- Conference Article
- 10.1109/ica65945.2025.11252007
Modelling and Controller Design Using NARX and Nonlinear MPC Based on Genetic Algorithm for Drum-Boiler Level Control System
- Aug 27, 2025
- Muhammad Zulsyahmie Mohd Zaki + 2 more +2
In a steam power plant, electricity is generated by a turbine-generator system driven by high-pressure steam produced by a drum-boiler. Changes in power output cause variations in the heating rate and water level, which, if not properly controlled, can lead to system shutdown. Water level control in such systems is still commonly performed manually or with PID controllers, which are less suitable due to the system’s nonlinear, MIMO characteristics and multiple operating points. Nonlinear Model Predictive Control (NMPC) has recently been adopted as it can handle these characteristics, but gradient-based optimization methods used in NMPC are prone to getting stuck in local optima. Genetic algorithms, as a gradient-free optimization method, offer an alternative by using a population-based approach, making them more capable of escaping local optima. This study aims to: (1) develop a Nonlinear Auto Regressive with Exogeneous Input (NARX) model representing the nonlinear drum-boiler system, and (2) design an NMPC controller based on genetic algorithms and compare its performance with NMPC using the interior-point method and PID gain scheduling in drum-boiler water level control system. The research involves collecting drum-boiler system data from industry, modeling with NARX, designing the genetic algorithm-based NMPC controller, tuning its parameters, and evaluating its performance. The challenge for the controller is to maintain water level despite varying power demands. The resulting NARX model achieved an RMSE of 5.2105 for training data and 3.6446 for testing data. The genetic algorithm-based NMPC maintained the water level effectively with an RMSE of 5.1944 and total control signal energy of 454590 (Ton/H)<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup>. The interior-point NMPC yielded an RMSE of 13.0492 and energy of 264990 (Ton/H)<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup>, while the PID gain scheduling controller had an RMSE of 13.5215 and energy of 1016600 (Ton/H)<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup>. This result demonstrates that the NMPC with genetic algorithm provides the best performance in maintaining water level stability with efficient control effort.
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