INDUSTRIAL CONTROL STREAM

FINAL PROJECT PROPOSAL

TITLE: PLC BASED INDUSTRIAL BOILER CONTROL
MEMBERS
Name Id.no
1. Leta Endashew 02356/04
2. Kahsay T/medhin 02332/04
3. Getachew Hailu 01911/04
4. Getnet Abera 01943/04
5. Getaney seyoum 01931/04
6. Getachew Awake 01910/04

Advisor: Mr.Behailu Guta and Co-Advisor: Mr. Solomon Habtamu

JIMMA, ETHIOPIA
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 Acknowledgment
Any attempt at any level cannot be satisfactorily completed without the support and guidance of
institution and experienced people. So, Firstly our thanks and appreciation goes for Jimma
University Institute of Technology for supporting us in every direction. Secondly, we give the
highest degree of excellence for school of electrical and computer engineering. Thirdly, we wish
to express our deep sense of gratitude especially, for advisor Mr.Behailu Guta for his
supervision. It was his understanding and helps that stimulate us during the moment of difficulty.
Finally, we genuinely thanks to co-advisor Mr. Solomon Habtamu for his advice and guidance.

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 Table of Content

Contents page
Acknowledgment ........................................................................................................................................... i
Table of Content ........................................................................................................................................... ii
Acronyms ...................................................................................................................................................... v
1. INTRODUCTION .................................................................................................................................... 1
1.1 Historical Background ........................................................................................................................ 1
1.2 Objective of the Project ...................................................................................................................... 2
1.2.1 General objective ......................................................................................................................... 2
1.2.2 Specific object .............................................................................................................................. 2
1.3 Statement of the problem .................................................................................................................... 2
1.4 Project Targeted Questions ................................................................................................................. 2
1.5 Significance of the project .................................................................................................................. 3
1.6 Limitation of the Project ..................................................................................................................... 3
1.7 Method and materials of the Project ................................................................................................... 3
1.8 Scope of the project ............................................................................................................................ 5
1.9 Task and Time Schedule ..................................................................................................................... 5
1.10 Cost Estimation ................................................................................................................................. 6
2. LITERATURE REVIEW AND SYSTEM MODELING ......................................................................... 8
2. 1 Literature Review............................................................................................................................... 8
2.1.1 Brief Descriptions of PLC............................................................................................................ 8
2.1.2 Brief Descriptions of Components ............................................................................................... 8
2.2 Block Diagram Descriptions ............................................................................................................... 8
2.3 Mathematical Model of Boiler .......................................................................................................... 10
3. EXPECTED RESULT ............................................................................................................................ 15
3.1 Expected Result ................................................................................................................................ 15
4. CONCLUSION ....................................................................................................................................... 16
REFERENCE.............................................................................................................................................. 17
Appendix ..................................................................................................................................................... 18

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 List of Tables
Table 1.1 Task and time schedule ................................................................................................................. 5
Table 1. 2 cost estimation ............................................................................................................................. 6
Table app.1 1 Nomenclature ....................................................................................................................... 18

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 List of Figures
Figure 2.1 Schematic diagram of PLC based industrial boiler control ......................................................... 9
Figure 2.2 Block diagram of PLC based industrial boiler control .............................................................. 10
Figure 2.3 model of boiler .......................................................................................................................... 11

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 Acronyms
AI Analog Input
AO Analog Output
CPU Central processing unit
DI Digital Input
DO Digital Output

