Boiler Instrumentation, Control and Optimization in Modern

Power Plants
J.J. Bahl, A.K. Chatterjee and Narender Sharma

ABC Paper, Saila Khurd, Dist, Hoshiarpur, Punjab-144 529

Steam boilers are used industrially both as a power source and in processing operations. Varying
demands of steam and power loads tend to destabilize the process when controlling the various
parameters manually. Hence, the role of various levels of instrumentation comes into picture. The
paper explains basic configuration of the boiler control loops and the role of various alterations
through Distributed Control System (DCS) to compensate the effect of variables. The discussions
have led to the conclusion that optimum instrumentation certainly makes a boiler capable of satisfying
the rapid changes in load with greater "Turndown" compared to other segments of a plant.

INTRODUCTION Feed Forward Control of Steam Pressure

The boiler optimization for improving the load- A feed forward control is effected in single boiler or in
following capability of power plant units has been boilers when total steam flow is measured with the
gaining considerable importance in modern power biggest contributor. Fig. 2 demonstrates such a loop
• plants. An optimized instrumentation and control using feed forward loop with back trim, where loops
system regards all major design and operational 101 and 102 measure the flow and pressure of steam
characteristics and therefore plays a major role in the generated where FT-102 is a high rangeability and linear
profitable operation of a power plant by achieving Transmitter. Firing rate demand signal is generated in a
availability, flexibility, reliability and efficiency. feed back manner by the pressure controller PIC-101. A
Distributed Control System (DCS) and Programmable feed forward trim is added to speed up the response of
Logic Control (PLC) are two main control systems used this loop to load changes. Therefore, as soon as the
in view above, an optimization in modern power plants. demand for steam changes, FY-102 will trim the firing
signal demand, without waiting for the steam pressure
Boiler Controls
to change. The dynamics of FY102 are adjusted to reflect
Fig. 1 describes a well-design scheme of a boiler control the time constants of the boiler, recognizing the time
loops and the tie up points for optimization. The various displacement between a change in firing rate and the
boiler controls have been described in the subsequent resulting change in the rate of steam generation
sections. sometime later.
Boiler pressure control/combustion control Fuel Control (Measurable Fuels)

This can be subdivided into 2 sections: Major fuels used in the boiler are Coal, Oil & Gas. But
other non-conventional fuels like waste gases, waste
1. Fuel Control and
sludges & waste products like saw dust & bark etc. are
2. Combustion air control system also being used. However, the scope of this paper has
The inter-relationship between the above 2 sub-sytems been restricted to commonly used fuels. Oil and gas are
necessitates the use of air-fuel ratio controls. Balance the simplest type of fuel that are easily measurable and
between the inflow and outflow of heat from the boiler require only a control valve with accessories to control
drum is indicative of the steam drum pressure. A change the quantity. Coriolis mass flow sensorsare commonly
in steam pressure will result from a change in firing rate used for such measurements in place of orifice plate.
only after a delay, depending upon the boiler load level Fig.3 an Fig.4 show the loops for a single fuel and dual
and therefore feed forward control, is incorporated. fuel controls, which are self-explanatory. In dual fuel
system a manual split requirement is possible via 2 Nos.

IPPTA J. Vol. 16, No.4 Oct 2004 81

 STEAM --.....,.-~~---l STEAM !'ROM PRIMARY SUPERHEATER
'----C>r4--- FEED WATER 8l0W-DOWN
TT
~12
FBI ••••

•
FlUJ;GAS8Y
I'ASS DAMPERS
r--- TIC PI SP
113 --1---
I
SP
TIE·IN
# 3
SP

T)<i.~~U:N~R I;~ X_~ !_;;D ~ST" I

PROGRA- I ~ HB I I
Ftt) MMER I TIC FBI ,.-------------'1 LSTM I

1""'--
y
102 --
Wn~N(jf:
------
111
I
~'
Lie SP~1C I
I~.
.
-80 I
I
as -------

®®
I I I PI 109 __1 AFY --'-
I ~
lE flAG Pll20"1. 4 MJ~: 1 RA 1 t 109

~
py
101 -
-WIC 101
SP
OA'

-
PT
101
FT
102
TT
111
I STEAM
I
I
,.
ATM.!
I~~
I

I
® ,~FW
I

1(J9
161~:(')ND I ': HEADER ISlWdDRUM I

I I I

Y :
I
I
I SP FIC
I 103

I
I
I
I
I
I
I
I I
I I
I I K 1

: ~Y e~~D :
103 (JAIN I
I
I
I@rlI
I F~2 FY MASS FLOW I

~~----r--~~-~--
I~

!
---~-----+
~~------@-:.--l- ~>
I ~

RI~A~O
I l 1(1"4 =CONSTfTfr

__~b).
I

i ~----~~_?l~!l..El~.'ili!L..- ~------_ -----1

Fig. 1 : Good Boiler Controls without Optimization

FIR INGRATE
Bias and manual control function relays.

