Instrumentation

Technologies for Safe,

Reliable & Efficient Boiler
Operations
Ryan Shea HVAC Product Marketing Manager
Siemens Industry, Inc. - Process Instrumentation

Internal Use Only/Confidential

Industrial Boiler Agenda

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Overview of Industrial Boiler Systems

Key Measurements
Combustion Control Systems
Furnace Pressure Control Systems
Feedwater/ Drum Level Control Systems

Internal Use Only/Confidential

Industrial Boiler Overview

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Industrial Boiler Background Information

Overview

Key Boiler Control Objectives

Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

Increased uptime and availability

Furnace Pressure

Decreased operating cost

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Reduced flue gas emissions

Increased boiler safety

Internal Use Only/Confidential

Industrial Boiler Agenda

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Overview of Industrial Boiler Systems

Key Measurements
Combustion Control Systems
Furnace Pressure Control Systems
Feedwater/ Drum Level Control Systems

Internal Use Only/Confidential

Key Boiler Measurement Points

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Combustion Air Flow

Fuel Flow
Furnace Pressure
Drum Level
Feedwater Flow
Steam Pressure
Steam Temperature
Steam Flow

Internal Use Only/Confidential

Pressure Measurement Devices

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Absolute Pressure
Gauge Pressure
Differential Pressure
Liquid Level Transmitter

Internal Use Only/Confidential

Temperature Measurement Devices

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Transmitters (Field, Head, Rail)

Elements (RTD, Thermocouple)
Thermowells

Internal Use Only/Confidential

Level Measurement Devices

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure

Differential Pressure

Radar

Guided Wave
Radar

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Capacitance

Point Level
Internal Use Only/Confidential

Flow Measurement Devices

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

Electromagnetic
Feedwater
Condensate

Furnace Pressure

Differential Pressure
Combustion Air
Steam
Fuel
Feedwater
Flue Gas

Clamp-On Ultrasonic
Feedwater
Condensate

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Vortex
Steam
Fuel

In-Line Ultrasonic
Feedwater
Condensate

Coriolis
Fuel Flow

Internal Use Only/Confidential

Industrial Boiler Agenda

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Overview of Industrial Boiler Systems

Combustion Control Systems
Furnace Pressure Control Systems
Feedwater/ Drum Level Control Systems
Key Measurements

Internal Use Only/Confidential

Industrial Boiler Combustion Controls

Stoichiometric Combustion
Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Combustion is the rapid oxidation of a fuel resulting in the release of usable

heat and production of a visible flame.
Carbon plus oxygen burn to form carbon dioxide plus heat.
(1)C + (1)O2 (1)CO2 + Heat
When burned with oxygen, hydrogen forms water vapor
plus heat:
(2)H2 + (1)O2 (2)H2O + Heat
When natural gas (methane) is burned with oxygen, both
carbon dioxide and water are formed:
(1)CH4 + (2)O2 (1)CO2 + (2)H2O + Heat

In this case, one cubic foot of methane and two cubic feet of oxygen are the
perfect, or stoichiometric mixture of fuels.

Internal Use Only/Confidential

Industrial Boiler Combustion Controls

Incomplete Combustion
Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Incomplete combustion yields carbon monoxide and hydrogen in the flue gas
that indicates the fuel is not being fully utilized.
AIR + Excess FUEL C + CO2 + H2O + CO + H2 + N2 + HEAT
Reduced combustion efficiency.
Increased gas emissions. NOx, CO, H2, Unburned Fuel, Soot
Fuel-rich environments - Potential safety hazards.

The primary objectives of combustion control are to maintain the air/fuel ratio
as close as possible to the ideal stoichiometric relationship.
Maximize efficiency
Maintain safety
Minimize emissions

Internal Use Only/Confidential

Industrial Boiler Combustion Controls

Overview

There are four different 'classifications' of combustion

control systems for various boilers:

Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

1. Single Point adjusted positioning type controls with no metering

of fuel or air. The adjustment comes from the master pressure
controller. Typically used on institutional packaged boilers.
2. Parallel adjusted positioning where the adjustment comes from
the master pressure controller. Typically used on industrial
process boilers with constant load.
3. Parallel adjusted with full metering of fuel and air and with fuel
limiting. Typically used on boilers with fluctuating load.
4. Any of types 1, 2 or 3 with combustion analysis device and
manual or automatic O2 trim. Used to obtain additional efficiency
from boiler.
Internal Use Only/Confidential

Boiler Master - Single Point Positioning

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Boiler Master - Parallel Positioning

