ISA-77.41.

01 Fossil Fuel Power Plant Boiler Combustion Controls

Revised Ma !010

ISA77.41.01-2010 Fossil Fuel Power Plant Boiler Combustion Controls ISBN: 1!17-"!!-"

Co#$ri%&t 2010 b$ ISA'&e International So(iet$ o) Automation. All ri%&ts reser*e+. Not )or resale. Printe+ in t&e ,nite+ States o) Ameri(a. No #art o) t&is #ubli(ation ma$ be re#ro+u(e+- store+ in a retrie*al s$stem- or transmitte+- in an$ )orm or b$ an$ means .ele(troni(- me(&ani(al- #&oto(o#$in%re(or+in%- or ot&erwise/- wit&out t&e #rior written #ermission o) t&e Publis&er. ISA !7 Ale0an+er 1ri*e P. 2. Bo0 12277 3esear(& 'rian%le Par4- Nort& Carolina 2770" ,SA

Copyright 2010 ISA. All rights reserved.

ANSI/ISAd77.41.01-2010

Pre"a#e
'&is #re)a(e- as well as all )ootnotes an+ anne0es- is in(lu+e+ )or in)ormation #ur#oses an+ is not #art o) ANSI5ISA-77.41.01-2010. '&e stan+ar+s re)eren(e+ wit&in t&is +o(ument ma$ (ontain #ro*isions w&i(&- t&rou%& re)eren(e in t&is te0t- (onstitute re6uirements o) t&is +o(ument. At t&e time o) #ubli(ation- t&e e+itions in+i(ate+ were *ali+. All stan+ar+s are sub7e(t to re*ision- an+ #arties to a%reements base+ on t&is +o(ument are en(oura%e+ to in*esti%ate t&e #ossibilit$ o) a##l$in% t&e most re(ent e+itions o) t&e stan+ar+s in+i(ate+ wit&in t&is +o(ument. 8embers o) I9C an+ IS2 maintain re%isters o) (urrentl$ *ali+ International Stan+ar+s. ANSI maintains re%isters o) (urrentl$ *ali+ ,.S. National Stan+ar+s. '&is +o(ument &as been #re#are+ as #art o) t&e ser*i(e o) ISA- t&e International So(iet$ o) Automationtowar+ a %oal o) uni)ormit$ in t&e )iel+ o) instrumentation. 'o be o) real *alue- t&is +o(ument s&oul+ not be stati( but s&oul+ be sub7e(t to #erio+i( re*iew. 'owar+ t&is en+- t&e So(iet$ wel(omes all (omments an+ (riti(isms an+ as4s t&at t&e$ be a++resse+ to t&e Se(retar$- Stan+ar+s an+ Pra(ti(es Boar+: ISA: !7 Ale0an+er 1ri*e: P. 2. Bo0 12277: 3esear(& 'rian%le Par4- NC 2770": 'ele#&one ."1"/ 4"-;411: Fa0 ."1"/ 4"-;2;;: 9-mail: stan+ar+s<isa.or%. '&e ISA Stan+ar+s an+ Pra(ti(es 1e#artment is aware o) t&e %rowin% nee+ )or attention to t&e metri( s$stem o) units in %eneral- an+ t&e International S$stem o) ,nits .SI/ in #arti(ular- in t&e #re#aration o) instrumentation stan+ar+s. '&e 1e#artment is )urt&er aware o) t&e bene)its to ,SA users o) ISA stan+ar+s o) in(or#oratin% suitable re)eren(es to t&e SI .an+ t&e metri( s$stem/ in t&eir business an+ #ro)essional +ealin%s wit& ot&er (ountries. 'owar+ t&is en+- t&is 1e#artment will en+ea*or to intro+u(e SI-a((e#table metri( units in all new an+ re*ise+ stan+ar+s- re(ommen+e+ #ra(ti(es- an+ te(&ni(al re#orts to t&e %reatest e0tent #ossible. Standard for Use of the International System of Units (SI): The Modern Metric System- #ublis&e+ b$ t&e Ameri(an So(iet$ )or 'estin% = 8aterials as I9995AS'8 SI 10"7- an+ )uture re*isions- will be t&e re)eren(e %ui+e )or +e)initions- s$mbols- abbre*iations- an+ (on*ersion )a(tors. It is t&e #oli($ o) ISA to en(oura%e an+ wel(ome t&e #arti(i#ation o) all (on(erne+ in+i*i+uals an+ interests in t&e +e*elo#ment o) ISA stan+ar+s- re(ommen+e+ #ra(ti(es- an+ te(&ni(al re#orts. Parti(i#ation in t&e ISA stan+ar+s-ma4in% #ro(ess b$ an in+i*i+ual in no wa$ (onstitutes en+orsement b$ t&e em#lo$er o) t&at in+i*i+ual- o) ISA- or o) an$ o) t&e stan+ar+s- re(ommen+e+ #ra(ti(es- an+ te(&ni(al re#orts t&at ISA +e*elo#s. CA$%I&' ( ISA )&*S '&% %A+* A', P&SI%I&' -I%. R*SP*C% %& %.* */IS%*'C* &R 0A1I)I%, &F A', PA%*'% RI2.%S ASS*R%*) I' C&''*C%I&' -I%. %.IS )&C$M*'%3 A') ISA )ISC1AIMS 1IABI1I%, F&R %.* I'FRI'2*M*'% &F A', PA%*'% R*S$1%I'2 FR&M %.* $S* &F %.IS )&C$M*'%. $S*RS AR* A)0IS*) %.A% )*%*RMI'A%I&' &F %.* 0A1I)I%, &F A', PA%*'% RI2.%S3 A') %.* RIS+ &F I'FRI'2*M*'% &F S$C. RI2.%S3 IS *'%IR*1, %.*IR &-' R*SP&'SIBI1I%,. P$RS$A'% %& ISA4S PA%*'% P&1IC,3 &'* &R M&R* PA%*'% .&1)*RS &R PA%*'% APP1ICA'%S MA, .A0* )ISC1&S*) PA%*'%S %.A% C&$1) B* I'FRI'2*) B, $S* &F %.IS )&C$M*'% A') */*C$%*) A 1*%%*R &F ASS$RA'C* C&MMI%%I'2 %& %.* 2RA'%I'2 &F A 1IC*'S* &' A -&R1)-I)*3 '&'-)ISCRIMI'A%&R, BASIS3 -I%. A FAIR A') R*AS&'AB1* R&,A1%, RA%* A') FAIR A') R*AS&'AB1* %*RMS A') C&')I%I&'S. F&R M&R* I'F&RMA%I&' &' S$C. )ISC1&S$R*S A') 1*%%*RS &F ASS$RA'C*3 C&'%AC% ISA 23 >ISI' www.isa.or%5Stan+ar+sPatents. &%.*R PA%*'%S &R PA%*'% C1AIMS MA, */IS% F&R -.IC. A )ISC1&S$R* &R 1*%%*R &F ASS$RA'C* .AS '&% B**' R*C*I0*). ISA IS '&% R*SP&'SIB1* F&R I)*'%IF,I'2 PA%*'%S &R PA%*'% APP1ICA%I&'S F&R -.IC. A 1IC*'S* MA, B* R*5$IR*)3 F&R C&')$C%I'2 I'5$IRI*S I'%& %.* 1*2A1 0A1I)I%, &R SC&P* &F PA%*'%S3 &R

Copyright 2010 ISA. All rights reserved.

)*%*RMI'I'2 -.*%.*R A', 1IC*'SI'2 %*RMS &R C&')I%I&'S PR&0I)*) I' C&''*C%I&' -I%. S$BMISSI&' &F A 1*%%*R &F ASS$RA'C*3 IF A',3 &R I' A', 1IC*'SI'2 A2R**M*'%S AR* R*AS&'AB1* &R '&'-)ISCRIMI'A%&R,. ISA re6uests t&at an$one re*iewin% t&is 1o(ument w&o is aware o) an$ #atents t&at ma$ im#a(t im#lementation o) t&e 1o(ument noti)$ t&e ISA Stan+ar+s an+ Pra(ti(es 1e#artment o) t&e #atent an+ its owner. A))I%I&'A11,3 %.* $S* &F %.IS )&C$M*'% MA, I'0&10* .A6AR)&$S MA%*RIA1S3 &R *5$IPM*'%. %.* )&C$M*'% CA''&% A'%ICIPA%* A11 P&SSIB1* APP1ICA%I&'S &R A))R*SS A11 P&SSIB1* SAF*%, ISS$*S ASS&CIA%*) -I%. $S* I' .A6AR)&$S C&')I%I&'S. %.* $S*R &F %.IS )&C$M*'% M$S% */*RCIS* S&$') PR&F*SSI&'A1 7$)2M*'% C&'C*R'I'2 I%S $S* A') APP1ICABI1I%, $')*R %.* $S*R4S PAR%IC$1AR CIRC$MS%A'C*S. %.* $S*R M$S% A1S& C&'SI)*R %.* APP1ICABI1I%, &F A', 2&0*R'M*'%A1 R*2$1A%&R, 1IMI%A%I&'S A') *S%AB1IS.*) SAF*%, A') .*A1%. PRAC%IC*S B*F&R* IMP1*M*'%I'2 %.IS S%A')AR). '?9 ,S93 2F '?IS 12C,89N' S?2,@1 B9 AAA39 '?A' '?IS 12C,89N' 8AB B9 I8PAC'91 BB 9@9C'32NIC S9C,3I'B ISS,9S. '?9 C288I''99 ?AS N2' B9' A1139SS91 '?9 P2'9N'IA@ ISS,9S IN '?IS >93SI2N. '&e )ollowin% #eo#le ser*e+ as members o) ISA Committee ISA77: 'AM* C. 8(Farlan+- 8ana%in% 1ire(tor @. Alt(&e& D. Batu% C. Co&ee 1. Crow 3. 9n% A. Ca*rilos D. Cilman A. ?o(4in% A. ?ollan+ 3. ?ubb$ ?. Do&ansen 3. Do&nson 1. @ee C. 8oo4er7ee D. 2lson P. 3ee*es 1. 3one$ 8. S4on(e$ '. Ste*enson C. 'a)t A. Fa+ira4a C&MPA', 9merson Pro(ess 8ana%ement Israel 9le(tri( Cor#. PP@ Ceneration @@C A##lie+ Control S$stems In*ens$s Fo0boro ?ita(&i Power S$stems Ameri(a ABB In(. DFC 'e(&nolo%$ 'rans)er @@C In*ens$s Pro(ess S$stemsE C?28?ill 3obert N. ?ubb$ Consultin% Be(&tel Power Cor#. IC 9n%ineerin% ABB In(. 1etroit 9+ison Co. 'ennessee >alle$ Aut&orit$ @uminant Power ,3S-Aas&in%ton 1i*ision First 9ner%$ Ceneration Cor#. Constellation 9ner%$ 'a)t 9n%ineerin% In(. Consultant

