Automatic Boiler Control for Water tube Boiler

ABC(Automatic Boiler Control)

ACC : Automatic Combustion Control FWC : Feed Water Control
STC : Superheated Steam Temperature Control ABC RTC : Reheated Steam Temperature Control FDC : Furnace Draft Control Others : Fan Speed Control, Tank level control Fuel oil Temperature Control GAH Cold end Metal Temperature Control etc.

ABC(Automatic Boiler Control)

BOILER MASS AND ENERGY BALANCE(1) Purpose of ABC : To keep Boiler Mass and Energy balance WATER
Hydrogen H2 Carbon C Sulfur S Nitrogen N2 Oxygen O2 Water H2O Ash Others Nitrogen N2 Oxygen O2 Water H2O Others Carbon dioxide CO2 Carbon monoxide CO Oxygen O2 Nitrogen N2 Nitrogen Oxide NOx Sulfur Oxide SOx Hydrogen H2 Water (Moisture) H2O

FUEL

Combustion Gas BOILER

AIR

ASH
Soot

STEAM

BOILER MASS BALANCE

ABC(Automatic Boiler Control)

BOILER MASS AND ENERGY BALANCE(2) Purpose of ABC : To keep Boiler Mass and Energy balance
Heat output by Generated steam

FUEL Heat Input by Combustion Combustion Air

Heat loss by Flue gas Heat loss by Radiation Heat loss by Unfired carbon

BOILER

Heat Input by Feed Water

Heat loss by blow down

BOILER ENERGY BALANCE

ACC(Automatic Combustion Control)

ACC

Master Control (Main Steam Pressure Control)

Combustion Control
Fuel Flow Control Combustion Air Control Flue Gas Oxygen Control

Purpose of Master Control : To maintain Main Steam Pressure Master Control 1) One element Control (only by Main Steam Pressure) 2) Two element Control ( by Main Steam Pressure + Feed forward signal by Main Steam Flow)

ACC(Automatic Combustion Control)

ACC
PT
FT

Main Steam
Fuel

Burner

BOILER
FDF (Forced Draft Fan)

maintain Boiler Energy balance

ACC(Automatic Combustion Control)

Master Control(1)
One element Control
Main Steam Pressure

Set Point

Master Controller
(Main steam pressure controller)

A/M Station

To other boiler controller

Load Distributor

To Combustion Controller

ACC(Automatic Combustion Control)

Master Control(2)

Flow, Pressure

Main Steam Flow Time Lug Main Steam Pressure

Two element One element

Required Combustion Signal

Time

ACC(Automatic Combustion Control)

Master Control(2)
Two element Control
Main Steam Pressure Flow Main Steam Pressure Flow

To Combustion Controller

To Combustion Controller

Type-1

Type-2

ACC(Automatic Combustion Control)

Combustion Control

Master Controller
Required Combustion Signal

COMBUSTION COMTROL Fuel Flow Controller Combustion Air Flow Controller

Air-Rich Combustion System : to avoid air-less condition at load change

ACC(Automatic Combustion Control)

Combustion Control
Main Steam Press Fuel Flow Air Flow

Master

Bias
Low selector High selector Air flow Controller

Fuel flow Controller

Fuel Flow Control Valve

FDF Inlet Vane Control Drive

Air-Rich Combustion System

ACC(Automatic Combustion Control)

Combustion Control

Time Load Constant Load Up Load Constant Load Down

Air-Rich Combustion System

ACC(Automatic Combustion Control)

Combustion Control
Main Steam Flow Main Steam Pressure Fuel Flow Air Flow Flue Gas O2 Content

Master

O2 Controller

Fuel Flow Controller

Air Flow Controller

Air-Rich Combustion System (Double Cross-limit)

ACC(Automatic Combustion Control)

Combustion Control

Time Load Constant Load Up Load Constant Load

Down

Air-Rich Combustion System (Double Cross-limit)

ACC(Automatic Combustion Control)

Combustion Control
O2 Controller
Required air Flow
from Steam flow

Air Flow

O2 Content(%)

O2 Controller

O2 Content

Air flow controller

Min.

Load

Max.

FWC (Feed Water Control)

Purpose of FWC (Feed water Control) : to maintain steam drum water level at desired level (NWL)

High Water level : Increase Carry-over

Scaling to Superheater tube Tube overheating Tube rupture Scaling to turbine blade excessive vibration, reducing efficiency Low Water level : poor water circulation Water tube overheating Tube rupture Method of FWC (Feed water control) 1) one element control (drum water level) 2) two element control (drum water level, steam flow) 3) three element control (drum water level, steam flow, water flow)

FWC (Feed Water Control)

FT

Main Steam

LT

FWC

FT

Feed Water

BOILER

Feed water Control Valve

Maintain Boiler Mass Balance

FWC (Feed Water Control)

One element Control

Drum Level Steam Flow

Set point

Drum Level

Feed water Control Valve

Time

One Element Control

Reverse Response of Water Level

FWC (Feed Water Control)

Two element Control
Drum Level Steam Flow Drum Level Steam Flow

Level Controller

Level Controller

I0 = I1 + (I2-50)

FWC (Feed Water Control)

Three element Control
Drum Level Feed water Flow Steam Flow Feed water Flow

Steam Flow

Drum Level

Level Controller

Level Controller

Feed water Controller

STC (Superheated Steam Temperature Control)

Purpose of STC (Superheated Steam Temperature Control) : to maintain main steam temperature at desired temperature
TE
From S/D

STC
from Feed water

Spray Control Valve

Min. Max.

Boiler Load

STC (Superheated Steam Temperature Control)

FT

TE
From S/D

TE

STC

Primary S/H

Secondary S/H
from Feed water

Spray Control Valve

STC (Superheated Steam Temperature Control)

Main Steam Temperature Spray out Steam Temperature Main Steam Temperature

Steam Flow

Steam Flow

Spray water control Valve

Spray water control Valve