DRUM LEVEL CONTROL FOR BOILR USING MICROCONTROLLER/JUNE 2008/2016/

Wolaita Sodo University

Collage of Engineering

Final Year Project on

Design and Implementation of Drum Level Control for Boiler

Using Microcontroller

Submitted By

NAME Id No
1. Teshale Shallo……………………………….....ENG/R/0872/04
2. Yusuf Ayub…………………………………….ENG/R/1281/04
3. Temesgen Mitiku……………………………….ENG/R/0602/04
4. Mintob Lupo……………………………………ENG/R/0589/04
5. Zahara Mohammed…………………………......ENG/R/0339/04
Department:-Electrical and Computer Engineering
Stream:-Control Engineering (SECTION 3)
Adviser: Instructor Wondimu Dewitt
June 10,2016

Wolaita Sodo Ethiopia

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Title on:-Design and Implementation of Drum Level Control

for Boiler Using Microcontroller

Submitted By

NAME Id No
1.Teshale Shallo……………………... ENG/R/0872/04
2.Yusuf Ayub……………………………ENG/R/1281/04
3.Mintob Lupo…………………………..ENG/R/0589/04
4.Temesgen Mitiku……………………. ENG/R/0602/04
5.Zehara Mohammed………………… ENG/R/0339/04
THESIS SUBMITTED TO DEPARTIMENTS OF ELECTRICAL AND COMPUTER
ENGINEERING IMPARTIAL FULFILMENTS OF THE REQURMENT FOR THE
AWARD DEGREE

OF
BACHELOR OF SCIENCE
IN
ELECTRICAL AND COMPUTERENGINEERING (CONTROL ENGINEERING)

June 10,2016

Wolaita Sodo Ethiopia

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DECLARATION
We hereby declare that the project entitled DESIGN AND IMPLIMENTATION OF
DRUM LEVEL CONTROL FOR BOILR USING MICROCONTROLLER is
submitted in partial fulfilment of the requirement for award of the degree in Bsc Degree
in Electrical and computer Engineering (control Engineering) ,Wolaita Sodo University
,is a record of our own work carried out by us during the academic year 2008/16 under
the supervision and guidance of Wondimu Dawit/M.sc./ ,Department of Electrical and
computer engineering, College of Engineering .The extent and source of information
are derived from the existing literature and have been indicated through the project at
the appropriate places. The matter embodied in this work is original and has not been
submitted for the awerd of any degree, either in this or any other university.

NO Student name ID Signature

1. Teshale Shallo ENG/R/0872/04 _________

2. Yusuf Ayub ENG/R/1281/04 _________
3. Mintob Lupo ENG/R/0589/04 _________
4. Temesgen Mitiku ENG/R/0602/04 _________
5. Zehara Mohammed ENG/R/0339/04 _________

Place _______________________

Date________________________

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Approval sheet
This is to certify that project report entitled DESIGN AND IMPLEMENTATION OF
DRUM LEVEL CONTROL FOR BOILER USING MICROCONTROLLER that is
submitted by this group members in partial fulfilment of the requirement for the award
of the degree BSC in ELECTRICAL AND COMPUTER ENGINEERING (STREAM
CONTROL) to Wolaita Sodo University, is a record of the candidate own work
carried out by him under my own supervision. The matter embodies in thesis is original
and has not been submitted for the award of any other degree.

_____________________ _______________

Name Sign.

______________________ ________________

Name Sign.

____________________ _______________

Name Sign.

_____________________ ________________

Chairperson sign.

______________________ _______________

Advisor sign.

______________________ _______________

Department Head Sign.

Place: __________________________

Date:___________________________

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ACKNOWLEDGEMENT
First of all, we would like to express our sincere gratitude to our project Supervisor, Mr. WONDIMU
DAWIT(M.sc.) for the commitment, encouragement and valuable advice he provided us along the
entire course of this project and report. His rigorous views to do the PROJECT and inspire the idea to
solve problems that are precious for our future career

Our appreciation also goes to our parents who has been so tolerant and supports our entire life. Thanks
for their encouragement, love and emotional supports that they had given to us.

We would like to thank to our colleague members, from ECENG class of 2015/16 Session for their
support and advice.

A special thanks to our School of ECENG who gives us the opportunity to continue our study.

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ABSTRACT

Conversion of water into steam is the primary function of a utility boiler. The steam pressure is used to
turn a steam turbine thus, generating electricity. Within the boiler drum there exists a steam/water
interface. Boiler steam drum water level is one of the important parameters of power plant that must
be measured and controlled. For safe and efficient boiler operation, a constant level of water in the
boiler drum is required to be maintained. Too low water level may cause damage boiler tube by
overheating. On the other hand too high drum water level leads to improper function of separators,
difficulty in temperature controlling and damage in superheated tubes. Turbine may also be damaged
by moisture or water treatment chemicals carryover. The amount of water entering the boiler drum
must be balanced with the amounts of steam leaving to accomplish the constant water level in the
drum. The boiler protection system is developed in order to protect the boiler and surrounding from
any danger that my cause system failure or explosions. Here we have developed the boiler drum water
level control system that keeps the water in the desired level in the drum. And also Pressure relief
control systems which releases the steam when high pressure is developed.

Therefore it is extremely important to have the knowledge of the operating principles, installation
requirements, strength and weaknesses of drum water level control system. In this paper design
aspects and installation requirements of boiler drum level control are discussed for safe and economic
operation.

The hardware designs are made providing the reasons and specifications of the components selected.
And the software design includes development of the C program for each system. The programs are
developed after developing the respective flow charts.

After the design process we have used Proteus professional simulation tool to integrate and simulate
the systems we developed. And we have tried to show the results we obtained.

Keyword:-drum level,boiler,water, microcontroller C program code

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Contents
Acknowledgment ……………………………………………………………………………………iv
Abstract ……………………………………………………………………………………………..v
Table of Content …………………………………………………………………………………….vi
List of Figure ………………………………………………………………………………………...ix
List of Table …………………………………………………………………………………………x
List of Acronmy……………………………………………………………………………………….x

CHAPTER ONE ............................................................................................................... 1

1. INTRODUCTION ...................................................................................................................... 1

1.1 Automation ...................................................................................................................................... 2

1.2 Statement of the problem ................................................................................................................. 2

1.3 Objective of the project ................................................................................................................... 3

1.3.1General objective ..................................................................................................................... 3

1.3.2 Specific Objectives ................................................................................................................. 3

1.4. Scope of the project ........................................................................................................................ 3

.1.5 Methodology................................................................................................................................... 3

1.5.1 System development methodology ......................................................................................... 3

1.5.2 System development ............................................................................................................... 4

1.5.3. Hardware developments and software development ............................................................. 4

1.5.4 Programming process(Soft ware development) ...................................................................... 5

1.6 Significants of the project ................................................................................................................ 5

1.7 Limitation of the project .................................................................................................................. 6

1.8 Overview of the project ................................................................................................................... 6

1.9. Organization of the paper ............................................................................................................... 6

CHAPTER TWO .............................................................................................................. 7

2. THEORY AND LITERATURE REVIEW .................................................................. 7

2.1 Introduction ..................................................................................................................................... 7

2.2 BOILERS ........................................................................................................................................ 7

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2.2.1 How Boilers Work .................................................................................................................. 7

2.3 Boiler processes ............................................................................................................................... 8

2.3.1 Boiler processes are highly interactive ................................................................................. 10

2.3.2 Process dynamics in boilers .................................................................................................. 11

2.4 Types of Boilers ............................................................................................................................ 12

2.4.1 Fire-tube boiler...................................................................................................................... 12

2.4.2 Water-tube boiler .................................................................................................................. 13

2.5 Key Components of Boilers .......................................................................................................... 15

2.6 Literature Survey ........................................................................................................................... 16

CHAPTER THREE......................................................................................................... 18

3. SYSTEM DESIGN AND DESCRIPTION ................................................................ 18

3.1. Introduction .................................................................................................................................. 18

3.2. Hardware design ........................................................................................................................... 18

3.2.1 Microcontroller PIC 16F877 ................................................................................................. 18

3.2.2 LCD....................................................................................................................................... 20

3.3 Measurement Techniques of drum level........................................................................................ 21

3.3.1 Gauge Glass .......................................................................................................................... 21

3.3.2 Conductivity Level probe Sensors ........................................................................................ 21

3.3.3 Water and Fuel pump ............................................................................................................ 22

3.3.4 Relay ..................................................................................................................................... 22

3.3.5 Control knobs ........................................................................................................................ 23

3.3.6 Solenoid valves ..................................................................................................................... 24

3.3.7 Wet Leg System .................................................................................................................... 25

3.4 Boiler protection control system.................................................................................................... 27

3.4.1 The Boiler Drum Level control system ................................................................................ 28

3.4.2 Shrink and Swell......................................................................................................................... 28

3.4.3 Drum Level Measurement .................................................................................................... 29

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3.4.4 Boiler Feed Water Control .................................................................................................... 30

3.4.5 Single Element Feed Water Control ........................................................................................... 31

3.4.6 Two-Element Feedwater Control ............................................................................................... 32

3.4.7 Three-Element Feedwater Control ........................................................................................ 32

3.5 Block diagram of Level control System ........................................................................................ 33

3.6. Software Design ........................................................................................................................... 34

3.6.1 Programming process............................................................................................................ 36

3.7 Level controller.............................................................................................................................. 39

CHAPTER FOUR ........................................................................................................... 41

4. RESULTS AND DISCUSSION ................................................................................. 41

4.1 The Proteus Design........................................................................................................................ 41

4.2 working principle of drum level controller .................................................................................... 43

CHAPTER FIVE............................................................................................................. 45

5 Conclusion and Recommendation ............................................................................... 45

5.1 Conclusion ..................................................................................................................................... 45

5.2 Recommendation ........................................................................................................................... 45

5.3 Future scope................................................................................................................................... 46

6. Reference..................................................................................................................... 47

7. Appendix ..................................................................................................................... 49
Appendix A: Specifications ................................................................................................................. 49

Appendix B: LCD pin descriptions ..................................................................................................... 51

Appendix C: Source code for the control systems............................................................................... 52

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List of Figure
figure 1.1 hard ware component block diagram ................................................................................... 4

Figure 2. 1 Elementary model for the boiler process ............................................................... 8

Figure 2.2 Expanded model for the boiler process .................................................................. 9

Figure 2.3 Heat input requirements for steam generation at atmospheric pressure ............... 10

Figure 2.4 Example of interaction of variables in the boiler process .................................... 11

Fig 2.5 fire tube boiler ........................................................................................................... 13

Fig 2.6 water tube boiler ........................................................................................................ 14

Figure 3.1: Over all block diagram of boiler drum level controller....................................... 18

