Boiler Control System

INTRODUCTION TO BOILER & BPR
CONTROL SYSTEM AND INSTRUMENT

SANMAX INDUSTRIES
WATER TUBE BOILER
• A high pressure water tube boiler is a type of boiler in which

water circulates in tubes heated externally by the fire.
• Fuel is burned inside the furnace, creating hot gas which boils
water in the steam-generating tubes.
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SANMAX INDUSTRIES
1- BOILER CONTROL SYSTEM

Boiler control system consist of :-
1- Boiler Water Level Control
1.1- Water Level Control ( 3 Element / Single-element)
2- Boiler Combustion Control

2.1- Induced Draught Fan (ID fan)
2.2- Force Draught Fan (FD fan)
2.3- Fuel Feeding gate control by pneumatic
2.4- Auger control by inverter
2.5- Force Draught damper control
2.6- Induced Draught damper control
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SANMAX INDUSTRIES
BOILER CONTROL PANEL
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SANMAX INDUSTRIES
BOILER CONTROL PANEL

Water level
Indicator
Water Level Controller Inlet Draft gauge
Chart Recorder
Outlet Draft gauge
Furnace Draft gauge

Pressure, FD and ID
damper controller
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SANMAX INDUSTRIES
WATER LEVEL CONTROL METHOD

• Single Element
o Instrument
i. Water Level
• Three Element
o Instrument
i. Water Level
ii. Water Flow
iii. Steam Flow Single-Element Controller
Three-Element Controller
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SANMAX INDUSTRIES
WATER LEVEL CONTROL METHOD
• 3 element control Method

i. Water Level
ii. Water Flow
iii. Steam Flow
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SANMAX INDUSTRIES
Water level control method
• Single Element Method

i. Water Level
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SANMAX INDUSTRIES
WATER LEVEL PANEL INDICATOR

High Water Level • Indicates the boiler water
level from controller and
Mobrey
• Extra low level indicator
Normal Water triggered by Mobrey or
Level water level controller
( Depends boiler maker)
Low Water Level but we suggest triggered
by mobrey to avoid false
reading of instrument
Extra Low Water
Level (MOBREY)
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SANMAX INDUSTRIES
BOILER PRESSURE FD,ID PANEL CONTROLLER

• Indicates boiler
Boiler Pressure pressure
• Control FD damper
FD opening percentage opening and closing
Proportional
FD Manual Regulator
Auto/Manual switch
Band
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SANMAX INDUSTRIES
COMBUSTION FLOW
SANMAX INDUSTRIES
FORCED DRAFT DAMPER (FD)

• FD damper is used
to control the air
flow going inside
the boiler
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SANMAX INDUSTRIES
BOILER PRESSURE PANEL LOADING
ID Opening • ID damper
percentage
(Auto) control
ID Opening
indicator
percentage
(Manual) • Auto Manual
switch
ID opening or • ID damper
closing
regulator
Pressure bias
ID bias
Opening
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SANMAX INDUSTRIES
INDUCED DRAFT DAMPER (ID)

• ID damper is used to
control the air flow
going outside the
boiler
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SANMAX INDUSTRIES
BOILER PRESSURE FEEDING GATE

CONTROL SWITCH
• Feeding gate control
signal is dependant
on FD percentage
Pressure opening
switch
Feeding • The pressure is
Gate 1
being set by the
pressure switch
located at the back
Pressure
switch
of panel
Feeding
Gate 2
15
SANMAX INDUSTRIES
BOILER INSTRUMENTS
1. Mobrey water level switch
2. Water Level transmitter
3. Boiler Pressure transmitter
4. Feed Water Control Valve
5. Water Flow transmitter
6. Steam Flow transmitter
7. Water Inlet Temperature transmitter
8. Steam Temperature transmitter
9. Flue Gas Temperature transmitter
10. Furnace Draft gauge
11. Inlet Draft gauge
12. Outlet Draft gauge
13. Paper/Paperless Chart Recorder
14. Smoke Density Meter
15. MC43 ( Pneumatic Panel Controller)
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SANMAX INDUSTRIES
Basic Instrumentation signal

