MARINE CONTROL

ENGINEERING AND
AUTOMATION
GROUP 02
1. Maria Catherine Mathew
2. Mohammed Faheem Ali T T
3. Mohammed Sahal P A
4. Nandakishore M P
5. Nivya J M
6. Poduval Ashray Gokuldas
7. Ridhin K
8. Saramba Krishnan C P
9. Shashwath G Nair
10. Shawn Sabu
Boiler Water Level Control
• Modern high pressure, high performance water tube boilers present a considerable
number of problems with regard to the control of water level. The drums are relatively
small in size and water capacity but have high outputs, whilst the reaction of the steam
and water in the drum to changes in steam demand and hence drum pressure, are
complex.
• A sudden increase in steam demand reduces the steam pressure in the drum, and to
drop the flashes off into steam causing the formation of a mass of steam bubbles which
tends to increase the drum level.
• The situation is aggravated by an increase in evaporation rate due to the increase in the
temperature difference(and thus heat transfer rate) due to the drop in saturation
temperature between the water in the tubes and the furnace and gas temperature. The
effect is known as swell and on a simple level control system would cause the feed
control valve to shut in--when in fact it should be opening.
• When the boiler load levels out, and the combustion system restores the pressure, the
saturation' temperature also rises, the steam bubble formation(ebullution) drops and
the level falls.
 Boiler Water Level Control
• To overcome the problems, Two Element feed water control has been devised(not to be
confused with two term which applies to a proportional and reset controller).
• Here steam flow is measured by an orifice plate or flow nozzle and working on the basis
that for a state of equilibrium feed flow into a boiler must equal steam flow out, the steam
flow (the first element of the system) Is used to position the feed water control valve.
• This valve is characterized so that for a given steam flow signal it is positioned to give &
matching feed water flow. To allow for blowdown, leakage, perhaps soot blowing, etc, and
for the time delay between a change in steam demand and the feed water control valve
moving, a second element, a level sensor and transmitter is used. This sends a signal to a
two-term controller which 'trims' the feed water control valve to restore the level should it
deviate.
• Thus, for a change in steam demand, the flow transmitter produces a signal which is
introduced into the control system by a summation relay and operates the feed water
control valve.
• If the change in loading is large,the steam flow signal change will be equally large, and the
effects of swell and shrinkage much less. Any subsequent change in level will be dealt with
by the level controller summating relay.
Two Element Boiler Water Level Control
Boiler Water Level Control
• Three Element Control
• In the previous system it is necessary to maintain a constant feedwater
pressure at the inlet of the regulating valve to optimize operation.
• Any fluctuation in feed water pressure will affect the drum level and this
control will then try to adjust the regulating valve to restore the desircd
level condition.
• This could cause cyclic conditions in the system, over working components
and compounding the trouble.
• A third element is therefore introduced, namely feed water flow. Basing
the operation upon the fact that for equilibrium steam flow must equal
feed water flow both of these conditions are monitored and the signals
compared in a differential relay, and provided they are equal, the output of
this is then added to the desired value of the water level in the drum.
Boiler Water Level Control
• This signal is then compared with the drum level measured value signal in
the two-term controller, and any deviation between the measured value
and the desired value plus the difference between the steam and feed
flows will cause the controller to reposition the feed water control valve to
restore the level
• When there is an increase in steam demand, the differential relay is
unbalanced and demands a higher drum level, counterbalancing the swell
effect and trying to close the feed water control valve.
• When the steam flow falls differential relay is again unbalanced and
demands a low level and alters shrinkage effect.
• Any variation in feedwater flow due to pressure fluctuation will be
detected by the flowmeter, repositioning the valve before the drum level is
affected.
Three Element Boiler Water Level Control
Fuel Oil Temperature Control
Fuel Oil Temperature Control
The sketch shows the system for automatic monitoring and regulation of fuel viscosity. The main
components of the system are:
Fuel Oil Heater: Uses steam as the heating medium although electrical models are in existence.
Tubular design.