Fig 3.2 Water and fuel pump ................................................................................................. 22

Fig 3.3- 5V Minature relay .................................................................................................... 23

Fig 3.4 Control knob used to set an operating point .............................................................. 24

Fig 3.5 Solenoid Valve structure ........................................................................................... 24

Fig 3.6 A wet leg installation ................................................................................................. 25

Figure.2.7 ............................................................................................................................... 26

Figure 3.8 wet leg installation with zero elevation. ............................................................... 26

Fig 3.9 .The Water in the Steam Drum Contains Steam Bubbles.......................................... 29

Fig .3.10 Boiler drum level management............................................................................... 30

Figure 3.11 Basic control function for drum level ................................................................. 31

Fig.3.12 Single element control ............................................................................................. 32

Fig.3.13. Single element feed water control .......................................................................... 32

Figure 3.14 Two element feedwater control. ......................................................................... 32

Figure 3.15: Three element feedwater control ....................................................................... 33

Fig 16 Dimension and Position of CLP in boiler drum level ................................................ 33

Figure 3.17 Block diagram of the level control systems ....................................................... 34

Fig 3.18 software development .............................................................................................. 35

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Figure 3.19: MikroC compiler IDE ....................................................................................... 38

Figure 3.20: Flow chart for level control system ................................................................... 39

Table 3.3: Input/output assignment of the level control system ............................................ 40

Figure 3.21: Loading the generated .hex file in to the MCU and finally we run the simulation
................................................................................................................................................ 40

Figure 4.1: Proteus Professional GUI .................................................................................... 42

Fig 4.2 Figure show the simulation pused ............................................................................. 42

Figure4.3. Simulation screenshot of the drum water level controller .................................... 43

Fig 4.4 Figure show that simulation run at LTL SENSOR opened ....................................... 44

List of Table
Table 1.1 hard ware component……………………………………………………………...4
Table 3.1: Comparison between PIC microcontroller and PLC ............................................ 20

Table A.1: Sensors ................................................................................................................. 49

Table A.2: Actuators .............................................................................................................. 50

Table A.3: Miscellaneous device ........................................................................................... 51

List of Acronym
AC Alternating Current
ADC Analog to Digital Converter
AVT Allied Vision Technologies
BTU British thermal unit
CLP Conductive Level Probe
COFF Common Object File Format
DAC Digital to Analog Converter
DC Direct Current
FW Feed Water
HP High Pressure
Hp Horse Power
HRSG Heat recovery steam generator
ICD in Circuit Debugger

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IDE Integrated Development Environment

LCD Liquefied crystal display
LED Light emitting diode
LTL Lower Threshold Level
MCU Microcontroller unit
Nm Newton-meter
PI Proportional Integral
PIC peripheral interface controller
PLC Programmable logic controllers
Psig pound per square inch gauge
PWM Pulse width modulation
RAM Random Access Memory
ROM Read Only Memories
Rpm rotation per minuet
S.C. Share Company
UTL Upper Threshold Level
VSMVirtu system modeling

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CHAPTER ONE

INTRODUCTION
Nowdays,almost nothing can be achieved without the use of computers. Most advanced factories
utilize robot arms to manufacture products such as cars, electronics boards, etc.The majority of robot
are industrial robots. This means that robots have replaced people in a factories and laboratories.
1.2. BACKGROUND
Boilers are systems designed to produce steam in varying quantities for a variety of applications
including space heating, process heating, sanitation, power generation and others. A boiler is a closed
vessel which is used to heat up water or other fluids and those heated or vaporized fluids are then
furthered used for different processes. The control system for a boiler–turbine unit usually needs to
meet the requirement of the amount of water in the steam drum must be maintained at a desired level
to prevent overheating of the drum or flooding of steam lines. Steam boilers are used to produce
saturated or superheated steam which are then used in different processes like the superheated steam is
used to run the turbines which in turn produces electricity, historically steam boilers were used in
trains to run the steam engines, steam is also used in chiller of central cooling system which helps in
maintaining the chemical soft inside the chiller or otherwise it will get harder and the chiller will not
work, it is also used in re-boiling operations and cooking and there are a lot more functions of steam
boiler[1].
A major benefit of using steam as a heat transfer medium is the large amount of heat released
when it condenses into water. With a latent heat of vaporization (or condensation) as high as
1,000 BTU per pound, it takes very little steam to carry a large amount of energy Other
advantages include the safe, nontoxic and nonflammable characteristics of steam plus its ability to
deliver heat at a constant and controlled temperature. Steam can also be delivered to users with
conventional piping and valve equipment that is inexpensive, is readily available, requires little
maintenance, and has a long service life. Compared to other heat delivery and distribution systems,
steam is less expensive to operate and is about 100% recyclable. [4]

Too high water level leads to improper function of steam separators, difficulties in temperature
control, and the moisture or water treatment chemical carryover can damage the super heater tubes and
turbines. In addition, the drum pressure control is adversely affected by poor level control
This is critical for the safe and economic operation of a power plant.
 Learn why drum level control is critical for boiler safety.

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 Boiler damage due to low water level is one of the largest issues.
 Proper drum level control minimizes downtime and cost.
 Drum level control is critical to good boiler operation, as well as safe boiler operation.
The drum level must be controlled to the limits specified by the boiler manufacturer. If the drum level
does not stay within these limits, there may be water carryover. If the level exceeds the limits, boiler
water carryover into the super-heater or the turbine may cause damage resulting in extensive
maintenance costs or outages of either the turbine or the boiler .If the level is low, overheating of the
water wall tubes may cause tube ruptures and serious accidents, resulting in expensive repairs,
downtime, and injury or death to personnel .A rupture or crack most commonly occurs where the tubes
connect to the drum.

1.1 Automation
Automation or automatic control, is the use of various control systems for operating equipment such as
machinery, processes in factories, boilers and heat treating ovens, switching in telephone networks,
steering and stabilization of ships, aircraft and other applications with minimal or reduced human
intervention. Some processes have been completely automated. The biggest benefit of automation is
that it saves labour, however, it is also used to save energy and materials and to improve quality,
accuracy and precision. The term automation, inspired by the earlier word automatic (coming from
automaton), was not widely used before 1947, when General Motors established the automation
department.
Automation has been achieved by various means including mechanical, hydraulic, pneumatic,
electrical and electronic and computers, usually in combination. Complicated systems, such as modern
factories, airplanes and ships typically use all these combined techniques [3].
Automation has many advantages, among them the main advantages are
Increased through output or productivity.

 Improved quality or increased predictability of quality.

 Improved robustness (consistency), of processes or product.
 Increased consistency of output.
 Reduced direct human labor costs and expenses.

1.2 Statement of the problem

All boilers require feed water flow control to make up for the steam that leaves the boiler. Most boiler
designs use a steam drum, which is where the feed water flow enters the boiler and where the steam
leaves. The water level in the drum must be maintained to provide responsive and stable control of the

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steam flow, as well as to prevent equipment damage. To maintain drum level, the feed water flow into
the drum must equal the flow of steam out on a mass flow basis.

1.3 Objective of the project

1.3.1General objective
Design and implementation of drum Level Controller for boiler Using Microcontroller.
1.3.2 Specific Objectives
 To design an automatic boiler drum level control
 To incorporate an interactive medium between the end user and the machine
 To avoid wastage of water
 Implementing the system by simulating with proper software.
 To be familiar with PIC microcontroller programming for industrial applications.

1.4. Scope of the project

Boiler is a system designed to produce steam in varying quantities for a variety of applications
including space heating, process heating, power generation and other huge industries. In order to
achieve the objectives of the project, several scopes had been outlined. The scope of this project
includes using MikroC Pro to program microcontroller PIC 16F877A for the system. We know that
boiler automation isa big system that can control everything automatically in the large industry or
power plants. But our project is specified for only BOILER DRUM LEVEL CONTROL systems due
to the time specified for the project

.1.5 Methodology
1.5.1 System development methodology
The system designs include the hardware design and the software designs that are based on the
PIC16F877A microcontroller, since they are suitable for different industrial applications. Therefore we
have developed the drum level control systems using microcontrollers by configuring (programming)
it to the desired operation.

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1.5.2 System development

Figure 1.1 hard ware component block diagram

1.5.3. Hardware developments and software development

Here we will discuss about the hardware design of the systems and components that had been used
including the microcontroller PIC 16F877A and LCD displays.
PIC Microcontroller 16F877 A microcontroller is the combination of a microprocessor, memory,
input and output ports and some of the special functions like timer, analogue to digital converter,
mathematics processor and PWM generator in one chip. A microcontroller will take an input from a
device it is controlling hence controls the device by sending signals to different components in the
device.

Sensor:-are devices that convert physician property or a change in the physician

property into a more easily manipulated form
Level sensor:-detect.level substance that flow including liquid s slurries, granular
materials and powders
Fuel pump:- The fuel pump makes fuel to reach the burner so that required heat energy to produce
steam is provided.
Exhaust valve: is a one type of valve that actuates -
Combustion air fan:-is Centrifugal blower
Solenoid valve:- Direct-acting 2/2-way plunger-type solenoid valves, also referred to as through-way
valves, are shut-off valves with two ports: one inlet P and one outlet.
Steering motor:-is Worm drive motor
Dosing pump:-used in a type of 16090SST

Relay:- A relay is a simple electromechanical switch made up of an electromagnet and a set

of contacts. It used where it is necessary to control a circuit by a lowpower signal (with complete
electrical isolation between control and controlled circuits), or where several circuits must be

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controlled by one signal.

Control knob:- is a rotary control used to provide input to a device when grasped by an operator and
turned
Digital to Analog Converter:- A ladder network accepts inputs of binary values at, typically, 0 V or
Vref (5V output of microcontroller) and provides an output voltage proportional to the binary input
value
Operational Amplifier:- Operational amplifiers are analogue integrated circuits designed for linear
amplification that offer near-ideal characteristics
ON/OFF Switch:-
Table 1.1 hard ware component
LCD :-This component is specifically manufactured to be used with microcontrollers, which means
that it cannot be activated by standard IC circuits. It is used for displaying different messages on a
miniature liquid crystal display.
RS:- Data/Instruction select
RW:- Determines if we read from or write to the LCD
E:- Enables or disables the LCD module
DB0-DB7

1.5.4 Programming process(Soft ware development)

MikroC PRO IDE
 The MikroC PRO for PIC is a powerful, feature-rich development tool for PIC
microcontrollers. It is designed to provide the programmer with the easiest possible solution to
developing applications for embedded systems, without compromising performance or control.
 PIC and C fit together well: PIC is the most popular 8-bit chip in the world, used in a wide
variety of applications, and C, prized for its efficiency, is the natural choice for developing
embedded systems. MikroC PRO for PIC provides a successful match featuring highly
advanced IDE, ANSI compliant compiler, broad set of hardware libraries, comprehensive
documentation, and plenty of ready-to-run examples.
 MikroC PRO for PIC allows you to quickly develop and deploy complex applications:
 Write your C source code using the built-in Code Editor (Code and Parameter Assistants, Code
Folding, Syntax Highlighting, Auto Correct, Code Templates, and more.)

