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Boiler Drum Level Control using FOPID Controller with DCS SW Application

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 Boiler Drum Level Control using FOPID
Controller with DCS SW Application
B. Mowafy H. Emara and A. Bahgat
Engineering Consultants Group (ECG), Cairo, Egypt Faculty of Engineering, Cairo University, Giza, Egypt

Abstract— this work provides a study for boiler drum level This papers aims at developing a control scheme for
control using Fractional Order PID (FOPID) controller. A boiler drum level in steam power plant. A conventional
comparative study is made on the performance of the FOPID Proportional-Integral-Derivative (PID) controller and
controller and conventional PID controller to obtain better Fractional Order Proportional-Integral-Derivative (FOPID)
control performance. MATLAB software is used for model
controller are used to regulate the drum level for a three
testing and response simulation using FOPID and conventional
PID. As the Distributed control system (DCS) is widely used in elements scheme. SIMULINK package is used to simulate
many industrial sectors and thermal power plants, this research different models and controllers for different disturbances. A
work presents the implementation of the ABB Freelance DCS distributed Control System (DCS) SW package from ABB
SW at the two levels: Direct Digital Control (DDC) and has been used to simulate the controllers and the boiler drum
Operator Interface System (OIS) for the Supervisory Control level process. Graphic displays have been developed to
and Monitoring of the Boiler Drum Level Control. visualize the results and tuning of controller parameters,
Results indicate the effectiveness of FOPID over PID
Keywords— Boiler Drum Level control; FOPID; DCS SW. controller in improving he dynamic process.
I. INTRODUCTION The paper is organized as follows. Section II shows the
A boiler is an integral device in a fossil fuel thermal boiler drum process. A brief survey of boiler drum level
power plant used to produce steam by applying heat energy control is given in section III. Boiler model and simulation
using PID and FOPID are presented in section IV. The use of
to water. In most of the places in the world
DCS SW for modeling and simulation of drum level control
the turbine is steam-driven. Water is heated, turns into steam
system is given in section V. Conclusions are derived in
using Boilers and spins a steam turbine which drives section VI.
an electrical generator. After it passes through the turbine,
the steam is condensed in a condenser and recycled to where
it was heated; this is known as a Rankine cycle as shown in
Figure 1[32].
One of the integral components of boiler is the steam
boiler drum containing hot water and steam, the main
function of this vessel is to provide a surface area and
volume near the top of the boiler where separation of steam
from water can occur.
For safe and efficient boiler operation, steam drum water
level control is a critical point to avoid the low level of water
which reduces the water to in boiler tubes, which overheats Fig. 1. Scheme of a typical thermal power station [32]
and can cause damage to the boiler tubes. Also the high level
reduces the surface area, and can lead to dissolved solids and II. PROCESS DESCRIPTION AND CONTROL
water entering the steam distribution system causing damage SCHEMES
to the distribution pipes and machines. A. Process description
The main objective of the drum level control system is to Boiler is usually composed of a combustion chamber
maintain the water-steam interface at the predefined where combustion of fuel takes place and two drums; first
specified level and provide a continuous mass balance by one is a steam drum at the top of the boiler containing hot
replacing every pound of drawn steam and water removed water and steam. The other drum is located at the bottom of
with the equivalent of feed-water. the boiler and provides the boiler with cold water.
The drum level is subjected to many disturbances, like The resulting burning gases pass around a group of vertical
steam and feed water disturbances. Steam pressure is being a tubes called water tubes connected between the two drums,
major one according to swell and shrink phenomenon , these tubes carry a mixture of water and steam. The water
which is one of the biggest problems facing the boiler temperature rises in the tubes and enters the steam drum
operation that produces change in the level of the water causes the water to circulate and steam to be released. Hot
surface in the boiler drum whenever boiler load changes water is distributed inside the steam drum after steam release;
[25]. the hot water starts to descend through the down comers
which carry the water down to feed the mud drum.
 level, steam flow element used to get the value of steam flow
in case of load change and feed-water flow element to check
and respond to the changes in feed-water demand.

