PLC Code Visilogic Appendix F PLC Web Page Code HTML Appendix G Stress Testing Results Excel Appendix H User Manual Word 42 48 50 52 54 oT 57 58 58 59 60 List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Natural Gas Plant Pipe Structure Heat Trace Cable Modern PLC Lost Profit of Running Heat Trace Wired vs Wireless Costs MQP Work Plan Gantt Chart Data Flow Diagram of the Monitoring amp Control System Map Diagram of the Monitoring amp Control System PLC Code Circuit Probe Table PLC Code Scan Sequence PLC Code Monitor HMI Screen PLC Code Alarm Configuration PLC Code Output PLC Main Options Screen IT Configuration Screen Password Circuit and Probe Configur
2. www naturalgas org naturalgas processing_ng asp 2 1 2 Background of Heat Trace Heat Trace is a term used frequently in the industrial world representing thermal cables It is derived from the term heat tracing which is the process of installing thermal cables onto an object to maintain a specific temperature Heat trace cables were invented in the mid 1900s the exact date is unknown as various companies invented their own type of heat trace Today there are various types of heat trace available The three main applications of heat trace are Freeze Protection Roof amp Gutter De Icing and Hot Water Maintenance Freeze protection is the broadest of the applications as it can include pipes turbines computer hardware motors etc The most common is pipes containing liquid or gas Figure 2 is a diagram of a typical pipe structure Pipe wall Air gap Insulation Air gap Weather Borrier Figure 2 Pipe Structure 12 Most pipes come with a considerable amount of insulation to prevent heat loss but during freezing ambient temperatures the insulation is not enough to keep it at a desired temperature especially if the pipe has to be shut off for a given period of time Heat trace cables like the one shown in Figure 3 are installed directly onto the pipe wall Figure 3 Heat Trace Cable To install heat trace a worker will have to access an opening or create their own through the weather barrier and insu
3. Navigate through circuits by clicking these 2 arrows Enter Circuit 1 Click here to change the circuit name Battery amp Communication indicators only BATTERT OK Click here to change probe names Click here to change Exp Amps or Amp Alarm setpoint Click here to go back to the Main Screen Figure 18 Circuit and Probe Configuration Screen KEI ee a SIGNAL OK CUIT BLED Output OFF Click on this button to Enable or Disable a circuit Click here to Save any changes you have made This is here to only indicate if the Output is ON or OFF Click here to change the Probe IDs which is NOT recommended This is here to only indicate temperature and amperage readings Click here to go to the second Configuration Screen Note when the CMI Module is deployed at a Customer Site all Circuits being monitored will be pre configured with the following information 1 Circuit Name which will include the Site Circuit Number if it does not correspond to the Circuit Position Number in the HMI Module 2 RTD Sensor Name Probe Name up to 3 allowed per Circuit 3 RTD Sensor Device ID Number Each RTD Sensor must have a unique ID for the wireless mesh network to operate correctly 4 Expected Amp reading for the Circuit This is an estimated value based on the characteristics of the Heat Trace on the Circuit 43 The Circuit Configuration Screen is used to make changes
4. the customer Wireless transmitters located throughout various parts of the power plant collect temperature readings from their attached RTDs and send the readings to the Gateway wirelessly The Gateway then passes this data to the PLC via a wired connection within the Panel Enclosure The PLC also collects GFI and Amperage readings from the CTs which are looped through the power connectors that attach to the Heat Trace Circuit Box each looped wire represents the power coming from one Heat Trace Circuit The PLC also collects alarm and output set points from the customer either through the PLC HMI screen or through the Remote Operator Utility which simply brings the PLC HMI screen to their PC Desktop Based on the actual temperatures and the associated set points the PLC will either turn the Heat Trace relays ON or OFF The PLC will organize this data into its Web Server which the customer can access on their PCs via the LAN Finally the PLC exports its data to the Sponsor s server every six hours where it is organized into a database and hosted onto a web site for the Customer to browse 32 Appendix B is the Panel Infrastructure Diagram which lays out the actual design of the Panel Enclosure in which the PLC is attached to the Gateway CTs Relays Ethernet Switch and its own I O Units Appendices C amp D are the electrical ladder diagrams for the Panel Enclosure 5 2 PLC Code The PLC code is written in the Ladder Logic pr
5. 5 has 3 amps below the set point it will show the actual amperage number highlighted in red 5 4 Database amp Historic Page Design The PLC will export its data via data tables every 6 hours Meanwhile the sponsor will run a program that accompanies Visilogic called DataXport which simply listens for incoming calls from the PLC and then collects the data tables It will reach the sponsor s server in a csv format and then be placed into a simple database The ordering of the placement will be based on the first two columns which are date and time The database which will be programmed in Unix will be follow the same exact structure as the data tables i e same columns but with an unlimited amount of rows representing data intervals every 5 minutes The sponsor will then host a web site based on the database The Historic Web Site will allow the customer to view historic data and trending The main tab will be Raw Data which will simply ask the user for a time amp date frame and then display the data in a table for them There will also be an additional three tabs which will show either temperature amperage or GFI for a specific circuit for a given time range and also create a line graph for the data This will allow the user for example to see the amperage output for a specific circuit over a period of time and perhaps trouble shoot an amperage problem 40 Chapter 6 Implementation The PLC Code Web Pa
6. Heat Trace Another way that power plants will profit from this solution is that it is wireless Most power plants have engineers and electricians that could potentially create an in house wired solution to monitor their heat trace But the cost of just the wiring for such a solution is over 40 000 on average Additionally the wires and conduit would take up a lot of space and clutter the plant which is a problem Our solution is more complex due to the wireless aspect but cheaper to implement and takes up less space Figure 6 below is a comparison chart of the costs of a wired solution vs a wireless solution 20 Costs to Install Control amp Monitoring System Dymocon Wired Wireless Points of Control amp Monitoring 20 20 Hardware Costs System 27 200 00 36 866 00 RTD s 2 100 00 included 20 x 105 RTD extension wire N A 3000 x 0 70 configuration programming 2 000 00 included 1 manhour x 20 x 100 labor to install conduit to RTD s 40 920 00 N A 13 64 ft ave x 3000 ft 13 64 for simple 23 36 for difficult install labor to wire into Distribution Panel 1 120 00 16 manhours x 70 Total installed Cost 7544000 O amo Figure 6 Wired vs Wireless Costs With this solution power plants will be able to locate and diagnose heat trace cables without having a maintenance electrician do it annually There are two downsides to having a maintenance electrician come once per year and check the
7. PLC allows the user to define a low amperage alarm set point e The PLC allows the user to define a low amperage set point e The PLC allows the user to define a GFI alarm set point e The PLC allows the user to disable or enable any specific circuit which will forcefully stop the output of the PLC to that circuit e The PLC allows the user to clear inactive alarms from the HMI screen including a GFI circuit trip which will forcefully stop the PLC output if not cleared PLC Output e The PLC will send a 24 volt output signal to our System Relays which will turn on a specific heat trace circuit This will happen only when the specific circuit is enabled by the user and the temperature has dropped below the user defined temperature set point PLC Alarms e When an alarm occurs a flashing red beacon will appear on the PLC HMI screen The PLC will contain nine alarms in total o Probe Communication Failure indicates that a Wireless Transmitter connected to an RTD has lost connectivity with the System Gateway When this alarm occurs the temperature readings for that circuit will become 0 until communication is re established o Gateway Communication Failure indicates that communication between the System Gateway and the PLC has failed By default this alarm will turn all circuits to on o Battery Low batteries on a Wireless Transmitter are below 3 volts and need to be changed to avoid a Communication Failure o GFI Warning gen
8. Programmable Logic Controller is a digital mini computer that gathers inputs and controls outputs The first PLCs appeared in the 1960s to improve the automobile industry by controlling the outputs of relays based on imbedded timers located inside the PLC Instead of somebody walking around the factory to switch relays on and off the PLC would do it automatically PLCs were initially preprogrammed using machine based language which was not easily changed or modified During the 1980s PLC operating systems were upgraded allowing users to connect computers to the PLC and download new programs The language used in PLCs is ladder logic which was supposed to replicate concepts of an electric circuit board design allowing electric engineers to easily learn it Now due to the complexity of PLCs even electric engineers will have to go through some training to program them During the late 14 1980s Human Machine Interface HMI screens were added to the PLCs which gave users more options than just set patterns and procedures Users could now adjust functions with the click of a button History of the PLC 2006 The modern PLC is complex and can perform a wide variety of functions Some of these functions include web server hosting data storage data exporting data importing TCP IP Ethernet communication remote access utilities intricate alarm functions etc There are multiple PLC manufacturers the most common being Alan Bradley ab
9. a specific probe Moving down you will find a small note reminding the user that the panel is not in control of the heat trace yet by request Below that is a red alarm indication box this box disappears when there are no active alarms Below the alarm box you will find the monitoring screen table The first column simply states the circuit number The second column states whether the user has Enabled or Disabled a circuit the user may disable a circuit to forcefully stop all of the output coming from that circuit even if the conditions call for power however alarms will still be active during this time The 53 third column is called Circuit Activity and simply indicates if our CMI Module is trying to turn a heat trace circuit on for example in the screenshot above Circuit 2 has a temperature below the set point so it is calling for power to turn that heat trace ON as opposed to Circuit 1 which has a temperature above the set point and does not need to call for power to turn the heat trace on The Circuit Description is simply the name of the circuit The 3 Probe Temperature columns either list the actual temperature or will say no probe if there was nothing configured at that location If a Probe Temperature cell is highlighted red this means it is either below the cold set point or above the high set point note that if the reading is directly on the set point it will still activate an alarm Als
