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Designing PID controllers for a boiler system with Master, Fuel, and Air loops—especially in
an Air-Fuel Ratio (AFR) control strategy—is a classic and critical control application. You're on
the right track with your structure: Master PID controlling steam pressure, cascading to Fuel
and Air PIDs with a low selector on the fuel side and a high selector on the air side.

Here's a step-by-step method to design and tune the PIDs:

🔁 Control Architecture Overview

1. Master Loop

 Controlled Variable (PV): Steam drum pressure

 Setpoint (SP): Desired pressure (e.g., 45 bar)

 Output: Fuel demand signal (used as input to both Fuel and Air PIDs)

2. Fuel Loop

 Controlled Variable: Fuel flow

 SP: Output of LOW selector (min of Master output and Air flow)

 Output: Fuel control valve opening

3. Air Loop

 Controlled Variable: Air flow

 SP: Output of HIGH selector (max of Master output and Fuel flow)

 Output: Air damper or FD fan speed

This setup ensures that:

 Fuel never exceeds air (avoids rich combustion)

 Air always matches or slightly exceeds fuel (safe and complete combustion)

⚙️Step-by-Step PID Tuning and Design

🔹 Step 1: Tune the Master Pressure PID

This is the slowest loop and must be tuned first.

 Type: PI (usually no D)
  Goal: Maintain pressure by adjusting fuel/air demand

 Tuning Suggestion:

o Start with conservative P and I

o Use methods like Ziegler-Nichols or Cohen-Coon if process dynamics are

known

o Example (if using Siemens PID Compact block):

ini

CopyEdit

Kp = 1.0

Ti = 100 s

 Tip: Use a long integral time, as pressure changes slowly.

🔹 Step 2: Tune the Fuel Flow PID

Fuel responds faster than pressure, so you can be more aggressive.

 SP: Output of low selector (min of master demand and actual air flow)

 Tuning Suggestion:

o Tight PI control for fast response

o Example:

ini

CopyEdit

Kp = 2.0

Ti = 20 s

🔹 Step 3: Tune the Air Flow PID

Air is typically faster-acting than fuel (fan speed/damper).

 SP: Output of high selector (max of master demand and fuel flow)

 Tuning Suggestion:

o Slightly faster than fuel loop to avoid rich mixture

o Example:

ini
CopyEdit

Kp = 2.5

Ti = 15 s

 Note: Oversupplying air slightly is okay and safer than undersupplying.

🧠 Key Design Considerations

Aspect Design Tips

If you're maintaining a fixed air/fuel ratio, implement a feedforward ratio

Ratio Control
block or multiplier ahead of the selectors.

Low/High Prevents unsafe operation. Fuel cannot exceed air (low selector), and air
Selectors always slightly exceeds fuel (high selector).

Signal Filtering Apply low-pass filters to measured flows to prevent oscillation from noise.

Failsafe In case of sensor failure, define safe fallback modes (e.g., fixed air/fuel
Defaults ratio).

Enable anti-windup in all PIDs to prevent integral overshoot during output

Anti-windup
saturation.

Mode Consider startup logic or auto/manual switches for warm-up and

Switching shutdown.

📊 Optional: Simulation & Testing

Before implementing on live equipment:

 Test logic in a PLC simulator (like Siemens PLCSIM + HMI)

 Use trend monitoring for pressure, fuel, and air

 Gradually introduce load changes (steam demand) and observe controller behavior

If you'd like, I can help draft the Siemens PLC logic using FB41 or PID Compact blocks, along
with selector logic. Let me know what PLC and HMI you're using!

DEEPSEEK
Designing a boiler control system with Master, Fuel, and Air PID controllers requires careful
tuning and coordination to ensure efficient combustion, stable steam pressure, and safe
operation. Below is a structured approach to designing these controllers,
including interlocks, selector logic, and initial PID tuning parameters.

1. System Overview

Control Objectives

1. Master PID (Steam Pressure Control)

o Input: Steam pressure (PV).

o Output: Sets the demand for fuel and air flow (SP for Fuel and Air PIDs).

o Goal: Maintain stable steam pressure under varying load.

2. Fuel PID (Fuel Flow Control)

o Input: Selected demand (low selector between Master output and Air flow).

o Output: Controls fuel valve position.

o Goal: Ensure fuel flow matches combustion demand while preventing rich
combustion (excess fuel).

