FEED WATER CONTROL SYSTEMS

INTRODUCTION
a. The Automatic feedwater control systems maintain boiler water level and
delivery pressure at a desired setpoint. This objective is accomplished by
manipulating a feed control valve and the speed of the main feed pump.
This lesson will provide the basic control functions and component
interrelationships understanding.
REFERENCES
b. Automatic Combustion and Feedwater Control Systems NAVSEA 0951036-9010
c. Steam Plant Controls NSTM Chapter 225
d. Boiler Technician 3 and 2 NAVEDTRA 10535 G, Chapter 6
INFORMATION
e. Feedwater Control Systems
f. Each boiler is installed with a three element feed system (Figure 1). It is an
automatic system which controls feed flow to each boiler. The three element
feedwater control systems position the feedwater control valves to each
boiler, maintaining normal water level in the steam drums. Steady water
level indicates that a balance exists between the water flow to the boiler and
the steam removed.
g. The feedwater control system is a three-element type, designed to monitor
changes in the primary sensing elements: steam flow, feed flow and drum
level. With changes in boiler load (steam flow) steam and feed flow become
unbalanced and water level consequently deviates from the normal position.
In such an event, the system changes water flow in the proper direction and
to the extent necessary to restore the balance between steam flow and feed
flow and return the water level to normal.
h. Three elements are measured by the system:
i. Steam flow is considered the demand signal.
j. Feed flow is considered the feedback signal.
k. Drum level is considered the supervisory signal.
l.

m.
n. Components:
o. Steam and feed flow transmitters are identical in construction. These
transmitters incorporate a differential pressure unit (DPU) which measures
the pressure drop across an orifice with a mechanical square root extractor.
The transmitter generates a pneumatic output signal that is proportional to
flow.
p. Drum level transmitters compare the weight of constant and variable legs of
water that result in a differential pressure. A continuous output signal is
provided that is proportional to drum level. The output of the drum level
transmitter will be 30 psig when the steam drum water level is normal.
q. The steam flow/feed flow relay for a Hagan system consists of a 4 chamber
totalizer with a 30 psig spring attached to chamber 3. The purpose of this
relay is to subtract the feed flow signal from the steam flow signal. The
spring adds 30 psig to the result. When the inputs of the steam flow and
feed flow transmitters are equal the output of the relay will be 30 psig.
r. Feedwater flow controllers in a Hagan system are 4 chamber ratio totalizers
which ifinction as proportional-plus-reset controller. Reset action is
accomplished by feeding the output of the automatic-manual transfer station
back to chamber 4 through a needle valve and volume tank. The purpose of
this controller is to compare demand signal to supervisory signal and
develop an output to return drum level to normal. Shrink and swell are

compensated for in the operation of the feedflow controller. On an increase

in boiler demand swell offsets the increased output of the steam flow/feed
flow relay by causing an increase in the drum level transmitter output.
These inputs received by the feedflow controller are both increasing, thus
the output remains the same to the automatic/manual control station. The
same is true for shrink with the exception that both inputs decrease.
s. Feedwater automatic/manual transfer stations allow the operator two modes
of control: automatic or manual. Automatic mode is used for routine
steaming operations and manual mode for plant startup, securing, and
casualty control.
t. Feedwater control valve and positioner are diaphragm control valves which
are normally operated by changes in pressure to the control air connection
from the positioner. A handwheel is fitted on the top of the valve to permit
manual closing during maintenance and local manual operation. The
feedwater control valve positioner is used to physically position the
feedwater control valve. A mechanical linkage on the positioner connected
to the valve stem provides feedback of the actual valve stem movement.
When the controller output calls for the valve stem to change position, the
positioner acts as a pneumatic relay, through a separate air supply, to
increase or decrease the pressure to the valve actuator and change the
position of the stem as required by the controller output signal.
u. System operation (Increase in boiler demand):
v. Increase steam flow sensed by steam flow transmitter
w. Steam flow transmitter output increases
x. Drum level transmitter output increases due to swell
y. Feed flow controller unchanged due to increased inputs from steam flow
transmitter and drum level transmitter balance
z. As swell decreases, feed flow controller output increases
aa. Feedwater automatic/manual transfer station passes signal through in
automatic
bb.Feedwater control valve positioner output decreases, to position control
valve stem in correct position to increase feed flow
cc. Feed flow transmitter senses increased flow and increases output signal
dd.Steam flow and feed flow transmitters balance

ee. Steam flow/feed flow relay returns to 30 psig

ff. Drum level returns to normal
gg.Drum level transmitter at 30 psig
hh.Feed flow controller balanced at new increased value
ii. Decrease in boiler demand is the opposite of an increase in demand.
jj.

kk.
ll. Main feed pump constant pressure control system (Figure 2)
mm. The main feed pump constant pressure control system ensures the main
feed pump maintains a constant discharge pressure.
nn.The control system consists of a hydraulic system which uses lube oil as a
control medium, and a pneumatic system which utilizes air as a control
medium. A pneumatic bellows, which actuates the turbine control system in
response to the pneumatic signal from the feedwater system, is mounted on
each turbine. The pneumatic control components for the main feed pumps
are located in a control panel in each fireroom, with automatic/manual
stations on the combustion control console.
oo.Components:
pp.Feedwater header pressure controller senses feedwater header pressure and
exerts a force on an installed beam. The set point spring, which opposes the
force exerted by the high pressure bellows is adjusted to balance the

regulated feedwater header pressure to setpoint. The output of the feed

header pressure transmitter is proportional to the pressure sensed.
qq.Signal range modifier acts as a system pressure interpreter. For example, the
Hagan system pressure range is from 5-60 psi representing 100 percent
range. The main feed pump governor has a working range of 3-47.5 psi
representing 100 percent. The range modifier in this application establishes
compatibility between the normal 5-60 psi range and that required by the
feed pump governor.
rr. Main feed pump automatic/manual transfer station gives the operator two
modes of control: automatic or manual. One is installed for each main feed
pump. Output goes to the bellows on the main feed pump turbine control
operator (governor). It is important to note that the main feed pump
governor will be reverse acting to the incoming signal. On an increase of
demand the increased demand signal will be reversed to a lower signal to
the pump controls allowing the pump to turn faster. The opposite occurs on
a decrease in demand.
ss. System operation (increase demand):
tt. Feed header pressure decreases
uu.Feed header pressure controller output decreases
vv.Signal range modifier decrease input gives decrease output
ww.

Automatic/manual transfer station passes signal through in automatic

xx.Decrease input to main feed pump causing increase in RPM

yy.Increased RPM causes rise in feed header pressure
zz. Decrease in boiler demand are opposite of increase in demand.
aaa. NOTE: There are a number of ships that do not utilize the Hagan feed
header pressure systems. These ships use a Leslie constant pressure
regulator that simply monitors header pressure and alters the position of the
steam admission valve to the main feed pump directly via a governor
assembly.
bbb.

System Deficiencies:

ccc. The control air must be free of moisture and particulate matter. The
smallest amount of moisture or particulate matter in a control system will
foul small orifices and cause a malfunction of the system. If a component in
the system malfunctions, securing the plant to repair it may not be required.
In many cases the control system may be placed in remote or local manual,

the component isolated and then replaced with a bulkhead spare. A complete
knowledge of the control systems functions is necessary to make such
critical decisions. It must be understood that when a control system is in
remote or local manual the plant load must be increased or decreased slowly
as an operator is not as responsive as the control system would be in
automatic.
ddd. Other problems are: improper PMS being preformed, leaking air lines
or fittings, component covers not installed, loose set screws on regulators,
and components not mounted correctly (missing bolts or not tight).