Podcast
Questions and Answers
EASY What is the primary purpose of pressure limit controls in steam boilers?
What is the measured variable in steam boiler control systems?
What is the final control element in steam boiler control systems?
What happens when there is more heat energy entering the hot water boiler than needed by the equipment?
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What is the primary purpose of temperature limit controls in hot water boilers?
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What is the measured variable in hot water boiler control systems?
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What is the process variable in hot water boiler control systems?
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What is the control strategy used in two-position firing rate control?
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What happens when the burner is on in two-position control?
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What is the purpose of the operating cycle in two-position control?
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Why do on-off boilers experience significant loss of heat?
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What is the main advantage of operating boilers continuously?
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What type of control system is used in smaller capacity boilers?
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What is the main difference between multi-position control and on-off control?
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What is the purpose of the low-fire control in a multi-position firing rate control?
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What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?
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What is the advantage of multi-position firing rate control over on-off control?
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What is the purpose of the two operating pressure controls in a multi-position firing rate control?
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What happens to the average steam pressure as the load increases in a multi-position firing rate control?
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What is the difference between the operation of multi-position firing rate control in steam boilers and hot water boilers?
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What is the primary focus of this chapter?
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What is the purpose of high limit controls in firing rate controls?
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What is the primary goal of firing rate controls?
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What happens when there is greater heat energy entering the boiler than required by the equipment?
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What is the consequence of a steam boiler continuing to fire at an excessive rate?
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What is the purpose of firing rate controls in boilers?
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What is the reference code for automatically fired boilers?
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What is the energy output of a boiler equal to?
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What is the function of the high-fire control?
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What is the purpose of the manual firing rate limit switch?
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What is the advantage of fully modulating firing rate control?
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How many pressure controls are required for steam boilers with fully modulating firing rate control?
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What is the function of the resistance slide-wire control?
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What happens when the boiler pressure rises to 65 kPa?
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What is the purpose of the high-pressure cut-off control?
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What is the advantage of fully modulating firing rate control in terms of plant efficiency?
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How many controls are required for hot water boilers with fully modulating firing rate control?
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What is the purpose of the operating pressure control?
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What is the purpose of the high-pressure cut-off in a steam boiler?
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What type of control devices are used in steam boilers?
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What is the purpose of the resistance slide-wire pressure control in a fully modulating firing rate control?
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What is required when starting up a cold boiler with a fully modulating firing rate control?
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What is the function of the programming controller in a fully modulating firing rate control?
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What is the purpose of the operating pressure control in a steam boiler?
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What type of sensors are used in hot water boilers to control the firing rate of fully modulating burners?
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What is required by ASME CSD-1 Part CW-310 for automatically fired steam boilers?
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What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?
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What is the difference between a two-position control device and a fully modulating control device?
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What is the minimum difference required between the HPCO setting and the safety valve setting?
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What type of switch is used in a two-position temperature control device?
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What is the minimum size of a siphon required to protect a pressure control device?
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What is the requirement for automatically fired hot water boilers according to ASME CSD-1 Part CW-410?
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What causes the bellows to expand in a mercury switch pressure control?
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What is the result of small cracks in the glass of a mercury switch?
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What happens when the high-temperature limit control is activated?
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What is the purpose of the operating temperature control?
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What happens when the steam pressure falls?
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What is the purpose of the high-pressure cut-off (HPCO)?
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What is the difference between the operating temperature control and the high temperature cut-off?
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What is the difference between the HPCO and the operating pressure control?
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What is the purpose of the MAN-AUTO control station?
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What is the recommended HPCO set point for steam heating boilers?
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What is the function of the bellows in the operating temperature control?
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What is the function of the crank arms in smaller packaged boilers?
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What is the purpose of the thermowell in the operating temperature control?
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What is the advantage of using two modulating motors in larger boilers?
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What is the purpose of the differential adjustment in a pressure control?
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What is the maximum temperature setting for the operating temperature control shown in Figure 15(a)?