Fig. 5. Three Elements Drum Level Control Scheme [9]

Fig. 2. Schematic of Boiler Unit [14]
C. Types of controllers
B. Drum Leveel control schemes
Two types of controllers shall be used to implement the
1) Single-Element Drum Level Control System drum level control system; Proportional- Integral-
It is the simplest technique of level control of drum Derivative (PID) controller and Fractional Order PID
boiler. It measures level using level instrument and (FOPID) controller.
accordingly regulates the feed-water flow to maintain the 1. PID Controller
level as set point. The PID refers to the first letter of the names that make
As shown in Figure 3, this consists of a process variable up the standard three term controller. These are P for the
(PV) coming from the drum level transmitter. PV is proportional term, I for the Integral term and D for the
compared with the set-point (SP); the resulting difference is derivative term in the controller. Three term or PID
the error value. The controller generates corrective action controllers are probably used by most widely industrial
(C)O) in the form of a proportional output to minimize the controller.
error signal.
1.1. Tuning of PID Controller
In 1942, Zeigler and Nichols presented two classical
methods to tune a PID controller. These methods are
widely used, due to their simplicity.

1.1.1. Zeigler Nichols Reaction curve Method

The output response of the plant to a unit step input is
obtained, then the required data L and T shall be calculated
Fig. 3. Single Element drum level control scheme [25]
as shown in Figure 6, then compensate in Table 1.
This system is suitable for small boilers where steady
steam demand which have slow load changes because of
swell and shrink causes wrong initial control reaction. In
case of load changes then more advanced schemes are
required to handle the shrink and swell effects.
2) Two - Elements Drum Level Control System
The two-elements drum level controller can be applied
for processes with moderate load where the feed-water is at a
constant pressure as shown in Figure 3. The two element
system includes : level transmitter to measure the drum level Fig. 6. S-shaped response curve [30]
sending a proportional signal to the controller and compared
with the set-point and accordingly controller sends a TABLE I. ZIEGLER-NICHOLS TUNING FORMULA (FIRST METHOD)
corrective action to the feed-water valve to regulate the flow,
Controller type
and steam flow element used to get the value of steam flow Kp Ti Td
T
in case of load change. P  0
L
T L
PI 0.9 0
L 0.3
T
PID 1.2 2L 0.5L
L

1.1.2. Zeigler Nichols Frequency domain Method

In the second method Turn the controller to P-mode only
and setting Ti = ∞ and Td = 0 and Kp = 0, try to increase Kp
Fig. 4. Two Elements Drum Level Control Scheme [25] slightly to a critical value Kp= Kcr at which the output signal
exhibit sustained periodic oscillation as shown in Figure 2.8.
3) Three - Elements Drum Level Control System
Mark these values for Pcr and Kcr. Using these values, the
The best scheme for tight control especially in case of controller parameters can be obtained using the formula in
any disturbance whatever from steam demand or the feed- Table 2.
water variations in pressure or flow. The three-element drum
level control include level transmitter to measure the drum
 A. Single Element Steam Drum Level Control without
Steam Load Disturbance
In single-element steam drum level control, a
conventional PID controller and a FOPID are used to
implement control schemes. The tuning method used here for
PID controller is Ziegler Nichols and FOCON toolbox for
Fig. 7. Sustained oscillation step response [30] FOPID Controller. The results are given in Table 3.
TABLE III. CONTROLLER PARAMETERS TUNING USING MATLAB MODULE
TABLE II. ZIEGLER-NICHOLS TUNING FORMULA (SECOND METHOD)
PID FOPID
Kp 0.96 Kp 1.3425
Controller type Kp Ti Td
Ki 0.002 Ki 0.0076
P 0.5 Kcr  0 Kd 0.983 Kd 2.3591
P𝑐𝑟  0.65
PI 0.45 Kcr 1.2 0  0.899
1
PID 0.5 Kcr 0.5Pcr Pcr
8

2. FOPID Controller
Fractional order PID (FOPID) is a special kind of PID
controller whose derivative and integral order are fractional
rather than integer. To design FOPID controller is to
determine the two important parameters λ (integrator order)
and μ (derivative order). Fig. 9. Single Element drum level control using PID or FOPID Controller
without steam load disturbance
2.1. Tuning of FOPID Controller
Several tools for fractional order system analysis,
modeling and controller synthesis. Among these tools are
MATLAB toolboxes CRONE [3], developed by the CRONE
team and NINTEGER which developed by Duarte Valério.
In this concern, FOMCON toolbox shall be used, which
is developed and tested in MATLAB software for FOPID
Controller optimization as shown in Figure 8.

