Allied Distillers - Gas Fired Boiler Control System Refurbishment

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The maximum output of the Boiler Plant is 90,000Kg of steam per hour which is consumed by the distillery process plant. The boilers respond to the steam demand created by the process that can vary considerably during the day in accordance with the required load profile. A secondary function of the plant is to incinerate waste gases which are produced by the process.

Various options were considered by the client such as a new CHP, or contract management of the plant, but eventually the decision was made to refurbish the plant by fitting a new control, burner management and instrumentation systemcomprehensive enough to run as an unmanned boiler plant.

Project Implementation

To achieve this, the client awarded Capula a full turn-key contract for the full refurbishment of the boiler controls. The scope of work included the new control system, SCADA system, burnermanagement system, automatic blowdown, variable speed drives, UPS cabling, actuators, and instrumentation.

One of the key aspects of the project was the tight timescales under which the contract was let. The installation had to be carried out during a short plant outage and the entire job had to be completed in six months from start to finish.
The contract involved extensive field design and installation work, both mechanical and electrical. This included all cabling, installation of the new field devices, mechanical design and fabrication ofmodified pressure pipe-work, installation of new valves, and so on.

A key feature of Capula's project team was the Site Manager, based on site throughout the installation and commissioning phase of the project co-ordinating all site activities which were achieved without incident.

The Solution

The new control system was based around dual Rockwell ControlLogix PLC systems, dual Fireye Burner Management Systems, and a Rockwell RSView32 SCADA. In addition, each boiler requires accurate speed control of the two forced draft fans and so the old Thyristor drives were replaced by modern Rockwell 143 KVA variable speed drives.