Final Year Project 2015 PDF

People’s Democratic Republic of Algeria
Ministry of Higher Education and Scientific Research

University M’Hamed BOUGARA – Boumerdes
Institute of Electrical and Electronic Engineering

Department of Power and Control
Final Year Project Report Presented in Partial Fulfilment of

the Requirements for the Degree of
MASTER
In Electrical and Electronic Engineering
Option: Control Engineering
Title:
BOILER DRUM LEVEL
CONTROLLER DESIGN AND
SUPERVISION Using SIEMENS S7-300
Presented by:
- ZENDI Amar
- MELLAZ Malik
Supervisor:
Dr. OUADI.A
Registration Number:…..…../2015
Abstract
The steam generator at the Algiers refinery is provided with several regulators, and
the targeted objective is maintaining the level of water inside one of its boiler drums at
a desired set point in order to reach the maximum point of efficiency and avoid getting
droplets of water in the produced steam.
In this project, first the boiler drum is modelled mathematically. Then, a new
control configuration called DCS (Distributed Control System) based on three element
control: feedwater flow, steam flow and measured level is designed using conventional
PID controller based on the models of the different elements of STAIN & ROUBAIX
Boiler and compared to the BAILEY configuration, the existing one.
The level control loop of the boiler is simulated using MATLAB/SIMULINK. The
designed controller is implemented and associated with a Supervision platform
describing the functionality of our process using WinCC Flexible to create the HMI
(Human Machine Interface) , SIMATIC Step 7 to program the PLC S7-300 and some
communication protocols to establish a connection between them.
I
ACKNOWLEDGEMENT
We would like to express our earnest gratitude to our project guides, Dr. OUADI
and Mr. MOUALHI Younes for believing in our ability to work and enriching us with
knowledge throughout our project work that crowned our efforts with success. Their profound
insights and working styles have inspired us. The invaluable guidance and support that they
have offered us has deeply encouraged us.
We wish to extend our sincere thanks to Mr. HEDIMI, Mr. LALAOUNA and Mr.
LAADJOUZI for their enriching knowledge about the subject. We would also like to thank all
people, faculty and non-teaching staff who have helped and inspired us during our project
work at Department of Power and Control Engineering of the Institute of Electrical And
Electronics Engineering, especially Ammi Rezki for extending their help and support as and
when required.
We would conclude with our deepest gratitude to our parents, and all our loved
ones. Our full dedication to the work would have not been possible without their blessings
and moral support.
Once again, we especially thank Dr. OUADI.A and MOUALHI.Y. It was a great
pleasure for us to conduct the project under their supervision.
ZENDI Amar
MELLAZ Malik
Boumerdes University
Institute of Electrical and Electronics Engineering
Control Engineering
II
Dedications
First of all we thank God the most almighty and most merciful for guiding
us during our life to follow the right ways and we pray him to show us the path
to success.
Then, I dedicate this work to my parents who helped me to get the ball
rolling from the beginning, and also to my sister and my three brothers and all
the members of my family.
I shall add special dedications to all the members of “les Matouachiche” and
all the friends that I have met in the University of Boumerdes and all the others
that I left years ago.
Finally, I dedicate this work to everyone who contributed from far or close
to the realization of this project and all the good and beneficial things that I did
in my life.
Z.Amar
I, dedicate this project to my loved parents, my brothers from the eldest to

the youngest: Achour, Mokrane, Lounis and Anis and all the members of my
family for their much appreciated support and encouragement.
I would thank all my friends, the students who I studied with, and all the
staff of teachers who encouraged me to do this work.
M.Malik
III
List of Figures
Figure Title N°
I.1 A two-pass fire-tube boiler 04

I.2 water-tube boiler 04
I.3 Schematic of boiler 05
II.1 General drum-boiler schematic 11
II.2 The feed-water response of the water level 13
II.3 The steam flow response of the water level 13
II.Response Response of feed-water and steam flow effects on the 15
drum level
II.4 Variables 16
II.5 Single element control system 20
II.6 Two element control system 21
II.7 Three element control system 23
II.8 Differential level transmitter 24

II.9 Pressure level terminology 24
II.10 Differential flow transmitter 25

II.11 Primary sensing element of the differential flow 25
transmitter
II.12 Simple feed-forward circuit 27
II.13 System response using the simple feed-forward and 28
PI controller
III.1 The proportional controller 30
III.2 Proportional-integral controller 30

III.3 Proportional-derivative controller 31
III.4 PID controller structure 32
III.5 Bailey regulation block diagram configuration 34
III.6 System response to an ultimate gain of 2.67 35
III.7 System response using a conventional PID controller 35
III.8 Output disturbance rejection 36
III.9 System response to 30 tons of steam demand increase 36
III.10 System response to the maximum (60t) of steam 36

demand increase
III.11 System response to 30 tons of steam decrease 37
IV
IV
III.12 System response to the maximum (60t) of steam 37
demand increase
III.13 Anti-balancing system 37
IV.1 Operation principle of a PLC 39
IV.2 Main components of a PLC 40
IV.3 PS 2A module 41
IV.4 PS 5A module 41
IV.5 Create a new project called Boiler-level control 44
IV.6 Hardware configuration of the PLC 45
IV.7 Network connection through MPI 45

IV.8 Programming structure 45
IV.9 FB1 and DB1 creation of ESD programming 46
IV.10 The data block DB1 46
IV.11 Alarm management functional block FB1 47
IV.12 Alarm management main program in OB1 48
IV.13 Simulation results of FB1 49

V.1 Main View Screen 53
V.2 Boiler Main View 54
V.3 Parameters Adjusting View 55
V.4 Different curves associated to PV, SP and error 55
V.5 Connecting the screen to the PLC 56
List of Tables
Table Title N°
II.1 Measurements of the level response to 14
feed-water and steam variations
II.2 Application chart for drum level 23
control system
III.1 Ziegler-Nichols tuning method 33
III.2 System performances comparison 38
V
V
Nomenclature
Tn Tons
h Hour
C Degree centigrade
V Voltage (v)
mA Mili-Ampers
t Time(s)
β Delay angle
ε Flying-up speed of the step response on the effect of the water flow
ε1 Flying-up speed of the step response on the effect of the steam flow
τ Pure delay time
K2 Amplification factor of the water level change
T2 Time constant of the water level change(s)
P1 Steam flow rate
P2 Level controller output
ρ The water density.
g The gravity.
ΔP Differential pressure
SP Set point
K1 The differential level transmitter
Q Flow of the feed-water or steam
Cv The discharge coefficient which is proportional to the orifice area
Gsm (s) Servo-motor transfer function
Ksm The servo-motor static gain
Tsm The servo-motor time constant
γ Dynamic viscosity of compressed air at 20° C
V Total volume of servo-motor chamber
VI
T Ambient Temperature in K°
K° Kelvin
D Compressed air pipe diameter
L Pipe length
LC Level controller
FT Flow Transmitter
FC Flow controller
LT Level Transmitter
LIC Level Indicator Controller
FIC Flow Indicator Controller
FV Flow Valve
FRCV Flow Regulation Controller Valve
D6 Easing drum
G4 Feeding pump
G25 Turbo-fun
H(s) Output level in S domain
W(s) Input feed-water flow in S domain
D(s) Disturbance signal of steam flow transfer function
Gd(s) Contribution of feed-water to the level transfer function
Gs(s) Contribution of steam to the level transfer function
PV Process variable
MV Measured variable
COS Controller Output Signal
u Step input
e(t) The error signal
Kp Proportional gain
Ti The integral time constant
Td The derivative time constant
Ku Oscillation period(s)
VII
Abstract…………………………………………………………………….. I
Acknowledgement…………………………………………………………. II
Dedications………………………………………………………………… III
List of Figures………………………………………………………………IV
List of Tables………………………………………………………………..V
Nomenclature……………………………………………………………….VI
Content
General Introduction……………………………………………………………………………1
Chapter I: Boiler description
I.1 Introduction ……………………………………………………………………….3
I.2 Generalities………………………………………………………………………...3
I.2.1 Boiler definition …………………………………………………………….3
I.2.2 Application of boilers ……………………………………………………….3
I.2.3 Boiler types ………………………………………………………………….4
I.2.3.1 Fire-tube boilers ………………………………………………………4
I.2.3.2 Water-tube boilers …………………………………………………4
I.3 Case study…………………………………………………………………………..5
I.3.1 Definition…………………………………………………………………….5
I.3.2 Boiler operation……………………………………………………………...5
I.3.3 Boiler components …………………………………………………………..6
I.3.3.1 Water-Steam side ……………………………………………………6
I.3.3.2 Combustion side …………………………………………………….8
I.3.3.3 Casing …………………………………………………………… ...9
I.4 Conclusion …………………………………………………………………………10
Chapter II: Boiler modeling and control strategies
II.1 Introduction ……………………………………………………………………….11
II.2 Drum-Boiler modeling…………………………………………………………….11

II.2.1 Shrink and Swell phenomena ……………………………………………….12
II.2.2 Dynamic characteristics of the Boiler Drum water level …………….............12
II.2.2.1 Dynamic Characteristics of the Level with the Effect of the feed-water
flow …………………………….……………………………...12
II.2.2.2 Dynamic Characteristics of the Level with the Effect of the steam
flow ………………………...........................................................13
II.2.2.3 Case study ………………………………………………………...14
II.3 Control strategies …………………………………………………………………16
II.3.1 Single Element Drum Level control ……………………………………….20
II.3.2 Two element Drum Level Control …………………………………………21
II.3.3 Three element Drum Level Control ………………………………………..22
II.3.4 Comparison and Selection ............................................................................23
II.4 Instrumentation …………………………………………………………………...24
II.4.1 Involved instruments ………………………………………………………24
II.4.1.1 Sensors ……………………………………………………………...24
II.4.1.2 Actuators …………………………………………………………..26
II.5 Simulation results …………………………………………………………………27
II.5.1 Simulation ………………………………………………………………….27
II.5.2 Results ……………………………………………………………………...28
II.5.3 Scope ……………………………………………………………………….28
II.6 Conclusion…………………………………………………………………………...28
Chapter III: PID Parameters tuning
III.1 Introduction ……………………………………………………………………….29
III.2 Generalities on PID controller …………………………………………………….29
III.2.1 The continuous PID controller ……………………………………………….30
III.2.1.1 The proportional control ……………………………………………30
III.2.1.2 Proportional – Integral (PI) control ………………………………...30
III.2.1.3 The proportional – derivative (PD) control ………………………...31
III.2.1.4 The PID controller ………………………………………………….32

