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Control and monitoring of a Fire-Tube Boiler

Control and monitoring of a Fire-Tube Boiler is often found in hospitals and most process plants that use steam either for process or building heating. The 6000 Series master communications opens up packaged solutions of recorders and controllers.

Solution

In this application the 2704 controls the water level and total dissolved solids (TDS). It also performs other boiler control functions such as Timed Bottom Blowdown and Steam Main Warm Up. A 6000A or 6000XIO is used to provide an HMI to the 2704 and act as a steam flow computer calculating the Saturated Steam Mass Flow. The 6000 can be directly connected to the factory Ethernet providing valuable energy management information.

2704 Boiler Controller

Incorporating all the main boiler control elements, the 2704 provides a very cost effective integrated control solution for packaged Fire-Tube boilers.

 

Features:

  • Water level

  • Boiler Pressure

  • continuous Total Dissolved Solids

  • Main Steam Warm-Up

  • Open Communications

  • Flexible User Interface 

The 2704 can be used solely to control Total Dissolved Solids (TDS), or also to control water level and boiler pressure. A specialist input module makes it compatible with standard TDS conductivity probes making both retrofit and new installations easy to accomplish. Additionally, Timed Bottom Blowdown and Steam Main Warm Up functions make use of the controller’s internal real time clock. For more detailed information on the 2704 as a boiler controller please refer to application note ANC169 on boiler types, and technical information note TIBC177 on TDS measurement. 

     

 

Boiler Pressure

Water Level

Total Dissolved Solids

 

Process Inputs

 

4-20mA

 

4-20mA

 

4-20mA
TDS Probe (conductivity)

 

Control Outputs

 

4-20mA
Dual relays

4-20mA
Dual relays

4-20mA
Dual relays

 

Control Functions

 

PID
Valve position

 

PID
Valve position

 

PID
On/off control
Valve position

 

Alarms

High, low

High, low

High, High-High

 

 

Standard Features

 

 

Main steam warm up

 

 

Single element

 

Timed bottom blowdown
Temp - compensation
Probe diagnostics

 

Calibration

 

Factory set

 

Factory set

 

User calibration

 

Advanced Features

 

Maths & Logic blocks timers & real time clock

 

Communications

 

Modbus RTU, Modbus master, Profibus DP, Devicenet

 

Power Supply

 

82-264Vac, 24Vdc/ac

 

6000 Flow Computer

The 6000 Flow Computers are ideal for energy and facility management. They can be used to monitor energy performance and to identify problems as they occur as well as for energy cost allocation.

 

  • Saturated steam calculations

  • Mass flow

  • Heat flow

  • Heat consumed

  • Easy to use touch screen technology

  • Up to 48 configurable input channels

  • Ethernet communications

  • Remote and mobile access

 

6000 series options have equations designed particularly for use with saturated steam. Mass Flow, Heat Flow and Heat Consumed can all be calculated and recorded. All of these equations can be set to use either pressure or temperature as the measured input and use look-ups from the 1999 ASME steam tables.

 

The 6000 Flow Computers are ideal for energy and facility management. They can be used to monitor energy performance and to identify problems as they occur as well as for energy cost allocation. Data can be presented and reported as required in Excel™ using Report software to access information from the secure process data files.

 

The 6000 Flow Computers have excellent communications capabilities allowing the units to be networked for data transfer to other systems or for remote access by the user, ensuring information is available wherever and whenever it is needed.

   

 

6100V-SFC

 

6180V-SFC

5000B-SFC

5100e-SFC

 

Display

 

5.5” TFT Touch
Screen

 

12.1” TFT Touch
Screen

 

None

 

5” STN
Touch

 

Input Channels

 

6 or 12

 

6 to 48

 

6 or 12

 

6

 

Calculation Channels

 

36

 

48

 

36

 

12

 

Internal memory for Process Data

 

5.5Mbyte

 

 

13Mbyte

 

13Mbyte

 

3Mbyte

 

Ethernet

 

Standard

 

Standard

 

Standard

 

Standard

 

 

The 6000 series User Screens and Master Communications make them ideal for use as a data acquisition device & HMI to 2704 boiler controllers.