Boiler Automation

Input for Boiler

I1 – Water Level Extra Low Boiler
I2 – Low Level of water in Boiler
I3 – Start / Power Supply
I4 – Burner Switch / Ignition
I5 – Emergency Stop (i.e. Stop all Outputs)
I6 – Photocell Sensor (Flame Sensor)
I7 / I8 – Extra
I9 – High Level of Water in Boiler
I10 – Damper Motor Flap in Closed Position
I11 - Damper Motor flap in Open Position
I12 - Reset (Alarms stop / Unlatch)
R1 – Feed water pump-1 FWP-1) flow sensor
R2 – Feed water pump-2 (FWP-2) flow sensor
R3 – Pressure switch for fuel pump
A1 - Steam Pressure (Low) I7-<=1.0
A1 - Steam Pressure (High) I7->=9.0

Output for Boiler

Q1 – Boiler ON/OFF indication
Q2 – Feed Water Pump –1
Q3 – Feed Water Pump –2
Q4 – Air Blower
Q5 – Ignition
Q6 – Solenoid Valve for Fuel Oil Supply
Q7 – Alarm (Visual)
Q8 – Alarm (Audio Hooter)

S1 – Damper Motor ON/OFF Indication

S2 – Fuel pump ON/OFF Indication
S3 - Fuel Pressure switch ON/OFF Indication
S4 – Alarm if fuel pump is faulty
S5 - Damper Motor (M) in clockwise direction
S6 – Damper Motor Anti Clockwise Direction
S7 – Alarm for FWP-1
S8 – Alarm for FWP-2
 Main Flow Chart

START

PRE-PURGE

WATER SUPPLY INITIALSATION PROCESS

FUEL SUPPLY INITIALSATION PROCESS

STEAM GENERATION PROCESS

POST-PURGE

STOP

1) 2)
START POST-PURGE
 
PRE-PURGE Stem pressure high (A2)
 
If damper flap is in closed position Boiler OFF indication
Start damper motor & in clockwise 
Till flap reaches open position Start air blower for 5-Sec.&then
 It should automatically become
Start air blower for 5-Sec.& then OFF
It should automatically OFF 
If flap is open position start
Damper motor & move it in Anti
Clockwise direction till flap reaches
Closed position

STOP
3) Water supply initialization process

Pre-Purge & Extra Low Level/ Low Level

Start FWP-1 Yes [R1 () Water high level F.W.P-1 (X) Go to
Even  F.S.I.P.
after 5 sec No [R1 (X)] Give Alaram (S7)

Start FWP-2  Yes [R2 () Water high level F.W.P-1 (X) Go to
Even  F.S.I.P
after 5 sec No [R2 (X)] Give Alaram (S7)

If S7 & S8 both are ON then Lock out condition [Q1, Q5 & Q6 (X)]

4) Fuel supply Initialization Process


Pre-Purge & Water level high

Open fuel supply valve

Start fuel pump  Yes [R3 ()] Go to steam generation process
Even 
after 5 sec  No [R3 (X)] Alarm & lock out Q1, Q5 & Q6 (X)
5) Steam Generation Process

Pre –purge & Water supply Initialization high & Fuel Supply Pressure &
 Steam Pressure Low
Start Burner Switch  Ignition

Flame Detect  (Yes) Boiler ON------------
 (No) 
No (Stop fuel supply) Steam pressure high
 
Go to Lock Out Post –Purge
When steam generation process is ON water level should not be ELL/LL
If water level becomes ELL/LL then go to Lock Out Q1, Q5 & Q6 (X)