BOILER CONTROL USING

DCSCENTUM CS3000

PREPARED BY:

Maulik V. Kunjadiya(IC-21)

Akash P. Patel(IC-42)

Akshay B. Patel(IC-43)

Jay V. Thakker(IC-62)

GUIDED BY:-

MR. MANJUNATH C.(EXTERNAL)

ASST. MANAGER,

YOKOGAWA INDIA LTD.

DR. V. A. SHAH

HEAD OF DEPT,

INST.& CONTROL DEPT,

DHARMSINH DESAI UNIVERSITY,

NADIAD.

CONTENTS

WHAT IS BOILER?

MAIN PARTS OF BOILER

BOILER CONTROL

P&ID OF BOILER CONTROL

PROJECT IMPLEMENTATION FLOWCAHRT

WHAT IS BOILER?

A boiler or steam generator is a device used to create steam by applying heat energy to water.

A boiler or steam generator is used wherever a source of steam is required.

The form and size depends on the application.

A boiler incorporates a firebox or furnace in order to burn the fuel and generate heat.

Types of boiler:-

1. Fire Tube Boiler

2. Water Tube Boiler

BOILER STEAM DRUM

FURNACE

SUPER HEATER

AIR PREHEATER AND ECONOMIZER

CONDESER

DEAERATOR

BLOW DOWN TANK

DESULFURIZATION

MAIN PARTS OF BOILER

BOILER STEAM DRUM

A steam drum is a standard feature of a water-tube boiler.

It is a reservoir of water/steam at the top end of the water tubes.

The drum stores the steam generated in the water tubes and acts as a phase-separator for the steam/water mixture.

FURNACE

A boiler incorporates a firebox or furnace in order to burn the fuel and generate heat.

Temperature in furnace control by air fuel ratio.

SUPER HEATER

The Super heater has an elaborate set up of tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature in now super heated above the saturation temperature.

The super heated steam is then piped through the main steam line to the high pressure turbine.

AIR PREHEATER AND ECONOMIZER

An air preheater heats the air sent into the combustion chamber to improve the efficiency of the combustion process.

An Economizer use the heat from the exhaust gases to heat the feed water.

The Condenser is a tube in which cooling water is circulated through the tubes.

The exhaust steam from the low pressure turbine enters the shell where it cooled and converted to water by flowing over the tubes.

The condenser generally uses either circulating cooling water from a cooling tower to reject waste heat to the atmosphere, or once through water from a river , lake or ocean.

CONDENSER

DEAERATOR

A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal.

Here, steam is used to maintain the tank water temperature at around 105°C, which removes air from the water.

Boiler blowdown is water intentionally wasted from a boiler to avoid concentration of impurities during continuing evaporation of steam.

The water is blown out of the boiler with some force by steam pressure within the boiler.

A steam boiler evaporates steam from liquid water; and requires frequent replenishment of boiler feed water for the continuous production of steam required by most boiler applications.

BLOW DOWN TANK

DESULFURIZATION

Flue-gas desulfurization (FGD) is a set of

technologies used to remove sulfur

dioxide (SO2) from exhaust flue gases of

fossil-fuel power plants, and from the

emissions of other sulfur oxide emitting

processes.

BOILER CONTROL

Boilers are the primary source of steam and hot water generation in industrial

processing plants where steam demands vary very frequently according to the

requirements.

Hence, a well designed boiler must be capable of giving immediate response to

these load demand variations.

While doing so it must also maintain its efficiency and safety features.

In order to achieve this, various techniques of boiler control are available, like

DDC(DIRECT DIGITAL CONTROL) or DCS(DISTRIBUTED CONTROL

SYSTEM)

Here we use DISTRIBUTED CONTROL SYSTEM for Boiler Control.

Boiler

Boiler Drum

Furnace

W

i

n

d

B

o

x

BF

W p

um

p

201FT

LC

201

202FT

Air

Filter Air-pre

heater

201PT

Fuel

103FT

FC

103

102FT

FC

102

201 TT

Deaerator

202PT

202LT Feed Water Tank

Flue

GasesBoiler Feed water

Boiler

Feed

water

Economizer

C

H

I

M

NE

Y

Fuel

Storage

FD fan

ID fan

condensor

Turbine

Superheater

condensate water

+

-

Fl

u

e

G

a

s

e

s

201TIC

Attempt.