1.6 Significants of the project

Boilers are systems designed to produce steam in varying quantities for a variety of applications
including space heating, process heating, sanitation, power generation and others

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1.7 Limitation of the project

Despite the fact that we have tried to solve different problems; the approaches we used to reach
solution are not very sophisticated. This is due to the time specified for the project and also for the
sake of cost reduction.
While developing the drum level control system we have omitted the shrinking and expansion
property of the water.
It is significant to know that this design is limited to 12v, 5amps electric pump and cannot be use to
control industrial water pump above 5 amps

1.8 Overview of the project

In this thesis work we have tried to develop automatic boiler level control system. This automatic
control system has two subgroups under it. The boiler protection control system and the boiler
performance enhancement control system. The boiler protection control system includes the Drum
water level Control system. These systems are developed in order to prevent the danger that may occur
during the boiler operation.

1.9. Organization of the paper

 The project is organized into five main chapters that are interrelated to each other and these are
described as follows.
 The first chapter describes the introduction part of the project including background, statement
of problem, objectives, limitation of the project, scope and over view of the project.
 The second chapter expresses about the basic theories that our project fells on including the
introduction, boiler operation, types and key components of boiler and the literature survey
about the Drum water level Control
 The third chapter describes details of our system design which includes the hardware design
and the software designs that are based on the PIC16F877 microcontroller for the drum level
control.
 The chapter four is about Results and discussion, discuss on the results of systems that are to
be controlled in our thesis boiler level control circuits using proteus 8 professional simulator.
 The last chapter discuss about, conclusion and future scope of our project

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CHAPTER TWO

2. THEORY AND LITERATURE REVIEW

2.1 Introduction
This chapter deals with the basic theories that our thesis fells on including the introduction, operation,
process types and key components of boiler and the literature survey about the Drum water level
Control.

2.2 BOILERS
Boilers are pressure vessels designed to heat water or produce steam, which can then be used to
provide space heating and/or service water heating to a building. In most industries heating
applications, the heating source in the boiler is a natural gas fired burner. Oil fired burners and electric
resistance heaters can be used as well. Steam is preferred over hot water in some applications,
including absorption cooling, kitchens, laundries, sterilizers, and steam driven equipment.
Boilers have several strengths that have made them a common feature of industries. They have a long
life, can achieve efficiencies up to 95% or greater, provide an effective method of heating an
application in industries, and in the case of steam systems, require little or no pumping energy.
However, fuel costs can be considerable, regular maintenance is required, and if maintenance is
delayed, repair can be costly [2]
2.2.1 How Boilers Work
Both gas and oil fired boilers use controlled combustion of the fuel to heat water. The key boiler
components involved in this process are the burner, combustion chamber, heat exchanger, and
controls.
The burner mixes the fuel and oxygen together and, with the assistance of an ignition device, provides
a platform for combustion. This combustion takes place in the combustion chamber, and the heat that
it generates is transferred to the water through the heat exchanger. Controls regulate the ignition,
burner firing rate, fuel supply, air supply, exhaust draft, water temperature, steam pressure, and boiler
pressure.
Hot water produced by a boiler is pumped through pipes and delivered to equipment throughout the
building, which can include hot water coils in air handling units, service hot water heating equipment,
and terminal units. Steam boilers produce steam that flows through pipes from areas of high pressure
to areas of low pressure, unaided by an external energy source such as a pump. Steam utilized for

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heating can be directly utilized by steam using equipment or can provide heat through a heat
exchanger that supplies hot water to the equipment [4].

2.3 Boiler processes

The job of a boiler is to generate steam in the correct condition through the combustion of various
types of fuel. Hence we can represent the essential process as a block flow diagram with two major
processes known as waterside systems and fireside systems.

Flue Gas
Feed water Steam
Heating, Evaporation &
Superheating

Blow Down
Radiant Hot Gas
Heat
Heat Transfer

Fuel

Mixing Combustion furnace

and heating

Air
Ash removal

Figure 2. 1 Elementary model for the boiler process

Figure 2.1 shows that the waterside consists of feed water into the boiler where it is heated and
converted into steam. The generation of steam requires vast amounts of heat, which of course must be
produced by the combustion of fuel and air in a furnace supported by a flue gas extraction system that
will draw the hot gases over the heating surfaces of the water system before it takes the flue gases
away. This is the fireside system. The really difficult part for the boiler designer is to arrange for:

 Efficient heat transfer between the fireside and the waterside.

 Safe containment of the water/steam circuits under high pressure.
 Safe and complete combustion of fuels
Maximum utilization of the heat energy of the fuel for the generation of steam. (There is no value in
heating the atmosphere or putting unburned fuel into the ash pit)[13].
This task has challenged boiler designers over the past 200 years along with the need to find steam
systems that can deliver steam at high pressures and at high superheat temperatures as needed for
power generation through steam turbines. This had led to the development of various boiler types
arranged according to size and performance requirements and we shall look briefly at the main types
in a moment. But from a control system point of view the basic features of the processes are generally

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common to most types of boiler. So in general we can work with block diagrams to describe the
processes that we must understand well enough to be able to develop and operate the control systems.
As a first step we can expand the basic process diagram to reveal more of the essential processes as
seen in Figure 2.2

Flue Gas Heat

Sat. Steam
Drum Steam to
Feed Water Superhtr Users
Economiser Heat to Heat to
Evaporation
Superheater
Atmosphere

Water Circulation
Warm
Air
Air Heater
Wind box
Combustion in furnace
Burners
F D Fan
Fuel

I D Fan

Figure 2.2 Expanded model for the boiler process

We can see some of the common components of a typical industrial boiler arranged by function
although their physical positioning is of course much different.
Water/steam system: On the water side the feed water is preheated by the flues gases leaving the steam
generation (or evaporation stage). Feed water then enters the boiler water system usually at the boiler
drum where it is heated by the hot flue gases to generate the steam. When superheating is included the
steam from the boiler drum passes through super heater tube assemblies mounted in the parts of the
furnace where radiant heat and hot flue gases will transfer heat into them. A typical de-super heater
spray point is shown where the temperature of the steam is controlled by cooling before the final super
heater tubes [13]
The steam generation process requires that heat be transferred into the water for heating, vaporization
and superheating and the relative amounts of heat required for each phase can be seen in the Enthalpy
diagram shown in Figure 2.3

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BTUs at atmospheric pressure

Figure 2.3 Heat input requirements for steam generation at atmospheric pressure
Furnace/combustion system: On the fireside, the diagram identifies a forced draft fan to drive air into
the furnace and provide fuel-mixing energy before the combustion stage. The furnace space provides
time, temperature and turbulence to enable complete combustion to take place provided enough air has
been supplied. The combustion product gases (flue gases) then flow over the heat transfer surfaces to
give up much of their heat before reaching the Induced Draft (ID) Fan and being discharged to
atmosphere. The last heat exchange stage is an air pre-heater which recycles some of the low-grade
(i.e. low temperature) heat in the flue gases into the combustion air feed [13]
2.3.1 Boiler processes are highly interactive
Whilst the process block diagram in Figure 2.3 is a highly simplified representation of the boiler
process it does serve to remind us that for the purposes of building effective control systems it must be
recognized that the process variables are highly interactive. i.e. if you change one variable in the
process it will affect several others.
This means that most control loops in a boiler have a complex response to a corrective action and
these factors must be allowed for when setting up measurements and control functions. The simplest
way to show these interactions is to draw up an input/output model to show cause and effect. Figure
2.4 shows how some of the basic variables in a boiler are influenced by each other. Later on we can
use this simple type of modelling to assist with the design of control functions. Bear in mind that this
model only shows directions of influence and does not show the time responses involved, these are the
process dynamics that we shall be learning about later.

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Fuel + Air + Steam Pressure

+
+
Steam Flow - Steam Temperature
+

Feed Water + Water Level

+

Steam Pressure
+

Figure 2.4 Example of interaction of variables in the boiler process

Figure 2.4 shows typical interactions without the presence of any controller actions. Imagine that the
boiler is operating in steady state conditions but all controls are frozen.
If we demand more steam flow from the boiler the model shows, as you would expect, that the
pressure would fall.
The steam temperature will also fall because more steam is passing through the super heater for the
same heat flux and the water inventory in the boiler will fall as we use the water but the water level
will rise initially because the pressure has fallen and more team bubbles have occurred in the water.
(Imagine a Coke bottle suddenly opened.
These directional and interactive responses can be exploited in boiler controls to achieve the stabilities
and smooth responses we are looking for. In particular whenever we can predict how changing one
variable will affect the others we can start to use feed forward techniques to provide compensation
without waiting for feedback effects to do the job for us [13]

2.3.2 Process dynamics in boilers

Process dynamics describe the ways in which process variables change over a time period in response
to disturbances. We are all familiar with the sorts of time delays and slow or quick responses that we
can experience with heating systems. Two examples:
Waiting for the geyser to warm up when you want to take a shower and the tank is cold. This is an
example of a simple but slow lag in temperature response to the heater input.

When the shower water is too hot the adjustment of the cold tap can sometimes be very fast and it
creates a cold shock! This could be because the time lag in mixing is very short. But sometimes there
is no response at all for several seconds. This is due to the “transport delay” or “process dead time”
before the change in settings appears at the sensing points!

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First order time lags and transport deals are typical dynamic effects in boilers. For example: There is
always going to be a time delay between the demand for more steam and the delivery of more steam
resulting from the time delays in getting the firing rate up to a higher level. However the stored energy
in the boiler allows the increased steam delivery to be drawn off immediately but only for a short
while before the pressure falls significantly. So with a well-designed control system the dynamic lags
of the steam system can be used to assist in overcoming the dynamic lags of the firing system.

We shall look into the basics of dynamic lags and dead times in the next module from a control system
point of view. Then we shall look at the particular dynamics of the main processes and their control
systems as we work through the main control functions in the modules of the workshop.

It should already be possible to see how some basic corrective control actions can be applied to the
process diagram in Figure 2. 4. We shall look at these in a moment but first it is a good idea to get to
know something about the various types of boilers and then see how the basic process appears in each
type [13].