Fig. 10. Output response of single element drum level without steam load
disturbance using PID and FOPID Controller
As shown in Figure 10, the FOPID response is better than
PID response specially in settling time and error value.
B. Single Element Drum Level Control with Steam Load
Disturbance
In a drum boiler, steam demand can usually vary. In this
case there is a disturbance block appearing in the single-
element drum control scheme. Transfer function considered
for steam load disturbance of 0.1 p.u. is shown in Figure12.

Fig. 8. Optimization tool from FOMCON toolbox for Fractional order PID
controller [27]

III. BOILER DRUM LAVEL MODELLING AND SIMULATION

The relationship between the feed water flow rate and drum Fig. 11. Single element steam drum level control with steam load
level for the boiler process are expressed by the following disturbance using PID or FOPID Controller
equations [9].
0.25(−S+1)
 Boiler drum transfer function : Gp (s) = (1)
S(2S+1)
1
 Valve transfer function: Gv (s) = (2)
(0.15𝑆+1)

 Steam flow disturbance transfer function:

−0.25(−𝑆+1)
Gd(s) = (3)
𝑆(𝑆+1)(2𝑆+1)

MATLAB/ SIMULINK environment is used to build the

process model with different drum level control schemes. Fig. 12. Unit step response of steam load disturbanceof 0.1 p.u. in case of
Single Element drum level control using PID and FOPID Controller
C. Two Elements Drum Level Control with Feed -Forward till the feed-water disturbance began to appear, so more
Steam Disturbance control schemes is required.
To control the effect of steam load disturbance, feed-forward
controller is used.
Figure 13 is the block diagram of feed-forward
compensation, by analyzing the block diagram of the feed-
forward control system.
The equation that relates the measured disturbance to the
outlet variable is [33]:
CV(s) = [Gd(s) + Gff(s) Gp2(s)]Dm(s) (4)

Fig. 16. Output response of the Two-Elements drum level control with feed-
water disturbance using PID and FOPID controllers
Fig. 13. Simplified block diagram of feed-forward compensation [33].
D. Three- Elements Drum Level Control
The purpose is to design a feed-forward controller enable Figure 17 shows the schematic of the three-elements
us to completely cancel the effect of the disturbance. The drum level control. Two controllers are used; feed water
only unknown, which is the controller, Gff(s), can be controller FWC and a cascaded level controller LC. Figure
determined by rearranging equation (4). The result is 18 depicts the output response in case of step change in level
Gd(s)
Gff(s) = - (5) set point of 1 p.u. for PID and FOPID for both FWC and LC.
Gp2(s)
−0.25S+0.25 FOPID shows a better response compared to PID controller.
While, Gp2(s) = Gp(s) Gv(s) = (6)
s(0.15S+1)(2s+1)
0.15S+1
Then Gff(s) = (7)
s+1

Combination of feedback controller along with feed-

forward controller is used for the two-element drum level
control, as shown in Figure 14.
Figure 14 depicts the Simulink model for the 2-element
steam drum level control using conventional PID controller.
Unit step is taken as input.
Unity feedback is used in this Simulink model. Figure 15
display the Simulink model for the 2-element steam drum Fig. 17. Schematic of the Three-Elements steam drum level control with
feed-forward of steam disturbance
level control.

