4BE3.5 U3 C5 Obj 1 EMH
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EASY What is the primary purpose of pressure limit controls in steam boilers?

  • To increase the steam pressure
  • To measure the steam pressure
  • To produce supersaturated steam
  • To reduce or stop the energy input (correct)
  • What is the measured variable in steam boiler control systems?

  • Fuel flow
  • Steam pressure (correct)
  • Water temperature
  • Airflow
  • What is the final control element in steam boiler control systems?

  • Pressure limit control
  • Combustion air dampers (correct)
  • Firing rate control valve (correct)
  • Safety valves
  • What happens when there is more heat energy entering the hot water boiler than needed by the equipment?

    <p>The temperature rises</p> Signup and view all the answers

    What is the primary purpose of temperature limit controls in hot water boilers?

    <p>To reduce or stop the energy input</p> Signup and view all the answers

    What is the measured variable in hot water boiler control systems?

    <p>Outlet water temperature</p> Signup and view all the answers

    What is the process variable in hot water boiler control systems?

    <p>Hot water supply temperature</p> Signup and view all the answers

    What is the control strategy used in two-position firing rate control?

    <p>On-Off</p> Signup and view all the answers

    What happens when the burner is on in two-position control?

    <p>The burner generates too much heat for the load demand</p> Signup and view all the answers

    What is the purpose of the operating cycle in two-position control?

    <p>To start and shut off the burner</p> Signup and view all the answers

    Why do on-off boilers experience significant loss of heat?

    <p>Due to the furnace draft carrying heat away from the boiler and up the chimney</p> Signup and view all the answers

    What is the main advantage of operating boilers continuously?

    <p>To reduce heat losses</p> Signup and view all the answers

    What type of control system is used in smaller capacity boilers?

    <p>On-off control</p> Signup and view all the answers

    What is the main difference between multi-position control and on-off control?

    <p>The number of operating pressure controls used</p> Signup and view all the answers

    What is the purpose of the low-fire control in a multi-position firing rate control?

    <p>To control the low-fire burner</p> Signup and view all the answers

    What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?

    <p>The high-fire burner starts</p> Signup and view all the answers

    What is the advantage of multi-position firing rate control over on-off control?

    <p>It reduces heat losses due to repeated purging</p> Signup and view all the answers

    What is the purpose of the two operating pressure controls in a multi-position firing rate control?

    <p>To control the high-fire and low-fire burners</p> Signup and view all the answers

    What happens to the average steam pressure as the load increases in a multi-position firing rate control?

    <p>It decreases</p> Signup and view all the answers

    What is the difference between the operation of multi-position firing rate control in steam boilers and hot water boilers?

    <p>The operating principle</p> Signup and view all the answers

    What is the primary focus of this chapter?

    <p>Boiler-firing circuits</p> Signup and view all the answers

    What is the purpose of high limit controls in firing rate controls?

    <p>To shut off the burner in case of an operating control failure</p> Signup and view all the answers

    What is the primary goal of firing rate controls?

    <p>To maximize boiler operating efficiency</p> Signup and view all the answers

    What happens when there is greater heat energy entering the boiler than required by the equipment?

    <p>The boiler pressure rises</p> Signup and view all the answers

    What is the consequence of a steam boiler continuing to fire at an excessive rate?

    <p>The boiler will over-pressurize and may explode</p> Signup and view all the answers

    What is the purpose of firing rate controls in boilers?

    <p>To adjust to varying load demands</p> Signup and view all the answers

    What is the reference code for automatically fired boilers?

    <p>ASME CSD-1</p> Signup and view all the answers

    What is the energy output of a boiler equal to?

    <p>The energy demand</p> Signup and view all the answers

    What is the function of the high-fire control?

    <p>To directly actuate the combustion air damper</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch?

    <p>To limit the firing rate during warm-up</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control?

    <p>It provides the highest efficiency and closest set point adherence</p> Signup and view all the answers

    How many pressure controls are required for steam boilers with fully modulating firing rate control?

    <p>Three</p> Signup and view all the answers

    What is the function of the resistance slide-wire control?

    <p>To position the modulating motor</p> Signup and view all the answers

    What happens when the boiler pressure rises to 65 kPa?

    <p>The firing rate drops to its minimum</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off control?

    <p>To cut off the burner above a certain pressure</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control in terms of plant efficiency?

    <p>It reduces purge losses</p> Signup and view all the answers

    How many controls are required for hot water boilers with fully modulating firing rate control?

    <p>Three</p> Signup and view all the answers

    What is the purpose of the operating pressure control?

    <p>To activate a call for heat</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off in a steam boiler?

    <p>To prevent generation of steam pressure above the maximum allowable working pressure</p> Signup and view all the answers

    What type of control devices are used in steam boilers?

    <p>Pressure-actuated two-position single-pole, single-throw switches</p> Signup and view all the answers

    What is the purpose of the resistance slide-wire pressure control in a fully modulating firing rate control?

    <p>To position the modulating motor</p> Signup and view all the answers

    What is required when starting up a cold boiler with a fully modulating firing rate control?

    <p>The boiler must be limited to low-fire until the boiler is sufficiently warm</p> Signup and view all the answers

    What is the function of the programming controller in a fully modulating firing rate control?

    <p>To enable modulation only when in RUN mode</p> Signup and view all the answers

    What is the purpose of the operating pressure control in a steam boiler?

    <p>To shut off the fuel supply when the steam pressure reaches a preset maximum operating pressure</p> Signup and view all the answers

    What type of sensors are used in hot water boilers to control the firing rate of fully modulating burners?

    <p>Variable resistance temperature-actuated sensors</p> Signup and view all the answers

    What is required by ASME CSD-1 Part CW-310 for automatically fired steam boilers?

    <p>At least one steam pressure control device that will shut off the fuel supply to each boiler</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?

    <p>To limit the firing rate to low-fire during warm-up</p> Signup and view all the answers

    What is the difference between a two-position control device and a fully modulating control device?

    <p>Two-position control devices do not modulate, while fully modulating control devices do</p> Signup and view all the answers

    What is the minimum difference required between the HPCO setting and the safety valve setting?

    <p>480 kPa</p> Signup and view all the answers

    What type of switch is used in a two-position temperature control device?

    <p>Single-pole, single-throw</p> Signup and view all the answers

    What is the minimum size of a siphon required to protect a pressure control device?

    <p>DN 8 (NPS ¼)</p> Signup and view all the answers

    What is the requirement for automatically fired hot water boilers according to ASME CSD-1 Part CW-410?

    <p>At least one temperature-actuated control</p> Signup and view all the answers

    What causes the bellows to expand in a mercury switch pressure control?

    <p>Increasing boiler pressure</p> Signup and view all the answers

    What is the result of small cracks in the glass of a mercury switch?

    <p>The mercury loses its lustre and may appear rusty</p> Signup and view all the answers

    What happens when the high-temperature limit control is activated?

    <p>The boiler shuts down and requires manual reset</p> Signup and view all the answers

    What is the purpose of the operating temperature control?

    <p>To shut off the fuel supply when the system water reaches a preset operating temperature</p> Signup and view all the answers

    What happens when the steam pressure falls?

    <p>The firing rate increases</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off (HPCO)?

    <p>To shut off the burner when the operating pressure control fails</p> Signup and view all the answers

    What is the difference between the operating temperature control and the high temperature cut-off?

    <p>The HTCO does not have a differential adjustment and has a manual reset button</p> Signup and view all the answers

    What is the difference between the HPCO and the operating pressure control?

    <p>The HPCO has a manual reset button</p> Signup and view all the answers

    What is the purpose of the MAN-AUTO control station?

    <p>To interrupt the control signal</p> Signup and view all the answers

    What is the recommended HPCO set point for steam heating boilers?

    <p>90 kPa</p> Signup and view all the answers

    What is the function of the bellows in the operating temperature control?

    <p>To activate the switch at the controller set point</p> Signup and view all the answers

    What is the function of the crank arms in smaller packaged boilers?

    <p>To operate the fuel valve</p> Signup and view all the answers

    What is the purpose of the thermowell in the operating temperature control?

    <p>To house the thermometer-sensing bulb</p> Signup and view all the answers

    What is the advantage of using two modulating motors in larger boilers?

    <p>To control the air and fuel flow separately</p> Signup and view all the answers

    What is the purpose of the differential adjustment in a pressure control?

    <p>To adjust the control differential</p> Signup and view all the answers

    What is the maximum temperature setting for the operating temperature control shown in Figure 15(a)?

    <p>115°C</p> Signup and view all the answers

    What is the purpose of the adjustable cam in the fuel valve?

    <p>To fine-tune the combustion conditions</p> Signup and view all the answers

    What happens when the HPCO activates?

    <p>The firing circuit is opened</p> Signup and view all the answers

    What is the result of the operator not intervening after the HPCO activates?

    <p>The burner remains shut off</p> Signup and view all the answers

    What is the purpose of the differential switch in the high-low fire control?

    <p>To adjust the inter-stage temperature differential</p> Signup and view all the answers

    What is the result of the opposite sequence occurring in the boiler?

    <p>The firing rate increases</p> Signup and view all the answers

    Why is the HPCO set point higher than the operating pressure control?

    <p>To avoid unnecessary lockouts</p> Signup and view all the answers

    What is the purpose of a modulating pressure control in steam boilers?

    <p>To adjust the firing rate to match the boiler load</p> Signup and view all the answers

    What is the function of the manual flame control potentiometer in a modulating controller?

    <p>To allow the firing rate to be kept at low-fire during warm-up periods</p> Signup and view all the answers

    What is the purpose of the proportional range setting in a modulating temperature control?

    <p>To control how closely the boiler pressure tracks the set point</p> Signup and view all the answers

    What happens when the steam pressure rises above the set point in a modulating pressure control?

    <p>The modulating motor drives to the closed position</p> Signup and view all the answers

    What is the function of the balancing relay in a modulating motor?

    <p>To balance the circuit and control the modulating motor</p> Signup and view all the answers

    What is the purpose of the bridge circuit in a modulating motor?

    <p>To balance the circuit</p> Signup and view all the answers

    What is the function of the feedback potentiometer in a modulating motor?

    <p>To provide feedback to the modulating controller</p> Signup and view all the answers

    Why is a manual-automatic switch required in a modulating controller?

