Auxiliary Boiler Automation

Boiler Automation Created by Sudhir Bhatia 1

 Auxiliary boiler
water level
control

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 Two-step or 0-1 control

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 Two-step or 0-1 control

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 Two-step control

• Also known as ‘ON–OFF’ or ‘0-1’ control

• Used for small auxiliary boilers only
• Water level signal is given by the level sensor
• When ‘cut-in’ water level is reached, the controller sends a
signal to the feed pump starter and starts the pump
• When water level reaches the ‘cut-out’ level, same process is
repeated and the pump is stopped
• By this system, water level varies in a huge range
• Not suitable for medium and high pressure boilers

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 Single element control

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 Single element control
• Controller receives measured value signal from the level
sensor
• It compares it with the Set Point and generates a
controller output signal which operates the feed
regulating valve actuator
• This adjusts the feed flow to correct any error in the
drum level
• A small diameter line from the discharge of the pump
back to the hotwell takes care of the heat of churning
when there is no water requirement in the boiler
• In large boilers, single element system does not work
due to ‘Swell & Shrink’ effects
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Boiling Point

• Before we move to
swell & shrink effects,
we should be very
clear about the
concept of boiling

• How do we define
boiling point ?

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 Boiling Point
Boiling point is the
temperature at which
vapour pressure of
the liquid becomes
equal to the
surrounding pressure

Pvap = Ps

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 Swell
• If steam flow from the boiler (Load) is increased rapidly, the level
should reduce requiring an increase in feed flow
• However, a sudden increase in steam flow will cause the steam
pressure to fall, resulting in corresponding decrease in saturation
temperature
• This will initially result in transient increase in steam bubble
production
• As volume of steam is more than that of water, this results in an
artificial rise in water level even with less water in the boiler
• Feed regulating valve is adjusted to reduce feed flow
• Fall in steam pressure will be corrected by the combustion controller
by increasing firing rate
• This will cause a rapid reduction in water level in the boiler and the
boiler will trip on low level

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 Shrink

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 Shrink
• If steam flow from the boiler (Load) is decreased rapidly,
the rise in steam pressure causes rise in saturation
temperature
• Steam bubbles collapse and the level artificially falls
• Feed regulating valve is adjusted to increase feed flow
• Combustion controller corrects steam pressure by
decreasing firing rate
• Steam bubble production increases to normal
• Water level rises rapidly and the boiler trips on high level

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 Two element control

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 Cascade Control
• A waterfall or a series of
small waterfalls over steep
rocks.
• A succession of stages,
processes, operations, or
units.
• A series of components or
networks, the output of
each of which serves as the
input for the next.

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 Two element control

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 Two element boiler water level control

• This is an improvement from the previous system in which steam

flow is also measured by a steam flow transmitter
• It predicts the future saturation temperature e.g. if the flow rises, the
temperature will fall in immediate future
• This signal is cascaded to the water level sensor signal by using a
‘Master-Slave’ system of controllers
• This is also known as a ‘Cascade control’ system
• This takes care of the swell and shrink effects
• During swell period, the level signal calls for less water, even though
the amount of water has actually decreased
• Simultaneously, increase in steam flow signal calls for an increase in
feed flow
• A combination of these two signals prevents the boiler from tripping

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 Three element control

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 Three element control

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 Three element control
• This system is used for high pressure boilers
• A third sensor is installed in the feed flow line
• A differential relay compares steam and water
flows and its output depends upon the difference
between the two measurements
• This gives the actual water required in the boiler
• This signal is cascaded to the output signal of
the master controller using ‘master slave’ system
• The output of the slave controller corrects the
feed regulating valve

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 Boiler combustion control

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 Boiler combustion control system can be
subdivided into two main systems

• Initializing sequence to fire the main burner

• Over and under firing protection system (actual

combustion control) to maintain the steam
pressure and efficient combustion by controlling
air fuel ratio (complete combustion, minimum
excess air)

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 Initializing sequence

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 Sequential control

• Forming or characterized by a
sequence, as of units or musical
notes.
•One after the other in some
consecutive order such as by name or
number.

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 Initializing sequence
• Starts when
Steam pressure is less than the cut-in pr
There are no trips activated

• Pre purge
FD fan starts
Damper opens full (time of pre purge controlled by a timer set
so that the furnace volume is replaced three times)

• Pilot burner
Damper adjusts to minimum air position (15%)
D.O. supply p/p starts and solenoid v/v opens
Igniter ON

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• Flame eye:
Senses the pilot burner flame, Igniter switched off

• Main burner
Damper adjusts
D.O. p/p starts, solenoid v/v opens or H.O. p/p starts, solenoid
v/v opens, thermostat in line

• Flame eye:
Senses the main burner flame, pilot burner switched Off

• As the objective of the initializing sequence has been

achieved (to fire the main burner), the system now hands over
controls to the Over & Under firing protection system
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• Anytime during the sequence, when a particular step is not
completed, the sequence takes the process through a
shutting down sequence and sits at Reset.

• When reset is done, the sequence starts from the very

beginning i.e. steam low pr cut-in

• When manual stop/ trip / high pr cut out gets activated, the
system follows a shutting down sequence.

• An ‘Emergency Stop’ is also provided on the panel which

immediately shuts the process by-passing the shutting down
sequence
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 Boiler Combustion Control

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 Objective #1

Maintain steam
pressure

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 Objective #2

Maintain efficiency
of combustion by
maintaining air:fuel
ratio

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 Over & Under firing protection system

• Master control signal in the system is boiler steam pressure and

has a manually adjusted set point

• Fuel control and air control loops are self contained

• Each acts on the master control signal to adjusts the supply of air
and fuel

• By means of feed back provided by measurement of fuel and air

flow, each loop counteracts any temporary disturbances in oil or
air flow before steam pressure can be affected

• Air fuel ratio is manually adjusted through air fuel ratio controller

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• To prevent black smoke during load changes, system is so
arranged that air will lead fuel on increasing demand and
that fuel will lead air on decreasing demand

• A low signal selector is inserted in the master demand to

fuel oil controller. Measured value from air flow signal is also
fed to it. Fuel demand is always limited by the combustion
air available and cannot increase at a rate faster than air
increase

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 Alarms & shut-downs

Alarms and shut downs are fitted to

safeguard the operation of the boiler unit.
The shutdowns will close down the
burner units and need to be manually
reset.

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 Shut downs
• Low-low water level
• High steam pressure
• Flame failure
• Loss of control power
• Loss of primary / FD air
• High water level on
turbine driven plants

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 Alarms
• Low water level
• Low steam pressure
• Low fuel oil
temperature
• Low atomizing pr for
burners
• High uptake temp

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