5-ACC.

doc Page 1(11)

2009-12-05

TEXON AUTOMATION BOILER CONTROLS

Texon ref. no. O-9114, O-9115, O-9116, O-9117

Vessels: LNG/C ”Al Khaznah”, LNG/C ”Shahamah”, LNG/C ”Ish”, LNG/C Ghasha”

Description and operating manual.

About the manual

The manual is divided into 10 sections:
1. General
2. Control panels, brief description of the different functions
3. Operation
4. Graphic display, operation and calibration data inputs
5. Detailed description of Combustion controls (steam pressure, fuel oil, gas, air, level and steam
temperature)
6. Detailed description of Burner management for fuel oil (purge sequence, boiler safety)
7. Detailed description of Gas firing
8. Flame scanners
9. Trouble shooting

5 Detailed description of Combustion controls (ACC)

Master and steam dump controls

Drawing no. 461.21.225

General
 The steam pressure is compared (in summing point) with the set point. The result is a deviation signal
which gives either a ”Power demand” signal or a dump signal.

Steam pressure transmitter selector

 Hardware input is 4-20mA from four transmitters to I/O
 Measured range is 0-100 bar.
 Two transmitters are connected (each boiler) to a transmitter selector.
o P-SH 101-102 for PORT boiler
o P-SH 201-202 for STBD boiler
 The highest of the two from each boiler is normally used
 The highest of these two is normally used as master steam pressure signal (pos. AUTO).
 However, either of the two boiler transmitters can be selected as master.
 The selection, ”STBD” - ”AUTO” - ”PORT”, is done by selector switch on HMI picture "Master".

Steam pressure set point

 The set point is set on the HMI "Master"

Steam pressure deviation

 The difference between steam pressure and steam pressure set point is the control deviation.
5-ACC.doc Page 2(11)
2009-12-05

Gain control
 The PID controller has a variable gain, which is a function of the steam pressure deviation. When the
deviation is zero or small, the gain is low. If deviation increases, the gain will also increase in order to
compensate.

Stop increase
 When “power demand” signal reach a certain level, the master controller is prevented to increase
further (due to the multiplication factor, see “H”).
 If one burner is on, the master signal will stop on 33%. At this value, the burner demand is 100% and
maximum.
 If two burners are on, the master signal will stop on 67%. At this value, the burner demand is 100% and
maximum.
 If three burners are on, the master signal will continue to 100%. At this value, the burner demand is
100% and maximum.

Power demand and Steam dump output

 There is one (master) controller for power demand and for steam dump.
 When the boiler is firing at the demand rate, the power demand signal varies between 0-100%
 This signal is called Power demand and is distributed equally to both boilers (see Boiler balance below)
 Should steam pressure increase, the Power demand signal will reduce
 If necessary, the Power demand will reduce to zero. In this case the signal to the steam dump will begin
to increase
 The ”Power demand” is normally in auto mode, but may be switched to manual operation if required
(MASTER CONTROLLER on the ECC control panel).
 The ”Steam dump” is normally in auto mode, but may be switched to manual operation if required.
(STEAM DUMP on the ECC control panel).
From the above the following result is obtained:
 During normal firing, power demand signal is 0-100% and steam dump signal is 0%
 If steam pressure increases, power demand will be reduced, and steam dump may begin to open,
but not until power demand is zero.

Steam dump control output

 The steam dump signal is 0-100%, corresponding to 4-20mA.
 When the signal is >1%, the steam dump piston valve will open

Boiler balance
 The power demand signal is normally distributed equally to the two boilers.
 The operator can balance the boiler loads on the HMI by +/-10%.
 A value from -10% to +10% can be entered. A positive value will increase the load on PORT boiler
 If 2% is entered, the PORT will increase 2% and STBD will decrease 2%, i e there will be a diff of 4%
5-ACC.doc Page 3(11)
2009-12-05

Gain control
The power demand from master controller is multiplied with a factor depending on the number of burners in
operation. A burner is operation if burner shut off valves (oil or gas) are opened and Flame ON.
The purpose of this is that when starting or stopping burners, the load on the boiler will remain the same.
 1 burner in operation: Multiplying factor is 3.0
 2 burners in operation: Multiplying factor is 1.5
 3 burners in operation: Multiplying factor is 1.0

Fuel limiter
 The demand signal is prevented to increase if actual air flow is insufficient, i e vanes fully open. When
inlet vanes are 99% open, burner demand will stop to increase, but is free to reduce.
 At 97% vanes signal, burner demand will be released and can increase again

Burner flow demand

 Burner flow demand is the set point to fuel controllers.

