Comm/ JB1153/C11

Rev 00 01/ 06.07.13

Isgec Heavy Engineering Ltd

SECTION 11 – BOILER CONTROL PHILOSOPHY

Instrumentation & Control controller.

System
3 Transmitter
Instrumentation and control system is
Secondary Element.
designed for minimum local manning
and operator attention with the It has the responsibility of passing the
facility for local start up and shut information acquired by the sensor to
down, if required. The basic need of controller and sending the controller
the instrumentation is for safe decision to the final control element.
operation and efficient functioning of Measurement and control signals may
the plant. This can be achieved by be transmitted or as electrical signals.
installing optimum number
measurement, indicating, Typical examples: Electrical
transmitting and controlling transmitters.
instruments for all required
parameters of the plants (e.g. 4 Final control element
pressure, level, temperature, flow etc.)
Operator supervision shall normally Have the task of actually implementing
be from DCS. Alarm annunciation for the control command issued by the
process and equipment malfunction controller on the process.
has been envisaged in DCS.
Typical examples: Control valve, VFD
BASIC COMPONENTS OF A motors, electric motors etc.
CONTROL SYSTEM/ CONTROL The importance of these components is
SYSTEM HARDWARE that they perform the three basic
operations that must be present in
every control system. These operations
There are four basic components of all
are:
control systems:

1. Sensor 1. Measurement (M): Measuring the

variable to be controlled is usually
Also often called as Primary Element. done by the combination of sensor
and transmitter.
Acquires information about the status
of the process variables. 2. Decision (D): Based on the
Typical examples: measurements and the set point,
RTD/Thermocouples (for temperature the controller must then decide,
measurements), Capacitance type what to do to maintain the variable
cells (for liquid level /draft /pressure at its desired value.
measurements), etc.
3. Action (A): As the result of the
controller's decision, the system
2. Controller must then take an action. This is
usually accomplished by the final
The Brain or Heart Of the control control element.
system (the decision maker).
It is the hardware element with Built-
in capacity for performing the only Operator Interface:
task requiring some forms of
Intelligence. For smooth operation of boiler, the
following minimum features are
Typical examples: Electronic required at DCS:
controllers, digital computers used as

1 x 60 TPH, 47 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 1

Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.
 Comm/ JB1153/C11
Rev 00 01/ 06.07.13
Isgec Heavy Engineering Ltd

- Real/ Historical trends pressure (Draft) is one of the boiler

- Data overview display interlock signals.
- Graphical mimic with dynamic
animation In this control loop, Furnace pressure is
- Data storage and retrieval controlled by ID fan Inlet Guide Vanes/
- On demand/ shift/ daily /weekly VFD. Furnace pressure signal is fed to
reports furnace draft controller which controls
- Extensive alarm management the furnace pressure by ID FAN Inlet
- Event storage Guide Vanes (IGV) opening / VFD speed
- Engineering software function as per the deviation from set point.
-Tuning of control parameters Control action of this controller is Direct
-Changing of alarm i.e. if draft value increases the opening
of IGV/speed command to VFD also
Signal using for realising close loop increases and vice versa.
control and data acquisition:
IGV and VFD is controlled by separate
-Transmitter signal: 4 to 20 mA controllers and at a time only one
-Thermocouple signal: mV controller will be in auto mode and the
-RTD signal : Resistance other one, which will be in manual,
should be given 100% command. Ratio
factor is provided to balance the load on
Major Control Loops of the boiler parallel fans as per the site condition.
Initially the ratio is kept 1.
- Furnace Draft Control
2. STEAM TEMPERATURE:
- Steam Temp Control
This loop maintains a constant
- Drum Level Control temperature of steam at final super
heater outlet. The outlet steam
- Combustion Control
temperature is sensed using
- Deaerator level control temperature sensors.
- Deaerator Pressure Control A cascade control strategy is followed to
take care of final super heater response
- CBD Tank level control
to the spray water control provided
- Start Up Vent Control between stages of the superheaters.
The master controller takes the input of
- BFP Discharge Header Pressure
main steam temperature and generates
Control
controller output used as set point to
- Soot Blower Pressure Control slave controller. The slave controller
gets process value of steam temperature
after attemperator and regulates the
attemperator valve.
For better control, in addition to this, a
part of feed forward signal of furnace
1. FURNACE DRAFT CONTROL:
temperature difference with respect to
Typically the boiler flue gas system time is added with the slave controller
comprises two Induced draft (ID) alias output.
flue gas fans with inlet vanes or inlet
damper, and the dampers after the 3. DRUM LEVEL CONTROL:
fan. Alternatively the control vanes
A. Drum level is measured using drum
can be replaced with Variable
level transmitters. The final output is
frequency Drives as speed controller
compensated for drum pressure. As the
for Fans.
characteristics of Drum pressure Vs
Furnace pressure transmitters are Drum level is non-linear, the
located at the same elevation in upper compensated signal is to be generated
section of the furnace. The furnace in DCS.