10. companies such as propane gas The most common by products to be removed from natural gas are oil water sulfur and carbon dioxide Gas power plants use a series of pipes to transport the natural gas from each station of by product removal until ultimately the gas is ready to be converted into energy at a gas turbine Sometimes plants will use a combined cycle in which the heat exhaust from the gas turbine is then sent across pipes full of water into a Heat Recovery Steam Generator HRSG which then uses the resulting steam to turn another turbine that produces electricity The pipes that connect to and from the HRSG need to be kept above freezing otherwise condensation will freeze when the pipes are not active and then expand and damage the pipes when they are turned on If the pipe bursts due to this it will cost the plant hundreds of thousands of dollars The overall process of burning natural gas into energy emits fewer harmful chemicals into the air than oil but also has a more complicated cycle of purifying Most natural gas plants will have an overwhelming amount of pipes Instead of going through the trouble of monitoring them all they will simply run their heat trace continuously which is expensive and inefficient Figure 1 shows a natural gas plant illustrating how complex their pipe line system is Processing Natural Gas 2011 Energy Justice Network 2011 11 Figure 1 Natural Gas Plant Taken from http
11. heat trace cables Each year it will cost the plant about 5 000 Also if a heat trace cable malfunctions in between the visits it could either slowly burn out and draw more energy or it could break and put their equipment at a very high risk Preserving the life of the heat trace itself is another value to plants By running the heat trace only when it is needed it will increase the life span of the cables which can save the plant thousands of dollars The application will monitor the amperage of the heat trace thus notifying the plants when a cable is starting to burn out so they can replace or fix it at the right time 21 The most prominent business value that plants will receive from this solution is the sense of security that it provides Plant operators will be alerted as soon as a heat trace cable malfunctions so they can act before a freeze occurs Even if no problems arise the energy savings will pay for itself in two years An average sized 2 Unit plant will lose a little over 52 000 due to power consumption This application will cost the plant about 70 000 Therefore the system will repay itself in 1 35 years on average 3 2 Feasibility Analysis A feasibility analysis was conducted to determine if the solution was possible with our current resources It analyzes our familiarity with the application and tools our staff budget and the amount of training if necessary The results are below Technical Fe
12. iS MAIN CIRCUIT 1 gt MONITOR MI 315 0 Num To ASCII A 15 ALARMS g g PROBLEMS E cT g SJ ee INACTIVE ALARM ms yds Trendi Trend Trend3 064 EN ENO EN ENO Trends CIRCUIT Data Tables Trend Write Row TrendS pacar A ALARMAC Trend og poy m mas Dymo gon Use Only Not ta p Copied 19 Library MI B Stting_Libeacy_1 oe on Lo Swng lban EEE jooon MB 103 MB 1180 String_Library_3 AMPS ALARM AH Amp Low Figure 14 PLC Code Output 39 5 3 Web Page Design The PLC has an internal web server which may be used to create a web page The web page itself is to be written in HTML code and then uploaded into the PLC directly The objective of the web page is for the user to have a single monitoring page on their PC which they may use to view the functionality of their plant s heat trace system The design will be a tabular view of all the circuits that they have enabled The rows will represent each circuit while the columns will represent data values The columns from left to right will include Circuit number circuit status enable disable circuit activity on off circuit name probe 1 temperature probe 2 temperature probe 3 temperature temperature set point amps alarm set point amps actual GFI status communication status of transmitters and battery status of transmitters Values highlighted in red will represent that they have triggered an alarm So for example if Circuit
13. of Change This document will discuss what can be changed without additional programming and what can be changed with additional programming Large changes such as the implantation of different measurement tools will be estimated in terms of cost and time This will help our sponsor approach the possibility of custom solutions in the future 11 Professional Demonstration A professional demonstration will be performed at the end of the project for our sponsor with testing gear such as live heat trace cables and light bulbs to show the functionality of the solution Chapter 2 Literature Review The Literature Review chapter of this MQP will discuss the components of a Heat Trace System and the Systems Development Life Cycle This chapter will also discuss Gas Power Plants and Programmable Logic Controllers which are both related to Heat Trace Systems 10 2 1 Heat Trace System Components 2 1 1 Gas Power Plants Power plans that utilize natural gas to produce energy are the main customers that this MQP will service Natural gas is a gas that is primarily made of methane It is very combustible which makes it ideal for energy production Deposits of natural gas are located deep beneath the earth usually in close proximity with other fossil fuels such as oil Before natural gas can be used to produce energy it must go through a complex process of by product removal Some of the by products are useful and can be sold directly to other
14. rockwellautomation com and Omega omega com We have chosen to use Unitronics The programming software is supplied for free by Unitronics and is called VisiLogic Unitronics also supplies a free remote access software called Remote Operator and a free data import software called DataXport The Remote Operator works by starting the software on a PC establishing a connection between the PLC and the PC either with physical wiring or through an Ethernet server and then simply running the software The program acts like the PLC HMI screen allowing access to the PLC from a distance For the PLC to export its data a person must program this function into the PLC first and then the DataXport software must be running on a PC or listening for the PLC to call the IP address and export its data via excel format Figure 4 is a picture of the PLC that we are using in this project Unitronics V570 The HMI screen is a touch screen Vision570 2011 Figure 4 Modern PLC Taken from http www unitronics com Series aspx page Vision570 15 2 2 Systems Development Life Cycle SDLC Our heat trace system solution is essentially an information system we are collecting information presenting the information and controlling outputs based on information The Systems Development Life Cycle SDLC is the cornerstone for developing a new information system It contains four phases which will guide the development of this project Planning A
15. the user may use their PC to view a real time monitoring screen Lastly the data is also logged and exported from the PLC directly onto our server database to allow users to view organized historic data 1 5 Sponsor Deliverables This section will outline the components of the project that will be directly delivered to our sponsor Note that all of these components will also be included into the MQP report but mostly located in the appendix section Below is a list of deliverables 1 Cost Benefit Analysis This document will contain cost savings estimations including energy consumption preventive maintenance costs costs of downtime repair costs etc 2 Stress Testing Sheet This document will be initially created from the Patent Requirements and then expanded as the project nears completion It will include a series of test protocols for the solution to ensure that it is working flawlessly in every possible circumstance Located in the confidential Appendix Folder 3 List of Materials This document will contain a full list of materials used for the solution with specifications such as measurement ranges operation temperatures size dimensions etc Located in the confidential Appendix Folder 4 Bill of Materials This document will include the price and company names from whom we purchased our materials Located in the confidential Appendix Folder 5 Diagram of Physical Infrastructure This will include detailed drawing
16. those readings to the PLC I O via a 4 20 milli amp signal Each board contains four CTs each CT can monitor a single heat trace circuit e Ethernet Switch A simple Ethernet hub which connects the PLC to the LAN network e RTD Probes Resistance temperature detectors which are drilled into a pipe that needs to be kept at a certain temperature The RTD is wired directly to the Wireless Transmitter and sends the temperature reading to it 29 e Wireless Transmitter A battery powered device which collects temperature readings from the attached RTD Probe and wirelessly sends the reading to the System Gateway e System Gateway A device that collects data from its Wireless Transmitters every five minutes and then over writes that data when new readings arrive It can manage up to 50 transmitters and is wired directly to the PLC For the Monitoring amp Control Solution to function as a system all of the devices must work together Four distinct diagrams have been created to illustrate how the system functions The first diagram shown below in Figure 8 is a traditional Data Flow Diagram which summarizes the flow of data and how it eventually reaches the customer 30 Monitoring amp Control Solution DFD Power Plant Pipes with Heat Trace Temperature Value wired Customer Alarms amp Setpoint Collect temperature configuration readings via RTD wireless transmitter Historic data Temperature Value wirel
17. value performing a feasibility analysis developing a work plan and familiarizing myself with the equipment October e Week 1 Literature Review Bill of Materials Cost Savings Analysis November e Week 2 Physical Infrastructure Design amp CAD drawings e Week 3 PLC Code design for web page amp database e Week 4 PLC Code design for web page amp database e Week 5 PLC Code design for web page amp database December e Week 6 PLC Code design for web page amp database e Week 7 PLC Code Testing web page amp database testing e Week 8 MQP Report User Manual e Week 9 MQP Report January e Week 10 Revisions Demonstration Final Submission Week Tasks Literature Review Bill of Materials Cost Savings Analysis Tasks Physical Infrastructure Design amp CAD drawings Tasks PLC Code design for web page amp database Tasks PLC Code Testing web page amp database testing Tasks MQP Report User Manual Tasks Revisions Demonstration Final Submission Figure 7 MQP Work Plan Gantt Chart 25 Chapter 4 Requirements Analysis The Monitoring and Control Solution was built and programmed at the laboratory of the sponsor during the course of this MQP The system was built inside a fiberglass enclosure and brought to WPI for a demonstration at the end of this project There was no current system available to work from so everything was assembled and programmed
