809

A simple dynamic model and stability analysis

of a steam boiler drum
S Bracco∗ , M Troilo, and A Trucco
DIMSET (Department of Machinery, Energy Systems, and Transportation), University of Genoa, Genoa, Italy

The manuscript was received on 24 March 2009 and was accepted after revision for publication on 15 May 2009.
DOI: 10.1243/09576509JPE783

Abstract: This study is focused on the steam boilers dynamics modelling used as a power-
ful instrument to predict the response of boilers to external inputs and transient operating
conditions.
The article describes a mathematical simulation model that has been developed to study the
stability of a steam boiler drum subjected to different initial operating conditions. The phe-
nomenological study has been based on several simulations that have been done considering
steam boilers characterized by different nominal values of both pressure and steam mass flowrate;
the attention has been given mainly to the effect of different pumping characteristics and thermal
flux values on the boilers stability. The article shows the main results of the simulations and lists
all the boilers’ possible operating conditions, both stable and unstable.

Keywords: steam boiler drum, dynamic simulation, stability analysis

1 INTRODUCTION environment and using the Maple software [10], of a

The present article deals with the development of
simplified simulation models able to describe and
evaluate the behaviour of steam boilers under dif-
ferent operating conditions. The control of a steam
boiler operation is very critical, mainly for safety rea-
sons [1–3]. Indeed a steam boiler is provided with a
large number of safety devices, first of all the relief
valve to assure the pressure is kept below the maxi-
mum value allowed by the stress analysis [2]. Another
necessary device is the water level control that pre-
vents dangerous situations that may occur in the case
of excessive filling or fully emptying.
In literature, there are many papers that describe
mathematical models developed to simulate the
dynamic behaviour of steam boilers in steam power
plants [4–6] or heat recovery steam generators in
combined cycle power plants [7–9].
The first step of the study here reported has been
the implementation, both in the Matlab/Simulink
∗ Corresponding author: DIMSET (Department of Machinery,
Energy Systems, and Transportation), University of Genoa, Via
Montallegro 1, Genoa 16145, Italy.
email: stefano.bracco@unige.it
mathematical model that reproduces the operation of
a steam boiler drum without taking into considera-
tion the control system. This model has been used to
test and analyse the response of the boiler to different
initial operating conditions; by this analysis several
interesting conclusions have been drawn about the
system stability. As a consequence, the originality of
the proposed study, compared with the analyses pro-
posed in references [4] to [6] and [9], is mainly due to
the fact that the developed mathematical model repro-
duces the dynamic behaviour of a steam boiler drum
without considering the pressure and water level con-
trol system, the aim of the study being that of analysing
the system stability from a phenomenological point of
view.
The stability analysis of dynamic systems is a well-
known problem and many papers in literature deal
with this topic, analysing it from a different point
of view [11–14]. It is important to cite the review
of two-phase flow dynamic instabilities in tube boil-
ing systems reported by Kakaç and Bon [14], that of
Greitzer about the stability of pumping systems [13]
and the theoretical results proposed by Strogatz [12]
and Jordan and Smith [11]. Taking into considerations
these different approaches, the boiler drum stability
has been analysed to determine its dependence on

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810 S Bracco, M Troilo, and A Trucco

significant factors such as the system initial operating lies over the liquid level. In equation (3), ρw is the liq-
conditions, in terms of pressure and the water level uid density in saturated conditions, ρs is the saturated
inside the boiler drum, the nominal thermal flux, and steam density, p is the pressure inside the drum, V is
the pumping system. the total internal volume of the drum, and Vw is the
volume occupied by the liquid inside the drum.
Substituting equation (3) into equation (2) one
2 THE MATHEMATICAL MODEL
obtains
In this simple model of the boiler drum, it has been
dρw (p) dp dVw (z) dz
assumed that the fluid enters the boiler as a liquid, Vw (z) + ρw (p)
then is heated to the saturation temperature, and dp dt dz dt
finally leaves as steam in saturated conditions [1, 13]. It dρs (p) dp dVw (z) dz
+ [V − Vw (z)] − ρs (p)
is important to remark that the boiler feedwater pump dp dt dz dt
is equipped with a bypass facility to adjust the water = ṁw − ṁs (4)
flow [13]; the thermal flux is provided to the fluid inside
the drum that is assumed to have a cylindrical shape.
The boiler drum contains the liquid and the steam in Equation (4) can be arranged as
saturated conditions and at the equilibrium.

