ISSN 00406015, Thermal Engineering, 2012, Vol. 59, No. 10, pp. 747–754. © Pleiades Publishing, Inc., 2012.

Original Russian Text © V.I. Pavlich, V.V. Pchelkin, I.L. Ryashchenko, A.G. Shchelokov, 2012, published in Teploenergetika.

Automation of the LargeCapacity HotWater Boilers Installed

at the Tyumen TETs2 Cogeneration Station,
a Branch of OAO Fortrum
V. I. Pavlicha, V. V. Pchelkinb, I. L. Ryashchenkob, and A. G. Shchelokova
a
Tyumen TETs2 Cogeneration Station, a Branch of OAO Fortrum, Shirotnaya ul. 200, Tyumen, 625053 Russia
b ZAO Engineering Center of Uraltekhenergo, ul. Malysheva 105, Yekaterinburg, 620062 Russia

Abstract—The basic solutions used in constructing the fullscale automated process control system for
KVGM180 hotwater boilers are outlined.
DOI: 10.1134/S0040601512100126

The Tyumen TETs2 cogeneration station, a facil
ity intended for supplying heat to the city of Tyumen,
which was commissioned in the 1980s, is equipped
with four 200MW power units. Three of these power
units are cogeneration ones and fitted with three
KVGM180 hotwater boilers. One of these power
units is equipped with six burners, and the remaining
two, with eight burners. The hotwater boilers operate
in seasonal and peakload modes; their operation
involves frequent startups and shutdowns and frequent
variations of heat load. In accordance with the project,
the operator of hotwater boilers performs their con
trol from a group control board (GCB) situated in a
separate room. Obviously, with such arrangement an
additional burden is placed on the cogeneration sta
tion’s operative personnel, because the power station
staff must include skilled shift personnel charged with
operation of the hotwater boilers, and it should be
noted that these boilers are not used in the summer
season. Therefore, when the need arose to replace the
automatic control systems of the hotwater boilers, the
strategy of fitting three hotwater boilers with a full
scale automated process control system (APCS) was
chosen. Not only does the use of this system allow the
hotwater boilers to be comprehensively automated,
but it also allows the boilers to be controlled both from
the GCB and from the 200MW power units control
room (UCR1).
The APCS project, the monitoring and control
algorithms, and the adjustment works were carried out
by specialists of ZAO Engineering Center of
Uraltekhenergo, which have gained great experience
with carrying out similar works at power facilities in
Russia.
In the fall of 2011, the work for retrofitting the
APCS of the hotwater boilers was accomplished. The
retrofitted APCS was constructed on the basis of the
KosmotronikaVenets computerized automation sys
tem (CAS) produced by ZAO PIK Progress (Mos
cow). It should be pointed out that earlier, specialists
of Uraltekhenergo’s Engineering Center used similar
CASs for constructing the APCS for two 200MW
power units at the Tyumen TETs2 cogeneration sta
tion. Concurrently with retrofitting the APCS, works
were carried out for bringing the boiler gas equipment
in compliance with the requirements of the existing
safety regulations, due to it became possible to con
struct a modern automated system for safely kindling
the burners.
In modernizing the boiler gas supply arrangement,
the two stop gate valves installed upstream of each
burner were replaced by a safetyandstop valve (SSV)
and a stopandcontrol valve (SCV) produced by
OOO NPP ENERGOMASHEngineering (the city of
Taganrog), which were installed along the flow of
gases. Both valves were of a balanced type with a rotary
gate.
The automatically cocked valve produced by ZAO
AMAKS was used instead of the manually cocked
boiler gas shutoff valve.
Some supplementary tasks were set forth in the
course of APCS construction in addition to the stan
dard requirements for the boiler monitoring and con
trol functions:
—The maximally possible automation of prepara
tory and startup operations had to be achieved with the
existing extent to which the boilers were fitted with
electrically operated valves and instrumentation.
—A system for safely kindling the burners had to
be developed, which would include the required scope
of process protections and interlocks prescribed by the
relevant standards and logic programs for checking the
tightness of the gas valve gate and for automatically
kindling the burner.
—Means had to be developed for automatically
bringing the boiler to operate at any heat load (within

747
748 PAVLICH et al.

