Design, simulation and verification of a PLC-Based sequence modification for enhancing dome valve reliability in ash handling systems
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Full Text |
Pdf
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Author |
Kent Martin D. Cartagena and Consorcio S. Namoco Jr.
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e-ISSN |
1819-6608 |
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On Pages
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1307-1315
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Volume No. |
20
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Issue No. |
16
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Issue Date |
November 30, 2025
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DOI |
https://doi.org/10.59018/0825149
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Keywords |
ash handling system, CFB power plant, dome valve, industrial automation, PLC modification, reliability engineering, rubber seal.
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Abstract
In circulating fluidized bed (CFB) coal-fired power plants, dome valves play a critical role in regulating the flow of abrasive fly ash during ash handling operations. However, the harsh operating environment, characterized by high pressure and particulate abrasiveness, frequently leads to premature failure of rubber seals, resulting in leakage, reduced operational efficiency, and increased maintenance downtime and costs. This study presents the design, simulation, and field verification of a modified control sequence aimed at mitigating these issues by improving the timing of valve actuation. The proposed modification introduces a directional valve and integrates a programmable logic controller (PLC)-based delay mechanism to ensure depressurization of the rubber seal prior to dome valve opening. Simulation of the control logic was conducted using a workshop-built PLC simulator configured with actual Allen-Bradley ControlLogix components. Field verification involved the installation of the modified system and subsequent testing over multiple operational cycles to assess performance consistency. Results confirmed that the modified sequence effectively delayed the opening of the diversion valve, enabled complete pressure release in the rubber seal, and prevented mechanical stress and leakage. No errors or faults were detected in the PLC system, and all installed components, including directional valves, relays, and sensors, operated reliably. The improved sequence demonstrated a promising solution for extending rubber seal life, reducing maintenance frequency, and enhancing overall system reliability in industrial ash handling applications.
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