Date:16.5.

09
CONTROL & INTERLOCK
PHILOSOPHY for RECOVERY BOILER
Sheet 2 of 13

INDEX

Sl. Nr. Content Page Nrs. Remarks

1 Introduction & Control Summary 3-4

2 Operation Procedure 4-5

3 Description of Closed Loop Controls 5-9

4 Safety Interlocks 9-11

5 Description of Open Loop Controls 11-12

6 Reference Drawings & Documents 13-13

PDF created with pdfFactory trial version www.pdffactory.com

 Date:16.5.09
CONTROL & INTERLOCK
PHILOSOPHY for RECOVERY BOILER
Sheet 3 of 13

1). Introduction & control summary :

The Recovery Boiler recovers heat from the exhaust gases of Rotary
Kiln with dust particles of Zinc carbonate ore and produces 15 tons of steam at
a pressure of 12 bar, g and Satuarted temperature of 192°C at the MSSV
outlet. Waste heat is available from the Rotary Kiln at a temperature of 350°C.
The hot gas pass through the Recovery Boiler with evaporator bundles. The
heat is transfered to the boiler water by the heating surfaces. All heating
surfaces are connected to the steam drum by downcomer and riser pipes.
Common down comer is connected to evaporator bundles and membrane
walls. The seperation of saturated steam takes place in the steam drum at a
pressure of approx. 12 bar, g & Temperature of 192°C

Boiler Feed Water is fed into the steam drum through BFW Pump from
Feed water tank. This boiler feed water of tempearture 105°C and a pressure of
20.5 bar, g. The Recovery Boiler is provided with the necessary instruments
and controls to ensure safe operation of the system. All the controls and
indications are implemented in the DCS system provided by Client. All the
requisite field instrumentation as per scope is supplied by TSPL.

For controlling boiler water quality, Dosing systems are used. Each
system consists of mixing cum storage tank with agitator, dosing pumps (one
running & one standby) along with necessary valves, instruments and local
starter panel for operation. Tri-sodium phosphate is injected into the boiler
steam drum to correct conductivity & pH of boiler water and Sodium Sulphate is
injected into the feed water tank to correct the boiler water alkalinity.

The feed water storage tank along with deaerator is used for removal of
oxygen in feed water and used as storage tank from where BFW pump delivers
water to the boiler. The water level in feed water storage tank is controlled by
controlling the DM water flow through a control valve in DM water line. In case

PDF created with pdfFactory trial version www.pdffactory.com