Table
Switching the main controllers into
Main process operations Method of carrying out operations
operation
Checking the tightness of gas line and FGC algorithm “Pressurization of gas line When taken from repair/standby
safety shutoff valves by air by air” and “Pressurization of burners” mode
Setting up circulation of water through Remote with keys control valve (operated –
the boiler by operator of boilers)
Removing the gas line plug Manual –
Speeding up the FDF, EF, and GRF, FGC algorithm “Starting the GAP” FUC, TAC (switched into operation
ventilating the boiler, and setting the by the GAP FGC system)
GAP kindling mode
Filling the gas line and checking the FGC algorithm “Gas admission” and GFC (mode P), switched into opera
tightness of gas valves by gas “Pressurization of burners” tion by the “Gas admission” algorithm
Analysis of the lack of: Manual –
CH4 in the firebox and flue of the
boiler;
O2 in the gas pipe of the boiler after
purging of natural gas
Kindling two lowertier burners ACLS “Kindling burner No. i” BGPC of burner No. i, GFC (mode P)
Kindling/disconnecting the burners and ACLS "Kindling burner No. i”, PAUK, GFC (mode F) and HLC are switched
picking up the preset boiler load HLC into operation by the operator
Note: FDF is a forced draft fan, EF is an exhaust fan, GRF is a gas recirculation fan, GAP is the boiler gas–air path, BGPC is the burner
gas pressure controller, PAUK is the automatic boiler control program, RFG—regulator of fuel gas; FUC is the furnace under
pressure controller, TAC is the total air controller, and HLC is the boiler heat load controller.

the working range of its loads) determined by the dis
patch schedule at a rate specified by the operator.
—The possibility had to be provided to control the
boilers both from the group control board and from the
power unit control room.
A set of functionalandgroup control (FGC) algo
rithms and the automatic closedloop control system
(ACLS) connected with these algorithms have been
developed. The scope of process operations performed
by the logic control subsystem and interconnection
between the FGC and the ALCS in starting the hot
water boilers and controlling their power output are
reflected in the table.
Without running into the technical details relating
to implementation of the algorithms listed in the table,
we will discuss the fundamental principles used to
construct the logic programs for performing func
tionalgroup control and automatic closedloop con
trol.
CHECKING THE TIGHTNESS OF THE GAS
VALVE GATE AND GAS LINE, AND
CARRYING OUT GAS ADMISSION
Tightness can be checked by air (usually after fin
ishing repair works or when the boiler is put in opera
tion from the standby mode) and by gas (immediately
before starting the boiler). The algorithm “Pressuriz
ing the gas line by air” can be enabled only if the inlet
valve in the boiler gas line is held closed.
Automatic checking of tightness by gas and admis
sion of gas into the gas line are permitted when the
boiler forceddraft installation (FDI) is in operation.
If the FDI is disconnected when the “Gas admission”
algorithm is in operation, the program is interrupted,
and the boiler gas line is automatically disconnected
(the stop valves are closed and the gas vents are
opened).
The methods of checking tightness by air and gas
are identical with each other. The tightness of stop gas
valves of a burner is checked by checking the pressure
between the SSV and SCV with the safety vent and
both valves held in the closed position. The tightness
check is carried out in the volume between the valves
at two levels of pressure: at atmospheric pressure and
at the pressure of gas upstream of the boiler. The
change (difference) of pressure occurred in the volume
for 5 s must not exceed the critical value equal to
0.015 MPa. This was adopted from the following con
dition: the leak of gas caused by the imperfect tightness
of the valve cannot create the concentration in the air
flow of the ventilated burner higher than 1/20 of the
gas ignition lower boundary.
For checking how tightly the gas shutoff valve
(GSV) is closed, a pressure difference is applied across
it (by momentarily opening the gas vent downstream
of the GSV) corresponding to 60% of the initial pres
sure upstream of the GSV and is observed for 5 min. If
the burner pressurization programs have not been car
ried out, the check is carried out once again with an
increased pressure difference. The permissible varia

THERMAL ENGINEERING Vol. 59 No. 10 2012

 AUTOMATION OF THE LARGECAPACITY HOTWATER BOILERS 749

1 2 3 4 1 19:27:44.759
100
1:0.3153
% 4 2:52.503
90 3:100
4:99.3284
80
4 3
70
1
60

