Boiler Control Solution
Boiler Control Solution
Instruments and Solution for
Automatic Boiler Control
LF3BUSS02-00EN
www.yokogawa.com
Best Solution for Automatic Boiler C
Sensors and controllers for the efficiency and environmental performance
Essential Equipments for Industries
Drum Level Measurement
Boilers are used in a broad range of industries such as electric power, pharmaceuticals, chemicals, ceramics, and paper and
pulp. Amid the rising energy costs, tightening environmental regulations, and increasing awareness of safety as of late, the needs
for high efficiency operation, low emission
operation, and safe and stable operation of
boilers are growing.
Overview and
Problems
• Drum level
measurement
• High stability
measurement
required under large
static pressure
change
Increasing Efficiency and Lowering
Emissions of Boilers
In order to ensure the air and fuel are combusted at an optimal ratio, the waste of fuel
is eliminated, and the exhaust gas is
cleaned, real-time monitoring of the oxygen
concentration of combustion gases is required. Equipped with an oxygen sensor
unit with a longer life span, the Zirconia
Oxygen Analyzer ZR series are capable of
measuring an oxygen concentration with
high reliability. The Stack Gas Analyzer
SG700 monitors exhaust gas components
such as NO x, SO 2, and CO 2 in order to ensure low emission operation.
EJX
EJA
Solution
Benefits
• Field proven silicon resonant
sensor guarantees long term
stability
EJA: 0.1 % of URL 5 years
EJX: 0.1 % of URL 10 years
Under all conditions
(temperature, static and over
pressures)
• Long term high
stability measurement
is realized under
actual plant conditions
Safe and Stable Operation
A single-loop controller can be used to properly distribute control functionality. Offering
the advantages of flexibility of building distributed control systems, simple maintenance, compatibility with conventional systems, and the like, the YS1000 Series of
Single-loop Controllers are ideal for safe and
stable operation at low costs.
Combustion Control
Overview and Problems
• Perform safe and stable control at
low cost
• Lower levels of emission output
Monitoring the drum level and steam
flow rate in accurate at any conditions
In order to ensure highly efficient and safely
operated boilers, it is also indispensable to
accurately monitor the drum level and
steam flow rate. The EJA and EJX Series of
Differential Pressure Transmitters are capable of measuring the drum level with high
stability even in actual applications at high
temperatures and high pressures. The DY
Series MV TYPE of Vortex Flowmeters with
a simple construction employ a built-in sensor to measure the steam mass flow with
high reliability.
Why Buy Yokogawa?
Yokogawa offers a wide variety of sensors
and controllers that are used to monitor and
operate boilers, and contributes to increasing the efficiency and environmental performance of boilers, as well as ensuring their
safe and stable operation.
We want you to explore Yokogawa's sensors and controllers in order to increase the
efficiency and environmental performance
of your boilers, and ensure their safe and
stable operation.
Solution
YS1000
• Simple programming by Function
Block wiring method
• Cascade primary direct control
- Stable level control when boiler
is started
• Cross limit control calculation
- Air and flow are calculated so
that air flow always exceed fuel
flow to prevent incomplete
combustion and explosion
• Feed forward control
- The main stream pressure and
feed water level are controlled
quickly in response to changes
in the main stream flow
Benefits
• Reduced debugging time
• Improvement of the reliability of
programs
• Safe and stable control at low
cost
Control
Steam Flow Measurement
Overview and Problems
• Flow measurement for utility steam
• Conventional orifice flowmeter requires complicated, high cost installation and is not
accurate
Solution
• Inline flowmeter
• Built-in temperature sensor, Digital YEWFLO MV type
• Steam mass flow measurement without additional temperature sensor/transmitter and
flow computer
• Accuracy 2 % of reading
Benefits
DY MV TYPE
• Low installation and operational costs
• Safety operation to reduce leakage points
• Save energy by accurate measurement
(Boiler master)
Main steam pressure control
Feed water level control
Fx
PV1
FF
Cascade
PRD control
PV2
PV
FF
Steam
Drum
level
SV
Air flow control
Main
steam
pressure
Main
steam
flow
Feed water
SV
Fuel flow control
PV
PV
Exhaust
gas oxygen
concentration
control
Fx
SV
Fuel oil
Fuel oil flow
Air flow
Air
Oxygen
Exhaust
concentration gas
Exhaust
Gas Monitor
E
S
lectrolyzer
olution
Combustion Control
Overview and Problems
• O2 control for optimum combustion
• Short sensor life by clogging
Solution
• Long life sensor with molecular bonding and special coating
• Cell life prediction
Benefits
ZR402G
ZR22G/S
• Fuel cost reduction
• Preventive maintenance
• Protect the environment, CO2 reduction
Combustion Control
Overview and Problems
• O2 control for optimum combustion of large-sized combustion equipment
• High installation cost for multipoint measurement
Solution
• Maximum 8 detectors can be connected to one AV550G converter
• O2 measurement of
multiple points, individual
concentration and average values
Benefits
Handles input of up to
8 oxygen detectors
• Accurate control by multipoint
measurement
• Installation cost reduction
C02
3.0%02
2.8%02
2.4%02
H20
H20
02
02
3.0%02
3.0%02
2.6%02
C02
C02
02
Large combusion facilities (Image)
Averaging Converter
AV550G
Exhaust Gas Analysis
Overview and Problems
• Air pollution control by continuous emissions monitoring
• High maintenance frequency
Solution
• Simultaneous measurement of up to five components, NOx, SO2,
CO, CO2, O2
• Sample conditioning system designed to reduce maintenance
• No moving parts in the sensor
Benefits
SG700
• Stable, long-term measurement
• High accuracy to suit the environmental regulations
Technologies Commit Users’ Benefits
Our Goal
Our shared goal is customer satisfaction through operational excellence.