1 x 60 TPH, 45 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 2

Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.
 Comm/ JB1153/C11
Rev 00 01/ 06.07.13
Isgec Heavy Engineering Ltd

B. Main Steam Flow 100% feed water flow control valve is

having option to control water flow in
Main Steam flow is measured with the
boiler in Single element drum level
help of steam flow transmitters.
control and Three element drum level
These transmitters output is
control.
compensated for main steam pressure
and main steam temperature. Three element drum level control loop
take care of sufficient water flow by
This compensated flow is computed in
considering the drum level with
flow computing circuit where
additional two parameters i.e. total feed
averaging of compensated steam flow
water flow and compensated main
signal is generated as per following
steam flow.
formula
In this control loop, 100% feed water
QC=Q x √ (Pa+1.033) x (Td+273) control valve is controlled. In this
(Pd+1.033) x (Ta+273) control we first take the difference of
Where compensated main steam flow and total
QC=Compensated Steam Flow feed water flow. Then this difference is
Q=Un-compensated Steam Flow from FT re-ranged from +100 to -100 with
Pa=Process Value of Main Steam Pressure respect to +feed water flow range to –
Ta=Process Value of Main steam temp.
feed water flow range. This value is then
Pd=Design Pressure
Td=Design Temperature.
multiplied with a factor called Steam
Load Factor (initially kept 0.3, which is
Note: Pd and Td are the values on finally adjusted during the
which DP calculations are done by commissioning of Boiler). This value is
nozzle supplier. All pressures are in passed through a selector switch which
Kg/Cm2 and Temperatures are in passes 0 when single element is
DegC. selected and passes the previously
calculated value when three element is
C. Feed Water Flow
selected. Output of selector switch is
Feed Water Flow is measured with the directly added to the output of PID
help of flow transmitter. The output of block which gives the output by
these transmitters is used in three considering the drum level.
element control.
Now if the selector switch is in single
Note: If spray water tapping is taken element position, selector switch passes
before feed water nozzle, Spray flow is 0 and then drum level control is
to be added with Feed water flow to considering the drum level only and if
calculate total water consumption. the selector switch is in three element
position, selector switch passes the
Control Loop
calculated value generated by the
Drum Level Control for 30% difference of compensated main steam
Control Valve: flow and total feed water flow which is
added in the output of PID block
The compensated drum level signal is
considering drum level. In three element
compared with the set point in the
control, a feed forward signal of the
primary level controller and the
difference in steam and feed water flow
output of the control controller is
is utilized to compensate the water fed
used to regulate the 30% control
to the drum in fluctuating conditions of
valve.
load to make the control more effective.
30% feed water flow control valve is
working only in Single element drum 4. COMBUSTION CONTROL:
level control loop and take care of
A. Combustion Air Control
boiler feed water demand at start-up
duration and at lower load. This control loop controls the air supply
to the boiler thru various fans and
Drum Level Control for 100% controls the fuel feeding depending on
Control Valve: the boiler load and maintains the boiler

1 x 60 TPH, 45 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 3

Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.
 Comm/ JB1153/C11
Rev 00 01/ 06.07.13
Isgec Heavy Engineering Ltd

pressure and excess air levels in the be immediately stopped if such

boiler. condition arises.
Required combustion air quantity of Control Loop:
solid fuel is determined based on air
Oxygen trimming controller is giving the
requirement at various loads. This is
O/P which is scaled between 0.9 to 1.1
compensated based on excess oxygen
and the same is multiplied and send to
level to increase or decrease the air
the air flow controller as a remote set
flow to maintain the required
point.
conditions.
Control action of this controller is
The fuel supply to the boiler shall
Reverse i.e. if flow value increases the
depend on the boiler load and the
output of controller decreases and vice
pressure of the boiler.
versa.
Control Loop:
C. Main Steam Pressure Control
This loop maintains required air flow
The objective is to match the boiler’s
in boiler as per the load v/s air flow
steam production to the steam demand
curve. In this control loop, FD air flow
of the process. To accomplish this
is controlled by fan Inlet Guide Vanes
objective the system must be designed
/ VFD.
to maintain a constant steam pressure
FD fan air flow signal with density and generate a demand for fuel to the
correction is fed to FD air flow boiler.
controller which controls the FD fan
The plant load change cause the steam
air flow as per the deviation from the
flow to change which in turn causes a
remote set point generated out of the
change in the main steam pressure.
curve depending on the load on the
Main steam pressure controller adjusts
boiler.
the demand to the fuel which eliminates
Control action of this controller is deviation between the pressure set point
Reverse i.e. if flow value increases the and the steam pressure measurement.
output of controller decreases and
The Boiler Masters output sets the
vice versa.
demand to the boilers fuel which in turn
B. Oxygen Trim Control respond accordingly to both satisfy the
steam flow demanded by the process
The oxygen trim controller is
and eliminate any deviation between the
responsible for controlling the boiler’s
main steam pressure and the pressure
excess air by trimming the air flow
set point.
based on the oxygen content
measured in the flue gas. The Control loop:
controller compares the oxygen
The main steam pressure control of the
content of the flue gas to the operator
boiler depends on the steam demand
adjustable set point and accordingly
from the system. If the steam demand
generates an output that will cause
from the system is high, then high
an adjustment to the set point of the
amount of fuel shall be required to
air flow controller. The adjustment is
maintain the pressure and vice versa. In
limited to ±10% of the required
order to maintain a constant pressure,
airflow.
the steam generation shall be increased
It should be noted that oxygen by increasing the fuel flow. Main Steam
content in flue gas is one of the most Pressure is considered as a major
important variables to be monitored parameters for combustion control.
during the operation of the boiler. A
The measured value is compared with
low content is indicative of fuel
main steam pressure set point meant
overfeeding into the combustion
for fuel flow and combustion air flow
chamber, and an alarm will be
control logic system. The master
initiated to warn the operators when a
pressure controller will generate the
low oxygen condition (typically<1%
demand signal for fuel.
O2) is detected. Fuel feeding should
1 x 60 TPH, 45 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 4
Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.
 Comm/ JB1153/C11
Rev 00 01/ 06.07.13
Isgec Heavy Engineering Ltd