50

40

30
2
20

10

0
19:00:00 19:05:00 19:10:00 19:15:00 19:20:00 19:25:00 19:30:00 19:35:00 19:40:00 19:45:00 19:50:00 19:55:00 20:00:00
29.02.2012 29.02.2012

1:1
1 DPD:0; 20349; B2HHA06CB051; Availability of flame of 62HWB burner,Outlet 3 (state) Bit1, Signal is available
19:00:00 19:05:00 19:10:00 19:15:00 19:20:00 19:25:00 19:30:00 19:35:00 19:40:00 19:45:00 19:50:00 19:55:00 20:00:00
29.02.2012 29.02.2012
Analog parameters
No. Type No. 1 Code PM name St. Outlet Min Max meas. unit A< P< P> A>
1 APD 10075 B2HHA06CP002 P gas to 62HWB burner 2 1 Steam 0 0.6 0 0.055 0.6 0.63
2 APD 10098 B2HHL06CP001 P air to 62HWB burner 2 1 Steam 0 400
3 APD 10227 B2HHA06AA801P Burner SCV to 62HWB 2 1 Steam 0 100
4 APD 10237 B2HHL06AAA801P Air CV of 62HWB burner 2 1 Steam 0 100
Binary parameters
No. Type No. 1 Code PM name St. Outlet Bit Bit description
1 DPD 20349 B2HHA06CB051 The presence of flame burners 62HWB 2 3 Cont. 1 Signal is available

Fig. 1. Kindling a gas burner in the automatic mode.

tion of pressure difference across the valve must not
exceed its measurement error. If the GSV or the gas
line has unsatisfactory tightness, the program is inter
rupted and the gas line is disconnected automatically.
During automatic admission of gas, the tightness of
the inlet gas gate valve is checked in a similar way, but
if insufficient tightness of this gate valve is detected,
the program continues to operate, and a warning mes
sage is produced to the operator. The results of the
valve tightness check are reported to the operator in
the information line of the gas line video frame and are
saved in the system memory until the sign “Start of
kindling on gas” appears. The pressurization signs are
reset when the appropriate algorithm is started.
If gas is admitted automatically, the prestart tight
ness check of the inlet gate valve and GSV may not be
performed (at the operator’s choice), e.g., when a
repeated startup is carried out. The operator selects the
necessary mode prior to start the program by pressing
the appropriate selection pushbutton. Gas is admitted
to the gas line with the GSV held open and the boiler
gas control valve held closed. Once the inlet gate valve
is set in the fully open position, the gas pressure con
troller is switched into automatic mode with a setpoint
equal to 0.04 MPa, and the gas line is purged through
the boiler gas vents.
KINDLING THE BURNERS
AND CONTROLLING THEIR POWER OUTPUT
The permission to start the program for automati
cally kindling a burner is not produced if the furnace
ventilation process is not organized and if there is false
monitoring of burner flame, which is regulated by the
technical specifications for implementing process
protections and interlocks. In addition, the program
includes supplementary safety precautions for the
firsttokindle burner. Its kindling is enabled if the
signs indicating the tightness of its SSV and SCV are
available, and if so are the signs indicating the tight
ness of the SSVs of all boiler burners (the tightness of
the gas line). The sign indicating the tightness of SSVs
is generated after all gas units of the boiler have been
pressurized or when the sign indicating the gas line
tightness is available. The latter signal is produced in
the “Gas admission” algorithm in the course of check
ing gas line tightness at two pressure levels. The per
mission for automatically kindling the burners is indi
cated on the boiler video frames.
The operation for kindling the igniter and burner
on gas is carried out with the air shutter held in par
tially closed position. In switching the gas igniter in
operation, the furnace operating mode is checked; if
abnormal conditions are revealed, the switching of the

