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CHAPTER–17
Boi
lerPr
otect
ionandI
nter
locks
1.
0 Safet
yCont r
olsonaBoiler
.
Safet
ycontrolsgener
all
yarethoset hatl
i
mi tener
gyi
nputandt
husshutdown
theequipmentwhenunsafecondit
ionsdevel
op.
Theyare:
(1)Pr
essure-
li
mitorTemperatur
e-l
imitSwit
ches,
(
2)Low-
wat
erFuel
Cut
off
s,
(
3)Fl
ame-
fai
l
ureSaf
etySuper
visor
ySy
stems(
FSSS)
,
(
4)Aut
omat
icI
gni
ti
onCont
rol
s,
(
5)Oi
landGasFuel
Shut
offVal
veCont
rol
s,
(
6)Ai
randFuel
Pressur
eInt
erl
ockCont
rol
s,
(
7)FeedWat
erRegul
ati
ngCont
rol
sand
(
8)Safet
yValves(orRel
i
efValves)ar
ethemosti mport
antsaf
etydevi
ce.Whil
e
notconsi
deredacontroli
ntheusualsense,i
tist
helastmeasureagai
nsta
ser
iousexplosi
on.
TheSaf
etyCont
rol
sguar
dagai
nstt
hef
oll
owi
ng:
(
a)Ov
erpr
essur
eleadi
ngt
oexpl
osi
onsf
rom t
hewat
ersi
deorst
eam si
de,
(
b)Over
heati
ngofmet
alpart
s,possi
blyal
soleadi
ngtoexpl
osi
oni
naf
ir
edboi
l
er
(
mainlyduet
olowwaterorpoorci
rcul
ati
on)and
(
c)Fi
resideexpl
osi
ons(f
urnaceexpl
osi
ons)duet
ouncont
rol
l
edcombust
ibl
e
mixturesont
hefi
ri
ngsi
de.
Theset ypesofacci dentsareconsider edmaj orandmayleadt olossoflif
eand
seriouspr opertydamage.Ot herpot enti
alsourcesofaccidentsarecr acking,
bulging from localov er
heating becauseofscal edeforming such ast ubes
bowi ng,thinni
ngofv i
talpressurepar ts,whichcanleadtocracki
ngorl ocali
zed
rupture,andexpansionandcont r
actionf ai
lurescausi
ngcracki
ngorr upt
uringof
met alparts.
Manufact
ures and st at
el aws ar et r
ying t o prevent,wi th saf et
y control
equi
pment,thet hreemaj ortypesofacci dent sofov erpressures,dr yfi
ri
ng,and
fur
naceexplosi ons.Whi l
et heot hertypesoff ai
luresar econtr ol
ledsomewhat
byautomat i
ccont rol
s,pr eventi
oni smost lybyl egalinspectionr equi
rement s
andbyproperoper at
ionandmai nt
enancepr acti
cesexpect edf rom theowner -
userofaboiler.Includearegoodf eed-watertreat
mentandt est
ingofcont rol
sat
peri
odi
cintervals,includi
ngsaf etyrel
iefvalves.

1.
1 Dist
inct
ivediff
er encesbetweenOper ati
ngControlsandSafet
yControls:
SeeFigure1.Oper at
ingcontr
olsregulat
etheboilersoitoper
atesundercertai
n
setcondit
ionsinv olv
ingload,feedwater
,andcombust i
on.Theaimi stoobt ai
n
the mostef fi
cientout putfrom the boil
erforeach pound off uelbur ned.
Operati
ngcontrol scanbev i
ewedasgov er
ningcontrol
sthatmakeadjustment s
offeedwater,f
uel ,ai
r,fl
uegas,andst eam fl
owasdemandedbyt hel oad.The
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cont
rol
sareofteninter
lockedwi
thsuchauxi
l
iar
iest
ot heboi
lerasfeedwat
er
pump,draf
tfans(dependingonthesizeoft
heboil
er)
,andtheprogramming
cont
rol
ssetupfortheunit.

Boi
ler

Oper
ati
ng Interlocks Saf
etyCont
rol
s
Contr
ols

Pr
essur
eLi
mit
s
Heati
nput– Worki
ngmedium – Heatout
put-
Combusti
on Feedwat
ercont
rol Load
Contr
ols
Temper
atur
e
Li
mits
Fl
ow Fl
ow
Fuel
–ai
rfl
ow

Hi–Low
Pr
essur
e Pr
essur
e Water
Fuel–ai
rPr
essur
e

Temper
atur
e Temper
atur
e I
gnit
ion
Pr
oving
Fuel–air
t
emperatur
e
Pur
it
y

Fl
uegasf
low Combusti
on
Pr
ovi
ng

Fluegas I
nter
locks
pressur
e
andtemperatur
e Fuel
Ai
r
I
gni
ti
on
Wat
er

St
eam
Bur
ning
Fl
uegas

Fi
g.1

Safetycontr
olsprovi
detheupperorlowerl i
mitssetf
orthesafeoper
ati
onofthe
boil
er.Ifthev ar
iabl
econditi
onsinvolv
ingt heboil
ergobey ondacertai
nsafe
l
imit,analarm warnsthatcorr
ect
iveactionsmustbet akenortheboil
eri
sshut
down.Thel argerandmor ecompl
ext heboiler
,themoresafetycont
rol
smaybe
needed.

1.
2 I
mpor
tanceofI
nst
rument
sforPr
oper
lyOper
ati
ngaBoi
ler
:
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Use ofi nstruments and knowledge ofsuch f act

or s as normaloper at i
ng
pressures,temper atur
es,fl
ows,draf
t,CO2content,Bt
u/kCal /kJheatinput,and
permissiblev ari
ati
ons int he r
eadings observed aret he mosti mpor tant
responsibil
it
ies ofanyoper at
ororownerofa boi ler.Instr
umentsi ndicate
conditi
onsi nt heboil
er.Thusanyvari
ati
onsfrom desi
gnorst ipul
atedconditions
serveaswar ningsofimpendingdangerorineff
ici
entoperati
on.