3. Air PID (Air Flow Control)

o Input: Selected demand (high selector between Master output and Fuel
flow).

o Output: Controls air damper position.

o Goal: Ensure sufficient air for complete combustion while preventing excess
air (heat loss).

Selector Logic

 Fuel PID Input: MIN(Master_PID_Output, Air_Flow) → Ensures fuel never exceeds air
(prevents rich combustion).

 Air PID Input: MAX(Master_PID_Output, Fuel_Flow) → Ensures air always exceeds

fuel (prevents lean combustion).

2. PID Controller Design

(A) Master PID (Steam Pressure Control)

Parameter Typical Value Explanation

Control Mode PID (Auto) Maintains steam pressure.

Steam pressure (e.g., 10– Measured by pressure

PV (Process Var.)
50 bar) transmitter.

Desired pressure (e.g., 30 Operator-set or auto-

SP (Setpoint)
bar) adjusted.

0–100% (Demand for Fuel Scaled to Fuel/Air flow

Output Range
& Air) range.

Initial Tuning (Ziegler-

Kp=1.0, Ti=30s, Td=5s Adjust based on response.
Nichols)

(B) Fuel PID (Fuel Flow Control)

Parameter Typical Value Explanation

Follows Master PID or Air flow

Control Mode PID (Cascade)
(whichever is lower).

PV (Process Fuel flow (e.g., 0–1000

Measured by flow meter.
Var.) kg/hr)

MIN(Master_Output,
SP (Setpoint) Ensures fuel ≤ air.
Air_Flow)

0–100% (Fuel valve

Output Range Controls fuel supply.
position)

Initial Tuning Kp=0.8, Ti=20s, Td=2s Tune for fast but stable response.

(C) Air PID (Air Flow Control)

Parameter Typical Value Explanation

Control Mode PID (Cascade) Follows Master PID or Fuel flow

Parameter Typical Value Explanation

(whichever is higher).

PV (Process Air flow (e.g., 0–2000

Measured by flow meter.
Var.) Nm³/hr)

MAX(Master_Output,
SP (Setpoint) Ensures air ≥ fuel.
Fuel_Flow)

0–100% (Air damper

Output Range Controls combustion air.
position)

Slower than fuel PID to prevent

Initial Tuning Kp=0.6, Ti=25s, Td=3s
oscillations.

3. Selector Logic Implementation

(A) Low Selector (Fuel PID Input)

 Purpose: Ensures fuel never exceeds air flow.

 Logic:

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Fuel_PID_SP = MIN(Master_PID_Output, Air_Flow_Actual)

(B) High Selector (Air PID Input)

 Purpose: Ensures air always exceeds fuel flow.

 Logic:

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Air_PID_SP = MAX(Master_PID_Output, Fuel_Flow_Actual)

4. Safety Interlocks

1. Air-Fuel Cross-Limiting
 o If air flow fails, fuel PID SP is forced to zero (shut fuel valve).

o If fuel flow fails, air PID SP is forced to minimum purge flow.

2. Flame Failure Protection

o If flame is lost, both fuel and air are cut off.

3. Oxygen Trim (Optional)

o Uses an O₂ sensor to fine-tune air flow for optimal combustion efficiency.

5. PLC Ladder Logic Example (Omron CJ2M)

(A) Master PID (Steam Pressure Control)

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|----[ PID Steam_Pressure SP=30.0 Kp=1.0 Ti=30 Td=5 Output=D100 ]----|

 D100 = Master PID output (0–100%).

(B) Fuel PID (Low Selector Logic)

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|----[ CMP D100 D200 ]----| // Compare Master output (D100) & Air flow (D200)

|----[ MIN D100 D200 D300 ]----| // D300 = MIN(D100, D200) → Fuel PID SP

|----[ PID Fuel_Flow SP=D300 Kp=0.8 Ti=20 Td=2 Output=D400 ]----|

 D400 = Fuel valve position (0–100%).

(C) Air PID (High Selector Logic)

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|----[ CMP D100 D500 ]----| // Compare Master output (D100) & Fuel flow (D500)

|----[ MAX D100 D500 D600 ]----| // D600 = MAX(D100, D500) → Air PID SP

|----[ PID Air_Flow SP=D600 Kp=0.6 Ti=25 Td=3 Output=D700 ]----|

 D700 = Air damper position (0–100%).