The equations governing the dynamics of the sys- dρw (p) dρs (p) dp
Vw (z) + [V − Vw (z)]
tem are written on the basis of the lumped parameters dp dp dt
analysis, identifying two state variables as: the pres-

dVw (z) dVw (z) dz
sure inside the drum (indicated by p) and the liquid + ρw (p) − ρs (p) = ṁw − ṁs
dz dz dt
level measured from the bottom of the drum (indi-
(5)
cated by z). This way, two differential equations govern
the dynamics of the boiler. These equations can be
obtained applying the equation of continuity and the 2.2 The energy equation applied to the boiler
energy balance equation to the component used to drum
model the steam boiler [1, 3, 4, 6, 8, 15–17].
The model considers a linear characteristic curve, This section describes the equation used to model
on the flowrate–pressure plane, for the feedwater the energy balance inside the drum, based on the
pump, assuming to keep constant the pressure at the following assumptions:
pump inlet once the design parameters of the boiler (a) the potential and kinetic energy changes of the
have been chosen. As a consequence, the liquid mass two-phase fluid are neglected;
flowrate is calculated as (b) the pressure drops inside the system are not taken
p2 − p1o into consideration;
ṁw = α ṁwo − (α − 1)ṁwo (1)
p2o − p1o (c) the boiler is insulated from its surroundings and
so the thermal flux is entirely used to produce the
where α depends on the slope of the pump character- saturated steam;
istic, while p1 and p2 are, respectively, the pressure at (d) the feed water enters the boiler at the constant
the pump inlet and outlet. temperature Tin .
The model determines the steam mass flowrate at
the boiler exit by considering the throttling valve, The thermal flux φT , which is transferred to the water
downstream of the boiler, in choking conditions. inside the drum, provides both the rise in the fluid tem-
perature to the saturation value at the boiler pressure
and the vaporization process to get saturated steam at
2.1 The mass balance of the boiler drum
the outlet of the boiler.
The mass conservation equation applied to the steam Taking the aforementioned assumptions into con-
boiler drum is sideration, the energy balance equation applied to the
present system becomes
dm
ṁw − ṁs = (2)
dt
dU
where ṁw is the liquid mass flowrate, leaving the feed- ṁw htw (p, Tin ) − ṁs hts (p) + φT = (6)
dt
water pump, ṁs is the saturated steam mass flowrate,
while the total mass contained in the drum is given by
where U denotes the total internal energy of the fluid
m = mw + ms = ρw (p)Vw (z) + ρs (p)[V − Vw (z)] (3) (liquid and steam) inside the drum, htw is the total
specific enthalpy of the inlet feedwater, and hts is the
where mw is the mass of liquid inside the drum, till total specific enthalpy of the saturated steam at the
the z-level, and ms is the mass of saturated steam that exit of the boiler.

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 A simple dynamic model and stability analysis of a steam boiler drum 811

The total internal energy U is given by where po is the reference pressure, well defined as
the nominal boiler operating pressure, and d is the
U = mw uw (p) + ms us (p) drum diameter, while the calculation of the quantities
= ρw (p)Vw (z)uw (p) + ρs (p)[V − Vw (z)]us (p) (7) CMP, CMZ, CUP, CUZ, SMM, and SMU is reported in
Appendix 2.
where uw is the specific internal energy of the liquid All the work needed to evaluate the expressions
phase, while us indicates the specific internal energy in the equation (10) has been performed, in the
of the saturated steam. Matlab/Simulink environment, through the use of
Substituting equation (7) into equation (6) one appropriate ‘embedded functions’ and thanks to the
obtains invaluable tool provided free on line that permits the
 direct calculation, within Matlab, of the steam prop-
dρw (p) duw (p) erties [18]. Derivatives of such properties with respect
Vw (z)uw (p) + ρw (p)Vw (z)
dp dp to pressure have been obtained by custom numerical
dρs (p) formulae.
+ [V − Vw (z)] us (p) In the Maple model, the steam properties, such
dp
 as the density or the specific enthalpy as a function
dus (p) dp of the pressure, have been calculated by polynomial
+ ρs (p) [V − Vw (z)]
dp dt expressions of appropriate order [4].