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What is the purpose of the adjustable cam in the fuel valve?
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What happens when the HPCO activates?
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What is the result of the operator not intervening after the HPCO activates?
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What is the purpose of the differential switch in the high-low fire control?
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What is the result of the opposite sequence occurring in the boiler?
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Why is the HPCO set point higher than the operating pressure control?
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What is the purpose of a modulating pressure control in steam boilers?
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What is the function of the manual flame control potentiometer in a modulating controller?
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What is the purpose of the proportional range setting in a modulating temperature control?
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What happens when the steam pressure rises above the set point in a modulating pressure control?
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What is the function of the balancing relay in a modulating motor?
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What is the purpose of the bridge circuit in a modulating motor?
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What is the function of the feedback potentiometer in a modulating motor?
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Why is a manual-automatic switch required in a modulating controller?
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What is the purpose of the MIN setting in a modulating pressure control?
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What happens when the boiler is in manual mode and the modulating controller is enabled?
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What is the primary goal of firing rate controls in boilers?
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What happens when there is less heat energy entering the boiler than required by the equipment?
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What is the primary purpose of safety valves in steam boilers?
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What happens when there is less heat energy entering the hot water boiler than needed by the equipment?
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What is the primary difference between steam boilers and hot water boilers?
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What is the purpose of the combustion air dampers in steam boiler control systems?
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What is the advantage of using a multi-position firing rate control over a two-position firing rate control?
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What is the purpose of the firing rate control valve in steam boiler control systems?
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What happens when a hot water boiler continues to fire at an excessive rate and this condition goes unchecked?
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What is the purpose of the automatic control system in steam boiler control systems?
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What is the advantage of using a fully modulating firing rate control over a multi-position firing rate control?
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What is the purpose of the temperature limit controls in hot water boilers?
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What is the purpose of the low-fire control in a fully modulating firing rate control?
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What happens when the boiler pressure rises to 65 kPa in a fully modulating firing rate control?
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What is the advantage of fully modulating firing rate control over on-off control?
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MEDIUM What is the function of the resistance slide-wire control in a fully modulating firing rate control?
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What is required when starting up a cold boiler with a fully modulating firing rate control?
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What is the purpose of the high-pressure cut-off control in a steam boiler?
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How many pressure controls are required for steam boilers with fully modulating firing rate control?
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What is the purpose of the operating pressure control in a steam boiler?
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What is the advantage of fully modulating firing rate control in terms of plant efficiency?
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What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?
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Why do boilers, regardless of the firing rate control system used, operate more efficiently continuously?
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What is the primary reason why two-position control is only used in smaller capacity boilers?
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What is the purpose of the low-fire control in a multi-position firing rate control?
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What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?
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What is the advantage of multi-position firing rate control over on-off control?
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What happens to the average steam pressure as the load increases in a multi-position firing rate control?
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What is the purpose of the two operating pressure controls in a multi-position firing rate control?
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What is the difference between the operation of multi-position firing rate control in steam boilers and hot water boilers?
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Why do on-off boilers experience significant loss of heat?
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What is the main advantage of operating boilers continuously?
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What is the primary purpose of a siphon in a pressure control device?
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What happens when the desired cut-off pressure is reached in a mercury switch pressure control?
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Why are mercury switches no longer manufactured?
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What is the primary difference between the high-pressure cut-off and the operating pressure control?
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What is the recommended HPCO set point for steam heating boilers?
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What is the purpose of the high-pressure cut-off in a steam boiler?
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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?
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What type of switch is used in a mechanical pressure control?
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What is the primary function of the modulating motor in smaller packaged boilers?
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What happens when the HPCO activates?
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Why is operator intervention required when the HPCO activates?
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What is the purpose of the adjustable cam in the fuel valve crank arm?
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What happens when the steam pressure (or water temperature) falls in a boiler control system?
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What is the purpose of the MAN-AUTO control station in a boiler control system?
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What is the advantage of using two modulating motors in larger boilers?