III.3 Tuning of PID parameters …………………………………………………………33
III.3.1 Ziegler-Nichols’ Tuning Method ……………………………………………..33
III.3.2 Case study …………………………………………………………………...34
III.4 Conclusion ………………………………………………………………………...38
Chapter IV: Programming logic controller
IV.1 Introduction ……………………………………………………………………….39
IV.2 Basic description of a PLC ………………………………………………………..39
IV.2.1 Definition .......................................................................................................39
IV.2.2 PLC S7-300 ………………………………………………………………..40
IV.2.2.1 Mounting Rail (rack) ………………………………………………..41
IV.2.2.2 Power Supply Module ………………………………………………41
IV.2.2.3 CPU (Central Processing Unit) ……………………………………..42
IV.2.2.4 Signal Modules ……………………………………………………..42
IV.2.2.5 Interface Module (IM) ……………………………………………..42
IV.2.2.6 Connection Processor (CP) ………………………………………..43
IV.2.2.7 Function Modules (FM) …………………………………………...43
IV.2.2.8 Software …………………………………………………………...43
IV.3 Programming the PLC S7-300 …………………………………………………….43
IV.3.1 Industrial Programming Languages ………………………………………..43
IV.3.2 Industrial Programming Software …………………………………………44
IV.4 Conclusion ………………………………………………………………………50
Chapter V: Supervision Platform using WinCC
V.1 Introduction ………………………………………………………………………..51
V.1.1 SIMATIC WinCC flexible definition ………………………………………..51
V.1.2 Parts of the SIMATIC WinCC flexible ……………………………………..52
V.1.2.1 Computer …………………………………………………………52
V.1.2.2 Tag Management …………………………………………………52
V.1.2.3 Structure Tag ……………………………………………………..52
V.1.2.4 Graphical Designer ……………………………………………… 52

V.1.2.5 Alarm Logging ………………………………………………… 53
V.1.2.6 Tag Logging …………………………………………………… 53
V.2 Case Study …………………………………………………………………………. 53
V.2.1 The different screens of the Supervision ……………………………………...53
V.2.1.1 Boiler Main View …………………………………………………...54
V.2.1.2 Set Parameters View ………………………………………………..55
V.2.1.3 Curves ………………………………………………………………55
V.2.1.4 About ……………………………………………………………….56
V.2.2 Connection Establishment …………………………………………………..56
V.3 Conclusion …………………………………………………………………………56
General Conclusion ……………………………………………………………………….............57
Appendices
Bibliography
GENERAL INTRODUCTION
GENERAL
INTRODUCTION
A refinery is constituted of different industrial equipments: Furnaces, Boilers,

Process Unities, and other elements which require to be regulated and maintained in the safe
operating point.
However; the boiler regulation requires a particular attention for two fundamental
raisons:
 Efficiency, reliability and the continuity of the process.

 Security of both the employees and installations.
The vocation of the two boilers of the refinery of Algiers is to produce a superheated
and dry steam. For this raison the level of water in the Drum mustn’t be too low in order to
supply the boiler tubes and not too high to avoid getting water droplets in the produced steam.
Another undesirable factor is the phenomenon of shrink and swell, where the level
can be misleading and can reach its high or low limits without informing the operator and
yields to a real disaster.
That’s what makes the level regulation of the water inside the drum a very important
task, not only for the boiler but for the whole process including steam turbines lifetime.
Another important factor is to ensure the amount of entering feedwater and leaving
steam equilibrium.
Our contribution is to choose another control configuration using three-element

strategy and to design the right PID controller to enhance mainly the efficiency and the
security of the Boiler and to realize that control using a PLC and a supervision platform.
In order to achieve our objective, we had to pass from different steps that are
organized in five chapters each with a precise objective.
In the first chapter, a rough description of boilers in general and a water tube boiler
of STEIN & ROUBAIX in particular are presented where we have stated the main
components of the boiler starting from the water treatment and purification to the steam
generation.
Page 1
In the second chapter, we focused on the mathematical models of the different

equipments and instruments involved in our regulation using datasheets and some system
identification methods.
We have also stated the different control strategies and chosen the appropriate one to
challenge the Shrink and Swell phenomena.
In the third chapter, we have designed our PID controller and tuned it and also stated
the importance of using both the feedback and feedforward in a control loop.
We have simulated our results and driven some comments and remarks.
In the fourth chapter, we introduced the Programmable Logic Controller and their
advantages in industry.
We described the PLC in use (SIEMENS S7 300) and its different modules and also
how to set its hardware and software configurations using SIMATIC STEP7.
We have shown the features of this software and how to create new projects and
program using ladder language.
In the last chapter, we introduced another software from SIMATIC which is the
SIMATIC WINCC Flexible that is used to create Human Machine Interfaces or supervision
screens in order to test our program functionality and enable the user to see the process
variations in a real time.
Page 2
Chapter one BOILER DESCRIPTION
Chapter One:
Boiler Description
CHAPTER I BOILER DESCRIPTION
I.1 Introduction:
Boilers produce steam for a wide range of industrial purposes: electricity
generation, chemical processes and heating. The process is continuous and large scale.
During this chapter, we will see the main literature description of Boilers. We
will focus on its working principle and the most common boiler types used in industrial
applications.
After understanding the steam generation process, we will describe the boiler
under study in this project.
I.2 Generalities:
I.2.1 Boiler definition:
Boiler is defined as a closed vessel in which steam is produced from water by
the combustion of fuel. Generally, in boilers, steam is produced by the interaction of hot flue
gases with water pipes, which is coming out from the fuel, liquid or gas. In boilers, chemical
energy of stored fuel is converted into heat energy and the water absorbs this heat energy,
which converts it into steam.
Boilers are manufactured in various designs and sizes, depending on

characteristics of the fuel used and the heating output. Some boilers are only capable of
producing hot water while others are designed to produce steam [1].
I.2.2Applications of Boilers:
Boilers can be used in several applications, some of them are stated below:
 Stationary applications to provide heat, hot water and steam for domestic use in many
industries.
 Mobile applications to provide steam for locomotion in applications such as trains,
ships, and boats.
 Heating systems for cement production.
 Electricity generation when using a thermal turbine.
Page 3
I.2.3Boiler types:
Boilers can be categorized according to the method used to transfer the thermal
energy. The most common types are fire-tube boilers and water-tube boilers.
I.2.3.1fire-tube boilers:
In fire-tube boilers, the hot combustion gases flow through a series of tubes that
are housed inside a water-filled outer shell. As the gases flow through the tubes, they heat the
water surrounding the tubes.
Modern fire-tube boilers often have cylindrical outer shells with a round
combustion chamber at the bottom, and they are mostly used in low-pressure applications in
order to avoid the need for a thick outer shell. This type of
boilers is often characterized by their number of passes,
referring to the number of times the combustion gases flow
through the outer shell. The number of passes depends on
the construction details, usually ranging from one to four
passes in common designs. Most designs can use a variety
of fuels such as oil, gas, coal and biomass. Figure I.1 shows
the basic design of a two-pass fire-tube boiler.
I.2.3.2Water-tube Boiler:
In water-tube boilers, the hot combustion gases are circulated around the
outside of a large number of water-filled tubes. In older designs, the tubes are either straight
or bent into simple shapes, while in modern designs they often have complex and diverse
bends. Because the pressure is contained inside the water tubes, water-tube boilers can be
used in high-pressure applications. They can have a number
of burners and can burn almost any type of liquid, solid or
gaseous fuel.
The design of the boiler can vary significantly

depending on what fuel it is intended to burn.
These designs differ mainly in the way the fuel

is fed to the combustion process and can therefore usually be
adapted for other types of fuel than the one it was originally
designed for. Figure I.2 shows the basic design of a water-tube boiler [17].
Page 4
I.3 Case Study:

I.3.1 Definition:
The steam-generating station of the refinery of Algiers consists of two water-
tube boilers with a rated power of 47 tons of steam/h each of STEIN & ROUBIAX
construction.
Each one of the boilers is planned to produce steam at a high pressure of 35
bars and a high temperature of 410° C in the best conditions of both efficiency and security
using gas and liquid fuels [19].
The boiler consists of three main circuits:
 Combustion circuit.
 Air-Exhaust circuit
 Water-Steam circuit.
A further clarification of the working principle of the boiler is presented below.
I.3.2Boiler operation:
To understand the working principle of a Boiler, it is important at first to
describe its main components and the role of each one of them.
There are two fundamental requirements for generating steam: water and heat.
These two aspects of steam generation are commonly referred to as the water-steam side and
the combustion side, respectively. Fig.I.3 is a schematic representation of a typical drum-type
boiler.
Page 5
 The water-steam side of the boiler process involves converting water into high-
temperature steam.
 The combustion-side involves burning fuel to generate the heat necessary for steam
generation. Fuel must be mixed with the correct volume of air in order to ensure
complete combustion.
I.3.3Boiler components:
I.3.3.1 Water-Steam Side:

Water Treatment:
The first phase in the steam generation process is water purification. Before
water can enter the boiler proper, debris and other suspended matter must be removed by
coagulation and filtration. The water must also be demineralized. If this is not done, these
impurities will be deposited on the inside of the tubes within the boiler and will quickly
reduce its efficiency.
Aeration:
Following chemical treatment, the water is fed to aerator tanks, where
dissolved gases are removed from the water. Even small traces of oxygen can cause corrosion
of the boiler surfaces at the high temperatures in the boiler. Carbon dioxide would pass into
the steam and turn into corrosive carbonic acid in the steam heat exchangers. To prevent this,
gases are removed by boiling and agitating the water and by venting the gases to the
atmosphere. The water is boiled by mixing it directly with steam.
The boiler under study has an aerator of a capacity of 71 T of aerated water / h.

