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Proceeding of the

International Conference on Electrical, Computer and Telecommunication Engineering


01- 02 December 2012 (ICECTE2012), RUET, Rajshahi-6204, Bangladesh

ICECTE2012: PI-0104

Design and Analysis of a Three Element Boiler Drum Level Control System
P. K. Bhowmik1*, P. Dutta2, S. K. Dhar3 and M. Dey4
1
Department of Instrumentation & Communication, Eastern Refinery Limited, Chittagong, Bangladesh
2
Department of Energy Auditing Unit-2, Bangladesh Power Development Board, Chittagong, Bangladesh
3
Member Institute of Electrical and Electronic Engineers, Chittagong, Bangladesh
4
Department of EEE, Chittagong University of Engineering & Technology, Bangladesh
E-mail: pkbcuet@yahoo.com, dpinky@yahoo.com, sagar378@gmail.com, mrinmoydey@yahoo.com

ABSTRACT 2. PROCESS SCHEMATIC DIAGRAM


This paper presents design and analyze of three The boiler drum level control system is as follows
elements boiler drum level control system for [1]-
ensuring system reliability, safety and robustness in
a cost effective way. The control system contains a
feedfoward loop using the steam flow signals and a
feedback PID loop using feed water flow and drum
level signal. Output of the two loops is summed to
establish set point for the actuator. In this way,
feedwater flow tracks steam flow and any
disturbances in the system will be arrested quickly. A
feedback PID controller plus adapt feedfoward
compensator can be successfully employed for the
level control in such a plant.

KEY WORDS: Three element control, boiler drum


level control, feedforward control, feedback control.

1. INTRODUCTION
Boiler drum level control is one of the critical control
loop for ensuring un-interruption of operation,
protection and safety of boiler system [4]. For boiler Fig. 1. Schematic diagram of boiler drum level
drum level control by manipulating the feed water control system
flow to the boiler, three elements: drum level, main
steam flow and feed water flow; the primary inputs
are normally being considered. In addition, drum
pressure, main steam pressure and temperature are
also considered for compensation [3]. The three-
element system provides tighter control for drum
level with fluctuating steam load, rapid change in
steam demand or system having multiple boilers and
multiple feedwater pumps or where the feedwater has
variations in pressure or flow. In the boiler the steam
flow changes according to the load demand that will
change ultimately the water level in the boiler drum.
The drum level controller manipulates the feedwater
flow setpoint in conjunction with feedforward signal
from the steam flow measurement [1]. The boiler
drum water level control of 3MW STG Unit-II of
Eastern Refinery Limited, Chittagong, Bangladesh is
taken as the reference model applied in this study. It
is analyzed in a systematic way and the simulation Fig. 2. Logic diagram of boiler drum level control
result of the system give the clear understanding system
about the system.
Proceeding of the
International Conference on Electrical, Computer and Telecommunication Engineering
01- 02 December 2012 (ICECTE2012), RUET, Rajshahi-6204, Bangladesh

ICECTE2012: PI-0104

3. PROCESS MODEL DEVELOPMENT 5. CONTROLLER CONFIGURATION AND


The performance of the three-element control system PROGRAM DEVELOPMENT
during transient conditions makes it very useful for In this paper the system analysis is performed using
general industrial and utility boiler applications. YOKOGAWA YS1700 controller which is
Plants which exhibit load characteristics of this type configured and programmed by YS1000 software.
are those with mixed, continuous, and batch Thus the system analysis requires the following steps
processing demands [5][6]. Figure 1 and 2 shows the [2]:
control scheme for three-element drum level control. System configuration:- this is mainly configures
In this system the output signals of the level the controller model and required system, input
controller (LIC) use as a cascade set-point input to and output.
feedwater flow controller (FIC). Feedwater flow and Parameter settings:- it consist of settings of PID,
steam flow are measured by the differential pressure controller actions, alarms, units, input & output
transmitters. The output signal of the flow transmitter
range
is linearized by a square root extractor (FY). The
Writing tax program:- writing program for the
feedwater flow controller produces the necessary
respective system according to the programming
corrective signal to feedwater flow control valve to
maintain feedwater flow. The steam flow signal instruction.
which is act as a disturbance in boiler drum level Upload all settings and tax program from YS1000
control system is computed by feed forward software to YS1700 controller & run the
compensator adds to the flow controller output [1]. controller.

4. CONTROL LOOP OF BOILER DRUM 5.1 Parameter settings and configuration


LEVEL CONTROL SYSTEM References In figure 4 the parameter settings of the
The control loop of three element boiler drum level controller are given. PID1 and PID2 are the
control system is shown in figure 3. Here, the proportionalintegral-derivative settings for primary
primary control loop consists of LIC and secondary and secondary control loop respectively. In the
control loop having FIC are connected in cascade config2 the control action of controller, controller
mode. The output of primary control loop controller output type and the input/ output signal settings are
is the input or set value to the secondary control loop. presented [2].
The feedback compensators both for primary and
secondary loop are used to improve the control action
of the whole control loop. The combination of
primary and secondary loop is the feedback control
design of boiler drum level control system. The feed
forward compensation which main objective is to
minimize the effect of disturbance, the steam flow in
drum level control system is sum with the output of
secondary loop controller (feedback control) and
finally gives actuating signal to the final control
element, the feed water flow control valve.

