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    Boiler Control Systems Engineering, Second Edition
    Boiler Control Systems Engineering, Second Edition
    Boiler Control Systems Engineering, Second Edition
    Ebook357 pages2 hours

    Boiler Control Systems Engineering, Second Edition

    By G.F. (Jerry) Gilman

    4.5/5

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    About this ebook

    This book is for anyone who works with boilers: utilities managers, power plant managers, control 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.
    LanguageEnglish
    PublisherInternational Society of Automation
    Release dateAug 20, 2012
    ISBN9781937560379
    Boiler Control Systems Engineering, Second Edition

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    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

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