Boiler Control and Instrumentation

PHASE 1 STEAM TURBINE AND BOILER
YOKOGAW01100 CONTROL SYSTEM :

INTRODUCTION :
Phase 1 control comprises of five number of steam turbine and boiler ,which consists
of control and monitoring cubicle panels are installed in the near to the central operation room,
all man-machine interface operation tools of giving,various controls,the recording instruction or
the auto/hand switching instructions.
GENERAL :
The control and instrumentation system which are provided for the boiler plant are
classified as follows :
1.Automatic Boiler control system
2.Local control system
3.Instrumentation Equipment
4.Boiler interlock system
5.Burner control system
6.Local instrument
AUTOMATIC BOILER CONTROL SYSTEM :

Electronic type of SYSTEM 1100 Series manufactured by YOKOGAWA Electric works
are adopted for
1.BOILER CONTROL
2.TURBINE CONTROL
3.DESALINATION PLANT CONTROL
LOCAL CONTROL SYSTEM :
Yokogawas pneumatic types of equipment types of equipments are adopted coupled with
Gedelius control valves with pneumatic actuators
INSTRUMENTAION EQUIPMENT :
1.RECORDERS
2.INDICATORS
The above instruments are required for monitoring the plant normal operation and
start-up/shut-down operation are provided and arranged suitabley on the boiler control console.
BOILER INTRELOCK SYSTEM :
Boiler protection interlock system provide the overall safety fuction for the boiler plant.
Sequence control system also involved in this system in conjunction with boiler
protection interlock and auxiliary equipment interlock.
AUXILIARY EQUIPMENT INTERLOCK :
1.START / STOP for fans,pumps etc
2.OPEN / CLOSE for motor operated valves
3.INTERLOCK for solenoid valves
4.OTHERS ( Lamp indications etc.)
BURNER CONTROL SYSTEM :
The system provide the function for BURNER MANAGEMENT and FUEL SAFETY
which is basically designed according to MITSUBISHIS sstandard philosophy to meet with
specific features on front firing boiler.
LOCAL INSTRUMENT ;
The local instruments are pressure gauages,temperature gauages etc.
AUTOMATIC BOILER CONTROL SYSTEM ( ABC ) :

It composed of parts
1.
2.
3.
4.
5.
Transmitters
Control cubicles
Control desk
Field
Electric and pneumatic actuators
It composed of items
1.Control stations on the boiler control console

2.Recorders / Indicators on boiler control console
3.Control cubicles
4.Feedback sensors
5.Final actuators
CONTROL STATIONS :
`
1.Hand / Auto staion

1.Hand / Auto selector pusbutton
2.Manual Increase / Decrease pushbutton
3.Fault lamp indication
4.Position or output signal indicators
2.Set Point Station
1.Dial for set point or bias adjustment
2.Deviation or bias signal indicators
3.Control indicator
It indicators measured value and or set point signal.
RECORDERS / INDICATORS :
Process value of the boiler such as
1.Pressure
2.Temperature
3.Level
4.Flow
are recorded or indicated on Boiler control console,so that the operator can
supervise the boiler operating condition in the plant control room.
CONTROL CUBICLE :
The control cubicle contain the main parts of the automatic boiler control system
such as
1.Controllers
2.Computing Relays
3.Signal convertors
4.Summers
5.Multipliers etc.
It composed of five cubicles
1.Power supplies
2.Auxiliary Controls ( Turbine )
3.Fuel Flow Control
4.Air Flow Control
5.Boiler Master Control
6.Feed Water Control
7.Steam Temperature Control
8.Auxiliary Controls ( BOILER )
FINAL ACTUATORS :
It consists of the
1.Control valves and Control drives ( Regulated the process values )
( Air operated valve )
CONTROL FUCTION AND OPERATION :
The Automatic Boiler Control system regulates the transfer of energy in a boiler to supply
the steam at desired conditions of pressure and temperature and sufficient rate to turbine.
The system composed of control loops is
1. BOILER MASTER CONTROL LOOP
2. COMBUSTION CONTROL LOOP
3. FEED WATER CONTROL LOOP
4. STEAM TEMPERATURE CONTROL LOOP
5. AUXILIARY CONTROL LOOP
BOILER MASTER CONTROL LOOP :
Generally to maintain the Turbine Inlet steam pressure at a preset value, proper demand
signal for fuel and air flow is produced from BOILER MASTER CONTROL LOOP
Pressure setting is set in adjustable by dial on meter pressure set point station.
STEAM PRESSURE MASTER DEMAND SIGNAL SET POINT FOR BOTH
FUEL FLOW CONTROLLER + AIR FLOW CONTROLLER
BOILER MASTER CONTROL = TO CONTROL AIR (FDF) AND FUEL
AIR FLOW IS MINIMUM 30 % OF LOAD
if loss of FD FAN trip, the air flow reduced then MASTER DEMAND SIGNAL will
trip the generator circuit breaker.
FUNCTION :
The boiler master controller, which is manually adjusted for the desired boiler operation,
senses the difference between them measured steam pressure and the manually adjusted set point
signal to produce the master demand signal.
This master demand signal, then, become the set point for both the fuel flow controller
and air flow controller.consequently, fuel flow and air flow are ultimately controlled to the set
point of the boiler master control.
Between the boiler master controller and the Fuel/Air controllers, there are RUN-BACK
CIRCUIT AND FST CUT BACK ( F.C.B ) circuit, which reduce the boiler master signal
forcedly to a preset value at a preset rate on LOSS OF ONE FD Fans and in the event of main
for GENERATOR CIRCUIT BREAKER TRIP.
The signal through these circuits is transmitted to the fuel flow and air flo0w control
subloops.
AUTO MODE SELECTION OF MASTER CONTROL :
After the fuel flow and air flow control sub-loops are selected on auto,the master control
is to be put on auto.
The load at which the boiler master control is possible to be put on auto is expected
around 30 % MCR.
Prior to the auto selection on the master set station,it is requested to adjust the set point to
eliminate the difference between the measured signal and the set point signal as small as
possible,and then depress the auto pushbutton.
MANUAL operation from the master station is provided only for emergency or transient
condition.
When the master control is MANUAL AND MANUAL operation is needed,care must be
taken to avoid the big disturbance on plant operating condition.
COMBUSTION CONTROL LOOPS :
It regulates the AIR FLOW and FUEL FLOW ( correct AIR and Flow ration ) and
prevents air defficiency in the furnance by the combined action of controllers and selectors
(HIGH / LOW ).
FUEL FLOW CONTROL SYSTEM :
1. HFO system
2. LFO system ( which is used only during start up period,is manually adjusted
from control station without automatic control )
AIR FLOW CONTROL SYSTEM :
( Mini. 30% FLOW )
1. Forced Draught Fan A and B
2. Flue gas Oxygen control function
Air flow by master signal or fuel flow signal whichever is higher.