dVw (z) dVw (z) dz
+ ρw (p)uw (p) − ρs (p)us (p)
dz dz dt
  4 THE DYNAMIC SIMULATOR OF THE STEAM
= ṁw htw p, Tin − ṁs hts (p) + φT (8) BOILER DRUM
In the actual case, the kinetic energy is very poor as
The study here presented is thoroughly based on
compared with the thermal energy and enthalpy, so
the Matlab/Simulink software. Once the mathemati-
the former has been always neglected.
cal description of the problem has been written, with
a number of simplifying hypotheses, most of the com-
3 THE NUMERICAL CALCULATION putational work is assigned to the aforementioned
code.
To implement the previously described mathematical The problem being deeply non-linear, the study is
model in the Matlab/Simulink and Maple environ- based on the time-domain approach, writing the state-
ments efficiently, equations (5) and (8) should be space model of the system and solving for selected
arranged for a straightforward implementation within initial conditions and critical parameters. There are
the software [10–12]. Working with non-dimensional two state variables, namely the boiler pressure p and
quantities is also recommended for at least two rea- the water level z inside the drum, which constitute
sons: to overcome numerical problems, arising when also the main outputs of the simulator. In addition to
dealing with quantities orders of magnitude apart, and the boiler design parameters, the main input variables
to give evidence of critical parameters when assessing are: the pressure at the pump inlet, the thermal flux,
the stability or other interesting features of the system. and the bypass ratio; in particular, the thermal flux
The system of the two differential equations (5) and the bypass ratio are important inputs that can be
and (8) can be written in the canonical form controlled from the exterior of the system, by means
⎡ ∗⎤ of suitable devices such as knobs or sliders.
dp
∗ The second simulator, implemented in the Maple
⎢ dt ⎥
⎢ ⎥ = F p∗ (9) software, has been created to accurately study the sys-
⎣ dz ∗ ⎦ z tem dynamic behaviour in the phase diagram that
dt plots the water level z as a function of the pressure
p [10–12, 19, 20].
as follows
⎡ ∗⎤
dp
−1
 5 THE STUDY OF THE BOILER DRUM STABILITY
⎢ dt ⎥
⎢ ⎥ = CMP CMZ
×
SMM
(10)
⎣ dz ∗ ⎦ CUP CUZ SMU
First of all, it appears that the boiler operation, in
dt the absence of regulators, is quite unstable. Even
having defined starred quantities as non-dimensional though a steady solution exists, of course, putting
counterpart of the dimensional ones, that is SMM = SMU = 0, in some cases a limited disturbance
to the inputs of the model determines a pronounced
p z unsteady behaviour of the system. No wonder about it,
p∗ = , z∗ = (11)
po d of course: the fact is well known both from the theory