THERMAL ENGINEERING Vol. 59 No. 10 2012

750 PAVLICH et al.
igniter in operation is delayed until the normal operat
ing parameters of the furnace device are restored.
If the igniter flame is available and if the SSV is in
the open position, the SCV is partially opened until
the gas pressure at the burner inlet reaches 0.005 MPa.
After the burner gas flame has been ignited, the burner
gas pressure controller (BGPC) is switched into the
automatic control mode with setting the position
“Minimal power” (around 50% of the burner nominal
power output); the air shutter is opened, and the
igniter is disconnected (Fig. 1).
A unified standard algorithm is used for kindling a
gas burner and for shifting the same burner operating
on fuel oil for firing gas; this algorithm has the follow
ing features:
(i) The gas burner with the operating fuel oil atom
izer is started without closing the air shutter.
(ii) Gas is ignited from the oil flame (without kin
dling the igniter).
(iii) Once the gas burner is brought to operate at the
minimal power output, the supply of fuel oil to the
atomizer is disconnected, and the regular interlock
opens the valve supplying steam for purging the atom
izer’s fuel oil channel.
The supply of steam to the fuel oil atomizer is dis
connected by the operator.
The burner control system includes an individual
algorithm for shifting the operating gas burner for fir
ing fuel oil. The following operations are carried out in
accordance with this algorithm:
(i) purging the atomizer fuel oil channel with steam
prior to switch the atomizer into operation;
(ii) disconnecting the supply of steam for purging
the atomizer and admitting steam for atomizing fuel
oil; and
(iii) supplying fuel oil to the atomizer.
The supply of steam to the burner is disconnected
by the operator by closing the SSV after receiving the
confirmation that the fuel oil flame has been ignited.
When execution of the program is in progress, mes
sages are produced to the operator about the course of
operations being performed and about deviations of
the parameters from their permissible values; these
messages are displayed on the appropriate individual
video frames of burners in the information zone of the
algorithm icon.
Automated kindling of a disconnected burner on
fuel oil is not used.
The burner is disconnected in a planned manner by
remotely closing the SSV from the operator’s work
place or from the burner’s local control console. The
other valves of the gas unit are brought in the initial
state by interlocks (closing the SCV, opening the safety
vent valve, and disconnecting the igniter). Emergency
shutdown is carried out via the protection circuits.
The burner power output (a transient mode) can be
adjusted by decreasing or increasing the pressure of gas
supplied to the boiler or burner by varying the SCV
position remotely or using the burner pressure con
troller. The controller maintains the ratio of gas pres
sures downstream and upstream of the SCV (this ratio
corresponds to a certain valve opening angle). The
boiler power output can be adjusted using the SCV on
one burner or on the group of burners in a tier if the
SCVs of these burners are in the automatic control
mode. In the latter case, the BGPCs establish the
equal gas pressure; the setpoints to individual control
lers are produced by a group setpoint adjuster that
controls the power output of burners in a tier. The set
point adjuster of any burner in a tier can be selected as
a group one. The setpoint established at a current
moment of time to the burner pressure controller is
transmitted to other burners in the group by clicking
on the button in the burner control window. The lower
boundary of the burner power adjustment range is
established by the maximum selection unit from the
values corresponding to the minimal burner power
output or to the minimal permissible value of gas pres
sure on the burner from the conditions of ensuring sta
ble burning of the flame (0.005 MPa).
CONTROLLING THE BOILER HEAT LOAD
(THE TEMPERATURE OF WATER
DOWNSTREAM OF THE HOTWATER BOILER)
Boiler load is controlled by applying a control sig
nal to the boiler fuel feed controller during its opera
tion on gas/fuel oil (GFC/OFC). Two control modes
are possible:
(i) Control of gas/fuel oil pressure upstream of the
boiler (the P mode). This mode is used in the course of
kindling the two first burners in the lower tiers and in
heating the boiler.
(ii) Maintaining the specified gas/fuel oil flowrate
(the F mode). This mode is used when the boiler oper
ates in the load adjustment range for covering the dis
patch schedule of network water temperature [the set
point assignment arrives from the heat load controller
(HLC)] or for stabilizing the fuel flowrate assigned by
the operator if the load controller is disconnected.
In both modes, the GFC receives signals that pro
hibit changing its output toward increasing or decreas
ing if the gas pressure upstream of the boiler or on any
operating burner goes beyond the corresponding per
missible limits. For the OFC this is valid with regard to
oil pressure upstream of the boiler.
The heat load controller maintains the preset tem
perature of water downstream of the boiler in the
adjustment range. In doing so, this controller changes
the setpoint assignment to the gas or fuel oil flowrate
controllers, thus changing the temperature from the
initial to the newly assigned level with the rate speci
fied by the operator in the controller setting window.
THERMAL ENGINEERING Vol. 59 No. 10 2012
 AUTOMATION OF THE LARGECAPACITY HOTWATER BOILERS 751

