BOILER AUTOMATION

A PROJECT REPORT

Submitted by

ETO23A BATCH STUDENTS

in partial fulfillment of the requirement for the award of the course in

ELECTRO TECHNICAL OFFICER (ETO)
AUGUST 2023

COIMBATORE MARINE COLLEGE, COIMBATORE

(Approved by Directorate General of shipping, Govt. of India)

Submitted to:- ETO Department

Under guidance of:- Mr. Karthick (HOD)
Mr. Rafi (Class in Charge)
Mrs. Rajeswari (Project in Charge)
Mr. K.Rajan
 CERTIFICATE

It is certified that ETO 23A has submitted the project report entitled " BOILER
AUTOMATION", in partial fulfilment of requirement for the award of Course in
Electro Technical Officer, approved by IMU. In the Department of ETO at
COIMBATORE MARINE COLLEGE, Tamil Nadu.

This work was carried out during a period from March to August 2023 Under the
guidance of Mr. Karthick & all ETO faculties.

Signature of H.O.D Class Teacher Signature of Project In-charge

(ETO Department)

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 DECLARATION BY STUDENTS

We here declare that it is an authentic work of us and we have not submitted

the matter presented in this project in any other institute for the award of
course of Electro Technical Officer.

This is certified that the above statement made by the candidates are correct to
the best of my knowledge and belief.

Signature of Project In-charge

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 ACKNOWLEDGEMENT

We are highly grateful to the HOD (ETO Department), Mr. Karthick, at

COIMBATORE MARINE COLLEGE, TAMIL NADU for providing this opportunity to
carry out the present project work.

The constant guidance and encouragement received from Mrs. Rajeswari

(Project In charge), Mr. Rafi (Class In charge) & Mr. Rajan has been of great help
in carrying out the present work and is acknowledged with reverential thanks.

We would like to express a deep sense of gratitude and thanks profusely to Mr.
Karthick in charge of our major project. Without the wise counsel would have
been impossible to complete the project report in this manner.

We express gratitude to other faculty members of ETO Department,

COIMBATORE MARINE COLLEGE for their intellectual support throughout the
course of this work.

Finally, we are indebted to all whosoever have contributed in this project report.
Work friendly stay at COIMBATORE MARINE COLLEGE TAMIL NADU.

ETO 23-A

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 TABLE OF CONTENTS

CHAPTER PAG
TITLE
NO E NO

1 ABSTRACT 6
2 INTRODUCTION 7
3 WORKING & PROCESS FLOW 8
SPECIFICATION OF
4 9
COMPONENTS UTILISED
Arduino UNO is a microcontroller
11
board based on the ATmega328P

Boiler 11

Solenoid valve 12

Thermocouple 13

Electric heater 14

Turbine 14

Relay board onboard 15

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 Pressure gauge 15

Relay external – Heater 16

Generator 16

Pressure transmitter 17

Step down transformer 17

Battery 18

5 CIRCUIT DIAGRAM 19
6 PROCESS FLOW DIAGRAM 20

7 PROGRAM 21

8 IMPLEMENTATION

Results 29

9 PROJECT ESTIMATION 30

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10 REFERENCES

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 ABSTRACT

The main aim of our project is to automate the entire boiler process.
Boiler is usually a steam vessel which is used to boil the water with the help of
heat energy thus producing steam which can be used for various purposes such
as power generation, etc.

There are many disadvantages associated with the conventional boilers

such as adjusting the temperature and pressure of the vessel all the time and
hence there is a high need of man assistance near the boilers all the time.

We propose a system in which the entire boiler process is automated by

controlling the temperature and the pressure of the boiler and delivering the
exact required amount of steam.

Our proposed system monitors boiler’s temperature and pressure and

volume via different sensors which is considered as the input. The output
controls the boiler temperature and pressure and gives out the user required
volume of steam.

All temperature and pressure variations are displayed and controlled

automatically. Optionally for safety measures, different automated solenoid
valves are used to release pressure.

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 INTRODUCTION

The core objective of boiler steam generation automation is to achieve

optimal efficiency while maintaining the highest safety standards. This involves
dynamically monitoring water levels and temperature in real time, ensuring that
steam output meets demand with minimal wastage.

Automation also enables automatic control, allowing operators to manage the

process, thereby enhancing operational flexibility and responsiveness.
Safety is of paramount importance in any industrial process, and steam
generation is no exception.

The incorporation of automation introduces advanced safety features, including

temperature and pressure monitoring. These measures not only protect
equipment and assets but also safeguard personnel by minimizing the risk of
accidents or hazardous situations.
This paper delves into the intricacies of boiler steam generation automation,
exploring the various components, technologies, and methodologies involved. It
examines the integration of sensors, actuators, control systems, and human-
machine interfaces, highlighting their roles in achieving seamless automation.