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What is the function of the fuel cam in the modulating motor control system?
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What type of switch is used in steam boilers as operating pressure controls, high and low firing controls, and high-pressure cut-offs?
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What is the purpose of the high-pressure cut-off control in a steam boiler?
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What type of control devices are used in hot water boilers to control the firing rate of fully modulating burners?
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What is the advantage of fully modulating firing rate control over on-off control?
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What is required when starting up a cold boiler with a fully modulating firing rate control?
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What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?
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What is the function of the resistance slide-wire pressure control in a fully modulating firing rate control?
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What type of sensors are used in steam boilers to control the firing rate of fully modulating burners?
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What is the difference between a two-position control device and a fully modulating control device?
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What is the purpose of the operating pressure control in a steam boiler?
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What is the primary purpose of the high temperature cut-off (HTCO) in hot water boilers?
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What is the requirement for automatically fired hot water boilers according to ASME CSD-1 Part CW-410?
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What is the function of the bellows-operated SPST switch in the operating temperature control?
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What is the difference between the operating temperature control and the high temperature cut-off (HTCO)?
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What is the purpose of the two-position temperature control device in hot water boilers?
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What is the requirement for the HPCO setting in relation to the safety valve setting?
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What is the function of the thermometer-sensing bulb in the operating temperature control?
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What is the purpose of the differential setting wheel in the two-position temperature control device?
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What is the advantage of using a remote temperature-sensing element in the operating temperature control?
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What is the purpose of the high-temperature limit control in hot water boilers?
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What is the main function of the manual flame control potentiometer?
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What is the purpose of the proportional range setting in a modulating temperature control?
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What happens when the steam pressure or water temperature rises in a modulating motor?
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What is the function of the balancing relay in a modulating motor?
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What is the purpose of the set point setting in a modulating pressure control?
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What is the advantage of fully modulating firing rate control?
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What is the purpose of the feedback potentiometer in a modulating motor?
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What happens when the MANUAL-AUTOMATIC switch is placed in MANUAL?
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What is the purpose of the differential setting in a modulating pressure control?
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What is the function of the bridge circuit in a modulating motor?
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What is the primary purpose of firing rate controls in boilers?
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What happens when there is less heat energy entering the boiler than required by the equipment?
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What is the code that most suitably addresses automatic firing rate controls?
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What is the consequence of a steam boiler continuing to fire at an excessive rate?
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In steam boiler control systems, what is the purpose of the final control elements?
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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?
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What must firing rate controls be able to adjust to?
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What is the energy output of a boiler equal to?
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What is the primary difference between steam boiler control systems and hot water boiler control systems?
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What is the purpose of the safety valves in steam boilers?
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What must high limit controls be able to do in firing rate controls?
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What is the consequence of a hot water boiler continuing to fire at an excessive rate?
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What is the primary focus of this chapter?
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What is the purpose of the automatic control system in steam boilers?
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What is the major difference between two-position control and multi-position control?
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What happens to the average heat input of the burner in two-position firing rate control?
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What is the purpose of the temperature limit controls in hot water boilers?
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What is the advantage of fully modulating firing rate control over on-off control and multi-position control?
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What is the primary disadvantage of on-off boilers?
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What is the primary advantage of multi-position firing rate control?
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What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?
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What is the purpose of the low-fire control in a multi-position firing rate control?
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HARD What happens to the average steam pressure as the load increases in a multi-position firing rate control?
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What is the primary difference between multi-position control and on-off control?
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What is the purpose of the two operating pressure controls in a multi-position firing rate control?
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Why are two-position control systems only used in smaller capacity boilers?
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What is the advantage of operating boilers continuously?
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What happens when the load is low in a multi-position firing rate control?
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What is the main purpose of the resistance slide-wire pressure control in a fully modulating firing rate control?
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What is the purpose of the high-pressure cut-off control in a steam boiler?
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What happens when starting up a cold boiler with a fully modulating firing rate control?
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What is the purpose of the manual firing rate limit switch in a fully modulating firing rate control?
