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PLC Control Systems for Industrial Scrubber Installations
The implementation of programmable logic controller (PLC) systems in industrial scrubbers enables precise automation, monitoring, and optimization of separation processes. This study outlines the development, programming, and remote monitoring of a PLC-controlled scrubber system, emphasizing installation design, communication protocols, data management, and post-commissioning support.
1. Introduction
PLC systems play a critical role in industrial automation by providing robust, reliable control over complex processes. In scrubber installations, PLC control ensures stable operation, facilitates system diagnostics, and supports remote optimization. Effective programming and communication between the client and supplier are essential for successful deployment.
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Operational Monitoring and Control Strategy
Overview of Monitoring and Control Functions
During operation of the wet gas scrubber system, a comprehensive monitoring and control strategy is implemented to ensure reliable performance, process stability, and equipment protection. The main control functions include pump monitoring, level control, and temperature monitoring, all of which are supervised by dedicated instrumentation and interlocks.
Pump Monitoring
The scrubber circulation pump is continuously monitored to verify correct hydraulic performance and to protect the system against abnormal operating conditions. A flow switch is installed to monitor the circulation flow. An increase in flow may indicate a worn or damaged spray nozzle, whereas a reduced flow typically indicates a restriction on the pump discharge side, such as fouling or partial blockage. If no flow is detected while the pump is running, the system will automatically stop the pump to prevent damage. The applicable flow limits and alarm thresholds are determined during commissioning. In addition, a pressure transmitter monitors the discharge pressure of the recirculation pump. Elevated pressure values can indicate nozzle clogging or downstream restrictions, while reduced pressure generally points to worn or broken nozzles. Pressure limits and setpoints are likewise established during commissioning to match the actual system characteristics.
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