UNIT 4

Control Loops in Boiler

Control Loops
Drum Level Control
Single element
2 element
3 element control
steam Temperature Control
Attemperators
Desuperheaters
Deareator control
Combustion control
Air/Fuel Ratio control
Furnace draft control

Super Heaters
Heating the steam further from saturation temperature
is called superheating
A superheater is a device used to convert saturated
steam or wet steam into dry steam used in steam
engines or in processes, such as steam reforming.
Super heater is generally employed between boiler and
turbine unit.
It is used to increase the temperature and pressure of
the working steam
It is also used to increase the power generation in steam
power plants.

Need of Superheater
temperature control
To Minimize thermal stress on boiler
To Minimize thermal stress on turbine

Challenging in steam
temperature control

Temperature is a slow process

Has time lag
Has long dead time
Nonlinear properties

Types of control
Fire side control
Water side control

EI1002 Power Plant

Instrumentation

DeSuperHeater

Fire Side Control Strategies

Water side control

strategies

Spray nozzle

Spray nozzle

Fire side control

EI1002 Power Plant

Instrumentation

17

Burner position

317-St.Joseph's College of Engineering

19

Control loops
Single stage steam temperature control

Simple feedback loop-reject the

disturbance after it affects the process

Fb control loop-Plant model

Cooling water from condenser

Non-return value to retrict the steam flow into water tube

Two stage control loop

Plant model

Cascade steam temperature

control

CASCADE CONTROL SYSTEM

Feed forward plus feedback

steam temperature control

Steam pressure control

Balance between the heat inflow and heat
outflow of a boiler indicated by drum pressure.

Change in firing rate change the steam

pressure after some delay.

Steam pressure in bus is control by firing rate

in the boiler

Steam header

Steam pressure control loop

Controller controls the firing rate demand.

Some boiler works constantly ,some works by

controlling,some boiler for emergency(open/close

Air-fuel circuit control

1)combustion control
2)furnace draft control

Combustion control
Types:
Oil or gas fuel to air control
Solid fuel to air control

Oil or gas fuel to air control

Combustion control
Simple fuel control by firing demand

Combustion control single

point positioning(jack shaft
control)

Controller controls the control value of fuel.

Mechanical link established between control value and

combustion air damper.

But it is very difficult to linearize the movement of control

value and damper due to different flow characteristics

Combustion control-parallel
positioning

Single controller gives control signal to both control values

and air damper

Combustion control:series
fuel air ratio control

Combustion control:parallel
fuel air ratio control

Problem if the Combustion Air Loop is Slow

blower that responds slowly to control commands, COc, relative to the valve
(thetime constantof the blower "process" is where the firing demand, SPw,
suddenly increases.The fuel flow valve responds quickly, increasing fuel feed
to the burner. The ratio relay will receive SPw and raise the set point of the
combustion air mass flow rate, SPc, so the two streams can remain in ratio.If
the air blower response is slow, however, a fuel rich environment can
temporarily develop. That is, there will be a period of time when we are below
the desired 5% to 20% of excess air (below the 105% to 120% oftheoretical or
stoichiometric air) as we wait for the blower to ramp up and deliver more air to
the burner.If there is insufficient air for complete combustion, then carbon
monoxide and partially burned fuel will appear in the exhaust stack. As such,
we have a situation where we are wasting expensive fuel and violating
environmental regulationsmuch larger than that of the valve)

OVERRIDE CONTROL

The second ratio relay receives theactualmeasured combustion

air mass flow rate, PVc, and computes a matching fuel flow rate
based on the design air/fuel ratio

Combustion control:metered
cross limited fuel air ratio
control

Metered parallel cross

limited air-fuel ration control

Steam automisation control

fuel demand split between

oil and gas

Bubbling bed fluidised-bed

boiler

Stack temperature
optimisation

Optimisation using stack

gas analysers

Combustion control

OVERFEED TRAVELING
GRADE

UNDER FEED

Underfeed stokers can be designed

for use with either anthracite or
bituminous coal,

FLUIDZED

Afluidized bedis formed when a quantity of asolidparticulate substance (usually present in a

holding vessel) is placed under appropriate conditions to cause the solid/fluid mixture to behave as
afluid. This is usually achieved by the introduction of pressurized fluid through the particulate
medium. This results in the medium then having many properties and characteristics of normal
fluids; such as the ability to free-flow under gravity, or to be pumped using fluid type technologies.
The resulting phenomenon is calledfluidization.
A fluidized bed consists of fluid-solid mixture that exhibits fluid-like properties. As such, the upper
surface of the bed is relatively horizontal, which is analogous to hydrostatic behavior. The bed can
be considered to be a heterogeneous mixture of fluid and solid that can be represented by a single
bulk density.
Furthermore, an object with a higher density than the bed will sink, whereas an object with a lower
density than the bed will float, thus the bed can be considered to exhibit the fluid behavior
expected ofArchimedes' principle. As the "density", (actually the solid volume fraction of the
suspension), of the bed can be altered by changing the fluid fraction, objects with different
densities comparative to the bed can, by altering either the fluid or solid fraction, be caused to
sink or float. This is illustrated in the following video:https://www.youtube.com/watch?
v=3BqVFGCUviY.
In fluidized beds, the contact of the solid particles with the fluidization medium (a gas or a liquid) is
greatly enhanced when compared topacked beds. This behavior in fluidized combustion beds
enables good thermal transport inside the system and good heat transfer between the bed and its
container. Similarly to the good heat transfer, which enables thermal uniformity analogous to that
of a well mixed gas, the bed can have a significant heat-capacity whilst maintaining a
homogeneous temperature field.

Application[edit]
Fluidized beds are used as a technical process which has the ability to promote high
levels of contact between gases and solids. In a fluidized bed a characteristic set of
basic properties can be utilised, indispensable to modern process and chemical
engineering, these properties include:
Extremely high surface area contact between fluid and solid per unit bed volume
High relative velocities between the fluid and the dispersed solid phase.
High levels of intermixing of the particulate phase.
Frequent particle-particle and particle-wall collisions.

1. Fuel Input-Fuel and limestone are fed into the combustion chamber of the boiler
while air (primary and secondary) is blown in to fluidize the mixture. The fluidized
mixture burns at a relatively low temperature and producesheat. The limestone
absorbs sulfur dioxide (SO2), and the low-burningtemperature limits the formation of
nitrogen oxide (NOX ) two gasesassociated with the combustion of solid fuels.
2. CFB Boiler-Heat from the combustion process boils the water in the water
tubesturning it into high-energy steam. Ammonia is injected into the boileroutlet to
further reduce NOX emissions.
3. Cyclone Collector-The cyclone is used to return ash and unburned fuel to
thecombustion chamber for re-burning, making the process moreefficient.
4. State-of-the-Art Air Quality Control System-After combustion, lime is
injected into the polishing scrubberto capture more of the SO2. A baghouse
(particulate control device)collects dust particles (particulate matter) that escape
during thecombustion process.
5. Steam Turbine-The high-pressure steam spins the turbine connected to
thegenerator, which converts mechanical energy into electricity.
6. Transmission Lines-The electricity produced from the steam turbine/generator
is routedthrough substations along transmissionlines and delivered to
distributionsystems for customer use.

Direct firing system for

pulverized coal

FD fan control(Forced draft

control)

Balanced draft control