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Boiler Combustion Control

The document discusses different types of boiler combustion control systems that maintain the proper air-fuel mixture under varying load conditions. It focuses on systems using the YS170 programmable loop controller. These include parallel positioning, single point positioning, and parallel metered cross limited systems. The YS170 can implement a dual loop controller configuration to control both combustion air and oxygen trim via inputs like air flow, firing rate demand, and percent oxygen measurements. This provides effective and efficient boiler combustion control in a cost-saving, easy-to-use solution.

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Sergio Gonzales
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355 views2 pages

Boiler Combustion Control

The document discusses different types of boiler combustion control systems that maintain the proper air-fuel mixture under varying load conditions. It focuses on systems using the YS170 programmable loop controller. These include parallel positioning, single point positioning, and parallel metered cross limited systems. The YS170 can implement a dual loop controller configuration to control both combustion air and oxygen trim via inputs like air flow, firing rate demand, and percent oxygen measurements. This provides effective and efficient boiler combustion control in a cost-saving, easy-to-use solution.

Uploaded by

Sergio Gonzales
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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APPLICATION NOTE

YS170 Boiler Combustion Control


OVERVIEW
The boiler combustion control system is designed to maintain a proper air/fuel mixture under varying load conditions and within safe limits. The system should provide nearly complete fuel combustion as efficiently as possible. Discussions here are limited to oil and/or natural gas fired industrial boilers. Control systems that perform these functions can be classified as positioning or metering systems. Positioning combustion systems use mechanical linkages between the fuel control valve and air damper to adjust for the proper ratio. Both single point positioning and parallel position systems are common. load range is difficult. Refer to the SAMA diagram below. This configuration is called a cross limited or lead-lag system. If an increase in firing rate is needed due to an increasing steam demand, the air flow leads the fuel. As the load curtails, the fuel decreases first, followed by a decrease in combustion air flow. A low limiter is used in the air controller to prevent the air flow set point to be reduced less than 25% of full span. This minimum setting is required by NFPA code and ensures safe operation in the event of loss of signals.
From Pressure Controller Fuel Flow Firing Rate Demand Low Select

PARALLEL POSITIONING
This system uses a master pressure controller to position the fuel valve(s) and air damper. An air/fuel ratio station is placed in the air damper circuit. Advantages are low installed cost and simplicity with only one controller to manipulate. The disadvantage is that it is not fail-safe. There is no inherent fuel cut back or air tracking the fuel if either drive were to fail.

SINGLE POINT POSITIONING


One of the most common combustion control system on oil and/or gas fired boilers is the single point positioning system, commonly referred to as a jackshaft. Refer to the drawing below. The fuel valve(s) and air damper are mechanically linked to a common rotating drive mechanism controlled by a master drive unit. Simple and safe, but requires a constant fuel pressure and BTU content. Maintaining the optimum air/fuel ratio throughout the
Automatic Adjustment of Blower Side of Shaft

PARALLEL METERED CROSS LIMITED SYSTEM

FT

FT
Air Flow

25%

Combustion Air

Single Point Positioning

In this combustion High Select system, the air and fuel flows are measured and are K K the process variables of two T A T A controllers. The air and fuel controllers receive a setpoint f(x) f(x) value from a master steam pressure Air Fuel Damper Valve controller. In the fuel controller, this value is compared to a modified air The YS170 Dual Loop flow signal in a low signal Programmable Controller is the selector. The lower value logical choice for boiler combustion is selected as the remote control. The controllers can be set point of the fuel flow easily implemented to perform the Jackshaft controller. full metering cross limited system configuration. The YS170 fuel Conversely, the pressure controller can transmit the fuel signal controller output is as an analog output to the air compared to the fuel flow controller for the cross limiting using a high signal action. Conversely, the YS170 air Fuel Valve selector in the air flow controller can transmit the air flow to controller. The higher the fuel controller. The limiting signal is selected.

<

>

f(x)

CCYS-G-01A 03-99

APPLICATION NOTE
signal selectors reside in each controller. Using discrete inputs and outputs, the fuel controller can track the air control MANUAL status and logic can be incorporated to not permit automatic fuel control until the air controller is in AUTO. These signals can be hard-wired between controllers or an optional peer-topeer digital communications network can transfer analog and status information over a single pair of twisted wires. Diagnostics of flow inputs allows the controllers to transfer the fuel and air outputs to safe conditions in the event of transmitter failure. The controllers can be forced into MANUAL mode (holding the last calculated output) and discrete outputs are available to activate an annunciator or other alarm device. If the YS170 controller were to fail, an integral hard manual station allows immediate backup. By raising the front panel assembly of the instrument, the manual station can be activated by a slide switch. A knurled thumb wheel can be adjusted to provide the appropriate output to the control element. A FAIL discrete output can be wired to an alarm device. A load index is created from the firing rate demand signal. The amount of excess oxygen varies inversely with steam demand, i.e., low loads have a higher excess oxygen. The operator can apply a manual bias to the index set point without changing the index slope or shape. Refer to the SAMA diagram below.
Air Flow

SUMMARY
YS170 Programmable Loop Controllers can be installed in a variety of applications. As discussed here, boiler combustion control can be implemented easily and cost effectively. Multiple analog and discrete inputs/outputs permit interaction with burner management equipment. YS170 controllers have been installed in dozens of boiler installations. Users are glad they selected this versatile easy-to-use controller. YS170 - The Logical Choice in Combustion Control!

FT

Firing Rate Demand

AT

Percent Oxygen

f(x)

f(x)
Operator Bias

K A T K

A +

X
To Air Controller

The output of the percent oxygen controller is adjusted for gain and bias and applied to the combustion air flow signal. Additionally, low and high limits are used to ensure continued operation during analyzer outage. The YS170 can be programmed to perform two independent P+I+D control algorithms. This is ideal to incorporate the combustion air and oxygen trim controls into one instrument. The multiple input/output capabilities permit air flow, percent oxygen, and firing rate demand inputs. Function generators residing in the microprocessor-based controller allow calculation of the load index described above and characterization of the air flow measurement. By implementing these two control strategies in one device, the purchase cost is lowered and installation costs are reduced.

FLUE GAS ANALYSIS


Flue gas analysis is a method of providing a more precise control of the air/fuel ratio. The intent is to minimize the amount of excess air rising through the stack which results in lower operating costs by using less fuel. An oxygen trim controller can be used to bias or trim the combustion air controller.

CCYS-G-01A 03-99

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