Himanshu Wakodkar_112009044 Batch - C

Experiment No. 2
Aim: Study & analysis of flow, pressure, temperature and level loop (Analysis includes
processparameters such as type of process, dead time, capacity etc.)

Objectives:
1) To understand the various process loops associated with given plant.
2) To identify various process parameters such as type of process, various process
parameters, dead time, capacity etc.
3) Analysis of identified process parameters.

Instrument/ setup:

Boiler: A boiler is a closed vessel (usually made of stainless steel) in which water orother fluid
is heated. The heated or vaporized fluid exits the boiler for use in various processes or heating
applications, including boiler-based power generation, cooking, and sanitation. The source of
heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas.
Electric steam boilers use resistance- or immersion-type heating elements. A boiler is a crucial
piece of equipment used in various industries to generate steam or hot water for heating,
power generation, and industrial processes. It operates based on the principles of
thermodynamics and heat transfer. Below is a detailed analysis of the components and
working of a typical boiler:

Components of a Boiler:

1. Fuel Source: The boiler requires a fuel source, which can be natural gas, oil,coal,
biomass, or electricity, depending on the type and design of the boiler.

2. Burner: The burner is responsible for mixing the fuel with air in the correct proportion
and igniting it in the combustion chamber. Proper combustion isessential for efficient
heat production.

3. Combustion Chamber: This is where the fuel-air mixture is burned, releasing

thermal energy in the form of heat. The design of the combustionchamber is critical to
maximize combustion efficiency and minimize emissions.
Himanshu Wakodkar_112009044 Batch - C

4. Heat Exchanger: The heat exchanger is the core component of the boiler. Itconsists
of a network of tubes or pipes where heat is transferred from the combustion gases to
the water. There are two main types of boilers based on the heat exchanger design:
fire-tube and water-tube boilers.

• In a fire-tube boiler, hot gases pass through tubes submerged in water. Heat
is transferred from the gases to the water surroundingthe tubes.

• In a water-tube boiler, water flows through tubes while hot gasesfrom

combustion pass over the outside of the tubes, heating the water inside.

5. Water Storage or Steam Drum: In water-tube boilers, a steam drum

collects and stores the generated steam. It also helps separate any moisture or
impurities from the steam.

6. Safety Valves: Safety valves are crucial for maintaining safe pressure levelswithin
the boiler. They open to release excess pressure, preventing explosions.

7. Pressure and Temperature Controls: These controls maintain the desired

pressure and temperature inside the boiler. They regulate fuel and air flowto achieve
the required conditions.

8. Feedwater System: The feedwater system supplies water to the boiler, often
preheating it to improve efficiency. It includes pumps, deaerators,and water
treatment equipment to remove impurities.

9. Blowdown System: This system removes concentrated impurities and sludge

from the boiler by periodically discharging a portion of the boilerwater.
Himanshu Wakodkar_112009044 Batch - C

Working of a Boiler:

1. Fuel Combustion: The process begins with the introduction of the fuel intothe
combustion chamber. The burner mixes the fuel with air in the right proportion, and
ignition occurs, producing a flame.

2. Heat Transfer: In a fire-tube boiler, hot combustion gases flow through thetubes,
transferring heat to the surrounding water. In a water-tube boiler, water flows through
the tubes while the hot gases pass over them, transferring heat to the water inside.

3. Steam or Hot Water Generation: The heat transfer causes the water to boiland
generate either steam or hot water, depending on the application.
Himanshu Wakodkar_112009044 Batch - C

4. Steam or Hot Water Distribution: The generated steam or hot water is directed
to its intended use through pipes and distribution systems. In industrial processes, it
may be used for heating, drying, or driving turbinesfor power generation.

5. Condensation and Return (for Steam): After performing its intended work,
steam can condense back into water. In a closed-loop system, the condensed water is
returned to the boiler for reuse.

6. Safety and Control: Throughout the process, various safety and control systems,
including pressure and temperature controls, maintain safe andefficient operation.
Safety valves prevent overpressure situations.

7. Maintenance: Regular maintenance, inspections, and cleaning are essentialto ensure

the boiler operates efficiently and safely over time.

Boilers are vital in various industries, including power generation, manufacturing,and heating
systems. Their efficiency, reliability, and safety are of utmost importance, and proper design,
operation, and maintenance are critical to their performance and longevity.

1. Flow Loop:

• Type of Process: The flow loop in a boiler plant typically involves thesupply
of water to the boiler, fuel intake, and steam outlet. It is important to identify
the specific flow processes involved, such as feedwater flow, fuel flow, and
steam flow.

