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Design and Implementation of a SCADA Based Boiler Monitoring and

Controlling System

Conference Paper · September 2024

DOI: 10.1109/ACIT62333.2024.10712619

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 Design and Implementation of a SCADA Based
Boiler Monitoring and Controlling System
1st Muaz Muhammad 2nd Md Mehedi Hassain 3rd Md. Khaled Hossain Jahin
Electrical & Electronic Engineering Electrical & Electronic Engineering Electrical & Electronic Engineering
IIUC University IIUC University IIUC University
Chattogram 4314, Bangladesh Chattogram 4314, Bangladesh Chattogram 4314, Bangladesh
[email protected] [email protected] [email protected]

4th Md. Ariful Islam 5th Md. Arafatur Rahman 6th Kazi Mohammad Abdullah
Electrical & Electronic Engineering Electrical & Electronic Engineering Electronic & Telecommunication Engineering
IIUC University IIUC University IIUC University
Chattogram 4314, Bangladesh Chattogram 4314, Bangladesh Chattogram 4314, Bangladesh
[email protected] [email protected] [email protected]

Abstract—The SCADA system offers a comprehensive perspec- microcontroller, GSM modem, sensors, and interface circuits
tive, and PLC technology is integrated for real-time monitoring carry out the control operations, assuring effective and tailored
and control. A focus on safety includes sensors that can react automation for the intended results [3]. This study introduces
quickly to deviations and turn on devices like the steam release
solenoid valve and feedwater supply pump. Potential damage an innovative automated boiler control system using a PLC to
is avoided by the proactive temperature control provided by minimize errors.Temperature thresholds are used by the system
a pump. Real-time visibility and prompt decision-making are to automatically start and stop the boiler. A sensor monitors
ensured by SCADA. Large-scale data storage and SCADA temperature by sending signals to the PLC. Furthermore, the
operations are carried out via the Haiwell Industrial IoT Cloud ON-OFF push button enables operation for a specified period
platform. Terminals on a variety of platforms, such as PC, iPad,
Android, iOS, and others, are supported by Haiwell Cloud. of time [4]. This study presents a smart boiler system that uses
Haiwell Cloud ensures proactive monitoring, instantly notifying LM35 temperature sensors, a buzzer to sound warnings, and
users via email if boiler temperatures surpass set limits. On- Arduino as the main controller. Two LM35 sensors are used to
site buzzers provide real-time alerts for swift response. The measure temperature, and the Arduino is used to process the
system exhibits versatility since it is tailored for a wide range of data. If the temperature rises above a threshold specified by
industrial applications.
Index Terms—SCADA Monitoring System, Sensor Based Mon-
a potentiometer, the buzzer will sound. Precise temperature
itoring System, Haiwell Cloud platform, Real time Alert. monitoring is ensured by the functional temperature range
of the LM35 sensors [5]. In this project, data is sent to
the microcontroller via a temperature sensor for the boiler
I. I NTRODUCTION
and a combined temperature and pressure sensor. Effective
Approximately 3000 boilers, or roughly 60 Percent of all boiler control is ensured by the LCD’s readings and buzzer
boilers in the nation, are used in Bangladesh’s RMG industry. alerts for variations in pressure and temperature in real time
About two-thirds of these industries are situated in Gazipur [6]. This system enhances fault detection in steam power
and Narayanganj, two nearby districts of Dhaka. The nation plants by integrating a novel approach into PLCs, surpassing
is rapidly becoming more industrialized, which has led to traditional hardware-based coding. It focuses on three major
an increase in the number of new boilers getting operating boiler failures, employing Allen Bradley PLC, and utilizes
permits and a 27 Percent increase in the overall number real-time SCADA visualization for comprehensive plant mon-
of licensed boilers in the entire country over the last four itoring and control [7].The Boiler Control and Monitoring
years [1]. Over the past decade, 237 events have occurred System utilizes the NodeMCU ESP8266 Wi-Fi module for
in 4,560 businesses within Bangladesh’s apparel industry. smooth communication. The ESP8266 MCU is used along
Building collapses accounted for 1.27 Percent, boiler breaks with water level, ultrasonic, temperature, and humidity sensors
for 3.38 Percent, fires for 94.09 Percent, and miscellaneous to automate boiler sector monitoring in the prototype [8].
events for 1.27 Percent. 6,870 lives lost 1,689 wounded and This innovative boiler automation project seamlessly inte-
5,181 killed were the result. There are urgent safety concerns grates PLC technology and SCADA for real-time monitoring
after a dramatic surge from 2011 to 2015 that left 1,287 people and control. With an emphasis on safety, it uses sensors to
dead and 3,800 injured [2]. This article uses a water level quickly react to deviations and turn on devices like the steam
sensor to measure the levels in the tanks, and temperature release solenoid valve and feedwater supply pump. While
sensors for each boiler to assure accurate management. A PIC SCADA provides fast decision-making and real-time visibility,
proactive temperature control averts damage. It is made for a monitoring are all part of the development process for boiler
variety of industrial uses and provides a firm basis to pursue monitoring and control. To effectively control boilers, PLC,
progress. Ensuring temperature control by PLC-triggered feed- SCADA, and Haiwell Cloud are used.
water delivery and real-time SCADA monitoring, the system is
activated at 30°C. An instantaneous PLC-managed shutdown A. Circuit Diagram of the System
takes place at 45°C, ensuring a regulated halt for increased de- The boiler system, depicted in Fig. 2, is efficiently con-
pendability and safety. By averting extremes, this temperature- trolled by a Mitsubishi FX3U-24MRES PLC with 14 in-
based approach enhances boiler automation’s general safety puts and 10 outputs. This PLC manages critical functions
and dependability. The system employs SCADA with PLC such as START (X0), STOP (X1), water levels (LOW=X2,
GXWorks2, HMI, and Haiwell industrial IoT cloud platform. MEDIUM=X3, HIGH=X4), steam temperature, and pressure
The PLC and SCADA communicate through Modbus TCP/IP. switches. Notably, only 10 inputs and 4 outputs are utilized
Validation of system accuracy involves comparing HMI data in this project. Inputs include START (X0), STOP (X1),
with SCADA and Haiwell Cloud. The Haiwell Cloud app Water Level (LOW=X2, MEDIUM=X3, HIGH=X4), Steam
supports various platforms, ensuring easy remote monitoring Temperature 01 (A0 - Analog IN), Auxiliary Steam Tempera-
and control. Its secure communication features include 128-bit ture 02 (A1 - Analog IN), Pressure Switch 01 (HIGH=X5,
SSL encryption, A-key/B-key, and password checks for device LOW=X6), Auxiliary Pressure Switch 02 (HIGH System
terminals, ensuring safe and stable remote access. Trip=X7). Outputs comprise Feed Pump (Y0), Heater (Y1),
Steam Outlet (Y2), and Alarm (Y3). The circuit’s clarity and
II. OVERVIEW OF THE SYSTEM
detailed representation of switch states and conditions, such
The block representation of the project is shown in Fig. 1. as water levels, provide insightful information on the system’s
This project employs a Mitsubishi Fx3u 24MRES PLC, operational aspects.
utilizing GXWorks2 Software to create a ladder diagram.
Three sensors (temperature, pressure, level) feed data to the
PLC, controlling components like the feed pump, heater
on/off, steam outlet, and alarm. The SCADA system, linked
to the PLC, is emulated using Haiwell cloud platform. An
HMI interface allows data review, while the Haiwell cloud
HMI Emulator facilitates simulation without physical devices.
Emergency switches and a start/stop system enhance safety.
Buzzers alert when temperatures exceed the predefined thresh-
olds. Use wireless SCADA to transform control dynamics
and provide smooth real-time monitoring and control. Our
interface combines historical patterns, current data, and system
status to present a holistic view. Have a strong alert system
and respond quickly to anomalies.