In conclusion, the automation of boiler steam generation processes signifies a

transformative step towards modernizing industrial operations. By harnessing
cutting-edge technologies, industries can unlock unparalleled efficiency gains,
safety enhancements, and operational improvements. This paper aims to
provide a comprehensive overview of boiler steam generation automation,
shedding light on its significance and potential to shape the future of industrial
processes.

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 WORKING & PROCESS FLOW

The automation of boiler water level and heater control involves the
integration of sensors, actuators, control algorithms, and communication
systems to ensure precise and efficient operation. The working principle of this
automation can be summarized as follows:

Sensor Input - Water Level Sensors: Sensors are placed inside the boiler to
continuously monitor the water level. These sensors provide real-time feedback
on the water level, preventing scenarios of low water levels that could lead to
dry firing or high-water levels that might cause carryover and damage.

Control System - Microcontroller: The control system processes the data

from the water level sensors and other relevant sensors, such as pressure and
temperature sensors. The controller runs control algorithms that determine the
optimal water level and steam generation based on predefined setpoints and
operational requirements.

Heater Control: The automation system regulates the electrical heater’s

operation, adjusting the heater’s power supply. By maintaining the temperature
and pressure conditions, the system ensures efficient heat transfer and steam
generation.

Water Level Control: The feedwater solenoid valve, controlled by the

automation system, regulates the inflow of water into the boiler. It adjusts the
water flow to maintain the desired water level, preventing both low and high-
water level situations.

Steam flow Control: The steam outlet solenoid valve, controlled by the
automation system, regulates the outflow of steam to the turbine coupled with
generator. It adjusts the flow to maintain the desired turbine’s RPM to generate
electricity.

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SPECIFICATION OF COMPONENTS UTILIZED

1. Arduino UNO is a microcontroller board based on the ATmega328P

2. Boiler vessel
3. Solenoid valve
4. Thermocouple
5. Electric heater
6. Relay board onboard
7. Relay external – Heater
8. Turbine
9. Pressure transmitter
10. Generator
11. Pressure gauge
12. Step down transformer
13. Battery

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Arduino UNO microcontroller:

Description:
The Arduino UNO R3 is the perfect board to get familiar with electronics and
coding. This versatile development board is equipped with the well-known ATmega328P
and the ATMega 16U2 Processor.
Features:
1. ATMega328P Processor, Memory AVR CPU at up to 16 MHz 32KB Flash 2KB SRAM 1KB
EEPROM
2. Security Power On Reset (POR) Brown Out Detection (BOD)
3. Peripherals 2x 8-bit Timer/Counter with a dedicated period register and compare
channels, 1x 16-bit Timer/Counter with a dedicated period register, input capture and
compare channels
4. 1x USART with fractional baud rate generator and start-of-frame detection
5. 1x controller/peripheral Serial Peripheral Interface (SPI)
6. 1x Dual mode controller/peripheral I2C
7. 1x Analog Comparator (AC) with a scalable reference input
8. Watchdog Timer with separate on-chip oscillator, Six PWM channels
9. Interrupt and wake-up on pin change
10. ATMega16U2 Processor 8-bit AVR® RISC-based microcontroller

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11. Memory 16 KB ISP Flash 512B EEPROM 512B SRAM debug
12. WIRE interface for on-chip debugging and programming, Power 2.7-5.5 volts

Boiler vessel:

Description:
A boiler vessel is a
specialized container designed to
generate and contain steam or hot
water, typically for heating or power
generation purposes.

It is an integral component of various

industrial and commercial processes
that require heat energy.

Provides requirements for all methods

of construction of power, electric, and
miniature boilers. high temperature
water boilers, heat recovery steam
generators, solar receiver steam
generators, and certain fired pressure
vessels to be used in stationary service.

Technical specifications:

1. Capacity-25 liters
2. Made of mild steel with 3mm
thickness
3. Boiler vessel 8-inch diameter and
16-inch height.

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 Solenoid valve:

A solenoid valve coil is an essential

component of a solenoid valve, which is
an electromechanical device used to
control the flow of fluids (liquids or
gases) through a system. The solenoid
valve coil is responsible for generating a
magnetic field that actuates the valve,
allowing it to open or close.

