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Combustion control retrofit

Wednesday, March 22, 2017   By: steammonkey [1913] 0 Stars
Am looking for any comments or opinions about grandfathering a CC system on a large industrial water tube boiler.
Will be removing drum level, feedwater, and steam flow as they were measured by mercury filled ledoux bell meters.
The plan is to update these functions to PLC control with updated transmitters. Also being incorperated into PLC
will be the boiler master which was on a single loop controller that had been an add on. This will be integrated into
the existing 1973 vintage Foxboro pneumatic controls which are currently running this boiler.
I dont like this plan for many reason and would like some input as to whether my feelings on this matter are
right or wrong. I appreciate any comments or helpful opinions.

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Friday, March 31, 2017   By: Ross [390] 5 Stars
Having thought about this a second time, your steam plant boiler and combustion controls changes are upgrades to integrate into perhaps a Building Information System.

Your watertube boiler water level controls are on-off and now you will likely be able to collect data on drum level measurement say every minute or whatever increment and record digitally.

As far as the flow meters, servicing is a problem and peoples nervousness in working with mercury. The 3rd thing about the older technology of your flow meters is their incapability or non-standard interface or lack of interface for data collection to an information bus.

It doesnt seem right that the boiler master is a single loop, but should it be then it certainly needs upgrading your combustion control system. I would suspect you have at least parallel positioning and to control combustion better your may need a metering scheme especially since you are problem a 2 or 3 element system.

Ross Burns

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Saturday, April 01, 2017   By: Greg Burns [1953] 0 Stars
I am curious as to what are your concerns. Though I would prefer a DCS for boiler controls todays PLCs are more than capable. You will now be able to enhance the controls by integrating the steam flow as a feed forward to your boiler master and as part of a three element drum level control scheme. Overall boiler response and control will improve. I have far greater concerns with the continued operation of the antiquated equipment that is most likely unserviceable.

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Friday, April 14, 2017   By: Day Brown [2138] 0 Stars
Stuxnet worked because an industrial standard PLC was hacked. Turns out OEM commonly stole software, cutting & pasting it from wherever, without the source code to really know what the chip could do. If security is an issue, consider discretes that operate off analogue input.

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Published on steamforum.com


High Sulfite Residual
By: Ross. [390]

First, I want to say that large amounts of Sodium Sulfite NaSO3 becomes a contaminate because it will produce foaming and other problems, but foaming is the primary problem.

Your 500-psi Water Tube Boiler is seems to have reasonable level of residual Sodium Sulfite NaSO3 remaining in the boiler water. Nice pH too.

Your 300-psi Waste Heat Recovery Boiler has twice what I would expect for Sodium Sulfite NaSO3 at ranging 80-ppm to 100-ppm. pH is good so you are getting a good yield.

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