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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) 4932825.
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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) 4932825.
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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) 4932825.
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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.
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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: jgilman@cinci.rr.com or (513) 522-4154
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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
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Boiler Fuels
Gas Oil Coal Fuel combinations

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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
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SAMA Symbols (contd)

MEASURING/READOUT 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 W = Weight 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.

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2003, ISA ES15w (1.0)

SAMA Symbols (contd)

FUNCTION SIGNAL PROCESSING SYMBOL FUNCTION SIGNAL PROCESSING SYMBOL

SUMMING AVERAGING DIFFERENCE PROPORTIONAL INTEGRAL DERIVATIVE MULTIPLYING DIVIDING ROOT EXTRACTION EXPONENTIAL NON-LINEAR FUNCTION TRI-STATE SIGNAL (RAISE, HOLD, LOWER)

or + /n or K or P or I d/dt or D X X
n

INTEGRATE OR TOTALIZE HIGH SELECTING LOW SELECTING HIGH LIMITING LOW LIMITING REVERSE PROPORTIONAL VELOCITY LIMITING BIAS TIME FUNCTION VARIABLE SIGNAL GENERATION TRANSFER SIGNAL MONITOR

-K or -P V f(t) A T H/, H/L, /L

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f(x)

Simple Feedback Control

PRIMARY VARIABLE XT

K SET POINT A T A

PROCESS

f(x) MANIPULATED VARIABLE

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2003, ISA ES15w (1.0)

Feedforward Plus Feedback Control

PRIMARY VARIABLE XT SECONDARY VARIABLE YT K PROCESS

SET POINT

f(x) MANIPULATED VARIABLE

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

f(x) MANIPULATED VARIABLE

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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

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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.
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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.
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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

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2003, ISA ES15w (1.0)

Boiler Components
SPRAY WATER FROM FEEDWATER PUMP DESUPERHEATER STEAM DRUM STEAM FROM SECOND BOILER STEAM FROM THIRD BOILER

SUPERHEATER

COLD AIR

STEAM HEADER

STEAM TO THE PROCESS

COLD AIR DAMPER

HOT AIR DAMPER HOT AIR SECONDARY AIR

COLD AIR

FEED WATER

FROM OTHER PULVERIZERS

FLUE GASES AIR HEATER

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

TOTAL AIR AMBIENT AIR

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

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Block Diagram of Boiler Control

+

INPUT

BOILER

OUTPUT

FEEDWATER CONTROL

FUEL DEMAND AIR DEMAND

FIRING RATE DEMAND

STEAM TEMPERATURE CONTROL

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2003, ISA ES15w (1.0)

Furnace Pressure Control

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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.
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2003, ISA ES15w (1.0)

Block Diagram of Boiler Control

INPUT

BOILER

OUTPUT

FEEDWATER CONTROL

FUEL DEMAND AIR DEMAND

FIRING RATE DEMAND

STEAM TEMPERATURE CONTROL

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Boiler Steam Drum/Swell Shrink

SATURATED STEAM

STEAM

FEEDWATER WATER

WATER

WATER-MIXED STEAM BUBBLES

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2003, ISA ES15w (1.0)

Single Element Feedwater Control

DRUM LEVEL LT PT f(x) X DRUM PRESSURE PRESSURE COMPENSATION

A SET POINT

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.
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Two Element Feedwater Control

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

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.

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2003, ISA ES15w (1.0)

Three Element Feedwater Control

STEAM PRESSURE PT FLOW FT DRUM FEEDWATER FLOW TEMPERATURE FT TE TEMPERATURE LEVEL PRESSURE TE LT PT

f(x) X

f(x) X PRESSURE AND TEMPERATURE COMPENSATION K

f(x)
PRESSURE COMPENSATION

f(x) X TEMPERATURE CONDENSATION

SET POINT

A M/A CONTROL STATION

Typical single-drive control system. For simplicity, redundant Typical single-drive control system. For simplicity, redundant transmitters havehave not been shown on this typical control drawing. transmitters not been shown on this typical control drawing. See Figure 4A for ANSI/ISA-5.1-1984 format. See Figure 4A for ANSI/ISA-S5.1-1984 format.

f(x)

FINAL CONTROL DEVICE

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Block Diagram of Boiler Control