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812 S Bracco, M Troilo, and A Trucco
and practice. Thanks to the relative slow response of
such systems, unsteadiness could be practically over-
come also by manual intervention; strategies normally
adopted are: to control pressure through thermal flux
or to control the water level by the bypass ratio, or
other actual flowrate regulation devices [4].
After having analysed several simulations, it has
been evident to admit that the boiler drum operational
stability is affected mainly by: the boiler initial oper-
ating conditions, in terms of initial pressure pini , the
pump characteristic, the thermal flux, and the valve.
In the following the boiler drum stability is analysed,
referring to steam boilers having the same design
pressure and the same nominal steam mass flowrate,
keeping constant the following quantities:
(a) the thermal flux (that evaluated at nominal oper-
ating conditions);
(b) the valve characteristic;
(c) the bypass mass flowrate (assumed to be null);
(d) the pressure p1 ;
(e) the water inlet temperature Tin (constant subcool-
ing temperature difference);
and varying:
(a) the initial conditions (pini and zini );
(b) the drum volume V to analyse the stable or unsta-
ble behaviour of boilers characterized by different
sizes;
(c) the slope of the feedwater pump characteristic.
Several simulations have been done, varying the
inputs listed above, for different values of the boiler
design point in terms of pressure and the flowrate. The
most significant results are here reported; in particular,
in section 5.5 three different steam boilers are going to
be analysed:
(a) low-pressure boiler (po = 20 bar, p1 = 2 bar, ṁso =
6 kg/s, Tin = 120.2 ◦ C, φT = 13.7 MW);
(b) intermediate-pressure boiler (po = 70 bar, p1 =
5 bar, ṁso = 40 kg/s, Tin = 151.8 ◦ C, φT = 85.2 MW);
(c) high-pressure boiler (po = 120 bar, p1 = 7 bar,
ṁso = 76.4 kg/s, Tin = 165.0 ◦ C, φT = 151.7 MW).
Before analysing each different case, it is impor-
tant to remark that the system’s stable or unstable
behaviour:
(a) is independent of both the zini value and the
volume V ;
(b) depends on the pump characteristic;
(c) depends on the pini value;
and if the initial pressure pini is higher than the nominal
pressure po the water level inside the drum decreases,
otherwise it increases.
It is possible to individuate a pump characteris-
tic curve, denoted as ‘border line’, which divides the
system stability field into two zones: if the feedwater
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pump has a characteristic, on the mass flow rate–
pressure plane, steeper than the border line the system
is stable for all the pini values, otherwise the system
is stable only if po
pini < pI , where pI is a ‘critical
pressure’ depending on the characteristic slope.
The operational stability of the system has been
studied by analysing the phase plane that shows, on
the pressure–water level plane, the ‘direction field’
plotted by vectors characterized by the two compo-
nents [(dp∗ /dt), (dz ∗ /dt)]. To best analyse the sys-
tem behaviour on the phase plane, the mathematical
model of the steam boiler has been also implemented
in the Maple environment.
Analogous behaviours have been found indepen-
dently of the boiler design parameters po and ṁso . In
the following the different stability fields are presented
considering as test case boilers having 70 bar and
40 kg/s as a nominal pressure and a steam flowrate.
5.1 Case a: pump characteristic steeper than the
‘border line’
This case can be analysed considering three different
conditions.
(a) pini = po , ∀ zini , ∀ V
The system remains in the steady-state condi-
tion (p = po , z = zini ).
(b) pini > po
The water level decreases ∀ zini , ∀ V .
Considering the same values of pini and zini ,
the system always reaches the same new equilib-
rium state (p = pf = po , z = zf ) independently of
the volume V ; the higher the drum volume is, the
longer is the time for reaching the new steady-state
operating condition.
For the same values of V and pini , the sys-
tem reaches the same final pressure (p = pf = po ),
independently of pini , unless the drum has emp-
tied out before; the higher zini is, the higher is the
final level value (z = zf ).
Considering the same values of V and zini , the
system reaches the same final pressure (p = pf =
po ), independently of zini , unless the drum has
emptied out before; the higher pini is, the less high
is the final level value (z = zf ).
This transient operating condition can be
described analysing Fig. 1, where P 0 is the nom-
inal operating point given by the intersection
between the pump characteristic and the valve
characteristic. It is possible to imagine the boiler
operating at pini (B) and suddenly subjected by
the control system to an instantaneous variation
of both the thermal flux (which is reduced to the
nominal value φT ) and the feedwater pump rota-
tional speed (which passes from nB to nA , where
nB > nA ). As a consequence, at the initial time
(t = 0 s) the feedwater mass flowrate decreases
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 A simple dynamic model and stability analysis of a steam boiler drum 813