Copyright 2010 ISA. All rights reserved.

ANSI/ISAd77.41.01-2010

'&is stan+ar+ was a##ro*e+ )or #ubli(ation b$ t&e ISA Stan+ar+s an+ Pra(ti(es Boar+ on GGGGGGGGGGG. 'AM* 8. Co##ler 9. Cosman B. 1umortier 1. 1unn D. Cilsinn 9. I(a$an D. Damison H. @in+ner >. 8a%%ioli '. 8(A*inew A. 8(Caule$ C. 8(Farlan+ 3. 3eimer N. San+s ?. Sasa7ima '. S(&naare D. 'atera I. >er&a##en 3. Aebb A. Aei+man D. Aeiss 8. Ai+me$er 8. Fielins4i C&MPA', Amete4- In(. '&e 1ow C&emi(al Co. S(&nei+er 9le(tri( Aram(o Ser*i(es Co. NIS'589@ AC9S In(. 9nCana Cor#oration @t+. 9n+ressI?auser Pro(ess Solutions AC Feltroni(s Cor#. Da(obs 9n%ineerin% C&a%rin >alle$ Controls- In(. 9merson Pro(ess 8ana%ement 3o(4well Automation 1uPont Bamata4e Cor#. 3osemount- In(. 'atera = Asso(iates- In(. In+ustrial Automation Networ4s- In(. ICS Se(ure @@C Consultant A##lie+ Control Solutions @@C Ha&ler 9n%ineerin%- In(. 9merson Pro(ess 8ana%ement

Copyright 2010 ISA. All rights reserved.

ISA77.41.01-2010

'&is #a%e intentionall$ le)t blan4.

Copyright 2010 ISA. All rights reserved.

ISA77.41.01-2010

Foreword
A *ariet$ o) (ombustion (ontrol s$stems &a*e been +e*elo#e+ o*er t&e $ears to )it t&e nee+s o) #arti(ular a##li(ations. @oa+ +eman+- o#eratin% #&iloso#&$- #lant la$out- an+ t$#e o) )irin% must be (onsi+ere+ be)ore t&e ultimate sele(tion o) a s$stem is ma+e. '&ere)ore- t&is stan+ar+ is not inten+e+ to limit t&e (om#le0it$ or s(o#e o) t&e (ombustion (ontrol s$stem +esi%n t&at one mi%&t wis& to im#lementbut rat&er to establis& a minimum o) (ontrol nee+e+. '&is stan+ar+ is #art o) a series resultin% )rom t&e e))orts o) t&e ISA77 Committee on Fossil Power Plant Stan+ar+s. It s&oul+ be use+ in (on7un(tion wit& t&e ot&er ISA77 series o) stan+ar+s )or sa)e- reliablean+ e))i(ient +esi%n- (onstru(tion- o#eration- an+ maintenan(e o) t&e #ower #lant. It is not t&e intent o) t&is stan+ar+ to establis& an$ #ro(e+ures or #ra(ti(es t&at are (ontrar$ to an$ ot&er stan+ar+ in t&is series.

Copyright 2010 ISA. All rights reserved.

'&is #a%e intentionall$ le)t blan4.

Copyright 2010 ISA. All rights reserved.

ANSI/ISAd77.41.01-2010

Contents
1 Scope........................................................................................................................................................ 11 2 Purpose..................................................................................................................................................... 11 3 Definitions................................................................................................................................................. 11 4 Minimum design requirements for combustion control system................................................................ 14 4.1 Process measurement requirements................................................................................................ 14 4.2 Control and logic requirements......................................................................................................... 15 4.3 Final control device requirements..................................................................................................... 16 4.4 System reliability and availability...................................................................................................... 16 4.5 Minimum alarm requirements........................................................................................................... 17 4.6 Operator interface............................................................................................................................. 18 Annex AReferences................................................................................................................................ 19 Annex BGeneral tutorial.......................................................................................................................... 21 Annex C Fault tolerance......................................................................................................................... 33

Copyright 2010 ISA. All rights reserved.

'&is #a%e intentionall$ le)t blan4.

S#o8e

'&e s(o#e o) t&is stan+ar+ is to a++ress t&e ma7or (ombustion (ontrol subs$stems in boilers wit& steamin% (a#abilities o) 200-000 lb5&r .2 4%5s/ or %reater. '&ese subs$stems in(lu+e- but are not limite+ to- )urna(e #ressure (ontrol .balan(e+ +ra)t/- air)low (ontrol- an+ )uel )low (ontrol w&en )irin% (oal- oil%as- or (ombinations t&ereo). S#e(i)i(all$ e0(lu+e+ )rom (onsi+eration are +e*elo#ment o) boiler ener%$ +eman+- all burner (ontrol- inter)a(e lo%i( s$stems- an+ asso(iate+ sa)et$ s$stems- as well as all (ontrols asso(iate+ wit& )lui+iJe+ be+ an+ sto4er-)ire+ (ombustion units.

Pur8ose

'&e #ur#ose o) t&is stan+ar+ is to establis& t&e minimum re6uirements )or t&e )un(tional +esi%n s#e(i)i(ation o) (ombustion (ontrol s$stems )or +rum-t$#e- )ossil-)uele+- #ower-#lant boilers.

)e"initions

'&e )ollowin% +e)initions are #ro*i+e+ to (lari)$ t&eir use in t&is stan+ar+ an+ ma$ not be rele*ant to t&e use o) t&e wor+ in ot&er te0ts. For ot&er +e)initions- #lease re)er to ANSI5ISA- 1.1-1"7" .31""K/Pro(ess Instrumentation 'erminolo%$. 9.1 air: t&e mi0ture o) o0$%en- nitro%en- an+ ot&er %ases- w&i(&- wit& *ar$in% amounts o) water *a#or- )orms t&e atmos#&ere o) t&e eart&. 9.! air 8ur;e: a )low o) air t&rou%& t&e )urna(e- boiler-%as #assa%es- an+ asso(iate+ )lues an+ +u(ts t&at will e))e(ti*el$ remo*e an$ %aseous (ombustibles an+ re#la(e t&em wit& air. Pur%in% ma$ also be a((om#lis&e+ b$ an inert me+ium. 9.9 alarm an au+ible an+5or *isible means o) in+i(ation to t&e #lant o#erator- an e6ui#ment or #ro(ess mal)un(tionor abnormal (on+ition. 9.4 balan#ed dra"t: a s$stem o) )urna(e #ressure (ontrol in w&i(& t&e inlet air)low or t&e outlet )lue %as )low is (ontrolle+ to maintain t&e )urna(e #ressure at a )i0e+ *alue .t$#i(all$ sli%&tl$ below atmos#&eri(/. 9.< boiler: t&e entire *essel in w&i(& steam or ot&er *a#or is %enerate+ )or use e0ternal to t&e *essel. '&is in(lu+es t&e )urna(e- (onsistin% o) waterwall tubes: t&e )irebo0 area- in(lu+in% burners an+ +am#ers: t&e (on*e(tion area- (onsistin% o) an$ su#er&eater- re&eater- e(onomiJer se(tions or an$ (ombination t&ereo)- as well as +rums an+ &ea+ers. 9.= burner: A +e*i(e or %rou# o) +e*i(es )or t&e intro+u(tion o) )uel an+ air into a (ombustion (&amber at t&e *elo(it$- turbulen(e- an+ (on(entration re6uire+ to maintain i%nition an+ (ombustion o) )uel. 9.7 #ombustion: t&e ra#i+ (&emi(al (ombination o) o0$%en wit& t&e (ombustible elements o) a )uel- resultin% in t&e #ro+u(tion o) &eat. 9.> #ombustible: t&e &eat-#ro+u(in% (onstituent o) a )uel- )lue %as- or )l$ as&.

