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© 2003
ISA
67 Alexander Drive
Research Triangle Park, NC 27709

ES15w

Introduction to
Boiler Control
Systems

© 2003
ISA
67 Alexander Drive
Research Triangle Park, NC 27709 Version 1.0

© 2003, ISA
ES15w (1.0)
 Seminar Logistics

• Seminar materials
− Downloadable presentation
− Question and Answer session (audio and email)
− Survey
− Earn 1 Professional Development Hour (PDH)

• Seminar length
− 60 minute presentation
− Three 10-minute question and answer sessions

Audio Instructions

• As a participant, you are in a “listen-only”

mode.
• You may ask questions via the internet, using
your keyboard, at any time during the
presentation. However, the presenter may
decide to wait to answer your question until
the next Q&A Session.
• If you have audio difficulties, press *0.
• If you have visual difficulties, call (866) 493-
2825.

© 2003, ISA
ES15w (1.0)
 Audio Instructions

• As a participant, you are in a “listen-only”

mode.
• You may ask questions via the internet, using
your keyboard, at any time during the
presentation. However, the presenter may
decide to wait to answer your question until
the next Q&A Session.
• If you have audio difficulties, press *0.
• If you have visual difficulties, call (866) 493-
2825.

Audio Instructions

• As a participant, you are in a “listen-only”

mode.
• You may ask questions via the internet, using
your keyboard, at any time during the
presentation. However, the presenter may
decide to wait to answer your question until
the next Q&A Session.
• If you have audio difficulties, press *0.
• If you have visual difficulties, call (866) 493-
2825.

© 2003, ISA
ES15w (1.0)
 Audio Instructions for Q&A Sessions

• Questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will

announce your name and affiliation to the audience and
then ask for your question.

• If other participants are asking questions, you will be

placed into a queue until you are first in line.

• While in the queue, you will be in a listen-only mode until

the operator indicates that your phone has been activated.
The operator will announce your name and affiliation and
then ask for your question.
7

Introduction of Presenter

• ISA Presenter
− Gerald F. Gilman, PE
− Consultant to companies for safety applications and
developer of training programs.
− He started consulting after 37 years at Proctor & Gamble as
a Control and Information Systems Manager in the Soap
Sector Engineering Department.
− He was responsible for the control and information systems
at three P&G sites, the coordinator for safety instrumented
systems and safety standards worldwide, and a key
resource for boiler control systems and boiler start-ups.
− Contact information: [email protected] or (513) 522-4154

© 2003, ISA
ES15w (1.0)
 Key Benefits of Seminar
• Understand control systems and instrumentation for boilers
• Understand process dynamics of a boiler and the process
control interactions
• Be able to describe
− boiler components and their function

− how the systems interact and how to set up the controls

− swell and shrink

• Be able to configure
− Furnace draft

− Drum level feed water control

− fuel air control

− steam temperature
9

Boiler Fuels

• Gas
• Oil
• Coal
• Fuel combinations

10

© 2003, ISA
ES15w (1.0)
 SAMA Symbols (Scientific Apparatus Makers Association)

ENCLOSURE SYMBOLS
Table 1
Function Symbol
Measuring or
Readout

Manual Signal
Processing

Automatic Signal
Processing

Final Controlling

Within a circle use a letter symbol from Table II

Within other enclosures us a symbol from Table III
11

SAMA Symbols (cont’d)

MEASURING/READOUT LETTERS
Table II

Process Variable Function

A = Analysis** R = Recording
C = Conductivity I = Indicating
FR
D = Density T = Transmitter
F = Flow RT = Recording
L = Level Transmitter
M = Moisture IT = Indicating
FRT
P = Pressure Transmitter
S = Speed
T = Temperature
V = Viscosity
W = Weight
Z = Position

**Self-defining symbols such as O 2, pH, etc., can be used in place of A.

12

© 2003, ISA
ES15w (1.0)
 SAMA Symbols (cont’d)
SIGNAL SIGNAL
FUNCTION PROCESSING FUNCTION PROCESSING
SYMBOL SYMBOL

SUMMING
∑ or + INTEGRATE OR TOTALIZE Q
AVERAGING
∑/n HIGH SELECTING

DIFFERENCE
∆ or - LOW SELECTING

PROPORTIONAL K or P HIGH LIMITING

INTEGRAL
∫ or I LOW LIMITING

DERIVATIVE d/dt or D REVERSE PROPORTIONAL -K or -P

MULTIPLYING X VELOCITY LIMITING V
DIVIDING
÷ BIAS
±
ROOT EXTRACTION
√ TIME FUNCTION f(t)
EXPONENTIAL n VARIABLE SIGNAL
X A
GENERATION
NON-LINEAR FUNCTION f(x) TRANSFER T
TRI-STATE SIGNAL
(RAISE, HOLD, LOWER)
b SIGNAL MONITOR H/, H/L, /L
13