1.
3 TheTwoGener
alTy
pesofI
nst
rument
ati
onFoundonBoi
ler
s:
Boil
ershav etwot ypesofI nstrument snamel y,(i)Recor dingand( i
i
)indicating.
Recording I nstr
ument spr ovideaper manentr ecor d orr eadingsofpr ocess
paramet er s. I
ndicat i
ng I nstrument st hough pr ov i
de onl yf or the v i
sual
observationofPr ocessPar amet err eadings, theyactast heey esoft heOper ator
thr
oughwhi chheabl ei skeepkeenwat chonal l-i
mpor tantpar ametersoft he
boil
erandi sabl
et oensur esaf et yandef ficiency .Boi lerRecor dingInst
rument s
generall
ycov erSt eam Pr essur e,St eam Fl ow,Ai rflow,Fl ue-gasTemper atur e,
FeedWat erTemper atures,etc.Anyi nstallationwi llbei mpr ovedbyt heuseof
i
nstrument swhent rainedoper ati
ngper sonnelar ei nat tendanceandmake
i
ntell
igentuseoft hedat aprov ided.I nstrument ationofl argerpackagedboi lers
shouldi nclude an Or sat appar atus f or obt aini ng f l
ue-gas anal y
sis and
determiningcombust ionef f
iciency .Moder nl argesi zedboi l
ersar e,howev er,
equippedwi thElectronicGasAnal yser s.
Somebasicinstr
umentsneededf
orlar
gepowerboi
ler
s,asami
nimum,per
recommendat
ionsoft
heASMEBoil
erCodear
ethef
oll
owing:
(
1) St
eam Pr
essur
egage,
(
2) FeedWat
erPr
essur
eGage,
(
3) Fur
naceDr
aftGage,
(
4) Anoutletpr
essur
egageont
heF.
D.Fanandani
nletpr
essur
egageont
he
I
.D.Fan,
(
5) St
eam Fl
owRecor
derf
orchecki
ngboi
l
erout
put
,
(
6) CO2r
ecor
dedt
ocheckoncombust
ion,
(
7) Super
heat
erI
nletandOut
letTemper
atur
eRecor
der
,
(
8) I
nletandOut
letTemper
atur
eRecor
der
sforAi
rHeat
ers,
(
9) Thermometer
sindi
cat
ingI
nletandOut
letSt
eam Temper
atur
esf
orBoi
l
er
Reheat
ers,
(
10)FeedWaterTemper
atur
eRecor
der
sforchecki
ngdegr
eeofdeaer
ati
onand
economi
zeroper
ati
on,
(
11)Pr
essureGaugesonPul
ver
izer
stocheckdi
ff
erent
ialpr
essur
eforf
uel
-ai
r
mi
xturest
oburner
s,
(
12)Pressur
e Gauges for oi
l
-fi
red boil
ers on OilLines t
o Bur
ner
s and
temperat
uregagesbef
oreandafteranyOilPr
eheat
ers,
(
13)Pressur
eGaugesforgas-
fi
redboi
l
ersont
hemai
ngasl
i
net
obur
ner
sand
onindiv
idual
bur
ners.
1.
3.1 Pr
essur
eGagesandpr
inci
pleoft
hei
rfunct
ion:
1.
3.1.
1Descr
ipt
ionofPr
essur
eGauge:
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Thet womai nt y pesofpressuregagesar et heBour dontubeandt heDiaphragm

type.Insingle-tubeBour dongauget hepr essureisappl i
edt oinsi
deofabent
tubeofov alcr osssect i
onwhi chiscl osedatoneendandconnect edatt he
othert oboilerpr essure.Thecl osedendi sat t
ached,byl i
nksandpi ns,toa
toothedquadr ant,whichi st ur
nmesheswi thasmal lpinionont hecent ral
spindle.Aspr essur ebuildsupi nsidetheov ertube,itattemptstoassumea
circul
arcrosssect ion,thustendingt ost rai
ghtenoutl engthwise.Thisaction
turnst hespindl ebyt hel i
nksandgear ing,causingt heneedl etomov eand
regist
erthepr essur eonagr aduateddial.
1.
3.1.
2 Si
phonr
equi
redi
nst
eam pr
essur
e-gagel
ines:
The siphon i
s simpl
ya pi gtai
lordr op l
eg i
nt he t ubi
ng tothe gage for
condensingst
eam, t
husprotecti
ngthespri
ngandot herdeli
catepart
sf r
om high
temperatur
es.ThreeformsofSi phonsareused.Ifthereisdangeroff reezi
ng
duri
nglongperiodsofshut
down, thesi
phonshouldber emov edordr
ained.

1.
3.1.
3 Met
hodsoft
est
ingofSt
eam Gauges:
Pr
essur
eGaugesar etestedinthefol
l
owingthreeways:
1.Bycompar i
sonontheboi l
erwithagoodfactor
y-t
est
edgage.
Herethetestgageisattachedtotheboi
l
erandt het
wogagesar
ecompar
ed
asboil
erpressur
erisesorfall
s.
2.Withascrewplungerpump( fi
g.2a).
Thetestgageandgaget obetestedareattachedt oascr
ewplungertest
er.
Tooper at
e,unscrew thetopcover,fil
lthecy li
nderwi
thwaterorlightoil
,
screw onthet opcov erandf or
cet heplungerdownwar dbyt ur
ningthe
handleonthethreadedrod.Thi
sputsequalpr essur
eonbothgages.
3.Wit
hadeadweightpl
ungerpump(fi
g.2b).
Thepl
unger
,worki
nginacyli
nder
,fl
oatsonoi
landi
sloadedbywei
ght
s.

Fi
g.2

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1.
3.1.
4 TheCoder
equi
rement
sforpr
essur
egagesonast
eam boi
ler
:
Theboi lermusthav eatl eastonepressuregagesol ocatedandofsuchsi ze
thatitiseasi l
yr eadableandwhichatal lt
imesindicatest heboil
erpressure.A
valveorcockmustbepl acedinthegageconnectionadj acenttothegagesoi t
canber emov edf orrepai
rs.Thegagemustbeconnect edtot hesteam spaceor
tot hewat ercolumnori t
ssteam connecti
on.Forast eam boi l
ert
hegageori ts
connectionmusthav esiphonformaintai
ningawat ersealt opr ev
entst eam
from ent eri
ngt hegaget ube.Theconnectionofapr essuregagemustbea
mi nimum of¼i n.I D.
Fortemperaturesov er4060F,nobr assorcoppert ubingshoul
dbeused.The
pressuregagedi alshouldbegraduatedt otwicetheSVset ti
ng,buti
nnocase
l
esst han11/2t i
mest hi
ssetti
ng.Av al
v econnectionofatleast¼-i
n.pipesize
mustbei nstall
edont heboil
erforexclusi
vepur poseofat t
achi
ngat estgage,
whent heboilerisoper at
ing,f
orcheckingt heaccur acyoftheboil
erpressure
gage.Thisconnect i
onisknownast heinspector’
sconnect i
on.
The pressure gage mustbe i l
luminat ed,free from objectionable gl
are or
refl
ecti
ont hatcani nanywayobst ructanoper ator’
sview whi l
enot hi
ngt he
setti
ngont hegage.Thepoi nteront hegagemustbei nanear -
verti
calposi
tion
when indicati
ng the normaloper ati
ng pr essure.Thi sis also tr
ue ofot her
pressuregagesi ntheboilerr
oom t hatar eusedonauxi l
iar
ies.Pressuregages
0
mustnotbet i
lt
edf or
war dmor ethan30 f r
om v ert
ical
,andthenonl ywheni tis
necessaryforproperviewingofthedial graduati
ons.
1.
3.2 Thecommonorpr
imar
ymeasur
ement
susedi
ncont
rol
li
ngboi
ler
s:
Alt
hough manufacturer
s dif
ferin approach,the f
oll
owing factor
s mustbe
consi
deredinanycont rolusedonaboi l
er:(1)st
eam pressureandf l
ow,( 2)
fur
nacepressur
eanddr aft
,(30airpressureandflow,(4)feedwaterpressure
andflow(i
ncl
udinglowwat er)
,(5)f
lue-
gasf l
owandcomposi ti
on,and(6)proper
i
gniti
onandburner0fl
amecont r
ol.
1.
3.3 Commoncomponent sinanautomat i
ccont r
olloopusedonboi l
ers:
Acont rol l
oop,whet herpneumat icorel ectri
corelectronic,i
susual l
ymadeupof
thefoll
owi ngbasiccomponent s:
1.Pr imar yMeasur ementEl ement sasenumer at
edi nanear li
erquesti
on.
2.An Er r
orDet ectororCompar atort hatcompar est hemeasur ementwi th
prefixedsetpoi ntsandmakesadj ustmentsi gnalstogett hemeasur edvalue
tothepr esetpoi nts(oreff
iciencypoi ntincompar atorappl i
cati
on).Thi
si s
actual l
ythecont roll
er.
3.AnAct uatorthatr espondstot hecont rol
lersignal
sshowi ngdev i
ati
onfrom
setpoi nts.
4.TheFi nalControlElementsuchasav alve,damper ,orv ari
able-
speedmot or
thatmakesadj ust mentsassi gnaledf rom thecont roll
edandact uatorsoas
tobr ingthevariablewithi
npr esetlimits.

