1. Control and regulation of boiler operation Heat Engines & Boilers

2. Contents Hot- and warm water boiler operation control and safety limits Domestic heating and hot water generation control Hot- and warm water boiler operation control and safety limits - Spray type superheat control - Water level control Boiler controls for operation without permanent supervision Steam supply system principals Steam traps

3. Hot- and warm water boiler operation control Thermal oil boiler control is similar In these type of systems there is not phase change only heating up of heat transfer medium happens. Useful heat can be expressed according to following expression. Q useful = m water  c  ( t out – t in ) Heat supply is controlled mainly by two ways: - In case of quantity control inlet and outlet temperature level constant and mass flow rate of heat transfer medium is modified - In case of quality control inlet and outlet temperature level modified and mass flow rate of heat transfer medium is constant Power level control happens generally from outlet temperature of the boiler (Power level control means burning fuel control done generally by fuel inlet quantity control)

4. Safety limits Maximal outlet temperature Minimal inlet temperature (in case of non condensing boilers) Overpressure limitation Heat transfer medium absence limitation Minimal flow limitation

5. Domestic heating system control

6. Heating water temperature variation

7. Domestic heating and hot water generation control

8. Steam generator operation control In case of steam generator useful heat can be calculated according to following expression: Q useful = m steam  ( h out – h in ) Heat demand variation results variation of steam mass flow rate. Mass flow rate variation at constant power level and at constant feed water parameters results outlet enthalpy and outlet pressure variation. Power level control happens generally by means of outlet pressure control, because of previously detailed phenomena. (Power level control means burning fuel control done generally by fuel inlet quantity control)

9. Outlet temperature control In case of saturated steam outlet temperature is not needs to be controlled, because outlet temperature is determined by saturation condition. But in case of superheated steam generation superheat temperature is affected by load conditions, and several operation parameters, so it needs to be controlled. Earlier several methods were used for superheat temperature control, but nowadays only spray type superheat control is used.

10. Spray type superheat control Of all the direct contact types, the spray attemperator has proved most satisfactory. Water of high purity is injected directed into the superheated steam main or into a mingling chamber. The water is sprayed in through a series of nozzles at the throat of a venturi section, forming a fine mist. It is quickly vaporized and first mixes with and then cools the superheated steam. The design must include a thermal sleeve to protect the piping from thermal shock caused by water droplets striking the hot surface.

11. Spray at different locations for outlet steam temperature control at the boiler outletin between two superheater

12. Installation of a spray type attemperator

14. Typical injector construction of spray type attemperators

15. Feed water quantity control According to actual evaporated water quantity the same amount of feed water needs to be fed into the boiler. Generally water level in the drum is used for this task. In case of once-through type boilers it has to be connected with power level control.

16. Water level sensors

17. Water quality control At any type of water treatment a certain amount of salt is delivered to the boiler with feed water. But the steam delivers nearly any salt out from the boiler. So salt is accumulated in boiler water. Over a certain concentration it can cause operation troubles e.g. foaming of water, etc. So salt concentration needs to be held below a certain concentration level. This is solved by letting out some boiler water quantity, which is called slugging or desalination. Fresh feed water will reduce salt concentration

18. General safety limitations Maximal outlet pressure is generally limited by both - electronic and - mechanical way with safety valves Maximal outlet temperature Water level limitation - minimal more important - maximal less important Boiler water quality limitation - salt concentration by means of water conductivity

19. Boiler operation supervision In general case boiler operation is potential danger, so it needs continuous attendance to supervise. With fulfilling special requirements boiler can be operated without permanent attendance. But it does not mean without attendance, it means only that supervisor visit needs to be held regularly, and not continuously. Special requirement means that boiler has to be protected automatically from all the possible dangerous operation condition

20. Boiler controls

21. Shell boilers controls

22. Condensate monitoring for salt and oil pollution

23. Boiler and auxiliary controls

24. Steam supply system principals

25. Flash steam formation

27. Example for steam trap installation

28. Float steam trap

29. Operation of a thermodynamic steam trap

30. Operation of a bimetal steam trap

31. Termic steam trap

32. Summary You are already familiar with Hot- and warm water boiler operation control and safety limits Domestic heating and hot water generation control Hot- and warm water boiler operation control and safety limits - Spray type superheat control - Water level control Boiler controls for operation without permanent supervision Steam supply system principals Steam traps

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