Master controller in auto

 On some occasions it may be desirable to operate the master controller in manual. The output from the
controller works as a fuel flow set point for fuel oil as well as fuel gas controllers. Therefore, if master is
in manual and fuel controls in auto, the fuel flow can be better monitored than with e g fuel oil
controller in manual.
 This fact may be used when firing up the first boiler from cold, but a better solution may be to use “Cold
start” and/or “Hot restart” functions. (See description of fuel oil controller.)

Fuel oil controls

Drawing no. 461.21.226

General
 The fuel oil flow is compared (in summing point) with the fuel oil modified set point.
 The modified set point is obtained from the following:
o Burner demand
o Hot restart rate
o Cold start rate
o Ignition pressure
o Pressure at start of subsequent burner

Fuel oil signal

 Hardware input for fuel oil pressure is 4-20mA from two pressure transmitters per boiler:
o P-FO 101-102 for PORT boiler
o P-FO 201-202 for STBD boiler
 The resulting fuel oil pressure is the average of the two
 Measured range is 0-30 bar.
NOTE: Open the transmitter selection box on the HMI to un-select a faulty transmitter!
5-ACC.doc Page 4(11)
2009-12-05

Fuel oil flow

 Fuel oil flow is calculated in a linearizer based on burner maker´s data.

Fuel mode setting

 When “Fuel oil" mode is set (only F.O. burners ON), the Burner flow demand is multiplied with a factor 1
 When “Gas only” or “Dual fuel” is set, the Burner flow demand is multiplied with a factor 0.
This means that as long as gas firing is selected, fuel oil demand will be zero and fuel oil firing will be
minimum, unless increased by fuel gas deviation, see below.

Fuel gas deviation

 If there is a deviation in fuel gas flow (i e fuel gas insufficient), this deviation is added to the setting for
minimum fuel oil flow. As a result, minimum fuel oil firing is increased.
Maximum fuel oil pressure
 The fuel oil pressure is not permitted to rise above this value. The selector automatically selects the
lowest of fuel oil demand and the maximum fuel oil pressure setting.

Minimum fuel oil pressure

 The fuel oil pressure is not permitted to fall below this value. The selector automatically selects the
highest of fuel oil demand and minimum fuel oil pressure setting.

Hot restart
 In case of boiler trip, the steam pressure will be raised automatically, after restart of boiler, to set point
with the preset ”Hot restart rate”, if the following conditions are true:
1. Heavy fuel oil selected (i e not Diesel oil)
2. Fuel oil control in auto
3. Combustion air control in auto
4. Steam pressure (transmitter for this boiler) >15 bar
5. Steam pressure (transmitter for this boiler) deviation >5 bar
 When steam pressure reaches set point within 0.5 bar, the firing will switch to demand signal.
 Should the boiler pressure not have fallen below 5 bar under the set point, the firing will follow the
demand signal after the boiler is started.
Note: The hot start rate setting is a value that sets a fixed fuel oil pressure.
It will not take into account the rate of steam pressure rise or rate of steam temperature rise!

Cold start
 After start of cold boiler, the steam pressure will be raised automatically with the preset ”Cold start
rate” if the following conditions are true:
1. Fuel oil control in auto
2. Comb. air control in auto
3. Steam pressure <15 bar
 When steam pressure reaches 15 bar, the firing will switch to ”Hot restart” and firing will continue as
described above.
 NB: The firing will continue in the cold start mode as long as "Diesel oil" is selected as fuel
(DIESEL OIL button is activated and the corresponding lamp is lit)
Note: The cold start rate setting is a value that sets a fixed fuel oil pressure.
It will not take into account the rate of steam pressure rise or rate of steam temperature rise!
5-ACC.doc Page 5(11)
2009-12-05

Fuel oil pressure during ignition or recirculation

 During ignition of first oil burner, the fuel oil pressure must be correct for safe ignition.
 When signal ”Go to ignition position” comes, the fuel oil set point is switched to a preset value.
 The set point is the same when F.O. recirculation is in progress (i e when the boiler is shut off).