2.
0 Cont
rolTheor
y
2.
1 Modesofcontrol
:
Modeofcontrolmeanst
hemanneri
nwhi
cht
heaut
omat
iccont
rol
l
eract
sand
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r
eact
st o st
orea vari
abl
equantit
yon a boil
er,such aspr
essur
e,f
low,or
t
emperat
ure,t
oadesignedcont
rol
ordesi
redval
ue.
2.
2 TypesofCont rol
lerSy
stemsusedtocont
rolaboi
ler
:
Therear ethreet y
pesofControl
l
erSystemsusedi nboi
l
ers.Thesear
ethe
fol
lowing:
(1)Pneumat i
c,
(2)El
ectri
c,and
(3)El
ectroni
c.
2.
3 Somecommonmodesofcont rol
:
Assumet hatahumanoper atorhast oregul atethet urbinest opv alueasl oad
demandi ncrease. Hecani nstantlyopent hevalvewi de,openi tsl owlyat
constantspeedasdemandi ncrease,openi tmor ewhendemandr ises,rapidl y,
oropeni taconst antamountf oreachuni tofdemandchange.Si mi l
arly,a
pneumat icorel ectri
ccont roll
ercanf oll
ow anyoft hef ollowingf ivepr incipal
modes, eithersingl
yori ncombi nati
on:
1.Two- posi ti
on,orOn- Of f.
2.Fi xed- positi
onfloat i
ng.Thi sdr i
vest hefinalcontrolel ementataf i
xedspeed
bet weeni tslimit-
swi tchcont acts.
3.Pr opor ti
onalposition.Her et hecont r
oll
erchangest hef inalcont r
olel ement ’
s
posi t
ion i n pr opor t
ion t o t he measur ed variable’ s dev i
ation,shown
diagr ammat i
cal
lyi nFi g.3.Butsi ncepr oporti
onalcont rolmustsensea
changei ndev i
ation( i
nt hi scase,pr essur edrop)soast opr oduceanew
valveposi ti
on,i
tpr ov idesexactcor r
ecti
onf oronlyonel oadcondi t
ion;atal l
otherl oadssomedev iationmustr emai n.Thiser rori scal led‘ offset’or
‘
dr oop’ .Thusi nFi g.3,a10per centpressur eerrorr emai nsev enaf tert he
valvehassomet or esti ni t
snewposi ti
on.Theonl ycor recti
oni st omanual l
y
resett hecont r
oller’ssetpoi nt,thuscompensat i
ngf oritsi nherentof fset
char act er
ist
ic.

Fi
g.3

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4.Variable-speedf l
oat i
ngmode.Her etheposi ti
onoft hef inalcont r
olel
ement
i
s changed ata r ate,which i
s proportionalt othe measur ed var
iable’s
deviati
on.Thegr eaterthedev i
ati
on,thefast erthev alvemov es.Butasl ong
asdev i
ationcont inues,sodoest hecor rectiontov alv
eposi ti
on.Thust he
controll
ercont inuest ooperat
eunt i
lanexactcor rectionhasbeenmadef or
anyl oadchange.Andsi ncevalveposit
ionv ari
esasani ntegralofdeviati
on
andt ime,v ariable-speedf l
oati
ngisof t
enr efer
redtoasi ntegralmode.Iti s
usuallyappl ied i n combinati
on with propor ti
onalcont r olto producet he
proportional-
pl us-i
nt egr
almodeshowni nFi g.4.

Fig.4
5.Der i
vati
on,orratecontrol(Fi
g.5).Thi
spositi
onsthevalv
ei npr oporti
ont o
therateofchangeofdev i
ati
on.I
tissensi
ti
vetodir
ecti
on.Thusi fpressureis
ri
sing,thecont r
oll
ertendst oclosethev al
veandhasagr eatst abi
li
zing
effect.Butsi
ncei tcannotsenseadat um,itmustbecombi nedwi t
hsome
othercontrol
mode, asshowni nFig.6.

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Fi
g.5

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Fi
g.6

2.
4 Appl i
cationofOn- Of fCombust ionCont r
olsandpr incipleoft hei roper ati
on:
On- of fcont rolsar el imi t
edt of iret ubeandsmal lwat ert ubeboi lers.Ast he
namei mpl ies,adr opi spr essur eact uat esa‘ pressur estat ’ormer cur yswi tcht o
star tthest okerorbur nerandopent heai rdamper ,ort or ev erset hepr ocess
whenpr essur er isesagai n.Sincecont rolisl imi tedt ov ar y i
ngt hel engt hsofon-
andof f-
per iods, combust ionsef fi
ciencyi slow.Showni nt heFi gur e7i sat y pical
on- offcombust i
on- cont rolandpr essur econt rolswi tcheshookedupi nel ect ri
c
ser i
es.Thus i fei t hercont rolopens,t he cur r
entt ot he bur nermot ori s
i
nt errupted.Thepr imar ycont rolconsi stsofanel ectromagnet icr elayt hati s
ener gizedbyt het her most at.
Ondemandf orheati nast eam sy stem,t het her most atwi llact uat e(bymeans
ofl ow v oltage)t hecl apperi nther elay.Ast hecl apperi spul l
edi n,i tt r
ansf ers
cur rentf rom t heNo.1t ot heNo.3t erminalont hepr i
mar ycont rol( seet he
sket chinFi g.7) .Thebur nermot orandi gnitionwi llt hencomeon, oper atingt he
unit.Ei t
heroneoft wocont rol
sdet ermi nest hesequenceofnor maloper ationof
thesy stem.Thesear et het her most ati ssat isfiedbyar isei nr oom t emper atur e,
i
twi llbreaki tscont actandde- ener gizet her elay,t husi nterrupt i
ngt hef low of
cur rentf rom t heNo.1t ermi nalt ot heNo.3,andt herebyst oppi ngt hebur ner .
Buti fal ongerper i
odoft imei srequi redt obr ingupenoughheatt osat isf yt he
ther most at, t
hepr essur e( l
imit)cont rolsettingmayber eached.Thi scont rolwi ll
thenshutof ft hecur rentt ot heNo.1t ermi nalont hepr i
mar ycont rol.Thi swi ll
de-ener gizet hepr imar yoft hest ep-downt ransf or mer .Thent het her most atwi ll
nol ongerbeabl et ohol dt hecl apperi n,ev ent houghi ti smaki ngcont act .Thus
thepr i
mar ycont rol isdepr iv
edofal l current, andt hebur nerwi ll stop.