Fig. 2. Circuit Diagram of the Project.

B. Data Transmission
The Modbus TCP protocol is widely used in industrial
control systems. Modbus-S Client and Modbus-S Server com-
munication is a feature of Modbus TCP/IP. A net filter is used
as a firewall for the Modbus TCP protocol gateway in order
to increase security. It uses a White List assessment system to
confirm the legitimacy of the data [9].
Fig. 1. Block Diagram of the Project. C. Website Data Storage and Alert
NET-Framework-based Haiwell Cloud SCADA is a plat-
III. METHODOLOGY form for managing and monitoring industrial automation.
This section outlines the steps to create a prototype of the Real-time and historical data can be transmitted across
system. Data Transmission, Data Storage and SCADA visual databases such as MySQL and SQL Server by using the
Haiwell data-link tool. Alarm displays and buzzer warnings are In Fig. 4, set or reset commands for water level (medium
used to immediately transmit alarm information to the SCADA X003, high X004), high and low setpoints from SCADA/Temp
during operation. M2, pressure switches 01-X005, and 3202-X006 are depicted.
Corresponding output commands for pump Y000, heater
D. PLC Ladder Diagram Design Y001, and steam outlet Y002 are also shown.

In Fig. 3, memory addresses M800, D424, and D430 are

used for temperature in Celsius. To set the temperature, the
analog command RD3A is used. K0 represents channel 1,
while K1 represents channel 2. The set value is a float number.
For sensors, memory addresses M40, M48, and M52 are
utilized. The START input is X000, and the STOP input is
X001.

Fig. 5. Ladder part c of the Project.

In Fig. 5, set or reset command for low water level (X003)

latched with pressure switch 02-X006 is depicted, with the
corresponding output command to alarm Y003.