Fig. 1 A typical transient condition starting at p > po

instantaneously, the pump new operation point plane depicted by Fig. 2. As shown by the figure, the
being A, while the steam mass flowrate is that vertical line at p = po contains infinite stable points,
of point B. Then, for t >0 s, the steam mass hence defined in accordance with the definition of
flowrate decreases, while the water mass flowrate ‘Liapunov stability’ given by Strogatz [12]; all these
increases, both reaching the nominal value corre- points are stable but not globally attracting because
sponding to the nominal state P o . each of them does not attract all trajectories in the
(c) pini < po phase plane. If the initial pressure pini is higher than
The water level increases ∀ zini , ∀ V . the nominal pressure po both the water level inside
Starting from equal values of pini and zini , the the drum and the pressure decrease, otherwise they
system reaches the same new equilibrium state increase. For example, if the system initial condition
(p = pf = po , z = zf ) independently of the volume corresponds to the point indicated as B in Fig. 2, which
V ; the higher the drum volume is, the longer is
the time for reaching the new steady-state oper-
ating condition. If zini is too low, the drum fills
completely before the pressure rises to po .
Considering the same values of V and pini , the
system reaches the same final pressure (p = pf =
po ), independently of pini , unless the drum has
already been completely filled; the lower zini is, the
lower is the final level value (z = zf ).
Considering the same values of V and zini , the
system reaches the same final pressure (p = pf =
po ), independently of zini , unless the drum has
already been completely filled; the higher pini is,
the lower is the final level value (z = zf ).
To explain the transient characterized by pini <
po , it is possible to imagine the system subjected
to an instantaneous variation of both the thermal
flux (which is increased to the nominal value φT )
and the feedwater pump rotational speed (which
passes from nC to nA , where nC < nA ).

The same conclusions about the system stability,

in the case of pump characteristic steeper than the
border line, can be drawn by the analysis of the phase Fig. 2 The phase plane (case a)

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814 S Bracco, M Troilo, and A Trucco

is the same situation described in Fig. 1, the system

reaches the nominal pressure and the water level that
characterizes the point P o at the end of the transient.

5.2 Case b1 : pump characteristic less steep than

the ‘border line’ (system stable not for all
p > po )
In this case, the system is stable for all pini
po but
not stable for all pini > po . In fact there is a pressure
value, denoted by pI (higher than po ), that delimits the
stability field of the system, as it will be better specified
in the following.
Case b1 can be analysed considering the following
different conditions.

(a) pini = po , ∀ zini , ∀ V

The system remains in the steady-state condi-
tion (p = po , z = zini ).
(b) pI > pini > po
The water level decreases ∀ zini , ∀ V . The final Fig. 3 The phase plane (case b1 )
pressure value is the nominal pressure po . The
water mass flowrate increases while the steam to the point indicated as D (pini = 96 bar, zini = 80 per
mass flowrate decreases and, at the end of the cent), the system reaches the point E characterized by
transient condition, they reach the nominal value. z = 0 (empty drum). As a consequence, for pini > pI
The system behaviour is the same analysed in the system becomes unstable.
section 5.1 for pini > po .
(c) pini  pI
The drum empties ∀ zini , ∀ V , and ∀ pini . Both 5.3 Case b2 : pump characteristic less steep than
the pressure and the steam mass flow rate increase the ‘border line’ (system unstable for all
while the water mass flowrate decreases. p > po )
Considering the same values of pini and zini , the
In this case, the system is unstable for all pini > po
system reaches the same state (p = pf  = po , z = 0)
because pI becomes equal to po . The pump char-
independently of the volume V ; the higher V is,
acteristic is less steep than the characteristic curves
the longer is the time for emptying the drum.
It is important to remark that, for these initial
conditions, the drum empties very quickly. This
is due mainly to the thermal flux that is too high
for the system initial operating condition: in fact,
the water mass flowrate, to which the thermal flux
is transferred, becomes too small and so the high
thermal flux causes the pressure increase.
(d) pini < po
The water level increases ∀ zini , ∀ V . The system
behaviour is the same analysed in section 5.1 for
pini < po .

The evaluation of the system stability, for case b1 , can

also be done by analysing the trajectories on the phase
plane reported in Fig. 3: the vertical line at p = po
contains infinite stable points that are not globally
attracting because each of them does not attract all
trajectories. If the initial pressure pini is higher than the
nominal pressure po but lower than pI both the water
level inside the drum and the pressure decrease, oth-
erwise for pini < po they increase. But if pini > pI , the
drum level empties while the pressure increases; for
example, if the system initial condition corresponds Fig. 4 The phase plane (case b2 )

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 A simple dynamic model and stability analysis of a steam boiler drum 815

considered by case b1 . For pini
po , the phase plane The drum empties ∀ zini , ∀ V , and ∀ pini . Both
is divided into two different zones each correspond- the pressure and the steam mass flowrate increase,
ing to a different dynamic behaviour of the system, as while the water mass flowrate decreases. The
described in the following. system is greatly unstable.
Case b2 can be analysed considering these different (c) po > pini > pII
conditions. The water level increases while the pressure
decreases. The water mass flowrate increases while
(a) pini = po , ∀ zini , ∀ V the steam mass flowrate decreases. The system
The system remains in the steady-state condi- tends to reach a new state (p = pf = pII , z = zf )
tion (p = po , z = zini ). unless the drum has already been completely
(b) pini > po filled.