18. ET File Edit Connection Table Row Column deog SAA FA PO PSB E Be aw CIRCUIT PROBE TABLE l CIRCUIT PROBE TABLE E CIRCUIT NAME XP AMPS 0 f LOW ALAR MPS ACTUA PROBE 1 NAME PLID PROBE 2 d WI TEMP CURRENT DATA String 24 Integer Integer Integer String 24 Integer String DATA LOG 1 10 0 0 0 0 WTC DATA INIT CKT 1 3 1 0 Probe 1 1 Probe ALARM ACTIVE IDS CKT 2 3 1 ny Probe 4 4 NAME THIS WITEMPS ALARM CKT 3 3 1 o NAME THIS PROBE 0 NAME THIS Addresses CKT 4 3 1 0 NAME THIS PROBE o NAME THIS ue mrs I EET j es Data Tables Col Si E Folders CKT 6 0 0 0 2 Data Toe 28 Name THIS File Types CKT 0 0 0 Column AMPs ACTUAL 7 NAME THIS DATA LOG 11 20 CKT 8 o o o T NAME THIS ALARM HISTORY CKT 9 o 0 o gpa Met NAME THIS CKT 10 o 0 o z NAME THIS CKT 11 o 0 o T Fatt of project NAME THIS CKT 12 0 0 o Read only NAME THIS CKT 13 o o o NAME THIS CKT 14 0 0 0 Min 32768 NAME THIS CKT 15 o o o NAME THIS Max 32767 CKT 16 o o 0 s NAME THIS CKT 17 0 o o Fometvew Decma E NAME THIS CKT 18 o o 0 NAME THIS CKT 19 0 0 0 Number of elements 7 NAME THIS CKT 20 o 0 a NAME THIS Close Apply Help Figure 10 PLC Code Circuit Probe Table The next data table to be constructed is strictly for the wireless transmitters This table will hold all of the real time temperatures battery levels and communication status for up to 60 wireless transmitters Eventually these temperature readings are moved into the main Circui
19. FTO S OD G6 Dee Cormon Boolean Compwe Math Loge gt Store Vedia Stings Utils Omataties SD Com gt FB gt it vt arnout emase Ft ne 8003 t02 oaTacosams f lt PTET Pua poonoose MONITOR E PROTECT FREEZ SS PROTECT FREEZ PROTECT FREEZ E PROTECT GA E PROTECT TEMP a By suanms wA Me 2042 iE COMMUNICATIONS STEP 4 Probe 00 00 00 Function 4 MODBUS TCP oo lt n a GS CONFIG a E NOA STUFF fxm LA EMO 7 2 ee amp BIG ALARM SCRE 2 CONFIGURATION Ee CONFIGURATION ge CONFIGURATION 1 E2 CONFIGURATION MB 8003 MB 6005 STEP 4 Probe STEP 5 Probe Scan Scan DE pamm E eat good date scan Figure 11 PLC Code Scan Sequence 5 2 3 HMI Screens At this point it is time to start collecting user defined set points and displaying data via HMI screens The two main screens will be the Monitor and Configuration screens It is best to keep the general structure of these two screens the same so they user may navigate through them easily Both screens will display information for a single circuit and have a navigational bar at the top which may be used to move to the next or previous circuit The Monitor screen will contain all of the information that we are collecting for the customer temperatures GFI amperage IDs names and two other indicators The first indicator is the Circuit Enable Disable button which is only able to be pushed by the user in the C
20. MQP DMS 1101 Monitoring and Control Solution For Electric Heat Trace Systems Major Qualifying Project for Management Information Systems By Teodor Serbanescu 1 4 2012 Submitted to the Faculty of Worcester Polytechnic Institute In Partial Fulfillment of the Requirements for The Bachelor of Science Degree Table of Contents Table of Contents List of Figures Acknowledgments Abstract Authorship Statement Chapter 1 Introduction 1 1 What is Heat Trace 1 2 Request for Proposal 1 3 Project Origination 1 4 The Monitoring amp Control Solution 1 5 Sponsor Deliverables Chapter 2 Literature Review 2 1 Heat Trace System Components 2 1 1 Gas Power Plants 2 1 2 Background of Heat Trace 2 1 3 Programmable Logic Controllers 2 2 Systems Development Life Cycle SDLC 2 2 1 Planning 2 2 2 Analysis 2 2 3 Design 2 2 4 Implementation 2 3 SDLC Development Options Chapter 3 Planning 3 1 Business Value 3 2 Feasibility Analysis 3 3 Work Plan Chapter 4 Requirements Analysis 4 1 System Requirements Chapter 5 Design 5 1 Materials amp Physical Infrastructure 5 2 PLC Code 5 2 1 Data Tables 5 2 2 Communication amp Scan Sequence 5 2 3 HMI Screens 5 2 4 Set Points amp Output 5 3 Web Page Design 5 4 Database amp Historic Page Design Chapter 6 Implementation 6 1 HMI Navigation 6 1 1 TCP IP OCmWADAADATDNAUAAN A N A A A SP HPWWWWWNN NNN NN PR RR RR PrP rR RK KF ee BarFrododaAananrwWwwnwuoUonantrnwowuoanntnrtaanrt vndKere
21. Numeric Ee Graph 2 Wt a E EE RTC i ES Se Timer Counter af iim SD R Zoom A Tools Lf Display MONITOR G Links amp Jumps Alarm Properties MONITOR Links I Const Max Value lA Hysteresis ON e z Delay Resolution Seconds max delay 1 minute z Hysteresis OFF fo z Delay 1 Second x Alarm ID 5 Alarm Active Bit MB 45 AAB AMPS ALARM ee al Alarm Group Group 03 AMPS PROTECT Reset Bit Po A Descripti lired x Mee L Sing D E1 Creat Anos Low A E 7 r Activation Settings required m Properties When Trigger is as From Template No Template h Alarm Trigger TD 23 00 00 10 00 Alarm ID 5 Trigger Halll Require Heset Ran s i I Const Value jal i gt Regue Ack Fore Back A Critical ka Log to History Password up to 8 chars ss 2 Additional Info up to 4 lines each line up to 25 chars when using lindirect Text make sure to stay within these limits String ID 32 Heat Trace is on Circuit mps Actual are Below Tha Catenint Uant IV Show Jump To Display Button H wa Cancel Help Figure 13 PLC Code Alarm Configuration 5 2 4 Set Points amp Output After a user inputs a series of set points in the Configuration screen then presses Save the set point values will be saved to memory integers of the PLC and saved in the data
22. asibility Can I build it Medium Familiarity with Application High e I worked part time with Dymocon for one year creating databases for customers and other tasks non related to this MQP About eight months ago my employers and I discussed the possibility of creating a Monitor amp Control Solution and making it my senior project Since that time I have worked on the early stage foundations of this project This work was separate from my normal operation within the company and specifically geared towards the MQP During these early stages I learned the programming language required for this MQP which is Ladder Logic Familiarity with Technology Medium e In addition to learning Ladder Logic I attended seminars paid for by the sponsor and created test code for our lab PLC ranging from simple to complex operations This training was intended to prepare me to assess the feasibility of this project as my MQP e Ihave very limited experience with HTML code which will be used for the web page of the solution To mitigate this risk the sponsor s web consultant will help me develop sections of the webpage 22 e Ihave no experience with Unix systems but I do have experience with databases The sponsor s web consultant will help me implement a Unix database which will be used to store historic data from the PLC e have a basic understanding of wiring schemes and industrial equipment such as relays power supplies gate
23. ation Screen Circuit Selection Screen Number Pad Alpha Numeric Keypad GFI and Set point Configuration Screen Password Reset Screen Circuit Monitoring Screen Groups with Pending Alarms Alarms in Group Screen PLC Web Page CMI Data Raw Data Tab CMI Data Alarm History 12 12 13 16 20 21 25 31 32 34 36 37 38 39 41 42 42 43 45 45 46 48 49 51 52 53 55 56 Acknowledgments I would like to thank my project sponsor Timothy R Mullen for supporting and funding the Monitoring amp Control MQP I would also like to thank my MQP advisor Diane Strong for guiding me throughout the project and giving valuable tips and hints Special thanks to our sponsor s electrician Roy Sjolander for helping me build a test panel I would also like to thank our web consultant Richard Stearman for helping me create the web pages Abstract This MQP utilizes MIS principles to provide our sponsor with a fully functional monitoring and control solution for heat trace systems The solution collects real time industrial measurements displays the data via HMI screens stores the data via an electronic database and triggers out of range alarms The MQP provides savings for clients through more efficient energy usage Authorship Statement This MQP was conducted and written by me Teodor Serbanescu Roy Sjolander helped me build a test panel for the MQP module and Richard Stearman helped me write portions of the HTML
24. b which if selected will take the User to Figure 25 the Alarms in Group Screen The Reset Tab in each Group ID row is used to clear Alarms that have been Acknowledged and Resolved The Refresh Tab at the lower left corner will refresh the view to add any new alarms in the groups shown or add other Groups with alarms that may have developed while monitoring this view The ESC Tab in the upper right corner of the Screen will take the User back to the previous screen viewed The first Row of information in Figure 24 is for Alarm Group ID 01 the Serial Communication Alarm Group and shows that there are 2 Pending Alarms The Red Tab at the end of the row opens the Alarms in Group Screen shown in Figure 25 51 Group ID 0 Alarms in Group ID Time On Ack Alarm Name Details 000 f 15 00 12 N PROBE COMM FAIL 003 11 45 55 COM FAIL MESHGATE Refresh Figure 25 Alarms in Group Screen There are 2 Rows of information in Figure 25 one for each Pending Alarm Each row shows the Alarm ID the Time it was Initiated Time On whether it has been Acknowledged the Alarm Name and a Red Magnifying Icon Tab to drill down even further into the Alarm Detail Screen The alarm detail screen will show the time that the alarm occurred and what specific alarm it was i e amperage alarm 6 2 Web Page Figure 26 is a screenshot of the PLC Web Page The web page consists of only one screen with one pop up sub screen which w
25. ce The next phase of the code is to establish communication with first the PLC I O units which gather amperage and GFI readings from the CT Boards Then communication is established with the Gateway which gathers transmitter readings The type of communication parameter is called MODBUS TCP IP and is established through communication function blocks in the code Once that is successful memory locations must be assigned to the slots of the PLC I O which will store the real time amperage and GFI values in the PLC they are updated continuously A scan sequence must be created to gather the transmitter values The code will create a vector of 60 addresses with values from 1 to 60 and scan them one by one Each time it scans an address it will compare the value to those of the Probe IDs which originate from the Circuit Probe Table If the ID matches then it will access the Gateway registries and gather data from that specific ID Once the data retrieval is done it will continue scanning for the next Probe ID and then repeat the process All of the data is processed into memory locations and organized into the data tables Figure 11 is a screenshot of the code which retrieves the temperature reading and places it into a data table 35 HTS WS5 LABO 20111130 vip Unitronics VisiLogic OPLC IDE Ladder Application COMMUNICATIONS MODBUS TCP Broject Gat yew rwert Mid Connection adder HME Tools Heb OSHA DE Xin 9 ER FBO SS
