Standards Certification Education & Training Publishing Conferences & Exhibits

Automation Connections ISA EXPO 2006

Boiler Control Systems Engineering Jerry Gilman

Standards Certification Education & Training Publishing Conferences & Exhibits

Control System Functions

A boiler is a process Regardless of what control technology is used all boilers require certain control functions.
Furnace Draft Drum Level Feedwater Fuel Air Steam Temperature

Control System Considerations

Draft Drum level feedwater
Single element Two element Three element

Fuel air ratio Final elements Valves etc

Valve Sizing

Basic Diagram of a Boiler

STEAM WATER STEAM/WATER SYSTEM BLOWDOWN

FUEL

MIXING OF FUEL & AIR

FURNACE

HEAT TRANSFER SURFACE

FLUE GAS

AIR

ASH

Steam & Mud Drum / Circulation

ST M ST M

URN

FLU

U M IR MU RUM WAT R CIRCULAT S CLOCKWISE

CIRCULATI N

SAMA Symbols
Scientific Apparatus akers Association

E CLOS RE SY BOLS Table 1 Function Symbol

easuring or Readout anual Signal Processing Automatic Signal Processing Final Controlling
ithin a circle use a letter symbol from Table II ithin other enclosures us a symbol from Table III

SAMA Symbols (contd)

MEAS RI G/READO T LETTERS Table II Process Variable
A = Analysis** C = Conductivity D = Density F = Flow L = Level M = Moisture P = Pressure S = Speed T = Temperature V = Viscosity = eight Z = Position
**Self-defining symbols such as O

Function
FR
R = Recording I = Indicating T = Transmitter RT = Recording Transmitter IT = Indicating Transmitter

FRT

2,

pH, etc., can be used in place of A.

SAMA Symbols (Table III)

FUNCTION SUMMING AVERAGING DIFFERENCE PROPORTIONAL INTEGRAL DERIVATIVE MULTIPLYING DIVIDING ROOT EXTRACTION EXPONENTIAL NON-LINEAR FUNCTION TRI-STATE SIGNAL (RAISE, HOLD, LOWER) SIGNAL PROCESSING SYMBOL FUNCTION INTEGRATE OR TOTALIZE HIGH SELECTING LOW SELECTING HIGH LIMITING LOW LIMITING REVERSE PROPORTIONAL VELOCITY LIMITING BIAS TIME FUNCTION VARIABLE SIGNAL GENERATION TRANSFER SIGNAL MONITOR SIGNAL PROCESSING SYMBOL

or + /n ( or -

K or P
or I

d/dt or D X
z

-K or -P V
s

f(t) A T H/, H/L, /L

f(x)
F

SAMA Legend
1. CO TROLLER
Measuring or Readout Automatic Signal Processing

A
SET POI T GE ERATOR PROPORTIO AL RESET

Manual Signal Processing Final Controlling

|

K T

MA AL SIG AL GE ERATOR

Signal Repeater /h Summing Difference Integral

Summing d/d1 Derivative K, -K X Multiplying

A TO./MA . TRA SFER S ITCH

Proportional, Reverse Proportional Dividing Root Extracting

2. A TO MA

AL + BIAS STATIO

f(x) Non Linear or Unspecified Function f(t) Time Function > High Selecting < Low Selecting Low|> Limiting