FBD Functional Block Diagram

PC Personal computer

PH Acidity or basicity

PLC Programmable Logic Control

RTD Resistance temperature detector

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 Abstract
Making convenience , controllable and suitable industrial boiler are useful to increase plant
production efficiency and controlling of boiler before damaging human and high cost equipment.
In this final project, we propose to control the parameters like the temperature of the steam, the
level of water, control of feed water pump, Pressure and PH of the steam. This can be done by
installing different sensors like temperature sensor, pressure sensor, level sensor and PH sensor
on the boiler. The analog signals sensed by the sensor are collected and transmit to PLC as an
input. PLC analysis the input signal and take an action or response before hazardous things
happen. The response can be giving signal as something will be happen. It will be in the form of
alarming, buzzer ring, lamps or indicators, activating contactors, motors and solenoids.
This project is very significant to measure the actual values of different parameters, to monitor
one or more variables and in case of operator failure to take remedial action for an upset
condition and for safe working.
Historically highest grade of wrought iron was used to make boilers. Later on steel was used
which is stronger and cheaper, with welded construction, which is quicker and requires less
labor. But, the current is controlled and automated fully by logo made PLC which uses logo
software. Using logo software we program ladder diagram by u sequencing, timing, etc the input
signal. Then it downloaded to PLC memory location and CPU. This PLC accepts the outputs of
those sensors incorporated within the boiler, evaluate them and generate appropriate signals
which will ultimately use to run on or terminate the output terminals.

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 1. INTRODUCTION

1.1 Historical Background

A steam boiler plays an important role in all types of industries. In industry steam boiler is
generally required for the following reasons:
Steam as a means of direct or indirect heating.
Steam as a raw material.
Steam as a means of generating electrical power.
A boiler is an enclosed vessel that provides a means for converting water into steam. The steam
under pressure is then used for transferring the heat to a process. Water is a useful and cheap
medium for transferring heat to a process. When water is boiled its volume increases by about
1600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to
be extremely dangerous and must be treated with a lot of care. The boilers operating conditions
is very necessary to control because the high pressures and temperatures are the main hazard
problems and it has the risk of explosion. Also steam boiler has very high manufacturing cost,
operating cost and maintenance cost.
Boilers are made up of different materials and composition of these materials change with the
passage of time due to demand in increase in strength of these pressurized vessels. Historically,
highest grade of wrought iron was used to make boilers. Later on steel was used which is
stronger and cheaper, with welded construction, which is quicker and requires less labor.
Fireboxes of these boilers are made of copper it was chosen because of high thermal conductivity
and its better formability. But, it has been replaced by the material such as steel because of the
rise in the copper price. In the past, steam boilers were used in trains to run the steam engines,
steam is also used in chiller of central cooling system which helps in maintaining the chemical
soft inside the chiller or otherwise it will get harder and the chiller will not work, it is also used
in re-boiling operations and cooking and there are a lot more functions of steam boiler.
In the project PLC based industrial boiler control we propose to control the parameters like the
temperature of the steam, the level of water, control of feed water pump, Pressure of the steam
and PH of the steam.
The overall logic that is the ladder diagram for the boiler operation is designed with the help of
logo software which is then downloaded into the PLC CPU memory. This PLC accepts the

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inputs from those sensors incorporated within the boiler, evaluate them and generate appropriate
signals which will ultimately use to run on or terminate the output terminals.

1.2 Objective of the Project

1.2.1 General objective
The main objective of our project is to make industrial boiler convenience, controllable and
suitable for good production efficiency.

1.2.2 Specific object

To increase productivity
Controlling boiler before damaging equipment and controlling boiler from hazards
To be familiar with PLC(programmable logic controller) softwares
To maximize quality
To reduce human intervention which indirectly minimize error
To increase consistency

1.3 Statement of the problem

Over the years the demand for high quality, greater efficiency and automated machines has
increased in the industrial sector. Industrial sector require continuous monitoring and inspection
at frequent intervals. There are possibilities of errors at measuring and various stages involved
with human workers. Thus this paper takes a sincere attempt to explain advantages that the
companies will face concerning boiler. The boiler control which is the most important part of any
plant, and its automation is the precise effort of this paper. In order to control boiler and
minimize human intervention, there is a need to develop a PLC that monitors the plant and helps
to reduce the errors caused by humans.