Fi
g.7
When t
he st
eam pr
essur
e dr
ops,t
he ci
rcui
twi
l
lbe r
est
ored,and i
fthe
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thermostatis sti
llcal
l
ing f
orheat(making contact)
,the unitwi l
lresume
operat
ion.Incaseofabnormaloper
ati
on(nof i
reorinsuff
icientf
ir
eappearing)
,
thesafetyfuncti
onoftheprimar
ycontr
oltakesoverandt heunitshut
sdown,
goingint
osaf et
y.
2.
5 Combust ionCont r
ol gener all
yusedonpackagedboi lers:
A posi tioningcont rolsy stem i sgener al
lyused,becausei ti smor ef l
exible.
Steam pr essur ei st hemeasur edv ari
able,andamast erpr essurecont roller
respondst ochangesi nheaderpr essureand( bymeansofpoweruni tsor
actuat ors)posi tionst hef orced-draftdampert ocontr olairfl
ow andt hef uel
valvet or egulatef uelsuppl y.Ani ndependentcont r
oll
er,posi ti
oningt heupt ake
damper ,mai ntainsf urnacedr aftwi t
hinthedesi redli
mi t
s.
Althoughposi ti
oning-ty pecont rolsystemsar eani mprov ementov ert heon- off
type,ai r
flowandf uelsuppl yareatt hei
rtheor et
ical
lycor rectrationatonl yone
setting.Thi si susual lyt hepoi ntatwhi cht heywer ecal i
bratedoni nstal
lati
on.
Posi ti
oningcont rolal soassumest hatagi venoutputsi gnalf rom themast er
cont roll
eral way spr oducest hesamechangei nthef l
ow ofcombust ionair,i n
stokerspeed,orf uelv alveset ti
ng.Butst okerspeedmi ghtbeaf f
ectedbyl ine
voltagev ari
ations, andai rf
lowbyboi lerslaggingorbar omet r
iccondi t
ions.Thus
manualadj ustmenti s st il
lnecessar y,notonl y on l oad changes butt o
count eractt hesel onger -t
erm effects.
2.
6 Acombust ioncont rolthatisconsi deredsuper i
ortoaPositi
oni
ngCont r
ol:
Amet eringcont rolisconsi deredsuper i
ort oPositi
oningCont
rol
.Itmeasur es
thef uelflow andai rflow andt henmodi f
iest hevalveanddamperpositi
onst o
mai ntaint hesemeasur edf l
owsr atherthani mpliedones.Thusi tholdsan
optimum ai r/f
uelr ati
oov erawi del oadr angewi t
houtmanualinter
venti
on.
Especi all
yv aluablei sitsinherentcompensat i
onf orsuchvar
iabl
esasboi l
er
cleanliness,voltageswi ngsinel ectri
cact uator
s,lostmoti
oninmechani calor
pneumat i
cdev i
ces,andchangesi nf uelqualit
y.
Forsimpli
city,l
etusconsi deronesy stem havi
ngapressure-
responsiv
eprimary
elementcont r
oll
ingfuelf
eedandai rfl
ow,plusanindependentfur
nace-pr
essure
contr
oll
er.Theout putsignalf rom thispri
maryelement,ormast erpressure
contr
oll
er,isf r
equentl
ymodi f
iedbyel ementssensit
ivetosteam flow,ai
rfl
ow,
fuel
-f
eedr ate,fl
ue-
gasanal ysi
s,orot hervari
abl
es.Andtheseelement smaybe
combinedi nfeed-f
orwardcont roli
nvar i
ousways.
2.
7 Reasonsf orCombust i
onCont rol
sbei nggearedt oPressureVar iati
oni na
boi
ler:
Tobegi n,pressurevar i
ati
oni scausedby :
1.Loadont heboiler.Ani ncreaseinloadwithoutaddit
ionalfuelinputcausesa
pressuredr op.Adecr easei nloadwithoutanaccompany i
ngdecr easeinfuel
i
nputcausesapr essurer i
se.
2.Fuel i
nputtot heboiler.Toohi ghaninputwillcauseapressur eri
se,whilet
oo
l
owani nputwi l
lcauseapr essuredrop.
Thuspr essur eregulationandf uelregul
ati
on,orcombust ioncont r
ols,are
di
rectlyr el
ated.Andf orthisreasoncombust i
oncontrolsar egearedf or
modul ati
onbypr essur ev ar
iat
ionswi t
hincl oseli
mits.Whi leairfl
ow and

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exhaustfl
owusual
lyfol
l
owfuelfl
ow,thelatt
eri
sdet
ermi
nedbyt
hepr
essur
e
-setl
i
mi t
swit
hinwhichaboi
l
eristooperate.
2.
8 Met hodofMeasur ementandCont rolofFurnaceDr af t
:
Draft-
measur i
ngelementsmaybecombi nedwi thacont r
oll
er(f
ig.8b).The
spiralBour don t
ube (Fig.8a)handl es draftmeasur ements wit
h greater
sensiti
vit
ythanthefai
rlyrigidelementusedf orhigh-pressur
eappli
cati
ons.The
diaphragm mechanism (Fig.8b)conv ert
s,throughapi lotval
ve,f
urnace-
draft
vari
ationsintopr
oport
ional changesint heoutputsignal.

Fi
g.8

2.
9 Met hodofMeasur ementandCont rolofSteam Fl ow:
Thepr incipl
eunder l
y i
ngf lowmeasur ementisshowni nFig.9a.Apr essuredrop
acrossanor i
fice,i
nt hi
scasei nthest eam li
ne, canbemeasur edbyt appingthe
pipe ateach si de oft he restri
cti
on.The r esult
ing pressure di
f f
erenti
alis
proportionaltot hesquar eoft hef lui
dv elocity.Butcor r
ectlocationoft he
tappingpoi ntsisimpor tant.Byusi ngnozzler estri
cti
on( Fig.9b)
,thebestr esul
t
(l
argestpr essurediffer
ent ialf
oragi venf l
ow)i sobtainedwhenconnect ionsare
l
ocat edaboutonepi pedi amet erupstream andone- hal
fdi ameterdownst r
eam
from thenozzl e’
sinletface.