Fuel oil flow modified set point

 The modified set point is compared to fuel oil flow signal in the summing point.

Control deviation
 The algebraic sum of modified set point and measured fuel oil flow is the control deviation, which is the
PID-controller input.

Control output (F.O. control valve)

 Control output is 4-20mA on analog output to the I/P-transducer for the fuel oil control valve

Fuel gas controls

Drawing no. 461.21.227

General
 The fuel gas flow is compared (in summing point) with the fuel gas demand signal (Burner demand).

Fuel gas flow (differential pressure) signal

 Hardware input is 4-20mA from one transmitter per boiler
o P-FG 101 for PORT boiler
o P-FG 201 for STBD boiler
 Measured range is 0-600 mbar.
 Fuel gas differential pressure transmitter is measuring the pressure drop in burner. The flow is calculated
in the linearizer. Gas flow is then multiplied with the calorific value (=N2 content). The result is a fuel gas
flow corrected for energy content.
 The range of fuel gas flow is 0-100%.

Fuel mode setting

 When “Gas only” or “Dual fuel” is valid (Gas firing is ON), the Burner flow demand is multiplied with a
factor 1. This means fuel gas is the priority fuel (in this case, the corresponding multiplication factor for
fuel oil is 0).
 When “Fuel oil only” is valid, the Burner flow demand is multiplied with a factor 0.

Fuel gas deviation

 If there is a deviation in fuel gas flow (i e fuel gas is insufficient), this deviation is added to the oil
demand in the fuel oil controller. As a result, fuel oil flow will be increased in order to compensate.
 The high selector means the deviation is always positive, i e will be added to minimum fuel oil firing, not
subtracted.
Note:
If fuel gas is on maximum firing, i e gas flow is 100% through the burner, there will be no deviation and thus
nothing to add to the fuel oil controller. In this case fuel oil will stay at minimum pressure. Increase of fuel oil
firing in this case may result in over firing the boiler!
5-ACC.doc Page 6(11)
2009-12-05

Maximum fuel gas differential pressure

 The fuel gas differential pressure is not permitted to rise above this value. The selector automatically
selects the lowest of fuel gas demand and (preset) maximum fuel gas differential pressure.
 The operator enters maximum permissible fuel gas diff. pressure, which is converted in the linearizer to
fuel gas flow.

Minimum fuel gas differential pressure

 The fuel gas differential pressure is under normal firing not permitted to fall below this value. The
selector automatically selects the highest of fuel gas demand and (preset, but operator adjustable)
minimum fuel gas differential pressure.
 The operator enters minimum permissible fuel gas diff. pressure, which is converted in the linearizer to
fuel gas flow.

Fuel gas modified set point

 The modified set point is compared to measured fuel gas flow in the summing point.

Control deviation
 The algebraic sum of modified set point and fuel gas flow is the control deviation, which is the PID-
controller input.

Stop increase
 If the measured signal (differential pressure drop) is above 95%, alarm is given and PID-controller is
prevented from further increase.

Fuel gas control valve position during ignition

 During start of gas firing, the fuel gas control valve must be in correct position for safe ignition. When
signal ”Fuel gas valve to ignition position” is set, the fuel gas control valve output is switched to a
(preset) value.
 When gas firing is ON, the valve is released and slowly increased to its set point.