Air Flow Measurement / Control

For air fuel ratio control combustion air flow

measurement is important (Table 1). Normal differential
OPTIMIZW pressure range of these measurement are between one
I--:=--I---H-"S""ET"".POINT
inch water column to six inches water column for
conventional sensors and as low as 0.1 inches water
column for area averaging pitted stations.

Dampers have been normally used for air controls

in the boiler. But of late, variable frequency drives are
STEAM HEADER taking their place. But it has been experienced that at
low speeds and loads, the variable drives do not function
Fig 2. : Firing Rate Determination using Feed satisfactorily and therefore a combination of dampers
Forward Loop with Feed Back Trim and variable drives are being preferred.

82 IPPTA J. Vol. Ip, No.4 Oct 2004

 RA
PI SET
FUEL DEMAND
PRESSUREc::l
TROL VALVE
0PC
~ PT

~ __-L__~,~~~-----
EQUAl. 'f. FlOW
CONTROL VALVE

FUEL DEMAND
TOTAL fUEL
SIGNAL
(ON AIR BASIS)
Fig. 3 : Fuel Controller to Keep Demand and Flow
in Linear Reletionship
OIL

Furnace Draft Controls

Fig 4. : Manual Splitting of Fuel Demand Between
In case of a balanced draft boiler the maintenance of
two Fuels on an Open-Loop Basis
constant furnace pressure keeps the forced and induced
draft in balance, the purpose of which is to avoid positive the induced draft as the furnace draft controller.
pressure in the furnace and provide combustion-air However, air demand signal is also given to induced
suitably. The measurement of furnace draft produces a draft fan control as fuel based signal. Air flow is a
noisy signal limiting the loop and air to low values. function of both induced draft fan and forced draft fan.
Force draft fan is normally used as air flow adjuster and

Table 1 : Flow Sensor Errors on Boilers

Flow Streams Type of Flow Inaccuracy (% of flow) at Rangeability Limitation

Measured Meter 10% 33% 100%
••

Fuel (Oil) Coriolis mass flow O.S O.S O.S 20:1 Not of gases
Steam and Vortex shedding 1-1.S 1-1.S 1-1.5 10:1
Water steam Min R=20,000
Max. Temp.=
Water 0.5-1 0.5-1 -.S-1 10:1 7S0°F(400°C)
Orifice NG* 2-S O.S 3:1 Rangeability can
be increased if
M
using two
conventional dl p
cells or a "Smart"
dip cell

Air Area averaging NG 2-10 0.S-2 3:1 Rangeability can

Pilot traverse be increased if
Station using two
conventional dl p
cells or a "Smart"
dip cell.
Multipoint S-20 2-S 1-2 10:1 Dual-range unit
thermal required
Piezometer ring NG 3-20 2-3 3:1 Can't be used
Orifice segment below 2S% of
Venture section maximum flow.
Airfoil section
* NG = Not good

IPPTA J. Vol. 16, No.4 Oct 2004 83

 -
._ STEAM

SPRAY ATTEMPERAlOR
l SHOWING THERMAL

,...---0)Y 91C __
, 112
,SLE/EVE
I
I I
; F{X): I
~~I

~~i/
Fig. 5 : Parallel Control of Inlet and Outlet Dampers

The common rule is that air flow should be measured h;\

and controlled on the same side of the furnace to ~
minimize interaction between flow and pressure loops.
FEED
One might also reduce interaction by connecting the
WAlER
two dampers/fans in parallel and using the furnace
pressure as a trimming signal as shown in Fig.5. Fuel:
air ratio is maintained with the help of gas analyzers
Ike 02' CO2, CO etc.