ANSI/ISAd77.41.01-2010

12

9.? #ontroller: an$ manual or automati( +e*i(e or s$stem o) +e*i(es use+ to re%ulate a #ro(ess wit&in +e)ine+ #arameters. I) automati(- t&e +e*i(e or s$stem res#on+s to *ariations in a #ro(ess *ariable. 9.10 #ontrol loo8: a (ombination o) )iel+ +e*i(es an+ (ontrol )un(tions arran%e+ so t&at a (ontrol *ariable is (om#are+ to a set#oint an+ returns to t&e #ro(ess in t&e )orm o) a mani#ulate+ *ariable. 9.11 #onve#tion: t&e transmission o) &eat b$ t&e (ir(ulation o) a li6ui+ or a %as- su(& as air. Con*e(tion ma$ be natural or )or(e+. 9.1! dra"t: t&e +i))eren(e between atmos#&eri( #ressure an+ some lower #ressure e0istin% in t&e )urna(e or %as #assa%es o) a steam %eneratin% unit. 9.19 e""i#ien# : t&e ratio o) ener%$ out#ut to t&e ener%$ in#ut. '&e e))i(ien($ o) a boiler is t&e ratio o) &eat absorbe+ b$ water an+ steam to t&e &eat e6ui*alent o) t&e )uel )ire+. 9.14 e@#ess air: air su##lie+ )or (ombustion in e0(ess o) t&eoreti(al (ombustion air. 9.1< "ail sa"e: t&e (a#abilit$ to %o to a #re+etermine+ sa)e state in t&e e*ent o) a s#e(i)i( mal)un(tion. 9.1= "inal #ontrol element: t&e (om#onent o) a (ontrol s$stem .su(& as a (ontrol *al*e/ t&at +ire(tl$ re%ulates t&e )low o) ener%$ or material to or )rom t&e #ro(ess. 9.17 "lue ;as: t&e %aseous #ro+u(ts o) (ombustion in t&e )lue to t&e sta(4. 9.1> "or#ed dra"t "an: a )an su##l$in% air un+er #ressure to t&e )uel burnin% e6ui#ment. 9.1? "uel: a substan(e (ontainin% (ombustible material use+ )or %eneratin% &eat: (oal- oil- an+ %as are )uels re)eren(e+ in t&is stan+ar+. 9.!0 "urna#e: an en(lose+ s#a(e #ro*i+e+ )or t&e (ombustion o) )uel. 9.!1 "urna#e 8ressure: t&e #ressure o) %ases in t&e )urna(e .see also +ra)t/. 9.!! indu#ed dra"t "an: a )an e0&austin% )lue %ases )rom t&e )urna(e. 9.!9 instrument: A +e*i(e use+ +ire(tl$ or in+ire(tl$ to measure an+5or (ontrol a #ro(ess *ariable. '&e term in(lu+es #rimar$ elements- )inal (ontrol elements- measurin% +e*i(es- (om#utin% +e*i(es- an+ ele(tri(al +e*i(essu(& as annun(iators- swit(&es- an+ #us& buttons. '&e term +oes not a##l$ to #arts t&at are internal (om#onents o) an instrument .e.%.- a re(ei*er bellows or a resistor/.

9.!4 inte;ral windu8: t&e saturation o) t&e inte%ral (ontroller out#ut- in t&e #resen(e o) a (ontinuous error- w&i(& ma$ (ause una((e#table res#onse in returnin% t&e #ro(ess to its set#oint wit&in a((e#table limits o) time an+ o*ers&oot. 9.!< load: t&e rate o) ener%$ out#ut- usuall$ e0#resse+ as lb5&r .4%5s/ o) steam or me%awatts o) ele(tri(al %eneration. 9.!= lo;i# s stem: +e(ision-ma4in% lo%i( e6ui#ment wit& its asso(iate+ #ower su##lies- I52 &ar+ware- an+ sensin% +e*i(es. 9.!7 8rimar air: (ombustion air t&at enters t&e )uel-burnin% Jone an+ +ire(tl$ su##orts initial (ombustion. 2n #ul*eriJe+ (oal-)ire+ units- t&e #rimar$ air is use+ to trans#ort t&e (oal )rom t&e #ul*eriJers to t&e burners. 9.!> redundant Aredundan# B: +u#li(ation or re#etition o) elements in ele(troni( or me(&ani(al e6ui#ment to #ro*i+e alternati*e )un(tional (&annels in (ase o) )ailure o) element. 9.!? se#ondar air: (ombustion air intro+u(e+ on t&e e+%e o) t&e burnin% Jone to su##lement t&e #rimar$ air )or su##ort o) t&e (ombustion #ro(ess. 9.90 se#ondar #ombustion: (ombustion t&at o((urs as a result o) i%nition at a #oint be$on+ t&e )urna(e. 9.91 set8oint: t&e +esire+ o#eratin% *alue o) t&e #ro(ess *ariable. 9.9! sCall3 sCould3 and ma : t&e wor+ LS?A@@M is to be un+erstoo+ as a 39N,I3989N': t&e wor+ LS?2,@1M as a 39C2889N1A'I2N: t&e wor+ L8ABM as a P938ISSI>9- neit&er man+ator$ nor re(ommen+e+. 9.99 tertiar air: t&e air su##lie+ to (ertain t$#es o) burners )or (oolin% t&e burner metal or to im#ro*e t&e (ombustion #ro(ess. 9.94 tCeoreti#al Astoi#Ciometri#B #ombustion air: t&e (&emi(all$ (orre(t amount o) air re6uire+ )or (om#lete (ombustion o) a %i*en 6uantit$ o) a s#e(i)i( )uel. 9.9< tra#Din;: )or(in% an ina(ti*e (ontrol )un(tion to )ollow t&e a(ti*e (ontrol )un(tion so t&at u#on a mo+e trans)er- no #ro(ess u#set o((urs.

ANSI/ISAd77.41.01-2010

14

Minimum desi;n reEuirements "or #ombustion #ontrol s stem

'&e (ombustion (ontrol s$stem s&all meet o#erational re6uirements an+ (orre(tl$ inter)a(e wit& t&e #ro(ess. 'o a((om#lis& t&is ob7e(ti*e- t&e )ollowin% re6uirements are +e)ine+ )or minimum s$stem +esi%n: a/ Pro(ess measurement re6uirements b/ Control an+ lo%i( re6uirements (/ Final (ontrol +e*i(e re6uirements +/ S$stem reliabilit$ an+ a*ailabilit$ e/ Alarm re6uirements )/ 4.1 4.1.1 2#erator inter)a(e Pro#ess measurement reEuirements Instrument installation "or #ombustion #ontrol

Pro(ess sensin% +e*i(es s&oul+ be installe+ as (lose as #ra(ti(al to t&e sour(e o) t&e measurement wit& (onsi+eration bein% %i*en to e0(essi*e *ibration- tem#erature- an+ a((ess )or #erio+i( maintenan(e. 1e+i(ate+ isolation *al*es an+ im#ulse lines s&oul+ be run to ea(& #ressure-sensin% +e*i(e use+ )or (ontrol in a((or+an(e wit& ISA-77.70.02 Instrument Pi#in% Installation an+ AS89 BK1.1 Power Pi#in%. 4.1.! Measurement and #onditionin;

Filterin% te(&ni6ues use+ to (on+ition #ro(ess measurements s&all not a+*ersel$ a))e(t stabilit$ or re+u(e (ontrol s$stem res#onse. 4.1.9 4.1.9.1 Pro#ess measurements Mass air"low measurement

'&e mass air)low measurement s&all be a re#eatable si%nal t&at is re#resentati*e o) t&e air enterin% t&e )urna(e. A&en *olumetri( air)low-rate measurement te(&ni6ues are em#lo$e+ an+ t&e air tem#erature at t&e )low-measurin% element *aries 0OF .2;OC/ or more- t&e measure+ .in+i(ate+/ )low s&all be (om#ensate+ )or )lowin% air +ensit$ to +etermine t&e true mass air)low rate. 4.1.9.! Furna#e 8ressure measurement

Furna(e #ressure s&all be measure+ wit& t&ree )urna(e #ressure transmitters- ea(& on a se#arate #ressure-sensin% ta#.

4.1.9.9

Fuel measurement

'&e )uel-)low measurement s&all be a re#resentati*e measure o) t&e total )uel ener%$ enterin% t&e )urna(e. 4.1.9.4 2as anal sis measurement

a/ A re#resentati*e )lue-%as o0$%en measurement s&all be #ro*i+e+. b/ A re#resentati*e )lue-%as measurement o) e6ui*alent (ombustibles s&oul+ be #ro*i+e+ )or monitorin% un+er low-e0(ess- air-)irin% (on+itions. 4.! 4.!.1 Control and lo;i# reEuirements Automati# tra#Din;

Automati( tra(4in% s&all be #ro*i+e+ )or bum#less (ontrol-mo+e trans)er. 4.!.! Combustion #ontrol

'&e (ombustion (ontrol- w&i(& res#on+s to t&e boiler ener%$ +eman+- s&all be a((om#lis&e+ wit& t&e )ollowin%: a/ Furna(e #ressure .balan(e+ +ra)t s$stems/ (ontrol b/ Air +eman+ an+ air (ontrol (/ Fuel +eman+ an+ )uel (ontrol +/ 90(ess air '&e +e*elo#ment o) t&e boiler ener%$ +eman+ is (o*ere+ in ISA-77.4K.01 ,nit5Plant 1eman+ 1e*elo#ment 1rum '$#e. 4.!.!.1 Furna#e 8ressure Adra"tB #ontrol

'&e )urna(e #ressure (ontrol s&all re%ulate )lue %as )low to maintain )urna(e #ressure at t&e +esire+ set #oint in (om#lian(e wit& t&e re6uirements o) NFPA ; . '&e )urna(e #ressure (ontrol s&all utiliJe a )ee+)orwar+ si%nal re#resentati*e o) t&e boiler air)low +eman+. 4.!.!.! Air demand and air #ontrol

Air)low +eman+ s&all be +e*elo#e+ )rom t&e boiler ener%$ +eman+ an+ use+ to (ontrol air)low to t&e )urna(e. '&ere s&all be a minimum air)low +eman+ limit to #re*ent air )rom bein% re+u(e+ below t&e unit #ur%e rate w&en t&e air (ontrol is in automati(. Suitable #ro*isions s&all be in(lu+e+ to #re*ent (ontroller win+u# un+er minimum air limit (on+itions. '&e minimum air)low limit s&all be in (om#lian(e wit& t&e re6uirements o) NFPA ; .