6. Tuning Recommendations

1. Start with Open-Loop Tuning

o Step-test each loop (Master, Fuel, Air) separately to observe response.

2. Use Ziegler-Nichols or Relay Tuning

o Adjust Kp, Ti, Td to minimize overshoot and settling time.

3. Fine-Tune in Closed Loop

o Ensure Fuel and Air PIDs respond faster than Master PID.

Conclusion

This design ensures:

✅ Stable steam pressure (Master PID).
✅ Safe combustion (Fuel ≤ Air via selectors).
✅ Efficient operation (cross-limiting prevents excess fuel/air).

For further optimization, consider O₂ trim and adaptive PID tuning. Let me know if you need
help with implementation! 🔥

GROK
Designing PID controllers for a boiler system with Master, Fuel, and Air loops, as described,
involves ensuring stable and efficient control of steam pressure while coordinating fuel and
air flows to maintain safe and optimal combustion. Below, I’ll outline the steps to design
these PID controllers, explain the control structure, and suggest basic parameter values for
tuning. The explanation assumes a typical boiler control scenario where the Master PID
controls steam pressure, and Fuel and Air PIDs manage combustion with cross-limiting logic
(low selector for fuel, high selector for air).

1. Understand the Control Structure

The system you described is a boiler combustion control system with cross-limiting to
ensure safe operation:

 Master PID Controller:

o Input: Steam pressure (process variable, PV).

o Setpoint: Desired steam pressure.

o Output: Demand signal (e.g., firing rate demand) that serves as the setpoint
for Fuel and Air PIDs.

o Purpose: Regulates steam pressure by adjusting the overall combustion rate.

 Fuel PID Controller:

o Input: Fuel flow (PV).

o Setpoint: Output from the Master PID, passed through a low selector that
compares Master output with measured air flow.

o Output: Fuel valve position or fuel flow control signal.

o Purpose: Controls fuel flow to meet the firing demand while ensuring it
doesn’t exceed the available air (preventing incomplete combustion).

 Air PID Controller:

o Input: Air flow (PV).

o Setpoint: Output from the Master PID, passed through a high selector that
compares Master output with measured fuel flow.

o Output: Air damper position or air flow control signal.

o Purpose: Controls air flow to provide sufficient oxygen for combustion,

ensuring excess air when needed.

 Cross-Limiting Logic:
 o Low Selector (Fuel): Ensures fuel flow setpoint is the lesser of the Master
demand or a value proportional to air flow. This prevents fuel-rich conditions
(too much fuel, not enough air).

o High Selector (Air): Ensures air flow setpoint is the greater of the Master
demand or a value proportional to fuel flow. This ensures enough air for
complete combustion, even during load changes.

This structure ensures that:

 During load increase: Air leads (increases first), fuel follows.

 During load decrease: Fuel leads (decreases first), air follows.

 This maintains safe air-fuel ratios, avoiding fuel-rich or air-deficient conditions.

2. Steps to Design the PID Controllers

To design effective PID controllers, follow these steps:

Step 1: Define System Requirements

 Steam Pressure (Master PID):

o Fast response to load changes without excessive overshoot.

o Stable pressure control under varying fuel and air conditions.

o Typical setpoint: 100–1000 psig (depends on boiler design).

 Fuel Flow:

o Precise control to match firing demand.

o Must respond to low selector constraints to avoid fuel-rich conditions.

o Typical units: lb/hr, kg/hr, or valve %.

 Air Flow:

o Maintains excess air (e.g., 10–20% above stoichiometric) for complete

combustion.

o Responds to high selector to ensure sufficient air during transients.

o Typical units: SCFM, Nm³/hr, or damper %.

 Safety Constraints:

o Air-fuel ratio must stay within safe limits (e.g., stoichiometric ratio + excess
air).
 o Avoid oscillations that could cause flame instability or trips.

Step 2: Model the Process

Each PID loop controls a process with unique dynamics:

 Steam Pressure (Master):

o Dynamics depend on boiler size, steam demand, and heat transfer.

o Typically a slow process with time constants in minutes (e.g., 1–5 min).

o May include dead time due to heat transfer delays.

 Fuel Flow:

o Faster response (seconds to tens of seconds).

o Depends on fuel valve/actuator dynamics and fuel type (gas, oil, coal).

o Minimal dead time unless fuel delivery has transport delays.

