Optimization Of Energy For Industrial Heater Using PLC and SCADA

—This research project mainly focus on proper coordination of heater and supporting components in order to reduce its energy consumption and optimize power for specific input parameters. Control algorithm measures critical parameters and adjust variable outputs to optimize power by turning ON/OFF the heater with improved performance. Temperature stability is a one of the basic requirement of this system. Implemented PLC base controller is compatible to handle any type of high and medium capacity heater system. It has online data system connected to the PLC frontend and the System can be controlled dynamically by varying the thresholds of input/control parameters. This controller eliminates the need of constantly turning ON the heater. Further electricity cost further reduces by around 5%. PLC and SCADA is used to model and realize the complete system and perform the experiment for result analysis. Automation is further enhanced by constant monitoring using SCADA screen which is connected to the PLC by means of communication cable. By means of tag values set to various variable in SCADA the entire process is controlled as required.