It is a physical aerator working under a high pressure.
The treated water and the condensate from the turbine reach the superior part
of the aerator where it is reheated using steam of pressure 3.5 bars until it reaches its boiling
point and then stocked in a feeding tank.
Feeding tank D8:
The feeding water tank of construction ALIECO has an overall capacity of

44m3and a useful capacity of 35m3.It is installed at 10 meters height above the ground and
supports the aerator.
Page 6
The feeding water is maintained inside the feeding tank at a constant pressure
of 3.5 bars and a constant temperature of 140° C.
The feeding tarpaulin is provided with an automatic level regulation (LC2) and
a quick evacuation device to the drain in case of fullness through the easing drum D6 (LC6).
Feedwater Pumps:
Following water purification and aeration, the water, referred to as feedwater,

is pumped into the economizer. The feedwater pump must supply at least enough energy to
overcome the pressure head in the drum. This is done using three feeding pumps (G4/1, G4/2,
and G4/S) of construction Sulzer. These pumps are of a multi cellular centrifuge type of eight
stages.
The nominal power absorbed by each pump is about 164 HP and permits a
horary flow of 80m3 under a temperature of 140° C and a push back pressure of 54 bars.
Two of these pumps (G4/1 & G4/2) are driven by a 204 HP asynchronous
motors supplied with a voltage of 5500 V whereas the third pump (G4/S) is driven with a
thermal turbine with 178 HP with an automatic start up if the pressure decreases below 42
bars [1] and [19].
Evaporation System:
The evaporation system of a drum-type boiler is comprised of a steam drum,

down-comers, water drum and risers.
The steam drum acts as a separator for the water and steam in the evaporation
system. Steam is drawn off the top of the steam drum and water is fed to the down-comers
which are situated at the bottom of the steam drum. The saturated steam in the steam drum
contains moisture droplets. These droplets could cause thermal shock if they fell on the high
temperature tubes in the super-heater. They are removed from the saturated steam by
mechanical separation devices called "scrubbers" or "separators" which return the moisture
droplets to the steam drum.
The level of water in the steam drum must be maintained very carefully. If the
drum water level falls too low, there is a risk of dry-out. If the drum water level rises too high,
the drum water surface area will be reduced, which, in turn reduces the amount of steam that
can be generated by the boiler. In order to provide accurate drum level control it is important
to have accurate and reliable drum level measurement.
Page 7
Blowdown:
The chemicals contained in the feed-water accumulate in the boiler water

drum. In order to maintain a proper chemical balance of the boiler water drum, they must be
removed. This removal is called blow-down.
Superheater:
The saturated steam in the drum must be superheated to a higher temperature

before it can do mechanical work in a turbine. In the turbine, the steam will lose heat and fall
in temperature. If the steam entering the turbine is saturated, it will condense back to water. If
condensation occurs in the turbine severe thermal shock will ensue. To prevent this occurring,
the steam must be heated to a sufficiently high temperature, so that it will still be superheated
as it leaves the turbine.
The steam can be superheated by radiation or convection. The steam

temperature in a radiant super-heater decreases as steam flow increases. The steam
temperature in a convective super-heater increases as steam flow increases.
Load:
A boiler supplies steam to one or more steam consuming processes such as

turbines or heating systems. The steam flow rate from the drum is partially determined by the
pressure in the steam drum and partially determined by the demands of the steam consuming
process.
I.3.3.2 Combustion Side:
Fuels:
Gas, oil and coal are the most common boiler fuels. Gas and oil are both fluids
and consequently are easier to manage than solid fuels such as coal. Simple gas or oil burners
are used for these. There are several methods for burning fuel, one of them is to be pulverized
(using compressed air from the compressor with a pressure of 7 bars) and burnt with
conventional burners.
STEIN & ROUBAIX boiler possesses 4 Burners of construction « Foyers –

Turbines » working with liquid and gas fuels in redundancy.
Page 8
Air:
The relative proportions of fuel and combustion air are important for a number
of reasons. If there is insufficient air for combustion, unburned fuel can collect downstream.
This unburned fuel may explode when it comes into contact with air. Black smoke and
poisonous carbon monoxide are other consequences of incomplete combustion. If there is an
excess of air, however, boiler efficiency is reduced as this excess air also absorbs some of the
heat from combustion.
The air used for combustion of our boiler is provided from the turbo-fan G25.
Combustion Chamber and Stack:
Fuel and air are mixed and ignited in the furnace. There may be several burners
in the furnace. By varying the tilt of these burners, or the proportion of fuel received by a
particular burner, it is possible to vary the amount of heat transferred to the risers or to the
superheater.
The combustion chamber of our boiler consists of 4 independent burners of

type GRC – G2 working with both liquid and gas fuels.
Flue Gas Treatment:
The flue gases produced by burning coal contain small particles of

incombustible solids and contaminating gases - notably sulphur and nitrogen oxides. For
environmental reasons, these contaminants must be removed before the flue gases enter the
atmosphere. The solids can be removed from the gas using filters or precipitators. The
contaminating gases are removed chemically [1] and [19].
I.3.3.3Casing:
The casing envelops entirely the generator. It is waterproof and composed of:
 Double corrugated iron casing planned for domestic boilers under pressure.
 Dismantling panels, issues and doors necessary for maintenance.
 All the issues are supplied with barrage air.
Page 9
I.IV Conclusion:
It is clear from the above description of the Boiler, that the steam generation is
a complex and potentially dangerous process, thus several parameters have to be controlled in
order to achieve the right working principle of a boiler.
One of the most important aspects of controlling a boiler is the drum level
which will be discussed in the upcoming chapters.
Page 10
Chapter Two Boiler Modeling And Control Strategies
Chapter Two:
Boiler Modeling and

control strategies
CHAPTER II BOILER MODELLING AND CONTROL STRATEGIES
II.1 Introduction:
As stated in the previous chapter, Boiler level regulation is a very important aspect in
controlling any industrial boiler. The boiler drum water level not only has a profound effect on the
steam quality and the stream-water separation speed, but also is an important parameter ensuring
safety in production. The water level should be maintained in the reasonable scope because either too
high or too low will result in serious harm. Exorbitant water level will affect the separation of steam
from water, causes the steam enters the steam pipeline containing water which may lead to wall
scaling and sharp reduction of superheated steam temperature; if the water level is too low, it will
destroy the boiler's water cycling system and even causes free water surface’s forming, which results
in the stagnation of the flow and increases the pipe burst likelihood due to local overheating.
Therefore, it’s necessary to control automatically in order to ensure the drum water level
within a prescribed technical specification and to do so it’s necessary to derive the mathematical model
describing the boiler drum level.
II.2 Boiler-Drum modeling:

The basic schematic of a boiler drum unit is presented in Fig. II.1. Heat fed to the risers
causes the water to boil, thus producing steam. The steam, due to gravity forces and thermosyphon
phenomenon, rises in the drum, causing circulation through the down-comer-riser system.
From the energetic point of view, water and heat are provided to the boiler and steam is
taken out. Steam is also present below the liquid level, which causes an undesired effect called the
shrink-and-swell phenomenon [2].
Page 11
II.2.1 SHRINK AND SWELL PHENOMENA:
If there is a necessity in power demand, more steam needs to be provided to the turbine
by opening the turbine valve. This causes a sudden drop of pressure in the drum, allowing the steam
bubbles under the liquid to expand in volume and therefore increase the water level. The phenomenon
is called the swell effect. On the other hand, taking into account the mass balance of the boiler, it is
expected that the water level decreases because the steam leaves the system. Eventually, the water
level decreases with delay, if the feed-water flow is kept constant.
The shrink effect is the opposite of the swell effect. This phenomenon takes place when
steam demand is reduced. Following the same principle, the pressure rises, causing the vapor bubbles
to shrink, resulting in a water level drop. Eventually, the water level rises if the feed-water flow is kept
constant.
The combined phenomenon is called shrink-and-swell and presents a challenge to water
level control due to its non-minimum phase behavior [2].
II.2.2 DYNAMIC CHARACTERISTICS OF THE BOILER DRUM WATER LEVEL:
The aim of the boiler drum water level control system is to maintain the level in a
limited and rational range. The water level often varies with the steam flow and the feed water flow.
So, in the control system, the water level is the regulated signal and the steam flow and the feed water
flow are the manipulating signals.
II.2.2.1 Dynamic Characteristics of the Level with the Effect of the Feed Water Flow:
The effect of the feed water flow on the water level is considered as the dynamic
characteristics of the control channel. Ideally, the drum and the feed water are the one-tank objects
with no self-balance ability, so the response of the water level should be a line. However, because the
temperature of the saturation water in the drum is higher than the temperature of the feed water, the
cold feed water makes the reduction of the water bladder in the drum and leads to the drop of the water
level. When the feed water flow suddenly increases, the water level doesn’t timely move up at the
beginning, but only after a time delay it would do with the change of the feed water flow.
Page 12
The response of the level can be described as Fig.II.2.
The transfer function of the response can be given by [13]:
( )
= (1)
( )
Where ε is the flying-up speed of the step response, τ is the pure delay time; H(s) is the output level
inside the drum and W(s) is the input feed-water flow.
II.2.2.2 Dynamic Characteristics of the Level with the Effect of the Steam Flow:
The effect of the steam flow on the water level is thought as the dynamic characteristics
of the disturbance channel. When the quantity of the fuel, here is natural gas, is not changed, the
sudden cost of the steam must lead to the fall of the drum pressure, the acute boil of the water in the
drum, and the increase of the water bladder, which moves the water level up. This process that the
water level untruly raises is the swell phenomenon. Fig.II.3 is the response of the water level on the
effect of the steam flow.
Page 13
The transfer function of the response can be given by [13]:
where ε1 is the flying-up speed of the step response on the effect of the steam flow, K2 and T2 are
respectively the amplification factor and the time constant of the water level change, which only
caused by the water bladder, H(s) is the output water level and D(s) is the disturbance signal of steam
flow.
II.2.2.3 Case Study:

Through the data gathered at the Refinery of Algiers from the old tests done on the
boiler STEIN & ROUBAIX, we have identified the parameters ε, τ,ε1, K2and T2 and therefore, we
obtained the transfer functions.
 Gd(s): the contribution of feedwater to the level.