Viscotherm: Basically consists of a small gear pump that pumps some of the oil through a capillary
tube. The pressure in the capillary increases as the viscosity of the oil increases.
DP Transmitter: Converts and transmits the differential pressure measured at the viscotherm to an
air signal.
P+I Controller: Amplifies the air signal from the DP cell and feeds it to the steam control valve via
the Hand/Auto station.
Hand/Auto Station: Can be used to directly control the air signal to the steam control valve.
Control Valve: Controls the amount of steam flowing to the heater.
Fuel Oil Temperature Control
• Consider a rise in the viscosity of the fuel being delivered to the
engine. The pressure in the capillary of the viscotherm increases,
leading to a rise in the differential pressure between the beginning
and end of the capillary.
• This increased differential pressure is converted into an air signal
which is proportional to the rise in differential pressure.
• The amplified output signal is fed via a hand/auto station to a control
valve which opens the steam control valve.
• The valve position may be fed back to the transmitter to provide
more accurate control of the valve and prevent hunting.
• The viscotherm is fitted with a bypass, and the steam control valve
can be operated by hand from the hand/auto station.
• The controlled condition (temperature of fuel oil) is monitored by detecting element or sensor
which is a differential manometer in this case. This produce a pneumatic signal known as the
measured value which is directly related to temperature of fuel oil. This measured value is taken by
a transmitter to a comparing element or comparator forming part of the controlling unit or
automatic controller (P+I controller). Here it is compared with a signal representing required fuel
oil temperature or set value (set point) or desired value. If the set value and measured value are the
same, deviation or error = 0.
• If it is not 0 it means that fuel oil temperature is not the required operating temperature and action
has to be taken to restore it. Controlling element develops the signal necessary for restoration of set
value.(oil temp) is known as controller output signal or control signal. Controller output signal is
then passed to the hand/auto station which converts the electric signal to pneumatic signal. This
signal is transmitted to motor element or diaphragm of a control valve which operates the
correcting element or valve. This then adjust the correcting condition or steam flow to enable oil
temperature to be restored.
Automatic Combustion Control
• In order to improve the response of high capacity boiler plant to fast
changes in loadings whilst maintaining stability, the primary signal to
the control loop may be taken from a steam flow sensor/transmitter.
• This would be in the form of a flow orifice or nozzle, possibly in the
boiler saturated steam pipe, with the pressure drop being measured
by a differential pressure transmitter in conjunction with a square
root extractor to make the output signal (measured value of steam
flow) linear, or proportional to steam flow and thus compatible with
the other control system signals. This signal is then fed into the
computing relay.
Automatic Combustion Control
• The steam pressure, either at the drum or superheater outlet, is
measured by a steam pressure sensor/transmitter. The output signal
from this (measured value of steam pressure) is fed to the master
steam pressure controller, a two-term (P+1) controller.
• Here, this measured value signal is compared with the signal
representing the desired value of steam pressure. Any deviation
signal is fed into the computing relay. The master steam pressure
controller acts as a trimming effect on the firing rate, prevents any
prolonged deviation from the desired value steam pressure and
overcomes any deficiency in the steam flow signal accuracy which can
occur at low loads.
Automatic Combustion Control
• The computing relay (adding or subtracting) output is now the steam flow
signal plus, or minus, the steam pressure signal, depending upon whether
the steam pressure is high or low.
• This master signal represents the fuel input requirements to the boiler. This
is then fed as a variable desired value signal to each of the two-term
controllers in the fuel control loop and the combustion air control loop, via
a high/low signal selector system.
• This ensures that when a change of load occurs, the combustion air flow is
always in excess of the fuel requirements to prevent bad combustion and
smoke. The problem arises due to the fast response of the fuel oil loop to a
load change, compared to the slow response of the combustion air loop.
 Automatic Combustion Control
• The master signal passing to the fuel flow controller is fed through a low signal
selector where it is compared with the signal representing the air flow. If this
master signal is lower, the selector passes it and the two-term controller
operates the fuel flow control valves. If the signal is higher, the low signal
selector blocks it and there is no change in the signal to these valves.
