INTRODUCTION TO BOILER & BPR

CONTROL SYSTEM AND INSTRUMENT

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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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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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BOILER CONTROL PANEL

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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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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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WATER LEVEL CONTROL METHOD

• 3 element control Method

i. Water Level
ii. Water Flow
iii. Steam Flow
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Water level control method

• Single Element Method

i. Water Level
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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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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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COMBUSTION FLOW
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FORCED DRAFT DAMPER (FD)

• FD damper is used
to control the air
flow going inside
the boiler

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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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INDUCED DRAFT DAMPER (ID)

• ID damper is used to
control the air flow
going outside the
boiler

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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
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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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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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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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Type of Transmitter
• Pressure Transmitter
• Unit : Barg/Psig

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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

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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

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BLOW OFF VALVE (BPR)

•
Description :-
• Blow off valve will
operated when BPR
more then setpoint
and operated in PID
mode.

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SETTING OF BLOWOFF VALVE

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• Q & A SECTION

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