XCELL BOILER ROOM CASE STUDIES
 

Case Study #3
Project Installation: Titan Wheel Co., Quincy, Il.
System Design: XCELL Mechanical Systems
System Installation: XCELL Mechanical Systemss
Boiler Control: Combustion Technologies

The Client
The Titan Wheel Co. of Quincy, Illinois is one of the premier manufacturing facilities of the downstate area. This worldwide company is made up of 14 facilities and is recognized as the worlds largest manufacturer of car, truck and implement wheels.
The Problem
  • Boiler system controls which were extremely aged
  • The few boiler controls that worked, did not work well
  • The coal to gas conversion left the boiler in a semi-manual operating condition
  • The flame supervision system required manual startup 
The Titan Wheel Company's.  steam requirements are partially fulfilled by one aged Babcock Wilcox watertube boiler, which has an Erie City dual burner. The few boiler and burner controls that existed, were manufactured by Hays Republic and was an electronic P.I.D. based, loop control system. 

Many of the system drives were no longer operable, which meant that they required manual adjusting in order to keep the system even moderately functional. The Fireye flame supervision system was of a vintage that required manual valve engagement upon a restart. The boiler firing system had to be operated at a minimum of 50%input in order to produce any noticeable quantities of steam for the plant.
Summary : Old control equipment, non-functional system components, extremely wide seasonal load swings, however, good fuel burning equipment.
 

XCELL BOILER ROOM SOLUTION
 

  • Combustion Technologies Annunciation
    Annunciation on the existing boiler control system was all but non-existent, with all control and flame supervision coming from one small panel with virtually no indication. The Combustion Technologies Ladder Graphic Annunciation system was the perfect solution to provide the control specific annunciation that a complex system of this type requires. The safety of the system has been restored and trouble-shooting is no longer a nightmare for maintenance personnel.

  • Hays Cleveland Multiple Loop Control
    The boiler operating system requires 4 individual control loops; Drum level, which in this instance is a single element control loop with single output control of a Warren feed valve; Firing rate , which is a single element control loop with a single output control of a Hays-Cleveland fuel-air drive; Primary Air trimming, which is a single element control loop with single output control of a Hays-Cleveland primary air drive; and Furnace Pressure Regulation, which is a single element control loop with single output control of a Hays-Cleveland outlet damper drive.

  • Bar Graph Indication
    Each of 4 controlled loops includes 2 bar graph indicators, one of which provides indication of the process value, the other provides indication of the output value. The bar graph indicators are strategically positioned so as to allow easy viewing of the system processes.

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