ANSI/ISAd77.41.01-2010

16

'&e )ollowin% are #rere6uisites )or t&e air)low (ontrol in automati(: a/ Furna(e #ressure (ontrol in automati( .balan(e+ +ra)t s$stems/ b/ 2ne or more )or(e+ +ra)t )ans .or ot&er air sour(e/ in ser*i(e an+ t&e asso(iate+ re%ulatin% +e*i(e.s/ in automati( (ontrol Pro*ision s&all be ma+e to ensure t&at t&e automati( re%ulation o) air s&all result in a )uel-to-air ratio t&at #ro*i+es sa)e boiler o#eration. '&is s&all in(lu+e limitin% o) )uel )low or air)low to ensure t&at )uel )low ne*er e0(ee+s t&e sa)e (ombustion limit t&at t&e air)low will su##ort. 4.!.!.9 Fuel demand and "uel #ontrol

Fuel +eman+ s&all be +e*elo#e+ )rom t&e boiler ener%$ +eman+ an+ use+ to (ontrol )uel )low to t&e )urna(e. 'otal )uel in#ut s&all be +etermine+ )rom one or a (ombination o) (al(ulate+ *alues- )uel measurementsor (&ara(teriJe+ )uel +eman+ out#uts. '&e )uel +eman+5)uel in#ut relations&i# s&all be use+ to (ontrol ener%$ balan(e on a Btu .4D/ basis. A&en t&e )uel (ontrol is in automati(- t&ere s&all be a minimum )uel +eman+ limit to #re*ent )uel )rom bein% re+u(e+ below t&e le*el re6uire+ to su##ort stable )lame (on+itions in t&e )urna(e. Suitable #ro*isions s&all be in(lu+e+ to #re*ent (ontroller win+u# un+er minimum )uel limit (on+itions. '&e )ollowin% are #rere6uisites )or )uel (ontroller in automati(: a/ Air (ontrol in automati( b/ 2ne )uel sour(e in ser*i(e an+ t&e asso(iate+ re%ulatin% +e*i(e.s/ in automati( (ontrol Pro*ision s&all be ma+e to ensure t&at t&e automati( re%ulation o) )uel s&all result in a )uel-to-air ratio t&at #ro*i+es sa)e boiler o#eration. '&is s&all in(lu+e limitin% o) )uel )low or air)low un+er all (on+itions to ensure t&at )uel )low ne*er e0(ee+s t&e sa)e (ombustion limit t&at t&e air)low will su##ort. 4.!.!.4 *@#ess air

90(ess air s&all be maintaine+ at all loa+s to assure #ro#er (ombustion o) t&e )uel enterin% t&e )urna(e an+ s&oul+ not allow t&e )urna(e to o#erate at an o0$%en le*el in t&e )lue %as below t&e boiler or burner manu)a(turerPs re6uirements. Suitable #ro*isions s&all be in(lu+e+ to #re*ent e0(ess air (ontroller win+u# un+er air)low limit (on+itions. 4.!.9 Burner mana;ement inter"a#e reEuirements

An$ inter)a(e between t&e (ombustion (ontrol s$stem an+ t&e burner mana%ement s$stem s&all (om#l$ wit& NFPA ; . 4.9 Final #ontrol devi#e reEuirements

All )inal (ontrol elements s&all be +esi%ne+ to )ail sa)e on loss o) +eman+ si%nal or moti*e #ower- i.e.o#en- (lose+- or lo(4 in #la(e. '&e )ail-sa)e #osition s&all be +etermine+ b$ t&e user an+ be base+ u#on t&e s#e(i)i( a##li(ation to meet all boiler #ur%e an+ interlo(4 re6uirements o) NFPA ; . 4.4 S stem reliabilit and availabilit

In or+er to establis& minimum (riteria- t&e (ombustion (ontrol s$stem s#e(i)i(ation s&all in(lu+e t&e )ollowin% as #art o) t&e s$stem +esi%n base:

a/ 8a0imum an+ minimum unit loa+ .steamin% (a#a(it$/ b/ Normal o#eratin% loa+ ran%e (/ Anti(i#ate+ loa+ (&an%es +/ Start-u# an+ s&ut+own )re6uen($ e/ 1e%ree o) automation )/ Boiler au0iliar$ ma0imum an+ minimum (a#a(ities

Fiel+ transmittin% +e*i(e re+un+an($ s&oul+ be #ro*i+e+ to t&e e0tent ne(essar$ to a(&ie*e +esire+ s$stem reliabilit$. A&en onl$ one transmitter is use+- an+ t&e (ontrol s$stem (an +ete(t a ba+ si%nal- t&e (ontrol loo# s&all be trans)erre+ to manual w&en a si%nal is +ete(te+ as ba+. A&en two transmitters are use+- t&e minimum- ma0imum- or a*era%e (an be sele(te+. I) bot& transmitters are %oo+ si%nals an+ e0(essi*e +e*iation between t&e transmitters e0ist- t&en an alarm s&all be %enerate+- an+ t&e asso(iate+ (ontrol loo# s&all be trans)erre+ to manual. I) one transmitter is a ba+ si%nal- t&en t&e sele(tion s&all trans)er to t&e %oo+ si%nal. I) bot& transmitters are ba+ si%nals- t&en trans)er t&e loo# to manual. A&en t&ree transmitters are use+- t&e me+ian si%nal s&all be sele(te+ )or (ontrol #ur#oses- an+ e0(essi*e +e*iation between t&e transmitters s&all be alarme+. I) one transmitter is a ba+ si%nal- t&en t&e two-transmitter strate%$ s&all be em#lo$e+. 4.< Minimum alarm reEuirements

8inimum alarm re6uirements s&all in(lu+e t&e )ollowin%: 4.<.1 Pro#ess alarms

a/ @ow air)low b/ @ow )lue-%as o0$%en (/ ?i%&5low )urna(e #ressure +/ Fuel alarms #er NFPA ; . 4.<.! S stem .ardware alarms

a/ @oss o) (ontrol #ower b/ @oss o) )inal +ri*e #ower (/ Control loo# trans)er to manual +ue to &ar+ware )ailure +/ Failure o) #ro(ess measurement si%nal e/ 3e+un+ant transmitters +e*iation alarm )/ Final +ri*es at (ontrol limit

ANSI/ISAd77.41.01-2010 %/ @oss o) re+un+ant (om#onents 4.= &8erator inter"a#e

18

8inimum o#erator inter)a(e s&all in(lu+e t&e )ollowin%: 4.=.1 ReEuired inter"a#e

'&e )ollowin% in)ormation use+ in t&e (ombustion (ontrol s$stem s&all be ma+e a*ailable to t&e o#erator: a/ Boiler ener%$ +eman+ b/ 'otal air)low (/ 'otal )uel )low .measure+ or in)erre+/ +/ In+i*i+ual )uel )low.s/ .a((or+in% to )uel t$#e )or multi#le )uels/ e/ Furna(e #ressure )/ Flue-%as o0$%en (ontent

%/ All alarms #re*iousl$ +e)ine+ in 4. &/ Control-loo# status an+ out#ut +eman+ i/ 7/ Set #oints Bias &8tional inter"a#e

4.=.!

In a++ition to t&e abo*e- t&e )ollowin% in)ormation- as a##li(able- s&oul+ be ma+e a*ailable to t&e o#erator: a/ Final +ri*e #osition.s/ an+ +eman+ +e*iation status b/ >al*e #osition.s/ (/ Fee+er s#ee+s +/ Control #ower status e/ 1ri*e moti*e #ower status )/ 2il or %as burner #ressure Mode inter"a#e

4.=.9

'&e s$stem s&all in(lu+e (a#abilities )or t&e automati( an+5or manual (ontrol o) ea(& in+i*i+ual )inal (ontrol +e*i(e.

Anne@ A(Re"eren#es
AM*RICA' P*%R&1*$M I'S%I%$%* AAPIB API 3P 0 Pt. I>-1";4 8anual on Installation o) 3e)iner$ Instruments an+ Control S$stems Steam Cenerators Ameri(an Petroleum Institute 1220 @ Street- NA Aas&in%ton- 1C 2000 .