1 2 3 4 5 6
19:35:35.011
100
1:161.6605
% 2:61.7216
90 3:64.3467
4:21343.8789
4 5:0.3511
80 6:121.1538

70

60
6 3 2
50

40
1
30

20
5
10

0
17:30:00 18:00:00 18:30:00 19:00:00 19:30:00 20:00:00 20:30:00 21:00:00
29.02.2012 29.02.2012
Analog parameters
¹ Type s.n. Code PM name St. Outlet Min Max meas. unit A< P< P> A>
1 APD 10102 B2HLA01CP001 P air to 2HWB 2 1 Steam 0 400 0 20 630 630
2 APD 10241 B2HLA01AA801P Guide vane of 2HWB fan 2 1 Steam 0 100
3 APD 10243 B2HNC01AA801P Guide vane of 2HWB exhaust fan 2 1 Steam 0 100
4 ARP 40049 B2HHG00CF911 F gas to 2HWB 2 1 Steam 0 24868
5 ROP 40805 B2HHG00CP910 P gas to the boiler downstream of 2HWB control valve 2 1 Steam 0 1.6 0.05 0.1 0.6 0.63
6 ROP 40808 B2NDA10CT910 T network water downstream of 2HWB 2 1 Steam 0 180 0 0 150 158

Fig. 2. Variation of the main parameters of the boiler in the course of its automatic loading. APD—analog design; ROP—redun
dant option payment and for the remaining notation, see Fig. 1.

Smooth changeover of the HLC to the automatic control
mode is ensured due to operation of static balancing.
The HLC structure includes a unit of process con
straints, which inhibits changing the assignment to the
fuel controller if any of the following boiler operating
parameters goes beyond the permissible (preset) limits:
(i) The pressure of gas supplied to the boiler is
below its permissible value and the setpoint assign
ment to the HLC is below the current temperature of
network water.
(ii) The pressure of gas supplied to the boiler is
above its permissible value and the HLC setpoint is
above the current temperature of network water.
(iii) The variation rate of network water tempera
ture exceeds the permissible value.
(iv) The flue gas temperature exceeds its permissi
ble level.
(v) The pressure in the furnace upper part is higher
than 0.02 kPa.
(vi) The position indicator of the exhaust fan (EF)
or forceddraft fan (FDF) guide vane is more than
96%.
(vii) The content of О2 in flue gases is smaller than
the permissible value and the HLC setpoint is higher
than the current temperature of network water.
For extending the heat load adjustment range dur
ing operation on gas, a special logic program called
PAUK is used, which automatically (i.e., without par
ticipation of the operator) connects and disconnects
gas burners. During operation on fuel oil, the boiler
heat load adjustment range is determined by the num
ber of atomizers switched into operation.
If the permitting conditions are available (the HLC
is switched into operation, no less than two lowertier
gas burners are in operation, the boiler has been
heated, etc.), the operator switches the PAUK pro
gram into operation. The program tracks the current
mode of boiler operation and connects or disconnects
gas burners if required.
The automatic boiler control program has been
developed with due regard to the following conditions:
(i) The two first burners of the lower tier used for
heating the boiler are selected and kindled by the oper
ator; the boiler heating process is carried out with the
burners operating at the minimal power output (the
burner SCVs are opened only partially).
(ii) Gas burners are connected automatically in the
course of increasing the boiler load (the preset load is
higher than its current value) if the gas pressure
upstream of the boiler has reached the preset threshold
value.
(iii) Burners are disconnected in the course of
decreasing the boiler load (the preset load is lower than
its current value) as the gas pressure decreases to the
preset threshold value.

