ID

C
IDC Technologies - Technical Training That Works
BOILER PLANT OPERATION

IDC Technologies Tech Briefs
(Mechanical Engineering)
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION USED ON A SHELL
BOILER
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 pressures, temperatures, flows, water
level
M4-2
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION
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
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION
PRESSURE TRANSMITTER
Where a remote pressure indicator required,
an electrical signal used
Separate transducer
Mounted on same branch as pressure
indicator

M4-4
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION
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
ID
C
IDC Technologies - Technical Training That Works
Typical Water Level
Gauge for Low Pressure Boiler
M4-6
ID
C
IDC Technologies - Technical Training That Works
Electronic and digital water level indicators
M4-7
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION
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
ID
C
IDC Technologies - Technical Training That Works
INSTRUMENTATION
TEMPERATURE MEASUREMENT
Flue gas exit temperature
An increase indicates fouling problems
Thermocouples, insulated from gas sampling
tube
M4-9
ID
C
IDC Technologies - Technical Training That Works
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
ID
C
IDC Technologies - Technical Training That Works
CONTROL AND SYSTEM
OPERATING PHILOSOPHY
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
ID
C
IDC Technologies - Technical Training That Works
CONTROL AND SYSTEM
OPERATING PHILOSOPHY
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
ID
C
IDC Technologies - Technical Training That Works
COMBUSTION CONTROL
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
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
ID
C
IDC Technologies - Technical Training That Works
COMBUSTION CONTROL
Two basic types of combustion control
systems:
Positioning
Metering
Pneumatic or Electrical control drives

M4-14
ID
C
IDC Technologies - Technical Training That Works
COMBUSTION CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
COMBUSTION CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
General Selection Chart for
Combustion Control Systems
Type of Fuel Type of Control Steam Generation
System Capacity Ranges
(kg/hr)
Coal Modulating positioning to 27 500
Full metering (Steam
/air flow) 18 000 36 000
Full metering with
Oxygen compensation above 36 000

Fuel Oil & Gas Modulating positioning to 11 500
Full metering (Steam
/ air flow) 11 500 45 000
Full metering with
Oxygen compensation above 45 000

M4-17
ID
C
IDC Technologies - Technical Training That Works
STEAM PRESSURE CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
STEAM PRESSURE CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
FEED WATER SUPPLY CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
FEED WATER SUPPLY CONTROL
Typical arrangements of feed water plant
:
Two or more pumps (standby) from hot well
tank (10-15 min. storage)
Either on-off operation or a feed valve station
Feed valve station :
Check valve
Stop valve
Feed control valve c/w isolation and bypass
valves
M4-21
ID
C
IDC Technologies - Technical Training That Works
FEED WATER CONTROL SYSTEMS
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
ID
C
IDC Technologies - Technical Training That Works
FEED WATER CONTROL SYSTEMS
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
ID
C
IDC Technologies - Technical Training That Works
Schematic of Three
Element Level Controller
M4-24
ID
C
IDC Technologies - Technical Training That Works
SOME CONSIDERATIONS REGARDING
WATER LEVEL CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
FURNACE PRESSURE CONTROL
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
ID
C
IDC Technologies - Technical Training That Works
AUTOMATIC CONTROLS
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
ID
C
IDC Technologies - Technical Training That Works
AUTOMATIC CONTROLS
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