C-11
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Fi
g.9a
Conv er
ting diff
erenti
alpr essur eto ausableout putsi gnalmaybedonei n
vari
ous way s.Two wi del y used secondary el
ement s ar e a mer cury-
float
manomet er(Fig.9c)oraLedouxbel lmechanism (Fi
g.9d) .InFig.9cthet wo
pressure-t
apings from t he pr i
maryel ementar e connect ed tot wo mer cury
chamber s,joinedbyaUt ube.Pressurevari
ati
onsr ai
seandl owerthef l
oat.A
pressure-t
ightshaf tconv eyst hi
smov ementtomechani call i
nkagewi t
hint he
control
ler.Checkv al
vesi nt hetwol egsoft heUt ubepr eventdamaget ot he
mechani sm result
ingfrom suddenchangesorr eversal
sinpr essuredi
ffer
ential.

Fi
g.9b&c

C-12
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Fig.9d
2.
10 APneumat i
cDifferentialPr essur eTransmi tter:
Fig. 10 i ll
ustr
ates a pneumat ic sy stem used f or di ff
erential pressure
transmission,whi chisconv ert
edt ost eam f low inani ndicating,recording,or
cont r
oldev i
ce.Diaphr agm mot ionmov est hef orcebeam andv ane.Mov ement
oft heforcebeam changest hev ane-noz zler el
ationship,thuschangi ngnozzl e
relati
onship,thuschangi ngnozzl ebackpr essure( NBP)i nchamberB oft he
resetboost errel
ay .Thi sopensei thert hei nletv al
ve( i
ncr easei nNBP)ort he
exhaustv alve(decr ease i n NBP)pr oduci ng a change i n boost erout put
repositi
onst herest ori
ngbeam.Ther estoringbeam,i ncont actwi ththef orce
beam t hr
oughr angeadj ustment ,mov est hemeasur i
ngdi aphragm backt othe
nor malcent er
edposi ti
onandr estoresv ane-nozzleatbal ancedi stance.The
boost eroutputpr essur e,whi chi spr opor ti
onalt ot hemeasur edl evel,i
sal so
transmitt
edt oindicating, recording,and/ orcont r
ol l
i
ngequi pment .

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Fi
g.10

2.
11 El
ect
ri
cPr
essur
eTr
ansmi
tt
er:

Fig.11
At ruef orce-bal
ancemechani sm characteri
zest hedct r
ansmi t
tedshowni nFi g.
11.Def l
ect i
onoft heBour dontubeexer t
saf orceont hebeam bal ancesy st
em;
ast hebeam st artst
omov e,theairgap,andt hust heinductanceoft heposition
detect or,changespr oporti
onall
yandi nturnv ari
est heosci l
lator-
ampl if
ieroutput
signal.Thenul l
-bal
ancef or
cemot or,a wi recoi lmaintained in an ai rgap
betweenper manent-magnetpol es,developsaf eedbackf orcebal ancedagai nst
thei nputf orcefr
om t heBourdont ube,t
husr estoringnull balance.
Nomat terhow t heout putsignalisgener ated,norwhatmeasur edv ari
ablei t
represent s,whetheri tbeal t
ernati
ngordi rectcur rent,itformst hei nputt oan
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electricorel ectr
oni ccontr
ol l
erwhoseci rcui
tsperf
ormt hesamef uncti
onsas
thebel lows, baff
les,andnozzl esofthepneumat i
ccontr
oller
.Theunitill
ustr
ated
handl espr essuresupt o10, 000psig.Ast heBourdon-
tubedeflecti
onr eact
son
the bal ance beam,i ts mov ementi s sensed bythe positi
on detectorand
conv ertedintoapr opor
ti
onalchangei nthe10-15mAout putcurrent.Theforce
mot or,i n series across this output
,act s as f
eedback in opposing beam
mov ement .
2.
12 Met hod ofel ectri
callytransmi tt
ing apr essur emeasur ementt oi ndicating,
recording,andcont rolequi pmentatar emot epoi ntandt henshowmeasur ed
pressur eatt hatpoi nt:
Inonedev i
ceaBour dont ubeposi tionsamov ablecor ei nat r
ansfor mer.The
corei sadjust edt otravelthesamedi stancef oral lpressurer anges, thusmaki ng
i
tpossi bl
et ot ransmittost andardel ectronicr ecei vers.Thecor eposi tion(fig.12)
determi nest hemagnet icfluxlinkagebet weent hepr i
mar yandt hesecondar y
windings.
The v olt
age i nduced i n each secondar y wi nding is pr oportionalt ot he
displacementoft hecor ef orm i t
scent erposi ti
on.Thus,t hecor eposi ti
on
determi nest hesi gnalv olt
ageout put.At100per centtrav el,v olt
ageE2 i slarger
thanE1 si ncet hecor eisneart het opoft het ransf ormer .Downwar dmot i
onof
thecor ecausesE2 t odecr easel inear l
yandE1 t oi ncreasel i
near l
yunt ilat0
percentt rav el,thev ol
tagemagni tudeshav er eversed.At50per centt rav el
,
voltage E2 and E1 ar e equalsi nce t he cor ei s center ed bet ween t he t wo
secondar ywi ndings.Wi t
hint heoper ati
ngr ange,adef i
ni t
el inearr elat
ionshi p
existsbet weeneachoft het wosecondar yv oltagesandt hecor eposition.

C-15
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Fig.12
Util
izingamov abl
ecoretransf
ormerwi thadupl i
catesetofsecondarywindi
ngs,
changi ngtheexternalconnecti
ons,ordoi ngbot h,permi tsawider angeof
applicati
ons usi
ng the same basi ctr
ansmi tt
er.The out putvol
tage on t
he
secondar ywindi
ngscanbecal ibratedforproporti
onalpressurer
eadingonthe
receivingend.
2.
13 Tr
endsi
nfeedwat
ercont
rol
inmoder
nboi
ler
s:

Mostboi ler
st odayuset wo-element( drum l ev
elandst eam f low)ort hree-
elementcont r
ol si n whi ch st eam f l
ow and wat erf low f orm t he primar y
measur edv ari
abl es,wi t
hwat erl ev elactingasat hir
di nput .Butt hesi ngle-
element( drum l evel)regulator( f
ig.13)i sstillpopular.Thisisat hermo- hydraulic
dev i
cebasedont hepr i
nciplet hatt hev ol
umeofagi venwei ghtofl ow- pr
essur e
steam isf argr eat erthant hatoft hewat erfrom whi chitisgener at ed.
Ther egulatorf ormsacl osedhy dr auli
csy stem,includingt heannul arspace
betweeni nnerandout ert ubesoft hest eam gener ator,theconnect i
ngt ubing,
andt hemet albel l
owsoft her egul at
ingv alve.Heatf r
om st eam i ntheupper
porti
onoft hei nnert ubecausest hesur roundi ngwat er( i
nt hespacebet ween
thet wot ubes)t oflashi ntost eam.Ther emai ni
ngwat eri st husf orcedoutof
thisspaceunt i
lt hewat erl evel
si nt het wot ubesar eequal .Thedi splacedwat er
passesi ntot heact uatorbel l
ows, t
huspar t
iallyopeningt her egulatingv alv
e.

