Automated control system for boiler with mechanical loading of fuel (woodchips) with 4 MW capacity

Project Prerequisites:

Upgrade of the boiler house in Obukhovo agrotown supplying a required boiler KVTSm-4.0 manufactured by PPSUE Leterm.

Goal of the Project:

Develop and commission a boiler ACS.

Description of the Project:

Hot water boiler with mechanical loading of KVTSm series with cyclone furnace designed to extract heat energy from bark and wood waste or milled peat, by burning them in a cyclone furnace.

Automated boiler control system consists of: 1. Boiler control cabinet (CC) on the basis of OWEN controller equipment and Weintek operators’ touchpad; 2. Fuel warehouse control cabinet (CC) based on INVT frequency converters; 3. Boiler operator’s AWP performing control functions, setting the basic technological parameters, process control and monitoring, data archiving.

The system created by ASU-Techno is used to control the following production equipment:

• Fuel warehouse:

  • Hydraulic power unit of the mechanized fuel warehouse of the “live bottom” type;

  • Fuel transporter, inclining;

  • Fuel transporter, transverse;

• KVTSm boiler:

  • Exhaust fan;

  • Air fan;

  • Air damper;

  • Hydraulic power unit of the boiler;

  • Fuel supply hydraulic cylinder;

  • Fire-extinguishing valve;

  • Hydraulic cylinders of the furnace grate.

The implemented control system interacts and processes signals from the following technological sensors:

• Flow switch;

• Water pressure and temperature sensors at the boiler outlet and inlet;

• Temperature sensors for the fuel in the hopper;

• Temperature sensor in the furnace;

• Exit gas temperature sensor;

• Input air temperature sensor;

• Exhaustion sensor in the furnace;

• Sensors of lower and upper levels of chips in the hopper.

ASU-Techno Company has also developed automated control systems for hot-water boilers with different types of furnaces (cyclone, stoker) with 0.5 to 4 MW capacity.

Results of the Project:

• A modern multipurpose ACS, ensuring a high-degree workflow automation of KVTSm-4.0 boiler was developed;

• Operational control of the main parameters of the boiler and their archiving was implemented;

• The software controls the boiler mechanisms in manual and automatic modes;

• Automatic mode allows to perform the necessary technological operations without operator intervention, maintaining the preset technological parameters according to the process flow diagram (exhaustion in the furnace, fuel/air supply, etc.);

• An intuitive and modern interface with maximum clarity and ease of operation was developed.