Steam Header Pressure
MG000191

PT

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

Steam
Pressure
Setpoint

A
PID

Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

f(x)

f(x)

f(x)

Fuel Valve
Actuator

Forced Draft
Fan Damper

Internal Use Only/Confidential

Full Metered Combustion Control

Cross-Limiting
Steam Header
Pressure

Fuel Flow

PT

FT

Air Flow

Overview
Key Measurements
PID

Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure

Air/Fuel
Ratio Trim

FT

f(x)

Fuel %
FRD

Air/Fuel Ratio
Profiler

Equivalent
Air % FRD

A
(FRD)

Firing Rate
Demand (FRD)

X
I

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

P
A

Release To
Modulate

Low Fire
T

Low Fire

Release To
Modulate

Purge

Purge

MG000232r2

Minimum Air

f(x)
T

Fuel Valve Damper

f(x)
Forced Draft Fan Damper

Internal Use Only/Confidential

Combustion Control Oxygen Trim

Steam Flow
(Load)

Oxygen
Concentration

Airflow

FT

AT

FT

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

f(x)
Excess Oxygen
Set Point
Profile

Air/Fuel Ratio
Profile

f(x)

+
I

P
Bias

Air % FRD
A

Furnace Pressure

Release To
Modulate
AND
Oxygen Sensor
Enabled

Standby Air/Fuel
Ration Trim
A

T
Ratio
Trim

Set Point FRD

Fuel % FRD

X
P

A
Minimum Air

MG000161r2

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

FD Fan
Damper

Internal Use Only/Confidential

Industrial Boiler Agenda

Overview

Overview of Industrial Boiler Systems

Key Measurements

Combustion Control Systems

Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

Furnace Pressure Control Systems

Furnace Pressure

Key Measurements

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Feedwater/ Drum Level Control Systems

Internal Use Only/Confidential

Furnace Pressure Control

Feedwater

Overview
Key Measurements
Fuel

Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Furnace

Combustion Air

Flue Gas
Induced
Draft
Fan
Forced
Draft
Fan

MG000222

Heat
Exchanger

- There are four types of draft furnace arrangements:

1. Natural = Air and gases are moved using the chimney effect. Furnace pressure is
less than atmospheric pressure. Control is via an uptake damper at the boiler outlet.
Higher stacks are required.
2. Induced = ID fan(s) draw gases through the boiler. Furnace pressure is less than
atmospheric pressure. High stacks are not necessary. Control is via ID fan speed or
damper opening.
3. Forced = FD fan(s) push combustion air into the furnace. Furnace pressure is
above atmospheric pressure. Control is via FD fan speed or damper opening.
4. Balanced = Uses both ID and FD fan(s). Furnace pressure is slightly below
atmospheric. Control is maintained by regulating the airflow through the unit by the FD
fan(s) and the furnace pressure by the ID fan(s).
Internal Use Only/Confidential

Furnace Pressure Control

Fur nace
Pressure

Combustion Air
Controlled Variable
Overview

PT

Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim

A
Set Point

PID

Furnace Pressure

1
S +1

Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

K
Conversion
Ratio
MG000211r2

Impulse
Compensation

f(x)

f(x)

FD Fan
Damper

ID Fan
Damper

Internal Use Only/Confidential

Industrial Boiler Agenda

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Overview of Industrial Boiler Systems

Combustion Control Systems
Furnace Pressure Control Systems
Feedwater/ Drum Level Control Systems
Key Measurements

Internal Use Only/Confidential

Drum Level Control Single Element

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Drum Level Control Two Element

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Drum Level Control Three Element

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Drum Level Control Pressure Compensation

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Internal Use Only/Confidential

Other Major Control Loops Required

Overview
Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Beyond the loops discussed here, the following

control loops are required for proper control of the
boiler and steam system:
Blowdown Control
Feedwater Pressure Control
Deaerator Level Control
Boiler Water Treatment
Internal Use Only/Confidential

Conclusion

Overview

The level of complexity typically affects savings.

Key Measurements
Combustion
- Single Point
- Parallel
- Full-metered
- Oxygen trim
Furnace Pressure
Drum Level
- Single Element
- Two Element
- Three Element
- Pressure Comp

Adding additional measurement devices provides

greater visibility of process conditions within the
boiler and allows for tighter control.

- Higher Efficiency
- Improved Reliability
- Improved Safety

Internal Use Only/Confidential

Thank You!
For application assistance and questions you
can contact me at:
Ryan.Shea@siemens.com
631-245-4985

Internal Use Only/Confidential