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
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
ICECTE2012: PI-0104
; 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