BOILER PLANT OPERATION

IDC Technologies Tech Briefs (Mechanical Engineering)

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INSTRUMENTATION USED ON A SHELL BOILER

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Fire-tube type boiler reviewed for simplicity Instrumentation:

Items that provide operator with indication of condition within the boiler Ensure indications are within SAFETY limits and design OPERATIONAL PARAMETERS
Operating

level

pressures, temperatures, flows, water

M4-2

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INSTRUMENTATION
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PRESSURE GAUGE
Normally Bourdon type of gauge Large with large numbers Graduated approximately double the pressure of safety valve setting, not < than 1,5 Located on top of shell/drum on an independent nozzle Supplied with a siphon (pigtail) to develop a water seal Must be calibrated at least once a year
M4-3

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INSTRUMENTATION
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PRESSURE TRANSMITTER
Where a remote pressure indicator required, an electrical signal used Separate transducer Mounted on same branch as pressure indicator

M4-4

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INSTRUMENTATION
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LEVEL COLUMNS
Provides VISIBLE water level indication Minimum 25NB pipe line connecting column to boiler TWO water gauge glasses for boiler pressure >28 bar Normally simple gauge glass type
Installed

such that with lowest reading on gauge glass, 75 mm water over highest point of tubes Visible range of water level approx. 125mm from NWL

Daily routine blow down to remove debris, scale, sludge

M4-5

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Typical Water Level Gauge for Low Pressure Boiler

M4-6

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Electronic and digital water level indicators

M4-7

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INSTRUMENTATION
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LEVEL SWITCHES
Float type (Mobrey) Single-element control (on-off or modulating) Normally located in an external chamber TWO chambers mandatory
Low

level alarm Low-low-level shut down

Weekly routine test to check correct operation of switches

M4-8

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INSTRUMENTATION
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TEMPERATURE MEASUREMENT
Flue gas exit temperature An increase indicates fouling problems Thermocouples, insulated from gas sampling tube

M4-9

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TYPICAL PROCESS AND INSTRUMENTATION DIAGRAM (P&ID)

COAL FIRED LP BOILER

Instrumentation Control loops

OIL OR GAS FIRED LP BOILER

Instrumentation Control loops

M4-10

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CONTROL AND SYSTEM OPERATING PHILOSOPHY

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CONTROLS :
Regulate the various quantities indicated by the instruments Shut down (with interlocks) the plant if parameters exceeded Manual operation to sophisticated automatic computer operation (DCS)

M4-11

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CONTROL AND SYSTEM OPERATING PHILOSOPHY

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To control a boiler, following quantities require to be regulated :

Fuel/air ratio to maintain optimum combustion conditions Water flow to match steam flow from boiler Steam flow and pressure to regulate heat input Combustion chamber pressure (balanced draught boilers) Combustion safety

M4-12

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COMBUSTION CONTROL
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Manual control cannot continuously control combustion in a reliable and efficient manner Automatic control systems used :
maintains fuel-air ratio to furnace at an optimum maintains a relatively constant steam pressure

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Combustion control mechanisms vary slightly depending on fuel fired No matter what fuel, four aspects that are regulated:
Air

supply; Fuel supply; Ratio of fuel to air; Flame safety

M4-13

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COMBUSTION CONTROL
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Two basic types of combustion control systems:

Positioning Metering

Pneumatic or Electrical control drives

M4-14

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COMBUSTION CONTROL
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Positioning Type Control:

Designed to control based on a change in steam pressure Components :
Master

steam pressure controller Fuel control valve with cam for oil / gas or feed control drive for coal Combustion air fan inlet vanes / outlet damper operator

Simplistic
cannot

maintain fuel air ratio at optimum over full load range

M4-15

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COMBUSTION CONTROL
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Metering Type controller :

Components as per Positioning type with :
Fuel

flow measuring device Air flow signal

Fuel-air ratio is controlled by a relay Capable of adjusting fuel-air ratio and where fuel pressure may vary

M4-16

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General Selection Chart for Combustion Control Systems

Type of Fuel Type of Control System
Modulating positioning Full metering (Steam /air flow) Full metering with Oxygen compensation Modulating positioning Full metering (Steam / air flow) Full metering with Oxygen compensation

Steam Generation Capacity Ranges (kg/hr)

to 27 500 18 000 36 000 above 36 000 to 11 500 11 500 45 000 above 45 000
M4-17

Coal

Fuel Oil & Gas

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STEAM PRESSURE CONTROL

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Main purpose of a steam boiler is to produce steam within a definite pressure range Steam pressure dictated by :
process plant steam demand heat input to the boiler furnace

Pressure fluctuates between minimum and maximum settings

M4-18

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STEAM PRESSURE CONTROL

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Modulating control linked to upper and lower pressure limits

On-off pressure switch low or high fire burner Definite limitation exists on burner minimum firing rate
turndown

ration varies : 4:1 gas; 2:1 oil

M4-19

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FEED WATER SUPPLY CONTROL

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Purpose is to provide sufficient feed water flow to ensure all heat transfer surfaces are cooled with water Visible water level provided by :
Two simple gauge glasses More sophisticated devices (electrodes, capacitance or conductivity type)

Water sensor controls :

Normally two independent Float operated Thermostatic
M4-20

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FEED WATER SUPPLY CONTROL

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Typical arrangements of feed water plant :

Two or more pumps (standby) from hot well tank (10-15 min. storage)
Either Check

on-off operation or a feed valve station

Feed valve station :

valve Stop valve Feed control valve c/w isolation and bypass valves
M4-21

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FEED WATER CONTROL SYSTEMS

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ON AND OFF FEED WATER PUMP

Small boilers with relatively large water storage, slow load changes Typical float operated water level controller, mounted at water line Also serves either as low-water level alarm or low water cut off

M4-22

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FEED WATER CONTROL SYSTEMS

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MODULATING LEVEL CONTROLLERS

Boilers with relatively small water volume relative to steam demand Thermostatic type regulator feeds water continuously to the boiler, stabilising the water level THREE types of modulating controllers :
Single

Element Level Controller Two Element Level Controller Three Element Level Controller
M4-23

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Schematic of Three Element Level Controller

M4-24

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SOME CONSIDERATIONS REGARDING WATER LEVEL CONTROL

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Rapid changes in steam flow rate can cause SURGING of the water level and carry-over VERY IMPORTANT that the :
steam qualities characteristics of boiler (size, firing system) MUST be properly matched to the OPERATING characteristics of water level controlling system

Highest water level, NWL, lowest level for safe operation should be MARKED on boiler outer shell
M4-25

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FURNACE PRESSURE CONTROL

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Only really required on coal fired boilers with FD and ID fan Required to :
prevent excessive negative pressure and uncontrolled air entering furnace products of combustion to percolate back to coal supply

Controller transmitter range not too narrow

typically +250 to 1250 Pa ideal control point 100 Pa
M4-26

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AUTOMATIC CONTROLS
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Instrumentation employed same as that for manual operation Rapid and continuous development of electronic control systems means systems for boilers are now DIVERSE Selection shall depend on owner / purchaser present complexity of control systems
M4-27

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AUTOMATIC CONTROLS
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ASPECTS that do not vary whether auto/manual :

Principles of operation Areas of control (control loops) Direct reading of instruments Safety devices and interlocks Selector for manual or automatic

M4-28

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