Fig. 14. Schematic of the Two-Elements drum level control with feed-
forward of steam disturbance
Fig. 18. Unit step response of 3-Element Boiler drum level control using
PID and FOPID Controllers

Fig. 15. Output response of the Two-Elements drum level control with feed-
forward of steam disturbance using PID and FOPID controllers
Fig. 19. Output response of 3-Element Boiler drum level control using PID
Figure 16 show the output response of 2-elemenrts with and FOPID Controllers
feed-water disturbance, as noted the output was stable
E. Three Elements Drum Level Control with added IV. USE OF DCS SW FOR SIMULATION OF BOILER
Nonliearities CONTROL SYSTEM
In this part a nonlinearity representing the opening of the This section describes the utilization of commercial DCS
control valve is added, as a limiter/saturation block with SW to implement controllers and to monitor the drum level
Minimum of 0.1 p.u. and Maximum of 1 p.u., as shown in process.
Figure 20. Simulation results of the drum level response in
case of step change in steam load of 0.1 p.u. using both A. DCS Archeticture and Applications
controllers PID and FOPID are given in Figures 14. The DCS application in power plant and process industry
tuned controller parameters are given in Table IV. Table IV offers great flexibility in the operation and control.
shows a comparison of response indices for two cases A and Supervisory Control and Monitoring (SC&M) functions
B, where FOPID is used as FWC instead of PID in case A, enable the operator to regulate and adjust different control
indicating better response compared to case B. loops at the process level. These features can be realized
based on the hierarchal structure of DCS shown in Figure
22. Field level includes sensors, that collect process
measurements, and actuators, that apply control action to
the process. At the control level there exist the distributed
direct digital control (DDC) units that implement the
control algorithms and perform data acquisition. At the
supervisory and monitoring level there exist Operator
Interface Stations (OIS), where operator observes the
process status, applies set point and control actions, and get
reports. The control data network is responsible for
Fig. 20. Schematic of 3 elements control system with added nonlinearity exchanging data between DDC units and the OIS units. In
some applications there exists an upper management level
for production reporting and scheduling. The DCS SW
packages are used to configure MMI graphic displays on
the OIS, configure HW I/O's, design the control functions
at DDC units, configure Data Base and the control data
network.
OIS
Monitoring &
Supervisory
Control

Control Data Network

DDC
Fig. 21. Drum level response for three elements with added nonlinearity for Control&
PID and FOPID Data
Acquistion
TABLE IV. CONTROLLER PARAMETERS TUNING USING MATLAB FOR THREE
ELEMENTS WITH NONLIEARITY

CASE A: LC PID - FWC FOPID

Field
LC : PID FWC : FOPID Units
Switches Valves Motors
Kp 0.4 Kp 0.8 Sensors

Ki 0.001 Ki 5
Kd 0.015 Kd 0.1
Fig. 22. DCS Architecture
 0.15
 0.1 The ABB DCS software package [9.2.7313] is installed
on PC. ABB Control Builder F is used to design the
CASE B: LC PID - FWC PID
control program using IEC61131-3 programming
LC : PID FWC : PID languages like the Function Block Diagram (FBD),
Kp 0.5 Kp 0.8 Instruction List (IL), Ladder Diagram (LD), and Sequential
Ki 0.0001 Ki 3.5 Function Chart (SFC), draw MMI and Faceplates, design
Kd Kd trends features, and give a tag for each variable. DigiVis is
0.05 0.01
the operator software provides user friendly interface,
graphics animations, alarm banner, controller faceplates,
TABLE V. : COMPARISON BETWEEN CASE A AND CASE B and trend display. DigiBrowse collects time stamped
Index Case A Case B values of specified variables in CSV file where data can be
Rise Time (s) 2.2 4.18 reported, archived, or exported to Excel File. Bulk Data
Settling time (s) 4.3 10 Manager (BDM) is an off line bulk engineering tool that
Steady state error (%) 0.1 0.3 allows manipulation of entities through Microsoft Excel
during engineering with Control Builder F.
Overshoot % 1.001 1.004
 The analysis of drum level is applied through VI. RESULTS AND DISCUSSION
simulating the controller and process model (emulator) According to the designed Function block diagram in Figure
using DCS SW, so basic analysis can be made away from 24, the control system including steam load disturbance and
real process. Figure 23 shows a user defined block drum-water level set-point change is to be examined for both
(Process_Sim) based on structure text code that has been PID and FOPID.
developed to simulate a discrete transfer function.
A. Steam Load Step Change
A steam load step disturbance is represented as a change
from value 40 to 43. Figure 26 shows the trend of the drum
level in case of PID controller, while Figure 27 shows the
drum level trend in case of FOPID controller.