202PIC

201PIC

201

FIC

202LIC

BLOW

DOWN

TANK

FROM Attempt. LINE

FROM Superheater LINE

301TI

302TI

303TI

305TT

AH

AL

AH

AL

305TIHH

304PT

304PIHH

LL

LL

302TT

ESP

Dust

P.A

.

fan

FCV201

PCV202

LCV201

LCV202

FCV103

FCV102

TCV201

301PT

302PT

LT201

303PT

303PI

302PI 301

PI

TO BD TANK

Oxidization gas

Lime StoneGypsum

Clean Gas

Circulation

Pump

Spray Tower

Flue Gas Desulfurization

P&ID FOR BOILER CONTROL

P

I

Process Line

Electric Line

Pneumatic Line

Fan

Pump

Heat

Exchanger

Control Valve

On Central control Panel

In the Field Panel

Computer Indicator

I/P converter

DP Transmitter

P&ID Legend

Symbol Symbol Name Symbol Symbol Name

TAG NAME COMMENT

FT102 AIR FLOW TRANSMITTER

FT103 FUEL FLOW TRANSMITTER

FT104 BLOW DOWN WATER FLOW TRANSMITTER

FT201 BFW FLOW TRANSMITTER

FT202 STEAM FLOW TRANSMITTER

TRANSMITTERS

FLOW TRANSMITTERS

TAG NAME COMMENT

TT201 STEAM TEMPERATURE TRANSMITTER

TT301 FLUE GAS TEMPERATURE TRANSMITTER

TT302 DEAERATOR TRANSMITTER

TT303 BFW TEMPERATURE TRANSMITTER

TT305 BOILER TEMPERATURE TRANSMITTER

TEMPERATURE TRANSMITTERS

TAG NAME COMMENT

PT201 STEAM PRESSURE TRANSMITTER

PT202 DEAERATOR PRESSURE TRANSMITTER

PT301 BOILER DRUM PRESSURE

PT302 BOILER DRUM PRESSURE

PT303 WIND BOX PRESSURE

PT304 BOILER PRESSURE TRANSMITTER

PRESSURE TRANSMITTERS

LEVEL TRANSMITTERS

TAG NAME COMMENT

LT201 BOILER DRUM LEVEL TRANSMITTER

LT202 DEAERATOR DRUM LEVEL TRANSMITTER

TAG NAME COMMENT

TI301 FLUE GAS TEMPERATURE INDICATOR

TI302 DEAERATOR TEMPERATURE INDICATOR

TI303 BFW TEMPERATURE INDICATOR

TI305 BOILER TEMPERATURE INDICATOR

PI301 BOILER DRUM PRESSURE INDICATOR

PI302 BOILER DRUM PRESSURE INDICATOR

PI303 WINDBOX PRESSURE INDICATOR

PI304 BOILER PRESSURE INDICATOR

TI306 STEAM TEMPERATURE INDICATOR

INDICATORS

CONTROL VALVES

TAG NAME COMMENT

FCV102 AIR FLOW CONTROL VALVE

FCV103 FUEL FLOW CONTROL VALVE

FCV104 BLOW DOWN WATER FLOW CONTROL VALVE

FCV201 BFW FLOW CONTROL VALVE

LCV201 DEAERATOR LEVEL CONTROL VALVE

LCV202 DEAERATOR LEVEL CONTROL VALVE

PCV202 DEAERATOR PRESSURE CONTROL VALVE

TCV201 STEAM TEMPERATURE CONTROL VALVE

PROJECT IMPLEMENTAION FLOWCHART

PROJECT CREATION

SYSTEM VIEW

FIELD CONTROL STATION CREATION

HUMAN INTERFACE STATION CREATION

NODE CREATION

ANALOG INPUT

ANALOG OUTPUT

DIGITAL INPUT

DIGITAL OUTPUT

CONTROL LOOP CREATION1. AIR FUEL RATIO CONTROL

2. 3 ELEMENT DRUM LEVEL CONTROL

CONTROL LOOP CREATION1. BOILER FEED WATER CONTROL FACEPLAT

3. DEAERATOR LEVEL CONTROL

4. DEAERATOR PRESSURE CONTROL

5. ATTEMPORATOR CONTROL

6. INDICATOR LOOPS

INTERLOCKS

INTERLOCKS

INTERLOCKS

INTERLOCKS

INTERLOCKS

OPERATOR GUIDE MESSEGS

OPERATOR GUIDE MESSAGE

HISTORICAL REPORT

HISTORICAL REPORT

TREND WINDOW

GRAPHICS WINDOW

GRAPHICS WINDOW

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GRAPHICS WINDOW

THANK YOU