2.4 Types of Boilers

Boilers are classified into different types based on their working pressure and temperature, fuel type,
draft method, size and capacity, and whether they condense the water vapour in the combustion gases.
Boilers are also sometimes described by their key components, such as heat exchanger materials or
tube design. Boilers can be classified in to different categories. But, based on their configurations there
are 2 main categories:-
 Fire-tube boiler and
 Water-tube boiler
2.4.1 Fire-tube boiler
Here in fire tube boiler, water partially fills a boiler barrel with a small volume left above to
accommodate the steam (steam space). This is the type of boiler used in nearly all steam locomotives.
The heat source is inside a furnace or firebox that has to be kept permanently surrounded by the water
in order to maintain the temperature of the heating surface below the boiling point. The furnace can be
situated at one end of a firetube which lengthens the path of the hot gases, thus augmenting the heating
surface which can be further increased by making the gases reverse direction through a second parallel
tube or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases may be taken
along the sides and then beneath the boiler through flues (3-pass boiler). In the case of a locomotive-
type boiler, a boiler barrel extends from the firebox and the hot gases pass through a bundle of fire

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tubes inside the barrel which greatly increase the heating surface compared to a single tube and further
improve heat transfer[2].
Fire-tube boilers usually have a comparatively low rate of steam production, but high steam storage
capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of the liquid or
gas variety.

Fig 2.5 fire tube boiler

2.4.2 Water-tube boiler
In this type, tubes filled with water are arranged inside a furnace in a number of possible
configurations: often the water tubes connect large drums, the lower ones containing water and the
upper ones, steam and water; in other cases, such as a mono-tube boiler, water is circulated by a pump
through a succession of coils. This type generally gives high steam production rates, but less storage
capacity than the above. Water tube boilers can be designed to exploit any heat source and are
generally preferred in high pressure applications since the high pressure water/steam is contained
within small diameter pipes which can withstand the pressure with a thinner wall [2].

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Fig 2.6 water tube boiler

The water tube type boilers are further classified based on the arrangement of the water tubes. These
are:
The D-style, The A-style and The O-style.
The D-style is a 100% membrane water-cooled furnace, reducing cost, time consumption, and
annual maintenance. The burner throat, front and rear walls are welded and refractory-free, utilizing
our Netcom burner design. D-style boilers can be customized to provide superheated steam. They can
be both single and dual-stage integral super heater systems with optional temperature control over
turndown.
The A-style design features, a large water-cooled furnace and an evaporator section with a low gas-
side pressure drop that reduces fan power consumption. The vertical gas outlet minimizes the width of
the overall package and allows for large steam capacities in restrictive footprints.
The O-style this rugged design has become the true workhorse of the rental boiler industry. The
vertical gas outlet on the O-style puts the economizer above the boiler, minimizing the width of the
overall package. Its symmetrical design is ideally suited for mounting on a trailer for over-the-road
transport. Cleaver-Brooks line of boilers for the rental industry continues to provide efficient and
reliable service year after year, while withstanding rapid emergency start-ups[4].
The boiler provides heat and moisture in the pasta and macaroni pant for the purpose of drying in the
production process. And in the bakery plant, the proofing section uses the steam to make the bread
spongy by letting pressurized steam in to the dough. Since the boilers are highly related with the
production process of the factory, the efficiency of the boilers quality and quantity of the steam
generated by the boilers directly affects the manufacturing process. So improving the quality and
quantity is indirectly improving the quality of products and increasing the production capacity.

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Boiler efficiency measures how much combustion energy is converted into steam energy, while
steam quality measures how much liquid water is present in the steam produced
Steam quality is a measure of the amount of liquid water contaminating the steam. (For example,
steam at 100% quality contains no liquid water and appears as a 100% clear gas, while steam at 90%
quality contains 90% steam by weight and 10% water by weight in the form of a fog, cloud, or
droplets.) Water droplets in high-velocity steam can be as abrasive as sand particles. They can erode
pipe fittings and rapidly eat away at valve seats. And if a puddle of water is allowed to accumulate in
steam pipes, it will eventually be picked up by the high-velocity steam and accelerated to near-steam
velocity, increasing chances of it crashing into elbows, tees, and valves. This can lead to erosion,
vibration, and water hammer. This water hammer will gradually - and sometimes catastrophically
loosen pipe fittings and supports [1].
Since steam is produced by the rapid boiling of water in high-heat flux boilers, it can entrain (or draw
in and transport) water as it escapes from the water surface. This entrainment, while damaging to the
steam system, is independent of boiler efficiency. Basically, both high- and low-efficiency boiler
operations can produce or not produce excessive entrainment. While entrainment cannot be completely
prevented, it can be minimized by proper boiler and steam system operation [1].
Boilers have so many different parameters to be controlled during their operation. The different
control mechanisms employed on the boiler highly contributed for its efficiency and performance. And
if they are automatic control systems it will be very advantageous.
Boilers are also one of the most deadly components of a factory. If they are not properly operated they
could go out of control. During this time boiler explosion may occur.

2.5 Key Components of Boilers

The key elements of a boiler include the burner, combustion chamber, heat exchanger, exhaust stack,
and controls. Boiler accessories including the flue gas economizer are also commonly used as an
effective method to recover heat from a boiler and will be discussed briefly in the section Best
Practices for Efficient Operation. Natural gas boilers employ one of two types of burners, atmospheric
burners, also called natural draft burners and forced draft burners, also called power burners. Due to
more stringent federal and state air quality regulations, low NOx burners and pre-mix burners are
becoming more commonly used and even required in some areas. By ensuring efficient mixing of air
and fuel as it enters the burner, these types of burners can ensure that NOx emissions are reduced.
The combustion chamber, usually made of cast iron or steel, houses the burners and combustion
process. Temperatures inside the combustion chamber can reach several hundred degrees very
quickly. Heat exchangers may be made from cast iron, steel tube bundles, or, in the case of some

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smaller boilers, copper or copper-clad steel. The exhaust stack or flue is the piping that conveys the
hot combustion gasses away from the boiler to the outside. Typically this piping is made of steel, but
in the case of condensing boilers it needs to be constructed of stainless steel to handle the corrosive
condensate. Another consideration is whether the exhaust stack will be under a positive or negative
pressure. This can determine how the joints of the exhaust stack must be sealed.
Boiler controls help produce hot water or steam in a regulated, efficient, and safe manner. Combustion
and operating controls regulate the rate of fuel use to meet the demand. The main operating control
monitors hot water temperature or steam pressure and sends a signal to control the firing rate, the rate
at which fuel and air enters the burner. Common burner firing sequences include on/off, high/low/off
and modulating.
Boiler safety controls include high pressure and temperature, high and low gas/oil pressure, and high
and low water level and flame safeguard controls. These controls are considered safeties or limits that
break the electrical circuit to prevent firing of the boiler. For example, in the event pressure in the
boiler exceeds the pressure limit setting, the fuel valve is closed to prevent an unsafe, high pressure
condition. The safety circuit of a flame safeguard control system typically includes switch contacts for
low water cut off, high limits, air proving switches, redundant safety and operating controls, and flame
detectors
Flame detectors often consist of flame rods, and ultraviolet or infrared scanner to monitor the flame
condition and deactivate the burner in the event of a non-ignition or other unsafe condition.Flame
safeguard controls are programmed to operate the burner and cycle it through the stages of operation
[2]

2.6 Literature Survey

This section will explain the literature study that is related to the project task. We got the information
from several sources such as books, websites, journals, magazines, and others.
Research on the main steam pressure control system of boilers based on microcontroller PI
control Strategic Technology (IFOST), 2011 6th International Forum on (Volume: 2) on 22-24
Aug. 2011at Harbin, Heilongjiang [5].
The main steam pressure control system of boilers has a lot of characteristics, include the large inertia,
the highly delay, and the nonlinear and time-varying, there are many disturbance factors in its
operation and it is hardly to control. In order to solve this situation, this article integrates the
advantages of the microcontroller based Control. We design the microcontroller based controller by
combining the proteus and microcontroller tool box organically [5].

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The simulation results show that this control method greatly enhances the control effect of the
nonlinear, hysteresis system, and improves the system's flexibility and adaptability [5].
G.F. Gilman, Jerry Gilman (2004) “Boiler drum level control”, Boiler control systems
engineering: retrieved, May 10, 2014 [6]
This section of the book describes the need of having a boiler drum level controller. It states that:
Drum level must be controlled to the limit s specified by the boiler manufacturer. If the drum level
doesn’t stay within these limits there may be water carry over. If the level exceeds the limits, boiler
water carry over in to super heater or the turbine may cause damage resulting in extensive
maintenance costs or outages of either the turbine or the boiler. If the level is low, over heating of the
water wall tubes may cause tube ruptures and serious accidents, resulting in expensive repairs, down
time, and injury or death to personnel [6].
A rupture or crack most commonly occurs where the tubes connect to the drum. When the drum level
gets too low, the boiler will trip to prevent damage to the tubes and cracks in the tubes where they
connect to the boiler drum. Because of the critical nature of this measurement a variety of device are
usually applied to monitor the drum level [6].
David Lindsley (2000) “Chapter 7 steam temperature control” Power-plant control and
instrumentation: the control of boilers and HRSG systems (page 135-151) retrieved, May 18,
2014.[1].
Here from this part of the book we have obtained some information about the boiler steam temperature
control. As stated in the book the rate at which heat is transferred to the fluid in the tube banks of a
boileror HRSG will depend on the rate of heat input from the fuel or exhaust from the gas turbine.
This heat will be used to convert water to steam and then to increase the temperature of the steam in
thesuperheatstates.So indirectly controlling the fuel valve means controlling the temperature of the
steam. Theboilertemperature will also be affected by the pattern in which the burners are fired, since
somebanksoftubespick up heat by direct radiation from the burners. In both types of plants the
temperature of thesteamwillalso be affected by the flow of fluid within the tubes, and by the way in
whichthehotgasescirculatewithinthe boiler. [1]

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CHAPTER THREE

3. SYSTEM DESIGN AND DESCRIPTION

3.1. Introduction
In this section we will show details of our system designs. The system designs include the hardware
design and the software designs that are based on the PIC16F877A microcontroller, since they are
suitable for different industrial applications. Therefore we have developed the drum level control
systems using microcontrollers by configuring (programming) it to the desired operation.

Pump Motor

Microcontroller
Contactors
Power Boiler drum
Buzzers
supply level sensor
Lamp/ indicater

Input Out puts

Figure 3.1: Over all block diagram of boiler drum level controller

3.2. Hardware design

Here we will discuss about the hardware design of the systems and components that had been used
including the microcontroller PIC 16F877A and LCD displays.

3.2.1 Microcontroller PIC 16F877

A microcontroller is the combination of a microprocessor, memory, input and output ports and some
of the special functions like timer, analogue to digital converter, mathematics processor and PWM
generator in one chip. A microcontroller will take an input from a device it is controlling hence
controls the device by sending signals to different components in the device.