1.4 Project Targeted Questions

The following are list of project questions:
What is boiler? Why we need boiler? Where we use? How we use?
How its mathematically modeled? How its system analyzed? How to design its system
variable?
Is boiler bringing hazards or damages to man, machineries, environmentetc? If so, how
to control? Either any method to control before? If so, what is the shortcoming of the

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 controlling method? How do you overcome this shortcoming? Either any other efficient
and effective method to control? What makes it effective and efficient? Are these control
methods economically feasible?
Are the control methods manual or automatic? If manual how? If automatic how? If
automatic are it use PLC or other? If PLC by what software? By what programming
method: Ladder diagram, FBD or any other?
How to simulate the program? Are the program has problem? How to interface the
software with hardware? Is there any problem during interfacing hardware? If ok, discuss
about the output?

1.5 Significance of the project

To measure the actual values of different parameters for which the boiler is designed.
Safe working range of the different parameters is maintained.
To monitor one or more variables at a time and provide input for automatic control.
In case of operator failure to take remedial action for an upset condition, it protects the
boiler by alarms and trappings.
To provide data on operating conditions before failure of the equipment for analyzing the
failure.

1.6 Limitation of the Project

Limitation of the projects is listed below.
Initial investment is very high
Need high skilled technician for maintenance and installation
Increase unemployment

1.7 Method and materials of the Project

In our project we have developed PLC based industrial boiler control. The boiler is controlled by
installing different sensors on the system and the analog values of the sensors are given to PLC.
In the PLC we embedded programming command with the help of logo soft PLC software and
uploading to PLC memory location and CPU.
The work flow of our project involves system development from hardware and software to the
integration of both elements. Then, the system is being tested to produce a certain results that

3
will be analyzed to produce the results that compatible with the system. By using the program
PLC control the output terminals.

Figure 1.1 Project development methods

The project has three basics:
1. PLC: programmable logic controller
2. The sensors: temperature sensor, Pressure sensor, level sensor, flow sensor
and PH sensor.
3. The outputs: solenoid valves, motors, buzzers, bulbs and contactors.
Additionally, different cable is needed for data transmission to PLC.

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1.8 Scope of the project
Industrial boiler is a system designed to produce steam in varying quantities for a variety of
applications including space heating, process heating, power generation and other huge
industries.
We know that boiler automation is a big system that can control everything automatically in the
large industry or power plants. But, our project is specified for only five systems.
Level Control
Pressure Control
Flow Control
Temperature Control
PH monitor

1.9 Task and Time Schedule

Table 1.1 Task and time schedule

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1.10 Cost Estimation
Table 1. 2 cost estimation

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 2. LITERATURE REVIEW AND SYSTEM MODELING

2. 1 Literature Review
2.1.1 Brief Descriptions of PLC
Programmable logic controllers (PLCs) are members of the computer family capable of storing
instructions to control functions such as sequencing, timing, and counting, which control
machine or a process. The PLC is composed of two basic sections, the Central Processing Unit
(CPU) and the Input/output (I/O) interface system. The PLC measures input signals coming from
a machine and through the internal program provides output or control back to the machine.
Ladder logic is the programming language used to represent electrical sequences of operation.

2.1.2 Brief Descriptions of Components

Switches: switches are the basic components of PLC. Two types of switches are available in
PLC.
i. Digital switch (ON/OFF).
ii. Analog switches (continuous varying).
Timer: is the electronics device which introduced delay in the circuit. In analog timers, when
the supply is given it start its countdown from a preset value set by the user. When the
countdown reaches zero the output of timer becomes high.
Sensors: are devices that convert a physical condition into an electrical signal. Some examples
of sensors are:
Level sensor: a low-energy float within these sensors measures liquid level at a certain
point.
PH sensor: is to detect the water whether it has an acidity or base content.
Temperature sensor: is used to sense the temperature value of the industrial boiler
automation by compare and contrast the set point with the measured value of the system.
Flow sensor: are related to devices called velocimeter that measure velocity of fluids
flowing through them.
Pressure sensor

2.2 Block Diagram Descriptions

An industry has an emergency stop button to stop the whole process instantly if any error
occurred during operation. The emergency stop buttons are normally closed type.