Control output (Fuel gas control valve)

 The control output is 4-20mA to the I/P-transducer for the fuel gas control valve.
5-ACC.doc Page 7(11)
2009-12-05

Combustion air controls

Drawing no. 461.21.228

General
 The combustion air flow is compared (in summing point) with the combustion air modified set point. The
modified set point is obtained from the following:
o Demand signal
o Ignition setting
o Furnace purge setting

Combustion air signal

 Hardware input is 4-20mA on I/O from two transmitters per boiler
o P-DA 101-102 for PORT boiler
o P-DA 201-202 for STBD boiler
 Measured range is 0-500mmWG.
 Two air flow transmitter is measuring the pressure drop in burner. The average of these two used as
input to the function generator.
NOTE: Open the transmitter selection box on the HMI to un-select a faulty transmitter!
 The air flow is obtained from a linearizing table.
 The range of air flow is 0-100%.

Comparator for “Ignition position proved”

 During ignition of first burner, air flow must be correct for safe ignition.
 The output “Ignition position proved” is shown on the HMI as "Air to ignition position/Feedback".

Comparator for “Air flow proved”

 During furnace purge (before ignition of first burner), air flow must be correct for safe ignition. The
output “Air flow proved” is set when all three registers are opened and RDL is above the setting for
purge.

Air/Fuel ratio
 This value is set on the HMI. It corrects for the specific calorific value for fuel oil

Air cross limiter

 The purpose of this limiter is to secure correct amount of air flow at all times.
Note:
 Fuel oil flow is taken into account only if Fuel oil firing is ON
 Fuel gas flow is taken into account only if Fuel gas firing is ON.

Combustion air primary set point

 The output from the cross limiter is multiplied by ”Air/Fuel” ratio, which is set on HMI

Minimum air differential pressure

 The combustion air is under normal firing not permitted to fall below this value. The selector
automatically selects the highest of demand and the minimum setting.
 The operator enters minimum permissible air diff. pressure, which is converted in the linearizer to air
flow.
5-ACC.doc Page 8(11)
2009-12-05

Air flow during ignition

 During ignition of first burner, the air flow must be correct for safe ignition.
 When signal ”Go to ignition position” is set, the air set point is switched to this preset value (normally
0%).

Air flow during furnace purge

 During purging of the furnace, the air flow must be sufficient to ensure safe ignition.
 When signal ”Go to purge position” is set, the air set point is switched to this preset value at a preset
rate.

Feed forward
(To ensure air is sufficient at increasing fuel oil.)
 The burner flow demand and the fuel oil flow are connected to derivating circuits. Gain and time
constants are individually set.
 The highest of the outputs from the derivating circuits is selected and then connected to feed forward
input of the controller.

Control deviation
 The algebraic sum of actual Air flow and the setpoint is the control deviation, which is the PID-controller
input.

Control output (Inlet vanes actuator)

 The control output is 4-20mA from the analog output

Combustion trim
Drawing no. 461.21.228

General
 The combustion trim is to control the content of oxygen in the smoke gas leaving the boiler.

HMI
 See picture "Combustion air" / ”Combustion trim”

Oxygen content signal

 Hardware input is 4-20mA on I/O from an oxygen analyzer.
 Measured range is 0.1-21.0 %O2.
Oxygen set point
 Set point is depending on the boiler load and can be set on picture “Oxygen setpoint generator”.

Conditions for O2 control

 Combustion trim in AUTO
 Combustion air in AUTO
 All three burners in operation
 Boiler load above the limit (see below)
5-ACC.doc Page 9(11)
2009-12-05

Load limit
 Enter a value of the desired boiler load at which Combustion trim can start. It can start only when boiler
load is above this value.

Control deviation
 The algebraic sum of measured oxygen and oxygen set point, is the control deviation, which is the PID-
controller input.

Control output
 The output from the controller is 0-100%. This is converted to a factor ranging from 0.8 (0%) to
1.2(100%).
 When the control is off, this factor is locked at 1.0

Multiplier
 The “Combustion trim factor” is adjusting the air/fuel ratio in this multiplier

Combustion trim factor out of range

 The Combustion trim factor is limited to 0.8-1.2. If the desired oxygen content cannot be reached, the air
fuel ratio may have to be changed.

Oxygen analyzer
 The O2 probe must be heated to 800ºC for correct measuring
 A thermocouple (type "R") in the probe is measuring the temperature
 The heating is controlled by means of controlling a static relay in the analyzer interface box.

