Project: Water Level Control System of Steam Boiler

A report submitted in partial fulfilment of the requirement for the course of

Control Engineering (BDA30703) SEM I 2021/22
Faculty of Mechanical and Manufacturing Engineering
Group 2
MUHAMMAD AFNAN BIN CHE MAZLAN CD200117
MUHAMMAD HADIF BIN MOHD ARIS CD200208
MUHAMMAD NIZAM BIN KHAMIS CD200232
NUR IFFA INSYIRAH BINTI KHAIRUZAMAN CD200056
SITI NUR HIDAYAH BINTI ABD RAZAK CD200224
Weigh
Rank Marks Remarks
tage
(WP1) Formulate (WP1)Originality
in analysis

Review on industrial process

0.5
Chapter 2: control
(/5)

Literature
review Review on control system
0.5
components
suitable solution (/5)

Mathematical model 0.25

Chapter 3:
Theoretical
calculation and Transfer function 0.25
analytical
procedure
LO5 - INDIVIDUAL & TEAM WORK & LO11 - PROBLEM

Block diagram 0.5

System construction in MATLAB

(WP3) Research

0.3
based (/5)

Chapter 3: Simulink
Theoretical
Open-loop system analysis
calculation and 0.3
method and procedure
analytical
Closed-loop system analysis
procedure 0.4
method and procedure
ANALYSIS

(WP3) Fundamental Profesional

based & principle disipline

References Use proper format 0.5

(/5)

Report writing Well presented and organized 0.5

analytical approach

Analysis on time response 0.4

Chapter 4: Analysis on frequency

(/5)

Results and 0.3

response
discussion
Analysis on stability 0.3
(WP4) Familiarity of

Chapter 1:
Objectives and scope 0.3
Introduction
issue (/5)

Chapter 5:
Conclusions Conclusions 0.4
and
recommendati Recommendations 0.3
ons
presentation

Proper attire 0.2

Group
LO

Fluency 0.3
5

Communication and contents 0.5

Total ( / 35)

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 TABLE OF CONTENTS

FRONT PAGE i
GROUP FORMATION AND RESPONSIBILITIES iv

CHAPTER 1 1 INTRODUCTION
1.1 Introduction 2
1.2 Steam Drum 2
1.3 Benefit of Steam Drum 2
1.4 Objective 2
1.5 Scope 2

CHAPTER 2 4 LITERATURE REVIEW

Type chapter title (level 2) 5
Type chapter title (level 3) 6

CHAPTER 3 4 THEORETICAL CALCULATION AND ANALYTICAL

PROCEDURES
3.1 Mathematical Model 5
3.2 Theoretical of Block Diagram and Transfer Function 6
3.3 Transfer Function 6
3.4 Block Diagram 6
3.5 Construction in MATLAB Simulink 6

CHAPTER 4 4 RESULTS AND DISCUSSION

4.1 Root Locus 5
4.2 Time And Frequency Response Analysis 6
4.3 Step Response With And Without Pid 6

CHAPTER 5 4 CONCLUSIONS AND RECOMMENDATIONS

ii
REFERENCES 4

iii
GROUP FORMATION AND RESPONSIBILITIES

PROJECT MANAGER
MUHAMMAD HADIF BIN MOHD ARIS
(CD200208)

PROJECT ENGINEERING
MANAGER QUALITY CONTROL MANAGER
MUHAMMAD NIZAM BIN KHAMIS MUHAMMAD AFNAN BIN CHE
(CD200232) MAZLAN (CD200117)

PROJECT ENGINEERING
QUALITY CONTROL MANAGER
MANAGER
NUR IFFA INSYIRAH BINTI
SITI NUR HIDAYAH BINTI ABD
KHAIRUZAMAN (CD200056)
RAZAK (CD200224)

iv
 CHAPTER 1
INTRODUCTION
1.1 Introduction
In power plants boiler drum is a closed vessel in which steam is produced by burning coal
in the furnace. The main input variable of the boiler drum are fuel, feed water and air. The
outputs of the boiler system are electrical power, steam pressure, steam temperature and flue gas.
According to these parameters the drum level may increase or decrease. The boiler drum level
should be monitored continuously. It should be within a certain limited value. If the
measurement of boiler drum level is not within the limited value, water carryover may be
occurred. If the level is low in drum overheating occur in boiler water tube this cause the
damages in boiler drum surface and creates the cracks in the surface. If the value of level in
boiler drums more than the limited value it may transfer the moisture into the turbine, which
reduce the boiler efficiency.