    <p>To permit low-fire operation when the boiler is cold</p> Signup and view all the answers

    What is the purpose of the MIN setting in a modulating pressure control?

    <p>To provide the finest pressure control</p> Signup and view all the answers

    What happens when the boiler is in manual mode and the modulating controller is enabled?

    <p>The control of the modulating motor is transferred to the manual flame control potentiometer</p> Signup and view all the answers

    What is the primary goal of firing rate controls in boilers?

    <p>To maximize boiler operating efficiency</p> Signup and view all the answers

    What happens when there is less heat energy entering the boiler than required by the equipment?

    <p>The boiler pressure falls</p> Signup and view all the answers

    What is the primary purpose of safety valves in steam boilers?

    <p>To reduce the energy input when the pressure limit controls fail</p> Signup and view all the answers

    What happens when there is less heat energy entering the hot water boiler than needed by the equipment?

    <p>The boiler temperature falls</p> Signup and view all the answers

    What is the primary difference between steam boilers and hot water boilers?

    <p>The type of sensors used</p> Signup and view all the answers

    What is the purpose of the combustion air dampers in steam boiler control systems?

    <p>To manipulate the fuel flow</p> Signup and view all the answers

    What is the advantage of using a multi-position firing rate control over a two-position firing rate control?

    <p>It is more efficient</p> Signup and view all the answers

    What is the purpose of the firing rate control valve in steam boiler control systems?

    <p>To manipulate the fuel flow</p> Signup and view all the answers

    What happens when a hot water boiler continues to fire at an excessive rate and this condition goes unchecked?

    <p>The boiler produces supersaturated hot water and over-pressurizes</p> Signup and view all the answers

    What is the purpose of the automatic control system in steam boiler control systems?

    <p>To maintain a steam pressure set point</p> Signup and view all the answers

    What is the advantage of using a fully modulating firing rate control over a multi-position firing rate control?

    <p>It is more efficient</p> Signup and view all the answers

    What is the purpose of the temperature limit controls in hot water boilers?

    <p>To maintain a hot water temperature set point</p> Signup and view all the answers

    What is the purpose of the low-fire control in a fully modulating firing rate control?

    <p>To limit the firing rate to low-fire during warm-up</p> Signup and view all the answers

    What happens when the boiler pressure rises to 65 kPa in a fully modulating firing rate control?

    <p>The firing rate decreases to low-fire</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control over on-off control?

    <p>Increased efficiency due to reduced purge losses</p> Signup and view all the answers

    MEDIUM What is the function of the resistance slide-wire control in a fully modulating firing rate control?

    <p>To position the modulating motor in response to the error between the control set point and the boiler pressure</p> Signup and view all the answers

    What is required when starting up a cold boiler with a fully modulating firing rate control?

    <p>To limit the firing rate to low-fire during warm-up</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off control in a steam boiler?

    <p>To shut off the burner when the boiler pressure exceeds a set point</p> Signup and view all the answers

    How many pressure controls are required for steam boilers with fully modulating firing rate control?

    <p>3</p> Signup and view all the answers

    What is the purpose of the operating pressure control in a steam boiler?

    <p>To call for heat when the boiler pressure is below a set point</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control in terms of plant efficiency?

    <p>Reduced purge losses</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?

    <p>To limit the firing rate to low-fire during warm-up</p> Signup and view all the answers

    Why do boilers, regardless of the firing rate control system used, operate more efficiently continuously?

    <p>Because it minimizes the heat losses due to frequent cycling</p> Signup and view all the answers

    What is the primary reason why two-position control is only used in smaller capacity boilers?

    <p>Because temperature and pressure swings are unacceptable in larger plants with more stringent pressure and temperature requirements</p> Signup and view all the answers

    What is the purpose of the low-fire control in a multi-position firing rate control?

    <p>To reduce the firing rate when the load demand is low</p> Signup and view all the answers

    What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?

    <p>The high-fire burner starts</p> Signup and view all the answers

    What is the advantage of multi-position firing rate control over on-off control?

    <p>Multi-position control reduces heat losses caused by repeated purging</p> Signup and view all the answers

    What happens to the average steam pressure as the load increases in a multi-position firing rate control?

    <p>It decreases</p> Signup and view all the answers

    What is the purpose of the two operating pressure controls in a multi-position firing rate control?

    <p>To control the high-fire and low-fire burners</p> Signup and view all the answers

    What is the difference between the operation of multi-position firing rate control in steam boilers and hot water boilers?

    <p>Steam boilers use two operating pressure controls, while hot water boilers use two operating temperature controls</p> Signup and view all the answers

    Why do on-off boilers experience significant loss of heat?

    <p>Because they cycle more often, resulting in heat losses due to frequent purging</p> Signup and view all the answers

    What is the main advantage of operating boilers continuously?

    <p>It minimizes the heat losses due to frequent cycling</p> Signup and view all the answers

    What is the primary purpose of a siphon in a pressure control device?

    <p>To prevent steam from entering the control</p> Signup and view all the answers

    What happens when the desired cut-off pressure is reached in a mercury switch pressure control?

    <p>The electrical circuit for the combustion system opens</p> Signup and view all the answers

    Why are mercury switches no longer manufactured?

    <p>Because they are prone to failure due to oxidation</p> Signup and view all the answers

    What is the primary difference between the high-pressure cut-off and the operating pressure control?

    <p>The HPCO has a manual reset button</p> Signup and view all the answers

    What is the recommended HPCO set point for steam heating boilers?

    <p>90 kPa</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off in a steam boiler?

    <p>To prevent excessive boiler pressure</p> Signup and view all the answers

    What is the minimum difference required between the HPCO setting and the safety valve setting for steam power boilers with a MAWP up to 2100 kPa?

    <p>Both a and b</p> Signup and view all the answers

    What type of switch is used in a mechanical pressure control?

    <p>SPST switch</p> Signup and view all the answers

    What is the primary function of the modulating motor in smaller packaged boilers?

    <p>To control the combustion air damper and firing rate control valve in unison</p> Signup and view all the answers

    What happens when the HPCO activates?

    <p>The firing circuit opens</p> Signup and view all the answers

    Why is operator intervention required when the HPCO activates?

    <p>Because the operating pressure control has failed</p> Signup and view all the answers

    What is the purpose of the adjustable cam in the fuel valve crank arm?

    <p>To fine-tune the combustion conditions</p> Signup and view all the answers

    What happens when the steam pressure (or water temperature) falls in a boiler control system?

    <p>The opposite sequence occurs, and the firing rate decreases</p> Signup and view all the answers

    What is the purpose of the MAN-AUTO control station in a boiler control system?

    <p>To interrupt the control signal during warm-up or base loading</p> Signup and view all the answers

    What is the advantage of using two modulating motors in larger boilers?

    <p>Independent control of air and fuel flow</p> Signup and view all the answers

    What is the function of the fuel cam in the modulating motor control system?

    <p>To fine-tune the combustion conditions</p> Signup and view all the answers

    What type of switch is used in steam boilers as operating pressure controls, high and low firing controls, and high-pressure cut-offs?

    <p>Pressure-actuated, single-pole, single-throw (SPST) switch</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off control in a steam boiler?

    <p>To prevent generation of steam pressure above the maximum allowable working pressure</p> Signup and view all the answers

    What type of control devices are used in hot water boilers to control the firing rate of fully modulating burners?

    <p>Variable resistance temperature-actuated sensors</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control over on-off control?

    <p>It provides more precise control over the firing rate</p> Signup and view all the answers

    What is required when starting up a cold boiler with a fully modulating firing rate control?

    <p>The boiler must be limited to low-fire until the boiler is sufficiently warm</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?

    <p>To limit the firing rate of the boiler to low-fire during startup</p> Signup and view all the answers

    What is the function of the resistance slide-wire pressure control in a fully modulating firing rate control?

    <p>To directly actuate the modulating motor that drives the combustion air damper and the firing rate control valve</p> Signup and view all the answers

    What type of sensors are used in steam boilers to control the firing rate of fully modulating burners?

    <p>Variable resistance pressure-actuated sensors</p> Signup and view all the answers

    What is the difference between a two-position control device and a fully modulating control device?

    <p>A two-position control device can only operate at two fixed firing rates, while a fully modulating control device can operate at any firing rate</p> Signup and view all the answers

    What is the purpose of the operating pressure control in a steam boiler?

    <p>To shut off the fuel supply to the boiler when the steam pressure reaches a preset maximum operating pressure</p> Signup and view all the answers

    What is the primary purpose of the high temperature cut-off (HTCO) in hot water boilers?

    <p>To shut off the burner when the operating temperature controls fail to stop the burner</p> Signup and view all the answers

    What is the requirement for automatically fired hot water boilers according to ASME CSD-1 Part CW-410?

    <p>One temperature-actuated control to shut off the fuel supply when the system water reaches a preset operating temperature</p> Signup and view all the answers

    What is the function of the bellows-operated SPST switch in the operating temperature control?

    <p>To activate the switch at the controller set point</p> Signup and view all the answers

    What is the difference between the operating temperature control and the high temperature cut-off (HTCO)?

    <p>All of the above</p> Signup and view all the answers

    What is the purpose of the two-position temperature control device in hot water boilers?

    <p>To control the operating temperature of the boiler</p> Signup and view all the answers

    What is the requirement for the HPCO setting in relation to the safety valve setting?

    <p>Whichever is greater between 5% lower and 480 kPa lower</p> Signup and view all the answers

    What is the function of the thermometer-sensing bulb in the operating temperature control?

    <p>To measure the boiler water temperature</p> Signup and view all the answers

    What is the purpose of the differential setting wheel in the two-position temperature control device?

    <p>To establish the cut-in and cut-out points</p> Signup and view all the answers

    What is the advantage of using a remote temperature-sensing element in the operating temperature control?

    <p>It allows for easier mounting of the controller</p> Signup and view all the answers

    What is the purpose of the high-temperature limit control in hot water boilers?

    <p>To prevent the water temperature from exceeding the maximum allowable water temperature</p> Signup and view all the answers

    What is the main function of the manual flame control potentiometer?

    <p>To adjust the firing rate during warm-up periods</p> Signup and view all the answers

    What is the purpose of the proportional range setting in a modulating temperature control?

    <p>To control how closely the boiler temperature tracks the set point</p> Signup and view all the answers

    What happens when the steam pressure or water temperature rises in a modulating motor?