Product Specification
1. Power Source – AC Voltage 220 V Frequency 50 Hz
2. Products Material - Brass, ABS Plastic
3. Power AC Output Voltage - 15VA ED100%
4. Ambient temperature - 120 Deree Celsius
5. Final Temperature - 160 Degree Celsius
6. INS Class - H Class IP65
7. Pressure - 8 MPa
8. Coil Code - 7000BH, Series 7000, Brand - Techno

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 Thermocouple:

A thermocouple is a temperature
measurement device that
consists of two different types of
metal wires joined at one end,
known as the sensing or
measurement junction. When
there is a temperature difference
between the two junctions (the
sensing junction and the
reference or cold junction), it
generates a voltage proportional
to that temperature difference.
This phenomenon is called the
Seebeck effect.

Product Specification
1. Temperature Range - 0 to 1250 deg C
2. Accuracy - +/- 2.5 deg C or +/- 0.75%)
3. Class - Class 1
4. Probe Material - Stainless Steel
5. Probe Termination
6. Lead Wire
7. Material Grad - SS310
8. Diameter of Probe - 10 mm

Specification:
1. Temperature measuring point: Pick shell / in1sulation / dew point.
2. Thread: 4/1, 5/16, M8, M6, M12.

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 3. Temperature range: -50°C~950°C.

Electric heater:
Electrically heated boilers make use of
electric current running through a
heating element to create heat, to boil
water into high-temperature and high-
pressure steam.
They can be classified into the
automatically controlled and the
manually controlled.

Voltage rating: 230 volts, AC

Power: 2000 Watts

Turbine:

Specifications:
1. Equipped or coupled with dc
generator.
2. 42 blades installed with 30
degrees inclination.
3. The turbine having 5-inch
diameter and 2-inch width.
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4. Steam pressure- 2.5 to 3 bar.
 Relay board:
Electrical Relay is nothing but an
electromechanical switch that is used to
control an electrical/electronic circuit
locally or remotely. But latest solid-state
relays use electronics components such
as the transistor, diode to control the
circuit without physical contact.
Relay-Solenoid valve (feedwater open/close)
Relay- Steam pressure delivery (open /close)
Product Specification:
1. Voltage - 12 V DC
2. Number of Poles - 2 Pole
3. Contact Rating - 10A at 220V AC / 110V AC / 28V DC
4. Coil Resistance - 70-ohm 5VDC
5. Contact Resistance - 1A 6VDC
6. Contact Capacity - 7A 250 VAC/30 VDC
7. Rated Coil Power - 360mW (48VDC 0.51W)
8. Insulation Resistance - 100 ohm
9. Release Time - 10ms/5ms

Pressure gauge:

Specification:

1. Range (0-100 kg/cm²)

2. Unit - kg/cm²
3. Type of measuring element Bourdon 16 | P a g e
 Relay external – Heater:

External relay used to switch the heater

ON/OFF, can withstand higher current
rating, 30A maximum.

Technical Specifications:
1. Coil Voltage - 230V ac
2. Contact Configuration - DPDT
3. Switching Current - 30A, Number of Poles - 2
4. Latching - No, Terminal Type - Quick Connect
5. Maximum Switching Voltage AC - 250V ac
6. Maximum Switching Voltage (AC) - 250V ac
7. Coil Resistance - 4000Ω, Coil Power - 3.6W
8. Maximum Operating Temperature - +70°C
9. Isolation Coil to Contact - 6kV, Contact Material - Silver Alloy
10.Minimum Operating Temperature - -40°C, Series - 66 Series

Generator (12 Volt DC Motor for Generator Or Dynamo) :

Specifications:

1. Operating Voltage: 6V-12V DC

2. No Load Current: 0.28A
3. Rated Current: ≤0.5A
4. Rated Power: 28W
5. Rated Speed: 10000RPM
6. Shaft Length: 5mm
7. Shaft Diameter: 2mm 17 | P a g e
Pressure switch:

Pressure switches are used for control,

monitoring and alarm systems in a wide
variety of industry applications.

KP pressure switches are mainly used

for gaseous fluid whereas KPI pressure
switches are more for liquid and
gaseous fluid. The products are
available in IP30 enclosure as well as
IP55 enclosure.
.
Specifications:
1. Ambient temperature [°C] -40 – 65 °C (for max. 2 hours up to 80 °C)
2. Media temperature [°C] Max. 100 °C
3. Fluid Liquids Parts in contact with lid Bellows
4. Pressure connector Free-cutting steel (nickel plated) Contact load, Silver
5. Alternating current: AC-1: 16 A, 400 V, AC-3: 16 A, 400 V, AC-15: 10 A, 400
6. Direct current: DC-13: 12 W, 220 V IP level IP22
7. Cable entry Rubber cable gland entry for 6 – 14 mm diameter cables
8. Mounted on backplate or wall bracket
9. Vibration-proof in the range 0 – 1000 Hz, 4 g [1g = 9.81 m/s2

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Battery (rechargeable):

A lead-acid rechargeable battery is a

type of battery that uses a lead
dioxide (PbO2) positive plate, a
sponge lead (Pb) negative plate, and a
diluted sulfuric acid (H2SO4)
electrolyte. These batteries are widely
used for various applications due to
their relatively low cost, robustness,
and ability to deliver high currents.