Boiler water level controls

Drawing no. 461.21.229

General
 The drum level is compared (in summing point) with the set point. The result is a deviation signal which
gives a signal to the PI-controller.

Boiler water level (drum level) transmitters

 Hardware input is 4-20mA from three differential pressure transmitters per boiler
o L-FW 101-103 for PORT boiler
o L-FW 201-203 for STBD boiler
 Measured range is +/-300mmWG

Transmitter selector
 The two transmitters that are closest to each other are selected
 The average of these two is used as the resulting level signal.
NOTE: Open the transmitter selection box on the HMI to un-select a faulty transmitter!
5-ACC.doc Page 10(11)
2009-12-05

Steam flow transmitter

 The steam flow is measured and is proportional to the boiler load.
 Hardware input is 4-20mA from one differential pressure transmitter per boiler
 F-SH 101 for PORT boiler
 F-SH 201 for STBD boiler
 The range is 0-10,000mmWG, corresponding to 0-61 ton/h

Feed water flow transmitter

 The feed water flow is measured and is proportional to the boiler load.
 Hardware input is 4-20mA from one differential pressure transmitter per boiler
 F-FW 102 for PORT boiler
 F-FW 202 for STBD boiler
 The range is 0-5,000mmWG, corresponding to 0-61 ton/h

Linearizer
 The steam flow signal signal is linearized to correspond to the flow characteristics of the control valve.

Level set point

 The set point is set on the HMI, and is normally 0 mm

PI controller
 The controller is a “Feed forward controller”, i e the feed forward signal (steam flow) is the main
component in the controller. The level signal is correcting in order to keep the level on setpoint.

Control output (Feed water control valve)

 The control output is 4-20mA to two control valves working in split range

Level comparators
The water level is continuously compared to six different limits:
 Extra High level +230mm Main Engine trip + Feed water motor valve close
 Very High level +200mm Main Engine will slow down
 High high level +150mm Alarm
 Low Low level -150mm Alarm
 Very Low level -180mm Main Engine slow down
 Extra Low level -230mm Boiler Trip
NOTE: When the motorized feed water valve has been closed, it must be manually reset (on the valve)
before it can open again!
5-ACC.doc Page 11(11)
2009-12-05

Superheated steam temperature controls

Drawing no. 461.21.231

General
 The superheated steam temperature is compared (in summing point) with the set point. The result is a
deviation signal which gives a signal to the PID-controller.

Secondary superheater outlet temperature transmitters

(for temperature control and high temperature trip of boiler)
 Hardware input is 4-20mA from three temperature transmitters per boiler
 T-SH 101, 102, 104 for PORT boiler
 T-SH 201, 202, 204 for STBD boiler
 Measured range is 300-600°C

De-superheater inlet temperature transmitter (for indication on HMI)

 Hardware input is 4-20mA from one temperature transmitter per boiler
 T-SH 103 for PORT boiler
 T-SH 203 for STBD boiler
 Measured range is 0-600°C

De-superheater outlet temperature transmitter (for temperature control)

 Hardware input is 4-20mA from one temperature transmitter per boiler
 T-SH 105 for PORT boiler
 T-SH 205 for STBD boiler
 Measured range is 300-600°C

Feed water spray flow transmitter

 The feed water spray flow is measured.
 Hardware input is 4-20mA from one differential pressure transmitter per boiler
 F-FW 101 for PORT boiler
 F-FW 201 for STBD boiler
 The range is 0-5,000mmWG, corresponding to 0-6.5 ton/h

Temperature set point

 The set point is set on the HMI, and is normally 510°C.

PID controller
The controller is a "Cascade" controller and consists of
 Primary controller. This is comparing the main setpoint (510°C) with the final temperature.
The output from this controller is the setpoint for the Secondary controller
 Secondary controller. This is comparing the intermediate setpoint with the intermediate
temperature (de-superheater outlet). The outlet from the controller (0-100%) is connected to the
steam temperature control valve (F.W. spray valve)

Control output
 The control output is 4-20mA to the water spray valve