26. ce e Heat Trace Life As mentioned heat trace cables have a life span before they stop working So for example if a heat trace cable if left on continuously for two years and then dies this would mean that if the cable was turned off during the warm seasons then during that time it could last up to four years instead Our system will utilize the run time of the heat trace based on temperature set points and increase the overall life of the cables e Replacing Heat Trace Without our system the user will have to play a guessing game in deciding when to replace their heat trace cables which is very risky Our system monitors the amperage and GFI of the heat trace output which will indicate when it is time to inspect or replace a heat trace cable For example if a heat trace cable usually outputs 13 amps and then over time outputs 8 10 amps this means that the cable is starting to burn out and needs to be replaced soon We will monitor these readings with the use of current transducers CTs which are relatively inexpensive e Accidents There are many possible ways for heat trace cables to be damaged most of which are unpredictable such as an inexperienced worker cutting one of them Our solution will provide plant managers with a greater sense of security knowing that regardless of what causes the heat trace to malfunction our system will detect it and report it before it accumulates into a bigger problem 1 3 Proj
27. chnical designs and implementations From that point on my paid IT internship had ended and I was working solely on the MQP project which was different from any of my previous work 1 4 The Monitoring amp Control Solution This MQP will create a unique Programmable Logic Controller PLC PC based application that will monitor and record wireless temperature readings on all circuit pipes the amperage that each heat trace cable is outputting and the Ground Fault Interrupter GFI of each cable The temperatures will be measured by Resistance Temperature Detectors RTDs directly attached to the pipes and our wireless transmitters This data will be sent wirelessly to our gateway which is then wired to our central PLC The amperage and GFI of the heat trace will be 8 measured by our Current Transducers CTs which are directly wired to our PLC as well The PLC also has the ability to control the system by turning on and off heat trace circuits based on a user inputted temperature set point If the actual temperature of the circuit is below the set point the PLC will turn the associated relay on which turns the circuit on Alarms are also created on the PLC letting the user know if a temperature amperage or GFI reading is below or above a set point The PC based component of this application is accomplished by the built in web server of the PLC which can create a webpage and host it on the power plant server So essentially
28. configured 1 GFI Warning Value For a 30 mA circuit this value will typically be set to 10 Any value from 0 to 999 can be entered here A Warning is generated if the mA value defined is exceeded This alarm is a Circuit level alarm 2 GFI Trip Value For a 30 mA circuit this value will typically be set to 30 Any value from 0 to 999 can be entered here An Alarm is generated if the mA value defined is exceeded This alarm is a circuit level alarm In addition to an alarm the system will shut the output off for that circuit until the user presses the GFI OK button 3 Temperature Set point F This is the temperature which must be maintained by the Heat Trace circuit during normal operation All Probes on the Circuit will be reporting temperatures at or above the Set point during normal Heat Trace operation If the actual temperatures fall below the set point the heat trace will turn on unless the circuit is disabled 4 Lo Set point F This is a temperature below the Set point temperature which indicates that the Heat Trace is not working or is not maintaining temperature at or above the Set point An Alarm is generated when this temperature is recorded by one or more of the Probes on a circuit This alarm is a circuit level alarm 5 Hi Set point F This is a temperature above the Temperature Set point which indicates that the Heat Trace is On and the temperature is above the Set point Abo
29. d 3 The Bottom of the Configuration Screen has an Active Alarms Beacon and Amps Expected Site User Defined and Amps Actual windows The Amperage Actual information is provided to help monitor the Status of the heat trace on each circuit and is provided by the CTs in the control panel for the CMI Module When Amps Actual is below Amps Expected the Solution will generate an alarm If Amps Actual is 0 this indicates the heat trace is off Finally the Bottom of the Configuration Screen has a Left Scroll Tab lt which is used to go back to the Main Options Screen Figure 0 1 The Right Scroll Tab gt is used to go to the GFI and Set point Configuration Screen Figure 21 Enter f CIRC ee Circuit DISABLED This tab only Click here to modify Output shows the Live GFI Warning or Trip p pi GFI Mili Amp setpoints OFF reading This button indicates i if a GFI trip occured If riri one has occured this iempandions GFI mA button will be yellow and will need to be pressed to reset the controls the GFI thus reactivating system Output the Output This will bring you TEMP F i This button is used for back to the Circuit pr de a de Configuration Screen the opposite ee the rit to one will bring you to the Dymocon Server the next screen setpoint which Figure 21 GFI and Set point Configuration Screen 46 The following parameter information needs to be entered in this Screen for each Circuit being
30. d and controlled by the CMI Module All information from wired sensors is real time all information from wireless sensors is based on updates at 5 minute intervals Nothing in this screen is open to modification to modify information or Enable Disable Circuits you must use the Configuration Screens To the top right of the screen Air F indicates the Outside Ambient Temperature at the Site being monitored 66 F in the Figure above Below the Circuit Number window is the Circuit Label Window which in Figure 23 is showing CKT 1 To the far right of the Label is the temperature Set Point for the Circuit which for CKT 1 is 40 F This is the temperature that will determine when the Heat Trace for this Circuit will turn on At temperatures below the Set Point the Heat Trace will remain on and at temperatures above the Set Point it will remain off unless the circuit is disabled which in this case would turn off the heat trace There can be up to 3 Probes for each Circuit and if one or more of the Probes reaches the Set Point the Heat Trace will be turned on 49 The bottom of the screen has a Left Scroll Tab lt which will take the User back to the PLC Main Options Screen To the right of that is a GFI indicator with a GFI reading and color coded status If the color is Yellow it means that the GFI was tripped A GFI Trip will turn the Heat Trace off for that Circuit and will require the Operator to manually reset the Ci
31. d know what they will like to see Rapid Application Design would have been too risky since the program takes a long time to write we could not afford to write an entire program and then go back to change if the customer did not approve The remainder of this MQP will be divided into the four sections of the SDLC Planning Analysis Design and Implementation The principles learned from each section of the SDLC will be directly applied to the project and explained in detail Appendices will be used for much of the final documentation and code A conclusion section will end the project by assessing the overall work and discuss future enhancements 18 Chapter 3 Planning 3 1 Business Value If an information system is not profitable then it is not worth making In this section we will discuss how power plants will profit from this project This MQP will be given to our sponsor and then used to service power plants Thus the project must be profitable to both our sponsor and his power plant customers The sponsor s business value is simple since they are selling the solution and this is of course to sell the solution for more money than production costs Due to the privacy rights of the company we cannot state exactly how much profit is being generated from this module Power plants will profit from this project in several ways The first being energy costs Weather is often unpredictable so most power plants will run their heat
32. e Alarm History tab works in the same way as the Raw Data in which you select a time interval and it shows you what alarms occurred in that range and on what circuit probes they triggered as shown in Figure 28 55 pe e DYM CON CMIDATA Home Edit Personal Info Log Out Currently Active Solution IPA BELL1 International Power Bellingham My Solutions Probe Info by Circuit Amp Info by Circuit Amp Info Across Circuits GFI Info Across Circuits Alarm History Raw Data Control Monitor Inform Alarm History m PLEASE SELECT GE OF DAYS Alarm ID Key e 0 Probe Comm Failure Start Date 25 November 2071 25 1 Gateway Comm Fallure 2 Battery Low End Date 23 November 2011 5 3 GFI Warning 4 GFI Trip 5 Amperage Low _Submit 6 Temperature Low 7 Temperature High Export Table Data to Excel C oae Tine na Locator annalo e onno a f 9 _ Figure 28 CMI Data Alarm History For every Battery or Probe Communication Alarm the location will be the Probe ID of the first probe of that circuit So for example if the battery was low on Circuit 2 the location of that alarm would be 4 since the first probe of Circuit 2 has the ID of 4 This was designed due to the nature of the mesh network Every other alarm aside from Battery and Probe Communication will have an alarm location specific to its circuit The remaining tabs Probe Info by Circuit Amp Info b
33. ect Origination The initial idea for this MQP came from Timothy R Mullen who has over 20 years of experience in the heat trace business He is our sponsor and project champion Prior to entering this business Tim had a successful career in managing industrial operations specifically in the valve systems industry He then bought the company Diamond Technical Services a well respected calibration firm and also created a sub division Diamond Thermal Systems which became one of the top suppliers in the country for heat trace systems The idea of a wireless monitoring and control solution for these heat trace systems lingered in Tim s thoughts for a few years as he became more and more aware of the deficiencies in how his customers managed their heat trace systems During this past year Tim decided to act upon his idea and began designing an application for these heat trace systems I joined the company as an IT intern during this time to work on various office tasks such as contact databases Due to a fortunate turn of events Tim discovered my ability to manage technical operations while understanding customer principles And after considering the circumstances that I was close to completing my degree at WPI the application was still in early development and the scope of the project tied in perfectly with my academic major Tim decided to transform his idea into my Master Qualifying Project and give me responsibility for all te
