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 controlvil 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