 Air Flow:

o Moderate response (tens of seconds).

o Depends on fan/damper dynamics and ducting.

o May have nonlinear behavior due to damper characteristics.

If possible, obtain process models via:

 Step Tests: Apply small step changes to valve positions and measure responses
(pressure, fuel flow, air flow).

 First-Order Plus Dead Time (FOPDT) Model: Approximate each process as

G(s)=Ke−θsτs+1 G(s) = \frac{K e^{-\theta s}}{\tau s + 1} G(s)=τs+1Ke−θs, where K K K
is gain, θ \theta θ is dead time, and τ \tau τ is time constant.

 Simulation Tools: Use software like MATLAB/Simulink or HYSYS to model boiler

dynamics if physical testing is limited.

Step 3: PID Controller Structure

 Form: Use standard PID form: u(t)=Kpe(t)+Ki∫e(t)dt+Kdde(t)dt u(t) = K_p e(t) + K_i \
int e(t) dt + K_d \frac{de(t)}{dt} u(t)=Kpe(t)+Ki∫e(t)dt+Kddtde(t), where:

o e(t)=SP−PV e(t) = SP - PV e(t)=SP−PV (setpoint minus process variable).

o Kp K_p Kp: Proportional gain.

o Ki K_i Ki: Integral gain (or reset time, Ti=Kp/Ki T_i = K_p / K_i Ti=Kp/Ki).
 o Kd K_d Kd: Derivative gain (or derivative time, Td=Kd/Kp T_d = K_d / K_p Td
=Kd/Kp).

 Mode:

o Master PID: Likely PI (no derivative) due to slow dynamics and noise in
pressure signals.

o Fuel PID: PI or PID, depending on valve dynamics.

o Air PID: PI or PID, depending on damper/fan response.

 Anti-Windup: Enable for all loops to handle actuator saturation (e.g., valve fully
open/closed).

 Bumpless Transfer: Ensure smooth transitions when switching control modes

(manual to auto).

Step 4: Initial Tuning

Use a tuning method to estimate initial PID parameters. Common methods include:

 Ziegler-Nichols (if step test data is available):

o Perform open-loop step test to find process gain K K K, time constant τ \tau τ,
and dead time θ \theta θ.

o Calculate ultimate gain Ku K_u Ku and period Pu P_u Pu (closed-loop test, if

safe).

o Apply Ziegler-Nichols rules for PI/PID settings.

 Cohen-Coon (for open-loop data):

o Better for processes with significant dead time.

o Use FOPDT model parameters to compute Kp K_p Kp, Ti T_i Ti, Td T_d Td.

 Lambda Tuning (for robustness):

o Choose desired closed-loop time constant (e.g., λ=1–3×τ \lambda = 1–3 \

times \tau λ=1–3×τ).

o Compute: Kp=τK(λ+θ) K_p = \frac{\tau}{K (\lambda + \theta)} Kp=K(λ+θ)τ, Ti=τ

T_i = \tau Ti=τ, Td=0 T_d = 0 Td=0 (for PI).

 Software Tools: Use tuning software (e.g., PID Tuner in MATLAB, DeltaV Tune) for
simulation-based tuning.

Suggested Initial Parameters (based on typical boiler dynamics, adjust after testing):

 Master PID (Steam Pressure):

 o Kp K_p Kp: 0.5–2 %/% (output % per % pressure error).

o Ti T_i Ti: 60–300 sec (slow integral to avoid oscillations).

o Td T_d Td: 0 sec (no derivative due to noise).

o Example: Kp=1 K_p = 1 Kp=1, Ti=120 T_i = 120 Ti=120 sec.

 Fuel PID:

o Kp K_p Kp: 0.2–1 %/% (output % per % flow error).

o Ti T_i Ti: 10–30 sec.

o Td T_d Td: 0–5 sec (if fast valve dynamics).

o Example: Kp=0.5 K_p = 0.5 Kp=0.5, Ti=20 T_i = 20 Ti=20 sec, Td=0 T_d = 0 Td
=0.