Fig.3. Control loop with associated feedback


compensator of boiler drum level control system
Proceeding of the
International Conference on Electrical, Computer and Telecommunication Engineering
01- 02 December 2012 (ICECTE2012), RUET, Rajshahi-6204, Bangladesh

ICECTE2012: PI-0104

5.2 Parameter settings and configuration


For developing the text program for boiler drum
level control system the respective program
instructions of YSS100 software are used keeping in
mind that text program should easily understandable
to new user. The developed program instruction for
the described system is given bellow with
explanation.

; Start program
LD Y1 Read output (Y1) of the controller.
ST T3 Store Y1 in temporary register T3
LD T2 Recall and load in temporary register
ST P4 Store in variable parameter P4
LD X3 Read input-3, Main steam flow
ST P5 Store X3 in variable parameter P5
ST T2 Store X3 in temporary register T2
CHG Status register interchange
- Subtraction
ST P6 Store X3-Y1 in variable parameter P6
LD P11 Load variable parameter (40.2%)
* Multiplication
ST FF2 Store in Feedforward compensator
LD X5 Read input-5, Drum level
ST P1 Store X5 in variable parameter P1
LD P12 Read variable parameter P12 (T1=9 sec)
LAG1 Computing first order lag 1/ (1+T1S)
ST P2 Store (1-e-t/9)X5 in variable parameter P2
LD X2 Read input-2, Feed water flow
ST P3 Store X2 in variable parameter P3
LD P13 Read variable parameter P13 (T2=5.2 sec)
LAG2 Computing first order lag 1/ (1+T2S)
ST P7 Store (1-e-t/5.2)X5 in variable parameter P7
LD P2 Read variable parameter P2
CHG Status register interchange
CSC Cascade Control
ST Y1 Store output to output-1
terminal (4~20mA)
ST Y2 Store output to output- terminal (1~5V)
LD T3 Read temporary register T3
LD X4 Read Control valve position (feedback)
- Subtraction
ABS Absolute Value of subtracted value
LD P9 Load variable parameter P9
LD P10 Load variable parameter P10
HAL1 High Alarm output
ST T1 Store in temporary register T1
END End of Program

Fig. 4. Parameter settings of controller (PID1, PID2 Fig. 5. Test program of boiler drum level control
and Configure-2) for boiler drum level control system in YSS1000 software.
system
Proceeding of the
International Conference on Electrical, Computer and Telecommunication Engineering
01- 02 December 2012 (ICECTE2012), RUET, Rajshahi-6204, Bangladesh

ICECTE2012: PI-0104

5.3 Program execution and simulation The simulation result also ensures the ability of the
After writing the text program in YSS100 software system to minimize the effect of disturbance (stem
then the program is uploaded to the YS 1700 flow) by taking preventive action called feedforward
YOKOGAWA controller and run the program [3]. In compensation. Thus the control system offers precise
AUTO mode controller always scan its input address set point tracking and effective disturbance rejection
and give output signals according to the program which is the desired goal of any control system.
instruction loaded to it.
7. CONCLUSION
To cope with the technological advancement and to
ensure higher efficiency, effectiveness and reliability
of boiler drum level system control in a more
economical way, the system presented in this paper
would be a great scope. It will also provide better
flexibility in customization of operation, error
checking and modification with minimum effort. The
paper has furnished itself to study the integral parts
of the entire process, their implementation and the
problems that can occur have also been investigated
with due importance.

8. ACKNOWLEDGEMENT
The author would like to thank Mr. Sharafat Ali,
Assistant General Manager, Dept. of Instrumentation
and Communication, Eastern Refinery Ltd.,
Bangladesh for his valuable guideline to complete
the task. Also thanks to Md. Ali Zulquarnain,
Member, Planning, Bangladesh Atomic Energy
Commission for his valuable review and comments.

REFERENCES

[1]. Operation Guideline of Boiler of STG Unit-2 of


Eastern Refinery Limited, Chittagong,
Bangladesh.
Fig. 6. Simulation result of boiler drum level [2]. YOKOGAWA YSS1000 Programmable
controller (a) Start from no level to set level, (b) Step Controller Software, YSS1000 programming
set level change instruction Manuals.
[3]. Combustion Management Solutions Boiler
For checking the control loop performance at first Drum Level (Feedwater) Control AD353-105,
assume that there is no water level in the drum, so the Rev-2, January 2005, Siemens Energy and
controller will give control signal to the control Automation.
element according to the program instruction to [4]. Mingliang WU, Lili WEI, Jiankang HUANG,
increase the feed water flow to maintain the drum Mingyong WU, The Cascade Three-elements
level. Thus result is shown in figure 6(a). The output Fuzzy auto-adapted PID Control System for
response of the controller for step change in level set Boiler Advanced Materials Research Vols. 139-
value is shown in figure 6(b). The response of the 141 (2010) pp 119-1923.
controller for steam flow change without changing [5]. Tatang Mulyana, Mohd Nor Mohd Than,
the drum level set value is also excellent. Dirman Hanfi, A Disctrete Time Model of
Boiler Drum and Heat Exchanger QAD Model
6. RESULT AND DISCUSSION BDT 921, International Conference on
The simulated result of the boiler drum level control Instrumentation, Control and
system ensure that it will track the set point without [6]. A Guide to Boiler Drum Level Equipment and
having considerable overshoot combining the effect Control Concept- presented by Clark Relience
of both LIC and FIC which are connected in cascade. Corporation, Strogsville, Ohio.

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