Simple Feedback Control

PRIMARY VARIABLE

XT

K
PROCESS
SET POINT

A T A

f(x)

MANIPULATED VARIABLE 14

© 2003, ISA
ES15w (1.0)
 Feedforward Plus Feedback Control
PRIMARY VARIABLE

XT

SECONDARY
VARIABLE

YT

PROCESS

SET POINT
A T A

f(x)

15
MANIPULATED VARIABLE

Cascade Control
PRIMARY VARIABLE

XT

SECONDARY
VARIABLE

ZT

PROCESS

SET POINT
A T A

f(x)

16
MANIPULATED VARIABLE

© 2003, ISA
ES15w (1.0)
 Ratio Control
UNCONTROLLED VARIABLE

YT

CONTROLLED
VARIABLE

XT

X
PROCESS
K

RATIO SET
A T A

f(x)

MANIPULATED VARIABLE 17

Audio Instructions for Q&A Sessions

• Questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will

announce your name and affiliation to the audience and then
ask for your question.

• If other participants are asking questions, you will be placed

into a queue until you are first in line.

• While in the queue, you will be in a listen-only mode until the

operator indicates that your phone has been activated. The
operator will announce your name and affiliation and then ask
for your question.
18

© 2003, ISA
ES15w (1.0)
 Live Question and Answer Session
• During Q&A, questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will announce
your name and affiliation to the audience and then ask for your
question.

• If other participants are asking questions, you will be placed into a

queue until you are first in line.

• While in the queue, you will be in a listen-only mode until the

operator indicates that your phone has been activated. The
operator will announce your name and affiliation and then ask for
your question.

19

Basic Control Functions

• Regardless of the
hardware and software
used certain control
functions are required

• These controls are

− Furnace Draft

− Drum Level Feedwater

− Fuel Air

− Steam Temperature

20

© 2003, ISA
ES15w (1.0)
 Boiler Components
SPRAY WATER FROM
FEEDWATER PUMP
DESUPERHEATER

STEAM DRUM
STEAM STEAM
FROM FROM
SECOND THIRD
BOILER BOILER
SUPERHEATER

STEAM TO
COLD AIR THE PROCESS
STEAM HEADER

COLD
AIR HOT AIR COLD AIR
DAMPER DAMPER

HOT AIR
FEED WATER
SECONDARY
AIR
FROM OTHER
PULVERIZERS
FLUE GASES
AIR HEATER

FEEDER TOTAL
AIR
PULVERIZED
COAL WITH
PRIMARY AIR AMBIENT
(P.A.) AIR

PULVERIZED
P.A. CONTROL
DAMPER
P.A. FAN F.D. FAN
I.D. FAN INLET DAMPER INLET
VANES

21

Block Diagram of Boiler Control

INPUT + OUTPUT
BOILER

FEEDWATER CONTROL

FUEL DEMAND FIRING

RATE
AIR DEMAND DEMAND

STEAM TEMPERATURE
CONTROL
22

© 2003, ISA
ES15w (1.0)
 Furnace Pressure Control

23

System Reliability & Availability ISA-77.41

• Field transmitter device redundancy should be
provided to the extent necessary to achieve desired
system reliability. The following conditions apply:
− When two transmitters are employed, excessive deviation
between the transmitters shall be alarmed and the associated
control loop shall be transferred to manual
− When three transmitters are employed, excessive deviation
between the transmitters shall be alarmed
• A transmitter select scheme shall be used for control
purposes

• Furnace pressure shall be measured with three

furnace pressure transmitters, each on a separate
measurement tap.
24

© 2003, ISA
ES15w (1.0)
 Block Diagram of Boiler Control

INPUT + OUTPUT
BOILER

FEEDWATER CONTROL

FUEL DEMAND FIRING

RATE
AIR DEMAND DEMAND

STEAM TEMPERATURE
CONTROL

25

Boiler Steam Drum/Swell Shrink

SATURATED

STEAM

STEAM

FEEDWATER

WATER

WATER

WATER-MIXED STEAM BUBBLES

26

© 2003, ISA
ES15w (1.0)
 Single Element Feedwater Control
DRUM LEVEL LT PT DRUM PRESSURE

f(x) PRESSURE
COMPENSATION
X

A ∆
K ∫
SET POINT

A T 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 2A for ANSI/ISA-5.1-1984 format.
27

Two Element Feedwater Control

STEAM
DRUM PRESSURE FLOW TEMPERATURE

PRESSURE PT LT LEVEL PT FT TE

f(x) f(x) f(x)

X X
PRESSURE TEMPERATURE
COMPENSATION AND PRESSURE
COMPENSATION
SET POINT A ∆ K
K ∫

A T 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-5.1-1984 format. 28

© 2003, ISA
ES15w (1.0)
 Three Element Feedwater Control
STEAM DRUM FEEDWATER
PRESSURE FLOW TEMPERATURE LEVEL PRESSURE FLOW TEMPERATURE