Yokogawa has brought true innovations to industry. We are committed to ensuring accuracy,
reliability, and safety of your production system throughout your business life cycle. Our comprehensive solutions and expertise help you achieve more results with less total costs of ownership. Below key technologies shall aim for your operational excellence.
YS1000 Dual CPU
EJA/EJX Silicone Resonant Sensor
By micro-machining the
resonators directly within
the single crystal silicon
material we are able to
derive the maximum benefits from the elasticity of
the single crystal silicon
material while enhancing
sensitivity and repeatability. The properties of
the resonators remain constant over time.
This makes DPharp the ideal pressure sensor
for harsh industrial automation environments.
DPharp delivers stability, repeatability and reliability that you can rely on.
W i t h d u a l - C P U c o nstruction, manual control
capability and display
Gate Array
continues even if an abnormality occurs on one
of the CPUs. If controller
CPU
self-diagnostics detects
a control circuit failure,
the controller can suspend analog/digital output, switch to manual
mode and allow manual control by operator.
CPU
Zirconia Oxygen Analyzers
(+) Preference gas
contact part
DY Key Technology
Ceramic
Conductor
(+) Electrode on
reference side
(-) Sample gas contact part
-Spectral Signal Processing (SSP)Spectral Signal Processing (SSP) technology
is built into the powerful electronics of the digitalYEWFLO vortex flowmeter, enabling new
functions. SSP analyses the fluid conditions
inside the digitalYEWFLO vortex flowmeter
and uses the data to automatically select the
optimum adjustment for an application, providing features never seen before in vortex
flowmeters.
Input signal
Frequency analysis (SSP function)
Judged to be
noise
Removed
Judged to be
vortex signal
Output
Judged to be
noise
Removed
Bolt
Calibration
gas pipe
Metal O-ring
- Get a long service life
and stable operation
with a Zirconia sensor
- sensor replacement
is easy
• A molecular bonding
method completes installation of platinum
Cell
Screen
electrodes, and its inBracket
herent connection prevents separation of
platinum from the Zirconia element.
• A lead-less electrode design eliminates electrical disconnection.
• Special coating protects the platinum and
prevents the sensors from deteriorating.
• No special tool is required for cell replacement.
A
D
O
For Your Operational Excellence
Temperature Transmitter
Direct In Situ Zirconia Oxygen Analyzers
ZR402G
YTA Series
• High resolution, high stability and
high versatility
• Dual compartment housing for
harsh environments
• SIL2 safety as standard feature
• Fieldbus communication capability
Pressure Transmitter
ZR402/ZR202
ZR22G/S
ZR202G/S
• Measurement with probe directly
inserted into furnace or boiler
• Integrated and separate types available.
• Also can be used as a high
temperature humidity analyzer
• Fully field-repairable probe
• HART communication
• Explosion proof (FM, CSA, ATEX)
(ZR22S, ZR202S)
Averaging Converter
DPharp EJA/EJX Series
AV550G
•
•
•
•
•
• Capable of accepting inputs from
up to 8 oxygen detectors and 8
individual outputs are available
• Averaging of multiple point
oxygen measurements is ideally
suited for combustion control
Best installed performance
Compact and rugged design
Multi-Sensing digital sensor
SIL2 as standard (EJX)
Fieldbus communication capability
Stack Gas Analyzing System
DigitalYEWFLO Vortex Flowmeters
• Best-in-class accuracy
• Superior stability though the unique
digital electronics SSP technology
• Complete range for temperature
and pressure
• Multivariable availability with
optional temperature sensor
• Fieldbus communication capability
SG700
• A complete self standing cabinet
including IR400 infra-red analyzer
and the sample conditioning
system
• Simultaneous measurement of up
to five components, NOx, SO2,
CO, CO2, O2
Single Loop Controller
YS1000 Series
•
•
•
•
•
Two programming method
High reliability
Compact and light weight
Expandable I/O
Compatible with YS170 and
SLPC
ADMAG AXF and DAQMASTER are registered trademark of Yokogawa Electric Corporation.
DPharp is a trademark of Yokogawa Electric Corporation. Ethernet is a registered trademark of Xerox Corporation.
Other company names and product names appearing in this document are registered trademarks or trademarks of their respective holders.
YOKOGAWA ELECTRIC CORPORATION
YOKOGAWA CORPORATION OF AMERICA
YOKOGAWA EUROPE B.V.
YOKOGAWA ENGINEERING ASIA PTE. LTD.
Phone: (81)-422-52-6329,
Phone: 800-888-6400,
Phone: (31)-88-4641000,
Phone: (65)-62419933,
Subject to change without notice.
All Rights Reserved, Copyright© 2008, Yokogawa Electric Corporation.
Fax: (81)-422-52-6619
Fax: (1)-770-251-6427
Fax: (31)-88-4641111
Fax: (65)-62412606
Printed in Japan, 904(KP) [Ed : 01/b]
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