Fig.13
Asst eam demandi ncr
eases,thewat erl eveli
nthedrum andgener at
orwi l
lfal
l
;
mor ewat erintheannularspacebet weent hetubesfl
ashesintost eam, andthe
regulatingvalv
eopensst i
l
lfar
ther.Thusi fthedrum l
evelr
ises,thewat erinthe
gener atorri
sesalso;cooledbyther adi ati
ngf i
ns,t
hiswatercondensespar tof
thest eam int heannul arspaceandi nt urnpermit
st her egulati
ngv alv
et o
parti
al l
yclose.Si
ncet hisisapr oportionaldev i
ce,i
tissuitableonl yforsmall
boil
erswi threl
ati
velystablest
eami ngrat es.

C-16
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Fi
g.14

Inlargerunits,drum l
evelmeasur ementf or msat ri
mmi ngsignal
,wi t
hst eam
andwat erf
lowast hepr i
mar yvari
ables.Displacer-t
ypeunitsarealsoreplacing
theself -
act
ing,t
hermo-hydrauli
cdev i
ce.Int hese,acy l
indri
calfl
oatordisplacer
i
sl i
ght enedbyt heweightoft hel i
quiditdi splaces.Thischangei nweighti s
detected byei t
hera t orque-t
ube ora f or ce-bal
ance system (Fig.14)and
convertedintoapneumat icorelect
ricoutputsi gnaltoacontrol
ler
.
2.
14 Howdoest hethree-el
ementfeedwat ercont r
olsy st
em wor k?
Int hi
s sy stem (fig.15)steam f l
ow,f eedwaterf l
ow,and wat erlevelar e
measur edandr ecordedbymechani call
yoper atedmet ers.Measurement sof
steam flow andwat erfl
ow arebal ancedagai nsteachot herwithdi
fferential
l
inkage.A pi l
otcont r
olisconnect ed tot hel i
nkageso t hatanydifference
betweent heamount sofsteam flowandofwat erflowcausesachangei nt he
pneumat icout putsignal
.Thissignali stransmittedtoanai rrel
aywher eitis
combinedwi ththepneumaticsi
gnal from thewat erlevel
r ecorder.

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Fi
g.15
Achangei nboi lerloadunbal ancest hedi f
ferentialli
nkage,t huspr oduci
nga
changei nt heout putoft hepilotcont rol.Thatintur nchangest heout putofthe
airrelay.Thi snew si gnalr eposit
ionst hef eed-watercont rolv alve,admi t
ti
ng
requir
edwat eri ntot heboi lerequalt ot hest eam f l
ow outoft heboi l
er.The
result
ingchangei nf eedwat erflowr ebalancest hedi ff
erenti
all i
nkageandbr i
ngs
thepilot-controlsignalbackt oitsneut r
alpoint.Asaf inalcheck,andt oensure
havingt hepr operdr um l ev
el,thesignalf r
om t hepi l
otcontrolint hewat erlevel
recorderr eadjuststhef eedwat ercont rolv al
ve,ifrequired.Thesel ectorval
vein
the sy stem pr ov i
des aut omat ic orr emot e manualcont rol.Undernor mal
operatingcondi t
ionst hecont rolpr essuregageont hesel ectorv al
vesisan
i
ndicat i
onofv al
veposi t
ion.
2.
15 Usualmet hodofcont rolofwat erlevelinboi l
ersofsmal lcommer cial,and
i
ndust r
ialtypes:
Onacl osed-loopheat i
ngboi ler,
itiscommont ofindnoaut omaticwat erfeedi ng
totheboi l
er.Inst ead,theat t
endantcheckst hegagegl assper iodicall
yand
maintainsthewat erlevelmanual l
y.Theownerr el
iesont heautomat iclow-wat er
cut
of ft
osav etheboi lerincaseofal ow-waterconditi
on.
Waterlevel i
susual l
ycont rol
ledby :
1.Manual feed( Fig.16a)
2.Aut omat icfeeder ,ei t
heramechani caloranel ectri
calsolenoid-oper ated
valv
e,act uatedbyaf loatorel ectr
odeint hewat erspaceoft heboi ler( Fig.
16b)
3.Combi nationlow- waterf uelcutoffandfeeder,basedont hewat erlevelint he
boil
er(Fig.16c) .
4.Combi nationlow- watercut offandpumpcont r
ol (
Fig.16d).

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Fig.16a&b
Fi
g.16( a)Manualmakeupf eedsy st
em.( b)Solenoi
d-operatedmakeup
waterfeeder;solenoi
d,actuatedfrom switch,cont
actsaf l
oat-operat
edlow-
watercut of
f.( c)Combi nat
ion waterf eederand l ow-watercut off
.(d)
Combinationlow- watercutof
fandpump- controlf
eed.(e)Combi nati
onlaw-
watercut of
fand f eederand pump cont roll
erwi t
h makeup f eederon
condensatetank.

Fi
g.16c&d

Thi
ssy stem isi nstalled att henor malboi l
erwat erl
ine.Thewat erl ev elis
mai ntainedbyconnect ingt hepumpcont rol directl
yt othecondensat epump.
Fort headdi t
ionalmakeupwat errequi r
ed,ar eceivertankmakeupf eederi s
install
edont hecondensat ereceivertank.I naddi ti
ont of uncti
oningasa
pumpcont r
olleract sasal ow-watercut of f
.Thi sstopst hebur nerifal ow-
wat ercondi t
ionoccur s.Thi stypeofwat erf eedi susedal soonpackaged
boilersofupt oabout10, 000l bperhrand200psi pressur e.
NOTE:Feedi sact uat edel ectri
call
ybyaf loat-swi t
chcombi nati
ontur ningon
andof fthepump.I ft hev alvefrom ther eceiv ertankt ot heboi l
eriscl osed,
thiscircuit
swi llnotsenset heneedf ormor ewat er,becauset hepumpcoul d
stil
loper at
ebutobv iouslydel iv
ernowat er .Thent heboi lerwoul dhav et obe
shutdownbyt hel ow- wat ercutofftopr otectitf r
om damage.
5.Combi nati
onl ow-wat ercut offandf eederact uatedbyt hedi rectcont actwit
theboi lerwaterlev elandpumpcont r
oll
er( Fig.16e) .Thisi sani mprov ement
upont hesystem descr ibedi nNo.4abov e.

