Boiler Control Systems Engineering, Second Edition
4.5/5
()
About this ebook
Related to Boiler Control Systems Engineering, Second Edition
Related ebooks
Thermal Power Plant: Pre-Operational Activities Rating: 4 out of 5 stars4/5Boiler Dynamics and Controls Rating: 0 out of 5 stars0 ratingsFundamentals of Process Control Theory, 3rd Edition Rating: 4 out of 5 stars4/5Measurement and Control Basics, 4th Edition Rating: 4 out of 5 stars4/5Boiler Operation Engineer Exam, Interview Q&A, Terminology, and Boiler Overview Rating: 0 out of 5 stars0 ratingsPlant and Process Engineering 360 Rating: 4 out of 5 stars4/5Condensed Handbook of Measurement and Control, 3rd Edition Rating: 4 out of 5 stars4/5Control System Design Guide: Using Your Computer to Understand and Diagnose Feedback Controllers Rating: 4 out of 5 stars4/5Advanced Distillation Technologies: Design, Control and Applications Rating: 0 out of 5 stars0 ratingsMajor Process Equipment Maintenance and Repair Rating: 4 out of 5 stars4/5Maintenance Fundamentals Rating: 5 out of 5 stars5/5Operator’S Guide to Centrifugal Pumps: What Every Reliability-Minded Operator Needs to Know Rating: 2 out of 5 stars2/5Gas Turbine Engineering Handbook Rating: 4 out of 5 stars4/5A Practical Guide to Piping and Valves for the Oil and Gas Industry Rating: 5 out of 5 stars5/5Safety Instrumented Systems Verification – Practical Probabilistic Calculations Rating: 4 out of 5 stars4/5Advanced Process Control: Beyond Single Loop Control Rating: 0 out of 5 stars0 ratingsMachinery Component Maintenance and Repair Rating: 5 out of 5 stars5/5Maximizing Machinery Uptime Rating: 0 out of 5 stars0 ratingsHydraulics and Pneumatics: A Technician's and Engineer's Guide Rating: 4 out of 5 stars4/5Applied Process Design for Chemical and Petrochemical Plants: Volume 1 Rating: 4 out of 5 stars4/5Reciprocating Compressors:: Operation and Maintenance Rating: 4 out of 5 stars4/5Compressor Performance: Aerodynamics for the User Rating: 0 out of 5 stars0 ratingsGas Turbines: A Handbook of Air, Land and Sea Applications Rating: 4 out of 5 stars4/5Heat Exchanger Equipment Field Manual: Common Operating Problems and Practical Solutions Rating: 4 out of 5 stars4/5Steam Generation from Biomass: Construction and Design of Large Boilers Rating: 5 out of 5 stars5/5Boiler Operator's Exam Prep Guide (PB) Rating: 0 out of 5 stars0 ratingsSuccessful Instrumentation and Control Systems Design, Second Edition Rating: 5 out of 5 stars5/5Thermal Power Plant: Design and Operation Rating: 4 out of 5 stars4/5Power Plant Performance Rating: 3 out of 5 stars3/5
Technology & Engineering For You
Electrical Engineering 101: Everything You Should Have Learned in School...but Probably Didn't Rating: 5 out of 5 stars5/5The 48 Laws of Power in Practice: The 3 Most Powerful Laws & The 4 Indispensable Power Principles Rating: 5 out of 5 stars5/5The Art of War Rating: 4 out of 5 stars4/580/20 Principle: The Secret to Working Less and Making More Rating: 5 out of 5 stars5/5How to Disappear and Live Off the Grid: A CIA Insider's Guide Rating: 0 out of 5 stars0 ratingsThe CIA Lockpicking Manual Rating: 5 out of 5 stars5/5The ChatGPT Millionaire Handbook: Make Money Online With the Power of AI Technology Rating: 0 out of 5 stars0 ratingsThe Homeowner's DIY Guide to Electrical Wiring Rating: 5 out of 5 stars5/5Motorcycling For Dummies Rating: 4 out of 5 stars4/5The Big Book of Hacks: 264 Amazing DIY Tech Projects Rating: 4 out of 5 stars4/5A Night to Remember: The Sinking of the Titanic Rating: 4 out of 5 stars4/5The Systems Thinker: Essential Thinking Skills For Solving Problems, Managing Chaos, Rating: 4 out of 5 stars4/5Smart Phone Dumb Phone: Free Yourself from Digital Addiction Rating: 0 out of 5 stars0 ratingsUltralearning: Master Hard Skills, Outsmart the Competition, and Accelerate Your Career Rating: 4 out of 5 stars4/5The Big Book of Maker Skills: Tools & Techniques for Building Great Tech Projects Rating: 4 out of 5 stars4/5My Inventions: The Autobiography of Nikola Tesla Rating: 4 out of 5 stars4/5Broken Money: Why Our Financial System is Failing Us and How We Can Make it Better Rating: 5 out of 5 stars5/5Artificial Intelligence: A Guide for Thinking Humans Rating: 4 out of 5 stars4/5Logic Pro X For Dummies Rating: 0 out of 5 stars0 ratingsU.S. Marine Close Combat Fighting Handbook Rating: 4 out of 5 stars4/5Understanding Media: The Extensions of Man Rating: 4 out of 5 stars4/5The Fast Track to Your Technician Class Ham Radio License: For Exams July 1, 2022 - June 30, 2026 Rating: 5 out of 5 stars5/5The Art of War Rating: 4 out of 5 stars4/5On War: With linked Table of Contents Rating: 4 out of 5 stars4/5The Wuhan Cover-Up: And the Terrifying Bioweapons Arms Race Rating: 0 out of 5 stars0 ratingsThe Total Inventor's Manual: Transform Your Idea into a Top-Selling Product Rating: 1 out of 5 stars1/5