34. en The Configuration screen is divided into two screens The first screen follows a similar format as the Monitor screen but allows the user to change all of the set point values and Enable or Disable a circuit The second Configuration screen allows the user to set the temperature and GFI set points which are not shown in the Monitor screen The main HMI allows the user to choose between Monitor and Configure and also adjust IP settings of the PLC which are pre configured for the user but still available to be adjusted The Configuration screen is also password protected so when the user chooses to configure from the main menu they will be prompted with a small password screen first In the Configuration screen there is also a Save button the PLC will be programmed to save all of the set points for any specific circuit when the Save button is pressed The last HMI screen is the Alarm Screen which is pre configured in Visilogic Once an alarm trigger is programmed the software allows the programmer to enter an alarm 37 configuration section which once filled will create an alarm HMI screen If an alarm is trigged the user will see a read flashing beacon once the user presses that beacon they will be brought to an alarm screen with a description of the alarm and the option to clear the alarm if it is no longer active Figure 13 shows the alarm configuration page with data for an Amperage Low alarm Shapes
35. erated if the milli amp warning value customer site defined is exceeded 27 o GFITrip Alarm generated if a milli amp trip value customer site defined is exceeded The circuit will be forcefully turned off if this occurs to protect the heat trace Once the issue is resolved the user must clear the alarm via the PLC HMI o Circuit Amps Low circuit is operating at amperage values below user defined amperage set point o Temperature Low generated when the temperature on one or more of the RTD probes drops to the user defined temperature set point o Temperature High generated when one or more RTD Probes reaches the user defined high temperature set point e When an alarm occurs the user will press the red beacon on the PLC HMI and be brought to an alarm description screen where they may clear the alarm only if the cause of the alarm is resolved PLC Web Page e The Unitronics PLC has a built in web server which may be accessed by anybody on the Ethernet network into which the PLC is wired e The PLC web page will be a non interactive monitoring page which will contain all of the information from the PLC Monitoring HMI Screen Historic Data Analysis e The PLC will export its data every six hours via Ethernet to the sponsor s web server e The sponsor s server will organize the data into a Unix database and also host a web site which the user may access to view the PLC s historic data 28 Chapter 5 Desig
36. ers all of the objectives determined in the analysis phase and decides how to implement them It describes in detail how the software should be programmed and how the hardware should operate It also describes how the network should communicate and how the data should be stored The first step will be to determine whether to work from scratch or to work from a system that is already in place Afterwards each aspect of the system should be described either in words or diagrams The design phase should essentially be an instruction manual on how to implement the system 2 2 4 Implementation The final phase of the SDLC process is the implementation where the system is physically built programmed and activated This phase starts with construction in which the system is built and tested for errors Then the system is installed and the old system is de activated Finally a support plan is implemented to ensure that the system is functioning properly and meets customer standards 2 3 SDLC Development Options There are multiple ways to approach the Systems Development Life Cycle each of which has certain strengths and weaknesses depending on the situation The three most common approaches are Waterfall Development Rapid Application Development and Agile Development Dennis 2009 Waterfall Development is the most basic approach in which each step of the SDLC is taken in sequential order Going back to previous steps in this approach i
37. ess All real time data readings collect temperature amps and GFI data organize and display data via PLC HMI determine if heat Sponsor s Database trace should be on or All PLC Data Readings off Stored by Date amp Time send data to database All real time data readings Amps amp GFI data Heat Trace circuit box Figure 8 Data Flow Diagram of the Monitoring amp Control System The next diagram figure 9 is a custom diagram that incorporates some elements from the traditional DFD type structure but also creates an overhead map based view of how the system will function in a power plant setting 31 Monitoring amp Control Solution for Electric Heat Trace Systems Customer Site Control Room Plant Field Interface amp Storage Collection Web Server i RTD Probes Real Ti Temperature Mani me Browser based Pipes Equipment onitoring Monitoring j contol Interface Configuration Wireless Collector Circuit Panel r DYM CON Processing ra Storage amp Support E Heat Trace I O 7 RETA Wireless Current Loe a pc a Storage Solid State Relays a Server j Logging J System Assessments Wireless f Alarm Analysis Gateway Solution Analysis Figure 9 Map Diagram of the Monitoring amp Control System As the DFD and Map Diagram show data moves to and from the PLC and eventually to
38. from scratch During the planning phase of this MQP we decided to use a Unitronics PLC as the central device We used various other instruments to collect data and report it back to the PLC The PLC then displays the data and create alarms based on user defined set points An organized Human Machine Interface HMI Monitoring Screen is essential to the system so they user may monitor their heat trace efficiently The next section will outline all of the functions that this system must complete 4 1 System Requirements PLC HMI Monitoring Page e The PLC collects amp displays temperature readings of the power plant pipes from the System Gateway e The PLC collects amp displays battery strength of the System Wireless Transmitters from the System Gateway e The PLC collects amp displays signal condition of the System Wireless Transmitters from the System Gateway e The PLC collects amp displays amperage readings of the heat trace from the Current Transducer Board e The PLC collects amp displays GFI readings of the heat trace from the Current Transducer Board PLC HMI Configuration of Set points amp Alarms e The PLC allows the user to name circuits as they please 26 e The PLC allows the user to define the temperature set point which will turn the heat trace on or off via the PLC output based on what the actual temperature is e The PLC allows the user to define a low amp high temperature alarm set point e The
39. ge Code User Manual and Testing Results are located in the confidential Appendix Folder Section 6 1 discusses the final end user module with associated screenshots 6 1 HMI Navigation The first screen of the PLC interface is the Main Options Screen shown in Figure 15 Each of the 3 tabs are reviewed in the following sections as well as the alarm system which is accessed by pressing the alarm light beacon on the lower left corner of the screen CMI Module for Heat Trace Systems Figure 15 PLC Main Options Screen 6 1 1 TCP IP Selecting this tab takes the user to the IT Configuration Screen shown in Figure 16 This information is Site specific and supplied by the Customer These values are input at installation and should not be changed 41 SUBNET 999999 2991999 DFLT GTWY J999 F999 f 999 f 999 cwayiP foo foo foao f ooo lt PRES TO INIT CARD Figure 16 IT Configuration Screen 6 1 2 Configuration The Configure Tab opens the screen shown in Figure 17 The User must enter a Password to access the Configuration Screens Press on the Bar with 6 asterisks to access the Password keypad The default Password is 0 Password Figure 17 Password 42 There are 3 Configure Screens Circuit Configuration GFI and Set point Configuration and Password Reset The first screen Circuit Configuration is shown in Figure 18 with surrounding commentary Jump to any circuit by clicking here
40. ill be discussed shortly The page shows all circuits that have been configured for a given site 52 DYM CON ce Control Monitor Inform 66 l View Circuit Descriptions Heat Trace CMI Monitoring Screen Last update 12 2 5 14 PM Note The Heat Trace Circuits at IPA Bellingham are NOT controlied by the PLC Circut Activity ON OFF information shown on this page only indicates when a circuit should be ON or OFF based on the temperature shown in the Set Point F column There are ALARMS that need immediate attention Circuit Monitoring Screen Unit 1 Circuit Circuit Probe 1 Probe 2 Probe 3 Amps Amps Amps GFI Comm z Spr Status Activity daa a Temp Temp Temp Jempa Expect Alarm SP Actual Status Status No Probe No Probe No Probe No Probe No Probe No Probe No Probe 2011 Dymocon Figure 26 PLC Web Page The screenshot demonstrates a 4 Circuit Unit with some active alarms Readings that are highlighted in Red signify an alarm At the top you will find basic information starting with the logo on the left then ambient temperature to the right followed by the Gateway Status whether or not the Gateway is communicating with the PLC and then the pop up sub screen labeled View Circuit Description If you click on that box a small screen will appear with a table of each circuit name and probe name This pop up screen is intended to save the user some time in case they forget the name of
41. lation to the inner pipe wall and then feed the heat trace alongside the wall for the length of the pipe Roof and gutter de icing consists of installing heat trace directly onto the surface of the roof and gutters to create a melted path for water to escape This prevents flooding water damage and weight induced damage to the roof Hot water maintenance is similar to freeze protection heat trace is installed onto water pipes to maintain a high water temperature There are three main types of heat trace cables mineral insulated constant wattage and self regulating Mineral insulated MI cables are the most common and most dependable type These are the ones that our project primarily monitors and controls They are constructed with a solid series resistor element on the outside and magnesium oxide on the inside When voltage is applied the cable heats up The heat to which the cable will rise depends on the way it is manufactured Companies create various model numbers for cables with different temperature outputs The cables run at a specific voltage input which must be exact While the cables are running a certain amount of amperage is flowing through them and by measuring this amperage amount we can tell whether or not the cable is getting too old The amperage increases over time until the cable burns out in which case the amperage drops to about zero Also as the cable gets old and the amperage increases the actual temperature o