 Gs(s): contribution of steam to the level.
Time (s) Level response to feedwater change Level response to steam change (%)
0.00 0.0 0.00
0.75 0.3 8.2
1.35 1.1 14.7
1.95 2.2 18.4
2.55 3.7 20.1
3.15 5.6 20.6
3.75 7.9 20.3
4.35 10.6 19.4
4.95 13.6 18.0
5.55 17.0 16.5
6.15 20.7 14.7
6.75 24.7 12.8
7.36 29.1 10.9
7.95 33.9 8.9
8.55 38.9 6.9
9.15 44.3 4.8
9.75 50.0 2.8
Table II.1 Measurements of the level response to feedwater and steam variations
We couldn’t be more precise because the instruments used at the refinery give a
measurement each 0.6 s.
Page 14
We have plotted the graphs representing these data and we obtained them to be as
follow (FIG Response):
We have used a system identification method [APPENDIX A] to identify the two

different transfer functions Gd(s) and Gs(s) and they are approximated to the following:
( ) .
Gd(s) = = (3)
( )
( ) . .
Gs(s) = = (4)
( )
Page 15
II.3 Control Strategies:

After getting a suitable model of the boiler drum, now we are going to present the
different drum-level control strategies and state the advantages and disadvantages of each one of them,
then we select the appropriate strategy.
Providing tight water level control in a drum is accomplished by utilizing one of the
three types of drum level control: single-element, two-elements, or three-elements.
But before starting the description of the control strategies, it is important to define
some concepts that are important:
PROCESS VARIABLE
In a control system, the variable, we want to control, is called a process variable or
PV. In industrial process control, the PV is measured by an instrument in the field and acts as an
input to an automatic controller (which is computer based) which takes actions based on the value of
PV. The process variable which is measured is called a measured variable (MV).
Here the process variable is the boiler drum level which is measured using a level
differential transmitter [20].
MANUPULATED VARIABLE
The factor that is changed to keep the measured variable at set point is called the
manipulated variable. If we control a particular level for instance, we manipulate a value to control
the level. Here, the valve position is called the manipulated variable and the measured level becomes
the process variable. In the case of a simple automatic controller, the controller output signal (COS)
drives the manipulated variable [20].
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SET POINT
The set point is a value for a process variable that is desired to be maintained. Set
points can also be maximum or minimum values.
ERROR
Error is the difference between the measured variable and the set point and can be
either positive or negative. The objective of any control scheme is to minimize or eliminate error.
. Therefore, it is imperative that error be well understood. Any error can be seen as
having three major components.
 Magnitude:
The magnitude of the error is simply the deviation between the values of the set point and the
process variable. The magnitude of error at any point in time compared to the previous error
provides the basis for determining the change in error.
 Duration:
Duration refers to the length of time that an error condition has occurred.
 Rate of change:
The rate of change is shown by the slope of the error plot.
MANUAL AND AUTOMATIC CONTROL

Before process automation, people, rather than machines, performed many of
process control tasks. For example, a human operator might have watched a level gauge and closed a
valve when the level reached the set point. Control operations that involve human action to make an
adjustment are called manual control system. Conversely, control operations in which no human
intervention is required, such as an automatic valve actuator that responds to a level controller, are
called automatic control systems.
PRIMARY ELEMENTS /SENSORS

Sensing devices are the first elements in the control loop to measure the process
variable, they are also called primary elements. Primary elements are devices that cause some
change in their property with changes in process fluid condition that can then be measured.
Examples of primary elements include:
 Pressure sensing diaphragms, strain gauges, capacitance cells.

 Resistance temperature detectors (RTD).
 Thermocouples…..etc.
Page 17
TRANSDUCERS AND CONVERTERS

Transducer is a device that translates a mechanical signal into an electrical signal.
For example, inside a capacitance pressure device, a transducer converts change in pressure into a
proportional change in capacitance.
A converter is a device that converts one type of signal in to another type of signal.
For example, a converter may convert current in to voltage for an analog signal in to digital signal.
. In process control, a converter used to convert a 4-20 mA current signal in to a 3-15
Psi pneumatic signal (commonly used by valve actuators) is called a current to pressure converter.
TRANSMITTERS
A Transmitter is a device that converts a reading from a sensor or transducer into a
standard signal and transmits that signal to a monitor or controller. Transmitter types include:
 Pressure transmitters
 Flow transmitters
 Level transmitters
SIGNALS
There are three kinds of signals that exist for the process industry to transmit the
process variable measurements from the instrument to centralized control system.
 Pneumatic signal
 Analog signal
 Digital signal
FINAL CONTROL ELEMENTS
The correcting or final control element is the part of the control system that acts to
physically change the manipulated variable. In most cases, the final control element is a valve used
to restrict or cut off fluid flow, but pump motors, louvers (typically used to regulate air flow),
solenoids, and other devices can also be final control elements. Final control elements are typically
used to increase or decrease fluid flow in any control loop, the speed with which a final control
element reacts to correct a variable that is out of set point is very important. Many of the
technological improvements in final control elements are related to improving their response time.
Page 18
ACTUATORS
An actuator is the part of the final control device that causes a physical change in
the final control device when signaled to do so. The most common example of an actuator is a valve
actuator, which opens or closes a valve in response to control signals from a controller. Actuators
are often powered pneumatically, hydraulically or electrically. Diaphragms, bellows, springs, gears,
hydraulic pilot valves, pistons, or electric motors are often parts of an actuator system.
TAG NUMBERS
Numbers on P & ID (Piping and Instrumentation Drawings) symbols that represent
instrument tag numbers. Often these numbers are associated with a particular control loop [20].
Let’s consider the instrument below:
During this project, we will be, mainly, considered with flow and level transmitters,
valve actuators and indicator controllers that are illustrated below:
FT: Flow Transmitter

LT: Level Transmitter
LIC: Level Indicator Controller
FIC: Flow Indicator Controller
FV: Flow Valve
FRCV: Flow Regulation Controller Valve
Page 19
II.3.1 Single Element Drum Level Control:

Single element drum level control is the simplest but least effective form of drum
level control. This consists of proportional signal or process variable (PV) coming from the drum
level transmitter. This signal is compared to a set point (SP) and the difference is a deviation
value. This signal is acted upon by the controller which generates a corrective action in the form
of a proportional output. The output is then passed to the boiler feed water valve, which then
adjusts the level of feed water flow into the boiler drum.
As seen below (FIG.II.5), there is a feed water pump to pump feed water into the drum, there is
an air to close control valve on the path of feed water. A level transmitter and a controller are also
provided. Controller is of direct acting type.
When level increases, we must decrease the feed water flow so as the level
transmitter senses this increase, the LC increases its output (since it is direct acting) and the valve
closes more (air to close). Thus the flow is reduced and the level is maintained at the desired
value. Since the level decreases, the controller output decreases and valve opens more and the
feed water flow will increase to maintain the level. This is feedback control system. Only after a
change occurs it will do corrective action so that the process is time lagging [4].
NOTES:
Only one analog input and one analog output required can only be applied to single
boiler/single feed pump configurations with relatively stable loads since there is no relationship
between drum level and steam or feed water flow possible inadequate control option because of
the swell effect.
Page 20
II.3.2 Two Element Drum Level Control:

The two element drum level control can be applied to a drum boiler where the feed
water is varying type. In this system, the difference or change in feed water flow to the drum is
sensed and sent to the controller by a flow transmitter and the controller takes corrective action to
take the desired flow rate to maintain the level. The flow is measured by using orifice plate. The
air to close valve controls the feed water flow, i.e. in two element controller, there is a flow
controller and a level controller, the flow controller is direct acting and the level controller in
reverse acting type.
One of the reasons for level change in the drum is the change in the feed water flow,
so an orifice plate is placed in the path of feed water to the drum to measure flow. This value is
sensed by flow transmitter and gives it to the direct acting flow controller. If the flow increases,
then output of FC increases and control valve closes more. If flow decreases, then output of FC
decreases and control valve opens more, thus maintaining a constant flow of feed water to
maintain constant level in the drum.
But if there is any fall in drum level due to reasons other than feed water flow, even
if the feed water flow is maintained constant, the process will get upset so again the flow must be
increased to afford the change in the drum level, so it is necessary to have an inter relation
between the level of water in the drum and feed water flow.
This is achieved by cascaded control. So we connect the output of LC to FC. Thus FC
is in cascade mode. Here FC acts as master and LC acts as slave control. Set point of LC is
external and set point of FC is output of LC, is shown below (FIG.II.6).
Page 21
Here we take two variables in consideration, i.e. level of water in the drum and feed
water flow. Hence this is called two element control. Hence the change in level is anticipated and
control action takes place before change in level occurs, this is called feed forward control,so the
system is more sensitive than single element control [4].
II.3.3 Three Element Drum Level Control:
In a boiler drum, there are many reasons for level change, in that level change, due to
change in the feed water flow is maintained by two element drum level controller. Another reason
for level change in the drum is change in the load (steam outflow from the boiler).
An important phenomenon occurs due to sudden change in the load, i.e.; swelling and
shrinking. Sudden withdrawal of steam causes swelling of water level (when the steam withdrawn
suddenly, there will be an apparent increase in level) and the level sensor misreads and the level
controller takes action to decrease the drum level by reducing the set point to the flow controller and
thereby the flow of feed water to the boiler decreases and level decreases. This is not desirable.
Similarly during sudden reduction, in steam withdrawal causes the phenomenon shrinking, i.e.;
sudden reduction in withdrawal causes apparent decrease in the drum level. In this case, the level
controller takes necessary actions for increasing the drum level by increasing the feed water flow
rate. Again this is not desirable.
A three element controller get rid of these disadvantages of two element control
scheme by takang the steam flow into account so that the apparent level changes and the changes
in the steam load are taken care of. The various parameters that are used in this controller are:
a) FEED WATER FLOW:
An orifice plate is used to measure the flow, a controller and a control valve to
control the flow rate.
b) STEAM FLOW:
An orifice plate measures the steam flow and gives this reading to a calculator.
c) DRUM LEVEL:
Level transmitters are used to measure the drum level and level controller and the
output of this level controller is given to a calculator.
Page 22
d) CALCULATOR:
This will calculate the set point for the feed water flow and give the output to FC.
Actually swelling and shrinking are only momentary phenomenon. This maymislead the controller
and cause unwanted oscillations. To prevent this, it is advisable to use three element drum level
control [4].
II.3.4 Comparison and Selection:
 From the above descriptions and the boiler STAIN & ROUBAIX used in the refinery of
Algiers, It is necessary to use a three element control strategy.
 In the following section, we’ll describe the different instruments involved in this control
strategy.
Page 23
II.4 Instrumentation:
II.4.1 Involved Instruments:
To achieve the right boiler level regulation using three-element control, the following
instruments are needed:
II.4.1.1 Sensors:
1-Level transmitter inside the boiler drum:
It is a level transmitter based on the differential pressure ΔP of the type 1151DP
ALPHLINE-ROSEMONT.
This device infers the level of the water within the drum by comparing the head pressure
generated by the water in the drum to a reference level. Typically, this reference is derived from a
chamber attached to the drum and filled with condensate derived from the sub cooling of steam. It
transmits a proportional 4 to 20 mA signal. The following figures II.8 & 9 represent Differential
Pressure Transmitter and the pressure-level relationship [21].
The difference in pressure is proportional to the level inside the drum:
ΔP = P2 – P1 = H.ρ.g where: H is the level inside the drum.
ρ is The water density.
g the gravity.
The differential level transmitter has a gain of Kl = 0.995.
Page 24
2-Backup Level sensor inside the boiler drum:

It is called Water gauge and it is an instrument that indicates the presence or the quantity
of water in the boiler drum. It consists of:
 Gauge glass which normally consists of a vertical glass tube connected top and bottom to the
boiler back plate. The water level must be visible within the glass at all times.
 A water column that is used on a steam boiler to reduce the turbulence and fluctuation of the
water level so the gage glass can provide a steady, accurate water level reading. The use of a
water column is not mandatory.
This sensor is used for security in case of failure of the differential water level transmitter.
3-Flow transmitters:
Two flow transmitters are used; one to sense the input feedwater flow and another to
sense the output steam flow.
These transmitters are of the type FT31ROUSEMONT model 1151 smart based on the
differential pressure as illustrated below (FIG.II.10):
This flow meter operates based on Bernoulli’s principle. It measures the differential-
pressure drop across a constriction in the flow’s path to infer the flow velocity as shown in the
following figure (Fig II.11):
Common types of differential-pressure flow meters are the orifice, the pilot tube, and the
venturi tube. An orifice flow meter is used to create a constriction in the flow path. As the fluid flows
through the hole in the orifice plate, in accordance with the law of conservation of mass, the velocity
of the fluid that leaves the orifice is more than the velocity of the fluid as it approaches the orifice. By
Bernoulli’s principle, this means that the pressure on the inlet side is higher than the pressure on the
outlet side.
Page 25
Measuring this differential pressure gives a direct measure of the flow velocity from
which the volumetric flow can easily be calculated.
The Differential-Pressure to the flow relationship is given by the following equation [21]:
Q = C v√
Where :
 Q is the flow of the feedwater or steam.
 Cv is the discharge coefficient which is proportional to the orifice area.
 ΔP is the differential pressure P2 – P1.
At the end we have found that the flow transmitter contributes in the feedback path and
the feed forward path with a gain of 0.0667.
II.4.1.2 Actuators:
1-Automatic valve:
A valve actuator is the mechanism for opening and closing a valve. Manually operated
valves require someone in attendance to adjust them using a direct or geared mechanism attached to
the valve. Power-operated valve actuators may be the final elements of an automatic control loop,
which automatically regulate the flow of the feedwater to the boiler.
To achieve an automatic control a servomotor is used to open and close the valve. Hence
the whole transfer function of the valve includes the discharge coefficient and the servo-motor transfer
function which is given as [22]:
Gsm (s) = Where:

( ∗ )
 Ksm: The servo-motor static gain.

 Tsm = 128 γ L V / π D2 R T: The servo-motor time constant.
γ: Dynamic viscosity of compressed air at 20° C.
V: Total volume of servo-motor chamber.
T: Ambient Temperature in K°.
D: Compressed air pipe diameter.
L: Pipe length.
Page 26
Using the data sheet of the servomotor and the parameters of the valve, the transfer
.
function of the final control element is found to be: Gsm (s) =
( ∗ )
II.5 Simulation and Results:

II.5. 1 Simulation:
After identifying the different transfer functions and the different gains involved in the
drum level regulation, it is necessary to simulate the results to see the response of the system.
We have implemented the old circuit used at the refinery (Bailey regulation) which is a
cascade regulation where the Master is the Level indicator controller (LIC) and the slave is the Flow
controller (FC).
The flow error is calculated by an FC, and then it is given as an input to the LIC which
takes actions and regulates opening percentage of the valve and this is better clarified in the following
Simulink circuit (Fig.II.12).
Page 27
We simulated the results using a window of 300 and we obtained the following
response (Figure.II.13):
II.5. 2 Results:
From the above response, we can see that the system is Stable; but slow with a considerable peak
overshoot and a small steady state error.
II.5. 3 Scope:
The objective of the coming chapter is to stabilize more the system by reducing its
peak overshoot and also to fasten the system besides eliminating the steady state error.
To achieve our objective another feed forward configuration will be used and a PID
controller, instead of a PI controller, must be properly designed.
II.6 Conclusion:
Even if the system is stable and fast enough, improvements can be made in order to
increase the efficiency and security of the boiler.
In the next chapter, we will go through the basic theory of a PID controller and the
different methods that are used to tune its parameters and we will select the appropriate one that yields
to better performances.
Page 28
Chapter Three PID Parameters Tuning
Chapter Three:
PID Parameters
Tuning
CHAPTER III PID Parameters Tuning
III.1 Introduction:
In this chapter, we will take a glance to the different techniques used in
process industries fortuning our controller. An evaluation of the parameters is done upon
the final response of the system to a fixed set point which is normally set at 45% and a
rejection of a steam demand disturbance which is varying from 0-60 tones/hour.
Hence the selection of the PID parameters (Kp, Ki and Kd) is crucial to
maintain the level as close as possible to the set point in a considerably short time.
III.2 Generalities on PID controller:

The PID controller is the most common controller structure in process
control and in many servo applications.
The PID controller is a controller structure, which combines proportional

action, integral action and derivative action. Its output is the sum of three parts:
 The first part is proportional to the error of the real system output Vs the reference
value (set point).
 The second part is proportional to the time integral of the error; the integral value
determines the reaction based on the sum of recent errors as past error.
 The third part is proportional to the time derivative of the error; the derivative value
determines the reaction based on the rate at which the error has been changing as a
future error.
Especially for control applications where the plant or the system model is of
a lower order and without or with a small time delay, the continuous PID controller gives
satisfactory results, which is the case in our drum boiler having a transfer function of the
second order and a small time delay.
Page 29
III.2.1 Continuous PID Controller:

III.2.1.1 Proportional Control:
This kind of control is represented in (Fig.III.1) The controller will amplify and
convert the error signal to alter the process output to bring it into the corresponding set point.
Mathematically, the control action of the P controller is given by [8]:
P (t)= .e(t) (1)
 = C(s) which the controller (Proportional gain).

 p(t) is the controller output.
 e(t) is the error signal.
In this control scheme, e(t) cannot be zero in the steady state because,
physically, cannot tend to infinity. However, increasing , decreases the steady state
error, but there is a limitation on the system stability.
III.2.1.2 Proportional – Integral (PI) Control:
A technique has been developed to overcome the problem of the steady state
error and the stability of the proportional controller. This technique is known as the integral
control mode which is added to the proportional mode to form the known PI controller [8].
The structure of a PI controller is shown below in (Fig.III.2):
Page 30
This controller will bring the steady state error to zero with the following control action:
pi(t) = K*[e(t) + ∫ ( ). ] (2)
Where: is the integral time constant.
Consequently, the PI controller has a better performance than the P controller.
However, the effectiveness of the PI controller is reduced in case of rapid

system disturbances, i.e., the controller cannot sense rapid disturbances to react against them.
III.2.1.3 Proportional – Derivative (PD) Control:
It is known that the faster change in the error signal (rate of change), the
greater the overshoot in the time response, and the longer the process to reach the steady state
or the desired level. Neither the proportional nor the integral modes of the PI controller
respond to that, so it is necessary to modify the controller to make it respond to the error rate
of change. This modification is done by the addition of another mode to the P controller. This
mode is known as the derivative mode [8].
The scheme of such controller is represented in (Fig.III.3):
The control action of the proportional- derivative controller is given by:
( )
pd(t)= K* [ e(t) + * ] (3)
Where: is the derivative time constant.
Page 31
The advantages of the derivative control mode are:
 It reduces the time required to bring the output signal to the desired value or the set
point.
 It also reduces the initial overshoot and the subsequent oscillations of the responses.
 It allows the proportional gain to take higher values that it could not take without the
use of the derivative mode, i.e., speeding up the system response to disturbances.
After knowing the three control modes and their effects on the system output
separately, one can deduce the effects on the system when gathering the three control modes
together to form what is called the PID controller which will be discussed in the next section.
III.2.1.4 PID Controller:
The scheme of the PID controller is represented below (Fig.III.4):
́́ ́́́
́́́́
́́́
The analog PID ́control action is given by:
( )
pid(t) = K*[ e(t) + ∫ ( ). )+ * ] (4)
The PID control would be used on systems that exhibit rapid and large
disturbances.
The tuning of the PID controller refers to the adjustment of its parameters, i.e. P, I and D.
Page 32
III.3 Tuning of PID Parameters:

Since our objective, as mentioned before, is to obtain all of the following
requirements for our control system:
 Fast response.
 Good stability.
 Output tracking
 Disturbance rejection.
Unfortunately, for practical systems these requirements cannot be achieved

simultaneously. In other words:
 The faster response, the worse stability.

 The better stability, the slower response.
So, for the control system, we look for the following compromise: acceptable
stability, and medium fastness of response.
Users of control systems are frequently faced with the task of adjusting the
controller parameters to obtain a desired behavior experimentally. There are many different
ways to do this. One way to do this is to go through the steps of Ziegler-Nichols’ Tuning
Method.
III.3.1Ziegler-Nichols’ Tuning Method:
This method is introduced by John G. Ziegler and Nathaniel B. Nichols. In this

method, the and gains are first set to zero. The Proportional gain (Kp) is increased from
zero until it reaches the ultimate gain Ku, at which the output of the loop starts to oscillate
with a constant amplitude [12].
The ultimate gain and the oscillation period are used to set the gains as
shown in the following table (Table.III.1):
Page 33
III.3.2 Case study:
In order to enhance the system performances; we proposed the use of another

feed forward configuration which is called the DCS Regulation.
It is a cascade regulation where the Master is the level controller (LC) and the
slave is the flow indicator controller (FIC). The flow transmitters transmit the feed-water and
the steam flows to the FIC which generates an output that is given to the LC as an input and
this ladder gives the final action to the FCVR.
The DCS Regulation block diagram is shown below (Fig.III.5):
Following the procedure given above (Section III.3.1), we set and to

zero, then the Proportional gain ( ) is increased till getting (Ultimate gain), when the
output response starts to oscillate with constant amplitude.
Page 34
At Ultimate gain = 2.67, we obtained the following response:
 We can notice that the system is oscillating with a constant amplitude.