PT FT TE LT PT FT TE

f(x) f(x) f(x) f(x)

X X PRESSURE
X
COMPENSATION TEMPERATURE
PRESSURE AND CONDENSATION
TEMPERATURE
COMPENSATION ∆ A SET POINT
K

∆
K

T A
M/A CONTROL
STATION
Typical
Typicalsingle-drive
single-drive control
control system.
system.ForForsimplicity,
simplicity,redundant
redundant
transmitters havehave
transmitters not been shown
not been on this
shown ontypical control
this typical drawing.
control See
drawing. f(x) FINAL
See FigureFigure 4AANSI/ISA-S5.1-1984
4A for for ANSI/ISA-5.1-1984 format.
format. CONTROL
DEVICE
29

Block Diagram of Boiler Control

INPUT + OUTPUT
BOILER

FEEDWATER CONTROL

FUEL DEMAND FIRING

RATE
AIR DEMAND DEMAND

STEAM TEMPERATURE
CONTROL

30

© 2003, ISA
ES15w (1.0)
 Firing Single Fuel/Cross Limiting
STEAM
Fuel FLOW HEADER PRESSURE AIR FLOW

FT PT FT

A f(x)
P I

A T

SP SP

P I LO SELECT HI SELECT P I
Fuel CONTROL AIR CONTROL
A T A T

f(x)
Fuel Feed
AIR DAMPER 31

Dual Fuel O2 Trim

GAS FLOW OIL FLOW STEAM HEADER
AIR FLOW BOILER O2 STEAM
0-90,000 SCFH 0-10,000 PPH PRESSURE
0-850 PSI FLOW
FT 0-30” WC FT PT FT 0-5” WC AT O2 10%
FUEL
X
SUMMER SP
X Y A HEADER X
X
f(x)
I PRESSURE f(x) AIR FLOW
P
A
CONTROL CHARACT... P I
X SP O2 TRIM
A T X A T CONTROL
Z Y
FUEL P I Y SUB
CONTROL MASTER
A T C

X PV X Y Y X PV
SP SP SP
Y Y P I X B X
P I LOW SELECT HIGH SELECT P I

A T GAS CONTROL A T OIL CONTROL A T AIR CONTROL

GAS VALVE OIL VALVE

FAN DAMPER
32

© 2003, ISA
ES15w (1.0)
 Audio Instructions for Q&A Sessions

• Questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will

announce your name and affiliation to the audience and
then ask for your question.

• If other participants are asking questions, you will be

placed into a queue until you are first in line.

• While in the queue, you will be in a listen-only mode until

the operator indicates that your phone has been activated.
The operator will announce your name and affiliation and
then ask for your question.
33

Live Question and Answer Session

• During Q&A, questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will announce
your name and affiliation to the audience and then ask for your
question.

• If other participants are asking questions, you will be placed into a

queue until you are first in line.

• While in the queue, you will be in a listen-only mode until the

operator indicates that your phone has been activated. The
operator will announce your name and affiliation and then ask for
your question.

34

© 2003, ISA
ES15w (1.0)
 Excess Air vs. Boiler Load
EXCESS AIR
(% o2)

BOILER LOAD
(%)
0 50 100
35

Non Linear Flow

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

Flow in %

120

100 100

90
80 80 81

70
64 Series1
60 60
Series2
50 49
40 40
36
30
25
20 20
16
10 9
4
0 0 1
1 2 3 4 5 6 7 8 9 10 11

36

© 2003, ISA
ES15w (1.0)
 Characterization
0 10 20 30 40 50 60 70 80 O U T
0 7.5 15 22.5 30 37.5 45 52 .5 6 0 IN

90

80 80

70 70

60 60 60

5 2 .5
50 50
45
40 40
3 7 .5

30 30 30

2 2 .5
20 20
15
10 10
7 .5

0 0
1 2 3 4 5 6 7 8 9

37

Block Diagram of Boiler Control

INPUT + OUTPUT
BOILER

FEEDWATER CONTROL

FUEL DEMAND FIRING

RATE
AIR DEMAND DEMAND

STEAM TEMPERATURE
CONTROL

38

© 2003, ISA
ES15w (1.0)
 Water Side Control Mechanisms
DESUPERHEATER

From Power magazine Special SUPER-

Report, “Steam Generation,”
by R.J. Bender, Associate Ed.
HEATER
McGraw Hill, NY SECTIONS