The process controllers have to be designed in a way, that simultaneously fulfill the load
demand as soon as possible, while at the same time bearing in mind safety and life span of the
plant crucial elements. One common challenge is the steam drum-boiler unit control, supplying
the steam turbine continuously with high pressure and temperature steam. The controller should
maintain drum pressure and water level within acceptable limits over the complete operating
range.

1.2 Steam Drum

The separated steam is drawn out from the top section of the drum and distributed for
process. Further heating of the saturated steam will make superheated steam normally used to
drive a steam turbine. Saturated steam is drawn off the top of the drum and re-enters the furnace
in through a superheater. The steam and water mixture enters the steam drum through riser tubes,
drum internals consisting of demister separate the water droplets from the steam producing dry
steam. The saturated water at the bottom of the steam drum flows down through the downcomer
pipe, normally unheated, to headers and water drum. Its accessories include a safety valve,
water-level indicator, and level controller. Feedwater of boiler is also fed to the steam drum
through a feed pipe extending inside the drum, along the length of the steam drum.

1
 A steam drum is used without or in the company of a mud-drum/feed water drum which
is located at a lower level. A boiler with both steam drum and mud/water drum is called a bi-
drum boiler and a boiler with only a steam drum is called a mono-drum boiler. The bi-drum
boiler construction is normally intended for low pressure-rating boiler while the mono-drum is
mostly designed for higher pressure-rating. On steam locomotives the steam drum is also called a
steam dome.

If the water level is too low in boiler drum it leads to boiler explosion. If the water level
is very in boiler drum it cause damage to turbine due to the affect of separator steam water.
Serious consequences occur in high or low level so we must take strict control. Conventional
Proportional integral derivative controller is popular three element control. If there is any process
disturbance the 3-element control does perform well due to the lack of proportional controller
gain knowledge .The collected data from the PID controller is used to gain the knowledge on the
intelligent control technique and developed fuzzy logic control.

1.3 Benefits of Steam Drum

 Reduces deposits on Turbine Blades, Super heaters and Steam Lines

 Reduces maintenance and increases run time
 Reduces overall operating costs for maintenance
 Increases operating efficiency from decreased downtime
 Reduce continuous Blowdown
 Stabilize liquid levels
 Higher availability with an innovative alternative

High pressure steam is critical for the operation of the refinery. For the production and
reliable supply of steam, accurate level measurement is required that allows efficient operation of
the steam boiler. Any steam raising plant will use steam drums, and these steam drums require
accurate and reliable level measurement to ensure the safety of the plant.

2
1.4 Objective of The Project

1. Engineering Knowledge
- The project objective to analyze the stability, steady-state errors and
transient response of controlled system using appropriate methods.

2. Problem Analysis
- The project is to demonstrates analysis and design of physical systems using
time and frequency response methods to the practical application in control
systems

3. Individual and Team Work

- Group member working on solvig problem with the principle learned in
control system and verify the concepts covered in basic control system by
hand calculation and simulation in computer-aided software in group
project.

1.5 Scopes
 To model the mathematical of the steam drum
 To analyse the water level in the steam drum
 To stimulate the suitable design for water level in steam drum

3
 CHAPTER 2
LITERATURE REVIEW

4
 CHAPTER 3

THEORETICAL CALCULATION AND ANALYTICAL PROCEDURES

3.1 Mathematical Model

In this part, the drum level calculation fundamental equations that have been found used to
describe the mathematical model of the boiler system. It consists of a steam drum, whose level is
measured and transmitted to a level controller through a level transmitter. The level controller's
control signal opens a valve that controls the flow of feed water. Flow transmitters are used to
measure the flow of feed water. The level-controller controls the feed water flow in response to
changes in the drum's level.