Fig. 23. Closed loop FBD with emulation function

B. Boiler Drum Level Simulation using FBD DRUM LEVEL

The designed model for boiler drum level control using PID
controller is shown in Figure 24.

STEAM FLOW

Fig. 26. Drum level trend for steam load step change using PID

Fig. 24. FBD for the drum level control using PID

V. VISUALIZATION DESIGN
Visualizatio design included the Include graphics layout, DRUM LEVEL
trend, faceplate, controller tuning, alarm report. STEAM FLOW

Figure 25, display the boiler process Mimic display, which

Fig. 27. Drum level trend for steam load step change using FOPID
include the Visualization of the following:
a. Controller parameters like Kp, Ki, Kd in case of PID Table VI shows a comparison between the response of drum
controller and Kp, Ki, Kd,  and  in case of FOPID. level for the two controllers PID and FOPID.
b. Trend, showing the data over time for the real
TABLE VI. DRUM LEVEL RESPONSE FOR STEAM LOAD STEP CHANGE
performance of a process.
c. Data analysis like Set point, drum level, water flow, Parameter
Set Peak Settling
Error (%)
steam flow and error. Point Value (%) time (s)
d. Controller Faceplates. PID 50 60 180 0.1
e. System display. FOPID 50 51 60 0.3
f. Data logger and history.
g. Any other display can be obtained from the system. B. Steam Load Pulse Change
A steam load pulse disturbance is represented as 40 to 43 to
40 change. Figure 28 shows the trend of the drum level in
case of PID controller, while Figure 29 shows the drum level
trend in case of FOPID controller. Table VII shows a
comparison between the response of drum level for the two
controllers PID and FOPID.

Fig. 25. Process OIS display

 VII. COMPARISON BETWEEN MATLAB AND DCS
Figure 32, show the output response of 3-elements drum
DRUM LEVEL level control usinf MATLAB model.
Figure 33, show the trend dsiplay for 3-element drum level
control using DCS.
TableVIII, shows the comparison and results, The result is
almost the same.
STEAM FLOW

Fig. 28. Drum level trend for steam load pulse change using PID

DRUM LEVEL

Fig. 32. Output response of 3-elements drum level control using FOPID
STEAM FLOW with 100% steam load disturbance

Fig. 29. Drum level trend for steam load pulse change using FOPID

TABLE VII. DRUM LEVEL RESPONSE FOR PULSE STEAM CHANGE

Set Peak Value Settling STEAM FLOW

Parameter Error (%)
Point (%) time (s)
PID 50 80 180 0.1
FOPID 50 68 60 0.3
DRUM LEVEL
C. Steam Load Change as Random Changes
A steam load random disturbance is introduced. Figure 30
shows the trend of the drum level in case of PID controller,
while Figure 31 shows the drum level trend in case of
FOPID controller.
Fig. 33. Trend of drum level control with 100% steam load dsitubance

TABLE VIII. DRUM LEVEL RESPONSE FOR STEAM LOAD STEP CHANGE

Set Peak Value Settling

Parameter Error (%)
Point (%) time (s)
DRUM LEVEL MATLAB 100 100.05 300 0.05
DCS 100 100.63 318 0.63

VIII.CONCLUSIONS
STEAM FLOW This work discusses a process control system, taking steam
boiler drum level control as a case study using different
schemes for steam drum boiler level control. As a result of
Fig. 30. Trend of drum level for steam load random changes the DCS implementation, the FOPID controller proved more
accurate and reliability over traditional PID (by introducing
the fraction of the integration “μ” & the fraction of
differentiation “λ”. The simulation examples have
demonstrated the superiority of the FOPID controller.
ACKNOWLEDGMENT
DRUM LEVEL
The authors would like to acknowledge the support of the
STDF Project 2663, Ministry of Scientific Research and
Technology of Egypt, and ABB Company Egypt, for
providing the experimental units.
STEAM FLOW

Fig. 31. Trend of drum level for steam load random changes
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