S V Controls provides Sustainability solutions for the Boiler

Reduce the costs and complexity of implementation in accordance with the applicable regulations within the food & beverage industry.

  • Native integration of requirements of 21 CFR Part 11 in our products.
  • Compliance with the standards for good practice (BPF, GMP, HACCP etc.).
  • Proven test and validation techniques to guarantee repeatability.
  • Standard validation models.

Industrial boiler systems can cope with much higher pressures than pressure cookers. These boilers are welded from thick steel plates that are up to 35 mm thick, making pressures of 30 bar and more possible.

A stable, robust design is also essential – if a boiler of this type were to collapse, explosive forces comparable to the explosive power of a ton of gelignite would be
released (milk boiling over in a pressure cooker is nothing in comparison to this).

A thermal output of up to 38 MW is possible from a single boiler, which corresponds approximately to the power of 500 average VW Golf cars. Up to five boilers can be combined economically. A boiler of this type, filled with water and ready for function, can weigh as much as 165 tons, which corresponds to the weight of 120 VW Golfs.

How an industrial boiler system works

The heart of an industrial boiler system is a hot water or steam boiler operated with a certain kind of fuel. The boiler heats up or evaporates the water inside it, which is then transported to the consumers via pipe systems. In case of hot water the transport energy is generated by pumps, in case of steam the transport is based on inherent pressure. The cooled water or the condensed steam returns to the boiler where it can be heated again. Loss of water must be compensated by treated fresh water to avoid corrosion. Flue gases created by combustion are
discharged into the atmosphere through a chimney. Particularly efficient systems additionally use the residual heat in the flue gases.

Applications of Boiler Industry

Integrated Boiler Control
At full capacity a boiler of this size converts 3 000 litres of fuel oil or a corresponding amount of natural gas to thermal or process heat every hour. This would be sufficient to heat more than
2000 houses.
System Control and Data Acquisition (SCADA) requires a communications network to transmit the information back to a central control centre (CCC).
Gas Burner Management
Boiler burner management system is a complicated control system which requires continuous monitoring and inspection at frequent intervals. There are possibilities of errors at measuring and various stages involved with operators.

BMS systems by Eurotherm are good options to overcome this problem.

Level & Pressure Control
A resistive pressure sensor is used to measure the boiler pressure, and the output is in 4-20 mA. As the temperature increases, the pressure also increases.
Continuous Blowdown
Boiler blowdown is water intentionally wasted from a boiler to avoid concentration of impurities during continuing evaporation of steam. The water is blown out of the boiler with some force by steam pressure within the boiler. Bottom blowdown used with early boilers caused abrupt downward adjustment of boiler water level and was customarily expelled downward to avoid the safety hazard of showering hot water on nearby individuals.
Pressure Control
Steam boilers require a device which senses steam pressure and cycles the burner or other source of heat in order to maintain a consistent, predetermined operating pressure. A second device is used to prevent the boiler from exceeding the maximum allowable working pressure (MAWP) indicated on the boiler nameplate.
TDS Control
As a boiler generates steam, any impurities which are in the boiler feedwater and which do not boil off with the steam will concentrate in the boiler water.
These solids will contaminate control valves, heat exchangers and steam traps.
Careful control of boiler water TDS level together with attention to the other factors should ensure that the risks of foaming and carryover are minimised.
Boiler Drum Level Control
The purpose of the drum level controller is to bring the drum up to level at boiler start-up and maintain the level at constant steam load.
A dramatic decrease in this level may uncover boiler tubes, allowing them to become overheated and damaged. An increase in this level may interfere with the process of separating moisture from steam within the drum, thus reducing boiler efficiency and carrying moisture into the process or turbine.
Biomass Power Plant
The unique feature of the project is that it employs an air cooled condenser instead of water cooling towers.
The Control System comprises our powerful Eurotherm Suite Distributed Control System, Eurotherm T940 Process Supervisor and 2500 I/0 units and Eurotherm T640 Integrated Loop processors.
The T940 Process Supervisor controls the entire plant by acquiring data through Eurotherm subsystems. Eurotherm Suite stations monitor the complete plant and provide live data to operators.
Flow Calculation
Calculation and display of the mass and volume flowrates through Venturi tubes
Calculation and display of the Reynolds number
Four different tapping types
Calculations for gas or liquid
Standard supervisory workstation interface
Timed Bottom Blowdown
Before boiler feed-water is passed into the boiler.
It must be chemically treated to remove the corrosive elements that may be present and would ultimately corrode the boiler as well as affect the quality of steam required within a process.

Chemicals entering the boiler via the feedwater must be removed from the boiler. Failure to do so can result in the boiler system suffering from scale formation, corrosion, brittle and cracking metal, carry-over and foaming.

Therefore a proper chemical balance must be maintained within the boiler itself.

Leak Detection
Leakage detection is necessary to avoid all of the problems associated with boiler. Many methods can be used acoustic spectrum analysis, filtering method or traditional method of detection.
Pump Sequence Control
One of the areas within a boiler plant that is critical to the process is the delivery of boiler feedwater.

Depending on the design and functionality, individual feed pumps servicing individual boilers or a bank of feed pumps may maintain a common feedwater pressure that feeds into the boilers.

Implementing pump sequence control allows the system to sequence and cycle pumps such that a minimum number of pumps are needed to maintain the feedwater flow to the boilers requiring it. The pump sequence control can also regulate (where variable speed pumps have been implemented) the output of each pump making its usage more energy efficient.

Steam Main Warm-up
Ensuring the working steam pressure is sustainable.