INTRODUCTION AUTOMATIC BOILER CONTROLS

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Functions

MEASURE

COMPARE
COMPUTE

CORRECT

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What Makes It Work?

Low pressure air system
Continuous supply High quality

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Automatic Boiler Controls

Consist of three sub-systems
Automatic combustion control Automatic FEEDWATER control Main feed pump constant pressure

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Combustion Control
Maintains steam drum or SUPERHEATER outlet pressure Within 5 PSI of SETPOINT during steady state conditions

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Combustion Control
MEASURES STEAM PRESSURE
ACC

GENERATES A MASTER DEMAND FOR FUEL AND AIR

STEAM DRUM

MANIPULATES THE FORCED DRAFT BLOWERS & FUEL OIL CONTROL VALVE
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Combustion Control
MEASURES STEAM PRESSURE ACC
FORCED DRAFT BLOWER

MANIPULATES AIR FLOW TO THE BOILER BY INCREASING/DECREASING THE SPEED OF THE FORCED DRAFT BLOWER
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Combustion Control
MEASURES STEAM PRESSURE
ACC

MANIPULATES FUEL FLOW TO THE BOILER BY INCREASING/DECREASING FUEL FLOW TO THE BURNERS

FUEL OIL CONTROL VALVE

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Combustion Control
MEASURES STEAM PRESSURE
ACC
FORCED DRAFT BLOWER

FUEL OIL CONTROL VALVE

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Automatic/manual Control Stations

PRIOR TO THE FINAL CONTROL ELEMENT TO ALLOW FOR HUMAN INTERVENTION
AUTOMATIC SYSTEM

FINAL CONTROL ELEMENT

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Automatic FEEDWATER Control

Maintains water level in boiler steam drum
Plus or minus one inch from normal All steady state load conditions

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Automatic FEEDWATER Control

3 Element Feed

Water Level
+/-1 inch of Normal

MANIPULATES THE FEEDWATER CONTROL VALVE TO REGULATE FEED FLOW TO THE BOILER

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THREE ELEMENTS TO CONTROL FEEDWATER FLOW

DLT

SFT

DLT

FWCV

FFT

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SFT SF/FF RELAY

DLT

FWCV

FFT

FFC
FWCV POS FWC A/M

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Compensates For Shrink And Swell

Steam flow and drum level will respond in the same direction upon a boiler load change
Increase to increase

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Shrink & Swell

During up PWR MANUEVERS, a temporary rise in BLR WTR LVL occurs -called swell During DWN PWR MANUEVERS, a temporary drop in BLR WTR LVL occurs - called shrink

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Swell
Increase in STM demand:
More STM leaves BLR. Drum press starts decreasing. STM bubbles in GEN tubes expand. WTR level appears to swell.

Swell
Automatic combustion CONTRL system (acc sys) senses decrease in drum press and increases firing rate Drum press increases and regains SETPOINT WTR LVL decreases as bubble size decreases

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Swell
WTR reaches normal and get slightly below normal Automatic boiler control system (ABC sys) will increase feed flow to match STM flow WTR LVL achieves normal

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Shrink
During a DWN PWR MANUEVER shrink has the opposite effect :
Co wants all stop -- man overboard! Throttle closes STM drum press rises WTR level lowers or shrinks

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Shrink
Acc sys decreases firing rate Drum press regains SETPOINT WTR LVL increases WTR LVL reaches normal, and slightly above normal ABC sys decreases feed flow
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Main Feed Pump Controls

Maintain a constant pressure FEEDWATER supply to the boiler while on line Designed to supplement the FEEDWATER control valve
150 -200 PSI above steam drum pressure
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Main Feed Pump Controls

The output of the header pressure controller will be directly proportional to the actual header pressure
Increase - increase

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Feed Pump Controls

MAIN FD PUMP CONT.

MEASURES FEED PRESSURE FROM A COMMON HEADER TO ONE OR MORE BOILERS

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Feed Pump Controls

MAIN FD PUMP CONT.

GENERATES A DEMAND SIGNAL TO THE FEED PUMP STEAM ADMISSION VALVE

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Feed Pump Controls

MAIN FD PUMP CONT.

THROUGH THE A/M STATIONS ON THE CONSOLE

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Feed Pump Controls

MAIN FD PUMP CONT.

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Constant Pressure Regulator

Feed pressure directly opposes spring compression

From common Header

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Boiler Control Test

On-line alignment and verification Boiler flexibility test
Overall system reliability

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Final Control Elements

Fail safe positions
Combustion to minimum Water level to maximum FEEDWATER control valve open Feed pump steam admission valve fully open
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BOILER FLEX COMPONENTS

F/F FWC S/F SPT

FINAL CONTROL ELEMENTS

D/L

FDB

FOCV

MFP

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Air Pressure Failure

Air lock system
Holds final control elements Allows WATCHSTANDERS to take control of the plant

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NEEDLE VALVE INDIVIDUAL TRIP VALVE 40 PSI

RESET

MASTER TRIP 65 PSI

FROM A/M STATION

REDUCER 80 PSI
ALARM PRESSURE SWITCH

75 PSI 125 PSI

TO FINAL CONTROL 62B-208-33 ELEMNT00 11 AUG

THREE WAY VENT

Modes Of Operation
Automatic
Remote MAUNUAL Local manual

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NOW WE KNOW OUR ABCS

THE END

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Introduction To ABC System

62b-208

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