The Future of Boiler Room Control SystemsTotal Integration Assures Safety, Energy and Fuel Savings, Low Emissions, and More

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

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

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

Integrated Control System

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Fuel Air

Burner Management

Combustion Control

• 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”

• 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

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

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

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

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%

Areas Of Focus For Overcoming Challenges:Variable Speed Drive Control

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Variable SpeedDrive Control

Burner Blower

Energy SavingsVSD Loop Controller

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

Areas Of Focus For Overcoming Challenges:Draft Control

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Stack DraftTransmitter

Stack Draft Damper

Draft Loop Controller

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

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

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

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

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

FGR With Integral Firetube Burner

Linkage is replaced with servo motor

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

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

The Old WayDeaerator/Surge Tanks

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How do I communicate?

New And ImprovedDeaerator/Surge Tanks

Tank Pressure

Tank Levels

Tank Temperature

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

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

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

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

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

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

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

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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Wendell PipkinControls and Conversions Manager

wpipkin@cleaverbrooks.com(229) 227-4408

cleaverbrooks.com

Total Integration Goes Far Beyond Controls

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