Specification:

1. Nominal Voltage - 12V, DC

2. Nominal Capacity 6Ah @ 10-hour rate F.V. (1.75V/cell)
3. Approx. Weight - 2100g(4.63lbs.)
4. Terminals - T1 (Faston Tab 187) T2 is optional
5. Internal Resistance - <22m Ω (Fully Charged)
6. Max. Discharge Current - 82.5 A (5 sec.)
7. Max. Charge Current - 1.65 A
8. Container Material – ABS (UL94-HB, UL94-VO is optional
9. Operating Temperature Range

Charge: 0°C-40°C (32°F-104°F)

Discharge: -20°C~50°C(-4°F~122°F)
Storage: -20°C-40°C(-4°F-104°F)

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CIRCUIT DIAGRAM

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 PROCESS FLOW CHART

START

Liquid crystal Input mapping

(Program declaration) pin code = Sensor input

Max 6675
Output mapping
(Hard declaration)
pin code = Relay ht , output

Variable
Initialization process
declaration
All the relay output
off condition.
digital wire (relay ht, stopping)
Initialization process
count = o
Boolean, starting = High
Icd.set cursor (1,0);
Boolean, stopping = Low
TEMP INC (display)
int started delay=100m

Serial communication,9600
Temp formula
baud rate communication
read Celsius in
established
the 11th register
Icd.set cursor (11,0)

Icd.begin (16,2) display After 1000 timer delay

16 character 2 line display clear the display

Icd.set cursor (0,0)

Display DIGITAL STEAM 21 | P a g e
 Process
conditions shut

Delay 1000ms
clear both the display
STEAM

Program:

#include <LiquidCrystal.h>
#include <max6675.h>
const int rs = 13, en = 12, d4 = 11, d5 = 10, d6 = 9, d7 = 8;
LiquidCrystal lcd(rs, en, d4, d5, d6, d7);

int Sensorlh = A0; /// Sensor fire

int Sensorlv = A1; /// Sensor smoke
int Sensorllv = A2; /// Sensor Pin
int Sensorps = A3; /// Sensor Pin

int Relayht = 4;////Realy pin

int Relayinsv = 5;////Realy pin
int Relayoutsv = 6;////Realy pin
int Relaylv = 7;////Realy pin
int Relayllv = 3;//// alarm

int thermoDO = A4;

int thermoCS = A5;
int thermoCLK = 2;

MAX6675 thermocouple(thermoCLK, thermoCS, thermoDO);

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int count_01 = 0;

//int rpmMaximum = 0;
bool starting = HIGH;
bool stoping = LOW;
int startingDelay = 100;
int delayTime = 100;
void setup()

{
Serial.begin(9600);
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("DIGITAL STEAM");
lcd.setCursor(0, 1);
lcd.print("BOILER AUTOMATION");
delay(1000);
lcd.clear();
delay(startingDelay);

pinMode(Sensorlh, INPUT_PULLUP);
pinMode(Sensorlv, INPUT_PULLUP);
pinMode(Sensorllv, INPUT_PULLUP);
pinMode(Sensorps, INPUT_PULLUP);

pinMode(Relayht, OUTPUT);
pinMode(Relayinsv, OUTPUT);
pinMode(Relayoutsv, OUTPUT);
pinMode(Relaylv, OUTPUT);
pinMode(Relayllv, OUTPUT);

digitalWrite(Relayht, stoping);
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 digitalWrite(Relayinsv, stoping);
digitalWrite(Relayoutsv, stoping);
digitalWrite(Relaylv, stoping);
digitalWrite(Relayllv, stoping);

// lcd.setBacklightPin(3, POSITIVE);
// lcd.setBacklight(LOW);

void loop()
{

lcd.clear();
lcd.setCursor(1, 0);
lcd.print("TEMP IN C");
//adc11=(adc1*100)/500;
// lcd.print(bat1/100);
lcd.setCursor(11, 0);
lcd.print(thermocouple.readCelsius());
delay(1000);

if ((digitalRead(Sensorlh) == LOW) && (digitalRead(Sensorlv) == LOW) &&

(digitalRead(Sensorllv) == LOW))