42. ly when monitoring important machinery As stated before due to the constraints of the current PLC to add another variable such as vibration the software would have to be modified and most likely delete one of the core readings such as amperage to free up space Pressure is another possible reading that may be of value for example in oil tanks or under water vessels 7 2 MQP Experience This MQP gave me the opportunity to manage an Information Systems project from start to finish I learned the importance of retrieving and outlining customer specifications throughout the planning phase of the project This helped me proceed to the design phase with a defined set of requirements and objectives Communication with the customer and project sponsor was also critical during the early phases to avoid back tracking later on I also learned that software glitches are common in most new programs and planning extra time for trouble shooting is necessary for success 58 References 1 Heat Trace Products Training Manual Chromalox 1998 E L Wiegand Div Emerson Electric 2 Processing Natural Gas NaturalGas Org 2011 Retrieved October 29 2011 http www naturalgas org naturalgas processing_ng asp 3 Energy Justice Network 2011 Retrieved October 29 2011 http www energyjustice net map ourproject ejmap html 4 Pinto Jim History of the PLC ZSA 2006 Retrieved November 2 2011 http www isa org Content ContentGroup
43. n 5 1 Materials amp Physical Infrastructure The Monitoring amp Control Solution MQP is centralized by the PLC which is located inside a fiberglass enclosure Most of the other system components are also located in this enclosure which includes the PLC I O the Relays the Current Transducer Boards the Power Supply the Gateway and the Ethernet Switch The only components that are not located inside the enclosure are the Wireless Transmitters attached to the RTDs and the sponsor s Database amp Web Site which collects the PLC data via internet Below is a list of materials that the system uses with descriptions How the materials interact with one other is discussed after these descriptions e Fiberglass Enclosure A weather proof enclosure where most of the materials are attached via din rail mounts e PLC A programmable logic controller to gather all of the data via I O generate alarms for the user and control heat trace output via I O e Power Supply A central power source to provide electric power to all of the materials inside the enclosure e Solid State Relay A power switch with is controlled by the PLC I O and may either provide power to the heat trace or deprive power to the heat trace Each relay can monitor a single heat trace circuit e Current Transducer Board An electric board which contains current transducers which are looped around the wires connected to the Relays They record amperage readings then send
44. nalysis Design and Implementation Dennis 2009 2 2 1 Planning The planning phase of a project is to determine why the information system should be built and how to build it A system request is the first task to complete usually involving a complete business value proposition If the business will not profit from the system then it should not be built A feasibility analysis should be conducted next consisting of three sections Technical feasibility can we build it Economic feasibility will it provide business value Organizational feasibility will the system be used efficiently if we build it If the feasibility analysis is positive and top management approves then a work plan must be constructed The work plan will assign responsibilities to the team deadlines and strategy Planning provides the project with a strong foundation 2 2 2 Analysis The objective of the analysis phase is to produce a system proposal This proposal will clearly distinguish who will use the system where and when the system will be built and what the system will do During this phase the current system will be analyzed for both weaknesses and strengths Requirements gathering will also take place typically involving interviews and questionnaires to find out exactly what the new system should do and not do After this phase the team should have a clear understanding of what the new system should produce 16 2 2 3 Design The design phase gath
45. o if a transmitter has lost communication the reading will fall to 0 degrees as demonstrated in the screenshot above in Circuit 2 Temperature Set point Amps Expected and Amps alarm Set point are self explanatory note that Amps Expected does not affect any alarm conditions and is there only for user comparisons Amps Actual will turn red into an alarm state when 2 conditions are BOTH met Actual Amps are below or equal to Amps Alarm Set point AND the Circuit Activity is ON meaning that the CMI Module is trying to power a specific heat trace circuit GFI Status will remain OK until a GFI reading rises above the set point which is defined by the user in the Configuration Screen of the PLC Comm and Batt Status represent the communication and battery status for the wireless transmitter of each circuit If the transmitter loses communication to the Gateway an alarm will occur as showed in Circuit 2 above and if the Battery of the transmitter drops below 3 volts its cell will turn red as well signifying that the transmitter batteries need to be replaced Note that the batteries are meant to last 5 7 years 6 3 Historic Web Site Customers are given a web address user name and password They may log into the Historic Web Site and view data based on user speficied time intervals Each tab of the CMI Data Web Page has a set of straight forward instructions and is easy to navigate through The first
46. ogramming language using the software Visilogic which is made by the same company that builds the PLCs Unitronics The code must establish communication with the gateway gather data from the gateway gather data from the CT Boards organize that data into real time data tables create 20 circuits that the user may navigate through create and populate HMI screens create set points and alarms control output and export the data to the sponsor s server The design of the PLC code is explained below 5 2 1 Data Tables The first step in designing the PLC code is to create data tables to hold data for each of the 20 circuits The system may be used for fewer than 20 circuits but not more The reason to create the data tables first is to establish a foundation for the code where the data are stored and then retrieved when necessary The main data table will contain all of the real time readings for all 20 circuits and be called Circuit Probe Table Each row will represent a circuit and each column will represent a specific data value The 16 data values will be as follows circuit name amps expected amps alarm set point amps actual probe 1 name probe 1 ID probe 2 name probe 2 ID probe 3 name probe 3 ID GFI warning set point GFI trip set point GFI actual temperature set point temperature low set point and temperature high set point Below Figure 10 is a screenshot of this data table s construction 33 lt 2 Data Tables E
47. omers will also be alerted immediately when their heat trace is not functioning properly and can pin point the problem before it escalates Customers will be able to monitor their entire heat trace system with a single color coded web page Furthermore every data reading will be saved and logged into the sponsor s database for the customer to analyze and trend at their convenience A test panel has been created with real equipment and live readings The module passed every stress test possible which was designed to simulate on site situations with real alarms The same test panel was used for the MQP demonstration Temperature amperage and GFI readings were all accurate and the PLC output was triggered successfully The panel was actively monitoring and controlling for over a week without any problems 57 7 1 Possibilities amp Limitations of Change The Unitronics PLC that we are using now does have some limitations for future expansions As of now it monitors and controls 20 circuits Most of the memory locations are being used with the current software To expand the number of circuits two PLCs would have to be used simultaneously Another option would be to use a more expensive PLC such as one from Alan Bradley however the cost would much higher and the software would have to be re written There are other types of industrial readings that this module may be able to monitor Monitoring vibration can be useful especial
48. onfiguration Screen This button simply disables a circuit forcing the output and alarms to stay off for that specific circuit This is useful if the plant is working on that circuit and does not want this system to interfere during the work The second indicator is the Output On Off tab which simply shows the user if PLC is 36 sending output or not to that specific circuit Figure 12 shows the Monitor HMI screen in construction Variable Numeric z x yj UiectLonnection y zg A A Zoom Q By Properties C S Keypad Entry T Linearization I Start with clear field Display L r Max Min I E z Ei Ma ooo Max I i ait B Up Down Arrows af eel z Increment Min Max MONITOR Text After Base Format Decimal Bb E p a r Leading No Leading gt Text Color _ Constant String String from Library IV Do not reserve space for sign Keyboard Type Complex Description Variable550 SSCs Part MS Sar ms Constant Sting Sting from Library Output m Links Colors m Link MI 61 HMI PROBE 11D Back Color JL OFF Hide MB 125 A PROBE 1 HIDE El a Petit Sa Disable view sd is favial 10 8 x i Masking wf Armen enter Cene z BATTERY OK SIGNAL OK l Touch a ok Cancel Hep PROBLEMS ACTIVE ALARM Figure 12 PLC Code Monitor HMI Scre
49. or additions to the User Defined Information about the Circuits being monitored by the CMI Module Enter Circuit Tab Shows the position number in the Solution of the Circuit to be configured The CMI Module by default can work with up to 20 Circuits These Circuits are pre numbered in the solution The first Configuration screen shown is always the Last Circuit configured or changed If the actual circuit at the Site does not correspond with the position number in the solution the Site Circuit Number should be included in the Circuit Label or Name If you press on the window the screen will change to the Number Pad Enter the Number of a Circuit and press Enter to go to that Circuit s Configuration Screen To the right of the Circuit Tab are Left and Right scrolling tabs These can be used to scroll to the Configuration Screens for the other Circuits being Monitored and Controlled by the Solution To the right of that is the Circuit Enabled Disabled Tab The Circuit Disabled option is used to prevent the Heat Trace Circuit from being turned on when the Temperature sensor calls for heat The Disabled option also prevents the GFI Warning and Alarm from being activated This option is made available to prevent the Heat Trace from being turned on when maintenance is being performed on the equipment being protected The user can select the Number Tab and go to the Circuit Selection Screen which allows the user to select a Circ