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To start the mechanism a start button (normally open type) switch is used which is connected
after stop button. When start button is made ON the lower level sensor sense the water level
below the lower level hence it start the motor to pump the water in to the boiler.
The pump runs till the water reaches the higher level sensor. After that the pump stops running.
The temperature sensor provides the temperature information to the PLC. If the temperature is
less than the pre-set value the heater starts after some second of motor OFF time. Temperature
rises continuously and form water steam. The temperature should not rise beyond tolerance level
of boiler hence the temperature should rise up to certain limit and the heater should stop at that
moment. The temperature again decreases and if goes below preset value it starts the heater. The
above process continues. The steam produce in the boiler exert a pressure on the boiler which is
picked up by the pressure sensor. If pressure reaches the pre-set value it make the valve open and
steam with a definite pressure goes out through the pipe. The pre-set value of the pressure should
be calculated carefully and it should not exceed maximum limit of boiler tolerance. This process
result in decrease in water level and if falls below the lower level sensor the motor starts during
which the heater stops and whole process repeats. The PH sensor also senses the acidity or
basicity property. If PH value is above seven the base valve is opened and if it is less than seven
the acid valve is opened until the system neutralized. The following figure shows the schematic
diagram of the system.

Figure 2.1 Schematic diagram of PLC based industrial boiler control

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 Figure 2.2 Block diagram of PLC based industrial boiler control

2.3 Mathematical Model of Boiler

()
To develop the mathematical model fuel mass flow rate is considered as input variables

and the pressure inside the boiler as output variables.

The following figure shows the model of boiler. In this model following parameters are
balanced.[3]
Mass
Energy
Momentum

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 Figure 2.3 model of boiler

Mass Balance [4, 5]

The density for homogeneous fluid:

= (a)

Taking the time derivative for constant volume:

For a constant volume conservation of mass gives:

= ( ) ( ) (b)

Putting equation (b) in (a)

= = ( ) ( ) (c)

From equation (c)

= + . (d)

Energy Balance [5-7]

For energy balance two quantities are considered to be conserved:
Conservation of Mass

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 Conservation of energy
Conservation of mass
Mass is a conserved property, it cannot be created or destroyed.
The conservation of mass can be stated as:

= ( ) ( ) (e)

The conservation of mass can be expressed in rate form as:

= ( ) ( )

Conservation of Energy
The conservation of energy can be stated as:

= + ( ) ( ) .. (f)

The conservation of energy can be expressed in rate form as:

= + ( ) ( )

Work flow [8]

It is the energy that is required to push fluid into or out of a control volume.
= (g)
=
=
=

= .. (h)

= + . (i)
= + ( + + ) Where = + + and = +
2
=+ + (j)
2

Substituting equation (j) into (f) with replacing =
2 2


= + ( + + ) ( + + )
2 2

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= + ( ) ( ).. (k)

Substituting = () in equation (k)

[ ]
= + ( ) ( ) (l)

Momentum Balance [9-11]
Four terms are conserved in momentum balance:
Friction
Hydrostatic head
Inertia
Acceleration
1) The change in pressure due to friction:
To determine the pressure drop, it is convenient to work with the Moody or Darcy friction
factor, which is dimension less parameter defined as:

= ( )
2
2
The pressure drop = P1-P2 associated with fully developed flow from the position x1 to x2 may
then be expressed as:
2
=
1
2
= 22
1
2
= 2(21).. (m)

2) The pressure loss due to hydrostatic head

Hydrostatic head loss:
The heat produced by coulomb friction due to fluid particles.