THERMAL ENGINEERING Vol. 59 No. 10 2012

752 PAVLICH et al.
1HWB(|)
011000.1HWB Ventilation of HWB 1HWBC 2HWBC 3HWBC
1HWB furnace 10 0
1HWB furnace 0 0
has been ventilated FDF1HWB 1
10000 CB –50
Air
0 GRF1HWB 0 CB
0 0 GAP startup
O
FDF speed
selector switch
0
0 0 EF1HWB 0
0 0
–12.5 to smoke stack
0 0 0 0 0
O 0 0 O
FDF speed
3 G3 G4 4 selector switch
0 0
A A
Name FDF EF GRF
1HWB 1HWB 1HWB
Toil bearing 1 EM 0 0
Toil bearing 2 EM 0 0
0 0 0 0
O 0 0 O Toil bearing 3 0 0 0
5 G5 G6 6 Toil bearing 4 0 0 0
0 0
A A

0 0 0 0 UCR1/GCB UCR1
O 0 0 O
selector switch
1 G1 G2 2

0 0
A A
0
0 0 7 0
0 0 0 0.8 0 A 5000
gas
O O

HLC PAUK O to forward

from NP water
Uraltekhenergo’s EC header
15:36:42.68

Fig. 3. Video frame of boiler No. 1.

(iv) Burners are automatically connected in diago failed to ignite in the course of connecting the pair of
nal pairs of burners in order to ensure symmetrical burners Nos. 5 and 8, burner No. 7 is connected auto
loading of the furnace. matically, and automatic connection of burner No. 6 is
(v) A pair of burners is connected by sequentially prohibited.
kindling them for the minimal power output using the (vii) The programs for kindling the secondtier
appropriate stepped programs performing functional burners can be switched on automatically if at least two
group control of burners; the SCVs are opened to the lowertier burners operate in the nominal mode (their
full extent after the pair of burners has been kindled if SCVs are open).
the pressure of gas supplied to the boiler is within the (viii) The operations for disconnecting the burners
range at which this operation is permitted. by closing the SSVs are carried out in the course of
(vi) If the program of kindling any burner fails, a decreasing the boiler load as the gas pressure is
sound alarm is generated, and the causes of this failure decreased to the preset threshold value.
are indicated on the video frame in the information (ix) Burners are disconnected in pairs in the
line near the icon denoting the algorithm of this sequence opposite to that during the kindling; the
burner; the nonkindled burner is automatically lowertier burners are not disconnected automatically.
replaced by another one with fulfilling the principle of
keeping the equal number of operating burners in the (x) The air shutter of the disconnected burner is
conditional halffurnaces of the boiler. For example, closed in a pulsed manner to the minimal position at
the operations for connecting the secondtier burners which adequate cooling of the burner throat is
are started from connecting the pair of burners Nos. 5 ensured.
and 8; if burner No. 5 failed to ignite, the pair of burn Figure 2 shows the main parameters of the boiler
ers Nos. 6 and 7 is connected, and automatic connec that are used in the course of automatically loading the
tion of burner No. 8 is prohibited. If burner No. 8 boiler.

THERMAL ENGINEERING Vol. 59 No. 10 2012

 AUTOMATION OF THE LARGECAPACITY HOTWATER BOILERS 753

1HWB Burner No. 1 (|)

ALGSt01111101000(|)
011101.1HWB. Burner No. 1 HWB 1HWBC 2HWBC 3HWBC
1 Kindling GU01
Through
2
1

Kindling GU 3
Start Stop Reset
Bypass

GU ALGSt01111101000(|)
Pressurization
Kindling GU01
Kindling OA 0 10
0 ô
1 Start Stop Bypass Reset Through Air
¹ Step name Next Altern. Tsp Tm Counter
1 Switching GU pressurization 2 4294! 0 3 0 Fuel oil
2 Checking kindling conditions 3 8 90 120 0
0
3 Kindling the igniter 4 8 60 55 0
4 Opening SSV 5 5 0 90 0
5 Opening SCV 6 6 0 15 0
0
6 Opening BAG, SCV AUTP 7 7 0 90 0
7 Disconnecting OA 4294 4294! 0 120 0
PPs acting on GB disconnection 0
8 Closing OA valve 4294 4294! 0 30 0
Name of PP PP sensors SP AAP/MAP operated PP operated
for signal
PP GB ign.fail/extinc Safety vent
PP GB1 disc. LCB
À
Reset of GB GB PPV
GPP operated
ô
60 Gas vent
Protections acting on disconnection of HWB OA
PP operated PP
Name of PP PP sensors SP AAP/MAP for signal operated 0 4
OA1 fail.ign/extinc. PP