 Air PID:

o Kp K_p Kp: 0.3–1.5 %/% (output % per % flow error).

o Ti T_i Ti: 15–40 sec.

o Td T_d Td: 0–5 sec (if damper response is fast).

o Example: Kp=0.8 K_p = 0.8 Kp=0.8, Ti=30 T_i = 30 Ti=30 sec, Td=0 T_d = 0 Td
=0.

Notes:

 Units depend on your system (e.g., %/% for normalized signals, or specific units like
psig for pressure).

 Fuel and Air PIDs need faster response than Master to track cross-limiting setpoints.

 Start with conservative (low) gains to ensure stability.

Step 5: Implement Cross-Limiting Logic

 Low Selector (Fuel):

o Input 1: Master PID output (firing demand, e.g., %).

o Input 2: Air flow (scaled to equivalent firing demand, e.g., air flow × air-fuel
ratio constant).

o Output: Min(Input 1, Input 2) → Fuel PID setpoint.

o Scaling: Ensure air flow is scaled to match fuel units (e.g., if fuel is lb/hr,
convert air flow to equivalent fuel demand using stoichiometric ratio + excess
air).
  High Selector (Air):

o Input 1: Master PID output (firing demand, e.g., %).

o Input 2: Fuel flow (scaled to equivalent air demand).

o Output: Max(Input 1, Input 2) → Air PID setpoint.

o Scaling: Fuel flow × (stoichiometric air-fuel ratio + excess air factor, e.g., 1.1–
1.2 for 10–20% excess air).

 Tuning Consideration:

o Cross-limiting introduces interaction between loops. Tune Fuel and Air PIDs to
respond faster than Master to minimize lag in setpoint tracking.

o Test selectors during load ramps to ensure air leads on increase and fuel leads
on decrease.

Step 6: Simulate and Test

 Simulation:

o Use a process simulator (e.g., Simulink, HYSYS) to test the control system with
estimated dynamics.

o Verify that cross-limiting prevents fuel-rich conditions and maintains excess

air.

o Check for oscillations or overshoot during load changes.

 Field Testing:

o Start with manual mode to verify sensor and actuator responses.

o Switch to auto with conservative PID settings.

o Perform small setpoint changes (e.g., ±5% steam pressure) and load ramps.

o Monitor air-fuel ratio, stack O2, and CO to ensure safe combustion.

Step 7: Fine-Tune

 Master PID:

o If pressure overshoots, reduce Kp K_p Kp or increase Ti T_i Ti.

o If response is sluggish, increase Kp K_p Kp or decrease Ti T_i Ti.

 Fuel PID:

o Adjust for fast tracking of low selector setpoint without valve chatter.

o Increase Kp K_p Kp for faster response, but watch for instability.

  Air PID:

o Ensure air flow tracks high selector setpoint smoothly.

o Add small Td T_d Td if damper oscillations occur (rare).

 Iterative Tuning:

o Tune Master PID first with Fuel and Air in manual (fixed outputs).

o Tune Fuel and Air PIDs together, checking cross-limiting behavior.

o Use trend data to analyze interactions and stability.

Step 8: Add Advanced Features (Optional)

 Feedforward Control:

o Add feedforward for steam demand changes (e.g., turbine load) to Master
PID.

o Adjust Fuel/Air setpoints proactively based on load signals.

 Gain Scheduling:

o Vary PID gains based on boiler load (e.g., low vs. high fire).

 O2 Trim:

o Add a slow outer loop to adjust air setpoint based on stack O2 measurement
(e.g., maintain 2–4% O2).

 Ratio Control:

o Fine-tune air-fuel ratio dynamically based on fuel type or operating condition.

3. Basic Parameter Values

The initial values below are starting points for a typical industrial boiler (e.g., 50,000–
200,000 lb/hr steam, gas-fired). Adjust based on your system’s dynamics and testing.

Controller Parameter Value Notes

Master (Pressure) Kp K_p Kp 1.0 %/% Adjust for ±0.5–2 based on response.

Ti T_i Ti 120 sec 60–300 sec, slow to avoid cycling.

Td T_d Td 0 sec Avoid due to pressure noise.

Fuel Kp K_p Kp 0.5 %/% 0.2–1, faster than Master.

Controller Parameter Value Notes

Ti T_i Ti 20 sec 10–30 sec, quick reset.

Td T_d Td 0 sec Add 1–5 sec if valve is fast.

Air Kp K_p Kp 0.8 %/% 0.3–1.5, balance speed/stability.