    <p>The resistance of the slide wire controller changes, unbalancing the circuit</p> Signup and view all the answers

    What is the function of the balancing relay in a modulating motor?

    <p>To balance the circuit when the steam pressure or water temperature is at the set point</p> Signup and view all the answers

    What is the purpose of the set point setting in a modulating pressure control?

    <p>To set the desired boiler pressure</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control?

    <p>It provides more precise control over the firing rate</p> Signup and view all the answers

    What is the purpose of the feedback potentiometer in a modulating motor?

    <p>To move to balance the circuit when the motor runs</p> Signup and view all the answers

    What happens when the MANUAL-AUTOMATIC switch is placed in MANUAL?

    <p>The control of the modulating motor is transferred to the manual flame control potentiometer</p> Signup and view all the answers

    What is the purpose of the differential setting in a modulating pressure control?

    <p>To control how closely the boiler pressure tracks the set point</p> Signup and view all the answers

    What is the function of the bridge circuit in a modulating motor?

    <p>To balance the circuit when the steam pressure or water temperature is at the set point</p> Signup and view all the answers

    What is the primary purpose of firing rate controls in boilers?

    <p>To maximize boiler operating efficiency</p> Signup and view all the answers

    What happens when there is less heat energy entering the boiler than required by the equipment?

    <p>The boiler pressure falls</p> Signup and view all the answers

    What is the code that most suitably addresses automatic firing rate controls?

    <p>ASME CSD-1</p> Signup and view all the answers

    What is the consequence of a steam boiler continuing to fire at an excessive rate?

    <p>The boiler explodes</p> Signup and view all the answers

    In steam boiler control systems, what is the purpose of the final control elements?

    <p>To manipulate the fuel flow and airflow</p> Signup and view all the answers

    What would happen to the temperature in a hot water boiler if there was less heat energy entering the boiler than needed by the equipment?

    <p>The temperature would fall</p> Signup and view all the answers

    What must firing rate controls be able to adjust to?

    <p>Varying load demands</p> Signup and view all the answers

    What is the energy output of a boiler equal to?

    <p>The energy demand</p> Signup and view all the answers

    What is the primary difference between steam boiler control systems and hot water boiler control systems?

    <p>The measured variable</p> Signup and view all the answers

    What is the purpose of the safety valves in steam boilers?

    <p>To prevent over-pressurization</p> Signup and view all the answers

    What must high limit controls be able to do in firing rate controls?

    <p>Shut off the burner to prevent unsafe operating conditions</p> Signup and view all the answers

    What is the consequence of a hot water boiler continuing to fire at an excessive rate?

    <p>All of the above</p> Signup and view all the answers

    What is the primary focus of this chapter?

    <p>Boiler-firing circuits</p> Signup and view all the answers

    What is the purpose of the automatic control system in steam boilers?

    <p>To change the firing rate as required to maintain a steam pressure set point</p> Signup and view all the answers

    What is the major difference between two-position control and multi-position control?

    <p>The number of firing rates</p> Signup and view all the answers

    What happens to the average heat input of the burner in two-position firing rate control?

    <p>It equals the average heat requirements of the process</p> Signup and view all the answers

    What is the purpose of the temperature limit controls in hot water boilers?

    <p>To reduce or stop the energy input</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control over on-off control and multi-position control?

    <p>It is more energy efficient</p> Signup and view all the answers

    What is the primary disadvantage of on-off boilers?

    <p>Significant loss of heat from the boiler due to frequent cycling</p> Signup and view all the answers

    What is the primary advantage of multi-position firing rate control?

    <p>All of the above</p> Signup and view all the answers

    What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?

    <p>The high-fire burner starts</p> Signup and view all the answers

    What is the purpose of the low-fire control in a multi-position firing rate control?

    <p>To provide low heat output</p> Signup and view all the answers

    HARD What happens to the average steam pressure as the load increases in a multi-position firing rate control?

    <p>It decreases</p> Signup and view all the answers

    What is the primary difference between multi-position control and on-off control?

    <p>Finer control of boiler steam pressure or temperature</p> Signup and view all the answers

    What is the purpose of the two operating pressure controls in a multi-position firing rate control?

    <p>To control high and low firing rates</p> Signup and view all the answers

    Why are two-position control systems only used in smaller capacity boilers?

    <p>Because of temperature and pressure swings</p> Signup and view all the answers

    What is the advantage of operating boilers continuously?

    <p>All of the above</p> Signup and view all the answers

    What happens when the load is low in a multi-position firing rate control?

    <p>The low-fire burner starts</p> Signup and view all the answers

    What is the main purpose of the resistance slide-wire pressure control in a fully modulating firing rate control?

    <p>To actuate the modulating motor that drives the combustion air damper and the firing rate control valve</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off control in a steam boiler?

    <p>To prevent generation of steam pressure above the maximum allowable working pressure</p> Signup and view all the answers

    What happens when starting up a cold boiler with a fully modulating firing rate control?

    <p>The boiler is limited to low-fire until the boiler is sufficiently warm</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?

    <p>To limit the firing rate to low-fire during warm-up</p> Signup and view all the answers

    What type of sensors are used in steam boilers to control the firing rate of fully modulating burners?

    <p>Pressure-actuated sensors</p> Signup and view all the answers

    What is the purpose of the operating pressure control in a steam boiler?

    <p>To maintain the steam pressure within a desired range</p> Signup and view all the answers

    What is required by ASME CSD-1 Part CW-310 for automatically fired steam boilers?

    <p>At least one steam pressure control device that will shut off the fuel supply to each boiler</p> Signup and view all the answers

    What is the difference between a two-position control device and a fully modulating control device?

    <p>A two-position control device has two positions, while a fully modulating control device has multiple positions</p> Signup and view all the answers

    What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?

    <p>The firing rate is adjusted to low-fire</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control over on-off control?

    <p>It is more efficient and provides better combustion efficiency</p> Signup and view all the answers

    What is the primary function of the air damper linkage in a high-low firing rate control?

    <p>To regulate the air-to-fuel ratio</p> Signup and view all the answers

    What happens when the boiler pressure reaches 70 kPa in a steam boiler with fully modulating firing rate control?

    <p>The burner turns off</p> Signup and view all the answers

    What is the purpose of the manual firing rate limit switch in a boiler with fully modulating firing rate control?

    <p>To limit the firing rate to low fire during warm-up</p> Signup and view all the answers

    What is the primary advantage of fully modulating firing rate control in steam boilers?

    <p>Reduced purge losses</p> Signup and view all the answers

    What is the purpose of the high-pressure cut-off control in a steam boiler?

    <p>To shut off the burner during high-pressure events</p> Signup and view all the answers

    What is the primary function of the operating pressure control in a steam boiler with fully modulating firing rate control?

    <p>To activate a call for heat</p> Signup and view all the answers

    What is the purpose of the resistance slide-wire control in a steam boiler with fully modulating firing rate control?

    <p>To position the modulating motor</p> Signup and view all the answers

    What is the primary purpose of the high-pressure cut-off control in a steam boiler?

    <p>To provide a last line of defense before the safety valve operates</p> Signup and view all the answers

    What happens when the boiler pressure falls to 55 kPa in a steam boiler with fully modulating firing rate control?

    <p>The modulating motor places the air and fuel in high-fire</p> Signup and view all the answers

    What is the primary advantage of fully modulating firing rate control in hot water boilers?

    <p>Reduced purge losses</p> Signup and view all the answers

    What is the minimum size of a siphon required to protect a pressure control device?

    <p>DN 8 (NPS ¼)</p> Signup and view all the answers

    What is the primary function of the programming controller in a fully modulating firing rate control?

    <p>To control the firing rate</p> Signup and view all the answers

    What happens when the mercury switch in a pressure control device fails?

    <p>The mercury loses its lustre and may appear rusty</p> Signup and view all the answers

    What is the purpose of the manual reset button on a high-pressure cut-off control?

    <p>To require operator intervention after a trip condition</p> Signup and view all the answers

    What is the recommended HPCO setting for steam heating boilers according to the National Board of Boiler and Pressure Inspectors?

    <p>90 kPa or less</p> Signup and view all the answers

    What is the purpose of a siphon or equivalent water seal in a pressure control device?

    <p>To prevent steam from entering the control</p> Signup and view all the answers

    What is the difference between a mercury switch and a mechanical switch pressure control?

    <p>Mercury switches are no longer manufactured, while mechanical switches are used instead</p> Signup and view all the answers

    What is the purpose of the differential adjustment in a pressure control device?

    <p>To adjust the cut-in and cut-out points of the control</p> Signup and view all the answers

    What is the recommended HPCO setting for steam power boilers with a MAWP up to 2100 kPa?

    <p>At least 10% lower than the safety valve setting, or 50 kPa lower</p> Signup and view all the answers

    What is the purpose of the MANUAL-AUTOMATIC switch in a modulating controller?

    <p>To permit low-fire operation during warm-up periods</p> Signup and view all the answers

    What is the function of the balancing relay in a modulating motor?

    <p>To balance the circuit and stop the modulating motor</p> Signup and view all the answers

    What happens when the boiler pressure falls to the cut-out point of the operating pressure control?

    <p>The burner shuts off, and the SSOVs close</p> Signup and view all the answers

    What happens when the steam pressure rises above the set point in a modulating pressure control?

    <p>The modulating motor drives the damper to the closed position</p> Signup and view all the answers

    What is the purpose of the feedback potentiometer in a modulating motor?

    <p>To provide feedback to the modulating controller</p> Signup and view all the answers

    What is the advantage of fully modulating firing rate control?

    <p>It is more efficient than on-off control</p> Signup and view all the answers

    What is the purpose of the high-temperature cut-off control in a hot water boiler?

    <p>To shut down the boiler in case of an emergency</p> Signup and view all the answers

    What is the function of the resistance slide-wire control in a modulating pressure control?

    <p>To operate the potentiometer</p> Signup and view all the answers

    What happens when the boiler temperature falls below the set point in a modulating temperature control?

    <p>The modulating motor drives the damper to the open position</p> Signup and view all the answers

    What is the purpose of the programming controller in a fully modulating firing rate control?

    <p>To enable the modulating controller when the boiler is in RUN mode</p> Signup and view all the answers

    What is the purpose of MAN-AUTO control station in boiler control systems?

    <p>To interrupt the control signal, so that the boiler can be kept at low-fire for warm up or base loaded</p> Signup and view all the answers

    How do larger boilers typically control the air and fuel flow?