A*ailable )rom:

AM*RICA' S&CI*%, F&R %*S%I'2 MA%*RIA1 AAS%MB Annual Boo4 o) Caseous Fuels: Coal an+ Co4e Atmos#&eri(- Parts 1" an+ 2! A*ailable )rom: Ameri(an So(iet$ )or 'estin% 8aterial

AM*RICA' S&CI*%, &F M*C.A'ICA1 *'2I'**RS AASM*B Boiler an+ Pressure >essel Co+e- Se(tion 1- 1";K ASME B31.1 A*ailable )rom: Power Piping for Boilers Ameri(an So(iet$ o) 8e(&ani(al 9n%ineers K4 9ast 47t& Street New Bor4- NB 10017

I'S%I%$%* &F *1*C%RICA1 A') *1*C%R&'ICS *'2I'**RS AI***B ANSI5I999 St+. 2!;-1";2 I999 St+. 02-1"; A*ailable )rom: '&e 8etri( Pra(ti(e Cui+e I999 Cui+e )or Prote(tion- Interlo(4in% an+ Control o) Fossil-Fuele+ ,nit Conne(tion Steam Stations Ameri(an National Stan+ar+s Institute 11 Aest 42n+ Street New Bor4- NB 100K!

ISA ( %.* I'%*R'A%I&'A1 S&CI*%, &F A$%&MA%I&' ISA- .1- 200" ISA- .4-1""1 ANSI5ISA- 1.1-1"7" .31""K/ ISA-77.70-1""K .32004/ ISA77.4K.01 .3200;/ Instrumentation S$mbols an+ I+enti)i(ations Instrument @oo# 1ia%rams Pro(ess Instrumentation 'erminolo%$ Fossil Fuel Power Plant Instrument Pi#in% Installation ,nit5Plant 1eman+ 1e*elo#ment 1rum '$#e

'&e Control o) Boilers- 2n+ e+ition- Sam 1u4elow 1""1

ANSI/ISAd77.41.01-2010

20

Boiler Control S$stems 9n%ineerin%- C.F. .Derr$/ Cilman 200 A*ailable )rom: ISA !7 Ale0an+er 1ri*e P. 2. Bo0 12277 3esear(& 'rian%le Par4- N.C. 2770"

'A%I&'A1 FIR* PR&%*C%I&' ASS&CIA%I&' A'FPAB NFPA ; Boiler an+ Combustion S$stems ?aJar+s Co+e 2007 9+ition A*ailable )rom: MISC*11A'*&$S Bab(o(4 = Ail(o0- Steam - Its Ceneration an+ ,se- 41st e+.- New Bor4- NB- 1""2. Sin%er- Dose#& C.- ABB Combustion: Fossil Power S$stems- 4t& e+.- ABB Combustion 9n%ineerin%- In(.1""1. S4rotJ4i- Bern&ar+t C.A.- L9le(tri( Ceneration: Steam Stations.M ,ltraS$stems- In(. .)or Na*al Ci*il 9n%ineerin% @aborator$/- L'&eor$ o) Boiler Control S$stems Q 2#eration 8anual-M N!2474-;1-C-"K;;- Ir*ine- CA- 142 ##. National Fire Prote(tion Asso(iation Nuin($- 8A 022!"

Anne@ B(2eneral tutorial

'&is a##en+i0 is in(lu+e+ )or in)ormation #ur#oses an+ t&ere)ore is not (onsi+ere+ a #art o) ANSI5ISA77.41.01-2010.

B.1 Pur8ose
'&e #ur#ose o) t&is a##en+i0 is to #ro*i+e tutorial in)ormation on t&e #&iloso#&$ un+erl$in% t&is stan+ar+ an+ to assist in s#e(i)$in% an+ a##l$in% (ombustion (ontrol strate%ies t&at will best ser*e t&e re6uirements o) t&e user.

B.!

Introdu#tion

'&e #ur#ose o) an$ (ombustion (ontrol s$stem is to sa)el$ an+ e))i(ientl$ maintain t&e +esire+ boiler out#ut wit&out t&e nee+ )or (onstant o#erator attention. '&ere)ore- t&e (ombustion #ro(ess insi+e t&e )urna(e must be (ontrolle+ w&ile t&e boiler out#ut (&an%es in res#onse to loa+ +eman+s. '&e basi( #rin(i#le o) (ombustion (ontrol is to meet t&e boiler loa+ re6uirements b$ re%ulatin% t&e 6uantities o) )uel an+ air w&ile a(&ie*in% o#timum (ombustion an+ maintainin% sa)e (on+itions )or o#erators an+ e6ui#ment.

B.9 Combustion 8ro#ess

As t&e (ombustion #ro(ess ta4es #la(e in t&e )urna(e- o0$%en in t&e (ombustion air (ombines (&emi(all$ wit& t&e (arbon an+ &$+ro%en in t&e )uel to #ro+u(e &eat. '&e amount o) air t&at (ontains enou%& o0$%en to (ombine wit& all t&e (ombustible matter in t&e )uel is (alle+ t&e Rstoi(&iometri(R *alue or t&eoreti(al air. It is im#robable )or e*er$ mole(ule o) )uel t&at enters t&e )urna(e to (ombine (&emi(all$ wit& o0$%en. For t&is reason- it is ne(essar$ to #ro*i+e more air t&an t&e stoi(&iometri( re6uirement. For most boilers it is (ustomar$ to #ro*i+e to 20 #er(ent more air t&an t&e stoi(&iometri( re6uirement to ensure (om#lete (ombustion. '&is a++itional air is (alle+ Re0(ess air.R A boiler )irin% at 1.2 times t&e stoi(&iometri( air re6uirement woul+ be sai+ to be )irin% at 20 #er(ent e0(ess air. I) insu))i(ient o0$%en is intro+u(e+ into t&e )urna(e- in(om#lete (ombustion o) t&e )uel will o((ur. '&is wastes )uel- (auses air #ollution- an+ results in &aJar+ous (on+itions in t&e boiler. '&e unburne+ )uel ma$ i%nite in t&e boiler or bree(&in% an+ result in se(on+ar$ (ombustion- (ausin% a +an%erous e0#losion. Pro*i+in% too mu(& (ombustion air re+u(es t&e e0#losion +an%er but also re+u(es e))i(ien($. '&e lar%est ener%$ loss in t&e boiler is t&e &eat t&at es(a#es as &ot )lue %as. In(reasin% t&e e0(ess air in(reases t&is ener%$ loss. ?i%& e0(ess air (an also result in unstable burner (on+itions +ue to t&e lean )uel5air mi0ture. In #ra(ti(e- a lar%e number o) items t&at a))e(t boiler e))i(ien($ are relate+ to e0(ess air. '&e #ro#er *alue o) e0(ess air is a )un(tion o) boiler loa+- )uel 6uantit$- air lea4a%e t&rou%& i+le burners- steam tem#erature- )lame stabilit$- an+ ener%$ losses.

B.4 Basi# #ombustion #ontrol strate;ies

>arious (ombustion (ontrol strate%ies t&at are base+ on re6uirements )or sa)e- e))i(ient- an+ res#onsi*e (ontrol o) boilers &a*e e*ol*e+. 8ore so#&isti(ate+ (ontrols were +e*elo#e+ as instrumentation be(ame more reliable an+ a((urate. '&e (ontrol strate%ies (an be +i*i+e+ into two ma7or (ate%ories: #ositionin% s$stems an+ meterin% s$stems.

ANSI/ISAd77.41.01-2010

22

In #ositionin% s$stems t&e )uel an+ air (ontrol +e*i(es are simultaneousl$ #ositione+- base+ on ener%$ +eman+. 9a(& #osition o) t&e )uel (ontrol +e*i(e assumes a (orres#on+in% #osition )or t&e air)low (ontrol +e*i(e. A (ontrol station is normall$ a*ailable )or t&e o#erator to trim t&e )uel5air ratio. '&e #ositionin% s$stem is sim#le an+ )ast res#on+in%- but it (annot (om#ensate )or *ar$in% )uel (&ara(teristi(s- atmos#&eri( (on+itions- +$nami( (&ara(teristi(s o) t&e )uel +eli*er$ e6ui#ment- or t&e imbalan(e o) t&e )uel-to-air ratio +urin% ra#i+ loa+ (&an%es. 8eterin% s$stems measure t&e a(tual )uel an+ air +eli*ere+ to t&e boiler. '&e measure+ )lows are use+ in )ee+ba(4 (ontrol s(&emes to #re(isel$ re%ulate t&e )uel +eman+ an+ to establis& a (ross-limite+ minimum air)low +eman+. '&e )uel )low in a %as or oil boiler (an also be rea+il$ measure+. Fuel )low in a (oal-)ire+ boiler (annot be +ire(tl$ measure+- an+ *arious s(&emes &a*e been +e*elo#e+ to in)er t&e )uel +eli*er$ rate base+ on ot&er *ariables. In a++ition- t&e &ea*$ e6ui#ment ne(essar$ to trans#ort t&e (oal an+ #re#are it )or burnin% #resents +$nami( o#erational an+ (ontrol #roblems. Air)lows (an be measure+ wit&out too mu(& +i))i(ult$. Air)low is use+ in a )ee+ba(4-(ontrol s(&eme to #re(isel$ re%ulate t&e air +eman+ an+ to establis& a (ross-limite+ ma0imum )uel-)low +eman+. '&e air)low must be (&ara(teriJe+ to t&e (orres#on+in% )uel +eman+ in t&e air)low +eman+ +e*elo#ment or in t&e )ee+ba(4 si%nal- but not bot&. '&e )uel-to-air ratio is a+7uste+ b$ an e0(ess air-)ee+ba(4 loo#. '&e e0(ess air loo# (an a+7ust t&e air)low +eman+ or air)low )ee+ba(4 si%nal- but not bot&. A t$#i(al (ombustion-(ontrol-)un(tion +ia%ram is s&own in Fi%ure B.1.

