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I. INTRODUCTION
Boiler burner management is a complicated control system
which requires continuous monitoring and inspection at
frequent intervals. There are possibilities of errors at
measuring and various stages involved with operators. In
order to automate the operation & control of boiler burner
management system and subsiding human intervention, PLC
based control system is a good option. The internal storage of
instructions of a PLC is used for implementing functions and
thus to control various types of equipment & process variables
through digital and or analog input or output modules [3-4].
The main control strategies in boiler burner management
system are primary control and combustion control. Primary
control allows fuel to flow only when all of the safe
conditions for fuel ignition are met. The combustion control
regulates furnace fuel and air ratio within limits for
continuous combustion and stable flame throughout the
demand operating limits of the boiler. The major steps in
boiler burner management system are checking boiler self
protection for start up, pre-purging, pilot trial and ignite, main
burner trial and ignite, maintaining air/fuel ratio according to
the load demand and post-purging after burner stop [1].
The ease of programming and simulation on the Siemens
S7-200 ensure accuracy of the system and reducing the
implementation time and cost. The conventional relay based
boiler burner management system of STG Unit-2 of Eastern
Refinery Limited; Bangladesh is taken as the reference system
model in this paper. PLC based control systems are now
widely used in the industries like; power plants, oil refineries,
process plant, and chemical industries etc[4]. It is anticipated
that this paper will be effective & helpful to keep pace with
the growing needs for PLC based automatic operation &
control in the sector of oil & energy. Fig. 1 Gas burner management system of a boiler [1]
978-1-4673-1436-7/12/$31.00 2012 IEEE
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A. Initial Start up by Checking for Pre purging FCV (Gas) MCR O2 FCV (Air)
At the initial start up the pre purging system are checked. FRA <0.95. <0.85. FRT
During this checking system mainly check the combustion air
flow, respective interlock, drum water level, fuel gas pressure FT- Flow Transmitter, PT- Pressure Transmitter, FIC- Flow Indication &
and alarm condition. If all the criteria for start up protection Controller, PIC- Pressure Indication & Controller, LSS- Low Level Set,
are safe condition than the air damper open to the pre purge HSS- High Level Set, AFR- Air Fuel Ratio, FCV- Fuel Control Valve
condition (10~15% opening) and illuminated the Furnace
Fig. 2 Logic schematic diagram of Air/ Fuel Ratio control of a boiler
ready to pre-purge lamp.
F. Burner Fail or Stop and Furnace Post-purging
B. Furnace Pre-purging
The gas burner will continue to operate until it is stopped
After illumination of the Furnace ready to pre-purge intentionally by the Gas Stop switch or by interlock failure,
lamp, the furnace pre-purging will be started by the Burner or by flame failure. After stop or fail of pilot or main gas
Start Switch. There is fixed time for furnace pre-purging. burner or flame fail after trial of burner the furnace post-
This is done to remove gases that may cause explosion during purging system will initiated & continue for a fixed time.
furnace firing.
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Fig. 3 Process flow diagram of gas burner management system Fig. 4 Process variable declaration for PLC system
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VII. CONCLUSIONS
To cope with the technological advancement and to ensure
higher efficiency, effectiveness and reliability in a more
economical way, the system presented in this paper would be
a great scope. It will also provide better flexibility in
customization of operation and control with minimum effort.
The paper has furnished itself to study the integral parts of the
entire processd, their implementation and the problems that
can occur have also been investigated with due importance.
ACKNOWLEDGMENT
The authors would like to thank Mr. Sharafat Ali, AGM,
Dept. of Inst. & Comm., Eastern Refinery Ltd., Bangladesh
and Md. Ali Zulquarnain, Member, Planning, Bangladesh
Atomic Energy Commission for their valuable guidelines,
review and comments to complete the task.
REFERENCES
[1] Operation Guideline of Boiler of STG Unit-2 of Eastern Refinery
Limited, Chittagong, Bangladesh.
[2] Warnock, Ian G., Programmable Controllers: Operation and
Application, Prentice-Hall, Englewood Cliffs, NJ, 1988.
[3] SIMATIC Step 7-MicroWIN V4.0.5.08, PLC Software
[4] P. K. S. Khan, A. A. Noman and R. K. Dey, PLC Based Operation of
Three Natural Gas Generator Models- A Learing Aid for
Undergraduate Students Third International Conference on Power
Systems, Kharagpur, INDIA December 27-29, 2009.