International Journal of Instrumentation Science and Engineering.

ISSN 2278-5825 Volume 4, Number 1 (2017) pp. 1-6

© Research India Publications
http://www.ripublication.com

Development & Control of Electric Boiler with

Parameters Monitoring Using IoT

A.T. Soni1, S.L. Kapare2, S.A. Jadhav3 and S.C. Rajgade4

1, 2, 3
Student of BE, Department Of Instrumentation and Control,
AISSMS IOIT, Pune University, Maharastra, India.
4
Assistant professor, Department Of Instrumentation and Control,
AISSMS IOIT, Pune University, Maharastra, India.

Abstract
Industrial Advancements dictates the need of integration of microcontrollers
with the existing systems in the process environment for controlling and
monitoring. Environmental norms motivate the need to develop systems which
minimize the harm to the environment. This paper describes the design,
development, control and monitoring of an electric boiler. The parameters of
the boiler which plays an important role in the dynamics are the steam
temperature, the boiler vessel pressure, the water level and the steam flow rate
(load) out of the boiler. Monitoring and control of these parameters are essential
for the smooth and safe operation of the boiler. The temperature and the level
of the boiler is controlled by a Programmable Logic Controller (PLC) while the
temperature and the steam flow rate of the boiler is monitored in the real time
by the Internet of Things (IoT) module. IoT module comprises of an Arduino
Uno microcontroller and a Wi-Fi module ESP 8266. The data monitored by the
IoT module is sent to a Webpage, from where it can be accessed. Safety is
enhanced by an interlocking system. To ensure the proper operation, it’s
availability for maximum period and maintenance; the parameters of the boiler
are needed to be recorded, analyzed and acted upon. All of the above points are
accomplished in the proposed method. This paper provides a way to integrate
the use of PLC and IoT to control and monitor the boiler parameters.
Keywords: Boiler, Temperature, Level, Steam Flow, PLC, Monitoring,
Controlling, IoT (Internet of Things)
2 A.T. Soni, S.L. Kapare, S.A. Jadhav and S.C. Rajgade

1) INTRODUCTION
A Boiler is an enclosed vessel that provides heat to be transferred into water until it
becomes heated water or steam. Steam is the gas formed when water passes from the
liquid to the gaseous state. The steam boiler is an energy conversion equipment or
device which transforms chemical energy of fuel such as coal, oil, gas or nuclear energy
into steam. [1] As conventional boilers rely on the use of fossil fuels such as coal, oil,
gas to produce heat, greenhouse gas emissions, mining destructions, emission of
harmful substances motivate the use of alternative source of energy for generation of
steam. An electric boiler can be considered as a serious contender in this regard. An
electric boiler uses electricity as source of energy to transform water into wet steam.
Saurav Kumar Mohanty [3] described a method to monitor and control a boiler’s
multiple parameters using a PIC controller. Therotically it is possible to operate with a
tedious efforts, a boiler manually. But it is difficult to maintain a disturbance constant.
There is a delay to respond to error and do correction which may lead to boiler upset.
Mechanical strength along with the control logic and instrumentation determines the
safety and reliability of a boiler.
Sunil P. U, Jayesh J Barve, P S V Nataraj [1] in their work proved a method for boiler
drum level control. The primary function of boiler is to maintain the steam energy in
balance with the load demand while maintaining the internal variables such as
temperature, pressure, level in a desired range.
L.Navneeth, V.Rukkumani [4] in their work described the use of IoT as a platform for
communication.
The existing systems lack the integration of PLC’s and microcontrollers. PLC’s are
designed for rugged factory environment and provide precise automation. PLC enables
the stable and smooth operation, maintaining temperature and the level of the boiler
vessel for steam generation. The microcontroller based IoT module collects the data of
the parameters, establish connection to the internet server (cloud) and display the data.

2) DESIGN CONSIDERATION
The current design objective is to provide low-cost energy with an acceptable impact
on the environment.