A
BIAS ADJ STME T A TO./MA . TRA SFER S ITCH

T A

MA AL SIG AL GE ERATOR

High Limiting | > +, -, Bias

Velocity or Rate Limiter

T Transfer A Analog Signal Generator

Simple Feedback Control

PRI ARY VARIABLE XT

SET POINT A

PROCESS

f(x) ANIPULATED VARIABLE

Feedforward Plus Feedback Control

PRIMARY VARIABLE XT SECONDARY VARIABLE YT K PROCESS

SET POINT A T A

f(x) MANIPULATED VARIABLE

Cascade Control
PRIMARY VARIABLE XT SECONDARY VARIABLE ZT K PROCESS K SET POINT A T A

f(x) MANIPULATED VARIABLE

Ratio Control
UNCONTROLLED VARIABLE YT CONTROLLED VARIABLE XT

X K RATIO SET A T A

PROCESS

f(x) MANIPULATED VARIABLE

Block Diagram of Boiler Control

I P T

BOILER

O TP T

FEED ATER CO TROL

F EL DEMA D AIR DEMA D

FIRI G RATE DEMA D

STEAM TEMPERAT RE CO TROL

Furnace Pressure Control

Block Diagram of Boiler Control

I P T

+
BOILER

O TP T

FEED ATER CO TROL

F EL DEMA D AIR DEMA D

FIRI G RATE DEMA D

STEAM TEMPERAT RE CO TROL

Boiler Steam Drum Swell / Shrink

SATURATED STEAM

STEAM

FEEDWATER WATER

WATER

WATER-MIXED STEAM BUBBLES

Single Element Feedwater Control

DRUM LEVEL LT PT f(x) X DRUM PRESSURE PRESSURE COMPENSAT ON

A SET PO NT

(
K

M/A CONTROL STAT ON

f(x)

F NAL CONTROL DEV CE

Typical single-drive control system. For simplicity, redundant transmitters have not been shown on this typical control drawing. See Figure 2A for ANS / SA-S5.1-1984 format.

Single Element Control Action

SWELL NWL DRUM LEVEL SHRINK

100

% STEAM FLOW

75 STEAM FLOW 50 * 25

* FEEDWATER FLOW

0 0 TIME

* INTERACTION WITH FIRING RATE CONTROL DUE TO IMBALANCE BETWEEN STEAM FLOW AND FEEDWATER FLOW.

Two Element Feedwater Control

STEAM DRUM PRESSURE PT f(x) X PRESSURE COMPENSATION SET POINT A K PRESSURE FLOW TEMPERATURE PT f(x) X FT TE f(x) TEMPERATURE AND PRESSURE COMPENSATION

LT LEVEL

M/A CONTROL STATION

f(x)

FINAL CONTROL DEVICE

Typical single-drive control system. For simplicity, redundant transmitters have not been shown on this typical control drawing. See Figure 3A for ANSI/ISA-S5.1-1984 format.

Performance Two Element (Ideal Conditions)

FEEDWATER PRESSURE SWELL NWL SHRINK DRUM LEVEL

100 % STEAM FLOW 75 STEAM FLOW 50 FEEDWATER FLOW

25

0 0 TIME

Performance Two Element (Effect of Feedwater Variation)

FEEDWATER PRESSURE

SWELL NWL SHRINK 100 % STEAM FLOW 75 STEAM FLOW 50 FEEDWATER FLOW DRUM LEVEL

25

0 0 TIME

Three Element Feedwater Control

STEAM PRESSURE PT FLO FT

DRUM FLO FT

FEED ATER TEMPERATURE TE

TEMPERATURE LEVEL PRESSURE TE LT PT

f(x) X

f(x) X PRESSURE AND TEMPERATURE COMPENSAT ON

f(x)
PRESSURE COMPENSAT ON

f(x) X TEMPERATURE CONDENSAT ON

(
K

SET PO NT

(
K

(K) (a) +K (b) + K (c) etc. + bias = output

M/A CONTROL STAT ON F NAL CONTROL DEV CE

Typical single-drive system. For simplicity, redundant transmitters Typical single-drive control control system. For simplicity, redundant transmitters have not been shown on this typical control drawing. have not been shown on this typical control drawing. ee Figure 4A for f(x) See Figure 4A for ANS / SA-S5.1-1984 format. ANS / SA-5.1-1984 format.

Performance Three Element

Block Diagram of Boiler Control

I P T

+
BOILER

O TP T

FEED ATER CO TROL

F EL DEMA D AIR DEMA D

FIRI G RATE DEMA D

STEAM TEMPERAT RE CO TROL

Firing Single Fuel/Cross Limiting

STEAM HEADER PRESS RE PT

Fuel FLO FT

AIR FLO FT

A P A T I

f(x)

SP P A T I LO SELECT Fuel CO TROL HI SELECT

SP P A T I AIR CO TROL

f(x) Fuel Feed AIR DAMPER

Cross Limit Control With O2 Trim

STEAM HEADER PRESSURE

GAS FLOW

AIR FLOW

O2

FT

PT

FT

AT

A P A T I

f( ) P I

A
STEAM FLOW

SP LO SELECT HI SELECT

SP

P A T

GAS CONTROL

P A T

AIR CONTROL

f( )
GAS ALVE AIR DAMPER

Flow Characteristics
100 AIR (B)