    <p>Using two modulating motors that receive the same signal from a single master pressure or temperature controller</p> Signup and view all the answers

    What is the purpose of the adjustable cam on the crank arm for the fuel valve?

    <p>To fine-tune the combustion conditions</p> Signup and view all the answers

    What is the common arrangement used in smaller packaged boilers to control the air and fuel flow?

    <p>A single modulating motor that operates both the combustion air damper and the firing rate control valve, in unison</p> Signup and view all the answers

    What happens when the steam pressure (or water temperature) falls in a boiler control system?

    <p>The opposite sequence occurs, increasing the fuel flow and air flow to restore the pressure or temperature to the set point</p> Signup and view all the answers

    What is the purpose of the master pressure or temperature controller in a boiler control system?

    <p>To provide a single signal to the modulating motors that control the air and fuel flow</p> Signup and view all the answers

    What is the minimum requirement for the HPCO setting in relation to the safety valve setting?

    <p>5% lower or 480 kPa lower</p> Signup and view all the answers

    What is the purpose of the high-temperature cut-off control?

    <p>To prevent the water temperature from exceeding the maximum allowable water temperature</p> Signup and view all the answers

    What is the difference between the high-temperature cut-off control and the operating temperature control?

    <p>The HTCO has a manual reset button</p> Signup and view all the answers

    What is the requirement for temperature controls in automatically fired hot water boilers according to ASME CSD-1 Part CW-410?

    <p>Each boiler must have at least one temperature-actuated control</p> Signup and view all the answers

    What is the function of the bellows-operated SPST switch in the operating temperature control?

    <p>To activate the switch at the controller set point</p> Signup and view all the answers

    What is the purpose of the two-position temperature control device?

    <p>To shut off the fuel supply when the system water reaches a preset operating temperature</p> Signup and view all the answers

    What is the requirement for the sensing element and operating switch in temperature controls according to ASME CSD-1 Part CW-410?

    <p>Each limit and operating control must have its own sensing element and operating switch</p> Signup and view all the answers

    What is the function of the differential switch in the high-low fire control?

    <p>To adjust the inter-stage temperature differential</p> Signup and view all the answers

    What is the purpose of the high-temperature limit control?

    <p>To prevent the water temperature from exceeding the maximum allowable water temperature</p> Signup and view all the answers

    What is the requirement for the high-temperature cut-off control in automatically fired hot water boilers?

    <p>The HTCO must be set higher than the operating temperature control</p> Signup and view all the answers

    Match the following boiler firing rate control strategies with their descriptions:

    <p>Two-position control = Either fully on or fully off Multi-position control = Can have multiple firing rates Fully modulating control = Can adjust firing rate to match demand On-off control = Can only be fully on or fully off</p> Signup and view all the answers

    Match the following boiler components with their functions:

    <p>High limit control = Shuts off the burner to prevent unsafe operating conditions Sensing element = Measures the process variable Controller = Adjusts the firing rate based on the measured variable Final control element = Executes the control action</p> Signup and view all the answers

    Match the following boiler operating conditions with their effects on pressure:

    <p>Greater heat energy entering the boiler than required = Pressure rises Less heat energy entering the boiler than required = Pressure falls Energy output equals energy demand = Pressure remains constant Excessive firing rate = Over-pressurization</p> Signup and view all the answers

    Match the following boiler control systems with their characteristics:

    <p>Two-position control = Significant loss of heat Fully modulating control = Maximum boiler operating efficiency Multi-position control = Multiple firing rates On-off control = Either fully on or fully off</p> Signup and view all the answers

    Match the following boiler control devices with their functions:

    <p>Resistance slide-wire control = Adjusts the firing rate based on pressure Programming controller = Adjusts the firing rate based on a schedule Manual firing rate limit switch = Limits the firing rate for safety High-pressure cut-off control = Shuts off the burner to prevent over-pressurization</p> Signup and view all the answers

    Match the following boiler codes with their descriptions:

    <p>ASME CSD-1 = Code for automatically fired boilers CW-310 = Part of ASME CSD-1 for automatically fired steam boilers NEC = Code for electrical installations OSHA = Code for workplace safety</p> Signup and view all the answers

    Match the following boiler firing rate control advantages with their descriptions:

    <p>Fully modulating control = Maximum boiler operating efficiency Multi-position control = Improved boiler operating efficiency On-off control = Simple and low-cost Two-position control = Less expensive than fully modulating control</p> Signup and view all the answers

    Match the following boiler control elements with their purposes:

    <p>Operating pressure control = Maintains the desired operating pressure High-pressure cut-off control = Shuts off the burner to prevent over-pressurization Low-fire control = Limits the firing rate to prevent over-pressurization High-limit control = Shuts off the burner to prevent unsafe operating conditions</p> Signup and view all the answers

    Match the boiler control systems with their characteristics:

    <p>On-Off Control = Non-modulating, two-position control Multi-Position Control = Permits finer control of boiler steam pressure or temperature Two-Position Control = Reduces heat losses caused by repeated purging Fully Modulating Control = Used in smaller capacity boilers</p> Signup and view all the answers

    Match the boilers with their operating principles:

    <p>Low-Pressure Steam Boiler = Cycles based on pressure Hot Water Boiler = Cycles based on temperature On-Off Boiler = Operates continuously for greater efficiency Multi-Position Boiler = Has a single operating pressure control</p> Signup and view all the answers

    Match the firing rate control systems with their components:

    <p>On-Off Firing Rate Control = One operating pressure control (pressuretrol) Multi-Position Firing Rate Control = Two operating pressure controls Fully Modulating Firing Rate Control = Resistance slide-wire control Two-Position Firing Rate Control = Manual firing rate limit switch</p> Signup and view all the answers

    Match the boiler operating conditions with their effects:

    <p>Low Load = Boiler cycles more often High Load = Boiler cycles less frequently Low Pressure = High-fire burner starts High Pressure = Low-fire burner shuts off</p> Signup and view all the answers

    Match the boiler control systems with their advantages:

    <p>On-Off Control = Less complex controls Multi-Position Control = Reduces heat losses caused by repeated purging Two-Position Control = Used in smaller capacity boilers Fully Modulating Control = Greater efficiency and plant efficiency</p> Signup and view all the answers

    Match the boiler firing rate control systems with their operating principles:

    <p>On-Off Firing Rate Control = Cycles on and off based on load demand Multi-Position Firing Rate Control = Permits finer control of boiler steam pressure or temperature Two-Position Firing Rate Control = Has a single operating pressure control Fully Modulating Firing Rate Control = Operates continuously for greater efficiency</p> Signup and view all the answers

    Match the boiler components with their functions:

    <p>Pressuretrol = Operates as a pressure-operated switch SSOV = Shuts, opens at a low-fire setting, or opens at a high-fire setting Aquastat = Controls high and low firing rates Burner = Produces heat energy</p> Signup and view all the answers

    Match the boiler operating conditions with their effects on efficiency:

    <p>Frequent Cycling = Reduces boiler efficiency Continuous Operation = Improves boiler efficiency Low Load = Increases cycling rates High Load = Reduces cycling rates</p> Signup and view all the answers

    Match the boiler control systems with their applications:

    <p>On-Off Control = Used in smaller capacity boilers Multi-Position Control = Used in larger capacity boilers Two-Position Control = Used in hot water boilers Fully Modulating Control = Used in steam boilers</p> Signup and view all the answers

    Match the boiler firing rate control systems with their characteristics:

    <p>On-Off Firing Rate Control = Non-modulating, two-position control Multi-Position Firing Rate Control = Permits finer control of boiler steam pressure or temperature Two-Position Firing Rate Control = Reduces heat losses caused by repeated purging Fully Modulating Firing Rate Control = Operates continuously for greater efficiency</p> Signup and view all the answers

    Match the following control devices with their respective functions in a fully modulating firing rate control system:

    <p>Operating pressure control = Activates a call for heat Resistance slide-wire pressure control = Positions the modulating motor High-pressure cut-off control = Cuts off the burner when the boiler pressure reaches a set point Manual firing rate limit switch = Limits the firing rate to low fire during warm-up</p> Signup and view all the answers

    Match the following types of boilers with their respective control strategies:

    <p>Smaller capacity boilers = On-off control Larger capacity boilers = Fully modulating firing rate control Hot water boilers = Multi-position control Steam boilers = Two-position firing rate control</p> Signup and view all the answers

    Match the following terms with their respective descriptions:

    <p>High-fire control = Directly actuates the modulating motor that drives the combustion air damper Low-fire control = Limits the firing rate to low fire during warm-up Pressuretrol = Operates the burner between high and low firing rates Modulating motor = Positions the combustion air damper and the firing rate control valve</p> Signup and view all the answers

    Match the following conditions with their respective responses in a fully modulating firing rate control system:

    <p>Boiler pressure below 50 kPa = Burner turns on Boiler pressure above 70 kPa = Burner turns off Boiler pressure between 50 kPa and 70 kPa = Firing rate is modulated Boiler pressure above 55 kPa = Firing rate gradually drops to its minimum</p> Signup and view all the answers

    Match the following terms with their respective applications:

    <p>Fully modulating firing rate control = High-efficiency boilers Two-position firing rate control = Small capacity boilers Multi-position firing rate control = Medium capacity boilers On-off control = Low-efficiency boilers</p> Signup and view all the answers

    Match the following control elements with their respective functions in a fully modulating firing rate control system:

    <p>Modulating motor = Positions the combustion air damper and the firing rate control valve Resistance slide-wire pressure control = Determines the firing rate Operating pressure control = Activates the burner High-pressure cut-off control = Limits the boiler pressure</p> Signup and view all the answers

    Match the following conditions with their respective consequences in a fully modulating firing rate control system:

    <p>Heat input exceeds load demand = Boiler pressure continues to rise Boiler pressure below 55 kPa = Firing rate increases Boiler pressure above 65 kPa = Firing rate gradually drops to its minimum Boiler pressure above 70 kPa = Burner turns off</p> Signup and view all the answers

    Match the following types of boilers with their respective control requirements:

    <p>Steam boilers = Three pressure controls Hot water boilers = Three temperature controls Small capacity boilers = Two pressure controls Large capacity boilers = Four pressure controls</p> Signup and view all the answers

    Match the following terms with their respective advantages:

    <p>Fully modulating firing rate control = Highest efficiency and closest set point adherence Two-position firing rate control = Simple and low-cost Multi-position firing rate control = Better efficiency than on-off control On-off control = Lowest cost</p> Signup and view all the answers

    Match the boiler control systems with their respective measured variables:

    <p>Steam Boiler Control System = Steam pressure Hot Water Boiler Control System = Outlet water temperature Multi-position Control System = Flow rate Two-position Control System = Energy demand</p> Signup and view all the answers

    Match the control strategies with their respective characteristics:

    <p>Two-position Control = Cycling on and off Multi-position Control = Firing at intermediate rates Fully Modulating Control = Cycling on and off On-Off Control = Firing at maximum heat rating</p> Signup and view all the answers

    Match the following control elements with their respective set points:

    <p>Operating pressure control = Cut-in at 50 kPa and cut-out at 70 kPa High-pressure cut-off control = Cut-out at 70 kPa Resistance slide-wire pressure control = Positions the modulating motor Manual firing rate limit switch = Limits the firing rate to low fire during warm-up</p> Signup and view all the answers

    Match the boiler types with their respective safety devices:

    <p>Steam Boilers = Safety valves Hot Water Boilers = Temperature limit controls Packaged Boilers = Pressure relief valves Industrial Boilers = High-pressure cut-off controls</p> Signup and view all the answers

    Match the control elements with their respective functions:

    <p>Combustion air dampers = Regulating airflow Firing rate control valve = Controlling fuel flow High-fire control = Limiting excessive heat input Low-fire control = Regulating airflow</p> Signup and view all the answers

    Match the boiler control systems with their respective process variables:

    <p>Steam Boiler Control System = Steam pressure Hot Water Boiler Control System = Hot water supply temperature Multi-position Control System = Flow rate Two-position Control System = Energy demand</p> Signup and view all the answers

    Match the control systems with their respective final control elements:

    <p>Steam Boiler Control System = Combustion air dampers and firing rate control valve Hot Water Boiler Control System = Fuel flow control valve Multi-position Control System = Airflow damper Two-position Control System = Fuel pump</p> Signup and view all the answers

    Match the boiler control systems with their respective manipulated variables:

    <p>Steam Boiler Control System = Fuel flow and airflow Hot Water Boiler Control System = Fuel flow and airflow Multi-position Control System = Fuel flow only Two-position Control System = Airflow only</p> Signup and view all the answers

    Match the control strategies with their respective advantages:

    <p>Two-position Control = Simple and low-cost Multi-position Control = More efficient and precise Fully Modulating Control = Improved plant efficiency On-Off Control = Reliable and easy to maintain</p> Signup and view all the answers

    Match the boiler control systems with their respective sensing elements:

    <p>Steam Boiler Control System = Pressure-sensitive sensors Hot Water Boiler Control System = Temperature-sensitive sensors Multi-position Control System = Flow rate sensors Two-position Control System = Energy demand sensors</p> Signup and view all the answers

    Match the boiler control systems with their respective control objectives:

    <p>Steam Boiler Control System = Maintaining steam pressure set point Hot Water Boiler Control System = Maintaining hot water supply temperature set point Multi-position Control System = Matching energy output to demand Two-position Control System = Regulating energy input</p> Signup and view all the answers

    Match the type of control devices used in steam boilers with their respective functions:

    <p>Two-position pressure control device = Operating pressure control, high and low firing controls, and high-pressure cut-offs Variable resistance pressure-actuated sensor = Controls the firing rate of fully modulating burners Modulating motor = Positions fuel valves and combustion air dampers Pressure-actuated single-pole, single-throw switch = Sensing element and operating switch</p> Signup and view all the answers

    Match the firing rate control devices with their respective applications:

    <p>Two-position control devices = On-off boilers Multi-position control devices = Hot water boilers Fully modulating firing rate control devices = Steam boilers High-pressure cut-off control devices = Power burners</p> Signup and view all the answers

    Match the requirements for pressure controls for steam boilers with the corresponding ASME CSD-1 Part CW-310 section:

    <p>At least one steam pressure control device = CW-310 a) High steam pressure limit control = CW-310 b) Manual reset = CW-310 c) No shutoff valve in the steam pressure connection = CW-310 d)</p> Signup and view all the answers

    Match the types of boilers with their respective control strategies:

    <p>Two-position boilers = On-off control Multi-position boilers = Modulating control Fully modulating boilers = Variable resistance control Power burners = Linkage and cam control</p> Signup and view all the answers

    Match the components of fully modulating firing rate control with their respective functions:

    <p>Programming controller = Places boiler in AUTO or HIGH mode Modulating motor = Positions fuel valves and combustion air dampers Resistance slide-wire pressure control = Positions modulating motor Manual firing rate limit switch = Limits firing rate to low-fire during warm-up</p> Signup and view all the answers

    Match the types of sensors used in boilers with their respective applications:

    <p>Pressure-actuated sensors = Steam boilers Temperature-actuated sensors = Hot water boilers Variable resistance sensors = Fully modulating burners Sensing elements = Operating pressure controls</p> Signup and view all the answers

    Match the advantages of fully modulating firing rate control with their respective benefits:

    <p>Improved combustion efficiency = Maximum heat output Reduced thermal stress = Increased boiler lifespan Increased plant efficiency = Optimized energy output Limiting firing rate to low-fire during warm-up = Prevents uneven thermal expansion</p> Signup and view all the answers

    Match the safety shutdown requirements with their respective ASME CSD-1 Part CW-310 sections:

    <p>Prevents generation of steam pressure above maximum allowable working pressure = CW-310 b) Causes safety shutdown and lockout when activated = CW-310 c) Requires manual reset = CW-310 d) Indicates when it is activated = CW-310 a)</p> Signup and view all the answers

    Match the functions of control devices in steam boilers with their respective locations:

    <p>Operating pressure control = Between the boiler and steam pressure connection High-pressure cut-off control = After the operating pressure control Low-fire control = Before the operating pressure control Modulating motor = After the resistance slide-wire pressure control</p> Signup and view all the answers

    Match the types of boilers with their respective firing rate control devices:

    <p>Two-position boilers = Two-position control devices Multi-position boilers = Multi-position control devices Fully modulating boilers = Fully modulating firing rate control devices Power burners = Variable resistance pressure-actuated sensors</p> Signup and view all the answers

    Match the boiler control components with their functions:

    <p>Modulating motor = Adjusts fuel flow for optimum combustion efficiency Jackshaft = Operates combustion air damper and firing rate control valve Fuel cam = Fine-tunes combustion conditions Master pressure controller = Provides signal to modulating motor</p> Signup and view all the answers

    Match the control systems with their characteristics:

    <p>Two-position control = Burner is either on or off Multi-position control = Burner firing rate can be adjusted Fully modulating control = Continuous adjustment of fuel flow MAN-AUTO control = Allows manual interruption of control signal</p> Signup and view all the answers

    Match the boiler control scenarios with their consequences:

    <p>Steam pressure falls = Fuel flow increases Steam pressure rises = Fuel flow decreases Boiler is base loaded = Firing rate is adjusted for low-fire Boiler is warm up = Firing rate is adjusted for low-fire</p> Signup and view all the answers

    Match the control components with their uses:

    <p>Crank arms = Operate combustion air damper and firing rate control valve Cam = Fine-tunes combustion conditions Master pressure controller = Provides signal to modulating motor Jackshaft = Converts rotary motion to linear motion</p> Signup and view all the answers

    Match the boiler control systems with their advantages:

    <p>Two-position control = Simple and cost-effective Multi-position control = Improves efficiency and reduces wear Fully modulating control = Provides precise control and flexibility MAN-AUTO control = Allows manual override for safety</p> Signup and view all the answers

    Match the boiler control components with their roles:

    <p>Modulating motor = Receives signal from master pressure controller Fuel cam = Adjusts fuel flow for combustion conditions Crank arms = Operate combustion air damper and firing rate control valve Jackshaft = Converts rotary motion to linear motion</p> Signup and view all the answers

    Match the following types of pressure control devices with their characteristics:

    <p>Mercury Switch = Relies on a bellows and a pressure adjustment spring to operate Mechanical Switch = Uses a pressure capsule to move levers and activate the switch High Pressure Cut-Off = Has a manual reset button and no differential adjustment Operating Pressure Control = Has a differential adjustment and is used for low-pressure boiler service</p> Signup and view all the answers

    Match the following types of boiler service with their recommended high-pressure cut-off settings:

    <p>Steam Heating Boilers = Not to exceed 90 kPa Steam Power Boilers (Up to 2100 kPa MAWP) = At least 10% lower than the safety valve setting, or 50 kPa lower than the safety valve setting, whichever is greater Steam Power Boilers (Over 2100 kPa to 6890 kPa) = At least 7% lower than the safety valve setting, or 200 kPa lower than the safety valve setting, whichever is greater Hot Water Boilers = No specific recommendation provided</p> Signup and view all the answers

    Match the following terms with their definitions:

    <p>Differential = The difference between the cut-out and cut-in points Process Variable = Not mentioned in the provided content Control Differential = Determines the difference between the cut-out and cut-in points SPST Switch = Single Pole Single Throw switch</p> Signup and view all the answers

    Match the following types of pressure control devices with their operating principles:

    <p>Mercury Switch = Tilting the mercury switch causes the mercury to flow to the opposite end of the tube, opening or closing the electrical circuit Mechanical Switch = Moving levers and activating the switch according to the spring tension on the pressure adjustment High Pressure Cut-Off = Not mentioned in the provided content Operating Pressure Control = Increasing boiler pressure causes the bellows to expand and tilt the mercury switch</p> Signup and view all the answers

    Match the following types of boiler control systems with their characteristics:

    <p>Two-Position Control = Relies on a mercury switch or mechanical switch to operate Fully Modulating Firing Rate Control = Uses a resistance slide-wire control to modulate the firing rate Multi-Position Control = Has a low-fire control and multiple operating pressure controls On-Off Control = Not mentioned in the provided content</p> Signup and view all the answers

    Match the following components with their functions:

    <p>Siphon = Protects the pressure control device from steam entering the control Mercury Switch = Operates the electrical circuit for the combustion system Pressure Capsule = Moves levers and activates the switch Bellows = Expands and tilts the mercury switch</p> Signup and view all the answers

    Match the following types of pressure control devices with their limitations:

    <p>Mercury Switch = Prone to failure due to small cracks in the glass allowing oxygen to enter Mechanical Switch = Not mentioned in the provided content High Pressure Cut-Off = Requires manual reset after activation Operating Pressure Control = Has a differential adjustment that may require resetting</p> Signup and view all the answers

    Match the following types of boiler service with their recommended operating procedures:

    <p>Steam Heating Boilers = Not mentioned in the provided content Steam Power Boilers = Requires operator intervention to reset the high-pressure cut-off after activation Hot Water Boilers = Not mentioned in the provided content Multi-Position Firing Rate Control = Requires operator intervention to reset the operating pressure control after activation</p> Signup and view all the answers

    Match the following types of pressure control devices with their settings:

    <p>High Pressure Cut-Off = Set higher than the operating pressure control and the low-fire control Operating Pressure Control = Set lower than the high-pressure cut-off Low-Fire Control = Set lower than the operating pressure control Multi-Position Firing Rate Control = Has multiple operating pressure controls with different settings</p> Signup and view all the answers

    Match the following types of pressure control devices with their failure modes:

    <p>Mercury Switch = Fails to close or open the switch contacts due to oxidation of the mercury Mechanical Switch = Not mentioned in the provided content High Pressure Cut-Off = Locks in the open position and requires manual reset Operating Pressure Control = Fails to stop the burner due to faulty differential adjustment</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>HPCO = High Pressure Cut-Off HTCO = High Temperature Cutoff Operating Temperature Control = Combines a filled system thermometer with a bellows-operated SPST switch ASME CSD-1 Part CW-410 = Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers</p> Signup and view all the answers

    Match the following controls with their functions:

    <p>High Temperature Cutoff = Shuts off the burner when the operating temperature controls fail to stop the burner Operating Temperature Control = Combines a filled system thermometer with a bellows-operated SPST switch High-Low Fire Control = Used for hi-low fired boilers to satisfy the requirement for two operating temperature controls High Pressure Cut-Off = Prevents the water temperature from exceeding the maximum allowable water temperature</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>Two-Position Temperature Control = A temperature-actuated, single-pole, single-throw (SPST) switch Multi-Position Firing Rate Control = Used in larger capacity boilers for more precise control High Temperature Limit Control = Requires manual reset and indicates when it is activated Operating Cycle = The process of the boiler firing and shutting off repeatedly</p> Signup and view all the answers

    Match the following controls with their characteristics:

    <p>High Temperature Cutoff = Has a manual reset button and locks in the open position when activated Operating Temperature Control = Has a differential adjustment and does not have a manual reset High Pressure Cut-Off = Prevents the water temperature from exceeding the maximum allowable water temperature High-Low Fire Control = Used in hi-low fired boilers and has two SPST switches operated by the same thermal element</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>ASME CSD-1 Part CW-410 = Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers HPCO Setting = Should be at least 5% lower than the setting of the safety valve, or 480 kPa lower, whichever is greater HTCO Setting = Factory set to 121°C, and has a fixed 11°C differential Operating Temperature Control = Used to shut off the fuel supply when the system water reaches a preset operating temperature</p> Signup and view all the answers

    Match the following controls with their functions:

    <p>High Temperature Limit Control = Prevents the water temperature from exceeding the maximum allowable water temperature High Pressure Cut-Off = Shuts off the burner when the operating temperature controls fail to stop the burner Operating Temperature Control = Combines a filled system thermometer with a bellows-operated SPST switch High-Low Fire Control = Used in hi-low fired boilers to satisfy the requirement for two operating temperature controls</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>Two-Position Control = A temperature-actuated, single-pole, single-throw (SPST) switch Multi-Position Firing Rate Control = Used in larger capacity boilers for more precise control High Temperature Cutoff = Requires manual reset and indicates when it is activated Operating Cycle = The process of the boiler firing and shutting off repeatedly</p> Signup and view all the answers

    Match the following controls with their characteristics:

    <p>High Temperature Limit Control = Requires manual reset and indicates when it is activated Operating Temperature Control = Has a differential adjustment and does not have a manual reset High Pressure Cut-Off = Prevents the water temperature from exceeding the maximum allowable water temperature High-Low Fire Control = Used in hi-low fired boilers and has two SPST switches operated by the same thermal element</p> Signup and view all the answers

    Match the following terms with their descriptions:

    <p>ASME CSD-1 Part CW-410 = Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers HPCO Setting = Should be at least 5% lower than the setting of the safety valve, or 480 kPa lower, whichever is greater HTCO Setting = Factory set to 121°C, and has a fixed 11°C differential Operating Temperature Control = Used to shut off the fuel supply when the system water reaches a preset operating temperature</p> Signup and view all the answers

    Match the following controls with their functions:

    <p>High Temperature Limit Control = Prevents the water temperature from exceeding the maximum allowable water temperature High Pressure Cut-Off = Shuts off the burner when the operating temperature controls fail to stop the burner Operating Temperature Control = Combines a filled system thermometer with a bellows-operated SPST switch High-Low Fire Control = Used in hi-low fired boilers to satisfy the requirement for two operating temperature controls</p> Signup and view all the answers

    Match the type of boiler with the required control:

    <p>Steam boilers = Modulating temperature control Hot water boilers = Modulating pressure control</p> Signup and view all the answers

    Match the control component with its function:

    <p>Manual flame control potentiometer = Allows low-fire operation during warm-up periods Bridge circuit = Positions the combustion air damper and the firing rate control valve Balancing relay = Unbalances the circuit to drive the modulating motor Feedback potentiometer = Operates the potentiometer in the form of a resistance slide wire</p> Signup and view all the answers

    Match the type of control with its characteristics:

    <p>On-off control = Has a single set point Modulating control = Has a proportional range setting Two-position control = Has a low-fire control Multi-position control = Has a single set point</p> Signup and view all the answers

    Match the boiler component with its description:

    <p>Modulating motor = Positions the combustion air damper and the firing rate control valve Resistance slide wire = Operates a potentiometer to adjust the firing rate High-pressure cut-off = Shuts off the boiler when the pressure exceeds a set point Manual-AUTOMATIC switch = Transfers control of the modulating motor to the manual flame control potentiometer</p> Signup and view all the answers

    Match the control system with the boiler type:

    <p>Modulating pressure control = Steam boilers with fully modulating burners Modulating temperature control = Hot water boilers with fully modulating burners On-off control = Smaller capacity boilers Multi-position control = Steam boilers with fully modulating burners</p> Signup and view all the answers

    Match the control setting with its function:

    <p>Set point = Determines the desired boiler pressure or temperature Differential setting = Controls how closely the boiler pressure tracks the set point Proportional range setting = Determines the desired boiler pressure or temperature MIN setting = Tracks the set point the closest, to provide the finest pressure control</p> Signup and view all the answers

    Match the control component with its purpose:

    <p>Programming controller = Enables the modulating controller when in RUN Manual flame control potentiometer = Allows the firing rate to be kept at low-fire during warm-up periods Modulating controller = Adjusts the firing rate to match the boiler load Balancing relay = Unbalances the circuit to drive the modulating motor</p> Signup and view all the answers

    Match the boiler operation with the required control:

    <p>Steam boiler warm-up = Manual flame control potentiometer Hot water boiler operation = Modulating temperature control Steam boiler operation = Modulating pressure control Hot water boiler warm-up = Modulating motor</p> Signup and view all the answers

    Match the control strategy with its characteristic:

    <p>Modulating control = Continuously adjusts the firing rate to match the boiler load On-off control = Has a single set point Two-position control = Has a low-fire control Multi-position control = Has a proportional range setting</p> Signup and view all the answers

    Match the control component with its effect:

    <p>Modulating motor = Adjusts the firing rate to match the boiler load Feedback potentiometer = Moves to balance the circuit Balancing relay = Causes the modulating motor to drive to the closed position Resistance slide wire = Operates a potentiometer to adjust the firing rate</p> Signup and view all the answers

    Study Notes

    Boiler Firing Rate Control

    • Firing rate control strategies are used to manage the energy output of a boiler to match the energy demand.
    • The energy output of a boiler must equal the energy demand to maintain a constant pressure or temperature.

    Steam Boilers

    • Produce a mass of steam at a particular rate, under certain conditions of temperature, pressure, and quality.
    • The measured variable is the steam pressure.
    • The manipulated variables are the fuel flow and the airflow.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a steam pressure set point.

    Hot Water Boilers

    • Produce a mass of hot water, flowing at a particular rate, at a particular temperature.
    • The measured variable is the outlet water temperature.
    • The manipulated variables are the fuel flow and the airflow.
    • The process variable is the hot water supply temperature.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a hot water temperature set point.

    Control Strategies

    • Two-position (on-off) control: the burner is either on or off.
    • Multi-position (high-low-off) control: the burner fires at high-fire, low-fire, or off.
    • Fully modulating control: the burner can operate at any firing rate between high-fire and low-fire.

    Two-Position Control

    • The burner cycles on and off to meet the energy demand.
    • The pressure (or temperature) swings above and below the desired set point.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Multi-Position Control

    • The burner fires at high-fire, low-fire, or off to meet the energy demand.
    • The control requires two operating pressure (or temperature) controls.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Fully Modulating Control

    • The burner can operate at any firing rate between high-fire and low-fire.
    • The control requires three pressure (or temperature) controls.
    • The control provides the highest efficiency and closest set point adherence.

    Firing Rate Control Devices

    • Sensing elements: measure the boiler pressure or temperature.
    • Final control elements: manipulate the fuel flow and airflow to control the firing rate.

