BOILER
ENGINEERING‘The information peesented in this publication is forthe general education of the reader.
Because neither the author nor the publisher have any control over the use of the inform2-
sion by the reader, both the author and the publisher discaimn any and all abiiey of any kind
arising out of such use. The reader is expected to exercise sound professional judgment in
using any of the information presented in 2 particular application.
‘Additionally neither the author nor the publisher have investigated or considered the effect
of any patents on the ability of the reader to use any of the information in a particular appli-
‘ation. The reader is responsible for reviewing any possible patents that may affect any
particular use of the information presented.
Any references to commercial products in the work are cited as examples only, Neither the
‘asthor nor the publisher endorses any referenced commercial product. Any twademarks ot
trade names referenced belong, to the respective owner of the mark or name, Neither the
author nor the publisher makes any representation regarding the availability of any referenced
‘commercial product at any time. The manofacturer’ instructions on use of any commercial
product must be followed at all times, even ifn conflict with the information in this publi-
pytight G 2005 by ISA ~The Instrumentation, Systems, and Automation Society
67 Alexander Drive
B.O.Box 12277
Research Triangle Park, NC 27709
All rights reserved,
Printed in the United States of America
1098765432
ISBN 1-88617-907-3
No part of this work may be reproduced, stored in 2 retrieval system, or transmitted in any
form or by any means, electtonic, mechanical, photocopying, reconling or otherwise, without
the prior written permission of the publisher.
Publication Data
Library of Congress Cataloging
Gilman, G.F (ery)
Boiler control systems engineering / G.E (ferry) Gilman,
pe
ISBN 1-55617-907-3 (pbk)
41, Seeam-boiless--Automatic control. I-Tite.
728.6527 2005
621.1994—de22
2005010930
About the Author
Jerry Gilman’ career has spanned over 35 years with Procter & Gamble (P&G), and its sub-
sidiaries.As 4 process control systems engineer for P&G, Gilman was dedicated to improving
control systems and implementing new cechnology in numerous product areas at P&G in the
US and foreign countries. One of his aeas of expertise has been with boiler contiol systems
engineering: improving efficiency, conserving energy, and working asa primary troubleshooter
fon boilers and other combustion systems.
A licensed profesional engineer, Jerry Gilman currently provides training and consulting to
numerous utility and industrial plants. This includes performing startups, tunting, and tou
bleshooting more than a hundred boilers and combustion systems such as dryers, roasters, and
ovens. Gilman's experte in fuels and combustion contol ranges from finding solutions for
new unit applications to retcofiting existing installations in order to save fel, change feels, or
improve overall contcol. He has applied his experience in combustion testing and energy uti
zation to help simplify boiler performanee monitoring technigues and methods. His
approaches are easy to understand and use effectively.
Jerry Gillman is ako an insteuctor and course reviewer for ISA (The Instrumentation, Systems,
‘and Automation Society) and developed the “ISA Boiler Control Systems Engineering” and
“ISA Burner Management Systems Engineering” taining courses. He has been a guest speaker
oon boiler control, burner management, and boiler safety issues at various ISA section meetings
and other user groups and seminars. Additionally, he was a technical advisor for “Win Boiler
Sins!” 2 PC based boiler taining program sold through ISA.
Jerry Gilman is an active member on the following ISA Standards Committees: ISA SP84 Pro-
igrmumable Electronic Systems (PES) for Use in Safery Applications, ISA SP84 Burner
“Management System Working Geoup; and ISA SP77 Fossil Fuel Power Plant Standards
About the Cover Illustration
‘The cover graphic is 2 representation of the fuel gas, water tube, forced draft boiler simulated
in the program Win Boiler Sim developed by Len Klochek and sold through ISA. The
Windows-based simulation program was developed as 2 taining cool, allowing personnel
swhose interests include boiler operations, as well as instrumentation and céntrol maintenance
and design, to obtain an understanding of the variows control strategies and tuning procedures
used on water tube boilers including: three clement/single clement drum level control, ait
flow/fuel flow cross limiting, and steam pressure control. In addition, a burner management
system that follows the requirements of the NFPA 85 Boiler and Combustion Systems Hazard
Code, 2004 Edition, Chapter 5: Single Burner Boiler, is part of the simulation allowing per-
sonnel to simulate a fall boiler startup ffom fling boiler drum, light-off to fill load. The
program is used by the author as part of the ISA. taining seminars on boiler controlvil
1
i
2
2
2
2
a5
ay
6
6
7
8
Table of Contents
Chapter 1 — Boiler Fundamentals .
Basic Boilers a
Boiler Components
Furnace. .
Fans.
Windbox
Flue Gas Heat Exchangers...
Combustion Air Preheater
Economizer .....
Supecheater eh
Boiler Drums 3
Piping and Instrament Diagrams (PIDs) .
Design Basis Check List
Chapter 2 — Control of Boilers
Control Strategies «
Bumopless Transier
Simple Feedback Control.
Feedforward plus Feedback Control.......2. 10
Cascade Control ....0060000+ : bee elt
Ratio Control SS pnesectgee le
Feedforward Control Ss Ogee ee
Controller Tuning a 13
Determining Gain, Reset, and Derivative... 0... 15
Gain vs. Propoztional Band (PB) v
Controller Actions. . : oa a
Conteollex Actions Setup ate 56 20
The Effects on Taning.....- cecee ee 20
Calibration Effect on Gain. . esol sgl
Transmitters he sirinkiiiop an 0
Redundancy : at
Interlock Circui Beacon sts e 21
Final Control Element... weve ne
Chapter 3 — Furnace Draft... sites aston 23
Pressure Fired Boilers. 23
Balanced Draft Boiler Fans. 4
Furnace Pressure Control, : 24