 We can also notice that the ultimate period is Pu = 395 s.
 Hence the parameters of the PID controller are tuned using the Table.III.1.
 Kp = 0.6 * 2.67 = 1.602.
 Ki = (2 * 1.602) / 395 = 0.00811139.
 Kd = (1.602 * 395) / 8 = 58.632.
 Using these parameters, We obtain the following response (Fig.III.7):
Page 35
The output disturbance rejection illustrates how fast our controller rejects
the disturbance and is illustrated in the following figure (Fig.III.8):
(
Discussion:
We can see from the system response and output disturbance rejection
above, that the conventional PID controller is sufficient for level regula
regulation as soon as
the perturbations are small enough.
Some scenarios including the most case one (to

(to go from 1T
1T/h to 60T/h of
steam) are simulated, their responses are given in the following figures (Fig.III.9 to
Fig.III.12):
 Stepping up:
Page 36
 Stepping Down:
We can see that for large perturbations, we are faced with a big peak
overshoot which is harmful for both the equipment and the employees.
While increasing or decreasing the steam demand, the operator is limited to

variations of only 5 tons / hour and this is ensured by the following Anti balancing
system.
Comments:
In order to compare the two configurations, it is necessary to compare the

system performances of each of them.
The least the peak overshoot the better the stability of the system and the
least the rise and settling times, the faster the system.
Page 37
These parameters are given in the following table (Table.III.2):
BAILEY DCS
Stability STABLE MORE STABLE
Rise Time (s) 19.3 5.98
Settling Time (s) 97.8 17.7
Peak Overshoot (%) 9.75 7.5
Table.III.2 System performances comparison
From the table above, it is clear that the DCS configuration with a good
PID design offers a very good control scheme of a water level inside the boiler drum.
III.4 Conclusion:
We could realize a controller that enhance the performance of the system by
reducing its Peak Overshoot, hence increasing the stability, reducing the settling and rise
times to make the response faster.
We could also add a mean of security in order to forbidden any large

perturbation to protect the equipment and the personnel.
In the next chapters, we will see how to implement the system and the
controller using Simatic Step 7.
Page 38
Chapter Four Programmable Logic Controller
Chapter Four:
Programmable Logic
Controller
CHAPTER IV Programmable Logic Controller
IV.1 Introduction:
After getting a suitable PID parameters and simulating the results in Matlab, we
are going to transfer everything to a PLC (Programmable Logic Controller).
During this chapter, we will go through the description of PLCs and their main
components and modules.
After that, we are going to state the advantages of the Simatic S7-300 and the
reasons that incited us to choose this PLC and its Hardware and Software Configurations.
IV.2 Basic Description of a PLC:

IV.2.1 Definition:
A PLC (Programmable Logic Controller) is an industrial computer control system
that continuously monitors the state of input devices and makes decisions based upon a
custom program to control the state of output devices.
Almost any production line, machine function, or process can be greatly enhanced
using this type of control system. However, the biggest benefit in using a PLC is the ability to
change and replicate the operation or process while collecting and communicating vital
information.
In essence, the programmable logic controller consists of computer hardware,

which is programmed to simulate the operation of the individual logic and sequence elements
that might be contained in a bank of relays, timers, counters, and other hard-wired
components [7].
The PLC works by looking

at its inputs and depending upon their
state, turning on/off its outputs as
depicted in Figure (Fig IV.1).
Today, PLCs are used in

many "real world" applications such
as machining, packaging, material
handling, automated assembly and
countless other industrial processes.
Page 39
IV.2.2 PLC S7-300:

SIMATIC S7-300 is the best-selling controller of the Totally Integrated Automation
spectrum with a host of successful reference applications worldwide from the most varied
industrial sectors.
The comparison of the other PLCs and Siemens PLCs based on both the
performance and cost shows that Siemens PLCs best suit for this application. The Siemens
PLC components are readily available and it has its complete hardware and software system
accessible to the HAMK Laboratory. For this application, SIMATIC S7-300 PLC is used.
The different components of the S7-300 PLC are [15]:
 Power Supply
 CPUs
 Signal modules
 Function modules
 Communication
 HMI (Human Machine Interface)
 Software
The basic structure of a S7-300 PLC is described in the following figure (Fig.IV.2).
Page 40
IV.2.2.1 Mounting Rail (rack):

It is the main carcass of the PLC where different modules and cards can be placed.
Each rack is reserved for a specific component and is not convenient for the other.
IV.2.2.2 Power Supply Module:

Since the PLC belongs to the family of computers, it consists of many active
components that need to be supplied permanently.
This supply of power is ensured by the PS module to energies both the active
devices of the PLC and its Output actions.
We have used the PS 307 2A to supply the PLC and another PS 307 5A to supply
the actuators.
a) Power supply module PS 307 2 A (6ES7 307-1BA01-0AA0):

Properties:

 Output Current 2 A
 Output voltage 24 VDC; short circuit-proof,
open circuit-proof
 Connecting to single phase AC mains
(rated input voltage 120/230VAC, 50/60 Hz)
 Safety isolation to EN 60
 Can be used as load power supply
b) Power supply module PS 307 2 A (6ES7 307-1BA01-0AA0):

Properties:
 Output current 5 A
 Output voltage 24 VDC; short circuit-proof,
open circuit-proof
 Connecting to single phase AC mains
(rated input voltage 120/230VAC, 50/60 Hz)
 Safety isolation to EN 60 950
 Can be used as load power supply
Page 41
IV.2.2.3 CPU (Central Processing Unit):

The processor is the central processing unit (CPU) of the programmable controller.
It executes the various logic and sequencing functions by operating on the PLC inputs to
determine the appropriate output signals. The processor is very similar in its construction to
those used in personal computers and other data-processing equipments.
We have used the CPU S7-300 313 C that has several features:
 The CPU with mid-range program memory and quality frame works.
 High processing power in binary and floating-point arithmetic
 Used as central controller in production lines with central and distributed I/O
 Component Based Automation (CBA) or PROFINET
 Combined MPI/PROFIBUS DP master/slave interface
Besides the processing unit, this CPU possesses 5 analog inputs, 2 analog Outputs,
24 digital inputs and 16 digital outputs.
IV.2.2.4 Signal Modules:

These modules ensure the connection of the PLC with the outside world; they are
responsible of getting the input signals from sensors and transmitters and giving instructions
to the actuators.
There exist two types of signal modules:
 DI/DO: These are the digital input/output modules that have two different
states, 1 or 0.
 AI/AO: These are analog input/output modules that can vary within an
interval according to the state of the input/output.
The most used standard intervals are 4-20 mA, 0-20 mA and 0-10 V.
IV.2.2.5 Interface Module (IM):

This module is used only for connecting one PLC to another in order to exchange
information and not used in this project.
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IV.2.2.6 Connection Processor (CP):

These modules ensure the connection of the PLC to the operator PC and HMI
(Human Machine Interface) and this is done through the MPI.
Also they can be used for connection among the PLCs in a Master/Slave networks
using a Profibus cable.
IV.2.2.7 Function Modules (FM):

These perform time-critical and memory-intensive process signal processing tasks,
such as positioning or regulation.
The only function module that is used in this project is the PID module.
IV.2.2.8 Software:
It is a Programming device (PG) or PC with the STEP 7 software package that is
used to configure, set parameters, program and test our S7-300.
The connection of the PG to the CPU is done through a PG cable and further details
on the programming software are discussed hereafter.
IV.3 Programming the PLC S7-300:

IV.3.1 Industrial Programming Languages:
The IEC61131-3 standard developed by the International Electro-technical
Commission (IEC), considers five different PLC programming languages.
These programming languages are Ladder Diagram (LD), Instruction List (IL),
Function Block Diagram (FBD), Structured Text (ST) and Sequential Function Chart (SFC).
Below, the three first languages are explained further:
 Ladder Diagram (LD) is a graphical programming language that resembles the basic
format of electric circuit diagrams, making it easy to understand and get started with,
even for people without any previous programming experience. This language is most
suitable for simple processing with basic reading of inputs and writing to outputs,
whereas functionality like PID-controllers and other complex calculations might be
difficult to implement. Ladder Diagram is, however, universally accepted around the
world and simplifies code modification.
Page 43
 Instruction List (IL) is a text-based programming language in which each line of code
represents a single operation. This language is similar to assembler language, which
makes it easy to follow for people with experience in low-level programming. If a
program is written in Instruction List using the set of instructions defined by IEC, it is
quite manageable to use the same program on different hardware platforms.
Instruction List has a high rate of acceptance in Europe and is well suited in areas
where the execution time in the PLC is important.
 Function Block Diagram (FBD) is a graphical programming language that also

resembles circuit diagrams. In this language, different blocks are connected in
sequences that are easily understood. The Function Block Diagram language uses the
same set of instructions that are used in Ladder Diagram, and is considered ideal for
more simple types of applications that are mainly using digital inputs and outputs with
basic processing needs [14].
IV.3.2 Industrial Programming Software:
The software used in order to program our PLC is SIMATIC S7/M7/C7 V5.5 +
SP1. In the following we are going to discuss some features of this software and illustrate
some functionalities that are quite important.
The first step is to create a new project as follow (Fig.IV.5):
Page 44
The second step is to make the hardware configuration by installing the different
components in the convenient rack as shown below (Fig.IV.6):
The Third Step is to establish the Network Connection to the MPI (Multi Point
Interface) as shown in the following figure (Fig.IV.7):
Finally, we are ready to start programming the different instructions, in order to

achieve the boiler drum level control.
The basic structure of programming is to create Functions (FC) or Function Bocks
(FB) with the associated Data blocks (DB) and then gather all the functions and function
blocks in the first Organization Block (OB1) as shown in the following figure (Fig.IV.8):
Page 45
As an example, we are going to create and simulate the Boiler Emergency Shut
Down functional block and the rest of the program will be found in [APPENDIX B].
We create an FB1 and DB1 and choose the ladder language as illustrated below
(Fig.IV.9):
We implement the following instructions inside FB1 using the Data from DB1:
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We open the FB1 and enter the following instructions where the main function is
the comparison between the PV (The water level) and the different thresholds:
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After that, This FB1 must be brought to The OB1 which the Main Program
Sweep (Cycle), and then be inserted as a function as shown in Fig.IV.12.
Page 48
Finally, the simulator is activated and the program is transferred to the PLC in order
to simulate it and test it and the results were satisfactory and are shown below (Fig.IV.13):
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Results:
We can see that the Functional Block FB1 is working properly:
 No Alarm is activated when the level is in the range ]32,72[