Figure 3.1: diagram of instrument steam drum level control

Figure 3.2: Block diagram for steam drum

From the diagram, the process function that are used are G p ( s) and Gv ( s). G p (s) is refer to boiler
drum transfer function and Gv ( s) refer to valve transfer function. While the r is the input and y
is the output. If we put in the equation it will be:

5
 e (t )=r ( t )− y (t )

For the modelling of Drum water level, we should consider the important influence factors on
water level control system. Steam flow, feed water flow variations, boiler pressure and drum
temperature all have a significant impact on the drum water level control system. The Drum
material balance equation is:

F ( t )=QW ( t )−Q D (t)

Where QW ( t ) is feed water flow and Q D (t) is steam flow of the steam Drum. F ( t ) is Drum water
level variation. Level transmitters are used for measuring the variations in steam and feed water
flow. We get the physical expression of the transmitter as,

dH (t )
Cρ =α √ ∆ pv −β √ ∆ p p
dt

𝛼 and 𝛽 are the feed water and steam flow coefficients. C is the boiler sectional area, 𝜌 is the
water severe of boiler, H(t) is water level of boiler, ∆ p vand ∆ p p are the pressure difference of
feed water and steam orifice flow respectively. After the derivation and simplification, we get a
differential equation [3], which includes the dynamic characteristics of boiler drum water level
under the effect of water supply flow and steam flow.

(
du v
)(
du p
)
2
d h dh
T 1T 2 2
+T 1 = T v +U v − T p +U p
d t dt dt dt

T 1, T 2 are water level transmitter coefficient and boiler sectional coefficient. T cv , are the flow
conversion coefficients of feed water flow transmitter. T p, are the flow conversion coefficients of
steam flow transmitter. The motion equation of regulation of drum water level under the effect of
water supply flow can be expressed as:

d2 h
d t
dh du
(
T 1 T 2 2 +T 1 = T cv v +U v
dt dt )
By taking Laplace transform on both sides of (4) and smaller T cv can be neglected.
y (s ) 1
Gv ( s )= =
r (s) s(1+T cv s)

6
The equation that we use for the steam drum flow are taken from the process that express in
equation [6] and equation [7] which is:
1
Gv ( s )=
T cv s+1

1 +T 1 s
G p ( s )= 2
T 2 s +s

3.2 Theoretical of Block Diagram and Transfer Function

 Open Loop System

An open-loop system, also known as a non-feedback system, is a type of continuous control

system in which the output has no influence or effect on the input signal's control action.
Furthermore, because an open-loop system has no knowledge of the output condition, it cannot
self-correct any errors that may occur when the preset value drifts, even if the deviation is
significant.

Formula that are used for open loop transfer function:

C (s )
=G ( s ) H ( s )
R (s )

The characteristic of open loop system:

i. No comparison between actual and desired values.

7
 ii. Has no self-regulation or control action over the output value.
iii. Each input setting determines a fixed operating position for the controller.
iv. Changes or disturbances in external conditions does not result in a direct output
change
 Closed loop System

A closed-loop control system, also known as a feedback control system, is a control system that
employs the forward path of an open loop system but includes one or more feedback loops.
Closed-loop systems are intended to achieve and maintain the desired output condition
automatically by comparing it to the actual condition. It accomplishes this by producing an error
signal that represents the difference between the output and the reference input. In other words, a
"closed-loop system" is a fully automatic control system whose control action is in some way
dependent on the output.

Figure 3.3: basic closed loop transfer function

Formula that are used for closed loop transfer function:

C( s) G( S)
=
R( s) 1± G ( S ) H ( S)

The characteristic of closed loop system:

i. To reduce errors by automatically adjusting the systems input.

ii. To improve stability of an unstable system.
iii. To increase or reduce the systems sensitivity.
iv. To enhance robustness against external disturbances to the process.

8
v. To produce a reliable and repeatable performance.

9
3.3 Transfer Function

The transfer function of mathematical model is organized to stimulate the water level steam
drum system.