Feed Water Control

Three-Element Control

Economic considerations make it highly desirable to Fig. 6 : Cascade Configuration for controlling the
reduce the size and increase velocities in the water and Desuper Heater Control Valve
steam systems therefore generating a need for 3-element
control for large boilers. In this, the two flow meters i.e.
boiler drum. Although use of attemperator is an energy
steam and water shall have identical ranges and their
wasting method, but at the same time, this is the most
signals are subtracted. If the two flows are identical, the
common and precise method. ABC paper Mill in its new
subtractor sends a 50% ~ignal to flow difference
6MW power plant boiler has adopted desuperheater by
controller. Any error in steam water balance will cause
a falling or rising level. attemperator in primary superheated steam location.
-.
Therfore, the level controller 'must readjust the set point
Temperature is sensed before primary superheater, after
spray and then in the final steam. This saves energy to
of the difference controller to s'trike a steady state balance. some extent i.e. it does not allow the temperature to up
An external feed back from the flow difference to a level more than required and then desuperheat. Fig.6
measurement is also applied to the level controller. In shows a smple loop adopted in ABC Paper.
this manner, incorrect action caused by the shrink, swell
Application of Boiler Instrumentation in 6 MW Power
and inverse response are reduced. To regulate feed water,
Plant:
pump-speed can also be regulated if the pump is driven
by steam turbine or variable speed drives. This can be A case Study in ABC Paper
used in place of control valves to save power.
M/ s ABC have invested nearly Rs. 95.00 lacs on the
Steam Temperature Control automation/instrumentation for new 6 MW Power
Plant. i.e. 2x28 TPH, 410°C & 35 kg/ em? Boilers with 2
Mostly, boiler steam is used to run steam turbines and
Nos. Turbines, 2x1.5 MW i.e. 2 Generators mounted on
the thermal efficiency of turbine is dependent on the
the same Turbine.
steam temperature control on the boilers. The
temperature of steam can be controlled by adjustment of To run the Power Plant more efficiently & smoothly, we
the amount of recirculation of the flue gas or an decided to make use of the flexibilities & features of a
attemperator and also by passing partial steam through distributed control system keeping a margin for
84 IPPTA J. Vol. 16, No.4 Oct 2004
 extension of the same in future to cater the needs of health monitoring system of a modern turbine.
Recovery /Evaporator Plant also. Optimizing loops like
those of three element controls, (incorporating feed CONCLUSION
forward control for combustion & drum level/feed The conclusion drawn from the above discussion is that
water), attemperator controls with cascade loops by boiler performance in power plants can be improved
mentioning pre/post primary superheater and final significantly by implementing proper instrumentation
steam temperature have also been introduced. and optimizing the boiler controls. The optimization in
All the fuel feeders and induced draft fans have been boilers should be concentrated to achieve the following
equipped with variable frequency drives for energy goals:
conservation keeping in mind. With the above, we are • Minimize flue gas temperature and excess air.
experiencing better thermal efficiency at Turbines,
• Minimize blow down.
precise Boiler pressure controls, better combustion
efficiency of fuel, Less manual labour deployment, better • Minimize steam pressure level i.e. reduced feed
safety of the equipments because of various safety pump discharge and heat loss through pipe walls
interlocks provided through distributed control system
• Efficiency Measurement
etc.
• Minimize transportation costs (use variable speed
fans, eliminate condensate pumps, consider variable
COUPUNG drives for feed water pumps)
RPM
~ TACHO- If the potential of all aspects of boiler instrumentation,
METER
(?,f control and optimization are exploited, the steam
generation costs can certainly be lowered with improved
BEARING
• TEMP. efficiency that ultimately compensates the optimization

RADIAl.
I
;;
costs.
1r
V.RATION 0
:z ACKNOWLEDGEMENr
LOW
~
Authors are extremely grateful to the Management of
POWER
SUPPLY 1: ABC Paper for granting their permission to publish this
ALARM ;
-< paper in IPPTA Journal
MODULE
RANAL
~ Nomenclature
VIBRATION
HIGH AT Analyser Transmitter
PRESSURE
BO Blow Down
AXIAL OPT Differential Pressure Transmitter
(THRUST)
FB Feed Back
POSITION
FIC Flow Indicating Controller
FO Fan damper Operator
FT Flow Transmitter
LT Level Transmitter
P Proportional
PD Proportional plus Derivative
Fig. 7: Turbine "HEALTH MONITORING" System PIC Pressure Indicating Controller
PID Proportional+ Integral+ Derivative
PRC Pressure Recording Controller
Steam Turbine Controls
PT Pressure Transmitter
Turbines are popular drives for rotary equipment and RT Resistance Temperature detector
are energy conservation machines. Energy from steam SP Set Point
is converted to Shaft-Work. Now, very high-speed TIC Temperature Indicating Controller
turbine even upto 12000 rpm are available. Higher the TIE Temperature Element
speeds, higher the accurate & precise controls and Safety TT Temperature Transmitter
supervisory instrumentation. Fig. 7 shows a typical

IPPTA J. Vol. 16, No.4 Oct 2004 85