    Two-Position Control Devices

    • Steam boilers use pressure-actuated two-position single-pole, single-throw switches as operating pressure controls, low-fire controls, high-fire controls, and high-pressure cut-offs.
    • Hot water boilers use temperature-actuated two-position single-pole, single-throw switches as operating temperature controls, low-fire controls, high-fire controls, and high-temperature cut-offs.### High-Pressure Cut-Off (HPCO)
    • Is a safety feature that shuts off the burner when the operating pressure control fails
    • Has a manual reset button and does not have a differential adjustment
    • Must be set higher than the operating pressure control and the high-low fire controls
    • National Board of Boiler and Pressure Inspectors recommends the following HPCO set points:
      • For steam heating boilers, the HPCO set point should not exceed 90 kPa
      • For steam power boilers:
        • Up to 2100 kPa MAWP, the HPCO setting should be at least 10% lower than the setting of the safety valve, or 50 kPa lower than the setting of the safety valve, whichever is greater
        • Over 2100 kPa to 6890 kPa, the HPCO setting should be at least 7% lower than the setting of the safety valve, or 200 kPa lower than the setting of the safety valve, whichever is greater
        • Over 6890 kPa to 13800 kPa, the HPCO setting should be at least 5% lower than the setting of the safety valve, or 480 kPa lower than the setting of the safety valve, whichever is greater

    Hot Water Boilers

    • Two-position temperature control devices are used as operating temperature controls (aquastats), high- and low-firing controls, and high-temperature cut-offs
    • ASME CSD-1 Part CW-410 Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers states:
      • Each automatically fired hot water boiler shall have at least one temperature-actuated control to shut off the fuel supply when the system water reaches a preset operating temperature
      • Each automatically fired hot water boiler shall have a high-temperature limit control that will prevent the water temperature from exceeding the maximum allowable water temperature, cause safety shutdown and lockout when it activates, require manual reset, and indicate when it is activated
      • Each limit and operating control shall have its own sensing element and operating switch

    Operating Temperature Control (Aquastat), High Fire Control, or Low Fire Control

    • Combines a filled system thermometer with a bellows-operated SPST switch
    • Pressure inside the thermometer increases when boiler water temperature increases, expanding the bellows and activating the switch at the controller set point
    • The opposite occurs when the temperature drops
    • Thermometer-sensing bulb is inserted in a thermowell located at the boiler hot water outlet
    • If equipped with a capillary tube, the controller may be mounted separately, at a more easily accessible location
    • Figure 15 shows two-position controls used for hot water boilers

    High Temperature Cut-off (HTCO)

    • Similar in operation to the operating temperature control
    • Bellows or pressure capsule, attached to a filled system thermometer, operates a SPST switch to open the firing circuit
    • Set higher than the operating temperature control, the high-low fire controls, and the modulating temperature control
    • Shuts off the burner when the operating temperature controls fail to stop the burner
    • Does not have a differential adjustment and has a manual reset button
    • When the HTCO activates, its switch locks in the open position, requiring operator intervention to reset

    Modulating Controllers

    • Steam boilers with fully modulating burners require a modulating pressure control, in addition to the operating pressure control and the high-pressure cut-off
    • Hot water boilers with fully modulating burners require a modulating temperature control, in addition to the operating temperature control and the high-temperature cut-off
    • Modulating controllers enable the firing rate to be continuously adjusted to match the boiler load as it varies
    • Figure 17 shows a modulating pressure control with its cover removed
    • Figure 18 shows a modulating temperature control used with hot water heating boilers

    Modulating Motors

    • Used in electrical control systems to position dampers and valves
    • In the case of boilers, they position the combustion air damper and the firing rate control valve
    • When the steam pressure (or water temperature) is at the controller set point, the circuit is balanced, and the modulating motor does not run
    • When the steam pressure or water temperature rises, the resistance of the slide wire controller changes, unbalancing the circuit, and causing the modulating motor to drive to the closed position
    • Some larger boilers may use two modulating motors to control the air and fuel flow
    • Smaller packaged boilers commonly use a single modulating motor that operates both the combustion air damper and the firing rate control valve, in unison

    Boiler Firing Rate Control

    • Firing rate control strategies are used to manage the energy output of a boiler to match the energy demand.
    • The energy output of a boiler must equal the energy demand to maintain a constant pressure or temperature.

    Steam Boilers

    • Produce a mass of steam at a particular rate, under certain conditions of temperature, pressure, and quality.
    • The measured variable is the steam pressure.
    • The manipulated variables are the fuel flow and the airflow.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a steam pressure set point.

    Hot Water Boilers

    • Produce a mass of hot water, flowing at a particular rate, at a particular temperature.
    • The measured variable is the outlet water temperature.
    • The manipulated variables are the fuel flow and the airflow.
    • The process variable is the hot water supply temperature.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a hot water temperature set point.

    Control Strategies

    • Two-position (on-off) control: the burner is either on or off.
    • Multi-position (high-low-off) control: the burner fires at high-fire, low-fire, or off.
    • Fully modulating control: the burner can operate at any firing rate between high-fire and low-fire.

    Two-Position Control

    • The burner cycles on and off to meet the energy demand.
    • The pressure (or temperature) swings above and below the desired set point.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Multi-Position Control

    • The burner fires at high-fire, low-fire, or off to meet the energy demand.
    • The control requires two operating pressure (or temperature) controls.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Fully Modulating Control

    • The burner can operate at any firing rate between high-fire and low-fire.
    • The control requires three pressure (or temperature) controls.
    • The control provides the highest efficiency and closest set point adherence.

    Firing Rate Control Devices

    • Sensing elements: measure the boiler pressure or temperature.
    • Final control elements: manipulate the fuel flow and airflow to control the firing rate.

    Two-Position Control Devices

    • Steam boilers use pressure-actuated two-position single-pole, single-throw switches as operating pressure controls, low-fire controls, high-fire controls, and high-pressure cut-offs.
    • Hot water boilers use temperature-actuated two-position single-pole, single-throw switches as operating temperature controls, low-fire controls, high-fire controls, and high-temperature cut-offs.### High-Pressure Cut-Off (HPCO)
    • Is a safety feature that shuts off the burner when the operating pressure control fails
    • Has a manual reset button and does not have a differential adjustment
    • Must be set higher than the operating pressure control and the high-low fire controls
    • National Board of Boiler and Pressure Inspectors recommends the following HPCO set points:
      • For steam heating boilers, the HPCO set point should not exceed 90 kPa
      • For steam power boilers:
        • Up to 2100 kPa MAWP, the HPCO setting should be at least 10% lower than the setting of the safety valve, or 50 kPa lower than the setting of the safety valve, whichever is greater
        • Over 2100 kPa to 6890 kPa, the HPCO setting should be at least 7% lower than the setting of the safety valve, or 200 kPa lower than the setting of the safety valve, whichever is greater
        • Over 6890 kPa to 13800 kPa, the HPCO setting should be at least 5% lower than the setting of the safety valve, or 480 kPa lower than the setting of the safety valve, whichever is greater

    Hot Water Boilers

    • Two-position temperature control devices are used as operating temperature controls (aquastats), high- and low-firing controls, and high-temperature cut-offs
    • ASME CSD-1 Part CW-410 Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers states:
      • Each automatically fired hot water boiler shall have at least one temperature-actuated control to shut off the fuel supply when the system water reaches a preset operating temperature
      • Each automatically fired hot water boiler shall have a high-temperature limit control that will prevent the water temperature from exceeding the maximum allowable water temperature, cause safety shutdown and lockout when it activates, require manual reset, and indicate when it is activated
      • Each limit and operating control shall have its own sensing element and operating switch

    Operating Temperature Control (Aquastat), High Fire Control, or Low Fire Control

    • Combines a filled system thermometer with a bellows-operated SPST switch
    • Pressure inside the thermometer increases when boiler water temperature increases, expanding the bellows and activating the switch at the controller set point
    • The opposite occurs when the temperature drops
    • Thermometer-sensing bulb is inserted in a thermowell located at the boiler hot water outlet
    • If equipped with a capillary tube, the controller may be mounted separately, at a more easily accessible location
    • Figure 15 shows two-position controls used for hot water boilers

    High Temperature Cut-off (HTCO)

    • Similar in operation to the operating temperature control
    • Bellows or pressure capsule, attached to a filled system thermometer, operates a SPST switch to open the firing circuit
    • Set higher than the operating temperature control, the high-low fire controls, and the modulating temperature control
    • Shuts off the burner when the operating temperature controls fail to stop the burner
    • Does not have a differential adjustment and has a manual reset button
    • When the HTCO activates, its switch locks in the open position, requiring operator intervention to reset

    Modulating Controllers

    • Steam boilers with fully modulating burners require a modulating pressure control, in addition to the operating pressure control and the high-pressure cut-off
    • Hot water boilers with fully modulating burners require a modulating temperature control, in addition to the operating temperature control and the high-temperature cut-off
    • Modulating controllers enable the firing rate to be continuously adjusted to match the boiler load as it varies
    • Figure 17 shows a modulating pressure control with its cover removed
    • Figure 18 shows a modulating temperature control used with hot water heating boilers

    Modulating Motors

    • Used in electrical control systems to position dampers and valves
    • In the case of boilers, they position the combustion air damper and the firing rate control valve
    • When the steam pressure (or water temperature) is at the controller set point, the circuit is balanced, and the modulating motor does not run
    • When the steam pressure or water temperature rises, the resistance of the slide wire controller changes, unbalancing the circuit, and causing the modulating motor to drive to the closed position
    • Some larger boilers may use two modulating motors to control the air and fuel flow
    • Smaller packaged boilers commonly use a single modulating motor that operates both the combustion air damper and the firing rate control valve, in unison

    Boiler Firing Rate Control

    • Firing rate control strategies are used to manage the energy output of a boiler to match the energy demand.
    • The energy output of a boiler must equal the energy demand to maintain a constant pressure or temperature.

    Steam Boilers

    • Produce a mass of steam at a particular rate, under certain conditions of temperature, pressure, and quality.
    • The measured variable is the steam pressure.
    • The manipulated variables are the fuel flow and the airflow.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a steam pressure set point.

    Hot Water Boilers

    • Produce a mass of hot water, flowing at a particular rate, at a particular temperature.
    • The measured variable is the outlet water temperature.
    • The manipulated variables are the fuel flow and the airflow.
    • The process variable is the hot water supply temperature.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a hot water temperature set point.

    Control Strategies

    • Two-position (on-off) control: the burner is either on or off.
    • Multi-position (high-low-off) control: the burner fires at high-fire, low-fire, or off.
    • Fully modulating control: the burner can operate at any firing rate between high-fire and low-fire.

    Two-Position Control

    • The burner cycles on and off to meet the energy demand.
    • The pressure (or temperature) swings above and below the desired set point.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Multi-Position Control

    • The burner fires at high-fire, low-fire, or off to meet the energy demand.
    • The control requires two operating pressure (or temperature) controls.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Fully Modulating Control

    • The burner can operate at any firing rate between high-fire and low-fire.
    • The control requires three pressure (or temperature) controls.
    • The control provides the highest efficiency and closest set point adherence.

