Table of Contents

Introduction to the Workshop ix

1 Introduction to Boiler Controls 1
1.1 Objectives of boiler controls 1
1.2 Boiler processes 3
1.3 Process dynamics in boilers 7
1.4 Overview of boiler types 8
1.5 Hazards of boiler operations 16
1.6 Boiler control functions 18
1.7 Safety control functions 23
1.8 Practical Exercise No. 1 23
1.9 Summary 24

2 Process Controls and Instrumentation 25

2.1 Overview of sensors, controllers and actuators 26
2.2 Sensor types 28
2.3 Final control elements or actuators 32
2.4 Control system equipment 33
2.5 Risk reduction by safety instrumented systems 34
2.6 Process modeling 54
2.8 Introduction to process control 63
2.9 Summary of this chapter 79

3 Feedwater and drum level control 81

3.1 Steam and water processes in the boiler 82
3.2 Drum level measurement systems 90
3.3 Safety systems for drum level protection 96
3.4 Measurement of steam flow 97
3.5 Water quality 100
3.6 Conclusions 101

4 Furnace and air draft controls 103

4.1 Furnace draft processes 103
4.2 Balanced draft boilers 106
4.3 Measurement of furnace draft 109
4.4 Draft control schemes 113

5 Combustion Control Systems 117

5.1 Introduction 117
5.2 Combustion Processes 118
5.3 Control Strategies 128

6 Burner Management Systems 149

6.1 Functions of Burner Management Systems 150
6.2 Safety Integrity Requirements of BMS 159
6.3 Ignition Systems 163
6.4 Flame Monitoring 165
 Slide Presentations 164
7 Steam pressure and load control 164
8 Steam temperature control 171

Appendix A 182

Practical Exercises 188

Appendix B 202

Answers to Practical Exercises 210