Fig. 5 The system internal energy (case a)

Fig. 6 The system internal energy (case b1 )

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816 S Bracco, M Troilo, and A Trucco

(d) pini < pII
Both the water level and the pressure increase.
The water mass flow rate decreases while the steam
mass flow rate increases. The system tends to reach
a new state (p = pf = pII , z = zf ) unless the drum
has already been completely filled.
The same considerations can be drawn by the ana-
lysis of the phase plane depicted in Fig. 4. As shown by
the figure, the vertical line at p = po contains infinite
unstable points. If the initial pressure is not much
higher than po the system pressure increases and
the drum empties very quickly. On the other hand if
the initial pressure is not much lower than po , the
system pressure decreases, showing a trend towards
pII , while the water level increases. For example, if
the system initial condition corresponds to the point
indicated as F (pini = 68 bar, zini = 50 per cent) the sys-
tem reaches the G condition characterized by z = 1
(full drum).

Fig. 7 The system internal energy (case b2 )

Fig. 8 The ‘stability field’ (po = 70 bar)

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 A simple dynamic model and stability analysis of a steam boiler drum
Figure 4 shows also that if the initial pressure is lower
than pII the system pressure rises, with a trend towards
pII , and the water level increases.
5.4 The system internal energy
As defined by equation (7) U denotes the total internal
energy of the fluid (liquid and steam) inside the drum.
It is useful to evaluate the system internal energy trend
during the transient operating conditions investigated
in sections 5.1–5.3.
In particular, Fig. 5 refers to case a described in
section 5.1. The figure indicates, by a circular sym-
bol, that if pini > po the water level inside the drum
decreases while it increases for pini < po . Then it is
possible to notice that:
(a) if pini > po , the internal energy U decreases from
the initial value to a new lower equilibrium value
(convex curve);
(b) if pini < po , the internal energy U increases from
the initial value to a new higher equilibrium value
(concave curve).
It is clear that U depends mainly on the water quan-
tity, contained into the drum, instead of the produced
steam: in fact when the water level rises U increases,
as shown by Fig. 5.
Figure 6 refers to case b1 described in section 5.2. The
figure shows that if pini > po the water level inside the
drum decreases while it increases for pini < po . Then:
Fig. 9 The ‘stability field’ (po = 20 bar)
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817
(a) if pini > pI , the internal energy U decreases without
reaching a new equilibrium value (concave curve)
and the drum empties;
(b) if pI > pini > po , the internal energy U decreases
from the initial value to a new lower equilibrium
value (convex curve);
(c) if pini < po , the internal energy U increases from
the initial value to a new higher equilibrium value
(concave curve).
The system is very unstable in case b2 , as shown by
Fig. 7, which indicates that:
(a) if pini > po , the internal energy U decreases with-
out reaching a new equilibrium value (concave
curve) and the drum empties;
(b) if pII < pini < po , the internal energy U increases
(convex curve quasi-linear);
(c) if pini < pII , the internal energy U increases (con-
cave curve quasi-linear).
For pini < po , the internal energy U does not reach
an equilibrium value because the drum becomes
completely full.
5.5 The ‘stability field’
A parametric and phenomenological study of the
