CONTROL SYSTEM SD9306#02.

Control system

1 General
The control system is designed to provide safe and functional operation of the boiler
plant both at the boiler and in the engine control room. The general design
comprises a local control section for each included boiler, a common power section
and a PC based control and monitoring system.
Figure 1 illustrates a typical configuration for a boiler system. The example shown is
for a MISSION OL twin boiler plant. The control system is constructed in a
similar way for other boiler types.
The communication between the local control panels, power panels, and engine
room PC is achieved through a 2-wire RS485 network. The cable type is a twisted
pair with shield. The 2 x 0.5 mm2 cable should not exceed 1000 metres in total
length.

Illustration of the control system

Figure 1 consyst101b.tif

Local control section

The local control section contains the local panel, communication interface, relays,
flame monitoring equipment, water level control equipment, switches for emergency
operation, etc. The cabinet gives an IP 55 insulation class and can be located in
ambient temperatures between 0-55ºC with a relative humidity up to 90%. The
maximum vibration level is 100 Gal at 10-30 Hz. The 115 or 230 V AC, 45-65 Hz

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 CONTROL SYSTEM SD9306#02.1

power supply, is supplied from the common power section. The maximum power
consumption of the local panel is approximately 50 VA. Figure 2 illustrates the
complete local control section.
The local panel as well as the power panels are constructed as a computerised
control and monitoring system. The panels are equipped with a number of digital
and analogue input/output connections. These input and output connections are
handled by the CPU, which operates the panels, the EPROM, which contains the
programme, and the E2 PROM, which stores specified plant data.
The local control section is located on the boiler. This provides the operator with a
clear view of the boiler operation. The complete boiler system can be operated from
the local panel with or without the PC system in service. By use of the soft keys
placed to the left of the display, the burner can be operated in manual mode, and
shut downs/alarms can be acknowledged. The soft keys placed to the right of the
display give access to the menu structure. The actual menu levels or menu item lines
are displayed on the four line crystal display (LCD).
Access to a number of different parameters, settings, etc. is limited by password
entering. This secures the operation from unintentional entering and modification,
which might cause damage to the boiler plant. The password routine is divided into
two steps. The entering of the common user password provides access to the most
common menu items, and the super user password, which is only known by Aalborg
Industries, provides access to the more vital functions.
In a twin boiler system alterations of settings for common equipment such as, e.g.
fuel oil pumps can only be performed from the boiler selected as the master boiler.

Illustration of the local control section

USER DEFINED VALUE 1 [VALUE 1]

USER DEFINED VALUE 2 [VALUE 2]
USER DEFINED VALUE 3 [VALUE 3]
[STATE] [MODE] [LOAD%]

Local panel

USER DEFINED VALUE 1 [VALUE 1]

USER DEFINED VALUE 2 [VALUE 2]
USER DEFINED VALUE 3 [VALUE 3]
[STATE] [MODE] [LOAD%]

Local control section

Figure 2 unisab8a.cdr

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 CONTROL SYSTEM SD9306#02.1

Common power section

The common power section contains power supply systems, common power
panel(s), motor starters and optional components like smoke density monitoring
system, salinity alarm equipment, oil detection equipment, etc. Furthermore,
switches for emergency operation are provided inside the common power section.
The common power section can be located almost anywhere in the engine room, but
it should be easy accessible because the power section must be operated during
emergency operation. The dimensions of the cabinet may differ from plant to plant
due to the different armament.
The number of power panels provided depends on the individual needs for the plant.
E.g. control of the fuel oil pumps is achieved by means of power panel 1 and control
of the feed water pumps, if provided, by means of power panel 2. Figure 3 illustrates
a power panel.
By use of the soft keys parameters, settings, etc. can be entered or modified, and the
actual menu levels or menu item lines are displayed on the display. During normal
operation, the entering or modification of parameters, settings, etc., should be
performed from the local panel(s). This is possible because all panels included in a
plant are connected via the RS485 network.

Illustration of a power panel

AALBORG INDUSTRIES
MISSION POWERPANEL 1
BOILER 1: [STATE]
BOILER 2: [STATE]

Figure 3 unisab1a.cdr

PC based monitoring system

The control system is provided with a PC with graphic user interface, which can be
installed in the engine control room.
The RS485 network connection enables the PC based monitoring system to retrieve
data from the control panels in the system and present the complete boiler plant on
the PC. This means that active control of the boiler plant can take place from the
keyboard or mouse input device. All parameters, settings, etc. can be controlled
from the PC and down loaded to the control system.
The graphic user interface is programmed in the well-known and standard windows
environment. This gives the operator a feeling of comfort from the very first time
the system is operated. Traditional windows pull down menus provide access to shut
down/alarm lists as well as swapping facilities between the different pictures
designed to present the complete system. Pop-up pictures enable the operator to start
and stop boilers or to change steam pressure set points, etc. In a twin boiler plant
selection of master and slave boilers can also be carried out from the PC.
A password system provides the logged-on user with permissions/restrictions and
ensures that no parameters can be changed by unauthorised personnel.
As shown in Figure 4 below, an optional hook up to the system may be provided
from a portable PC (laptop or similar).

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 CONTROL SYSTEM SD9306#02.1

Illustration of the PC and optional laptop

PC in engine control room Portable PC (optional)

Figure 4 unisab9.cdr

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