Reviews for Boiler Control Systems Engineering, Second Edition
15 ratings1 review
- Rating: 5 out of 5 stars5/5good book for ever I love it pls refere it
Book preview
Boiler Control Systems Engineering, Second Edition - G.F. (Jerry) Gilman
Edition
BOILER CONTROL
SYSTEMS ENGINEERING,
Second Edition
G. F. (Jerry) Gilman
The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application.
Additionally, neither the author nor the publisher has investigated or considered the affect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented.
Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or trade names referenced belong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturer’s instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.
All rights reserved.
Printed in the United States of America
10 9 8 7 6 5 4 3 2
ISBN 978-1-936007-20-2
ebook ISBN 978-1-937560-37-9
No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.
Library of Congress Cataloging-in-Publication Data
Gilman, G. F. (Jerry)
Boiler control systems engineering / G.F. (Jerry) Gilman. -- 2nd ed.
p. cm.
ISBN 978-1-936007-20-2 (pbk.)
1. Steam-boilers--Automatic control. I.Title.
TJ288.G527 2010
621.1'94--dc22
2010022406
About the Author
Jerry Gilman’s career has spanned more than 37 years with Procter & Gamble (P&G), and its subsidiaries. As a process control systems engineer for P&G, Gilman was dedicated to improving control systems and implementing new technology in numerous product areas at P&G in the US and foreign countries. One of his areas of expertise has been with boiler control systems engineering: improving efficiency, conserving energy, and working as a primary troubleshooter on boilers and other combustion systems.
A licensed professional engineer, Jerry Gilman currently provides training for ISA (International Society of Automation) and consulting to utility plants, industrial power plants and engineering contractors. This includes performing startups, tuning, and troubleshooting more than a hundred boilers and combustion systems such as dryers, roasters, and ovens. Gilman’s expertise in fuels and combustion control ranges from finding solutions for new unit applications to retrofitting existing installations in order to save fuel, change fuels, or improve overall control. He has applied his experience in combustion testing and energy utilization to help simplify boiler performance monitoring techniques and methods. His approaches are easy to understand and use effectively.
Jerry Gilman is the developer of the ISA Boiler Control Systems Engineering
and ISA Burner Management Systems Engineering
training courses. He has been a guest speaker on boiler control, burner management, and boiler safety issues at various ISA section meetings and other user groups and seminars. Additionally, he was a technical advisor for Win Boiler Sim,
a PC-based boiler training program developed by Len Klochek and sold through ISA.
Jerry Gilman is an active member on the following ISA Standards Committees: ISA84 Programmable Electronic Systems (PES) for Use in Safety Applications; ISA84 Burner Management System Working Group; and ISA77 Fossil Fuel Power Plant Standards.
Introduction
Boilers are a key power source for electrical generation in the United States and around the world and for providing heat in process industries and buildings. Regardless of the capacity or fuel, there are certain fundamental control systems required for boiler control. Large utility systems are more complex due to the number of burners and overall capacity and equipment. Although there are numerous ways to achieve control, the purpose is always the same — to control the firing of a boiler safely, reliably, and efficiently.
One of the keys to good control is accurate measurement. If you cannot measure a process variable, the variable cannot be controlled. This book addresses issues to consider when defining transmitter measurements and specifications. The characteristics and sizing of final control elements are also reviewed.
This book is for anyone who works with boilers: utilities managers, power plant managers, controls systems engineers, maintenance technicians or operators. The information deals primarily with water tube boilers with Induced Draft (ID) and Forced Draft (FD) fan(s) or boilers containing only FD fans. It can also apply to any fuel fired steam generator.
