BOILER CONTROLS

Operational Philosophy,
Control Logics & Instruments

AT HOTEL SURYA PALACE, VADODARA

Hemendra Dholakia & Ansuman Sen Sharma

What is our
objective?

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 Objective

Significance of various process

parameters in Boiler

Objectives of the principal boiler

control functions

Principles and design concepts of

important controls

Basics of Instruments used for

measuring process parameters
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 Objective

Setting up and tuning of boiler control

loops

Safety control and start-up interlock

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Steam Generating System

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 Steam Generator

The steam generator is a plant for energy

conversion and transfer

Conversion of Heat Energy from Chemical

energy of fuel

Transfer of Heat energy into water &

Steam

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 Steam Generating System
PF Boiler

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 GEN

IP LP
HP

Attemperator ID Fan

ESP

Economizer FD Fan & PA Fan

APH

Turbine Extraction
RH
SH-1 SH-2

Deaerator

LP Heater
Down comer
Riser

Riser

HP Heater

Boiler Feed Pump

FROM FUEL HANDLING Cond. Extraction Pump

SYSTEM

From Turbine
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Feed Water System:

Boiler Circulating Water & Steam System :

Fuel System :

Combustion Air System :

Flue Gas System :

Steam System :

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 You cannot Manage what you
cannot Measure

(Accurately)

- Jack Welch, CEO, General Electric

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 Parameters Measured:

Pressure

Temperature

Flow

Level

Gas composition

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Boiler Feed Water System:

PT
PT LT TE
LT

Economizer

SH-1 SH-2
TE

TE

TE Deaerator

LP Heater
Down comer
Riser

Riser

HP Heater
FT
PT

TE
TE

Boiler Feed Pump

Cond. Extraction Pump

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 Air and Gas System
TE TE

AT
PT FT

ID Fan

ESP

FD Fan

APH

TE PT

PT

TE

PT 14
Three Questions:

How do we Measure?

Why do we measure?

How the control works?

Lets start by understanding the

fundamental of measurement with help of
Instrumentation

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P&ID
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 Piping & Instrumentation Diagram
The P&ID is an important document establishing the
blueprint for every process.
P&ID drawings outline
the plants operation,
identify/describe the role of equipment,
show all the interconnecting pipe lines.
The instrumentation part provide the main
schematic of how plant processes are controlled to
facilitate a smooth and safe operation.
Symbolic presentation of the various equipment,
devices and control concepts that go into our plants.
Schematic presentation of functional relation of
piping, instrumentation and system equipment
components
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 Piping & Instrumentation Diagram
understanding of P&ID interpretation is
important to virtually every discipline
involved in a process plant from process
engineering and detail design through
construction, commissioning/start-up,
operations and management.

P & ID talks through symbols, about

What is that device?
Where is it located?
Why is it there? ( especially
instrumentation)

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 Piping & Instrumentation Diagram
A P&ID should typically include:
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings, sampling
lines, reducers and increasers etc.
Permanent start-up and flush lines
Flow directions
Interconnections references
Control inputs and outputs, interlocks
Annunciation inputs
Computer control system input
Vendor and contractor interfaces
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 Piping & Instrumentation Diagram
Identification of components and subsystems
delivered by others
Intended physical sequence of the equipment
Equipment rating or capacity

Typical Exclusions are :

Instrument root valves
control relays
manual switches
primary instrument tubing and valves
pressure temperature and flow data
elbow, tees and similar standard fittings
extensive explanatory notes

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P& I Diagram Mechanical Equipment
Symbols

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P&I Diagram Process valve symbols

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 P&I Diagram Line symbols

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P&I Diagram Line Connection symbols

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P&I Diagram Instrumentation symbols

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P&I Diagram Instrumentation symbols

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 P&I Diagram Instrumentation symbols
Valve Actuator Types

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 P&I Diagram Instrumentation symbols
Valve Failure Modes

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 P&I Diagram Instrumentation symbols
Flow Measurement Devices Flow left to right

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 P&I Diagram Instrumentation Tagging

The letters on the first line are in accordance with

ISA standard 5.1

legend
P&I Diagram Instrumentation Tagging

P First Letter stands for Pressure

D Second letter is a modifier for the first and

stands for Differential

I Third letter stands for Indicating

T Fourth letter stands for Transmitter

1703 is the loop number

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P&I Diagram Instrumentation Tagging
 The ISA S5.1
recommended
tagging system

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Symbols in Piping & Instrumentation
Diagram

For every P&ID set there are Legend Sheets

Legend sheets also called lead sheets narrate

symbols used

Study of P&ID in conjunction with Legend

sheets develop understanding of the Plant

Example-PIDs-and-Lead-Sheets

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 SUMMARY : P&I DIAGRAMS
Schematic presentation of functional relation of
piping, instrumentation and system equipment
components
For every discipline involved in a process plant from
process engineering and detail design through
construction, commissioning/start-up, operations and
management.
P & ID talks about
What is that device?
Where is it located?
Why is it there?
Standardized SYMBOLS form the language of the
diagram.
Legend Sheets or Lead Sheets explain symbols used
that develop understanding of the plant
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LOOP DIAGRAM AS PER SAMA STANDARD

Scientific Apparatus Makers Association (SAMA)

Functional control diagrams for the power industry are
often referred to as SAMA diagrams.
Symbols categorized as

Enclosure symbols

Signal continuation symbols

Signal processing symbols

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SAMA Enclosure Symbols

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SAMA Signal Continuation Symbols

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SAMA Signal Processing Symbols

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 SAMA Loop Diagram

Measuring Device
(Transmitter) Continuously variable
signal

Proportional + Integral
Manually varied Automatic controller
set point
Auto/Manual transfer

Manually operated
Variable signal Generator Output Generator in
Manual Mode

Final Control Element

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ISA v/s SAMA Diagram
Transmitter

Controller

Auto/ Manual signal

selection/ operation

Final
Control
Element
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