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The microcontroller acts like the brain of the control systems available in the system. The
microcontroller chip that has been selected for the purpose of controlling the control systems is
PIC16F877 manufactured by Microchip. This chip is selected based on several reasons [10].
Its size is small and equipped with sufficient output ports without having to use a decoder or
multiplexer.
Its portability and low current consumption.
It has PWM inside the chip itself which allow us to vary the duty cycle of AC motor drive. d) Ability
and ease of computation.
It is a very simple but powerful microcontroller. Users would only need to learn 35single word
instructions in order to program the chip.
It can be programmed and reprogrammed easily (up to 10,000,000 cycles) using the universal
programmer in robotics lab.
Their temperature properties depend on the manufacturer. Normally they can withstand temperature
from 0°C to 80°C during operating.
Nowadays PLCs are being chosen over Microcontrollers, but when we consider scope of the controller
the width of the area of the control, if it is of small range or if the control system is for single unit of
the plant; microcontrollers are chosen over PLC due to the fact that:
No. Properties PIC PLC
1 Cost Cheap Expensive
2 Size Smaller Bulky
3 Board area Can be reduced Need large area compared to
PIC
4 Programming Easy to change Changing program requires
program physically moving the existed
PLC

5 Handle complex program at one time Easier Difficult

6 Ease of design Simpler Harder

7 Can choose any i/o as an output Yes No
8 Required voltage 5v 12v, 24v
9 Temperature 0-80 0C 0-60 0C
10 Maintenance cost Low High

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Table 3.1: Comparison between PIC microcontroller and PLC

3.2.2 LCD
This component is specifically manufactured to be used with microcontrollers, which means that it
cannot be activated by standard IC circuits. It is used for displaying different messages on a miniature
liquid crystal display. The model described here is for its low price and great capabilities most
frequently used in practice. It can display messages in two lines with 16 characters each. It can display
all the letters of alphabet, Greek letters, punctuation marks, mathematical symbols etc. It is also
possible to display symbols made up by the user. Other useful features include automatic message
shift (left and right), cursor appearance, LED backlight etc.
Along one side of the small printed board of the LCD display there are pins that enable it to be
connected to the microcontroller. There are in total of 14 pins marked with numbers (16 if there is a
backlight). Their function is described in the Appendix B:
LCD display contains three memory blocks:-
 DDRAM Display Data RAM.
 CGRAM Character Generator RAM and
 CGROM Character Generator ROM
DDRAM memory is used for storing characters to be displayed. The size of this memory is capable of
storing 80 characters. Some memory locations are directly connected to the characters on display.
CGRAM is Apart from standard characters, the LCD display can also display symbols defined by the
user itself. It can be any symbol in the size of 5x8 pixels. RAM memory called CGRAM in the size of
64 bytes enables it
CGROM memory contains a standard character map with all characters that can be displayed on the
screen. Each character is assigned to one memory location:
Depending on how many lines are used for connecting an LCD to the microcontroller, there are 8-bit
and 4-bit LCD modes. The appropriate mode is selected at the beginning of the operation in the
process called 'initialization'. The 8-bit LCD mode uses outputs D0- D7 to transfer data as explained
on the previous page.
The main purpose of the 4-bit LCD mode is to save valuable I/O pins of the microcontroller. Only 4
higher bits (D4-D7) are used for communication, while others may be left unconnected. Each piece of
data is sent to the LCD in two steps- four higher bits are sent first (normally through the lines D4-D7),
then four lower bits. Initialization enables the LCD to link and interpret received bits correctly [11].

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3.3 Measurement Techniques of drum level

Precise measurement of drum level is very difficult due to several factors.
 The steam drum itself may not be at perfectly level.
 Even at steady state conditions, considerable turbulence in the drum can cause the level to
fluctuate.
 Changing rate of water inflow and steam outflow adds to the potential for measurement error.
Measurement of boiler steam drum level using differential pressure transmitter must take into account
of certain physical properties of the fluid.
 The steam drum contains a two-phase mixture of water and steam at saturation condition.
 The densities of water and steam vary with saturation temperature and pressure.
 The density of saturated steam above water must be considered, as well as the density of
saturated water in the drum.
There exist several instruments which provide for determination of the boiler drum level by direct
observation such as gauge glasses. This device provides the direct viewing of the liquid level. Various
designs are available providing reflex, transparent or refraction (Bi-colour) images. However for
accurate measurement of drum level and transmit to various equipment’s for processing differential
pressure transmitter is used.
3.3.1 Gauge Glass
It is the transparent tube may be mostly enclosed within a metal or toughened glass shroud is mounted
on boiler for direct indication of water level. Two issues are essential in selecting gauge glasses.
Firstly, the ASME (American Society of Mechanical Engineers) Code requires each fired boiler to
have gauge glass and secondly gauge glasses for all boilers operating above 400 PSI. The gauge
glasses must be visible to the boiler operator at the location where immediate control action is
initiated.
3.3.2 Conductivity Level probe Sensors
Conductive level probes are intelligent conductive level sensors used for level monitoring and feed
water pump control of conductive liquids to determine the presence of a conductive liquid at a set level
by sensing conductivity. It rely on the liquid level sensing capability of probes (electrodes) that are
housed inside fittings designed to accommodate one or more probes. These probes allow for the
measurement of conductivity between the probe fitting and end, which is isolated by a ceramic
insulator, or between the probe ends of two probes. The concept is simple: take advantage of a liquid’s

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conductive properties to complete a circuit and cause a control relay to actuate. These single-or multi-
point sensors have no moving parts and the solid stainless steel heat and corrosion-resistant electrodes
can be cut to the desired length.
Multiple probes per fitting allow control of several functions in less space with less expense for
equipment and installation. The CLP can be mounted in any orientation in a tank, tee fitting, or any
compatible threaded port.
3.3.3 Water and Fuel pump
Water pump is used to feed water to the boiler shell it is one of the most important component, it starts
automatically whenever there is water at the threshold level and this will keep the boiler’s water level
always above the threshold level. As this keeps the boiler away from boiling dry so it plays a part in
the safety issue of boiler. It is also operated with 5v volts dc relay and needs 220 volts to start pumping
water inside the boiler. The water pump provides constant flow of feed water to the boiler.
Fuel pump is the main part of the boiler system. The fuel pump makes fuel to reach the burner so that
required heat energy to produce steam is provided. The fuel pump is also required to provide a
constant fuel supply to the burner physically the water pump and fuel pump are more or less similar.

Fig 3.2 Water and fuel pump

3.3.4 Relay
A relay is a simple electromechanical switch made up of an electromagnet and a set of contacts.
Relays are found hidden in all sorts of devices. Relays are used where it is necessary to control a

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circuit by a low power signal (with complete electrical isolation between control and controlled
circuits), or where several circuits must be controlled by one signal.
In our case we have used a 5v miniature relays, since the output of the microcontroller is 5v. The
miniature relays have the capacity to handle a maximum switching voltage of 220v DC and 250v AC.

Fig 3.3- 5V Minature relay

In General, Relays Transform a Control Signal into a Control Action
Isolation between Input and Output
Leverage (Small Signal Can Control Large Action)
Automation (Minimize Human Interaction with a Control Process
3.3.5 Control knobs
A control knob is a rotary control used to provide input to a device when grasped by an operator and
turned, so that the degree of rotation corresponds to the desired input. Such knobs are one of the most
common components in control systems and are found on all sorts of devices Such knobs vary
greatly in form, but as a rule they are expected to be grasped by the fingertips. By
convention a clockwise rotation ordinarily produces an "increased" input, whatever that is understood
to be. Knobs may turn continuously or may have detents to produce discrete selections; they
commonly have a scale with a pointer to aid achievement of the desired setting, though it is common
for the gradations in the scale to have no concrete meaning (e.g. the markings of a pressure control).
There is frequently a fixed "off" position at the origin of movement in which the knob actuates a
switch shutting down whatever behaviour is controlled, rather than having a separate on/off switch.

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Fig 3.4 Control knob used to set an operating point

3.3.6 Solenoid valves
Direct-acting 2/2-way plunger-type solenoid valves, also referred to as through-way valves, are shut-
off valves with two ports: one inlet P and one outlet A see Figure below: Inlet P is connected to the
pressurized fluid or gas. In the de-energized state, the core spring, assisted by the fluid pressure, forces
the solenoid core (plunger) with the valve seal onto the valve seat; passage to outlet A is thus shut-off.
If voltage is applied, the solenoid core with the valve seal is pulled into the coil as the result of the
magnetic force and the valve opens; the passage is unobstructed again.

Fig 3.5 Solenoid Valve structure

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3.3.7 Wet Leg System

For precise measurement of drum level Wet Leg System is useful. In a wet leg system, differential
pressure transmitter is used where the low pressure impulse line is completely field with liquid
(usually the same liquid as the process), and hence the name wet leg. The schematic diagram of wet
leg system is presented at figure1.

Fig 3.6 A wet leg installation

A level transmitter (LT), in association with three valves manifold, is used in an identical manner as
the dry leg system. The gas phase or vapour will be condensed in the wet leg and the catch tank. The
catch tank, with the inclined interconnection line, maintains a constant hydrostatic pressure on the low
pressure side of the level transmitter. This pressure, being a constant, can easily be compensated for by
calibration. Depending on the installation technique and position of level transmitter in respect of
boiler drum, it is necessary to introduce offset at time of calibration of transmitter. Two approaches are
explained here with mathematical interpretation.
Zero Suppression: In some cases, the level transmitter has to be mounted X meters below the base of
an open tank as shown in figure 2.

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Figure.2.7
The liquid in the high pressure impulse line exerts a constant pressure ( . ) on the high pressure side. S
is the constant applied for Pressure to height relation. When the liquid level is at H meters, pressure on
the high pressure side of the transmitter will be
The transmitter has to be negatively biased by a value of (– . ) so that the output of the transmitter is
proportional to tank level (. ) only. The above procedure is called zero suppression and it can be done
during calibration of the transmitter.
b, Zero Elevation: When the height of the wet leg (X) is equal to or greater than the maximum height
of the liquid column (H) inside the tank as shown at figure 3, zero elevation offset is to be applied
while calibration of level transmitter.

Figure 3.8 wet leg installation with zero elevation.

In a wet leg installation the low pressure side of the level transmitter will always experience a higher
pressure than the high pressure side. When the liquid level is at H meters, we have:

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P_High=P_gas+S.H
P_Low=P_gas+S.X
P_Diff=P_High-P_Low=S.H-S.X=-S(X-H)

The differential pressure PDiff sensed by the transmitter is always a negative number (i.e. low pressure
side is at a higher pressure than high pressure side). For proper calibration of the transmitter, a positive
bias (. ) is introduced to elevate the transmitter output. The positive biasing technique is called zero
elevation.

