Babcock Engineering

1 Osborne Lane Bedfordview, 2007 PO Box 4561 Johannesburg, 2000 South Africa Tel +27 (0)11 601 1000 Fax +27 (0)11 601 1146 E-mail: enquiries@babcock.co.za www.babcock.co.za
CONTROL PHILOSOPHY

SAPPI TUGELA MILL

BOILER 10 CONTROL PHILOSOPHY

Project Document Number Revision

: : :

DA 47 Boiler 10 Conversion DA 47-T- C- CP 01 C

Registration in South Africa No. 1968/008464/07 A division of Babcock Africa Services (Pty) Limited A member of Babcock International Group PLC Directors: R. OCallaghan W.H. Steyn D.L. Brook* R.T. Hillcoat* M.C. Hughes N.C. Penson D.J. Milner* T.P. Ward* * British

Document Information
Title Doc Number Revision Date Classification Synopsis Functional Specification DA 47-T- C- CP 01 03 25/11/05

Document History
Rev. 1 2 3 Date 21/11/05 25/11/05 Author Riaan Hoffman Riaan Hoffman G.Brownson Changes First Issue Detailed and updated Changed to suit base load operation

Document Approval
Action Author Technical Verified Approved Function Designate Date Signature

Page 2 of 23

The control loop employed on drum level is the standard three- element control. This three-element control is a cascaded feed-forward control loop, which maintains water flow input to the drum equal to steam flow demand. The basic three elements are drum level, steam flow and feed water flow. The PVs of these three controllers are measured using differential pressure transmitters. The steam feed forward signal is then introduced before the final output is then transferred to the feed water controller. The drum level high and low signals are alarmed in the control room. Protection is provided by using the conductivity probes on the Clarke Reliance hydra step type level device. The outputs of these probe trip the boiler on lo-lo drum level. The hi-hi level only registers an alarm and the operator needs to take the required action.

FLUE GAS MONITORING Allowance is made for temperature and pressure measurements between each heat exchanger and other devices in the flue gas path to monitor the outlet gas conditions. All these signals are displayed on the operator control panel. The differential pressure across the scrubber is calculated. This differential pressure signal is passed on a controller that keeps the differential pressure to a specific value by manipulating the scrubber control damper which is located in the entrance to the to the cyclone section of the scrubber.

START UP BURNER The gas burner is supplied to heat up the bed from cold start-up conditions. The gas (SASOL methane rich) is supplied from an existing station in the plant. The burner is controlled by a local burner management system, which is interfaced with the DCS. The burner is supplied with all equipment and valves which together with the BMS ensures safe start up and shut down of the burner. The burner control panel reports the status of the burner to the DCS and allows the burners to be operated locally from the firing floor or remotely from the control room. The burner firing rate is controlled by electronic regulation with step motors on the air damper and gas butterfly. The burner incorporates a fan complete with motor for the supply of combustion air to the burner. The fan remains in operation at minimum flow during burner shut down in order to maintain a flow of cooling air to the burner tip. This feature is incorporated into the burner management system. In the event of a fan trip an alarm will sound in the control room and after a time delay the boiler will trip.

BED MANAGEMENT SYSTEM The sand replenishment system comprises of 1 sand hopper, which contains the sand for the bed. Due to combustion the bed level may increase or decrease with time depending on many variables such as type of fuel, operation etc. A simple bed management system is employed for the boiler, which is based on manual loading and drainage. The bed level is derived from static pressure measurement in the plenum chambers and an average bed level is calculated by using the pressure signals from the pressure transmitters installed in the plenum chambers.
Page 7 of 23