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What type of sensors are used in steam boilers to control the firing rate of fully modulating burners?
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What is the purpose of the operating pressure control in a steam boiler?
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What is required by ASME CSD-1 Part CW-310 for automatically fired steam boilers?
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What is the difference between a two-position control device and a fully modulating control device?
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What happens when the boiler pressure falls to 35 kPa in a multi-position firing rate control?
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What is the advantage of fully modulating firing rate control over on-off control?
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What is the primary function of the air damper linkage in a high-low firing rate control?
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What happens when the boiler pressure reaches 70 kPa in a steam boiler with fully modulating firing rate control?
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What is the purpose of the manual firing rate limit switch in a boiler with fully modulating firing rate control?
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What is the primary advantage of fully modulating firing rate control in steam boilers?
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What is the purpose of the high-pressure cut-off control in a steam boiler?
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What is the primary function of the operating pressure control in a steam boiler with fully modulating firing rate control?
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What is the purpose of the resistance slide-wire control in a steam boiler with fully modulating firing rate control?
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What is the primary purpose of the high-pressure cut-off control in a steam boiler?
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What happens when the boiler pressure falls to 55 kPa in a steam boiler with fully modulating firing rate control?
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What is the primary advantage of fully modulating firing rate control in hot water boilers?
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What is the minimum size of a siphon required to protect a pressure control device?
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What is the primary function of the programming controller in a fully modulating firing rate control?
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What happens when the mercury switch in a pressure control device fails?
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What is the purpose of the manual reset button on a high-pressure cut-off control?
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What is the recommended HPCO setting for steam heating boilers according to the National Board of Boiler and Pressure Inspectors?
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What is the purpose of a siphon or equivalent water seal in a pressure control device?
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What is the difference between a mercury switch and a mechanical switch pressure control?
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What is the purpose of the differential adjustment in a pressure control device?
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What is the recommended HPCO setting for steam power boilers with a MAWP up to 2100 kPa?
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What is the purpose of the MANUAL-AUTOMATIC switch in a modulating controller?
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What is the function of the balancing relay in a modulating motor?
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What happens when the boiler pressure falls to the cut-out point of the operating pressure control?
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What happens when the steam pressure rises above the set point in a modulating pressure control?
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What is the purpose of the feedback potentiometer in a modulating motor?
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What is the advantage of fully modulating firing rate control?
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What is the purpose of the high-temperature cut-off control in a hot water boiler?
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What is the function of the resistance slide-wire control in a modulating pressure control?
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What happens when the boiler temperature falls below the set point in a modulating temperature control?
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What is the purpose of the programming controller in a fully modulating firing rate control?
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What is the purpose of MAN-AUTO control station in boiler control systems?
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How do larger boilers typically control the air and fuel flow?
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What is the purpose of the adjustable cam on the crank arm for the fuel valve?
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What is the common arrangement used in smaller packaged boilers to control the air and fuel flow?
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What happens when the steam pressure (or water temperature) falls in a boiler control system?
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What is the purpose of the master pressure or temperature controller in a boiler control system?
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What is the minimum requirement for the HPCO setting in relation to the safety valve setting?
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What is the purpose of the high-temperature cut-off control?
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What is the difference between the high-temperature cut-off control and the operating temperature control?
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What is the requirement for temperature controls in automatically fired hot water boilers according to ASME CSD-1 Part CW-410?
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What is the function of the bellows-operated SPST switch in the operating temperature control?
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What is the purpose of the two-position temperature control device?
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What is the requirement for the sensing element and operating switch in temperature controls according to ASME CSD-1 Part CW-410?
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What is the function of the differential switch in the high-low fire control?
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What is the purpose of the high-temperature limit control?
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What is the requirement for the high-temperature cut-off control in automatically fired hot water boilers?
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Match the type of control devices used in steam boilers with their respective functions:
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Match the requirements for pressure controls for steam boilers with the corresponding ASME CSD-1 Part CW-310 section:
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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.