Case Studies
Commissioning Case Study
Background:
- Plant decommissioned existing coal fired boilers that were being phased out during the quest for cleaner energy and NOx reduction.
- Plant procured four 120,000 lb./hr. superheated water tube boilers and two 75,000 lb./hr. superheated watertube boilers to replace the coal fired boilers.
- Due to the operational deadline of this project our commissioning expertise was requested.
Solution:
- Provided the commissioning and onsite project management of the new boiler systems. This included new Ultra-low NOX burner technology.
- Designed & commissioned the Rockwell based Combustion Control System and Burner Management System.
- Calibrated all instrumentation.
- Integrated existing feedwater system with the new boiler systems.
- Integrated the boiler controls systems with Rockwell based SCADA system for monitoring boilers.
- Designed and installed and commissioned Plant Master Control System which provided lead lag and firing rate control of boilers.
Conclusion:
- System currently operating with vastly improved operation time and achieved emissions within the permit values.
Commissioning and tuning Case Study
Background:
- New Ethanol Plant which includes the commissioning of two 80,000 lb. saturated steam watertube boilers.
Solution:
- Provided the startup with new burner technology.
- Commissioned Rockwell based Combustion Control System with Flame Safeguard for Burner management system.
- Calibrated all instrumentation.
- Commissioned new feedwater and DA system for boiler utilization.
- Integrated the boilers within the plant DeltaV SCADA system for monitoring boiler and feedwater systems.
Conclusion:
- Achieved Emissions well within the permit values.
- Due to the high level of commissioning provided by our team, we have developed a service contract to complete semi-annual inspections, calibrations, and tuning of plants fired equipment. This includes upgrading firing equipment and controls for better performance and improved operational time.
Controls Upgrade Case Study
Background:
- Major Oil refinery upgraded vertical fired oil heater with 5 burners and control system. This heater was converted from manual control to fully automated burner combustion control.
- This upgrade was necessary to provide safe operation of the unit.
Solution:
- Provided the commissioning and onsite project management of the new boiler systems. This included new Ultra-low NOX burner technology.
- Designed & commissioned the Rockwell based Combustion Control System and Burner Management System.
- Integrated the boiler controls systems with Rockwell based SCADA system for monitoring boilers.
Conclusion:
- System currently operating with vastly improved operation time and achieved emissions within the permit values of sub 9ppm NOx.