INPUT

+
BOILER

OUTPUT

FEEDWATER CONTROL

FUEL DEMAND AIR DEMAND

FIRING RATE DEMAND

STEAM TEMPERATURE CONTROL

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2003, ISA ES15w (1.0)

Firing Single Fuel/Cross Limiting

Fuel FLOW FT STEAM HEADER PRESSURE PT AIR FLOW FT

A P A T I

f(x)

SP P A T I LO SELECT Fuel CONTROL HI SELECT

SP P A T I AIR CONTROL

f(x) Fuel Feed AIR DAMPER

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Dual Fuel O2 Trim

GAS FLOW 0-90,000 SCFH FT 0-30 WC FUEL SUMMER X Y A FUEL CONTROL A X PV P I A T SP Y GAS CONTROL X SP I Y T SP X Y P I A T Y Y X SP P I A T AIR CONTROL OIL FLOW 0-10,000 PPH FT STEAM HEADER PRESSURE 0-850 PSI PT
X

AIR FLOW FT 0-5 WC

BOILER O2 AT O2 10%

STEAM FLOW

A P A T I

HEADER PRESSURE CONTROL

X SP X f(x) f(x) AIR FLOW CHARACT... P I O2 TRIM X A T CONTROL Y Z

SUB MASTER C PV

X X B LOW SELECT HIGH SELECT OIL CONTROL

GAS VALVE

OIL VALVE FAN DAMPER

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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.
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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.
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2003, ISA ES15w (1.0)

Excess Air vs. Boiler Load

EXCESS AIR (% o2)

50

100

BOILER LOAD (%)

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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

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2003, ISA ES15w (1.0)

Characterization
0 0 10 7.5 20 15 30 22.5 40 30 50 37.5 60 45 70 52 .5 80 O U T 6 0 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 2 2 .5 40 30 50 45 3 7 .5 60 5 2 .5 70 60 80

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Block Diagram of Boiler Control

INPUT

+
BOILER

OUTPUT

FEEDWATER CONTROL

FUEL DEMAND AIR DEMAND

FIRING RATE DEMAND

STEAM TEMPERATURE CONTROL

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2003, ISA ES15w (1.0)

Water Side Control Mechanisms

DESUPERHEATER

From Power magazine Special Report, Steam Generation, by R.J. Bender, Associate Ed. McGraw Hill, NY

SUPERHEATER SECTIONS

PURE WATER SPRAYED INTO THE SUPERHEATED STEAM VAPORIZES; DEGREE OF SUPERHEAT IS REDUCED HEAT OF VAPORIZATION.

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Typical Single Element Superheat Control

FINAL STEAM TEMPERATURE TT

SET POINT

A K

M / A CONTROL STATION

A 0%

SPRAY INTERLOCK

A 0%

A 100%

f(x) SPRAY CONTROL VALVE

OPEN CLOSE SPRAY CONTROL VALVE

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2003, ISA ES15w (1.0)

Typical Two-Element Superheat Control

Final Steam Temperature
TT

Transient Correction Signal(s) Load Index(es)

Setpoint

A
K

Feedforward Calculation

M / A Control Station

A 0%

Spray Interlock

A 0%

A 100%

f(x)

Spray Control Valve

Open Close Spray Block Valve

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Typical Three-Element Superheat Control

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

Transient Correction Signal(s) Load Index(es)

Set Point

A K

Feedforward Calculation

M / A Control Station

A 0%

Spray Interlock

A 0%

A 100%

Note: 1. Attemperator Outlet Temperature or Spray Flow

f(x) Spray Control Valve

Open Close Spray Block Valve

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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.
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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: info@isa.org
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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-77.441995 Fossil Fuel Power Plant Instrument Piping Installation ANSI/ISA-77.70-1994

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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.

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Seminar Survey (contd)

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 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?

VG

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

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2003, ISA ES15w (1.0)

Seminar Survey (contd)

Name of Presenter: _____________________
P 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 F G VG E

21+

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

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Seminar Survey (contd)

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

11. How did you hear about this seminar? _____________________________________________ _____________________________________________

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

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2003, ISA ES15w (1.0)

Seminar Survey (contd)

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.

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2003, ISA ES15w (1.0)