50. rcuit by selecting the GFI OK in the Configuration Screen Finally at the bottom of the Circuit Monitoring Screen are 3 windows with Amperage information for the Circuit Amps Expected Amps Alarm Set point and Actual Amp Reading In the lower right corner of the screen is the Alarms Beacon which in Figure 23 is showing Blue indicating there are no Active Alarms on the System This Icon is not specific to a Circuit or a screen Any Alarm on any Circuit will change the Icon from Blue to Yellow Red 6 1 4 Alarms By selecting the Alarms Beacon on any PLC screen the Groups with Pending Alarms screen is accessed Figure 24 This view shows the Alarms that are Active and have not been Acknowledged by the Operator across all Circuits being monitored After an Alarm has been Acknowledged and Resolved it will only be accessible through the Alarm History Tab of the CMI Data Web Page which is discussed later 50 Groups with Pending Alarms ee Group Name Details 01 l Reset 2 SERIAL COMMUNICATION T 02 Reset 1 GFI PROTECT ESI 03 Reset 1 AMPS PROTECT Sl 04 Reset 1 FREEZE PROTECT DO Refresh Figure 24 Groups with Pending Alarms The Groups with Active Alarms Screen Figure 24 shows 4 Rows of Pending Alarms information one for each of the 4 Groups of Alarms Each Row of information shows the Alarm Group ID a Reset Tab the number of Pending Alarms in the Group the Alarm Group Name and a Red Magnifying Glass Ta
51. re used at power plants to keep various machines and pipes from freezing PLC Input Output C O Units Physical devices which are directly wired to the PLC which can receive or send electric signals to outside devices Power Supply A device which distributes electric current to multiple other devices Programmable Logic Controller PLC A mini computer with an attached touch screen that gathers inputs and controls outputs Modern PLCs also have networking functions discussed under Chapter 2 2 3 Relays Devices that act as a power switch between a power supply and another device They can either allow power to reach the desired unit or not allow power to reach it based on the signal given to it which in this case comes from our PLC I O Units Resistance Temperature Detectors RTDs Thermal devices that measure temperature and report it via attached wires which do not require power Transmitter or Node A device which collects data and wirelessly sends it to the gateway 60
52. s very difficult since each step has a lot of time and approvals already invested The main advantage of this approach is its simplicity and organization in the aspect of following instructions and requirements set forth in the early stages of the project 17 Agile Development splits objectives into individual processes in which a lot of face to face communication is utilized to complete an entire system Each objective is taken one step a time to eventually create an information system This approach involves a lot of customer interaction which is good in some cases but bad in others The last approach is Rapid Application Development in which early stages of the project are rushed for the purpose of creating a prototype system for the user to test and comment on This approach is best for complex systems that users are not completely sure about yet For example if the user has no idea of how their HMI screens should look then this is most likely the best approach In this project we are using the Waterfall Development approach We have invested much time and thought into the planning phase of this project We have clear objectives and know exactly what should be produced by the project We also know what tools and programming languages to use in accomplishing these goals Agile Development would take too long to complete by requiring us to check with the customer after each individual step we have already analyzed the customer an
53. s News 2006 February24 History_of_the_PLC htm 5 Vision570 Unitronics 2012 Retrieved November 2 2011 http www unitronics com Series aspx page Vision570 6 Dennis Adam Wixom Barbara Roth Roberta System Analysis and Design Ed 4 John Wiley amp Sons Inc 2009 59 Glossary Current Transducer CT A device that is installed around an electric wire measuring the amount of amperage coming from it It then sends out a 4 20 milliamp signal representing the amperage amount Enclosure A protective box housing made from plastic or metal and usually weather proof Gateway There are many different types of gateway but for the purpose of this project a gateway is a master device which wirelessly communicates with a series of transmitters Ground Fault Interrupter GFI A device used to protect equipment from electric surges It powers down the equipment when milliamp mA readings become too high A GFI Reading is simply a reading of the mA value Through the use of CTs and PLC I Os this solution will have the functionality of a GFI among other things Heat Trace A thermal cable that produces heat after receiving electric current Heat Trace is usually wrapped around an object to keep it from freezing or to keep it at a desired temperature Heat Trace System A series of heat trace cables installed at various locations which all connect back to one power source or breaker box Heat Trace Systems a
54. s of how the solution will be installed into a metal or plastic enclosure where each individual component will be placed and how they will be wired to one another Wireless communication will also be illustrated as well as data flow This will be done in CAD and possibly include 3D modeling as well Located in the confidential Appendix Folder 6 PLC Code The PLC is a mini computer which controls all of the operations of this solution The code for it will be written in the language Ladder Logic with the software VisiLogic This code cannot be converted into any other type of file so it will remain as a VisiLogic extension Located in the confidential Appendix Folder 7 Web Page Code The PLC has a built in web server which can import HTML code The HTML file will contain the code for the web page design The Web Page will be a real time summary of all the data points intended for users to monitor Located in the confidential Appendix Folder 8 Database Website The PLC also has the functionality of exporting its data to another location In this case the Dymocon Office will receive the exported data from the PLC every six hours and organize this data into a Unix Database An interactive web site will be created to view the historic data 9 User Manual This document will be provided for the end user as an instruction sheet for using the solution Located in the confidential Appendix Folder 10 Possibilities amp Limitations
55. second year the customer will save 51 000 on energy consumption per year which would have been spent on running their heat trace cables inefficiently Intangible Costs and Benefits High e The customer will be alerted of heat trace problems before they cause major damage to the plant e Ifa major disaster such as a pipe freeze that causes an explosion is prevented by this MOP then the return on investment would be about 1 000 percent of the cost for that year Organization Feasibility Who will take part in the project High Project Champion e Timothy R Mullen Sponsor amp CEO of Dymocon Project Engineer e Teodor Serbanescu WPI Undergraduate Senior Management e Richard Stearman Web Consultant help with HTML and Unix Database Users e Staff of Dymocon and end user power plant customers Alignment with Business e The project will provide an application for our sponsor to sell to power plant customers e The project will save power plants money by deducing energy consumption and preventing heat trace problems 3 3 Work Plan This project begun at the beginning of B term 2011 October 25 and finished before the start of C term January 11 Below is a rough time line of waypoints and objectives for this MQP followed by a Gantt Chart of the project work plan Figure 7 24 January October e Planning Phase Learning software identifying project deliverables amp objectives assessing business
56. step is to click on My Solutions and choose from a drop down menu the Plant for which you would like to see historic data Once you have set that as your active solution you may begin viewing your data The most basic way to view your historic data is via the Raw Data page shown in Figure 27 54 E DYM CON DYM CO CMIDATA My Solutions Probe Info by Circuit Amp Info by Circuit Amp Info Across Circuits GFI Info Across Circuits Alarm History Raw Data Raw Data Log PLEASE CT A RANGE OF DAYS AND CIRCUITS Start Date 25 gt November gt 2011 amp Please Note Retrieving data for this page can be time intensive and could take up to 1 minute End Date 28 gt November gt 2011 5 The wider range of dates you request the longer it will take to return Submit Please be patient Export Table Data to Excel Circuit Time CircuitTemp Amps Amps AmpsAlarm GFI GFIWarning GFIAlarm Probe1 Probe1 Probe1 Probe2 Probe2 Probe2 Probe3 Number Setpoint Expected Actual Setpoint Actual Setpoint Setpoint Temp Enable Battery Temp Enable Battery Temp obe 3 Probe 3 nable Battery a 2011 annann 32 ant 4 sA 25A 2 25 3 ant 4 ama ast 1 DOLE 3202A nt n 202A a Figure 27 CMI Data Raw Data Tab In this tab you simply select the date range you want to view and then click Submit to view all of the data for that time period Th
57. t Probe Table but first they are stored here As the PLC scans through the Gateway s modbus registries it gathers readings for each transmitter and assign those readings to the appropriate row of this table Each row represents the transmitter ID so if the PLC collects data for transmitter ID 6 it organizes the temperature battery and status directly into the 6th row Two alarm tables are programmed One for the wireless transmitters and one for amperage temperature and GFI The wireless transmitters alarm table will contain columns for the transmitter ID battery alarm and communication alarm Each time an alarm is triggered the associated row value will turn from 0 to 1 signifying that there is an alarm active for that transmitter The same applies for the circuit based alarms which include temperature high amp low GFI trip amp warning and amperage low The last tables are used for historic data readings These tables are directly exported as csv files to the sponsor s server The first table contains all data readings for circuits 1 10 while the second contains circuits 11 20 and the final table contains alarm history Each row is 34 organized by actual time amp date recorded by the PLC s internal clock Each column is organized by circuit number The code exports the data at midnight 6AM noon and 6PM The destination of the data tables is the IP Address of the sponsor 5 2 2 Communication amp Scan Sequen
58. tables As the program collects data readings such as amperage it will compare the value to the set point and if the value is below the set point or above in some circumstances it will trigger an alarm For example if the amperage low set point is 5 amps and the actual value is 4 amps an amperage alarm will trigger 38 The only set point that controls the output of the PLC is the Temperature Set point If any of the probe temperature readings of a specific circuit go below this set point the output for that circuit will be triggered until the actual temperature has risen above it Figure 14 is a screenshot of the code that controls the output for Circuit One The output is turned on only if all of the following conditions are met the circuit is enabled the temperature set point is triggered and there is no GFI trip active Once the output is triggered the amperage alarm system is also turned on for that circuit PROTECT FRE CKT PROTECT FREEZ PROTECT GFI PROTECT TEMP te Me270 MB 320 MB 250 Ti Ss i Ey o ALARMS E Circuk 1 20 CKT1 20 Cecu 1 20GFI CIRCUITI CKT1 Coane nacocicies A Enable Status OUTPUT ON m OUTPUT CONFIG E ee 2 ee NDA STUFF a Gr METRY i Start Up Module 5 Z Stat Updisoly 8 S BIG ALARM SCRE E ler A CONFIGURATION 4 S CONFIGURATION EN ON CHECK CURRENT AMP WITH EXPECTED 0 1 AMPS CONFIGURATION f S CONFIGURATION 064