• In the passing to the FD fan two-term controller, via a high signal selector, the
master signal is compared with a signal representing fuel flow, and if it is
lower than the latter it is blocked, if higher, passed on. The controller then
operates the louvre positioner and actuator and/or the fan speed positioner
and actuator. Thus, for a rising steam load the increasing master signal to the
fuel oil flow and combustion air controllers is fed firstly to the high/low signal
selectors. At the high signal selector it is passed on to the ID fan controller
which acts to increase the combustion air flow. This increase is detected by an
air flow transmitter, the signal output from this being made proportional to air
flow by a square root extractor. This signal then acts on the air flow controller,
being compared to new desired value set by the master signal and adjusting
the air flow until a balance is achieved.
Automatic Combustion Control
• The signal representing air flow is also passed to the low signal selector
which, on detecting an increase in combustion air supply to the boiler,
switches over to pass the master signal to the fuel oil controller.
• The master signal then adjusts the desired value of this and so increases
the fuel flow. The increase is then measured by a flow orifice, a dp cell and
the signal, via a square root extractor, passes to the fuel flow controller
where it is compared with the new desired value signal, the output signal
then being adjusted to achieve a balance.
• Fuel to air ratio requirement is fed into the combustion air flow signal from
the air flow transmitter. The fuel flow may be controlled by two valves in
split range to give good control over a wide operating range. The
combustion air flow may initially be controlled by vanes on the air inlet to
the fans and then on fan speed.
Automatic Combustion Control
• Switches may be operated by the steam pressure signal to cut out the
steam. Flow transmitter signal if the safety valve lifting pressure is
approached.
• For a decreasing steam load the master signal representing the fuel oil
requirement is passed initially only to the ail fuel flow controller.
Arrangements can be made to prevent the ‘base’ burner being lost at low
oil fuel flow due to controller saturation by means of a cut off relay in the
line from the controller to the valve. Fig. 112(b) shows basis of a burner
light-up programme. Conditions which allow or prevent any automatic
procedure from continuing are known as ‘permissive interlocks”, i.e.
Permission is given or refused depending upon whether or not a required
condition is attained.
STEAM PRESSURE
CONTROL SYSTEM
Steam pressure control system
• Under normal steaming condition the exhaust gas boiler supplies boiler
feed, circulation, bilge and ballast pumps, heating and a turbo alternator at
about 11 bars. Reducing valve (1) is fully open.
• The circulation pump takes water from the bottom drum of the boiler and
pumps it through the middle section of the exhaust gas boiler, returning the
water steam mixture to the boiler drum which acts as a steam separator.
• The outlet steam from the drum passes through the exhaust gas boiler
superheater, whilst incoming feed passes through this boiler economizer.
• When in port the main boiler supplies all steam at approximately 30 bars via
its uptake superheater and the reducing valve and the exhaust gas boiler
superheater. Valve (2) is normally shut at all times except when the exhaust
gas boiler has to be isolated.
STEAM PRESSURE
CONTROL SYSTEM
CONTROL SYSTEM
STEAM PRESSURE
Steam pressure control system
• Steam pressure control when at sea is carried out through pressure
transmitter(A) supplying a measured value signal through the selector
switch (MV) to controller (D). If the measured value drops below the set
point signal fed into(D) this controller sends a signal to light up one burner
in the boiler, which is on stand-by.
• Transmitter (A) also supplies a measured value signal to controller
(C)which provides a signal to adjust the gas control dampers in the exhaust
gas boiler to maintain the steam pressure.
• In port when the boiler is in operation, the pressure transmitters (A) and
(B)monitor the steam pressure. According to the set point entered into the
system by the selector switch, the pressure of the main boiler will be
maintained by con-troller (D) comparing the measured value steam pressure
with the signal representing the set point steam pressure. This will control
the FD fans, fuel oil pressure, and burner sequencing events.