PURE WATER SPRAYED INTO THE SUPERHEATED STEAM

VAPORIZES; DEGREE OF SUPERHEAT IS REDUCED HEAT
OF VAPORIZATION. 39

Typical Single Element Superheat Control

FINAL STEAM
TEMPERATURE

TT

SET POINT A ∆
K ∫

M / A CONTROL
A T A
STATION

0%
SPRAY
INTERLOCK A T T A

0% 100%

f(x) OPEN
CLOSE

SPRAY CONTROL VALVE SPRAY CONTROL VALVE 40

© 2003, ISA
ES15w (1.0)
 Typical Two-Element Superheat Control
Final Steam
Temperature

TT

Setpoint
∆
A
Transient
K ∫
Correction
Signal(s)
Load Feedforward
Calculation Σ
Index(es)

M / A Control
A T A
Station
0%

Spray
A T T A
Interlock
0% 100%

f(x) Open
Close
Spray Control Valve Spray Block Valve 41

Typical Three-Element Superheat Control

Final Steam Transmitter
Temperature Feedback (Note 1)
TT/
TT
FT

Set Point A
∆
Transient
K ∫
Correction
Signal(s)
Load Feedforward
Σ
Index(es) Calculation

∆
K ∫

M / A Control
A T A
Station
0%

Spray
A T T A
Interlock
0% 100%

Note: 1. Attemperator Outlet f(x) Open

Temperature or Spray Flow Close
42
Spray Control Valve Spray Block Valve

© 2003, ISA
ES15w (1.0)
 Audio Instructions for Q&A Sessions

• Questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will

announce your name and affiliation to the audience and
then ask for your question.

• If other participants are asking questions, you will be

placed into a queue until you are first in line.

• While in the queue, you will be in a listen-only mode until

the operator indicates that your phone has been activated.
The operator will announce your name and affiliation and
then ask for your question.
43

Live Question and Answer Session

• During Q&A, questions may be asked via your telephone line.

• Press the *1 key on your telephone key-pad.

• If there are no other callers on the line, the operator will announce
your name and affiliation to the audience and then ask for your
question.

• If other participants are asking questions, you will be placed into a

queue until you are first in line.

• While in the queue, you will be in a listen-only mode until the

operator indicates that your phone has been activated. The
operator will announce your name and affiliation and then ask for
your question.

44

© 2003, ISA
ES15w (1.0)
 Related Resources from ISA

• Complete, hands-on course on this topic

available through ISA Training Institute online
at www.isa.org/training
− Boiler Control Systems Engineering (ES15)
− Burner Management Systems Engineering (ES16)
− Available any time as on-site training

• Books, software, videotapes, interactive

multimedia
• Standards, journals, membership services

Phone: (919) 549-8411

E-mail Address: [email protected]
45

Additional ISA Resource Materials

• Fossil fuel power plant standards

− Boiler Combustion Control ANSI/ISA-77.41-1992
− Feedwater Control System ANSI/ISA-77.42.01-1999
− Plant Demand Development ANSI/ISA-77.43-1994
− Steam Temperature Control System ANSI/ISA-77.44-
1995
− Fossil Fuel Power Plant Instrument Piping Installation
ANSI/ISA-77.70-1994

46

© 2003, ISA
ES15w (1.0)
 Seminar Survey

• Web-based Seminar Surveys are tools to help ISA

maintain the quality of our training programs.
• Please complete the following four slides of the
survey and fax to ISA when it is complete.

Please fax completed survey pages to (919) 549-8288.

47

Seminar Survey (cont’d)

Date of Web-Seminar ___________________________

Please mark only one circle for each question.
Scale Definition: P-Poor; F-Fair; G-Good; VG-Very Good; E-Excellent
P F G VG E
1. Seminar objectives were clear and
attainable with the allotted time.
2. Pre-program seminar description
was accurate.
3. How was registration process?
4. How was the audio quality?

Please fax completed survey pages to (919) 549-8288.

48

© 2003, ISA
ES15w (1.0)
 Seminar Survey (cont’d)
Name of Presenter: _____________________
P F G VG E
5. Demonstrated practical
knowledge about the subject.
6. Provided clear answers to
questions/comments.

7. How many people listened at your site?

1-5 6-10 11-15 16-20 21+

Please fax completed survey pages to (919) 549-8288.

49

Seminar Survey (cont’d)

8. Would you participate in another
virtual seminar? Yes No
9. Did the web component add
to the value of the virtual seminar? Yes No
10. Did the seminar satisfy your
professional objectives? Yes No

11. How did you hear about this seminar?

_____________________________________________
_____________________________________________

Please fax completed survey pages to (919) 549-8288.

50

© 2003, ISA
ES15w (1.0)
 Seminar Survey (cont’d)
12. List other topics you would like to view as a web
seminar, along with your overall impression of the
program.
________________________________________________
________________________________________________

Name of Participant (optional) ____________________

Name of Your Company __________________________

Please fax completed survey pages to (919) 549-8288.

51

© 2003, ISA
ES15w (1.0)