 The ESD is activated when the level is greater than 83% or smaller than 18%.
 The High Limit Alarm is activated when the level belongs to the interval [72,83[
 The Low Limit Alarm is activated when the level belongs to the interval ]18,32]
Using the same principle, we designed several functions, Functional Blocks and one
Organizational Block OB35 where the PID block must be plugged.
IV.4 Conclusion:
Programmable Logic Controllers are very powerful controllers for automating
industrial processes. They offer both the security and efficiency.
Among all the PLCs, the quality and the price of Simatic S7-300 made it one of
the best choices for engineers.
SIMATIC S7/M7/C7 V5.5 offers several functions and ready blocks that make
the programming of the PLC much easier and flexible.
Page 50
Chapter Five Supervision Platform Using WINCC
Chapter Five:
Supervision Platform
Using WINCC
CHAPTER V Supervision Platform Using WINCC
V.1 Introduction:
After establishing the right step 7 program of the whole process; a supervision
platform is created in order to see the process reactions in real time, we are going to use one
of the Human Machine Interface (HMI) software that is SIMATIC WINCC flexible 2008.
This software will permit us to test the program in real time which will be the main
objective of this chapter.
V.1.1 SIMATIC WinCC flexible definition:
WinCC is a product of Siemens, and stands for Windows Control Center. It’s the
first SCADA/HMI software that is completely integrated with the production process.
SIMATIC is currently considered to be the global number one in automation. One

of the decisive reasons for this is that SIMATIC exhibits the eight system features of Totally
Integrated Automation (TIA) [26] and [24]:
 Engineering
 Communication
 Diagnostics
 Safety
 Security
 Robustness
 Technology
 High availability
SIMATIC WinCC flexible is the innovative HMI software under Windows for all
machine level applications. The range of operator panels extends from Micro Panels, which
are designed for applications with SIMATIC S7-200 controllers, to on-site solutions with
SIMATIC Panel PCs or IPCs.WinCC flexible stands for maximum configuration efficiency:
Libraries with preassembled objects, and intelligent tools extending to automated text
translation for multilingual projects.
Page 51
V.1.2 Parts of the SIMATIC WinCC flexible:

SIMATIC WinCC consists of different parts. These parts are given in a tree
structure and are:
V.1.2.1 Computer
Enter some general properties for the project, e.g. languages, time, graphical
runtime properties, etc. Important here is to fill in the right computer name. With this name
WinCC can find the right IP-address, to successfully establish the connections.
V.1.2.2 Tag Management
With this tool, we can connect WinCC to the PLC by choosing a driver, depending
on the type of the PLC that is used. Once the driver is selected, we can add it, and create the
tags. Tags are just the same as the variables in the PLC, but in WinCC they are not called
variables, but tags.
There are internal and process tags. Internal tags are used just in WinCC, and have
no connection with any variable in the PLC. Process tags are connected to variables in the
PLC, and will have the same value as those variables.
V.I.2.3 Structure tag
We use a structure tag if we have to connect a lot of variables in the PLC. One
condition is required: The variables have to be created by a fixed pattern, e.g. we got 10
pumps, with each 10 variables. So in total we will have 100 tags. If the variables of the pumps
are created in a fixed pattern, we can make a structure tag for these pumps. Now we have to
connect only 10 structure tags, instead of 100 process tags. This saves a lot of time, and
reduces the chance for making mistakes.
V.1.2.4 Graphical Designer
In this tool, we can develop the layout of the HMI. With the library, we can insert
graphical drawings, e.g. pumps, valves, tanks, etc. In the object palette we find all kind of
figures and tools that we need, e.g. I/O fields, text lists, trend templates, etc. With the
properties of a figure, we can set up almost everything we want, e.g. size, color, display, etc.
Important here is to make our figures dynamic by connecting them to tags, e.g. Connect an
Page 52
I/O field to the tag that contains the temperature of a tank. This ladder will show the
temperature of the tank.
V.1.2.5 Alarm Logging
This tool is used to create an alarm in particular circumstances. We can generate

the alarm, show it and archive it with this tool.
V.1.2.6 Tag Logging
With Tag Logging also we can show variables of the PLC as curves or in tables.
We can archive the variables and report them. To archive the values of the variables, the
values are stored on the hard disc in a buffer, or in a full archive.
V.2 Case Study:

Using SIMATIC WinCC flexible we proceeded as above to create our supervision
platform that is mainly composed of five screens and one template.
V.2.1 The different screens of the Supervision:

The main screen is the front page called “MENU” and is shown below (Fig.V.1):
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From this main view, we can navigate to the different screens of the supervision
platform that we have designed to be:
V.2.1.1 Boiler Main View:

This view shows the whole process in real time and permits the operator to
observe the status of the transmitters and actuators permanently and helps him to supervise
the system. This main View is shown below (Fig.V.2):
It consists of four burners that turn on/off according to the measured level (PV):
 In the Normal state i.e. when the level is in between 18% and 72% , only two burners
are operating (B1 & B2) and all the pumps are operating (P1, P2 & P3) and the two
controllers are manipulating the regulating valve FRCV in order to bring the level to
its set point.
 In the High Level alarm state i.e. when the level is in between 72% and 83%, three
burners are operating (B1, B2 and B3) and the security valve SV 2 is turned on and so
are the pumps.
 In the Low Level alarm state i.e. when the level is in between 18% and 32%, only one
burner (B1) is operating, the security valve SV 1 is turned on and so are the pumps.
 In the Emergency Shut Down state i.e. when the level is in below 18% or above
83%, all the burners are turned off (B1, B2, B3 and B4) and the security valves SV1
and SV 2 are turned on and the pumps are turned off.
When the ESD is activated, an alarming light and message are displayed to the
operator and this ladder can reset this mode after the level is stabilized.
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V.2.1.2 Set Parameters View:

This view is designed to adjust and set the different parameters of the system and
is shown in the following figure (Fig.V.3):
This view consists of selecting:
 The modes of the PID controller (P, I and D) and their values.
 The level set point.
 The steam Demand.
 The manual/Automatic modes
 A button to get back to the main view.
V.2.1.3 Curves:
This is designed to display the different curves associated to three parameters and
is shown below (Fig.V.4):
Page 55
At any time, the operator can observe the level variations through the process
variable graph compared to the set point graph and also to visualize the error.
V.2.1.4 About:
This view is an optional one that is designed to describe our project and to provide
the user of the application by some useful information to better understand the problem and
the objectives of the project.
V.2.2 Connection Establishment:

In order to connect our HMI screen to the PLC and synchronize the different
variables created is Step7 with the different tags in WinCC, we have to establish a network
connection via the MPI (Multi Point Interface) as shown in the following figure (Fig.V.5):
V.3 Conclusion:
The HMI is a mandatory part that we have to take in consideration when
designing controllers in order to let the operator supervise the system and communicate easily
with its devices and components.
One of the most powerful software to design HMIs is SIMATIC WinCC flexible
that we have used during this project.
Four screens have been created in order to organize the work:
 Boiler Main View to see the whole process.

 Set Parameters View to adjust and set the different parameters by the operator.
 Curves to better visualize the PV, SP and Error.
 About helps the user to better understand the project.
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GENERAL CONCLUSION
GENERAL
CONCLUSION
GENERAL CONCLUSION
The work that we have done during this project was very profitable for us; we have
used much of the knowledge acquired during our undergraduate and graduate study.
It consisted mainly on how to select the right tool to solve the different problems that
we have met during the realization of the project.
Beside the application of the background that we had, we have learned lot of things
that we can meet only when we are in the real processes in industry and those are the
problems that are not figured out in theory.
We built an approximate model of the boiler used in the refinery of Algiers and this
is very profitable for their engineers for further enhancements.
We have got an interaction with the different instruments used in oil and gas
industry, the way they are calibrated and used, the different types of controllers and PLCs and
security protocols like BMS and CCS.
Finally, this project has permitted us to penetrate in the deep of an exciting field that
is the field of « automation» and its practical applications.
It has also permitted us to get familiarized with the world of Industry and get a good
knowledge on the real problems of the Regulation in industrial processes.
As a further work, we are willing to use another control mode such as Adaptive PID
controller or Fuzzy Logic Controller in order to challenge the problem of large perturbations.
Page 57
APPENDICES
APPENDICES
APPENDIX A DRUM MODEL IDENTIFICATION
Least square method is a major tool for parameter estimation from experimental data,
there are other methods for estimation parameters such as likelihood method, but the least
square method continue to be the most well known one, because it is easier to deal with, and it
is unbiased (the error is very small when the noise is present).
1) Identifying the transfer function Gs(s)
The transfer function Gs(s) has a form of: Gs(s) = where the unknown values
a, b and c are to be determined.
So as to determine those unknown values, we will follow the procedure given below:
Gs(s) can be written as:
as+b
Gs(s) = = +
s2 +s
Where: can be written as + ; using Partial Fraction Expansion method:
 A= b
 B= - (b.c)
.
So the whole transfer function Gs(s) can be rewritten as: Gs(s) = + –
Rearranging Gs(s), we get:
/
Gs(s) = + -
/ /
Changing the domain from the Laplacian to Z with a sampling time T=1s, we get:
. . b.z
Gs(z) = / + - z−e−1/c
( – ) .
Gs(z)= / + …………………………………. (1)
After rearranging the equation (1) and multiplying the numerator and the denominator by
, we get the following transfer function in Z-Domain:
Gs(z)=
( )
a
Letting: X0 = c , X1= 1− − , X2= − 1 + and X3= ( )
We can write Gs (z) as:
. ( )
Gs(z) = = ………………….. (2)
. . ( )
 T: represents the time (in seconds).