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NATI
ON
DLP/
BOE-
II
/17-01092001

Fig.16e
A st
ate code f or l
ow-
pressure steam boil
ersr equi
res addi
ng a
mechani
cal
waterfeedertoanel
ectr
icalpumpsy st
em i
nthesewor ds:
“Wherewaterofcondensati
onofallofthesteam generat
edbytheboil
ercannot
beretur
nedbygr avit
ytot heboil
er,andpumps,t raps,orot
herdeviceso\are
usedforthispur
pose,orsteam i
susedf orprocesseswherether
ewoul dbeno
waterofcondensat
iontoretur
ntotheboi l
er,anautomati
cwaterfeedi
ngdevice
shoul
dbei nst
all
ed.
”
2.
16 Descri
ptionoft hr
eetypesoflow-wat
ercutof
fsusedi
npackagedboi
ler
sfort
he
prev
entionofl owwater:
Thelow-wat ercut
off(Fi
g.17)
,Separ
atefr
om thepr
ogr
ammingsequencecont
rol
,
i
mmedi atelyshutsdownt heboil
eri
fthewaterdr
opst
oadangerousl
ylowlevel
.
Thethreetypesar easfol
lows:

Fi
g.17
1.Thef l
oat-
magnett ype( Fig.17a)hasaf err
ouspl ungerononeendofaf loat
rod.Thepl ungerslideswi thinanonf err
oussl eev e.A per manentmagnet ,
with amer curyswi tch af fi
xed,i ssuppor ted byapi votadj acentt ot he
nonf err
oussl eeve.Undernor malwat ercondi t
ions,t hef errouspl ungeri s
abov eandoutofr eachoft hemagnet i
cf i
eld.Int hisposi ti
ont hemer cury
switchi sinahor i
zontalpl ane,keepi ngthebur nerci rcuitclosed.Buti ft he
boiler-
waterlev eldrops,t hef l
oatalsodr ops,br ingingt hef errouspl unger
withint hemagnet i
cf ield.Thent hemagnetswi ngst hr oughasmal lar c
towar dtheplunger;themer cur yswit
cht i
lt
s, openingt hebur nerci rcuit
.
2.Thef l
oat-
li
nkedt ype( Fig.17b)hasaf l
oatconnect edt hroughl inkaget oa
platesuppor ti
ngamer cur yswi tch.Becauset hepl atei shor izont alint he
normalwat er-
levelpositi
on,t heswitchhol dthebur nercircuitclosed.I ft he
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ALFORSECONDCLASSBOI
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SPROFI
CIENCYEXAMI
NATI
ON
DLP/
BOE-
II
/17-01092001

wat
erl
evel
drops,
thef
loatdr
ops,
til
ti
ngt
hepl
atesot
heswi
tchopensci
rcui
t.

3.Thesubmer ged-elect
rodetype( Fi
g.17c)usesboilerwatertocomplet
ethe
burnercir
cuit.Ifthewaterleveldropsbelowtheelectr
odetip,
curr
entfl
owis
i
nterrupt
ed,shut tingdownt hebur ner
.Onf tboil
ers,thelow-wat
ercutof
f
generall
yincludesani nt
ermediateswi t
chthatcont
rol
st hef
eedpump.
2.
17 Thecor rectwayt ohookupt wo-watercutoffs,oneoft heel
ectrodet ype,the
otheroft hefl
oattype:
Formaxi mum protect
ion,thesecondaddi t
ionallow-watercutoffshoul dbe
mount edont heoppositedrumheadwi thindi
v i
dualconnecti
onsandbl owdown
pi
pingandv al
ves.Andbothunitsshouldbewi redandproperl
yint
er l
ocked.
REMEMBER:Duall ow-watercutof
fsprovidedualprotect
iononlywheni ndivi
dual
drum connectionsareprovi
ded.

2.
18 Reasonswhyar emanualr esetcontr
olsusef ulonpr essur
eort emperat
ure
high-
li
mi tcontrols:
Themanualr esetmechani sm ont hehigh- l
i
mi tcontrolcall
sattenti
onifthe
operati
ngcont rol(nothigh-li
mit)hasmal functi
oned,t husprohi
biti
ngfurt
her
boil
eroper at
ionunt ilcor
rected.Atti
mes,thismal funct
ionmaybeduet ofused
contacts,aleakinggasv alve,ashortedwire,etc.Thust heboil
ershouldnotbe
operateduntilthisi
scor r
ected.
2.
19 Met hodofcont roloft hefuel/airrati
oinsmal lindust
rialandcommer cial
automat i
cpackaged-typeboil
ers:
Valvecont r
oloft hef uel
/ai
rr at
ioisachi evedbyuseofconst antpr essure
vari
abl eareas.Asimplemechani sm canbeusedt ocauset heopeni ngareaor
twov al
vest ovaryinproport
iont ooneanot her
.Ift
hev al
vechar acteri
sti
csar e
nott hesame, thefuelandairf
lowswi llmat
chatonlyt wopointsthroughoutt he
range.I fthemov ementi snotdirect
lyproporti
onal
,themixt ur
ewi l
lbel eanat
somef i
ringrat
esandr i
chatot hers.