• Dead Time: Dead time in a flow loop can vary depending on the size of the
plant and the control system. It's essential to measure the timedelay between
changes in flow setpoints and actual flow rate responses.

• Capacity: Understanding the capacity of the flow loop is crucial for ensuring
that the system can handle the required flow rates withoutcausing issues like
cavitation or inadequate flow.
Himanshu Wakodkar_112009044 Batch - C

2. Pressure Loop:

• Type of Process: Pressure control in a boiler plant involves maintaining

appropriate pressure levels in the steam and watercircuits. This can
include boiler drum pressure, steam header pressure, and various safety
relief systems.

• Dead Time: Dead time in a pressure loop is typically minimal, as pressure

changes should propagate relatively quickly through the system. However, it's
essential to account for any delays in pressurecontrol actions.

• Capacity: The capacity of pressure control valves, safety relief valves,and

pressure transmitters should be considered to ensure they can handle the
required pressure ranges and flow rates.

3. Temperature Loop:

• Type of Process: Temperature control is crucial in a boiler plant to maintain

the desired operating conditions. Temperature loops can involve boiler outlet
temperature, superheater outlet temperature,and other critical points in the
system.

• Dead Time: Dead time in a temperature loop can vary depending onthe
location and size of the temperature sensor and the thermal inertia of the
process. It's essential to measure these delays accurately.

• Capacity: Ensure that the temperature control system has the capacity to
handle the required temperature ranges and respond torapid changes in
demand.

4. Level Loop:

Type of Process: Level control is vital in boiler systems to prevent overfilling or low water
levels in the boiler drum. Understanding the specific level control points, such as drum level
or feedwater tanklevel, is crucial.
Himanshu Wakodkar_112009044 Batch - C

• Dead Time: Dead time in a level loop can be significant, especially in large
systems. It's important to measure the time it takes for changesin control
actions to affect the level.

• Capacity: Consider the capacity of level sensors, control valves, andpumps to

ensure they can handle variations in level without causing issues like water
carryover or boiler trips.

1. Closed Loop (Feedback Control Loop):

• Feedwater Control Loop: This is a closed-loop system where the control

system regulates the flow rate of feedwater into the boiler based on feedback
from sensors that measure parameters like steampressure, water level, or
temperature. The goal is to maintain stable boiler operating conditions.

• Steam Pressure Control Loop: A closed-loop system that regulatesthe

steam pressure by adjusting the fuel input or steam flow rate based on
feedback from pressure sensors. This ensures that the boiler operates within
the desired pressure range.

• Water Level Control Loop: This loop maintains a consistent water level
inside the boiler. It adjusts the feedwater flow rate or steam discharge to
prevent the water level from falling too low or rising toohigh, which can be
dangerous.

• Combustion Control Loop: In a closed-loop combustion control system,

feedback from combustion sensors is used to adjust the fueland air supply to
maintain optimal combustion efficiency, while keeping emissions within
acceptable limits.
Himanshu Wakodkar_112009044 Batch - C

2. Open Loop (Feedforward Control Loop):

• Fuel Flow Control: Typically an open-loop system where the controlsystem

adjusts the fuel supply rate to the boiler based on a predetermined setpoint
without direct feedback from combustion conditions. Some advanced systems
may incorporate feedback elements to improve accuracy.
• Air Flow Control: Similar to fuel flow control, it regulates the airflowinto the
boiler based on a setpoint without direct feedback from combustion
conditions. Again, advanced systems may include feedback elements for better
control.

• Blowdown Control: Often, blowdown control is semi-automatic or manual,

with operators adjusting blowdown valve settings based onscheduled
maintenance or water quality considerations. It may not always have closed-
loop control.

• Chemical Feed Control: The addition of water treatment chemicals is

typically controlled based on predefined setpoints and schedules, which can be
considered open-loop control. However, some systemsmay incorporate
feedback from water quality sensors for more precise control.
Himanshu Wakodkar_112009044 Batch - C

Conclusion: The study of the boiler plant has highlighted the critical importance of precise
control and monitoring of flow, pressure, temperature, and level parameters. Ensuring safety,
efficiency, and reliability in boiler operation remains the primary objective. To achieve this, it is
essential to understand the specific processes involved, consider dead times and capacity
limitations, and implement effective control strategies. Additionally, ongoing maintenance and
data analysis are crucialfor optimizing performance and preventing operational issues, ultimately
contributing to the plant's long-term success and sustainability.
Himanshu Wakodkar_112009044 Batch - C