For better control, in addition to this, Pressure control valve. The Deaerator
a part of feed forward signal of Pressure signal is fed to controller
furnace temperature and main steam which controls the Pressure by Pressure
flow difference with respect to time is control valve as per the deviation from
added with the controller output. set point.
The fuel demand signal of master Control action of this controller is
pressure controller is given as set Reverse i.e. if Pressure value increases
point to individual fuel feeder drives the opening of control valve decreases
with adjustable gain factor. and vice versa.
Individual analog output signal is
provided with an Auto/Manual station
7. CBD TANK LEVEL CONTROL
in DCS system to each feeder.
The CBD tank level is controlled by the
Control action of this controller is
control valve which is located between
Reverse i.e. if pressure value
the blow down tanks.
increases the output of controller
decreases and vice versa. The loop maintains the CBD vessel level
at a predetermined value. The level is
Secondary Air Header Pressure
sensed by the level transmitter and
Control
used as a feed forward signal to the
In this control loop, SA fan discharge controller This final output of the
pressure is controlled by regulating controller will regulate the control valve.
the SA fan. SA fan discharge pressure
Control action of this controller is Direct
signal is fed to SA fan discharge
i.e. if level value increases the output of
pressure controller which controls the
controller increases and vice versa.
discharge pressure as per the
deviation from set point.
8. START UP VENT CONTROL
Control action of this controller is
Start up vent control valve maintains
Reverse i.e. if SA pressure increases
the minimum main steam flow and the
the opening command decreases and
main steam pressure (in case pressure
vice versa.
increases beyond a predetermined
5. DEAERATOR LEVEL CONTROL: value). Main steam Pressure and
Minimum steam flow is maintained by
In this control loop, Deaerator level is
two different controllers by higher
controlled by Deaerator level control
output selection.
valve. Deaerator level signal is fed to
controller which controls the Control action of main steam pressure
Deaerator level by level control valve controller is Direct i.e. if pressure value
as per the deviation from set point. increases the output of controller
increases and vice versa.
Control action of this controller is
Reverse i.e. if level value increases the Control action of minimum main steam
opening of control valve decreases and flow controller is Reverse i.e. if flow
vice versa. value increases the opening of control
valve decreases and vice versa.
DEAERATOR OVER FLOW
CONTROL
9. SOOT BLOWER PRESSURE
High-High level, operates the over flow CONTROL
control valve in On/Off mode, thereby
maintaining the water level in In this control loop, Soot blower
Deaerator up to desired limits. Pressure is controlled by soot blower
Pressure control valve. Soot blower
6. DEAERATOR PRESSURE Pressure signal is fed to controller
CONTROL: which controls the soot blower Pressure
by Pressure control valve as per the
In this control loop, Pressure of
deviation from set point.
Deaerator is controlled by Deaerator

1 x 60 TPH, 45 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 5

Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.
 Comm/ JB1153/C11
Rev 00 01/ 06.07.13
Isgec Heavy Engineering Ltd

Control action of this controller is

Reverse i.e. if Pressure value
increases the output of controller
decreases and vice versa.

10. BFP DISCHARGE HEADER

PRESSURE CONTROL

In this control loop, BFP discharge

header pressure is controlled by
VFD/Fluid Coupling. BFP discharge
header pressure signal is fed to
controller which controls the BFP
discharge header pressure by
regulating the VFD speed /scoop
command as per the deviation from
set point. The normal set point for
this controller is 5 to 10 kg/cm2
above drum pressure.
Control action of this controller is
Reverse i.e. if Pressure value
increases the output of controller
decreases and vice versa.

1 x 60 TPH, 45 kg/cm2(a), 400+- 10 deg C,Slop fired TG Section 11, Page 6

Boiler
M/s. Bajaj Hindusthan Sugars Ltd, U.P.