IV. PROGRAMMING, IMPLEMENTATION AND

RESULTS
A. Flowchart
The boiler system control process is smoothly orchestrated
Fig. 3. Ladder part A of the Project. by our project’s operational approach, as illustrated in Fig. 6.
The water level, temperature, and steam pressure are evaluated
against calibrated values when the PLC and SCADA activate
both systems. In accordance with high, medium, or low
ratings, the burner, safety lamp, and pump motor operate.
Alerts for surpassing temperature or pressure restrictions, as
well as system tripping, are safety measures. Accurate mea-

Fig. 4. Ladder part b of the Project. Fig. 6. Flowchart of the Projrct.

surements are guaranteed through PLC and SCADA activation, Fx3u 24MRES PLC analog input A0 is at 1.5V. The water
concurrent parameter verification, and calibrated changes. Low level drops, the burner stops, and the steam level is high.
water levels cause the pump motor to turn on, while high
water levels cause it to turn off. After heating up to a certain
temperature, the hob deactivates. Above a certain pressure
threshold, the safety valve lets go of extra steam. Data pro-
cessing, distribution, and visualisation are made possible by
SCADA, that saves all system data.

B. Result & Analysis

The Overiew of the project are depicted in Fig. 7. The
Mitsubishi FX3U-24MRES PLC is included in this system
together with SMPS, an indicator, a solenoid valve, a buzzer,
temperature, water level, pressure, and magnetic conductor
sensors. It uses the Modbus TCP/IP communication protocol to
provide accurate temperature management. At 30°C, it initiates Fig. 8. The simulation of starting state.
feedwater delivery, and at 45°C, it starts a PLC-managed
shutdown for further safety. Real-time monitoring is made
possible via the Haiwell IoT cloud and SCADA solution.
By comparing data from HMI, SCADA, and Haiwell Cloud,
system accuracy is verified, ensuring stability. Because of its
strong security features, the Haiwell Cloud app allows for
remote monitoring and control, which improves the boiler
automation system’s overall dependability and safety. Alarm
displays and buzzers immediately transmit information to the
SCADA system during operation.

Fig. 9. The simulation of operating state.

In Fig. 10, the simulation depicts the stop state of the boiler
system. The system automatically shuts down for additional
safety when the temperature exceeds 45°C.

Fig. 7. Overview of the Project.

In Fig. 8, the simulation illustrates the initial state of the

boiler system. The system activates when the temperature Fig. 10. The simulation of stop state of boiler system.
reaches or exceeds 30°C, and the voltage in the analog input
A1 of the Mitsubishi Fx3u 24MRES PLC is at 1.5V. The Reports on operations are generated in real time by Hai-
boiling of water in the boiler initiates, leading to an increase well Cloud. A representation of the operating history data is
in steam pressure. presented in Fig. 11, which demonstrates the way the date,
In Fig. 9, a simulation illustrates the operating state of the boiler temperature, and burner temperature have evolved over
boiler system. The system shuts off when the temperature time. This visual aid is integrated to assist operators analyse
reaches or exceeds 45°C, and the voltage in the Mitsubishi performance.
 PCB board, a shift to commercial production could lower the
estimated cost of the current prototype, which is currently
estimated to be around 15950 BDT, to about 14000 BDT.
Even though these figures suggest possible cost-effectiveness,
a thorough feasibility study is necessary.
VI. C ONCLUSION
The boiler system is an instance of an innovation in in-
dustrial control, utilising SCADA and emphasising real-time
monitoring, current security technologies, and increased effi-
Fig. 11. Haiwell Cloud Real time data Visualisation. ciency. Activating at 30°C and assuring a secure shutdown at
45°C, our system combines real-time SCADA monitoring and
PLC-triggered feedwater supply to achieve exact temperature
The cloud-generated data table is depicted in Fig. 12. The
control. With Haiwell Cloud, users are able to simulate PLC-
times and dates specified in the table are altered in real time
SCADA communication in Modbus TCP/IP and have proactive
within specified intervals. Users are able to analyse real-time
monitoring with real-time email warnings for temperature
project data from SCADA with the assistance of this data.
deviations. Buzzers placed on-site ensure quick response, as
well as SCADA and large-scale data storage are made easier
by the Haiwell Industrial IoT Cloud platform. By supporting
several platforms, Haiwell Cloud improves overall system
dependability and security by ensuring accessible on PC,
iPad, Android, iOS, and etc. With its adaptability, durability,
and responsiveness, it redefines the industrial environment
and moves fluidly between manual and digital modes. This
technology is a pioneer in industrial and power plant au-
tomation, providing unparalleled long-term cost-effectiveness,
less downtime, and enhanced safety standards—all at a higher
initial cost. With its advanced data visualisation, in-depth
analysis, and massive history logging, it generates enormous
cost savings, optimises operations, and proactively prevents
equipment issues. This method is further enhanced by the
inclusion of machine learning. It sets a new standard with
remote accessibility and comprehensive analytics, offering
cost-effective boiler control solutions for the industrial era.
Fig. 12. Real-Time Data Table. R EFERENCES
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