 H: represents the level response to steam change (in %).
From equation (2)
X0.T(z) +X1. .T(z) = H(z) + X2. .T(z) +X3.z . T(z)
Taking the inverse of the Z-Transform:
X0.T(k) + X1.T(k-1) = H(k) + X2.H(k-1) +X3.H(k-2) ;
Thus, H (k) = X0.T(k) + X1.T(k-1)– X2.H(k-1) – X3.H(k-2) ………………….(3)

In matrix notation, we can write equation (3) as:
H(k) = [T(k) T (k-1) -H (k-1) - H (k-2) ]*
Or H(k) = M(k) * (k) where :
 M (k) = [ T(k) T(k-1) -H(k-1) -H(k-2) ] the matrix of Input/Output values.
 (k) = the unknown vector.
Using the Simple Least Square Method:
(k) =(M M) ∗ M ∗H …………………………………. (5)

From the Table II.1, the matrix M and the vector H are given below:
So:
So, from equation (5), the unknown vector (k) is found to be:
.
(k) = = .
.
.
1
X3= ( ) = 0.9355 → c = − ln (0.9355) = 14.9983≈ 15
a
X0 = 0.2050 = c → a= c.0.2050 =15 *0.2050 = 3.0747
X1+ . .
b=
1− −1/
= / = -0.0351
So the unknown values a, b and c are approximately:
a= 3.075
b= -0.035
c= 15
. .
The identified transfer function is Gs (s) = =
2) Identifying the transfer function Gd(s)

Using the same procedure given above, we can identify the transfer function of the
feedwater response to the water level.
The form of the transfer function that we want to identify is Gd(s) = where the
unknown values ε and τ are to be found.
Gd(s) can be rewritten as: Gd(s) = +
Using Partial Fraction Expansion:
( . )
Gd(s) = - = -
/
Converting the transfer function of Gd(s) from S-Domain to the Z-Domain, we get:
. .
Gd(z) = − / ………………………………..(e)
After rearranging the equation (e), we get:
Gd(z) = .
( )
Letting: Y0 = ε 1 − e , Y1= - 1 + e and Y2 = (e )
Now, We can write Gs(z) as :
∗ ( )
Gd(z) = = …………………………….(f)
∗ ∗ ( )
 T: represents the time (in seconds).

 L: Level response to feed-water change (in %).
From equation (f):
Y0. .T(z) = L(z) + Y1. .T(z) +Y2.z . T(z)
Taking the inverse of Z transform:
Y0.T(k-1) = L(k) + Y1.L(k-1) +Y2. L(k-2)
Thus, L(k) = Y0.T(k-1) – Y1.L(k-1) – Y2.L(k-2) …………………..(g)

In matrix notation: we can write equation (g) as:
L(k) = [T(k-1) -L(k-1) -L(k-2) ]*
Or L(k) = D(k) *∅(k) where :
 D(k) = [ T(k-1) -L(k-1) -L(k-2) ] the matrix of Input/ Output values.

 ∅(k) = is the unknown vector.
Using the Simple Least Square Method:
∅(k)= (D D) ∗ D ∗L …………………………………….. (j)
From the Table II.1, the matrix D and the vector L are given below:
So:
(D D) =
From equation (j) we can find the unknown vector ∅(k):
.
∅(k)= = .
.
So, the value of τ can be found as:
τ= ( )
= .
= 30.003
Y0 .
And the value of ε is found to be: ε =
1−e−1/c
= / = 0.0349
So the unknown values τ and ε are approximately:
= 0.035
=30
.
Finally, the identified transfer function is Gd(s) =
APPENDIX B THE WHOLE PROGRAM
The content of this appendix is supposed to help the future readers and not to make them lazy.
I Mnemonics Table:
II The Data Blocks:
II.1 DB1:
II.2 DB2:
II.3 DB3:
II.4 DB4:
II.5 DB35:
III Organizational Blocks:

III.1 OB 35:
This Block is reserved to the PID controller and is shown below:
III.2 OB 1:
This is the main block where we have to put all the other blocks:
IV Functional Blocks:
IV.1 FB1:
IV.2 FB2:
IV.3 FB3:
IV.4 FB4:
IV.5 FB41:
This block is locked by the constructor and can be found in the standard Library.
V Functions:
Only one function is used and can be found in the Standard Library in the TI-S7 converting
blocks with a name of SCALE or a symbolic name FC 105.
BIBLIOGRAPHY
BIBLIOGRAPHY
BIBLIOGRAPHY
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(February, 1997).
2] Boiler Drum-Level modeling by S. R. Tawfeic, Minia University, Minia, Egypt (April,

2013).
3] The Design for the Boiler Drum Level System Based on Immune Control, by Gui Li Yuan
And Ji Zhen Liu (March, 2012).
4] Water Level Control of Boiler Drum Using One IEC61131-3-Based DCS , by Yang
Qiliang, Xing Jianchun,and Wang Ping, at the university of China, (July, 2007).
5] Drum-boiler dynamics K.J. Astrom , by R.D. Bell", at Lund Institute of Technology,

(March 1999).
6] A Guide to Boiler Drum Level Equipment and Control Concepts, presented by

Clark.Reliance, American Society Of Mechanical Engineers World Technology Center NY,
NY (2001).
7] Data communication between programmable logic controllers in the industrial distribution

applications, by Anna BYSTRICANOVA, Andrej RYBOVIC1, University of Zilina,
Univerzitna, (june, 2011).
8] PID Controller Tuning: A Short Tutorial, by Jinghua Zhong , Mechanical Engineering,

Purdue University (Spring, 2006).
9] Discete time systems, by Kemal ARI Faik Tekin ASAL, and Mert COŞGUN, MIDDLE
EAST TECHNICAL UNIVERSITY (june, 2000).
10]Controlling a Robotic Arm Manipulator with a PLC, by Bhim Bahadur Lama,Degree

Programme in Mechanical Engineering and Production Technology, (April,2012).
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System by T. Rajkumar, V. M. Ramaa Priyaa and K.Gobi, (Volume II, April’13).
12] Performance of Different Control Strategies for Boiler Drum Level Control Using
LabVIEW by Pragyan Paramita Kar & Priyam Saikia, (May, 2013).
13] The Study of Boiler Control System of Water Level of Steam Drum Based on New
Immune PID Controller, by Zhou Li & Sun Xia, (2011 Second International Conference on
Digital Manufacturing & Automation).
14] SIMATIC. Standard Software for S7-300 and S7-400 PID Control V5.1. Source:
www.ad.siemens.de
15] SIMATIC S7-300 Automation System, Hardware and Installation: CPU 313C.
16] SIMATIC S7-300 PID Temperature Control.
17] Boiler control- improving efficiency of boiler systems, by Hjalti Kristinsson, Sofie Lang,
(December,2010).
18] Importance of three element-elements boiler drum level control and its installations in
power plant, By Sanjoy Kumar Chakraborty, Nilotpal Manna and Surodh Dey, (April, 2014)
19] Document of the refinery of Algiers, « Production and Distribution of the steam», (2007)
20] Website: WWW.LinkedIn.com
21] Website: WWW.Rousemont.com
22] Project (Régulation de Niveau d’une Chaudière dans une unité pétrochimique, 2008).
23] Website: WWW.SteamEngineering.com
24] Simulation of boiler control using. PLC and SCADA,By Schital.chopade, Pradhuman
Verma, and Prashat Verma (IJEAT), (December, 2013).
25] Simulation of control of water level in boiler drum, By Wang ZHou, Wang Shichao
(China).
26] Website: WWW.Siemens.com

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People’s Democratic Republic of Algeria

Ministry of Higher Education and Scientific Research

Institute of Electrical and Electronic Engineering

Final Year Project Report Presented in Partial Fulfilment of

Institute of Electrical and Electronics Engineering

I, dedicate this project to my loved parents, my brothers from the eldest to

I.1 A two-pass fire-tube boiler 04

II.8 Differential level transmitter 24

II.10 Differential flow transmitter 25

III.2 Proportional-integral controller 30

III.10 System response to the maximum (60t) of steam 36

IV.1 Operation principle of a PLC 39

IV.2 Main components of a PLC 40

IV.5 Create a new project called Boiler-level control 44

IV.6 Hardware configuration of the PLC 45

IV.7 Network connection through MPI 45

IV.12 Alarm management main program in OB1 48

IV.13 Simulation results of FB1 49

τ Pure delay time

K2 Amplification factor of the water level change

T2 Time constant of the water level change(s)

P1 Steam flow rate

P2 Level controller output

ρ The water density.

K1 The differential level transmitter

Q Flow of the feed-water or steam

Cv The discharge coefficient which is proportional to the orifice area

Gsm (s) Servo-motor transfer function

Ksm The servo-motor static gain

Tsm The servo-motor time constant

γ Dynamic viscosity of compressed air at 20° C

V Total volume of servo-motor chamber

D Compressed air pipe diameter

LIC Level Indicator Controller

FIC Flow Indicator Controller

FRCV Flow Regulation Controller Valve

H(s) Output level in S domain

W(s) Input feed-water flow in S domain

D(s) Disturbance signal of steam flow transfer function

Gd(s) Contribution of feed-water to the level transfer function

Gs(s) Contribution of steam to the level transfer function

COS Controller Output Signal

e(t) The error signal

Ti The integral time constant

Td The derivative time constant

Chapter I: Boiler description

I.1 Introduction ……………………………………………………………………….3

I.2.1 Boiler definition …………………………………………………………….3

I.2.2 Application of boilers ……………………………………………………….3

I.2.3 Boiler types ………………………………………………………………….4

I.2.3.1 Fire-tube boilers ………………………………………………………4

I.2.3.2 Water-tube boilers …………………………………………………4

I.3 Case study…………………………………………………………………………..5

I.3.2 Boiler operation……………………………………………………………...5

I.3.3 Boiler components …………………………………………………………..6

I.3.3.1 Water-Steam side ……………………………………………………6

I.3.3.2 Combustion side …………………………………………………….8

I.3.3.3 Casing …………………………………………………………… ...9

I.4 Conclusion …………………………………………………………………………10

Chapter II: Boiler modeling and control strategies

II.1 Introduction ……………………………………………………………………….11

II.2 Drum-Boiler modeling…………………………………………………………….11