We assume the value that need to be insert in the equation are:

Water level transmitter coefficient (T ¿¿ 1)=0.25 ¿

Water level transmitter coefficient (T ¿¿ 2)=2¿

boiler sectional coefficient.(T ¿¿ cv )=0.15 ¿

1. Transfer function of open-loop model

y (s )
=G(s) H ( s)
r (s)

¿
( 1+T 1 S
T2 S +S 2
)( 1
T cv S +1 )
1+ T 1 S
¿
( T 2 S + S ) ( T cv S+ 1 )
2

1+0.25 S
¿ 2
(2 S + S)( 0.15 S+1)
1+0.25 S
¿ 3 2
0.3 S + 2.15 S + S

2. Transfer function of closed-loop model

y (s ) G(S )
=
r (s) 1+G ( S ) H (S)

1+T 1 S
2
T2S +S
¿
1+
( 1+ T 1 S
T 2 S +S
2
)( 1
T cv S+1 )
10
 1+ T 1 S
2
T2 S + S
¿
1+T 1 S
1+
(T 2 S 2+ S ) ( T cv S+1 )
1+T 1 S
T 2 S2 + S
¿
(T 2 S 2+ S ) ( T cv S+1 ) +1+T 1 S
( T 2 S 2+ S ) ( T cv S+1 )
1+T 1 S
2 (T 2 S2 + S ) ( T cv S +1 )
T 2 S +S
¿
T 2 T cv S3 +T 2 S2 +T cv S2 + S+1+T 1 S

( 1+T 1 S ) ( T cv S+ 1 )
¿ 3 2 2
T 2 T cv S +T 2 S +T cv S + S+1+T 1 S

T 1 T cv S 2 +T 1 S +T cv S+1
¿
T 2 T cv S3 +T 2 S2 +T cv S2 + S+1+T 1 S

Insert the value into equation:

y (s ) ( 0.25 ) ( 0.15 ) S2 +0.25 S+0.15 S+1
=
r (s) ( 2 ) ( 0.15 ) S 3+ (2 ) S2 +0.15 S 2 +S +1+0.25 S
2
y (s ) 0.038 S +0.4 S+1
=
r ( s) 0.3 S3 +2.15 S 2 +1.25 S+1

3.

11
3.4 Block Diagram

The transfer function for this water level steam drum system could be calculate from the
equations above, as shown in Figure 2.

Figure 3.4: An open-loop block diagram for Mathematical modelling steam drum water level system

In additon, by installing the a valve transfer functioning as feedback signal in steam drum
system, the open-loop model from Figure 2 will become a closed-loop model as shown in
Figure

12
 Figure 3.5: A closed-loop block diagram for Mathematical modelling steam drum water level system

As we can see, after we insert the value of variable T 1 , T 2 and T cv we can simplify the equation
and continue to do the root locus, step response, bode diagram, nyquist diagram and nicholes
chart.

3.5 Construction in MATLAB Simulink

Simulink is a graphical programming environment for MATLAB-based multidomain dynamical

systems that allows for modelling, simulation, and analyzing. It is used to model a system and
then simulate the dynamic behavior of the system. It is primary user interface consists of a
graphical block diagramming tool and a set of block libraries that can be customized. It may be
used to drive MATLAB or be programmed from it and enables close connection with the rest of
the MATLAB environment. Simulink is extensively used in digital signal processing and
automatic control for multidomain simulation and model-based design.

Figure 3.6: a block diagram of open loop transfer function by using Simulink MATLAB without PID.

13
Figure 3.7: a block diagram of closed loop transfer function by using Simulink MATLAB without PID.

14
 CHAPTER 4
RESULTS AND DISCUSSION

The objective of this simulation is to identify the differences in feedback control system
responses, such as step responses, root locus, bode diagram, nyquist diagram, and nichols chart,
between open-loop system and closed-loop system. To achieve the objective, Matlab and
Simulink are used to determine the differences in time and fequency responses.

4.1 Root Locus

Open-Loop System Closed-Loop System

Figure 4.1 Root Locus for Open-Loop and Closed-Loop System

According to Figure 4.1 above, the open-loop and closed-loop models have two distinct root
locus. The poles for the open loop were at -0.657 and -6.73, respectively, with a gain value of
0.339 and 0.187. For the closed loop model, the breakaway and break-in points were located at
poles of -4.13 and -6.41.