steam boiler drum stability has been done considering
different pump characteristics, as described in sec-
tions 5.1–5.3, and varying the boiler nominal pressure;
the aim of the analysis has been that of evaluating if
the system stability depends also on the value of the
Proc. IMechE Vol. 223 Part A: J. Power and Energy
818 S Bracco, M Troilo, and A Trucco
Fig. 10 The ‘stability field’ (po = 120 bar)
designed operating pressure: three different pressures
are here compared.
Figure 8 shows, on the mass flowrate–pressure
plane, the valve characteristic and three different
pump characteristics (cases a, b1 , and b2 ) for the boiler
designed for a nominal pressure of 70 bar. It is pos-
sible to distinguish the light grey area from the dark
grey one, where the first contains the pump character-
istic curves, or only a portion of them, which make the
system stable: they are the curves denoted by case a
and case b1 , the last considered only for pressure val-
ues lower than pI . On the other hand, the dark grey
area contains the curves denoted by case b2 and case
b1 , the last considered only for pressure values higher
than pI . In consequence of what has been explained in
sections 5.1–5.3 about the system stability, the light
grey area represents the boiler drum ‘stability field’
while the dark grey area is considered to be an unstable
zone.
As shown by Fig. 9, a steam boiler characterized by
a low nominal pressure, specifically 20 bar, is more
stable than a boiler designed at 70 bar and becomes
unstable only if the pump characteristic slope is very
slight. On the contrary, the system is very unstable
if designed at elevated pressure as shown by Fig. 10,
which refers to a steam boiler characterized by a
nominal pressure equal to 120 bar.
5.6 The steam boiler control system
According to the actual experience, the simulator
makes clear a link between the thermal flux required
to obtain a target pressure and the bypass ratio
needed to keep the water level within a suitable
Proc. IMechE Vol. 223 Part A: J. Power and Energy
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range, as suggested by safety rules [1, 3, 4, 15, 21].
A suitable control system has been introduced in
the simulator, by means of two PID (Proportional–
Integral–Derivative) regulators:
(a) PID 1 controls the thermal flux, on the basis of
the difference between the actual and the target
pressure;
(b) PID 2 controls the bypass ratio on the basis of the
difference between the actual and the target water
level.
6 CONCLUSIONS
A simple mathematical model of steam boiler drum
dynamics has been developed by means of the
mass and energy balance equations, written in non-
dimensional form. The pressure and the water level
inside the boiler drum are assumed as state variables
while the main inputs of the mathematical model are:
the boiler design parameters, the thermal flux, and the
feedwater bypass ratio. On the other hand, the main
outputs of the model are: the boiler pressure, the steam
mass flowrate, the water level, and the internal energy
of both the liquid phase and the steam contained into
the system.
The mathematical model has been implemented
using both the Matlab/Simulink software and the
Maple mathematical tool. Several simulations have
been done to evaluate the system stability. The results
here reported show that the boiler operational stability
is affected mainly by the boiler initial operating con-
ditions, the designed parameters, the feedwater pump
characteristic, the thermal flux, and the valve arranged
JPE783
 A simple dynamic model and stability analysis of a steam boiler drum 819