Reset of OA OA PPV Selector switch LCB

GPP operated at the LCB
7
60 0 0.8
Gaz PKCC01162005054(|)
SW LCB/WS GB1 1HWB
Gas disc. Oil disc. Reset of OA Fuel disc. PPV
PPV operated PPV operated PPV HWB PPV operated
5
LCB
180 180 180 180

Uraltekhenergo’s EC
47012 PKCC01162005054 SW LCB/WS GB1 1HWB 15:44:18.04

Fig. 4. Video frame of burner No. 1.

CONTROLLING THE BOILER with compensating the deviations of air temperature

GAS–AIR PATH from the calculated value. The sensor is calibrated in
the course of adjusting the boiler operation modes by
The functionalgroup logic control algorithm the flowrate of natural gas and air excess factor in flue
“Starting the GasAir Path” performs automatic gases.
speeding up of the FDI, ventilation of the boiler, and
setting of the kindling mode. In organizing the The assignment to the correction loop for О2 is
required operating modes of the gas–air path (GAP), generated with respect to “fuel flowrate” in accor
the total air controller (TAC) is switched into the pres dance with the operating chart (operating instruc
sure control mode (the P mode) and automatically tions), and the boiler operator can correct it. The set
receives the assignment required in the particular point assignment signal to the controller is summed
mode of GAP operation. with the output signal of the О2 corrector.
Once two burners have been kindled, the TAC is
switched to operate in the “Ratio” mode for organiz CONTROLLING THE FUNCTIONALGROUP
ing automatic control of boiler load. When operating CONTROL ALGORITHMS
in this mode, the controller maintains the ratio of
fuel–air flowrates with correction for the content of The GCB, which accommodates three worksta
oxygen in flue gases and with limitation imposed to tions of the process operator and the emergency con
decreasing the output for the content of CO. The air trol console for the possibility to disconnect the equip
flowrate setpoint signal is generated from the calcu ment in bypass of the CAS in the case of its full failure,
lated fuel–air ratio taking into account the nominal air is the main place from which operation of the hot
excess factor recommended by the operating chart. water boilers is controlled.
The air flowrate signal is produced proceeding from Control (of valves and actuators) is performed from
the pressure difference measured across the air heater the video frames on displays through socalled virtual

THERMAL ENGINEERING Vol. 59 No. 10 2012

754 PAVLICH et al.
control windows using a mouse manipulator and stan
dard keyboard.
The general video frame of a boiler is shown in
Fig. 3 and the burner video frame is shown in Fig. 4.
The unit control room (UCR1), accommodating
three workstations of the process operator similar to
those at the GCB, serves as an auxiliary place from
which operation of the hotwater boilers can be con
trolled.
The place from which control has to be performed
is selected from the UCR using the virtual UCR/GCB
switch (Item 1 in Fig. 3). The pushbuttons in the con
trol windows on the video frames of the nonselected
control place are disabled, but these video frames con
tinue to indicate the states of actuators, valves, and the
values of process parameters.
The operation of the functionalgroup control
algorithms is controlled by calling the appropriate vir
tual control window (item 2 in Fig. 4). The control
window of a particular algorithm is called by double
click of the lefthand mouse button on the algorithm
icon 1. The area on the right of the algorithm icon
contains the information zone, which displays mes
sages generated by the algorithm program during its
operation.
“Extended” window 3 can be called from algo
rithm control window 2, which contains more detailed
information about the steps of the running algorithm.
The boiler burners can be controlled from the
burner local control board (LCB). The place from
which control has to be performed is selected from the
GCB (or from the UCR) by virtual selector switch
LCB/GCB 5, which is called by clicking the lefthand
mouse button on switch icon 4. If control from the
LCB is selected, the pushbuttons in the virtual control
windows at the GCB are disabled. In this case, the
burner valves are controlled by means of switches on
the local control board.
In December 2011, the APCS of the hotwater
boilers at the Tyumen TETs2 cogeneration station
passed tests and was put in experimental operation.
THERMAL ENGINEERING Vol. 59 No. 10 2012