Future Of Boiler Room Controls-05-15-12b - Cleaver …cleaverbrooks.com › reference-center ›...
Transcript of Future Of Boiler Room Controls-05-15-12b - Cleaver …cleaverbrooks.com › reference-center ›...
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The Future of Boiler Room Control SystemsTotal Integration Assures Safety, Energy and Fuel Savings, Low Emissions, and More
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Topics
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Today’s Challenges
Areas Of Focus For Overcoming Challenges
The Future:The Integrated Package
Linked Up: Communication and Logging Systems
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Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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Today’s ChallengesParallel Many Boiler Requests
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Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
Fuel savings
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Pulled together by the transmission
Today’s ChallengesThe Boiler And Car Analogy
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Aerodynamic body
High powered fuel injected engine
Advanced suspension and steering
Pulled together by the integrated controls
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Integrated Control System
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Fuel Air
Burner Management
Combustion Control
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• C.C. power and modulating motor energized• Limit line and low fire switch• Pre-ignition interlock• Blower motor & terminal “B” in mod. motor• High fire switch• (30 second purge timing)• Running interlock circuit (CAPS)• Terminal “W” in mod. motor• Trial for pilot• Flame proving• Main valve energized (proven)• Release to modulation• Alarms
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Burner Management System Sequence“The Gate Way”
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• Parallel positioning• Fully metered/cross
limited• O2 trim • Draft control• FGR• Variable speed drive• Feedwater control• Lead lag control
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Integrated Control System
Fuel Air
Burner Management
Combustion Control And Sub-Systems
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Meeting Today’s Challenges
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Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
Fuel savings
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Mod Motor
Firing Rate Signal From Boiler Controls
Fuel Valve
Mechanical Adjustable
Cam
Common Shaft and Linkage Connections
and Control
FGR valve(If Used)
Combustion Air
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Single Jack Shaft Control
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Servo
FGR
Required for Low NOX –
around 30 ppm and below
PP Loop Controller
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Parallel PositioningFuel Air Ratio Control
Servo
FUEL 2
Servo
FUEL 1
Servo
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Readers andSensors
Areas Of Focus For Overcoming Challenges:O2 Trim Control
ServoServo
FUEL
O2 Loop Controller O2 Probe Analyzer
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Areas Of Focus For Overcoming Challenges:O2 Trim Control
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Benefits
Flue gas O2 consistencyFlue gas O2 consistency
Better combustionBetter combustion
Fuel-air corrections in conjunction with ambient air
temperature changes
Fuel-air corrections in conjunction with ambient air
temperature changes
Fuel-to-steam efficiencygains at an average of 1%Fuel-to-steam efficiency
gains at an average of 1%
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Areas Of Focus For Overcoming Challenges:Variable Speed Drive Control
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Variable SpeedDrive Control
Burner Blower
Energy SavingsVSD Loop Controller
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Areas Of Focus For Overcoming Challenges:Variable Speed Drive Control
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Benefits
Electrical savingsElectrical savings
Better combustionBetter combustion
Better control of excess airBetter control of excess air
Increased turndown capabilities
Increased turndown capabilities
Noise reduction atmid-to-low speedsNoise reduction atmid-to-low speeds
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Areas Of Focus For Overcoming Challenges:Draft Control
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Stack DraftTransmitter
Stack Draft Damper
Draft Loop Controller
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Areas Of Focus For Overcoming Challenges:Draft Control
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Benefits
Better flame stabilityBetter flame stability
Better combustionBetter combustion
Ability to maintain a positive furnace pressure
Ability to maintain a positive furnace pressure
Better control of excess airBetter control of excess air
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Areas Of Focus For Overcoming Challenges:Economizer Control
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Economizer By-Pass(if used):
Diverts flue gas around economizer on low flue gas temps
Stack Temperature
Cooler Water In
Heated Water Out
Flue Gas FromBoiler Outlet
Economizer Loop Controller
Less waste out the stack
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Areas Of Focus For Overcoming Challenges:Economizer Control
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Benefits
Increased efficiency between 2-4%Increased efficiency between 2-4%
Recovery of “normally lost” stack gasheat to pre-heat boiler feedwater
Recovery of “normally lost” stack gasheat to pre-heat boiler feedwater
By-pass helps alleviate condensingat low flue gas temperatures
By-pass helps alleviate condensingat low flue gas temperatures
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What It Takes To Accomplish This
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FiringRate
Control
Fuel-AirRatio
Control
O2Trim
DraftControl
Economizer Control
VSD Control
Requires• Individual loop
controllers
• Separate control panel
• Interface wiring for BMS
• Relays and timers
• Extra wiring
• Expert tuning
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The Future: The Integrated Package
• Logic PLC Controller• Touch Screen• Integrated Programming for Parallel
Positioning• Integrated Programming for O2 Trim
and Monitoring• Integrated Programming for Draft
Control• PLC Based Firing Rate Control
• Lead/Lag Programming• Stack Temp with High Limit Cut-off• Burner Management• Thermal Shock Protection• Dual Set Points• Remote Set Point Modulation• VSD Control• Economizer Control
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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Servo
FGR
Required for Low NOX –
around 30 ppm and below
Servo
FUEL 2
Servo
FUEL 1
Servo
FGR For NOx Reduction
Burner Blower
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FGR With Integral Firetube Burner
Linkage is replaced with servo motor
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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Boiler Lead-Lag Control
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The Future: The Integrated PackagePLC Based Systems for IWTs
Full Metered Control – 1,2,3 Element Feedwater
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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The Old WayDeaerator/Surge Tanks
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How do I communicate?
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New And ImprovedDeaerator/Surge Tanks
Tank Pressure
Tank Levels
Tank Temperature
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New And ImprovedDeaerator/Surge Tanks
Recirculation Automatic By-Pass
Tank LevelIndication
Variable Speed Drive Pump Control
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New And ImprovedDeaerator/Surge Tanks
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232 F
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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The Future: The Integrated PackageEasy Set and Configuration
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The Future: The Integrated PackageTypical Status Overview Screen
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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The Future: The Integrated PackageTypical Status Overview Screen
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The Future: The Integrated PackageTypical Firing Rate Control Screen
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The Future: The Integrated PackageUser Friendly Set Point Screens
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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The Future: The Integrated PackageTypical Alarm History Screen
Maintains Last 100 Alarm Points
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Boiler Room
Boiler Controls
Other Auxiliary
Equipment
Communications
System Flow Instrumentation
Flow Control for Hot Water Boilers
Surge Tank Controls
DA Controls
The Future: The Integrated PackageControlling the Balance of the Boiler Plant
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Linked Up: Communication And Logging Systems
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Universal
Premium
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Linked Up: Communication And Logging Systems
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Linked Up: Communication And Logging SystemsSCADA System: Elite Data Logging Option
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For Hawk Family of Products
Alarm Printer
Data Printer
Uninterruptable Power Supply
Data transmitted from all connected CB Hawk boiler
control systems, CB ADAC DA and surge tanks systems and other balance of plant controls
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Building Management System Integration
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOXburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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• Integrated burner management system
• Integrated combustion control system –separated for maximum safety (NFPA 85)
• Integrated sub systems
• Integrated alarming
• All operating parameters and faults easily seen
• Advanced low water control
Ultimate Safety
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Magnetostrictive Level Control
Level Master
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Meeting Today’s Challenges
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Fuel savings
Energy savings
Increased efficiencies
EPA regulations
Low NOxburner control
Reducedoperating costs
Ultimate safety
Precise load control
Expandability
Easy integration
Ease of operation
Data logging and communications
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Total Integration Goes Far Beyond Controls
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