• Power supply (24VDC)
• Transmitter
i. 4-20mA output
Power supply
• Controller Transmitter
i. 4-20mA input
ii. 1-5V input
• Control valve
i. 4-20mA input
Controller
Control Valve
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SANMAX INDUSTRIES
MOBREY FLOAT SWITCH
Type of Sensor : Contact Signal

Source Of input : 240VAC/24VDC
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Type of Transmitter
• Differential Pressure Transmitter
i. Water level
ii. Water flow
iii. Steam flow
Unit : mmh20
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SANMAX INDUSTRIES
Type of Transmitter
• Pressure Transmitter
• Unit : Barg/Psig
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SANMAX INDUSTRIES
Control valve
• Feed Water Control
Valve
• Control the feed
water into the boiler
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Type of Transmitter
• Temperature Transmitter
i. Water inlet Temperature
ii. Steam Temperature
iii. Flue gas Temperature
• Unit : Deg c
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Basic Transmitter signal wiring

diagram
• Signal • Signal
o 4-20mA o 1-5V
4-20mA Output 4-20mA Output
4-20mA input 1-5V input
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Basic Control Valve wiring diagram

• Signal 4-20mA Input
o 4-20mA
4-20mA Output
Control Valve
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Instrument placement
• Water level
mmH20
Low High
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INSTRUMENT PLACEMENT
• Water flow
• Steam flow
Orifice plate
High Low SANMAX ENGINEERING 26

SANMAX INDUSTRIES
MAKE UP VALVE
LIST OF INSTRUMENTS
1- BPR Pressure Transmitter
2- Boiler Pressure Transmitter
Operation :-
1- Make up valve will operated when BPR less then setpoint and boiler
more then setpoint
2- Followed by the FGV Mill current situation,Sterilizer process will

integrated with make up valve meaning,when sterilizer in a “drain “
mode make up valve doest work.
3-Normally we set the maximum opening for make up valve is ( 30 –

50%) to prevent high steam flow
27
SANMAX INDUSTRIES
BLOW OFF VALVE (BPR)

•
Description :-
• Blow off valve will
operated when BPR
more then setpoint
and operated in PID
mode.
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SANMAX INDUSTRIES
SETTING OF BLOWOFF VALVE
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SANMAX INDUSTRIES
• Q & A SECTION
30

Boiler Control System

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Boiler Control System

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INTRODUCTION TO BOILER & BPR

CONTROL SYSTEM AND INSTRUMENT

WATER TUBE BOILER

• A high pressure water tube boiler is a type of boiler in which

1- BOILER CONTROL SYSTEM

2- Boiler Combustion Control

BOILER CONTROL PANEL

BOILER CONTROL PANEL

Water Level Controller Inlet Draft gauge

Furnace Draft gauge

WATER LEVEL CONTROL METHOD

WATER LEVEL CONTROL METHOD

• 3 element control Method

Water level control method

• Single Element Method

WATER LEVEL PANEL INDICATOR

BOILER PRESSURE FD,ID PANEL CONTROLLER

FORCED DRAFT DAMPER (FD)

BOILER PRESSURE PANEL LOADING

INDUCED DRAFT DAMPER (ID)

BOILER PRESSURE FEEDING GATE

Basic Instrumentation signal

MOBREY FLOAT SWITCH

Type of Sensor : Contact Signal

Basic Transmitter signal wiring

4-20mA Output 4-20mA Output

4-20mA input 1-5V input

Basic Control Valve wiring diagram

High Low SANMAX ENGINEERING 26

2- Followed by the FGV Mill current situation,Sterilizer process will

3-Normally we set the maximum opening for make up valve is ( 30 –

BLOW OFF VALVE (BPR)

SETTING OF BLOWOFF VALVE

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