{ delay(1000);
// lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("WATER LOW LOW LEVEL ");
lcd.setCursor(0, 1);
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 lcd.print("WATER INLET ");
delay(1000);
digitalWrite(Relayinsv, starting);
digitalWrite(Relayoutsv, starting);
digitalWrite(Relayllv, starting);
digitalWrite(Relaylv, stoping);
digitalWrite(Relayht, stoping);
count_01 = 0;

if ((digitalRead(Sensorlh) == HIGH) && (digitalRead(Sensorlv) == HIGH) &&

(digitalRead(Sensorllv) == HIGH))

{ delay(1000);
lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("WATER LEVEL FULL");
lcd.setCursor(0, 1);
lcd.print("HEATER ON ");
delay(1000);
digitalWrite(Relayinsv, stoping);
digitalWrite(Relayoutsv, stoping);
digitalWrite(Relayllv, stoping);
digitalWrite(Relaylv, stoping);
digitalWrite(Relayht, starting);
count_01 = 0;

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 if ((digitalRead(Sensorlh) == LOW) && (digitalRead(Sensorlv) == LOW) &&
(digitalRead(Sensorllv) == HIGH))

{ delay(1000);
lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("WATER LOW LEVEL");
delay(1000);
digitalWrite(Relaylv, starting);
digitalWrite(Relayllv, stoping);
digitalWrite(Relayht, stoping);
count_01 = 0;

if ((digitalRead(Sensorlh) == LOW) && (digitalRead(Sensorlv) == HIGH) &&

(digitalRead(Sensorllv) == HIGH))

{ delay(1000);
lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("WATER LOW LEVEL");
delay(1000);
digitalWrite(Relaylv, stoping);
digitalWrite(Relayllv, stoping);
digitalWrite(Relayht, starting);
count_01 = 0;

}
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if (digitalRead(Sensorps) == LOW)

{ delay(1000);
lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("STEAM FULL");
delay(1000);
digitalWrite(Relayoutsv, starting);
delay(180000);

count_01 = 0;

if (digitalRead(Sensorps) == HIGH)

{ delay(1000);
lcd.clear();
lcd.begin(16, 2);
lcd.setCursor(0, 0);
lcd.print("STEAM LOW");
delay(1000);
digitalWrite(Relayoutsv, stoping);
delay(3000);

count_01 = 0;

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 delay(100);
}

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ETO 23A Student Batch Details:

S.NO NAME ROLL NUMBER

1 ABISTON ESTHO CMC23ETA01

2 ALBIN THOMAS CMC23ETA02
3 ANUPAMA SIYA CMC23ETA03
4 ASHUTOSH.S. SINGH CMC23ETA04
5 CHANDRU MADASAMY CMC23ETA05
6 ESILTON CMC23ETA06
7 GUNALD KUMAR CMC23ETA07
8 ISRATH ALI CMC23ETA08
9 JOVINSON PITCHAI CMC23ETA09
10 NANDHAGOPAL CMC23ETA10
11 MADHU SUDAN MEENA CMC23ETA11
12 MAHISUMAN.M. N CMC23ETA12
13 MOHAMMAD ISHAQ RAWTHER CMC23ETA13
14 MOHAMMED RIYAZ UKKAYYE CHETTA CMC23ETA14
15 MOHAMMED SAFWAN CMC23ETA15
16 MULGURI JALANDHAR CMC23ETA16
17 MUNIASAMY RAMAKRISHNAN CMC23ETA17
18 PRIYANTH CMC23ETA18
19 SAMUEL JEROMIAH CMC23ETA19
20 SATHEESH BABU GANGATHARAN CMC23ETA20
21 SELVA SEENIVASA PRABHU CMC23ETA21
22 SENTHIL KUMAR MURUGAN CMC23ETA22
23 SHALEM CMC23ETA23

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 24 SUKUMARAN KRISHNAN CMC23ETA24
25 VENDHAN MANI CMC23ETA25
26 VIGNESH CMC23ETA26
27 SENTHILKUMAR VIJAYAKUMAR CMC23ETA27
28 CIRRABOYINA VIJAYARAJU CMC23ETA28
29 VISHNUPRASAD SIVANANDAN CMC23ETA29
Project Estimation
SI.N COST ESTIMATED IN
MATERIAL
O RUPEES
Arduino UNO is a microcontroller board based on
1 10000
the ATmega328P
Boiler vessel
2 20000

Solenoid valve
3 3442

Thermocouple
4 1440

5 Relay board onboard 2970

Relay external – Heater
6 3884

Turbine
7 543

Generator
8 786

Pressure gauge
9 542

10 Step down transformer 680

Electric heater
11 3650

Pressure transmitter
12 6490

13 Battery 1047
Total Cost 55174

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