Fuel flow by master signal or air signal whichever is smaller
FEED WATER CONTROL LOOP :
1. Single element control loop

2. Three element control loop
The system is composed of both three elements ( Feed water flow,Steam flow and
Dreum level ).
In Single Element method the measeured drum level is compared with the set point
and output signal of the controller is transmitted to feed water start up.
The three element control loop is composed of feed forward signal and feedback
signal.The feed forward signal is the steam flow measurement,which manipulates the set
point of the feedwater flow controller,and therefore manipulates feedwater flow to equal
the rate of steam being withdraw from the drum.
SUPER HEATER STEAM TEMPERATURE CONTROL LOOP :
The superheater steam temperature control system is a cascade system that maintains the
final superheater outlet steam temperature at a manually set value by regulating desuperheating
spray water flow.The temperature set point is to be adjusted by the dial on the set point staion.
AUXILIARY CONTROL LOOPS :
1.
2.
3.
4.
5.
Air heater control

Heavy oil pump outlet pressure control loop
Primary and secondary air damper controls
Chemical dosing pump control
FDF outlet damper control
POWER SUPPLY SYSTEM :

The ABC system employs a dual power supply system with two separate AC 110 V
power source.( DC +15V,-15V and +24V ) and the DC outputs of both power units are combined
together with auctioneering diode and supplied to the entire system via common bus.
DC +15 V and DC 15 V are used as the power supply for Analog modules
DC +24 V for interlocking Logic Realys, Lamp indications on the Control Stations and
Position Transmitters.
1. One AC source is taken from the inverter to which battery power is fed,
2. Second from transformer which is connected with 480 V bus.
BOILER PROTECTION INTERLOCK :
The boiler protection interlock is one of the most important and is designed to protect the
boiler by tripping all kinds of fuels in to the furnance.
The system includes the following three main functions :
1. Master fuel trip ( MFT )
2. H.O and L.O shut off valve interlock
3. Ignitor gas shut off valve interlock
CAUSE OF MASTER FUEL TRIP :
1.
2.
3.
4.
5.
6.
7.
8.
MFT push button

Furnance pressure High
Both FDF stopped
All flame loss
Unstable power supply
Air flow < 25 %
Drum level Low Low
Boiler fired
SEQUENCE CONTROL SYSTEM :

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Forced draft fan start

Forced draft fan stop
Heavy fuel oil pump start
Heavy fuel oil pump stop
Furnance purge
Light fuel oil leak test
Heavy fuel oil leak test
Heavy fuel oil warming ( 1 )
Heavy fuel oil earming ( 2 )

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PHASE 1 STEAM TURBINE AND BOILER

YOKOGAW01100 CONTROL SYSTEM :

AUTOMATIC BOILER CONTROL SYSTEM :

AUTOMATIC BOILER CONTROL SYSTEM ( ABC ) :

1.Control stations on the boiler control console

1.Hand / Auto staion

CONTROL FUCTION AND OPERATION :

Air flow by master signal or fuel flow signal whichever is higher.

1. Single element control loop

Air heater control

POWER SUPPLY SYSTEM :

BOILER PROTECTION INTERLOCK :

MFT push button

SEQUENCE CONTROL SYSTEM :

Forced draft fan start

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