Today’s Topic:Insights in Optimal Boiler Room Controls

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Insights in Optimal Boiler Room ControlsPresented by Steve ConnorSeptember 18, 2013

Overview

5

Energy Conservation

Today’s Key Drivers

Integration & OperationReduced Operating Costs

Emission Control

Answering the Drivers

Energy Conservation

7

O2 Trim Control

Servo Servo

FUEL

Transmitters and Sensors

O2 Loop Controller

O2 Probe Analyzer

Energy Conservation

8

Draft Control

Stack Draft Damper

Draft Loop Controller

Stack Draft Transmitter

Energy Conservation

9

Hydronic System Control

Reduced Operating Costs

10

Variable Speed Drive Control

Variable Speed Drive

Control

VSD Loop Controller

Burner Blower

Energy Savings

Reduced Operating Costs

11

Data Logging

Maintains Last 100 Alarm Points

Emission Control

12

Control Strategy Impact

• NOx Reduction• Turndown• Combustion Efficiency

Integration & Operation

13

PLC vs Loop

Integrated Control System

14

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• Purge to High Fire and proving switch

made• (30 second purge timing – 4 air changes)• Running interlocks proven• Purge to Low Fire and proving switch made

• Trial for Pilot and Flame Proven• Main Valve Energized and Flame Proven• Release to Modulation• Any Burner Related Alarms

15

Burner Management System Sequence

• Traditional Jack Shaft Control

• Parallel Positioning w/Cross Limited Feedback Control

• O2 trim • FGR Damper Control• Variable Speed

Drive on Burner Blower Motor

• Draft Control• Feedwater control• Lead lag control• Full Metered Control

Integrated Control System

16

Fuel Air

Burner Management

Combustion Control And Sub-Systems

Mod Motor

17

Single Jack Shaft ControlFiring Rate Signal From

Boiler ControlsCommon Shaft and

Linkage Connections and Control

Mechanical Adjustable

Cam

Fuel Valve

FGR Valve(If Used)

BurnerBlower

Combustion Air

Single Jackshaft or Single Point Positioning

Servo

Parallel Positioning: Fuel Air Ratio Control

19

Servo

FUEL 2

Servo

FUEL 1

Servo

PP LoopController

BurnerBlower

FGR

Required for Low NOx- around 30 ppm

and below

20

Diverts flue gas around economizer on low flue gas

temps

Cooler Water In

Heated Water Out

Economizer Control

Flue Gas From Boiler Outlet

Economizer By-Pass (if used)

Less waste out the stack

Economizer Loop Controller

Stack Temperature

21

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

What It Takes To Accomplish This

Solution Concept: An Individual Control Loop Controller

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• 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

22

Solution Concept: Best Practices (BACT) Controls

Cleaver-Brooks Integrated Controls Solutions

23

C-B Hawk 1000

C-B Hawk 4000

C-B Hawk 5000

Precise Load Control

24

Firing Rate Control Screen

Boiler Lead-Lag Control

25

Ease of Operation

26

Easy Set and Configuration

27

The Integrated Package

Typical Status Overview Screen

Ultimate Safety

28

Level Master

Magnestrictive Level Control

PLC Based Systems for IWTs

29

Full Metered Control – 1,2,3 Element Feedwater

New & Improved: Deaerator/Surge Tanks

Tank Pressure Tank Level

Tank Temperature

New & Improved: Deaerator/Surge Tanks

31

232 F

Linked Up: Communication & Logging Systems

32

Universal

Premium

33

Data transmitted from all connected CB Hawk boiler

control systems, CB ADAC DA and surge tanks systems and

other balance of plant controls

SCADA System: Elite Data Logging Option

Uninterruptable Power Supply

Data Printer

Alarm Printer

For Hawk Family of Products

34

Cloud Based Communications

Pulled together by the transmission

35

Aerodynamic body

High powered fuel injected engine

Advanced suspension and steering

Pulled together by the integrated controls

The Boiler and Car Analogy

Open Discussion with Expert PanelCleaver-Brooks:Wendell PipkinBill KovalcikBoris Tynkov

Manufacturer’s RepresentativesJon Craig, C & C BoilerTom Wiley, R.F. MacDonaldFor additional information:Email us at marketing@cleaverbrooks.com