3.4 Boiler protection control system

The boiler protection system provides safe operation to the boiler. When worst cases happen due to the
failure of one component, overrides the operation of the boiler and takes its own control measure. The
boiler protection system provides safe operation to the boiler. When worst cases happen due to the
failure of one component, overrides the operation of the boiler and takes its own control measure.
Good thermal mixing of the cooler bottom drum water with the hotter surface interface water and
Provide surface area and volume for the efficient release of the entrained steam bubbles from the
boiler water.
The surface area and volume of the vapor space in the water/steam drum is critical to the efficient
separation of the steam bubbles from the water. Too small an area (If the drum water level gets too
high) can result in an excessive surface tension and high velocities, which result in wasted heat and
drum water carry-over. Too large an area (If the drum water level drops too low) may cause the boiler
to suffer thermal stress damage, Pressure can also build to dangerous levels.
All boilers require feed-water flow control to make up for the steam that leaves the boiler. The water
level in the drum must be also maintained to provide responsive and stable control of the steam flow,
as well as to prevent equipment damage.
To maintain drum level, the feed water flow into the boiler must equal the flow of steam out on a mass
flow basis. Therefore, boiler load changes, which change the steam flow demand out of the boiler,
require that the feed water flow be changed to control and maintain the drum level.
So we intended to develop boiler drum level controller to maintain the water/steam interface at its
optimum level to provide a continuous mass/heat balance by replacing the amount of steam leaving the
boiler with the same amount of feed-water to replace it.Under this control system the boiler drum level
control and the boiler drum pressure relief control system are included.

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3.4.1 The Boiler Drum Level control system

The drum level must be controlled to the limits specified by the boiler manufacturer. If the drum level
does not stay within these limits, there may be water carryover. If the level exceeds the limits, boiler
water carryover into the super-heater or the turbine may cause damage resulting in extensive
maintenance costs or outages of either the turbine or the boiler. If the level is low, overheating of the
water wall tubes may cause tube ruptures and serious accidents, resulting in expensive repairs,
downtime, and injury or death to personnel. A rupture or crack most commonly occurs where the tubes
connect to the drum. Damage may be a result of numerous or repeated low drum level conditions
where the water level is below the tube entry into the drum.
When the drum level gets too low, the boiler must have a boiler trip interlock to prevent damage to the
tubes and cracks in the tubes where they connect to the boiler drum. The water tubes may crack or
break where they connect to the drum, or the tubes may rupture resulting in an explosion. The water
tube damage may also result in water leakage and create problems with the drum level control. The
water leakage will affect the drum level because not all the water going into the drum is producing
steam.
Poor level control also has an effect on drum pressure control. The feed water going into the drum is
not as hot as the water in the drum. Adding feed water too fast will result in a cooling effect in the
boiler drum reducing drum pressure and causing boiler level shrinkage.

3.4.2 Shrink and Swell

Shrink and swell must be considered in determining the control strategy of a boiler. During a rapid
increase in load, a severe increase in level may occur. Shrink and swell is a result of pressure changes
in the drum changing water density. During a rapid increase in load, a severe rise in level may occur
because of an increase in volume of the bubbles. This increased volume is the result of a drop in steam
pressure from the load increase and the increase in steam generation from the greater firing rate to
match the load increase. If the level in the drum is too high at this time, it may result in water
carryover into the super heater or the turbine. The firing rate cycle can result in drum pressure cycles.
The drum pressure cycles will cause a change in drum level.
The firing rate change has an effect on drum level, but the most significant cause of shrink and swell is
rapid changes in drum pressure expanding or shrinking the steam bubbles due to load changes. When
there is a decrease in demand, the drum pressure increases and the firing rate changes, thus reducing
the volume of the bubbles.

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A sudden loss in load could result in high drum pressure causing shrinkage severe enough to trip the
boiler on low level. A boiler trip at high firing rates creates a furnace implosion. If the implosion is
severe enough, the boiler walls will be damaged due to high vacuum in the furnace.
Typically, for redundancy, there are three different methods used to measure drum level. In the “Boiler
drums/level measurement” example, the bull’s eye technology is a direct reading level measurement.
The differential pressure transmitter represents the level control measurement.

Fig 3.9 .The Water in the Steam Drum Contains Steam Bubbles
3.4.3 Drum Level Measurement
The FIG-2 is an example of the arrangement of a differential drum level measuring transmitter. The
differential transmitter output signal increases as the differential pressure decreases. The differential
pressure range will vary between 10 and 30 inches, depending on the size of the boiler drum, with a
zero suppression of several inches. On the high pressure side of the measuring device, the effective
pressure equals boiler drum pressure plus the weight of a water column at ambient temperature having
a length equal to the distance between the two drum pressure connections. On the low pressure side,
the effective pressure equals boiler drum pressure, plus the weight of a column of saturated steam
having a length from the upper drum pressure connection to the water level, and the weight of a
column of water at saturation temperature having a length from the water level to the lower drum
pressure connection.
On high pressure boilers, a condensate pot is connected on the top water leg to keep the leg full of
condensate. If the condensate level varies in the top connected leg, the drum level measurement will
not be accurate. On low pressure boilers, a condensate pot may not be required. The “Drum level
connections” image is an example of the correct method of installing a differential pressure

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transmitter. The correct installation allows the sediment to remain in the blow down line without
getting into the transmitter.
Problems with drum level measurement can be a result of improper installation of the sensing legs
from the boiler drum to the transmitter. It is critical that lines be sloped at least a half inch per foot
from the boiler drum to the transmitter. If not properly sloped, air pockets may form in the lines
creating improper drum level measurement.
When a differential pressure transmitter is used to measure drum level and the instruments used are
sensitive to density variation, density compensation techniques must be employed. A mass steam flow
and water flow signal is required for two and three element control systems

Fig .3.10 Boiler drum level management.

3.4.4 Boiler Feed Water Control
Some boilers utilize a reasonably steady load so only drum level control from single element drum
level measurement is possible. Single element control is used on boilers during startup or low load
regardless of capacity or rapid load swings. Single element control has often been unsatisfactory
because some of the newer boiler designs have minimum water storage compared to the steaming rate
of the boiler. A majority of the larger sized units and those subject to rapidly fluctuating loads require
different methods of control. A two element system controlling the feed water control valve from the
steam flow signal and resetting the drum level signal is able to handle some of the less difficult
systems. Larger units with small storage capacity related to throughput, and units experiencing severe,
rapid load swings, usually require three element controls, whereby water flow is matched with steam
flow and reset from the drum level signal.
The water level in the boiler shell or in the drum must be kept as stable as possible by fully automatic
control. The process variable is the water level and the manipulated variable is the feed water flow
rate. Figure 3.11 shows the basic block diagram notation for this function in its simplest form.

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SP

+
Level control

MV PV

Feedwater
supply rate
+ Drum LT

Steam flow

Figure 3.11 Basic control function for drum level

The level measurement transmitter LT is compared to the set point and the controller adjust feedwater
flow either by pump speed or by a control valve or a combination of both. This control function is not
as simple as it appears at first but it is essential for good performance from the boiler.

3.4.5 Single Element Feed Water Control

Single element drum level control measures drum level only. This is a simple feedback control loop.
The mass of the water flow and the steam flow must be regulated so mass water flow equals the mass
steam flow to maintain drum level. The feed water control regulates the mass water flow to the boiler.
The effects of the input control actions interact, since firing rate also affects steam temperature and
feed water flow affects the steam pressure, which is the final arbiter of firing rate demand. The overall
system must be applied and coordinated in a manner to minimize the effects of these interactions. The
interactions can be greatly affected by the control system design. If the boiler operates under varying
steam pressure, the calibration of the liquid level transmitter will also vary with steam density.
When a single element control system is implemented, the level transmitter (LT) sends a signal to the
level controller (Figures 3.12 and 3.13). The process variable (input signal) to the controller is
compared to the set point (SP). Single element control is the minimum feed water control system.
When the system consists of single and two or three element control, two controllers are required
because the controller tuning is different.

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Fig.3.12 Single element control

The output signal is modified and adjusts the final control device. The diagram for a P&ID would
typically be in ISA symbols (Figure 13).The final control device can be a control valve, pump speed
control, or a combination of both. For simplicity, redundant transmitters are not shown on the P&ID
drawings.

Fig.3.13. Single element feed water control

3.4.6 Two-Element Feedwater Control

The two-element control uses the steam flowrate measurement in addition to the level measurement, to
avoid the ”swell” and ”shrink” problem. The two variables are usually controlled using feed-forward-
plus-feedback cascade control. Variations in the steam flow will adapt the feedwater flow and the level
is measured to changes caused by discrepancies in the flows.

Figure 3.14 Two element feedwater control.

3.4.7 Three-Element Feedwater Control
In the three-element control it’s measured the feedwater flowrate, in parallel with the level and the
steam flowrate. The steam flowrate is compared with the feedwater flowrate in order to equal both.In
this system it’s possible to change the water and steam speed, by changing the steam set point

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Figure 3.15: Three element feedwater control

3.5 Block diagram of Level control System

As steam demand increases, there is an initial lowering of the drum pressure resulting in an artificial
rise in drum level as the steam bubbles expand and swell the drum water level. This phenomenon
sends a false control signal to reduce feed-water flow, when in fact the feed-water flow should be
increasing to maintain mass balance. Conversely, on a loss of steam demand, there is an initial rising
of steam drum pressure which acts to lower the drum level by compressing the steam bubbles and
shrinking the drum water level. This sends a false signal to increase feed-water flow when in fact it
should be decreasing to maintain mass balance. Based on the single-element control strategy we have
developed a control system. The system we developed has two main objectives:
1. Boiler drum level adjustment
2. Protection of the boiler from damage during under filling of the drum.
Maintaining the correct water level in the drum is critical for many reasons. A water level that is too
high causes flooding of the steam purification equipment; resulting in the carryover of water and
impurities into the steam system. A water level that is too low results in tube failure due to overheating
from lack of cooling water on the boiling surfaces. Normally drum level is expected to be held within2
to5cmoftheset-pointwithsometolerancefortemporaryloadchanges.

Fig 16 Dimension and Position of CLP in boiler drum level

During the installation of the boiler it was tried to make the amount of steam leaving the boiler and the
water fed to the boiler equal, by adjusting the operation of the pump. But this technique is irresponsive
to sudden increase or decrease in steam load

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The control system includes two conductive level (probes) sensors (UTLs and LTLs), MCU,
contactors and two pumps (Feed-water and Fuel) as actuators. During normal operation the water
level is between the upper threshold and lower threshold levels. And when the steam load increases the
flow of steam increases, during this the water level in the drum decreases and if the level keeps
decreasing and reaches to level that is more than 7cm the LTL sensor becomes OFF. During this time
the MCU automatically sends control signal to shut the fuel pump OFF, but the feed water pump keeps
running.

