PLC-Based Steam Boiler Control in Structured Text (ST). A Practical Handbook
This practical guide is intended for automation engineers, PLC programmers, and boiler commissioning specialists. It covers in detail the automation of steam boilers — from physical fundamentals to the implementation of advanced control algorithms in Structured Text (ST) according to IEC 61131-3.
A steam boiler is a high-risk facility with complex dynamics. Control errors can lead to accidents, explosions, and severe consequences. Therefore, the automation system must be not only efficient but also highly reliable, with multi-level protection.
The book systematically covers:
Physical fundamentals of steam boilers: thermodynamics of saturated steam, energy balance, process dynamics.
Safety system — multi-level protection: Low Water Cut-Off, High Pressure Trip, flame monitoring, safety valves, E-Stop.
Control system architecture — sensors (pressure, level, flow, temperature, O₂, flame), actuators (gas valves, dampers, pumps), operator interface (HMI/SCADA), redundancy.
PID control — theory and practical tuning for steam boilers: proportional, integral, derivative terms, anti-windup, rate-limiting.
Water level control — three schemes: single-element (On/Off), two-element (level + steam flow), three-element (level + steam flow + feedwater flow) with full compensation for swell & shrink effects.
Burner Management System (BMS) — start-up, ignition, flame control, emergency shutdown sequences; state machine in ST.
Cascade control — pressure-power, fuel-air ratio; improved control quality.
Boiler cascade control — master-slave, start/stop algorithms, load distribution, rotation for even wear.
Complete code examples in ST with comments — ready-to-use function blocks for PID, BMS, three-element level control, and cascade management.
The book includes theoretical explanations, thermodynamic tables, diagrams, graphs, calculation formulas, and ready-made code that can be directly used in CoDeSys, TwinCAT, and other IEC 61131-3 environments.
This guide is useful for automation engineers, PLC programmers, boiler commissioning specialists, students and teachers of technical disciplines. It will help you create a reliable, efficient, and safe steam boiler control system that complies with industrial safety standards (GOST, TR TS, NFPA).
Introduction — purpose, scope, physical fundamentals, safety requirements.
Theoretical background — saturated steam properties, energy balance, dynamics, time constants, critical parameters.
System architecture — sensors (pressure, level, flow, temperature, O₂, flame), actuators, HMI/SCADA, redundancy, PLC selection.
Safety system — multi-level protection, Low-Low level, High-High pressure, flame monitoring, E-Stop, safety valves, error codes.
Parameter monitoring — measurement and scaling of pressure, level, flow, temperature, O₂; filtering and compensation.
PID control fundamentals — theory, tuning, discrete implementation, anti-windup, Ziegler-Nichols, practical tuning.
Steam pressure control — cascade control, tuning, disturbance rejection, rate-limiting.
Water level control — single-element, two-element, three-element control; complete code; selection guidelines; boiler house project example.
Burner Management System (BMS) — sequences, state machine, flame detection, filtering, flame failure detection.
Cascade control systems — pressure-power, fuel-air ratio; programming and application.
Boiler cascade control — master-slave concept, hysteresis, load distribution, rotation, full ST algorithm.
Conclusion — key principles, recommendations, references to standards.
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