Ti T_i Ti 30 sec 15–40 sec, moderate reset.

Td T_d Td 0 sec Add 1–5 sec if damper oscillates.

Cross-Limiting Parameters:

 Air-fuel ratio: Set stoichiometric ratio + 10–20% excess air (e.g., 1.1–1.2 ×
stoichiometric for gas).

 Scaling constants: Calibrate based on flowmeter ranges (e.g., fuel flow max = 1000
lb/hr, air flow max = 12,000 SCFM).

4. Best Practices for Optimal Design

 Stability First: Prioritize stable operation over aggressive response. Boilers are critical
systems where oscillations can cause trips or damage.

 Safety: Always verify that cross-limiting prevents fuel-rich conditions. Monitor stack
O2 and CO during tuning.

 Robustness: Design for varying loads (e.g., 25–100% capacity). Test at low, medium,
and high fire.

 Data Logging: Use DCS trends to analyze PV, SP, and output signals during tuning.

 Documentation: Record tuning parameters and test results for future reference.

 Maintenance:

o Regularly calibrate flowmeters and pressure sensors.

o Check valve/damper hysteresis to avoid control issues.

5. Challenges and Solutions

 Nonlinearities:

o Problem: Dampers and valves may have nonlinear responses (e.g., gain
changes with position).
 o Solution: Use gain scheduling or characterize nonlinearities in the control
system.

 Interactions:

o Problem: Fuel and Air loops interact via cross-limiting.

o Solution: Tune Fuel and Air PIDs to be faster than Master, and test under
dynamic conditions.

 Dead Time:

o Problem: Pressure response may lag due to heat transfer delays.

o Solution: Use conservative integral action or add feedforward for load

changes.

 Noise:

o Problem: Pressure or flow signals may be noisy.

o Solution: Apply filtering (e.g., first-order filter with 1–2 sec time constant) and
avoid derivative action.

6. Example Workflow

1. Setup:

o Configure Master PID to control steam pressure (e.g., SP = 150 psig).

o Set Fuel PID to control fuel flow with low selector (Master output vs. air flow).

o Set Air PID to control air flow with high selector (Master output vs. fuel flow).

2. Initial Test:

o In manual, step fuel valve 5% and measure fuel flow response.

o Step damper 5% and measure air flow response.

o Step firing demand 5% and measure pressure response.

3. Tuning:

o Tune Master PID with Fuel/Air in manual (e.g., Kp=1 K_p = 1 Kp=1, Ti=120 T_i
= 120 Ti=120 sec).

o Tune Fuel PID to track setpoint changes (e.g., Kp=0.5 K_p = 0.5 Kp=0.5, Ti=20
T_i = 20 Ti=20 sec).

o Tune Air PID similarly (e.g., Kp=0.8 K_p = 0.8 Kp=0.8, Ti=30 T_i = 30 Ti=30 sec).
 4. Dynamic Test:

o Ramp steam pressure setpoint ±10 psig.

o Verify air leads on increase, fuel leads on decrease.

o Check O2 levels (e.g., 2–4%) and ensure no CO spikes.

5. Refine:

o Adjust gains if overshoot occurs.

o Reduce Ti T_i Ti if steady-state error persists.

7. Notes on Implementation

 DCS/PLC: Implement in a distributed control system (e.g., Honeywell Experion,

Emerson DeltaV) or PLC (e.g., Siemens S7, Allen-Bradley).

 Scaling: Normalize signals (e.g., 0–100%) for consistency, or use engineering units
with proper scaling.

 Alarms: Set alarms for low O2, high CO, or pressure excursions to catch tuning issues.

 Simulation: If unsure, simulate using boiler models from vendors or open-source

tools before field implementation.

8. Final Answer

To design the best PID controllers for your boiler system:

 Master PID: Controls steam pressure (e.g., Kp=1 K_p = 1 Kp=1, Ti=120 T_i = 120 Ti
=120 sec, Td=0 T_d = 0 Td=0).

 Fuel PID: Controls fuel flow with low selector (e.g., Kp=0.5 K_p = 0.5 Kp=0.5, Ti=20
T_i = 20 Ti=20 sec, Td=0 T_d = 0 Td=0).

 Air PID: Controls air flow with high selector (e.g., Kp=0.8 K_p = 0.8 Kp=0.8, Ti=30 T_i
= 30 Ti=30 sec, Td=0 T_d = 0 Td=0).