    Firing Rate Control Devices

    • Sensing elements: measure the boiler pressure or temperature.
    • Final control elements: manipulate the fuel flow and airflow to control the firing rate.

    Two-Position Control Devices

    • Steam boilers use pressure-actuated two-position single-pole, single-throw switches as operating pressure controls, low-fire controls, high-fire controls, and high-pressure cut-offs.
    • Hot water boilers use temperature-actuated two-position single-pole, single-throw switches as operating temperature controls, low-fire controls, high-fire controls, and high-temperature cut-offs.### High-Pressure Cut-Off (HPCO)
    • Is a safety feature that shuts off the burner when the operating pressure control fails
    • Has a manual reset button and does not have a differential adjustment
    • Must be set higher than the operating pressure control and the high-low fire controls
    • National Board of Boiler and Pressure Inspectors recommends the following HPCO set points:
      • For steam heating boilers, the HPCO set point should not exceed 90 kPa
      • For steam power boilers:
        • Up to 2100 kPa MAWP, the HPCO setting should be at least 10% lower than the setting of the safety valve, or 50 kPa lower than the setting of the safety valve, whichever is greater
        • Over 2100 kPa to 6890 kPa, the HPCO setting should be at least 7% lower than the setting of the safety valve, or 200 kPa lower than the setting of the safety valve, whichever is greater
        • Over 6890 kPa to 13800 kPa, the HPCO setting should be at least 5% lower than the setting of the safety valve, or 480 kPa lower than the setting of the safety valve, whichever is greater

    Hot Water Boilers

    • Two-position temperature control devices are used as operating temperature controls (aquastats), high- and low-firing controls, and high-temperature cut-offs
    • ASME CSD-1 Part CW-410 Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers states:
      • Each automatically fired hot water boiler shall have at least one temperature-actuated control to shut off the fuel supply when the system water reaches a preset operating temperature
      • Each automatically fired hot water boiler shall have a high-temperature limit control that will prevent the water temperature from exceeding the maximum allowable water temperature, cause safety shutdown and lockout when it activates, require manual reset, and indicate when it is activated
      • Each limit and operating control shall have its own sensing element and operating switch

    Operating Temperature Control (Aquastat), High Fire Control, or Low Fire Control

    • Combines a filled system thermometer with a bellows-operated SPST switch
    • Pressure inside the thermometer increases when boiler water temperature increases, expanding the bellows and activating the switch at the controller set point
    • The opposite occurs when the temperature drops
    • Thermometer-sensing bulb is inserted in a thermowell located at the boiler hot water outlet
    • If equipped with a capillary tube, the controller may be mounted separately, at a more easily accessible location
    • Figure 15 shows two-position controls used for hot water boilers

    High Temperature Cut-off (HTCO)

    • Similar in operation to the operating temperature control
    • Bellows or pressure capsule, attached to a filled system thermometer, operates a SPST switch to open the firing circuit
    • Set higher than the operating temperature control, the high-low fire controls, and the modulating temperature control
    • Shuts off the burner when the operating temperature controls fail to stop the burner
    • Does not have a differential adjustment and has a manual reset button
    • When the HTCO activates, its switch locks in the open position, requiring operator intervention to reset

    Modulating Controllers

    • Steam boilers with fully modulating burners require a modulating pressure control, in addition to the operating pressure control and the high-pressure cut-off
    • Hot water boilers with fully modulating burners require a modulating temperature control, in addition to the operating temperature control and the high-temperature cut-off
    • Modulating controllers enable the firing rate to be continuously adjusted to match the boiler load as it varies
    • Figure 17 shows a modulating pressure control with its cover removed
    • Figure 18 shows a modulating temperature control used with hot water heating boilers

    Modulating Motors

    • Used in electrical control systems to position dampers and valves
    • In the case of boilers, they position the combustion air damper and the firing rate control valve
    • When the steam pressure (or water temperature) is at the controller set point, the circuit is balanced, and the modulating motor does not run
    • When the steam pressure or water temperature rises, the resistance of the slide wire controller changes, unbalancing the circuit, and causing the modulating motor to drive to the closed position
    • Some larger boilers may use two modulating motors to control the air and fuel flow
    • Smaller packaged boilers commonly use a single modulating motor that operates both the combustion air damper and the firing rate control valve, in unison

    Boiler Firing Rate Control

    • Firing rate control strategies are used to manage the energy output of a boiler to match the energy demand.
    • The energy output of a boiler must equal the energy demand to maintain a constant pressure or temperature.

    Steam Boilers

    • Produce a mass of steam at a particular rate, under certain conditions of temperature, pressure, and quality.
    • The measured variable is the steam pressure.
    • The manipulated variables are the fuel flow and the airflow.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a steam pressure set point.

    Hot Water Boilers

    • Produce a mass of hot water, flowing at a particular rate, at a particular temperature.
    • The measured variable is the outlet water temperature.
    • The manipulated variables are the fuel flow and the airflow.
    • The process variable is the hot water supply temperature.
    • The final control elements are the combustion air dampers and the firing rate control valve.
    • The automatic control system changes the firing rate to maintain a hot water temperature set point.

    Control Strategies

    • Two-position (on-off) control: the burner is either on or off.
    • Multi-position (high-low-off) control: the burner fires at high-fire, low-fire, or off.
    • Fully modulating control: the burner can operate at any firing rate between high-fire and low-fire.

    Two-Position Control

    • The burner cycles on and off to meet the energy demand.
    • The pressure (or temperature) swings above and below the desired set point.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Multi-Position Control

    • The burner fires at high-fire, low-fire, or off to meet the energy demand.
    • The control requires two operating pressure (or temperature) controls.
    • The control is non-modulating, meaning it cannot adjust the firing rate to match the energy demand.

    Fully Modulating Control

    • The burner can operate at any firing rate between high-fire and low-fire.
    • The control requires three pressure (or temperature) controls.
    • The control provides the highest efficiency and closest set point adherence.

    Firing Rate Control Devices

    • Sensing elements: measure the boiler pressure or temperature.
    • Final control elements: manipulate the fuel flow and airflow to control the firing rate.

    Two-Position Control Devices

    • Steam boilers use pressure-actuated two-position single-pole, single-throw switches as operating pressure controls, low-fire controls, high-fire controls, and high-pressure cut-offs.
    • Hot water boilers use temperature-actuated two-position single-pole, single-throw switches as operating temperature controls, low-fire controls, high-fire controls, and high-temperature cut-offs.### High-Pressure Cut-Off (HPCO)
    • Is a safety feature that shuts off the burner when the operating pressure control fails
    • Has a manual reset button and does not have a differential adjustment
    • Must be set higher than the operating pressure control and the high-low fire controls
    • National Board of Boiler and Pressure Inspectors recommends the following HPCO set points:
      • For steam heating boilers, the HPCO set point should not exceed 90 kPa
      • For steam power boilers:
        • Up to 2100 kPa MAWP, the HPCO setting should be at least 10% lower than the setting of the safety valve, or 50 kPa lower than the setting of the safety valve, whichever is greater
        • Over 2100 kPa to 6890 kPa, the HPCO setting should be at least 7% lower than the setting of the safety valve, or 200 kPa lower than the setting of the safety valve, whichever is greater
        • Over 6890 kPa to 13800 kPa, the HPCO setting should be at least 5% lower than the setting of the safety valve, or 480 kPa lower than the setting of the safety valve, whichever is greater

    Hot Water Boilers

    • Two-position temperature control devices are used as operating temperature controls (aquastats), high- and low-firing controls, and high-temperature cut-offs
    • ASME CSD-1 Part CW-410 Requirements for Temperature Controls for Hot-Water Heating and Supply Boilers states:
      • Each automatically fired hot water boiler shall have at least one temperature-actuated control to shut off the fuel supply when the system water reaches a preset operating temperature
      • Each automatically fired hot water boiler shall have a high-temperature limit control that will prevent the water temperature from exceeding the maximum allowable water temperature, cause safety shutdown and lockout when it activates, require manual reset, and indicate when it is activated
      • Each limit and operating control shall have its own sensing element and operating switch

    Operating Temperature Control (Aquastat), High Fire Control, or Low Fire Control

    • Combines a filled system thermometer with a bellows-operated SPST switch
    • Pressure inside the thermometer increases when boiler water temperature increases, expanding the bellows and activating the switch at the controller set point
    • The opposite occurs when the temperature drops
    • Thermometer-sensing bulb is inserted in a thermowell located at the boiler hot water outlet
    • If equipped with a capillary tube, the controller may be mounted separately, at a more easily accessible location
    • Figure 15 shows two-position controls used for hot water boilers

    High Temperature Cut-off (HTCO)

    • Similar in operation to the operating temperature control
    • Bellows or pressure capsule, attached to a filled system thermometer, operates a SPST switch to open the firing circuit
    • Set higher than the operating temperature control, the high-low fire controls, and the modulating temperature control
    • Shuts off the burner when the operating temperature controls fail to stop the burner
    • Does not have a differential adjustment and has a manual reset button
    • When the HTCO activates, its switch locks in the open position, requiring operator intervention to reset

    Modulating Controllers

    • Steam boilers with fully modulating burners require a modulating pressure control, in addition to the operating pressure control and the high-pressure cut-off
    • Hot water boilers with fully modulating burners require a modulating temperature control, in addition to the operating temperature control and the high-temperature cut-off
    • Modulating controllers enable the firing rate to be continuously adjusted to match the boiler load as it varies
    • Figure 17 shows a modulating pressure control with its cover removed
    • Figure 18 shows a modulating temperature control used with hot water heating boilers

    Modulating Motors

    • Used in electrical control systems to position dampers and valves
    • In the case of boilers, they position the combustion air damper and the firing rate control valve
    • When the steam pressure (or water temperature) is at the controller set point, the circuit is balanced, and the modulating motor does not run
    • When the steam pressure or water temperature rises, the resistance of the slide wire controller changes, unbalancing the circuit, and causing the modulating motor to drive to the closed position
    • Some larger boilers may use two modulating motors to control the air and fuel flow
    • Smaller packaged boilers commonly use a single modulating motor that operates both the combustion air damper and the firing rate control valve, in unison

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    Description

    This chapter covers boiler firing circuits, building upon instrumentation topics and referencing ASME CSD-1 codes for automatically fired boilers. It discusses firing rate controls and their responses to temperature or pressure set points.

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