Workshop on Efficient Operation & Maintenance of Boilers

COMBUSTION CONTROLS
Combustion controls assist the burner in regulation of fuel supply, air supply, (fuel to
air ratio), and removal of gases of combustion to achieve optimum boiler efficiency.
The amount of fuel supplied to the burner must be in proportion to the steam
pressure and the quantity of steam required. The combustion controls are also
necessary as safety a device ensuring the boiler operates safely.

A drop in steam pressure necessitates an increase in the fuel supplied to the burner.
Conversely, an increase in steam pressure necessitates a decrease in the fuel
supplied. Any change in the amount of fuel supplied requires a corresponding
change in the air for combustion supplied to the burner.

To maintain high combustion efficiency, the air to fuel ratio must be balanced from
the lowest firing rate to the highest firing rate. If there is an imbalance in the air to
fuel ratio, smoking, flame failure, wasted fuel and in extreme cases an explosion
could result.

Combustion controls also regulate the removal of gases of combustion by

maintaining a consistent furnace pressure throughout different firing rates. By
maintaining a consistent firing rate, combustion controls improve regulation of
feedwater and superheat temperature. A consistent firing rate reduces fluctuation of
the boiler water level and increases the life of the boiler drum and tubes.

In addition to the choice of burner type, consideration must be given to the control
system required.

On/Off control

The simplest control ON/OFF control means that either the burner is firing at full rate
or it is OFF. This control is limited to small boilers up to 300 KW.

High/Low/Off Control

Slightly more complex is HIGH/LOW/OFF system where the burner has two firing
rates. The burner operates at slower firing rate and then switches to full firing as
needed. Burner can also revert to low firing position at reduced load. This control is
fitted to boilers with an output of up to 3.5 MW.

Modulating Control

The modulating control operates on the principle of matching the steam pressure
demand by altering the firing rate over the entire operating range of the boiler.
Modulating motors use conventional mechanical linkage or electric valves to regulate
the primary air, secondary air, and fuel supplied to the burner. Full modulation means
that boiler keeps firing, and fuel and air are carefully matched over the whole firing
range to maximize thermal efficiency. This type of control can be fitted to boilers
above 1 MW.

National Productivity Council, Gandhinagar

 Workshop on Efficient Operation & Maintenance of Boilers

Trouble Shooting Chart For Combustion

COMPLAINT CAUSES AND REMEDIES

1. Starting Difficult i. No oil in the tank
ii. Excessive sludge and water in storage
tanks.
iii. Oil not flowing due to high viscosity/low
temperature.
iv. Choked burner tip.
v. No air
vi. Strainers choked

2. Flame goes out or i. Sludge or water in oil

splutters
ii. Unsteady oil and air pressures.
iii. Too high a pressure for atomizing medium
which tends to blow off the flame.
iv. Presence of air in oil line. Look for leakages
in suction line of pump.
v. Broken burner block, or burner without
block.

3. Flame flashes back. i. Oil supply left in ON position after air

supply was cut off during earlier shut off.
ii. Too high a positive pressure in combustion
chamber
iii. Furnace too cold, during starting, to
complete the combustion (when
temperature rises, unburnt oil particles
burn)
iv. Oil pressure too low.

4. Smoke and soot i. Insufficient draft or blower of inadequate

capacity.
ii. Oil flow excessive
iii. Oil too heavy and not preheated to the
required level.
iv. Suction air holes in blower plugged.
v. Chimney clogged with soot/damper closed.
vi. Blower operating at too low a speed

5. Clinker on refractory i. Flame hits refractory since combustion

chamber is too small or burner is not
correctly aligned.
ii. Oil dripping from nozzle.
iii. Oil supply not cut off before the air supply
during shut-off.

6. Coking of fuel in burner i. Nozzle exposed to furnace radiation after

shut-off.

National Productivity Council, Gandhinagar

 Workshop on Efficient Operation & Maintenance of Boilers

ii. Burner fed with atomizing air over 300oC.

iii. Burner block too short or too wide.
iv. Oil not drained from nozzle after shut off.

7. Excessive fuel oil i. Improper ratio of oil and air.

consumption ii. Burner nozzle oversized.
iii. Excessive draft.
iv. Improper oil/air mixing by burner.
v. Air and oil pressure not correct
vi. Oil not preheated properly.
vii. Oil viscosity too low for the type of burner in
use
viii. Oil leaks in oil pipelines/preheater
ix Bad maintenance (too high or rising stack
gas temperature)

National Productivity Council, Gandhinagar