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Preferred Instruments

Preferred Instruments manufactures microprocessor based controllers, instruments, and electric actuators for combustion and process applications. Preferred Instruments also manufactures oil tank gauging and leak detection equipment. A major component of the Instrument group sales is from control systems integration and personal computer based Supervisory Control and Data Acquisition systems. Preferred Utilities' industrial factory is located in Danbury, CT

BurnerMate TS Boiler Control System

BurnerMate TS is a custom programmable boiler control and flame safeguard system that includes one or two DCS-III loop controllers and a flame safeguard microprocessor communicating via Modbus with a 10” or 15” OIT touch screen.

Overview

BurnerMate TS is a custom-programmable boiler control and flame safeguard system that includes one or two DCS-III loop controllers and a flame safeguard microprocessor communicating via Modbus with a 10” or 15” OIT touch screen. The system provided includes an industrial enclosure with necessary pushbuttons, selector switches, power supplies, terminal blocks; factory wired and tested with other field devices for a complete system. Each system is programmed to the job specific requirements of the project.

Advanced Combustion Control Options:

  • Single Point Positioning (Jackshaft) control. Effective control with remote monitoring for smaller boilers
  • Parallel Positioning control with Oxygen Trim and Variable Speed Fan Combustion Air Flow Control
  • Combined fuel and electrical savings for fast payback
  • Fully Metering control with Oxygen Trim and variable speed fan combustion air flow control – superior control for Low NOx burner applications. Essential for simultaneous dual fuel firing, multiple burner boilers and balanced draft applications
  • Optional Drum Level, Draft and/or Flue Gas Recirculation Control

Integral Flame Safeguard:

  • Independent, industrial-hardened microprocessor
  • Automatic single burner, dual fuel, gas or oil firing, sequencing, ignition and flame monitoring protection.

Easy to Order, Stock and Field Upgrade:

  • Factory wired and tested control system

Integrated Boiler Management:

The BurnerMate TS is a combined combustion control, flame safeguard, and SCADA monitoring and control system. It incorporates Preferred’s high quality DCS-III Multiple Loop Controller for boiler control functions, an industrial-hardened microprocessor for flame safeguard functions, and a PC -based SCADA workstation for graphical monitoring and operation. BurnerMate TS is a full scope control package that assures safe and efficient control with undivided system integration responsibility.

Flexible & Expandable:

A second, optional DCS-III Multiple Loop Controller can be supplied to provide draft and drum level control loops and balance of plant monitoring with up to 15 analog inputs, 6 analog outputs, 5 triac pair outputs, 6 relay outputs, 13 digital 120 VAC inputs or combinations of these.  BurnerMate TS is designed to be monitored and controlled by the optional SCADA/Flex Distributed Control System.

Easy to Operate: BurnerMate TS with its large, industrial-grade color touch screens provides an intuitive, easy-to-use control system that displays current boiler status, alarms, and historical logging. The system is password-protected for security. Historical trending is standard. An optional flash card allows historical data to be exported to MS Excel. Scalable objects enable accurate process displays. X/Y plots are provided for intuitive Fuel/Air Curves display and commissioning. The NEMA 4X front panel eliminates the need for protective viewing doors. Easy-to-use OIT_Edit® configuration software can be used to customize graphic pages.

Integral Oxygen Analyzer:

The ZP Oxygen Probe is directly connected to the DCS-III controller (eliminating the need for a field mounted transmitter), which simplifies installation. The Model ZP with DCS-III-Zxxx  is a full function analyzer which includes specific analyzer diagnostic codes for rapid trouble shooting and continuous cell impedance checking for cell health prediction.

Easy Commissioning:

Using “Learn Mode” – F(x) characterizer curves are set by manually positioning fuel and air for safe and reliable operation and optimum Oxygen level and then pressing the “STORE” button.  Air and oxygen setpoint curves are simultaneously setup. The process can be repeated for a maximum of 11 load points. Independent curves for each fuel are automatically selected.

Remote Control and Monitoring:

The optional SCADA/Flex Distributed Control System provides remote operation, graphic display of information, alarm message displays, alarm printing, and remote boiler tuning capabilities. The system is networked to the boiler control and Flame Safeguard Systems.

Features

Standard Features:

  • Advanced Communication- 10 Base T/100 Base TX Ethernet
  • One RS-485, Second Optional
  • Two RS-232 Ports
  • Remote Web Access
  • Isolated, Simultaneous Modbus Master and Slave
  • Real Time & Historical Trending Standard, optional Flash Card allows historical data to be exported to Microsoft Excel
  • Scalable objects enables accurate process displays
  • X/Y Plots, for intuitive Fuel/Air Curves display and commissioning
  • NEMA 4X Front Panel eliminates the need for protective viewing doors
  • Easy To Use OIT_Edit® Configuration Software

Major Benefits:

  • Integration with DCS-III Controllers enables intuitive commissioning without the use of Laptops or PCC-III Controller Faceplate
  • BurnerMate TS Systems may be commissioned without the need for blockware training or laptops

Specification

Hot Water Boiler Single Point Positioning Combustion Control

Application: Supply a self-contained Boiler Control System with 10” (or 15”) color touch screen to provide process control of steam pressure, combustion air, and fuel flow. The control system shall be microprocessor-based and suitable for wall or windbox mounting.  All the logic required to ensure that pre-purge, post-purge, light-off, and burner modulate cycles are automated shall be provided.

Combustion Control: A PID-based single point positioning combustion control logic scheme shall be used to maintain steam drum pressure at setpoint. The fuel flow control valve shall be mechanically linked to the air flow control device to assure an air rich fuel/air ratio.  Mechanical linkage adjustment shall be required to adjust the fuel/air ratio. A combustion control microprocessor failure shall not prevent the continued manual operation of the boiler.  Fuel valve and air damper shall be modulated in response to an external Plant Master demand signal or measured boiler drum pressure compared to setpoint. At a minimum, the control system shall display the following: Steam Pressure, Steam Pressure Setpoint, Boiler Firing Rate and alarm messages for Low Pressure, High Pressure, and Pressure Setpoint Deviation. The following color touch screen graphic pages shall be provided: Boiler Overview, Flame Safeguard Overview, Control Panel Faceplate with real time and historical trending, Set up and Commissioning screens, and Boiler Alarm.

Boiler Controllers

To assure system integrity, a pre-wired and factory-tested, microprocessor-based, multiple loop controller system shall be provided. The controller shall include process variable and “first – out” annunciator, 120 VAC discrete inputs and outputs, and 4-20 mADC analog inputs and outputs. Configuration and calibration data shall be stored on redundant non-volatile EEPROM memory modules. The backup memory module shall automatically download into the primary memory in the event of primary memory data corruption.  All control logic, tuning, and fuel/air ratio curves shall be field configurable. If required to allow field modifications to the controller logic, provide one configuration tool or laptop computer per facility.

Communication

Each controller shall be equipped with an optically isolated RS485 modbus communications data highway connection to the color touch screen. The touch screen shall communicate with the plant BAS, EMS, or DCS by a Modbus over Ethernet communications data highway and shall allow: Auto/Manual mode change, setpoint change, variation of the manual output, sensing and silencing of alarms, change of any configuration parameter (including PID tuning constants), change of timers, etc. Provide all equipment capabilities specified in this paragraph, even if a connecting SCADA system is not included in this project.

Quality Assurance

The system shall be factory manufactured and tested according to UL508A requirements (CSA C22.2 #14 for use in Canada). The control system shall be a Preferred Instruments, Danbury, CT, BurnerMate TS Model BMTS-STSPx (‘x’ = “C” or “T” to denote a Current or Triac Control Output).