= . (n)

3) The inertial term for the pressure loss

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 Using Newtons 2nd law:

()
= =

2
()
2
= . (o)

4) The acceleration term for the pressure loss is given by:

Using Newtons 2nd law:
()
= = = ()

= ( )

= ( ) ( )

2 =

2
2
2
2
2
= 2 ( 2
2
)

2 2
2
= 2
( 2
).. (q)
2

Combining equation (m), (n), (q) and (o) gives the total conservation of momentum equation

2
() 2 2
2 2 2
= 2(21) + + + 2 ( ).. (p)
2
2

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 3. EXPECTED RESULT

3.1 Expected Result

1. Flow sensor
First the level sensor checks weather the tank level is low or high and if the tank is at low level
the coil energizer energizes the motor pump. When motor starts the flow sensor sense the value.
Otherwise, the motor pump is turn off. Next to level sensor, the PH value of the water is
measured and also the temperature and pressure of the tank is checked with the temperature
sensor and pressure sensor consequently.
2. Pressure sensor
First the pressure of the boiler inlet valve and out let valve is sensed by the sensors respectively.
And if the pressure is out of the pre set value the alarm is turn on and the valve is closed. The
timer is needed to indicate continues operation.
3. Temperature sensor
The temperature sensor checks weather the temperature is at the pre set value and if it is so the
heater is on. Otherwise, the heater is off. The timer is needed to indicate continues operation.
4. PH and level sensor
As usual also the level is checked by the level sensor and if it is above the pre-set value pump
motor is off and proceed to check the acidity or base of the water in the tank by Ph sensor. If it is
acidic the base valve is open and the acid valve is closed and vice versa. The timer is needed to
indicate continues operation.

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 4. CONCLUSION
PLC based industrial boiler control project plays an important role in minimizing hazardous
damage which occurs due to an improper use of boiler. When boilers used unwisely it may
explode and burn expensive materials.

In this project some parameter of boiler internal system is described. The parameters are:
temperature, pressure, level of water, flow of the system and PH value.

These systems are controlled by installing different sensors on and around the boiler. Then, the
physical variables which detected by the sensors are transmitted to PLC memory and CPU. The
PLC analyzes the input variable based on the pre set value programmed and uploaded to the
CPU. Based on these it decides to on and off the system output device or different indicators.

Generally, making convenience , controllable and suitable industrial boiler are useful to increase
plant production efficiency and controlling of boiler before damaging human and high cost
equipment.

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REFERENCE
[1] J. Makovicka, V. Havlena, and M. Bene, "Mathematical modeling of steam and flue gas
flow in a heat exchanger of a steam boiler," in Proceedings of ALGORITMY2002. Conference
of Scientific Computing, 2002, pp. 171-178.
[2] J. Bujak, "Mathematical modeling of a steam boiler room to research thermal efficiency,"
Energy, vol. 33, pp. 1779-1787, 2008.
[3] M.-N. Dumont and G. Heyen, "Mathematical modeling and design of an advanced once-
through heat recovery steam generator," Computers & chemical engineering, vol. 28, pp. 651-
660, 2004.
[4] C. Kothandaraman, Fundamentals of heat and mass transfer: New Age International, 2006.
[5] F. P. Incropera, A. S. Lavine, and D. P. DeWitt, Fundamentals of heat and mass transfer:
John Wiley &Sons, 2011.
[6] M. Thirumaleshwar, Fundamentals of heat and mass transfer: Pearson Education India, 2009.
[7] R.-G. Cai and S. P. Kim, "First law of thermodynamics and Friedmann equations of
Friedmann-Robertson- Walker universe," Journal of High Energy Physics, vol. 2005, p. 050,
2005.
[8] Y. Cengel, Introduction to Thermodynamics and Heat Transfer+ EES Software vol.
77235657: McGraw Hill Higher Education, London, ISBN, 2007.
[9] W. Graebel, Engineering fluid mechanics: CRC Press, 2001.
[10] Y. A. Cengel, M. A. Boles, and M. Kanoglu, Thermodynamics: an engineering approach
vol. 5: McGraw-Hill New York, 2011.
[11] H. Yamaguchi, Engineering fluid mechanics vol. 85: Springer Dordrecht, Netherlands,
2008.
[12] Albert Ting-pat so. Intelligent Automation System.
[13] Automation technology with Siemens PLC ABB 2008

[14] Jon S. Wilson - Google Books Sensor Technology Handbook

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 Appendix
Nomenclature
Table app. 1 Nomenclature

Table app.1 1 Nomenclature

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