B.1 - % 8i#al #ombustion #ontrol "un#tional dia;ram

ANSI/ISAd77.41.01-2010

24

B.< Air"low reEuirements #on#e8ts

Air)low measurements (an be establis&e+ b$ #rimar$ elements lo(ate+ on eit&er t&e air si+e or t&e )lue%as si+e o) t&e unit. A suitable #la(e to measure air)low is t&e entr$ o) t&e )or(e+-+ra)t )an. A&en t&ere is #otential lea4a%e between t&e )or(e+-+ra)t )an an+ t&e )urna(e- a #re)erre+ lo(ation ma$ be t&e air +u(t between t&e )or(e+-+ra)t )an an+ t&e burners +ownstream o) t&e air &eater. An alternate- but less #re)erre+- lo(ation )or air)low measurement is on t&e )lue-%as si+e o) t&e boiler. Conne(tions )or a +i))erential #ressure transmitter are lo(ate+ a(ross a se(tion o) t&e boiler- an+ t&e #ressure +ro# o) t&e )lue %as is measure+. '&e (onne(tions s&oul+ be lo(ate+ to a*oi+ t&e #ressure +ro# a(ross t&e air &eater. Potential #roblems wit& t&is met&o+ are t&e (orrosi*e e))e(ts o) t&e )lue %as an+ lea4a%e.

B.= *@#ess air reEuirements #on#e8ts

'&e (ombustion air nee+e+ in an a(tual boiler will be in e0(ess o) t&e t&eoreti(al air. '&is e0(ess air is nee+e+ be(ause some o) t&e (ombustion air su##lie+ to t&e boiler will not rea(t wit& t&e )uel. '&e amount o) e0(ess air re6uire+ )or %oo+ (ombustion is +e#en+ent u#on t&e boilerSs burner an+ )urna(e +esi%n. 'o minimiJe t&e re6uirement )or e0(ess air- t&e )uel must be t&orou%&l$ atomiJe+ an+ mi0e+ wit& t&e (ombustion air. '&e (ombustion air must im#art turbulen(e an+ momentum to t&e )lame- an+ t&e )urna(e must be siJe+ to allow a+e6uate resi+en(e time to ensure (om#letion o) (ombustion. '$#i(all$- a Jir(onium-o0i+e-base+ o0$%en anal$Jer is a +ire(t measurement o) o0$%en an+- base+ on a %i*en )uel- a +ire(t measurement o) t&e e0(ess air in t&e (ombustion #ro(ess. '&e measurement is ta4en be)ore t&e air #re-&eater to re(ei*e a re#resentati*e sam#le o) t&e (ombustion air. '&e e0(ess air re6uirement is non-linear as a )un(tion o) loa+. '&us- a loa+ in+e0 si%nal is use+ to #ro%ram t&e e0(ess air set#oint. A (ontroller a(ts on t&e resultin% error an+ a+7usts t&e )uel5air ratio. Suitable #ro*isions s&oul+ be in(lu+e+ to #re*ent (ontroller win+u# un+er minimum air)low-limit (on+itions. A+7ustment o) t&e )uel5air ratio (an be a((om#lis&e+ b$ eit&er a+7ustin% t&e air)low +eman+ or air)low )ee+ba(4. Pla(in% t&e trim on t&e +eman+ in&erentl$ ma4es more sense an+ is easier )or users to un+erstan+ an+ (ommission. I) more air is re6uire+- t&en in(rease t&e air)low set#oint to in(rease air)low. B$ a+7ustin% t&e +eman+- t&e (alibration o) air)low +eman+ (ur*e- minimum air)low set#oint- air)low tri#s an+ #ur%e rate are easil$ establis&e+ be(ause air)low re#resents t&e (orre(t mass air)low rate into t&e )urna(e. ?owe*er- +rawba(4s in(lu+e more (om#li(ate+ )uel-(ross-limit +esi%n- an+ tren+ #ens +o not o*erla$ ea(& ot&er in terms o) T8C3. A&en +esi%ne+ an+ (alibrate+ #ro#erl$- eit&er met&o+ .i.e.- trim +eman+ or trim )ee+ba(4/ (an #ro*i+e sa)e an+ reliable e0(ess air-trim (ontrol. '&e trim on +eman+ is #re)erre+.

B.7 Furna#e 8ressure Adra"tB reEuirement #on#e8ts

Furna(e #ressure .+ra)t/ (ontrol is re6uire+ on balan(e+ +ra)t boilers. A&ile eit&er t&e )or(e+ +ra)t )an.s/ or t&e in+u(e+ +ra)t )an.s/ (oul+ be use+ to (ontrol t&e )urna(e #ressure- in+ustr$ t$#i(all$ uses t&e in+u(e+ +ra)t )an to (ontrol )urna(e #ressure. A t$#i(al )urna(e #ressure (ontrol )un(tional +ia%ram is s&own in Fi%ure B.2. '&e (ontrol strate%$ uses a )ee+)orwar+ si%nal (&ara(teriJe+ to re#resent t&e #osition o) t&e air)low (ontrol +e*i(e.s/. A me+ian-sele(te+ )urna(e #ressure is (om#are+ to an o#erator )urna(e #ressure set#oint. An$ error is use+ to mo+ulate a trim (ontroller. In a #ro#erl$ +esi%ne+ an+ (alibrate+ s$stem- t&e out#ut o) t&e )urna(e #ressure (ontroller will remain near its mi+ran%e )or all air)lows. A manual5auto station is #ro*i+e+ to allow t&e o#erator manual (ontrol o) t&e )urna(e #ressure (ontrol +e*i(es. As re6uire+- t&e )urna(e #ressure +eman+ is interlo(4 #er t&e re6uirements o) t&e burner mana%ement s$stem. '&e interlo(4 (an be )or boiler #ur%e- boiler natural +ra)t .e.%.- 100T/- or )an start-

u# .e.%.- 0T/. An$ interlo(4 (omman+s will )or(e t&e manual5auto station to tra(4 t&e +ownstream +eman+. 1ownstream o) t&e auto5manual station- o*erri+es- an+ +ire(tional blo(4in% are #ro*i+e+ to minimiJe )urna(e #ressure e0(ursion in eit&er auto or manual mo+e. A )an o*erri+e +eman+ is #ro*i+e+ to minimiJe ne%ati*e )urna(e #ressure e0(ursions )or t&e #re*ention o) a )urna(e im#losion. A main )uel tri# .8F'/ o*erri+e is #ro*i+e+ to minimiJe ne%ati*e )urna(e #ressure e0(ursion as a result o) a )lame (olla#se on loss o) )lame. 1ire(tional blo(4in% is #ro*i+e+ to #re*ent t&e )inal (ontrol +e*i(e )rom mo*in% in t&e wron% +ire(tion an+ (reatin% a lar%er )urna(e #ressure error.

ANSI/ISAd77.41.01-2010

26

B.! - % 8i#al "urna#e 8ressure #ontrol "un#tional dia;ram

B.> Control o" ;as- and oil-"ired boilers

Cas- an+ oil-)ire+ boilers o)ten allow burnin% %as an+ oil se#aratel$ or to%et&er. Pro*isions must be ma+e to assure t&at t&e )uel-to-air ratio is maintaine+ as multi#le )uels are intro+u(e+ into t&e boiler. '&is (an be a((om#lis&e+ b$ summin% t&e in+i*i+ual )uel )lows on a Btu .4D/ *alue basis. '&e out#ut o) t&e summer be(omes t&e Rtotal )uelR in t&e (al(ulation o) t&e )uel-to-air ratio. @imitin% (ir(uitr$ s&oul+ be #ro*i+e+ to ensure a sa)e )uel-to-air ratio. A&en t&e )uel (ontrol is in automati(- t&ere s&all be a minimum )uel +eman+ limit to #re*ent )uel )rom bein% re+u(e+ below t&e le*el re6uire+ to su##ort stable )lame (on+itions in t&e )urna(e.

