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INTRODUCTION
a. The Automatic feedwater control systems maintain boiler water level and
delivery pressure at a desired setpoint. This objective is accomplished by
manipulating a feed control valve and the speed of the main feed pump.
This lesson will provide the basic control functions and component
interrelationships understanding.
REFERENCES
b. Automatic Combustion and Feedwater Control Systems NAVSEA 0951036-9010
c. Steam Plant Controls NSTM Chapter 225
d. Boiler Technician 3 and 2 NAVEDTRA 10535 G, Chapter 6
INFORMATION
e. Feedwater Control Systems
f. Each boiler is installed with a three element feed system (Figure 1). It is an
automatic system which controls feed flow to each boiler. The three element
feedwater control systems position the feedwater control valves to each
boiler, maintaining normal water level in the steam drums. Steady water
level indicates that a balance exists between the water flow to the boiler and
the steam removed.
g. The feedwater control system is a three-element type, designed to monitor
changes in the primary sensing elements: steam flow, feed flow and drum
level. With changes in boiler load (steam flow) steam and feed flow become
unbalanced and water level consequently deviates from the normal position.
In such an event, the system changes water flow in the proper direction and
to the extent necessary to restore the balance between steam flow and feed
flow and return the water level to normal.
h. Three elements are measured by the system:
i. Steam flow is considered the demand signal.
j. Feed flow is considered the feedback signal.
k. Drum level is considered the supervisory signal.
l.
m.
n. Components:
o. Steam and feed flow transmitters are identical in construction. These
transmitters incorporate a differential pressure unit (DPU) which measures
the pressure drop across an orifice with a mechanical square root extractor.
The transmitter generates a pneumatic output signal that is proportional to
flow.
p. Drum level transmitters compare the weight of constant and variable legs of
water that result in a differential pressure. A continuous output signal is
provided that is proportional to drum level. The output of the drum level
transmitter will be 30 psig when the steam drum water level is normal.
q. The steam flow/feed flow relay for a Hagan system consists of a 4 chamber
totalizer with a 30 psig spring attached to chamber 3. The purpose of this
relay is to subtract the feed flow signal from the steam flow signal. The
spring adds 30 psig to the result. When the inputs of the steam flow and
feed flow transmitters are equal the output of the relay will be 30 psig.
r. Feedwater flow controllers in a Hagan system are 4 chamber ratio totalizers
which ifinction as proportional-plus-reset controller. Reset action is
accomplished by feeding the output of the automatic-manual transfer station
back to chamber 4 through a needle valve and volume tank. The purpose of
this controller is to compare demand signal to supervisory signal and
develop an output to return drum level to normal. Shrink and swell are
kk.
ll. Main feed pump constant pressure control system (Figure 2)
mm. The main feed pump constant pressure control system ensures the main
feed pump maintains a constant discharge pressure.
nn.The control system consists of a hydraulic system which uses lube oil as a
control medium, and a pneumatic system which utilizes air as a control
medium. A pneumatic bellows, which actuates the turbine control system in
response to the pneumatic signal from the feedwater system, is mounted on
each turbine. The pneumatic control components for the main feed pumps
are located in a control panel in each fireroom, with automatic/manual
stations on the combustion control console.
oo.Components:
pp.Feedwater header pressure controller senses feedwater header pressure and
exerts a force on an installed beam. The set point spring, which opposes the
force exerted by the high pressure bellows is adjusted to balance the
System Deficiencies:
ccc. The control air must be free of moisture and particulate matter. The
smallest amount of moisture or particulate matter in a control system will
foul small orifices and cause a malfunction of the system. If a component in
the system malfunctions, securing the plant to repair it may not be required.
In many cases the control system may be placed in remote or local manual,
the component isolated and then replaced with a bulkhead spare. A complete
knowledge of the control systems functions is necessary to make such
critical decisions. It must be understood that when a control system is in
remote or local manual the plant load must be increased or decreased slowly
as an operator is not as responsive as the control system would be in
automatic.
ddd. Other problems are: improper PMS being preformed, leaking air lines
or fittings, component covers not installed, loose set screws on regulators,
and components not mounted correctly (missing bolts or not tight).