2.1 Calculation of boiler vessel

 Height of the boiler : 500 mm
 Diameter of the boiler : OD- 1012.5 mm ID - 1008.5 mm
 Thickness : 4mm
Development & Control of Electric Boiler with Parameters Monitoring Using IoT 3

 Working gas pressure : 1.66 MPa

 Working temperature of feed water : 25°C
 Working pressure range : 2.5 baR

2.2 Material and stress calculations

Yield Strengths: 400 N/m2
σcomp = load/area
Load = P =2.5 bar = 2.5 x 106 N/m2
σv = stress in circumferential direction = Pr/t
σlong = stress in longitudinal direction = Pr/2t
σ = σv+ σlong
σ = Pr/t + Pr/2t
σ = 189.09375 KN/m2
Yield stress of vessel = 400 N/mm2
Yield stress of vessel = 400 x 106 N/m2

3) SYSTEM ARCHITECTURE
The main components of the system are as follows:

Figure (1) Development and Control of an Electric Boiler with Parameters

Monitoring Using Internet of Things (IoT) Block Diagram
4 A.T. Soni, S.L. Kapare, S.A. Jadhav and S.C. Rajgade

3.1 Input Sensors and Output Elements:

The sensors used are Resistance Temperature detector (RTD), Level Switch, Outlet
Steam flow sensor. The output are an inlet solenoid valve and the heating elements.
Along with this, a relay panel is designed to interface high rating relays to the PLC. A
pressure gauge is used for the pressure indicating purpose, a pressure relief valve for
safety, a sight glass for the indication of the water level in the boiler.

3.2 Boiler:

Figure (2) Boiler Vessel

The boiler material is medium carbon steel 55C8 .The boiler structure mountings are
as shown in the figure (2).

3.3 Programmable Logic Controller:

Programmable Logic Controller (PLC) is a digital computer used for the automation of
various electromechanical processes with ability to re-program the logic as per
requirements of user in industries. It is used to control the boiler operation.

3.4 The Internet of Things Module:

The IoT module consists of the Arduino Uno microcontroller, the ESP 8266 Wi-Fi, IoT
application webpage and Application Program Interface.
Development & Control of Electric Boiler with Parameters Monitoring Using IoT 5

3.5 Internet(Webpage):
Using the configured IP address, user can access the control interface of the system.
User needs to access this IP address from Web browser.

4) DISCUSSIONS AND CONCLUSION:

In the proposed design of the electric boiler, the wet steam will be generated. The Inlet
water, temperature and the level of the water will be controlled by the PLC. The
temperature and the steam flow rate will be measured and act as inputs to the Arduino
Uno Microcontroller. The real-time data of the parameters will be sent to the cloud via
a Wi-Fi module. This cloud data can then be accessed via a webpage.
Existing methods lacks the use of both PLC and Microcontrollers on a single platform.
The integration of PLC and IoT is achieved.

5) RESULTS:

Figure (3) Steam temperature pressure relation

The graph shows the relation between the steam temperature and the steam pressure
with and without control. As the temperature crosses the boiling point of water, that is
100°C (or 212°F), the pressure starts building up. The pressure of about 1 bar is
6 A.T. Soni, S.L. Kapare, S.A. Jadhav and S.C. Rajgade

achieved at the temperature of 121°C (or 250°F). As the Boiler vessel has the Factor of
Safety (FOS) that can sustain the pressure of approx. 2 bar, the maximum temperature
that can be reached is 135°C (or 275 °F). Once this temperature is reached, safety valve
is actuated preventing further buildup of the pressure.
When the boiler operation is controlled, it is kept to its set point.
The real time temperature and flow data is transmitted via ESP 8266 to the web server.
By entering an appropriate IP address the data can be read from a web page.

Figure (4) Real-Time Parameters on the webpage

REFERENCES:
[1] Sunil P. U, Jayesh J Barve, P S V Nataraj, 28-30 November 2013,“Boiler drum
level control using QFT”, Nirma University International Conference on
Engineering,NUiCONE-2013.
[2] B. Wayne Bequette, 2003, “Process Control: Modeling, Design, and Simulation
Prentice Hall Professional”
[3] Saurav Kumar Mohanty, “Multi-parameter monitoring & controlling for a
Boiler using PIC controller”, International Journal of Scientific & Engineering
Research, Volume 5, Issue 4, April-2014
[4] L.Navneeth, V.Rukkumani, “Boiler Monitoring in Power Plant Using Internet
of Things”, International Journal of Computer Techniques -– Volume 3 Issue
3, May – June 2016.