AIR % FUEL AND AIR FLOW 50 (C) (D) FUEL (A) FUEL

50 % CONTROL RAN E

100

A,B BASIC FLOW CHARACTERISTICS OF CONTROLLED DEVICES C,D CHARACTERISTICS AFTER LINEARIZATION AND ALI NMENT

Non Linear Flow

0 0 10 1 20 4 30 9 40 16 50 25 60 36 70 49 80 64 90 81 100 100

F lo w in %

120

100 90 80 70 64 60 50 40 30 25 20 10 0 1 0 2 1 3 4 4 5 6 7 8 9 10 11 20 16 9 40 36 60 49 80 81

100

S e r ie s 1 S e r ie s 2

Non Linear Flow

0 0 10 1 20 4 30 9 40 16 50 25 60 36 70 49 80 64 90 81 100 100

Flow in
120

100 90 80 70 60 50 40 30 25 20 10 0 1 0 2 1 3 4 4 5 6 7 8 9 10 11 20 9 16 40 36 60 49 64 80 81

100

Series1 Series2

Characterization
0 0 10 7.5 20 15 30 22.5 40 30 50 37.5 60 45 70 52.5 80 OUT 60 IN

90 80 70 60 50 40 30 20 10 0 1 0 2 3 4 5 6 7 8 9 10 7.5 20 15 30 22.5 40 30 50 45 37.5 60 52.5 70 60 80

Control Valve Sizing Calculations

Cv = umber of S gallons of water at 60oF that flows through a valve in one minute when the pressure differential across the valve is one pound per square inch
Valve sizing water no density consideration:
The term Cv is generally used in industry for calculating the relative flow capacity in valves

Q ! gpm SG ! specific g ravity P ! pressure d rop across valve

Control Valve Sizing Calculations

(contd)

Valve sizing water no density consideration:

(P = pressure drop across valve typical third of drop

C v ! GPM SG z P
600,000 pph water = 600,000 z 8.34 lb/gal = 1200 gpm (P = pressure drop across valve, typical a third of drop Pump pressure = 2000 psi, Drum pressure = 1400 psi 2000  1400 = 600

600 v 1/3 = 200 valve drop

Control Valve Sizing Calculations

The calculation 600,000 pph is:
C v ! GPM C v ! 1200 S G z (P 1.0 z 200 ! 84.85

(contd)

The calculation for 250,000 pph is:

Cv ! 300 1.0 z 150 ! 24.49

Control Valve Sizing Calculations

(contd)

Valve sizing water 450oF, SG = 0.827 The calculation 600,000 pph is:

Cv ! GPM S G z (P Cv ! 1200 0.827 z 200 ! 77.16

Cv at 60o = 84.85 Cv at 450o = 77.16

Control Valve Sizing Calculations

Valve sizing steam:

(contd)

pph Cv ! 63 v (P z V V ! specific volume, Steam at 1000 lbs ! 0.44956 P ! 1400  1000 ! 400 One third of 400 ! 133, 133 z 0.44956 ! 17.2 100,000 100,000 Cv ! ! ! 92.3 1083 63 v 17.2

Control Valve Sizing Calculations

Valve sizing steam:

(contd)

pph Cv ! 63 v (P z V V ! specific volume, 800 o F superheate d steam at 1000 lbs ! 0.6875 (P ! 1400 - 1000 ! 400 One third of 400 ! 133, 133 z 0.6875 ! 13.9 100,000 100,000 ! ! 114.1 Cv ! 63 v 13.9 876.6

Summary
Regardless of the hardware and or software used certain control functions are required. These controls are
Furnace Draft Drum Level Feedwater Fuel Air Steam Temperature

Measurement / transmitter specifications

Calibration Calibration span Valve Sizing

Final elements Valves etc

Questions and Discussion

Related Resources from ISA

Boiler Control Systems Engineering Jerry Gilman The Control of Boilers Sam G. Dukelow ISA Courses ES15 Boiler Control System Engineering
Three day course One day overview EB introduction course

ES16 Burner Management System Engineering

Three day course One day overview

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