Figure 3.17 Block diagram of the level control systems

When there is steam load drop, the inflow of feed water will be greater than the outflow of the steam
this makes the water level in the drum to rise. During this if the level keeps rising and reaches to the
UTL sensor the sensor will be ON, then the MCU shuts the feed water pump OFF while the Fuel
pump is still running.
The LCD module is used to display the status of the operation undergoing. Specifically the LCD
displays, the status of the UTL and LTL probes, the fuel pump and the water pump.

3.6. Software Design

Software is computer program, instructions that cause the software, the machine to do work.
Software as whole can be divided into a number of categories base on the type of work done. The
two primary software are operating software (system software), which controls the working of the
computer, application software, which addresses the multitude of task for which people use
computer. Application software, perform word processing, data base management, and the like. Two
additional categories that are either system nor, application software, and language software, which

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provide programmers with tools they need to write programs. In addition to these task-based
categories, several types of software are described based on their application.

PLANING HARDWARE

BUILDING THE
PROGRAM
SETTINGPROPERTIES COMPILING

WRITING CODES

TESTING

Fig 3.18 software development

Software development involves series of steps or is a set of activities that are necessary to be taken
for the development of reliable and maintenance software, It is of great importance because hardware
design cannot be used with micro-controller base system without depending on software. A typical
micro-controller development systems (MDS) include, VDU registers, RAM which serve as a stone
for the PROM programmer. Software system is the term use to describe a program that is provide by
the manufacturer to aid the development of users (applications) programs. These include programs
that convert assembly language into machine code (assembler), or high level language into machine
code (interpreter or compiler). It also include programs that facilitate modifications (edition), the
computer aided development methodology, which is essential for software development is
summarized below
TEXT EDITOR
This is kind of word processing that is used. After keying in the used in programs code using the
input device and the programs is display on the VDU, the text edition can be used to check and
correct errors in the programs. In a nutshell, the text edition is used to edit the programs after it has
been written.
TRANSLATOR
There are two types of translators, assembler, interpreter and compiler.

An assembler translate assembly language in the form of ammonic (memory aids) into machine
code. A good feature of assembler is creating a list that shows the machine code and the assembly
language of the programs side by side

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A compiler on the other hand translates a high-level language into machine code. An interpreter
reads the source code of our programs one line at a time and performs the specification instructions
contained in that line
LINKER/LOCATOR
This is used to join the different modules that make up the programs together in the correct sequence
and this is to be bound to addresses. The linker/locator pair works together to co-ordinate between
the separate modules for smooth programs execution.
LOADER The loader aids in loading an object code into RAM
TESTING
After the programs is written ,it was tested, this involve executing the programs with selected input
called test cases, the result whether or not the program is functioning as desired.
DEBUGGING
This involves detecting out and removing errors in the program.
For software implementation, we have used MikroC IDE to program microcontroller in C language.
Besides, proteus 8.0 professional is used for user interface purpose and for monitoring the controlling
algorithms of the system.
3.6.1 Programming process
MikroC PRO IDE
The MikroC PRO for PIC is a powerful, feature-rich development tool for PIC microcontrollers. It is
designed to provide the programmer with the easiest possible solution to developing applications for
embedded systems, without compromising performance or control.
PIC and C fit together well: PIC is the most popular 8-bit chip in the world, used in a wide variety of
applications, and C, prized for its efficiency, is the natural choice for developing embedded systems.
MikroC PRO for PIC provides a successful match featuring highly advanced IDE, ANSI compliant
compiler, broad set of hardware libraries, comprehensive documentation, and plenty of ready-to-run
examples.
MikroC PRO for PIC allows you to quickly develop and deploy complex applications:
Write your C source code using the built-in Code Editor (Code and Parameter Assistants, Code
Folding, Syntax Highlighting, Auto Correct, Code Templates, and more.)
Use included MikroC PRO for PIC libraries to dramatically speed up the development: data
acquisition, memory, displays, conversions, communication etc.
Monitor your program structure, variables, and functions in the Code Explorer.
Generate commented, human-readable assembly, and standard HEX compatible with all programmers.

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Use the integrated Mikro ICD (In-Circuit Debugger) Real-Time debugging tool to monitor program
execution on the hardware level.
Inspect program flow and debug executable logic with the integrated Software Simulator.
Generate COFF (Common Object File Format) file for software and hardware debugging under
Microchip's MPLAB software.
Active Comments enable you to make your comments alive and interactive.
Get detailed reports and graphs: RAM and ROM map, code statistics, assembly listing, calling tree,
and more.
MikroC PRO for PIC provides plenty of examples to expand, develop, and use as building bricks in
your projects. Copy them entirely if you deem fit – that’s why we included them with the compiler.
MikroC pro for PIC compiler
MikroC is a full-featured ANSI C compiler for 5 different microcontroller architectures. It is the best
solution for developing code for your favorite microcontroller. It features intuitive IDE, powerful
compiler with advanced SSA optimizations, lots of hardware and software libraries, and additional
tools that will help you in your work. Each compiler comes with comprehensive Help file and lots of
ready-to-use examples designed to get you started in no time. Compiler license includes free upgrades
and a product lifetime tech support, so you can rely on our help while developing.

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Figure 3.19: MikroC compiler IDE

To develop the programs for each control system we have used systematic approach listed as follows:
Step1: Determine the system sequence of operation.
Step2: Assignment of Inputs and outputs
Step3: Writing of the program
Step4: Programming into Memory
Step5: Running the system and simulate
An algorithm has to be developed to make the microcontroller to read the input and respond
accordingly. Therefore, the algorithm is established and represented by a flowchart. These flowcharts

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are then translated into C language and compiled using MikroC Pro C IDE and compiler. The
programs of each system in C language can be referred in Appendix C.
We start the programming structure by developing flow charts for each controlling systems we
develop as follows.

3.7 Level controller

The level controller system contains different components, so in the programming of the system our
first step is determining the sequence of the system. As shown in the flowchart below, when the
system starts to run the MCU ports are initialized. Then the MCU reads value from the UTL and LTL
sensors. The program simultaneously checks the status of the sensors and based on that decides a
control action and takes measure.

Figure 3.20: Flow chart for level control system

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Input/output assignment
Inputs Port Pins Remark
1 UTLs PORT D RD7 Upper threshold level sensor
2 LTLs PORT D RD6 Lower threshold level sensor
Outputs
1 FWP PORT B RB1 Feed water pump relay contactor
2 FFP PORT C RC0 Fuel feed pump relay contactor
3 LCD PORT D RD0--RD5 2x16 Liquid Crystal Display
Table 3.3: Input/output assignment of the level control system
After the assignment of the input output port and pins of the MCU we then developed the C program
on MikroC Pro IDE and compiler. The program is shown in Appendix C.
After developing and compiling the program we download the generated “.hex” file in to the program
memory of the MCU. As shown below:

Figure 3.21: Loading the generated .hex file in to the MCU and finally we run the simulation. On
proteus 8 professional.

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CHAPTER FOUR

4. RESULTS AND DISCUSSION

After we finish the software and hardware designs of our project the final work that we are doing is to
simulate the control circuits using proteus 8 professional simulator. So in this section we will discuss
about the simulating software we used to simulate the systems we developed and also we will show
the results we obtained after simulating the systems on Proteus.

4.1 The Proteus Design

Proteus Virtual System Modeling (VSM) combines mixed mode SPICE circuit simulation, animated
components and microprocessor models to facilitate co-simulation of complete microcontroller based
designs. For the first time ever, it is possible to develop and test such designs before a physical
prototype is constructed.
This is possible because you can interact with the design using on screen indicators such as LED and
LCD displays and actuators such as switches and buttons. The simulation takes place in real time (or
near enough to it): Proteus VSM also provides extensive debugging facilities including breakpoints,
single stepping and variable display for both assembly code and high level language source.
The Proteus Design Suite is wholly unique in offering the ability to co-simulate both high and low-
level micro-controller code in the context of a mixed-mode SPICE circuit simulation. With this Virtual
System Modeling facility, you can transform your product design cycle, reaping huge rewards in terms
of reduced time to market and lower costs of development.
If one person designs both the hardware and the software then that person benefits as the hardware
design may be changed just as easily as the software design. In larger organizations where the two
roles are separated, the software designers can begin work as soon as the schematic is completed; there
is no need for them to wait until a physical prototype exists.
In short, Proteus VSM improves efficiency, quality and flexibility throughout the design process.

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Figure 4.1: Proteus Professional GUI

Fig 4.2 Figure show the simulation pused

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4.2 working principle of drum level controller

In drum level control if system starts operation with empty drum i.e. water level is below LTL, only
the water pump runs while the fuel pump is stopped. And when the water level reaches the LTL the
fuel pump automatically starts to work.

Figure4.3. Simulation screenshot of the drum water level controller

Upper threshold level -OFF lower threshold level-ON

Fuel pump-RUN mode Feed water pump-RUN mode
But, this state exists until the drum level reaches UTL.
When the water level reaches UTL, feed water pump stop feeding and fuel pump continues on
pumping fuel.
Upper threshold level-ON lower threshold level-ON
Fuel pump-RUN mode feed water pump-STOP mode
This continues until feed-water level reduced below lower threshold level.

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Fig 4.4 Figure show that simulation run at LTL SENSOR opened

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CHAPTER FIVE

5 Conclusion and Recommendation

5.1 Conclusion
Boilers automation is one of the main ways to increase efficiency of a given production plant. It
reduces fuel consumption and provide trouble-free running. The trend towards boiler automation is
related to implementation of new technologies, including computer technologies, into boilers’ control.
The most important aspect of most production plants is the boiler control. Several techniques can be
implemented to control the boiler in power plant. The method that has to be used relies on varied
objectives like superior quality, increased efficiency, high profit and other such points depending upon
the purpose of the company that implies it. With the prime objective of catering to these necessities
and the needs of the industrial sector, significance has been given here to automation.
The control system for a boiler–turbine unit usually needs to meet the requirement of the amount of
water in the steam drum must be maintained at a desired level to prevent overheating of the drum or
flooding of steam lines.
The boiler level control is important because;
 the boiler is the heat sink for the reactor and too little water means possibility
of inadequate cooling
 the boiler is the source of steam for the turbine and too much water means
 the possibility of the steam flow carrying water over into the turbine and
Damaging it.
Boiler level is controlled as a function of reactor power. It is raised with power to accommodate the
swell due to increased voiding associated with increased boiling. By doing this, there is a minimum
change in the mass inventory in the steam generator.