 Cross-Limiting: Ensures air leads on load increase, fuel leads on decrease, with 10–
20% excess air.

 Steps:

1. Model processes (pressure, fuel, air) using step tests or FOPDT.

2. Tune conservatively using Ziegler-Nichols, Cohen-Coon, or Lambda.

 3. Test dynamically to verify stability and safety.

4. Fine-tune based on overshoot, settling time, and combustion metrics (O2,

CO).

 Tools: Use DCS trending, simulation software, or tuning calculators for precision.

Adjust parameters based on your boiler’s specific dynamics (size, fuel type, load range) and
test thoroughly to ensure safe, stable operation. If you have specific data (e.g., boiler
capacity, fuel type, or step test results), I can refine the tuning further—let me know!

CLAUDE

Boiler Control System with Master, Fuel, and Air PIDs

I'll help you design a cascaded PID control system for your boiler with a master controller
and fuel/air flow controllers. This is a common approach for optimizing combustion
efficiency while maintaining stable steam pressure.

System Architecture

Your control system has three main PID controllers:

1. Master PID: Controls steam pressure and outputs a demand signal

2. Fuel PID: Controls fuel flow based on the lower of master demand or air flow

3. Air PID: Controls air flow based on the higher of master demand or fuel flow

This cross-limiting strategy (using selectors) is excellent for safety and efficiency, as it:

 Prevents fuel-rich conditions (low air) which can be dangerous

 Avoids fuel-lean conditions (excess air) which reduce efficiency

 Ensures proper fuel-air ratio during load changes

PID Parameters and Design Approach

Master (Steam Pressure) PID

Process Variable: Steam Pressure

Setpoint: Desired Steam Pressure

Output: Demand Signal (0-100%)

Initial Parameters:

 Proportional Gain (Kp): 0.8-1.5

 Integral Time (Ti): 60-180 seconds

 Derivative Time (Td): 0-10 seconds

 Output Limits: 0-100%

The master controller should be tuned for relatively slow response to avoid oscillations in
the combustion system. Consider a slightly lower proportional gain and longer integral time.

Fuel Flow PID

Process Variable: Fuel Flow

Setpoint: Output from Low Selector (min of Master Output or Air Flow)

Output: Fuel Valve Position

Initial Parameters:
  Proportional Gain (Kp): 0.5-1.2

 Integral Time (Ti): 10-40 seconds

 Derivative Time (Td): 0-5 seconds

 Output Limits: 0-100%

The fuel controller should be faster than the master but not too aggressive.

Air Flow PID

Process Variable: Air Flow

Setpoint: Output from High Selector (max of Master Output or Fuel Flow)

Output: Fan Speed/Damper Position

Initial Parameters:

 Proportional Gain (Kp): 0.6-1.5

 Integral Time (Ti): 8-30 seconds

 Derivative Time (Td): 0-5 seconds

 Output Limits: 0-100%

The air controller should be slightly more responsive than the fuel controller to ensure
proper air-fuel ratio during transients.

Tuning Procedure

1. Start with Manual Mode:

o Put all controllers in manual mode

o Establish stable operation at 50% load

2. Tune Air Flow PID First:

o Set to auto mode with initial parameters

o Make small setpoint changes and adjust parameters

o Aim for minimal overshoot and fast settling

3. Tune Fuel Flow PID Next:

o Similar process as air flow tuning

o Ensure fuel flow follows setpoint changes with minimal overshoot

4. Tune Master PID Last:

 o This should be more conservative (slower response)

o Test with small pressure setpoint changes

o Verify the cascaded response works properly

5. Test Cross-Limiting Logic:

o Verify that during load increases, air flow leads fuel flow

o During load decreases, fuel flow should decrease before air flow

Additional Considerations

1. Feedforward Control: Consider adding feedforward signals for major load

disturbances

2. Anti-windup Protection: Essential for all PIDs, especially during startup and when
reaching output limits

3. Fuel-Air Ratio Curve: You may need to implement a characterization curve rather
than a simple 1:1 relationship between fuel and air

4. Oxygen Trim: Consider adding an oxygen analyzer in the flue gas to fine-tune the air-
fuel ratio for optimal efficiency

Would you like me to expand on any specific aspect of this control system design?