59. trace for the entire seasons of Fall Winter and Spring This will cost them a lot of money depending on how much heat trace they have A small natural gas power plant with only one main combustion engine or Unit will consume 168 kilowatts per hour on average to power their heat trace One kilowatt will cost the average plant 0 07 So on an average day a small plant will spend 282 24 to power their heat trace Figure 5 below is a chart of this information for a few sizes of power plants Our solution will turn the heat trace on only when the temperature drops beyond the set point So for example at a small plant if the temperature stays above the set point for roughly 120 days during the Fall and Spring then the plant will save 33 869 in energy bills that year If the plant has more than one Unit the savings will further increase 19 Ave of circuits per panel Ave of panels per unit Ave footage per circuit Ave wattage per cable of units per plant of units per plant of units per plant Total wattage of heat trace plant Kw hours Total wattage of heat trace plant Kw hours Total wattage of heat trace plant Kw hours Nov 1 March 31 151 days 151 days operating Ave cost of Kilowatt hour 0 07 Ave cost to run heat trace per day kwatt hours x cost of kwatt hour 282 24 564 48 Ave LOST PROFIT due to improper control of electric heat trace system Figure 5 Lost Profit of Running
60. trace on all the time and un monitored which causes them to lose money while risking potential malfunctions Some power plants have their own in house monitoring and control solution for their heat trace system but most do not Instead they manage it by turning the heat trace on during the Fall Winter and Spring then turning it off during the Summer Due to the life span of the heat trace which in most cases cannot be accurately predicted most plants will change their heat trace long before they expire which is very expensive And some however will take the risk of running the heat trace until it comes close to or dies out If the heat trace stops working the condensation from a steam pipe may freeze and when the plant activates the pipe new steam will evaporate that condensation with a high amount of pressure and cause the pipe to burst This may cost the plant up to millions of dollars Below is a list of problems that these plants have which will be solved by this MQP solution e Energy amp Operating Costs Without our proposed system power plants will run every heat trace circuit for three seasons per year They will lose a lot of money on energy this way Our system will turn on the circuits only when the temperature is below the set point of that specific circuit If a circuit is meant to be left off it will not power that circuit until the user turns the circuit on via our programmable logic controller s PLC interfa
61. uit by entering its number from the keyboard or through the number pad on the screen Figure 19 is the keypad entry 44 ENTER CIRCUIT 1 40 ee pi 2 2 K3 lt i gt Figure 19 Circuit Selection Screen Number Pad The SAVE Tab in the upper right hand corner of the screen must be selected before leaving the configuration screen to retain any changes made to parameters being configured A Circuit Name or Label must be given to each Circuit Selecting the Label box will open an alpha numeric key pad screen shown in Figure 20 which is used to insert the Name or Label for the circuit Select letters or numbers from the key pad 1 25 characters to insert the Name Label desired At the top of the screen information in a grey box will prompt you about the Name Label being entered For example the screen below is for entering the Circuit Name Label lt j j GIVE CIRCUIT NAME 4 25 CHARS Figure 20 Alpha Numeric Keypad 45 Each Circuit can have up to 3 RTD Probes Each Probe being deployed should be given a Name or Label with a reference to its position along the Circuit When selecting the Probe Label Box an Alpha Numeric Key Pad Screen as shown in Figure 2 3 will open so the Name Label for the Probe can be entered The Key Pad Screen for each Probe will show at the top the Probe Number it relates to For example Probe 1 Name will show for Probe 1 The same will happen for Probes 2 an
62. utput decreases 13 Constant wattage cables are similar in the aspect that once you provide a power source it functions but they are more complex in the way they are constructed The advantage of constant wattage cables is that if one section of the cable is damaged it will continue to function at the parts that are not The cost of these cables is higher than MI ones which is why they are not as popular Self regulating cables are the newest and most complex They are built with a type of resistor that can act according to what the surrounding temperature is thus providing a wide range of heat The setback for these types of cables aside from high costs is that they are not as robust as the other two and most customers will not risk their equipment by relying on them to function properly at all times A heat trace system is a collection of heat trace cables which are installed in multiple locations all connect back to a central power source A gas powered plant will have a series of pipes moving gas from one location to another In this case power lines will extend from the main breaker box to the start locations of each heat trace to provide power to them Some power plants will go one step further and create their own monitoring system for their heat trace system but most do not have the time money or experience Heat Trace Products Training Manual 1998 Timothy R Mullen 2011 2 1 3 Programmable Logic Controllers A
63. ve this temperature damage to the Heat Trace may occur An Alarm is generated when this temperature is recorded by one or more of the Probes on a circuit 47 The GFI and Set point Configuration Screen shows the Circuit Number Enter Circuit and the Label of the Circuit At the top of the screen are scroll Left Right Tabs which can be used to scroll to this same window for other Circuits The Bottom of the Configuration Screen has a Left Scroll Tab lt which is used to go back to the Circuit Configuration Screen shown in Figure 18 Also at the bottom of the screen is and Alarm Status Beacon Red Yellow when there is an Active Alarm Situation When there is no Active Alarm this Beacon is Blue The GFI Window in the Upper Right corner of the Screen provides a value generated in real time by the solution measuring leakage to ground The Right Scroll Tab gt is used to go to the Password Reset Screen Figure 22 This screen is used to change the password required to enter the Configuration Tabs The numeric pad that appears is the same as the others CHANGE CONFIGURATION PASSWORD PRESS BELOW TO CHANGE Figure 22 Password Reset Screen 6 1 3 Monitor The Monitor Tab brings you to the Circuit Monitoring Screen shown in Figure 23 48 CIRCUIT DISABLED BATTERT OF Figure 23 Circuit Monitoring Screen The Circuit Monitoring Screen provides real time status information about each circuit being monitore
64. ways and current transducers It will be enough for me to design the layout wiring scheme and integrate the data into the PLC without any problems Project Size Large e This size of the project would be overwhelming for an MQP if I had no previous experience in the field As mentioned previously I spent time during the last eight months familiarizing myself with the programming language and running test code on the PLC The scope of the project is now manageable due to my experience with the language Economic Feasibility Should I build it High Sponsor Economic Feasibility Tangible Costs and Benefits High e Cost for the project will be 10 000 paid by the sponsor to WPI e Materials for lab testing and demonstration equipment will be paid for by the sponsor and cost 5 000 e Materials for customer installation will be paid for by the sponsor and be discussed in the Bill of Materials appendix section e Sales profits will not be discussed due to privacy rights but should exceed all costs including R amp D after the fourth sale to an average power plant Intangible Costs and Benefits High e The project will provide a foundation for future solutions Power Plant Customer Economic Feasibility Tangible Costs and Benefits High e For an average 2 Unit power plant the cost of this module will be about 70 000 23 e The return on investment will begin in the second year after installation After the
65. web page code Chapter 1 Introduction 1 1 What is Heat Trace The purpose of this MQP is to develop an application that will monitor and control heat trace systems A heat trace is an electric thermal cable which is installed directly onto or around an object that is meant to be heated When electricity is provided to the heat trace cable it will heat up The quality and type of heat trace cable will determine what temperature it will heat up to and a rough estimate of the cable s life span which can vary from just a few months to several years A heat trace system is a collection of heat trace cables which are installed in multiple locations and all connect back to a central power source which is usually a breaker box A simple example of a heat trace system is the installation of heat trace cables onto a house roof so that during the winter the snow will not accumulate too much and add too much pressure to the structure The heat trace systems for which we will be developing an application are installed at natural gas power plants These heat trace cables are installed onto circuits of pipes which must not freeze otherwise major damage will occur to the plant See the glossary for definitions of the technical terms used in this MQP 1 2 Request for Proposal The problem in the way that power plants are currently managing their heat trace systems which calls for this solution is that they leave the heat
66. y Circuit Amp Info Across Circuits and GFI Info Across Circuits have the same data as the Raw Data tab except they automatically create graphs of the data which can be used for trending and analyzing Just as the other tabs the user inputs time ranges and then clicks submit 56 6 4 Building a Test Environment To accurately test this MQP module we had help from the sponsor s electrician to build a test panel This was a four circuit panel with all of the components that would be present in an actual plant panel The electrician built a device that attaches to the top of the enclosure with four light bulbs representing four heat trace lines When the PLC was intended to turn a heat trace circuit on it would turn on the associated light bulb A GFI device was also created to trip the GFI alarm of a specific circuit The test enclosure weighs less than 50 pounds and is mobile which is good for demonstrating purposes as well as testing All of the stress test results were successful Every alarm was triggered and the outputs were activated properly A complete log of the stress test is in Appendix G Chapter 7 Conclusion The Monitoring amp Control Solution MQP has successfully built an all in one module to manage heat trace systems Power plant customers who install this module will benefit from decreased energy costs as their heat trace will only be turned on when needed which also equates to longer heat trace life Cust

Monitoring and Control Solution - Worcester Polytechnic Institute

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