Future Of Boiler Room Controls-05-15-12b - Cleaver …cleaverbrooks.com › reference-center ›...
52
The Future of Boiler Room Control Systems Total Integration Assures Safety, Energy and Fuel Savings, Low Emissions, and More
Transcript of Future Of Boiler Room Controls-05-15-12b - Cleaver …cleaverbrooks.com › reference-center ›...
The Future of Boiler Room Control SystemsTotal Integration Assures Safety, Energy and Fuel Savings, Low Emissions, and More
Topics
2
Today’s Challenges
Areas Of Focus For Overcoming Challenges
The Future:The Integrated Package
Linked Up: Communication and Logging Systems
1
2
3
4
Today’s Challenges
3
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
4
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
5
Aerodynamic body
High powered fuel injected engine
Advanced suspension and steering
Pulled together by the integrated controls
Integrated Control System
6
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
7
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
8
Integrated Control System
Fuel Air
Burner Management
Combustion Control And Sub-Systems
Meeting Today’s Challenges
9
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
10
Single Jack Shaft Control
Servo
FGR
Required for Low NOX –
around 30 ppm and below
PP Loop Controller
11
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
12
Areas Of Focus For Overcoming Challenges:O2 Trim Control
13
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
14
Variable SpeedDrive Control
Burner Blower
Energy SavingsVSD Loop Controller
Areas Of Focus For Overcoming Challenges:Variable Speed Drive Control
15
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
16
Stack DraftTransmitter
Stack Draft Damper
Draft Loop Controller
Areas Of Focus For Overcoming Challenges:Draft Control
17
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
18
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
19
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
20
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
21
Meeting Today’s Challenges
22
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
23
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
25
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
26
The Future: The Integrated PackagePLC Based Systems for IWTs
Full Metered Control – 1,2,3 Element Feedwater
27
Meeting Today’s Challenges
28
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
29
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
31
New And ImprovedDeaerator/Surge Tanks
32
232 F
Meeting Today’s Challenges
33
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
34
The Future: The Integrated PackageTypical Status Overview Screen
35
Meeting Today’s Challenges
36
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
37
The Future: The Integrated PackageTypical Firing Rate Control Screen
38
The Future: The Integrated PackageUser Friendly Set Point Screens
39
Meeting Today’s Challenges
40
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
41
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
42
Linked Up: Communication And Logging Systems
43
Universal
Premium
Linked Up: Communication And Logging Systems
44
Linked Up: Communication And Logging SystemsSCADA System: Elite Data Logging Option
45
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
46
Meeting Today’s Challenges
47
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
48
• 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
49
Magnetostrictive Level Control
Level Master
Meeting Today’s Challenges
50
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
Total Integration Goes Far Beyond Controls
52