15
4.2 Time And Frequency Response Analysis

4.2.1 STEP RESPONSE

Open-Loop System Closed-Loop System

Figure 4.2 Step Responses for Open-Loop and Closed-Loop System

The amplitude vs. time graphs are created for the step responses to display the responses
based on the transfer functions. For both open-loop and closed-loop graphs, the rising
period varies. For both systems, the peak amplitudes for the closed-loop and open-loop
models are considerably dissimilar. Additionally, the times for the two models are not
equal; the open-loop models take 9.06 seconds, while the closed-loop ones take 16.1
seconds.

16
4.2.2 BODE DIAGRAM

Open-Loop System Closed-Loop System

Figure 4.3 Bode Diagram for Open-Loop and Closed-Loop System

Models with open-loop and close-loop feedback are depicted in a bode diagram in Figure
4.3. The magnitude of the two models differed; for open-loop, it was -0.706 dB, while for
closed-loop, it was 0.00217 dB. The frequency for each model is then shown to be
different. Phase angle makes up the second plot and likewise displays various outcomes.

17
4.2.3 NYQUIST DIAGRAM

Open-Loop System Closed-Loop System

Figure 4.4 Nyquist Diagram for Open-Loop and Closed-Loop System

The Nyquist diagram, on the other hand, clearly illustrates the differences between open-
loop and closed-loop systems. It is evident that minimum phase closed-loop models are
stable since the Nyquist plot of open loop transfer functions does not encircle them.

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4.2.4 NICHOLS CHART

Open-Loop System Closed-Loop System

Figure 4.5 Nichols Chart for Open-Loop and Closed-Loop System

Another simulation for frequency-response is the Nichols Chart, which uses a log-
magnitude vs. phase plot for the chart. The Nichols chart is plotted using the information
from the Bode diagram as illustrated in Figure 4.5.

19
4.3 Step Response With And Without Pid

A PID controller is a device that regulates temperature, flow, pressure, speed, and other process
variables in industrial control applications. PID controllers, which stand for proportional integral
derivative, are the most precise and reliable controllers because they use a control loop feedback
mechanism to control process variables. In order to control the error and increase system
stability, a closed-loop PID system is created in this project.

Figu
re 4.6 Block diagram of closed-loop with PID

Figure 4.7 Step Responses of Closed-Loop System with PID

The graph above displays the results of the proposed steam drum system with PID, which was
generated by Simulink using the block diagram in Figure 4.6 as a basis.

20
 Table 4.1 The results comparison between with PID and without PID
With PID Without PID
Rise time (s) 0.555 1.163
Amplitude 9.476x10-1 4.466x10-1
Overshoot (%) 21.341 48.507

The comparison of the results following the installation of the PID controller in the proposed
steam drum system is shown in Table 4.1. The data demonstrates significant improvements with
the installation of PID controllers, such as a reduction in time. Additionally, we were unable to
obtain a good outcome due to overshoot. So, the PID could be adjusted to achieve the desired
outcome. The PID is set to 10 for proportional (P), 1 for integral (I), and 1 for derivative (D) in
this situation.

In order to try to obtain the optimal outcome for the modelled system, the "trial and error
method" is used. On the second try, the PID controller's variable is set to 10 for P, 10 for I, and
10 for D. The outcome is then presented in Table 4.2 and Figure 4.8.

Figure 4.8 Step Responses of Closed-Loop System with PID (2nd try)

21
 Table 4.2 The results comparison between with PID and without PID
With PID Without PID
Rise time (s) 0.486 1.163
Amplitude 9.931x10-1 4.466x10-1
Overshoot (%) 4.737 48.507

When comparing data with and without PID, the results show yet another outcome. As the value
of rise time and amplitude indicates a great lot more in comparison to without PID even with the
first try of variable value, we almost exactly achieve the intended outcome after altering the
variable from the PID.

Although there are a few other analyses done by altering the value of another variable to obtain
various outcomes. The variable values that changed on the last try were 100 for P, 100 for I, and
100 for D.

Figure 4.9 Step Responses of Closed-Loop System with PID (3rd try)

In conclusion, the most stable responses, according to a comparison of all the results, is a step
response with a PID that has no amplitude (equal to 1). PID aids in lowering steady state error to
increase stability and enhance the system with a quicker settling time for the system response
effectively.

22
 CHAPTER 5
CONCLUSION AND RECOMMENDATIONS

23
REFERENCES

24
25