Other books have been published on boiler control; however, they do not cover engineering details on control systems and the setup of the various control functions. Boiler Control Systems Engineering provides specific examples of boiler control including configuration and tuning.
The requirements as stated are based on the NFPA 85 Code 2007 Edition, and the following ISA standards:
• ANSI/ISA-77.41.01-2005 - Fossil Fuel Power Plant Boiler Combustion Controls
• ANSI/ISA-77.42.01-1999 (R2006) - Fossil Fuel Power Plant Feedwater Control System (Drum-Type)
• ISA-TR77.42.02-2009 - Fossil Fuel Power Plant Compensated Differential Pressure Based Drum Level Measurement
• ANSI/ISA-77.44. 01-2007 - Fossil Fuel Plant-Steam Temperature Controls
Dedication
The book is dedicated to my wife, Judy, and our children Jeff, Kelly, Tom, and Doug. Our love for one another has always been my greatest blessing.
I want to thank my wife for her many hours of typing and proofreading assistance and ISA, particularly Susan Colwell, who has guided me through the publishing process and for her many hours of assistance.
A special thanks to Harold Wade for creating the new drawings.
Table of Contents
Chapter 1 — Boiler Fundamentals
Basic Boilers
Boiler Components
Furnace
Fans
Windbox
Flue Gas Heat Exchangers
Combustion Air Preheater
Economizer
Superheater
Boiler Drums
Piping and Instrument Diagrams (P&IDs)
Design Basis Check List
Chapter 2 — Control of Boilers
Control Strategies
Bumpless Transfer
Simple Feedback Control
Feedforward plus Feedback Control
Cascade Control
Ratio Control
Feedforward Control
Controller Tuning
Determining Gain, Reset, and Derivative
Gain vs. Proportional Band (PB)
Controller Actions
Controller Actions Setup
The Effects on Tuning
Calibration Effect on Gain
Transmitters
Redundancy
Interlock Circuitry
Final Control Elements
Chapter 3 — Furnace Draft
Pressure Fired Boilers
Balanced Draft Boiler Fans
Furnace Pressure Control
Summer
Chapter 4 — Feedwater
Once-Through Boilers
Drum Level Feedwater Control
Transmitters
Shrink and Swell
Single Element Level Control
Two Element Level Control
Three Element Level Control
Control System Configuration
Summer
Chapter 5 — Coal Fired Boilers
Pulverized Coal Fired Boilers
Raw Coal and Feeder
Stoker Boilers
Cyclone Boiler
Graphics: Pulverizer Coal Boiler
Chapter 6 — Fuel and Air Control
Fuel and Air Control Gas Oil
Fuel and Air Control Characterization
Excess Air to Oxygen
Multiple Fuel Control
Oxygen (O2) Trim Control
Multiple Boilers
Chapter 7 — Steam Temperature
Three Element Level Control
Chapter 8 — Burner Management Systems
Burner Management System (BMS) Control
NFPA 85 Code 2007
Boiler Control and Operating Documentation
Combustion Control
Purge Control
Requirement for Independence of Control (Hardware/Software)
Flame Detection
Flame Monitoring and Tripping System (Multiple Burner Boilers)
Flame Tripping Validation
Examples of Permissive Starting Logic and Protective Tripping Logic
Chapter 9 — Environment
NOx and NOx Control
Excess Air to Oxygen
Boiler Efficiency Computations
Input/Output Example
Chapter 10 — Control Valve Sizing.
Valve Characteristics
Valve Characteristic Graph
Recommended Velocities
Valve Sizing for Different Control Media
Control Valve Sizing Calculations
Gas Valve Sizing
Chapter 11 — Steam Temperature Control
Purpose
Introduction
Principles and Methods of Transient Superheat Steam Temperature Control
NOx Control
Redundancy
Reset Windup Prevention
Advanced Steam Temperature Control
Acronyms
Appendix A
Appendix B
Appendix C
Appendix D
Bibliography
References
Kraft Pulp Mill
Index
Figures and Tables
CHAPTER 1
Boiler Fundamentals
Basic Boilers
A boiler is comprised of two basic systems (Figure 1-1). One system is the steam water system also called the waterside of the boiler. In the waterside, water is introduced and heated by transference through the water tubes, converted to steam, and leaves the system as steam.
Boilers must maintain a chemical balance. The manner in which this is done can interact with the feedwater control system. The amount of blowdown must be considered in the feedwater control scheme, especially if the blowdown is continuous. Often, the blowdown flow is divided by the concentration ratio times the feedwater flow. Continuous blowdown is the common method for controlling the chemical concentration. On large boilers this may be done automatically by measuring the boiler water conductivity to control the blowdown rate. The blowdown rate may also be achieved by combining the conductivity with ratio control of