5.2 Recommendation
This paper presented here has kept in mind, the constant changes that are persistently taking place in
the contemporary scenario of the industrial segment. Emphasis has been given to the automation
process that is now rapidly taking its place in all the production plants across the globe. The Paper has
furnished itself to study the integral parts of the entire process involved. on the boiler at. The paper is
based on the existing problems at the factory and we have been tried to present solution for those
problems under the scope of the paper.

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5.3 Future scope

In this project automatic microcontroller based control solutions has been introduced.
But our paper is dealing only to a one specific systems to control automatically using microcontroller,
but this is not enough to control the entire industrial boiler components.
Therefore the areas where this project can grow more are:
 Drum level controller that considers the shrinking and expansion property of the water.
 Flue gas treatment for the environmental protection
 Presure relief control system
 Temperature sensor control system
 PH development amounts of water control system
 Developing multi-point pressure relief control system
 Chemical treatment of the boiler feed water treatment
 Changing this distributed automation into integrated PLC based control system.
Despite the fact that we have tried to solve different problems; the approaches we used to reach
solutionare not very sophisticated. This is due to the time specified for the project and also for the sake
of cost reduction. While developing the drum level control system we have omitted the shrinking and
expansion property of the water. The reason we omitted these factors is that such occasions do not
occur. The demand of the plant s from the boiler quite constant .so we consider the effect of the water
shrinking and expansion property negligible. On the pressure relief control system we haven’t
determined the maximum pressure limit of the steam header. So we just used the maximum
temperature as a little bit above the operating pressure.
And finally our feed water treatment system contain only a PH controller but practically the feed water
Treatment contains series of different chemical treatment to make the feed water suitable for the
operation.

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6. Reference
[1]. David Lindsley (2000) “Chapter 7 steam temperature control” Power-plant control and

Instrumentation: the control of boilers and HRSG systems (page 135-151)

Retrieved, May 18, 2014.

[2]. Frederick M. Steingress (2001). Low Pressure Boilers (4th Edition). American Technical
Publishers. ISBN 0-8269-4417-5. Retrieved, April 19, 2014.

[3]. Frederick M. Steingress, Harold J. Frost and Darryl R. Walker (2003). High Pressure Boilers (3rd
Edition). American Technical Publishers. ISBN 0-8269-4300-4 retrieved, April 13, 2014.

[4]. ASME Boiler and Pressure Vessel Code, Section I. Updated every 3 Page -55-64
Retrieved, April 21, 2014.

[5]. Research on the main steam pressure control system of boilers based on

Microcontroller PI control Strategic Technology (IFOST), 2011 6th International

Forum on (Volume: 2) on 22-24 Aug. 2011at Harbin, Heilongjiang

Retrieved, May 23, 2014.

[6]. G.F. Gilman, Jerry Gilman (2004) “Boiler drum level control”, Boiler
control systems Engineering: retrieved, May 10, 2014.

[7]. Sensors+FP311+price&catId. [http://www.aliexpress.com] (28-8-2010)

Accessed on,June 10, 2014.
Ke-fa Cen, Yong Chi, Jianhua Yan (2009),” Challenges of Power engineering and
Environment: Proceeding of the international conference on Power Engineering: Held
On April 2007”.Retrieved, May 29, 2014.
[10]. MikroC PRO for PIC – C compiler for microchip PIC microcontrollers.
[http://www.mikroe.com/mikroc/pic/] Accessed on, June 04, 2014[11].Specifications of LCD
Module[https://www.sparkfun.com/datasheets/LCD/GDM1602KExtended.pdf] Accessed date May
02, 2014
[12]. Sensors & Hydronic Controls for boilers [http://ecc.emea.honeywell.com/oem/
combustion/residential_heating/boilers/sensor_hydronic_controls.htm] Accessed date June 07, 2014
Appendix A: Specifications
[13] Website: www.idc-online.com
[14] D. G. Andone , J. I. Fagarasan and M. R. Dobrescu "Advanced control of asteamgenerator" Proc.

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 DRUM LEVEL CONTROL FOR BOILR USING MICROCONTROLLER/JUNE 2008/2016/

3rd Int. IEEE Conf. Intell. Syst., pp.338 -343 2006.

[15] M. Mercangöz and F. J. Doyle "Distributed model predictive control of an experimental
fourtank system", J. Process Control 17, pp.297 -308 2007.
[16] A. J. Gaikwad , P. K. Vijayan , K. Iyer , S. Bhartiya , R. Kumar , H. G. Lele , A. K. Ghosh , H. S.
Kushwaha and R. K. Sinha "Effect of loop configuration on steam drum level control for a multiple
drum interconnected loops pressure tube type boiling water reactor", IEEE Trans. Nucl. Sci., vol. 56,
no. 6, 2009.
[17] G. Y. Qiliang , X. Jianchun and W. Ping "Water level control of boiler drum using one
IEC61131-3-
based DCS", Proc. 26th Chinese Control Conf., pp.252 -255 2007.
[18] W. Dong, J. M. Doster and C. W. Mayo "Steam generator control in nuclear power plants by
water mass inventory", Nucl. Eng. Design 238, pp. 859 -871 2008.
[19] W. J. Peet and T. K. P. Leung "Improved drum level control for load cycling", Proc. IEEE 2nd
Int.Conf. Adv. Power Syst. Control, Operat., Manage., vol. 1, pp.130 -134 1993.

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7. Appendix
Appendix A: Specifications
Sensors
Sensor Type Quantity Estimated Specifications
cost (optional)
Level sensor LVC-E11 2 $5/unit Output: 4-20 mA or
(Conductive level 5Vdc across125ohm
Probe) Supplyvoltage:5Vdc
Current draw: same
as sensor output
Table A.1: Sensors

Actuators
Actuators Type Quantity Cost Specifications
estimation(Optional)
Fuel water pump Ac Induction 2 $124.99/ unit Voltage supply 220
Vac
Frequency: 50 Hz
Current: 2.6A
Pumping capacity:
40L/min
Power: 0.5 HP
Exhaust valve Pressure relief 1 `$57.50/unit ValveSize:0.50to3.00
valve inch (12.70to76.20
mm)
Actuation: Electric
Maximum Pressure:
3500.00 psi(2463 m
H2O)Operating
temperature : -40 to
275°FMaximum
working pressure: 125
psig
Combustion air Centrifugal 1 $132.52/unit Power = 1.1Kw
fan blower Airvolume=19m3/min
Voltage = 220
Speed = 2800R/min
Solenoid valve Plunger type 1 $20.50/unit Voltage: 220Vac
Orifice: 16mm
Temperature: -5°C to
80°C
Pipe size:0.5 in
Operating pressure:
0kg/cm2 to 10
kg/cm2

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Steering motor Worm drive 1 $109/unit Rated Voltage 12Vdc

Motor Torque: 20Nm
Rated power: 200W
180 RPM
Dosing pump 16090SST 1 $100/unit Maximum stroke rate:
160 stroke/min
Connector size: 1’’ –
15 (R’’ - DN)
Permissible priming
pressure, suction
side: 2 bar
mL/stroke: 11.4
min pump capacity at
max back
pressure : 16 bar , 99
L/hr., 26gph
Table A.2: Actuators

Miscellaneous Devices
Devices Type Quantity Estimation of Specifications
cost(optional)
Relay 5v miniature 3 $2.25/unit Operate Time=4
ms
Operating
Temperature= -
40oc to 850c
Maximum Current
Rating=2 A
Maximum AC
Voltage
Rating=125 V
Maximum DC
Voltage
Rating=220 V
Control knob Rotary (6539) 3 $14/unit Resistance
tolerance: ±15%
Power rating:
1.0W
Mechanical angle:
continuous
Digital to Resistor 2 $0.99/unit Resistance:
Analog Ladder network 10kΩ,20kΩ
Converter Powerrating;
0.25W
Tolerance: ±5%
Maximum
working voltage:

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250V
Operational LM675 Power 2 $2.71/unit Supply
Amplifier amplifier Range=16V–60V
Current
Capability=3A
Gain Bandwidth
Product=5.5 MHz
ON/OFF Switch PN 6006 5 $1.95/unit Maximum
Voltage=48V DC
Cable Size to
Meet Ratings=4/0
AWG (120mm²)
Weight =0.65lb
(0.29 kg)
Switch
Positions=2
Table A.3: Miscellaneous device

Appendix B: LCD pin descriptions

Number Symbol description
1 Vss 0v Power Supply (GND
Level
2 Vdd Power Supply for Logic
Circuit
3 Vee For adjusting the contrast
of the display. Usually,
when this pin is grounded
the pixels will be the
darkest
4 RS Data/Instruction select
5 S/W Determines if we read from
or write to the LCD
6 E Enables or disables the
LCD module
7-14 DB0-DB7 Bi-directional data bus

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Appendix C: Source code for the control systems

Code for level controller
// LCD module connections sbit
LCD_RS at RD4_bit; sbit LCD_EN at
RD5_bit; sbit LCD_D4 at RD0_bit; sbit
LCD_D5 at RD1_bit; sbit LCD_D6 at
RD2_bit; sbit LCD_D7 at RD3_bit; sbit
LCD_RS_Direction at TRISD4_bit; sbit
LCD_EN_Direction at TRISD5_bit; sbit
LCD_D4_Direction at TRISD0_bit; sbit
LCD_D5_Direction at TRISD1_bit; sbit
LCD_D6_Direction at TRISD2_bit; sbit
LCD_D7_Direction at TRISD3_bit; // End
LCD module connections unsigned
char ch; char *text; void main()
{
TRISA.F5 = 1; //Configure bit5 of PORTA as input
TRISA.F4 = 1;
TRISB= 0; //Configure 1st bit of PORTB as output
TRISC=0;
TRISD=0xC0;
ADRESL=0;
ADRESH=0;
Lcd_Init(); // LCD display initialization Lcd_Cmd(_LCD_CURSOR_OFF); // LCD
command (cursor off)
Lcd_Cmd(_LCD_CLEAR); // LCD command (clear LCD)

text = "Boiler Drum"; // Define the first message

Lcd_Out(1,1,text); // Write the first message in the first line
text = "Level controller"; // Define the second message

for(;;)

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{
if(PORTD.F6==1)
{
PORTC=0b00000001;
text="LTL=ON Fp=RUN";

Lcd_Out(2,1,text);
}
else

{
PORTC=0b00000000;
text="LTL=OFF Fp=STP";

Lcd_Out(2,1,text);
}
if(PORTD.F7==1);
{
PORTB=0b00000000;
text="UTL=ON Wp=STOP";

Lcd_Out (1,1,text);
}

else

PORTB=0b00000010;

text="UTL=OFF Wp=RUN";

Lcd_Out(1,1,text);
}
}
//while (1);

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