The main object of automatic boiler combustion control is to regulate automatically, the heat input to a boiler in terms of fuel and air supplied in relation to output or steam demand. This should be implemented as efficiently as possible in terms of combustion quality and furnace stability.

Steam pressure is taken as the indication for boiler load as the steam pressure decreases in increasing load and vice versa.

Hence variations in steam pressure is detected and the supply of the fuel and air adjusted accordingly. The successful operation of the combustion control system depends upon the capability to vary the fuel supply to the furnace based on the signals from the control system. The boiler steam demand may vary irrespective to process requirement or power requirement. The fuel fed to the boiler should be controlled to give the necessary quantity of steam. The steam demand increase or decrease will be indicated by the boiler outlet pressure. Hence combustion control is essentially a control to keep the boiler outlet pressure constant. The steam pressure transmitter in the main steam line send the signal to the controller which in turn sends an output signal to the feeder motors in the solid fuel fired boilers and to the fuel control valve in the case of oil and gas fired boilers.

In high pressure boilers, when the steam demand of the boiler increases suddenly, the withdrawal of steam from the steam drum will be higher than the steam generation as combustion control will take some time to react and increase the fuel heat input to the boiler. This will result in drum pressure falling temporarily, this loss of pressure will result in the formation of steam bubbles in the drum water due to the enthalpy difference between the two pressure levels. This bubbling in the drum water will result in the foaming and increase in the volume leading to the level going up spuriously. The level transmitter will transmit this increase in drum level to the controller leading to reduction in feed water flow instead of increasing the feed water flow due to higher demand on boiler. To avoid such a wrong control 3 element drum level control is required.

We at KS provide Steam Network Manager that is an Industrial Internet based advanced control application for on-line controlling and optimization of steam network. It secures process steam supply and quality in disturbances and compensates load changes as economically as possible.

By supervising and regulating the whole steam network it ensures that steam consumption and production are in balance every moment in all production situation with most economical way, supports mill operator in process risk control and management and improves mill’s energy and environmental efficiency.

KS Steam Network Manager provides numerous operational and financial benefits for power plant operations and steam consumers including.

  • Improved steam availability and quality
  • Minimized steam venting losses
  • Optimized steam and electricity production
  • Increased back-pressure power generation
  • Secures process steam supply and quality in disturbances
  • Reduced risk of unplanned shut-downs
  • Reduced need of operator actions
  • Reduced usage of secondary fuels

Our process optimization solution comprises four key areas: Combustion optimization,fuel power compensation, Steam network optimization and district heating network optimization. 

In case of retrofit project KS carry out process performance study to evaluate the improvement potential before delivering the solution. Typical pay-back time for the solution is less than one year and part of the solution price can be bonus based and related to success of delivery and capitalized improvement potential.

 KS experts are systematically monitoring your processes, handling deviations and supporting you in trouble shooting situations. You will get Process Performance Analysis Report in selected intervals (monthly or quarterly).

Required control loops for Boiler Automation

  • Drum level ( Via 3 element control & Single element control)
  • Combustion control
  • Deaerator level control
  • Deaerator pressure control
  • Furnace pressure control function
  • PRDSH
  • Super Heated Steam Temperature control
  • Boiler interlocks level

 For more information, please  contact us

 

 

 

boiler automation
turbine automation
STP automation
process automation
boiler automation turbine automation STP automation process automation