B.? Control o" 8ulveriFed #oal-"ired boilers

'wo ma7or (onsi+erations in t&e +e*elo#ment o) a meterin%-t$#e (ontrol strate%$ )or a #ul*eriJe+ (oal)ire+ boiler are (om#ensation )or #ul*eriJer +$nami(s an+ t&e sele(tion o) an in)erre+ (oal )low si%nal. In a++ition- t&e )uel +eman+ si%nal must be (orre(te+ )or t&e number o) #ul*eriJers in ser*i(e. A&en t&e )uel (ontrol is in automati(- t&ere s&all be a minimum )uel +eman+ limit to #re*ent )uel )rom bein% re+u(e+ below t&e le*el re6uire+ to su##ort stable )lame (on+itions in t&e )urna(e. B.?.1PulveriFer d nami#s Pul*eriJers in+u(e time la%s into t&e (ontrol #ro(ess. '&ere is a )inite time between t&e intro+u(tion o) (oal into t&e #ul*eriJer an+ t&e +eli*er$ o) )uel to t&e )urna(e. '&e %rin+in% an+ +r$in% o) t&e (oal in t&e #ul*eriJer an+ t&e time re6uire+ to trans#ort t&e (oal5air mi0ture to t&e burners bot& (ontribute to time la%s. In a++ition- t&e *olume o) (oal in t&e #ul*eriJer in(reases as t&e loa+ on t&e #ul*eriJer in(reases. B.?.!Ball tube 8ulveriFers '&e ball tube or ?ar+in%e-t$#e #ul*eriJers utiliJe small-+iameter .2-in(&/ steel balls in a rotatin% +rum to %rin+ (oal. '&ese #ul*eriJers e0&ibit lar%e (oal stora%e (&ara(teristi(s. It is (ommon )or t&is t$#e o) #ul*eriJer to #ro+u(e (ontrolle+ (oal )low )or 10 to 1 minutes a)ter t&e (oal )ee+er is sto##e+. '&e (oal )ee+er si%nal is- t&ere)ore- useless in t&e (ontrol s(&eme as a )uel )low si%nal. An im#lie+ )uel )low si%nal (an be +eri*e+ )rom boiler &eat release- #rimar$ air)low- lineariJe+ (lassi)ier +i))erential- (&ara(teriJe+ #rimar$ air +am#er #osition- or e0&auster inlet +am#er #osition. Sin(e t&ese si%nals- wit& t&e e0(e#tion o) &eat release- (an #ro+u(e an a##arent (oal )low in an em#t$ mill- t&e si%nals must be *eri)ie+ b$ lo%i( si%nals monitorin% t&e mill le*el an+ )ee+er status. In a ball tube #ul*eriJer- t&e (oal )ee+er normall$ o#erates in+e#en+entl$ o) t&e boiler ener%$ +eman+ or )uel +eman+ si%nals. '&e (oal )ee+er (ontrol )or ball tube #ul*eriJers ma$ be base+ on t&e )ollowin%: a/ Pul*eriJer le*el .+i))erential measurement/ b/ Pul*eriJer +B .soun+ measurement/ (/ Pul*eriJer 4A .#ower measurement/ +/ Pul*eriJer 4A an+ +B '&e usual (ontrol o) t&e )ee+er is base+ on #ul*eriJer (oal le*el wit& a sli%&t )ee+)orwar+ or +eri*ati*e )rom boiler ener%$ +eman+ or )uel +eman+. B.?.9 'on-ball tube mills

ANSI/ISAd77.41.01-2010

28

Pul*eriJe+ (oal-)ire+ boilers normall$ use a so#&isti(ate+ (ombustion (ontrol s$stem &a*in% se*eral #ul*eriJers- ea(& su##l$in% multi#le burners. It is not onl$ im#ortant to maintain t&e (orre(t )uel-to-air ratio at all times- but t&e )uel )rom ea(& #ul*eriJer to its asso(iate+ burner s&oul+ be #ro#erl$ #ro#ortione+ an+ +istribute+ )or stable an+ e))i(ient boiler o#eration. '&e )uel +eman+ is (om#are+ to t&e total measure+ )uel )low .summation o) all )ee+ers in ser*i(e +eli*erin% (oal/ to +e*elo# t&e +eman+ to t&e )uel (ontroller. '&e )uel +eman+ si%nal is t&en a##lie+ in #arallel to all o#eratin% #ul*eriJers. S&oul+ an u#set in a*ailable air o((ur so t&at air is limite+- an error si%nal )rom air)low (ontrol s&oul+ re+u(e t&e )irin% rate +eman+ to t&e )uel (ontroller to maintain a minimum a((e#table )uel5air ratio. @imitin% (ir(uitr$ s&all be #ro*i+e+ to ensure t&at air)low is alwa$s abo*e +eman+e+ )uel )low: &en(e- a sa)e (ombustion mi0ture is alwa$s #resent. '&is +eman+ is (om#are+ wit& total )ee+er s#ee+s or t&e &eat absorbe+ si%nal. S&oul+ t&ere be a +i))eren(e between t&e )uel +eman+ an+ total )uel )low- t&e )uel (ontroller will rea+7ust t&e s#ee+ o) t&e )ee+ers in ser*i(e to t&e e0tent ne(essar$ to eliminate t&e error. Sin(e t&ere ma$ be some +ela$ between a (&an%e in )ee+er s#ee+ an+ t&e a(tual (&an%e in (oal to a )urna(e- a la% .mill mo+el/ is in(or#orate+ into t&e s#ee+ )ee+ba(4- so t&at t&e air)low an+ )uel )low (ontrol are 4e#t in ste# wit& t&e a(tual (oal to t&e )urna(e. 1urin% (on+itions o) a mill o*erloa+- t&e )ee+er s#ee+ +eman+ si%nal s&oul+ be re+u(e+ until t&e o*erloa+ (on+ition is resol*e+. B.?.4 PulveriFer #oal-air #ontrol s stem '&e #rimar$ (ontrol )or a #ul*eriJer is t&e (oal-)low +eman+ to t&e #rimar$ air )ans. '&e se(on+ar$ (ontrol is t&e (oal-air mi0ture tem#erature. '&e (oal-air tem#erature (ontrol is im#ortant- )or it re%ulates t&e amount o) sur)a(e moisture remainin% in t&e )ines %oin% to t&e burner. '&e sur)a(e moisture a+*ersel$ a))e(ts bot& #ul*eriJer #er)orman(e an+ t&e (ombustion #ro(ess b$ u# to 0 #er(ent. In-mill +r$in% is t&e a((e#te+ met&o+ )or #re#arin% (oal )or burnin%. B$ measurin% t&e tem#erature in t&e #ul*eriJer outlet #i#es- t&e (ontrols are able to re%ulate t&e amounts o) &ot air an+ tem#erin% air to #ro*i+e a+e6uate +r$in%. '&e outlet tem#erature (ontroller set#oint is usuall$ ran%e+ between 140 170 +e%rees Fa&ren&eit- +e#en+in% on w&at t$#e o) )uel is burne+. A sin%le set#oint (ontrols bot& t&e &ot an+ tem#erin% air-+am#er a(tuators. Sele(tin% too &i%& a set#oint (oul+ (reate a &aJar+ous (on+ition be(ause t&e (oal is too +r$ an+ *er$ *olatile. Sele(tin% too low a set#oint- t&e (oal will not )low as (leanl$ in t&e (oal #i#es- t&ere)ore (ausin% (oal-#i#e #lu%%in%. '&ere)ore a #ul*eriJerSs out#ut is limite+ b$ its +r$in% (a#a(it$ an+ not its %rin+in% abilit$. B.?.4 Re"eren#e "or 8ulveriFer #ontrol '&e #ul*eriJer manu)a(turer is t&e #rime sour(e )or in)ormation (on(ernin% re(ommen+e+ (ontrol strate%ies. B.10 )ual Fuel Firin;

A meterin%-t$#e (ontrol strate%$ )or a boiler (a#able o) +ual )uel )irin% simultaneousl$ &as to a((ount )or t&e total )urna(e &eat in#ut an+ +i))erent )uel5air ratios. A t$#i(al +ual )uel )irin% strate%$ is s&own in Fi%ure B.K. '&e basi( strate%$ o) t&e boiler ener%$ +eman+ establis&in% t&e total )uel +eman+ to t&e boiler an+ )uel-to-air ratio on a boiler basis is to be satis)ie+. 1ual )irin% ma$ in(lu+e one or more o) t&e )ollowin% o#eratin% mo+es: a/ 2ne )uel in manual wit& se(on+ )uel automati(all$ )ollowin% boiler ener%$ +eman+. b/ 2ne )uel in automati( wit& o#erator )low set#oint wit& se(on+ )uel automati(all$ )ollowin% boiler ener%$ +eman+. (/ Bot& )uels automati(all$ )ollowin% boiler ener%$ +eman+.

I) bot& )uels are )ollowin% a boiler ener%$ +eman+- t&en an o#erator a+7ustable )uel ratio setter +etermines t&e ratio o) )uel bein% )ire+. ,nless bot& )uels are automate+ to )ollow t&e boiler ener%$ +eman+- t&e )uel ratio setter will tra(4 t&e a(tual )uel-)low ratio. 8eterin% s$stems measure t&e a(tual )uel an+ air +eli*ere+ to t&e boiler. '&e measure+ )lows are use+ in )ee+ba(4 (ontrol s(&emes to #re(isel$ re%ulate t&e )uel +eman+ an+ to establis& a (ross-limite+ minimum air)low +eman+. '&e )uel )low in a %as or oil boiler (an also be rea+il$ measure+. Fuel )low in a (oal-)ire+ boiler (annot be +ire(tl$ measure+- an+ *arious s(&emes &a*e been +e*elo#e+ to in)er t&e )uel +eli*er$ rate base+ on ot&er *ariables. In a++ition- t&e &ea*$ e6ui#ment ne(essar$ to trans#ort t&e (oal an+ #re#are it )or burnin% #resent +$nami( o#erational an+ (ontrol #roblems. Air)lows (an be measure+ wit&out too mu(& +i))i(ult$. Air)low is use+ in a )ee+ba(4 (ontrol s(&eme to #re(isel$ re%ulate t&e air +eman+ an+ to establis& a (ross-limite+ ma0imum )uel-)low +eman+. '&e air)low must be (&ara(teriJe+ to t&e (orres#on+in% )uel +eman+ in t&e air)low +eman+ +e*elo#ment or in t&e )ee+ba(4 si%nal- but not bot&. A&en )irin% +ual )uels simultaneousl$- t&e air)low +eman+ is to be (&ara(teriJe+ base+ on t&e ratio o) )uels bein% )ire+ to establis& t&e (orre(t )uel-to-air ratio. '&e )uel-to-air ratio is a+7uste+ b$ an e0(ess air )ee+ba(4 loo#. '&e e0(ess air loo# (an a+7ust t&e air)low +eman+ or air)low )ee+ba(4 si%nal- but not bot&. A&en )irin% +ual )uels simultaneousl$- t&e o0$%en set#oint is (om#ute+ base+ on t&e ratio o) bot& )uels.

