Instruments for Safe Operation and

Improving Efficiency in Boilers

N. Nagendra Prasad
B.E.(Mech.), MIE, AVSI(Sugar Engg.), C.Eng(I), BOE

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010
email: svec.vja@gmail.com

Control Systems for Boilers.N. Nagendra Prasad

Why
Control ?
S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Safe
Operation
S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Efficiency
S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

TYPES OF CONTROLS

Manual Control
Automatic Control

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Essential
Components

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

SENSORS

TRANSMITTERS

CONTROLLERS

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

OUTPUT CONVERTERS & DEVICES

I/P Converters

Control Valve
Pneumatic Cylinder with Hand Wheel
S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Single Loop Control
Process
Signal
Pressure
D.P.
Temp.
etc.

Input Sensor
& Converter

4-20mA

PID
Controller

Set Point
SV

4-20mA

Output
Converter

O/p Signal

Output Device
Control Valve /
Cylinder etc.

Fig. 1

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

CONTROL OF ALL BOILER ESSENTIAL PARAMETERS BY MULTI LOOP CONTROLLER
Fig. 2
Set Value
PV Process Value
Constant
(Drum Level)
SV Set Value
Drum Level

Steam Flow

IP 1
PV
IP 2

Steam Temp. IP 3
IP 4
Steam Press.
Feed Water IP 5
Flow

PID

Multiply

EV
X

Compensation

ADD

EV Error Value
X Makup for Drum
Y Evaporation quantity
T Total Water requirement
CSV Cascade Set Value
O/P 1

Y
CSV

PID

PV
3 Element Drum Level Control
(With Compensation)

Feed Water
Control Valve

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Fuel Feeding (Steam Pressure) Control

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

OTHER ESSENTIAL CONTROLS
Furnace
Pressure

IP 6

PV
PID

Set Value
(F.Pressure)

O/P 3

Balanced Draft Control

Deaerator
Level

IP 7

Deaerator IP 8
Temperature

ID Damper Adjusting
Cylinder or VFD I/p

PV
PID

Set Value
(Level)

O/P 4

Deaerator Level Control

PV

Set Value
(Temp.)

PID

Makup Water
Control Valve

O/P 5

Deaerator Temperature Control

LP Steam
Control Valve

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

ADVANCED CONTROLS

S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

Control Systems for Boilers.N. Nagendra Prasad

Instruments for Improving Efficiency
Oxygen Analyser & Trimming For measuring Oxygen in
flue gas and to trim (reduce) excess air
CO/CO2 Analyser For measuring the CO/CO2 in flue gas
to know the status of complete combustion and to reduce
incomplete combustion loss
Optical Pyrometer / IR Camera For monitoring and
controlling combustion in furnace / radiation losses
CBD Tank Level control For utilisation of Flash steam (to
De-aerator or other) from CBD water
LP/HP Heater Controls For improving the overall system
efficiency of Power Plant
S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459

 S.V. Engineers & Consultants, #86, J.D. Nagar, Patamata, Vijayawada 520010 Ph: 9440978459