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R&D Project to develop an AI Process Monitoring System for Chlor - Alkali cell process lines

Sector: Research and Development

Developing greater control of the system with minimal additions to the hardware.

Monitoring Configuration

Product Description

Castlet recognized the need for a cost-effective solution for monitoring cell process lines in the Chlor – Alkali industry.

The Castlet design allows users to monitor the condition of cells via measurement, analysis and display of electrical parameters critical to proper operation. The system monitors individual electrolyser cell voltages, total electrolyser voltage plus symmetry within each electrolyser. We also offer an option to monitor total electrolyser current.

Configuration is modular starting with a single junction box connected to a maximum of 100 channels. Multiple junction boxes can be installed up to a total of 1,000 channels all connected to a monitoring unit. The example system below is configured to monitor 168 cells connected to a PLC / DCS

Electrolyser Junction Boxes

To manage the high number of voltage sensing connections, a junction box is utilized for each electrolyser stack. Typically, each junction box accepts up to 100 channels of cell voltage inputs. To ensure the DC voltage signal is not corrupted, the junction boxes are mounted near the electrolyser. Each junction box retransmits the optically isolated analogue data to the PLC panel. The enclosures are constructed of fiberglass with a gland plate for input and output cables.

Network connection

The electrolyser system is equipped with multiple junction boxes and an electrolyser monitor. Multiple electrolyser systems can be connected to a central SCADA system with an operator’s workstation to provide plant wide monitoring. Communication between the central computer and electrolyser monitor is typically accomplished via Fibre optic due to distances on site.

A Typical single PLC system will include:

  • SIMATIC S7-1500, CPU 1511, 1PC
  • SIMATIC S7-1500 analog input module, 2PCs
  • SIMATIC S7-1500, digital output module, 1PCs
  • SIPLUS S7-1500, System power supply, 1PCs
  • Industrial Ethernet Switch, 1 PC
  • Option equipment could include HMI if no SCADA package is required

Additional parts including: Enclosure, Terminals, rails, Fuses etc.

Alarm Outputs

The system can be programmed with multiple alarm outputs dependent on customer requirements. Typical options include:

  • Symmetry alarm monitoring: Typical range being +0.2V to +1.2V
  • Symmetry trip: Typical range being +0.4V to + 2.4V
  • Individual cell voltage out of range: Under/ Over voltage 0.0V to 0.4V
  • Individual cell voltage trip: Under/ Over voltage 4.0V

Castlet is currently working on an AI monitoring system for enhanced monitoring of the above system.