downstream of the boiler. The system stability has
been analysed on the phase plane by a paramet-
ric and phenomenological study considering different
pump characteristics and varying the boiler nominal
pressure.
20 Birkhoff, G. and Rota, G. C. Ordinary differential equa-
tions, 1989 (John Wiley & Sons, New York, NY).
21 Choi, J. Y. and Van Landingham, H. F. Empirical data
modelling and state estimation for a steam boiler system.
IEE, 1995, 5, 3943–3948.

© Authors 2009
APPENDIX 1
REFERENCES
Notation
1 Ricard, J. Équipement thermique des usines génératrices
d’énergie électrique, 1962 (Dunod, Paris).
d diameter (m)
2 Annaratone, D. Pressure vessel design, 2007 (Springer- h specific enthalpy (J/kg)
Verlag, Berlin, Heidelberg). m mass (kg)
3 Kern, D. Q. Process heat transfer, 1990 (McGraw-Hill, New ṁ mass flowrate (kg/s)
York). n rotational speed (r/min)
4 Adam, E. J. and Marchetti, J. L. Dynamic simulation of p pressure (Pa)
large boilers with natural recirculation. Comput. Chem. t time (s)
Eng., 1999, 23, 1031–1040. T temperature (K)
5 Flynn, M. E. and O’ Malley, M. J. A drum boiler model for u specific internal energy (J/kg)
long term power system dynamic simulation. IEEE Trans. U internal energy (J)
Power Syst., 1999, 14(1), 209–217.
V volume (m3 0
6 Franke, R., Krüger, C., and Rode, M. On-line opti-
mization of drum boiler startup. In Proceedings of the
z level (m)
3rd International Modelica Conference, Linköping, 2003,
287–296. α slope coefficient
7 Kim, T. S., Lee, D. K., and Ro, S. T. Dynamic behaviour ρ density (kg/m3 )
analysis of a heat recovery steam generator during start- φ thermal flux (W)
up. Int. J. Energy Res., 2000, 24, 137–149.
8 Kim, T. S., Lee, D. K., and Ro, S. T. Analysis of thermal
stress evolution in the steam drum during start-up of a Subscripts
heat recovery steam generator. Appl. Thermal Eng., 2000,
20, 977–992. f final
9 Alobaid, F., Postler, R., Ströhle, J., Epple, B., and in inlet
Hyun-Gee, K. Modelling and investigation start-up pro- ini initial
cedures of a combined cycle power plant. Appl. Energy,
s steam
2008, 85, 1173–1189.
t, T total
10 Lynch, S. Dynamical systems with applications using
maple, 2001 (Birkhäusen, Boston, MA). w water
11 Jordan, D. W. and Smith, P. Nonlinear ordinary differen-
tial equations, 1991 (Clarendon Press, Oxford). Superscripts
12 Strogatz, S. H. Nonlinear dynamics and chaos, 1994
(Addison-Wesley Publishing Company, Reading, Mas- ◦ nominal value
sachusetts). ∗ non-dimensional
13 Greitzer, E. M. The stability of pumping systems. J. Fluids
Eng., 1981, 103, 193–242.
14 Kakaç, S. and Bon, B. A review of two-phase flow APPENDIX 2
dynamic instabilities in tube boiling systems. Int. J. Heat
Mass Transf., 2008, 51, 399–433.
15 Ordys, A. W., Pike, A. W., Johnson, M. A., Katebi, R. M., In the following, the notations [ ]∗w,p and [ ]∗s,p signify
and Grimble, M. J. Modelling and simulation of power quantity pertaining to water (subscript w) or to steam
generation plants, 1994 (Springer-Verlag, Berlin). (subscript s), eventually derived with respect to the
16 Bohn, M. and Kreith, F. Principles of heat transfer, 2000 pressure (subscript p), and made non-dimensional by
(Thomson Learning College, Pacific Grove, California). proper choice of reference. These last were:
17 Bejan, A. Convection heat transfer, 1995 (Wiley, NewYork,
NY). (a) ρwo the density of saturated water at the reference
18 Holmgren, M. X Steam for Matlab, 2006, available from pressure;
http://www.x-eng.com. (b) uwo the specific internal energy of saturated water
19 Tabor, M. Chaos and integrability in non-linear dynam- at the reference pressure;
ics, 1989 (John Wiley & Sons, New York). (c) ṁso the steam nominal mass flowrate.

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820 S Bracco, M Troilo, and A Trucco

Moreover, it has been posed CMZ = f,z∗ (z ∗ )(ρw∗ − ρs∗ ) (17)

∗ ∗
Vw (z) CUP = f (z )(ρw,p uw∗ + ∗
uw,p ρw∗ )
f (z ∗ ) = (12)
V + [1 − f (z ∗ )](ρs,p
∗
us∗ + us,p
∗
ρs∗ ) (18)
df (z ∗ ) 1 dVw (z)
f,z∗ (z ∗ ) = ∗
= (13) CUZ = f,z∗ (z ∗
)(ρw∗ uw∗ − ρs∗ us∗ ) (19)
dz V dz ∗
1
that could be developed as SMM = (ṁ∗ − ṁs∗ ) (20)
tR w
1   1
SMU = (ṁw∗ ht∗w − ṁs∗ ht∗s + φT∗ ) (21)
f (z ∗ ) = arccos(1 − 2z ∗ ) − 2(1 − 2z ∗ ) z ∗ (1 − z ∗ ) tR
π
(14)
where
8 ∗
f,z∗ (z ∗ ) = z (1 − z ∗ ) (15) ρwo V
π tR = (22)
ṁso
After some algebra one obtains
can be easily taught as a characteristic time constant
CMP = f (z ∗ )(ρw,p
∗ ∗
− ρs,p ∗
) + ρs,p (16) of the dynamic system.

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