Fig.18
Figur
e18ashowst worot
ary-
typev
alv esonacommonshaf t
.Fi
gure18bshows
tworotary-
typev
alv
esdri
venbyapar all
el-
armli
nkage.Oneorpr
efer
ablybot
hof
thevalvesshoul
dembodymanualadj ustmentoftheval
veopeni
ng(inaddi
ti
on
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CIENCYEXAMI
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DLP/
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tothehandleadj ust
ment)soast opermitadjust
mentofthefuel/
airrati
o.The
val
ve cont r
olsy st
em r equi
res an air blower with a constant
-pressur
e
character
ist
icandoi lorgaspr essureregulator
saheadoft hecontrolv al
ve.
Thust heupstr
eam pressuresforbothai
randf uelmustbeconst
antatt hevalv
e
becausev ar
iat
ionsintheoilvi
scosit
ywouldaf f
ectthef
lowrat
e.
2.
20 Descr i
pt ionofat ypicalcont rolsy stem f orpul v erized- coal -
firedboi lers:
Thebasi cpr inciplei st ocont rolt hef uelandcombust ionai rsimul taneousl ywith
changesi nst eam pr essur eandr eadjust ingai rf l
ow asneededt omai nt ai
nt he
opt i
mum ai r
/fuelr atio.Inst eadofdi rect lyconnect edcont r
ollers,act uat edbyt he
processv ari
ablebei ngmeasur ed,transmi t
terssenset hev ariablesdi r ect l
yand
thent ransmi tappr opriatepneumat icorel ectri
csi gnalst ot hecont rol lers.Iti s
equippedwi thpr essur i
zed,bal l-t
y pepul verizer
s.TheFDf ansuppl iespr eheat ed
combust ionai r
.Inpassi ngt hr ought hepul veri
zer ,thisai rpicksupt hecoaland
car r
iesitt ot hebur ner s.Thusr egulatingt hef low ofpr i
mar yai rcont rolsfuel
suppl y.
Combust i
onai rf rom t heFD andpr imar y-ai
rf ansi scont r
olledf rom st eam
headerpr essure,posi tioningadamperatt hei nl ett oeachpul v erizer .Sensi ng
thisairflow i saf eedercont rolsub- loop( self-
cont ainedcont rolsy st em) ,whi ch
regulatest hesuppl yofr awcoall eav i
ngt hef eeder ,relativetoai rflow, inor derto
ensur eaconst antcoall eveli nt hepul v erizer.Theai r/fuelrat i
oi smai nt ainedby
meansofanai r/st eam- flowr atiocont roller,sensi ngst eam headerf lowand,i n,
turn,posi ti
oningt heFD f anout letdamper .Thusv ary i
ngai rflow t hrought he
pulverizersmeet sl oadchanges.
Asecondsub- loop( coal -airt emper aturecont rol )sensest hepul ver izerout l
et
temper at ureandr egul atest hepr opor ti
onoft emper i
ngai rcombi nedwi ththat
from theai rheat erbef orei tent er sthepr imar yai rf an.Aswi tht heot hercont rol
circuit
s,ahandaut o-select orenabl est heoper atort oassumemanualcont rol
whenr equi r
ed.Whent woormor epul verizersar eoper at
edi npar allel,ei t
her
manualoraut omat i
ccompensat ioni smadef ort henumberi nser vice,sot hat
eachshar esthet ot al l
oadequal l
y .
2.
21 Met
hodofCont
rolofSuper
heatandReheatSt
eam Temper
atur
es:
Todayst eam t emper atureof10000Fi scommonanduni t
sar ebeingi nstall
edf or
0
1050 and 1000F.Because t hese high t emper atures ar el i
mi t
ed onl y by
met allurgy,steam t emper at ur
esmustbehel dtoclosel imitsforsaf etyaswel l
asf oreconomy .Sixbasi cmet hodsareusedf orcont roll
ingthet emper aturesof
steam l eavingt heboi l
er:
1.By passdampercont rolwi thasi ngleby passdamperorser i
es-and-shunt
damperar rangementf orby passing fluegasar ound thesuper heateras
requi red.
2.Spr ay -
typedesuper heat ercont r
olwher ewat erisspr ayeddi r
ect l
yi nt
ot he
st eam wi t
haspr ay-wat ercont r
olvalvef ortemperat ur
er egulati
on.
3.At temper atorcont rolwher e a cont roll
ed porti
on oft he steam passes
thr oughasubmer gedt ubul ardesuper heaterandacont r
olvalveint hest eam
linet othedesuper heaterorat temper atorisused.
4.Condensercont rolwi thdesuper heatingcondenser -t
ubebundl eslocat edi n
thesuper heat eri nl
etheaderandwat er -
controlvalveorv al
vest or egulatea
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ALFORSECONDCLASSBOI
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SPROFI
CIENCYEXAMI
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ON
DLP/
BOE-
II
/17-01092001

portionoft hefeedwat erfl

owt hroughthecondenserasr equir
ed.
5.Tilt
ing-burnercont rolwher et het i
l
tangl eoft hebur nersisadjusted to
changet hefurnaceheatabsor ptionandresult
antsteam temperat
ure.
6.Flue-gas-recir
culat
ioncont rolwhereapor ti
onoft hefluegasi sr
ecir
culated
i
nt ot hef urnacebymeansofanauxi li
aryf anwithadampercont rolto
changet hemassf low throught hesuperheaterandt heheatabsorpti
oni n
thef urnace,asrequiredformai ntai
ningsteam temperatur
e.
2.
22 Basi ccont r
olsusedononce- throughboi ler
s:
Unliket henat ural-
cir
culationboi l
er,wher evary i
ngt her ati
oofheatabsor ption
betweenst eam- generat
ingsur faceandsuper heatingsur facebestat tainsst eam
-temper aturecont rol
,theonce- throughuni tcanmai nt
aint hedesi redst eam
temper atureov eramuchwi derloadr ange.Ifther atioofheati nputoff l
uidf low
i
scor rect,heatabsor pt
ioni ssel f
-adjusting.Spr ayat temper ati
ont henpr ovides
rapidt empor arycontroloft emper at ureonl oadswi ngs.
Thef iringr ateofasi mpl i
fiedi nt
egr atedcont rolsy stem fornor maloper at i
oni s
closelyt i
edt of eedwaterf l
ow cont rol.Andt hesear eal sobei ngcont r
olledt o
mai ntain bot h desir
ed l oad and desi red st eam t emper ature.The t urbine
gov ernorcont rolsareal sot iedi ntot hesy st em t ogi vequi ckr esponseand
stabili
ty .Asmal lamountofspr aydesuper heat i
ngi susedi nt heupanddown
deviation of l oad f or bet ter st eam- temper ature cont roldur ing t ransient
condi ti
ons.
2.
23 Stepst hatar ebei ngt akent ohel papowerpl antoper atorunder standbet ter
thef unct i
onsoft hecomput eri nai dinghi mt ooper ateapl ant :
Thecompl exi t
yofamoder npowerpl anthasl edcont r
olengi neer stosear chf or
bettercommuni cat ionbet weent hecomput erandt hehumanoper ator.One
resultist heuseofl ighted,col or-codedpushbut t
onsgr oupedadj acentt ot heir
respect i
v eedgewi sei ndicators.Act uat i
onof“ increase”and“ decrease”but tons
replacest heoper ationofconv entionalcont rolhandl es.Flashi ngal arml amps,
similarl
yl ocat edi nt hepushbut tons,dr aw inst antat tentiont ot hepi ecesof
equipmentconcer ned,sav i
ngt het imeot herwi sewast edi nr elatinganal arm
signal t
oi tssour ce.
Anot hersol ut i
ont ot hesamepr obl em i st ol inkt hepr ocesscomput erwi t
han
audibleal ar m Annunci ator.Onesuchpowerpl anti nstall
at i
onhasanaudi ble
Annunci at orcoupl edwi t
hacont i
nuousl oop16- trackt ape-recor di
nguni t.When
the comput er recogni zes an out -of-limiti nput si gnal,i t simul taneousl y
addr essesbot hanal arm pr interandt het apeuni t.Whi l
et hepr intert ypesa
statementoft heal arm occur rence,t het apeuni tselects,from sev eralhundr ed
prerecor dedv ocalmessages,t heonemessagest at i
ngwhatal arm si gnalhas
beenr ecei vedandbr oadcast sitov ert heAnnunci ator.
Shoul d out -of-li
mi ti nput s occurf astert han t hey can be announced;t he
comput eri spr ogrammedt ost or
et hesi gnalsandannouncet hem ei theri nthe
orderi nwhi cht heyoccurori nor deroft heirpr iori
ty.Bot hal arm war ningsand
remedi alinst ructi
onscanbepr erecor dedont het ape.Ami crophonedat a-i
nput
facil
ityletst hepr ogr ammeroroper at orchanget hist apedinf ormat ionatwi l
l.

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