ANSI/ISAd77.41.01-2010

30

'&is #a%e intentionall$ le)t blan4

 29

ANSI/ISA-77.41.01-2005

ANSI/ISAd77.41.01-2010

31

Copyright 2005 ISA. All rights reserved.

Copyright 2010 ISA. All rights reserved

'&is #a%e intentionall$ le)t blan4

 33

ANSI/ISAd77.41.01-2010

Anne@ C ( Fault toleran#e

'&is a##en+i0 is in(lu+e+ )or in)ormation #ur#oses an+ t&ere)ore is not (onsi+ere+ a #art o) ANSI5ISA 77.41.01-2010. '&e abilit$ o) a (ombustion (ontrol s$stem to tolerate )ailures an+ still #ro*i+e an a((e#table le*el o) #er)orman(e is in)luen(e+ b$ t&e userPs +e(isions re%ar+in% s$stem +esi%n. '$#i(all$- t&e *en+orPs &ar+ware is mo+ular an+ (an be (on)i%ure+ in man$ )orms. '&e wa$ t&e s$stem +esi%n utiliJes t&ese mo+ules &as a si%ni)i(ant e))e(t on t&e abilit$ o) o*erall s$stems to tolerate )ailures. A (are)ul re*iew o) t&e entire s$stem is ne(essar$ to +etermine t&e e))e(t o) e6ui#ment )ailures an+ t&e abilit$ o) t&e o#erator to (ontinue o#erations.

C.1 2eo;ra8Ci# distribution

Ceo%ra#&i( +istribution results )rom #la(in% t&e &ar+ware .(ontrollers- +ata a(6uisition mo+ules- #ower su##lies- et(./ in #&$si(all$ remote areas o) t&e #lant an+ (onne(tin% t&em *ia a +i%ital (ommuni(ations networ4. '&is &ar+ware is normall$ #la(e+ in a (on*enient lo(ation (lose to t&e e6ui#ment bein% monitore+ or (ontrolle+. A&ile %eo%ra#&i( +istribution ma$ en&an(e reliabilit$- it will also re6uire a++itional e))ort an+ e0#ense i) re+un+ant #ower sour(es- air-(on+itione+ en*ironments- or re+un+ant (ommuni(ation (&annels are ne(essar$. 2)ten- %eo%ra#&i( +istribution is use+ to re+u(e wirin% (osts or relie*e o*er(row+e+ e6ui#ment rooms.

C.! Fun#tional distribution

'&e %oal o) )un(tional +istribution is to limit t&e e))e(ts o) a &ar+ware )ailure to an a((e#table le*el. B$ #artitionin% t&e s$stem into mo+ules- t&e e))e(t o) a sin%le &ar+ware )ailure is minimiJe+ to #re+e)ine+ situations. All o) t&e elements o) a s#e(i)i( (ontrol tas4 .i.e.- )urna(e #ressure- #ul*eriJer A- et(./ are se%re%ate+ into a mo+ule (a#able o) in+e#en+ent o#eration. 9a(& mo+ule s&oul+ be (a#able o) (ontinue+ o#eration at some minimal le*el wit&out +e#en+in% on in#uts )rom ot&er mo+ules. As#e(ts to be (onsi+ere+ are t&e #ower sour(e.s/- transmitters- o#erator inter)a(e- in#ut5out#ut (ir(uits(ommuni(ations lin4s- an+ (om#utational re6uirements.

C.9 Fail-sa"e 8ositionin;

Final +ri*e units must be e*aluate+ to +etermine t&e #re)erre+ )ailure mo+e u#on loss o) moti*e #ower. 8ost +ri*e units (an be sele(te+ to )ail o#en- )ail (lose+- or )ail in #la(e. In a++ition- t&e e))e(t o) t&e loss o) t&e +ri*in% si%nal must be (onsi+ere+. In some (ases- air-to-(lose .or in(reasin% (urrent-to-(lose/ +am#ers are #re)erre+.

C.4 Redundant #om8onent

'&e mo+ular +esi%n o) most *en+orsP e6ui#ment allows t&e user to ta4e a buil+in%-blo(4 a##roa(& to sele(tin% (om#onents. 8o+ules (an be a++e+ or +elete+ as nee+e+. In most (ases- t&e number o) in#uts- out#uts- an+ (om#utational #ower is )le0ible wit&in (ertain limits. '&is allows t&e user to a++ re+un+ant mo+ules to a(&ie*e t&e +esire+ le*el o) )ault toleran(e. C.4.1 Power su88lies Power su##lies +ri*en )rom se#arate #rimar$ )ee+s s&oul+ be (onsi+ere+- es#e(iall$ )or o#erator inter)a(e (onsoles. 9a(& #ower su##l$ s&oul+ be (a#able o) (ontinuous o#eration in t&e e*ent o) )ailure o) t&e ot&er. Batter$ ba(4u# or ,PS are o#tions.

Copyright 2010 ISA. All rights reserved.

ANSI/ISAd77.41.01-2010 C.4.! Communi#ations

34

As a minimum- t&e (ommuni(ation (&annels s&oul+ be re+un+ant. I) #ortions o) t&e s$stem are %eo%ra#&i(all$ +istribute+- se#arate (able routes s&oul+ be (a#able o) (ontinuous o#eration in t&e e*ent o) )ailure o) t&e ot&er. C.4.9 Controllers 3e+un+ant (ontrollers (an be utiliJe+ in a 1-to-1 (on)i%uration or in a 1-to-N (on)i%uration. In t&e 1-to-1 (on)i%uration- ea(& (ontroller &as a ba(4u# (ontroller. In t&e 1-to-N (on)i%uration- one ba(4u# (ontroller monitors t&e o#eration o) se*eral (ontrollers an+ automati(all$ re#la(es t&e )un(tions o) a )aile+ unit but (annot su##ort multi#le (ontroller )ailures. C.4.4 &8erator inter"a#e Console units- manual5automati( stations .i.e.- &ar+ or so)t stations/- an+ )ailure mo+es must be (onsi+ere+ to%et&er w&en e*aluatin% o#erator inter)a(es. No )irm rules e0ist )or minimum re6uirements (on(ernin% re+un+an($. '&e %oal s&oul+ be to maintain t&e o#eratorPs abilit$ to (ontrol t&e boiler in s#ite o) an$ e6ui#ment )ailures. 8ulti#le- )un(tionall$ in+e#en+ent (onsole units ma$ be #re)erre+ to a sin%le (onsole wit& manual5automati( stations ser*in% as ba(4u#. I) multi#le (onsole units are use+ to a(&ie*e re+un+an($- t&e (onsoles s&oul+ be as in+e#en+ent as #ossible wit& +ue re%ar+ to e(onomi(s an+ (on*enien(e. As a %ui+eline- a sin%le e6ui#ment )ailure or loss o) a #ower sour(e s&oul+ not #re*ent t&e o#erator )rom res#on+in% to emer%en($ situations. ?ar+ manual5automati( stations &a*e tra+itionall$ been (onsi+ere+ R)ail-sa)eR (om#onents. ?owe*ermanual5automati( stations ma$ in(or#orate a si%ni)i(ant number o) ele(troni( (om#onents t&at must remain )un(tional )or t&e o#erator to &a*e R&ar+ manualR (ontrol o) t&e #ro(ess. Stron% (onsi+eration s&oul+ be %i*en to t&e use o) a(tual )inal element #osition t&rou%& t&e #osition )ee+ba(4 sensors )or +is#la$ on 85A stations an+ )or use in t&e o#eration o) t&e (ombustion (ontrol s$stem in lieu o) R+eman+ out#ut.R C.4.< Field devi#es Fiel+ +e*i(e re+un+an($ s&oul+ be #ro*i+e+ to t&e e0tent ne(essar$ to a(&ie*e t&e re6uire+ reliabilit$ an+ meet t&e re6uirements o) t&e stan+ar+. In most (ases- t&is re6uires a (ase-b$-(ase (onsi+eration o) (riti(al #arameters.

Copyright 2010 ISA. All rights reserved.

1e*elo#in% an+ #romul%atin% soun+ (onsensus stan+ar+s- re(ommen+e+ #ra(ti(es- an+ te(&ni(al re#orts is one o) ISASs #rimar$ %oals. 'o a(&ie*e t&is %oal- t&e Stan+ar+s an+ Pra(ti(es 1e#artment relies on t&e te(&ni(al e0#ertise an+ e))orts o) *olunteer (ommittee members- (&airmen- an+ re*iewers. ISA is an Ameri(an National Stan+ar+s Institute .ANSI/ a((re+ite+ or%aniJation. ISA a+ministers ,nite+ States 'e(&ni(al A+*isor$ Crou#s .,S'ACs/ an+ #ro*i+es se(retariat su##ort )or International 9le(trote(&ni(al Commission .I9C/ an+ International 2r%aniJation )or Stan+ar+iJation .IS2/ (ommittees t&at +e*elo# #ro(ess measurement an+ (ontrol stan+ar+s. 'o obtain a++itional in)ormation on t&e So(iet$Ss stan+ar+s #ro%ram- #lease write: ISA Attn: Stan+ar+s 1e#artment !7 Ale0an+er 1ri*e P.2. Bo0 12277 3esear(& 'rian%le Par4- NC 2770" ISBN: 1!17-"!!-"