On this page we have provided summaries for recent Burner Management/Fuel Regulatory and Combustion Control System projects that we have undertaken. Detailed summaries in .pdf file format are available for selected projects by clicking on the project .pdf link.

Our profiles include:

• Rotary Hearth Furnace BMS Upgrade
• Reheat Furnace Regulatory Controls System Upgrade
• Energy Optimization Project 
• Recovery Boiler Auxiliary Burner Upgrade
• Recovery Boiler ESP System Audit
• #2 Boiler Regulatory Controls and BMS Upgrade
• MPV's- BMS Upgrade at Vale- Copper Cliff Smelter
• #1 and #2 Flash Furnaces Vale- BMS Upgrade
• #2 Flash Furnace Vale - O2 Afterburners
• Reheat Furnace Evraz - Regina

Rotary Hearth Furnace BMS Upgrade

The scope of this project was the final phase of upgrade of the two control systems associated with an 8-zone rotary furnace. Both the existing TDC 2000 DCS for the regulatory controls and the existing Modicon 484 PLC for the BMS were previously replaced with two new Allen Bradley ControlLogix based PLC systems. This phase involved the installation of safety shutoff valves on all 212 burners, installation of new igniters, flame scanners and roof burners in one zone, and installation of Bloom regenerative burners and auxiliary equipment in one zone. KMH designed the new PLC cabinets, including TSSA requirements for BMS . KMH provided PLC programming for new BMS and regulatory control functions, commissioning and startup support, including fuel-air curve development, rotary furnace control loop tuning and certification trip testing for local authority’s certification. The BMS system is now certified to the latest CSA B149.3 standard for fuel burning appliances and equipment

Reheat Furnace Regulatory Control System Upgrade  

The scope of this project was to upgrade the regulatory control system associated with a 6-zone walking beam reheat furnace. The existing TDC 2000 DCS for the regulatory controls was replaced with a new Allen Bradley ControlLogix based PLC system. There was also field equipment upgrades for the regulatory control system including the installation of new replacement gas flow control valves, gas and air flow control valve actuators, the upgrade of existing and installation of new flow and pressure measuring instrumentation and the installation of new zone air flow temperature elements. KMH design the PLC cabinets and provided commissioning and startup support, including fuel-air curve development and furnace control loop tuning.  

Energy Optimization Project

KMH Engineering Inc. has completed the detailed engineering design and DCS configuration required to develop and implement an Energy Optimization system for fuels, and steam and power generation at the Essar Steel Algoma Inc. plant in Sault St. Marie Ontario. The control method will maximize the use of by-product gases (Blast Furnace Gas and Coke Oven Gas) to minimize the cost of generating steam, maximize revenue from power generation, and minimize wasteful flaring of by product gases. The system takes control of boiler and plant masters by intelligently scheduling fuels, turbines and PRV’s. Plant dynamics were simulated in the DCS development system for debugging and FAT testing purposes. Implementation is scheduled for the fall of 2010. 

Recovery Boiler Auxiliary Burner Upgrade

KMH completed the detailed electrical and instrumentation design for Babcock & Wilcox for the replacement of auxiliary fuel burners on a black liquor recovery boiler. Commissioning and start-up services were also provided.

Recovery Boiler ESP System Audit

KMH has completed audits of black liquor recovery boiler to asses compliance with guidelines issued by the Black Liquor Recovery Boiler Advisory Committee (BLRBAC). Items found not to be in compliance were documented and presented to the client.

MPV's  Vale, Copper Cliff Smelter Complex - BMS Upgrade

This project involved upgrades to four MPV (Multi Purpose Vessel) burner management systems (BMS’) in the copper finishing circuit of the smelter complex.  The upgrades were driven by the requirement to meet the Technical Standards and Safety Authorities (TSSA) order to comply with CSA B149.3, the TSSA is the governing body for fuels safety in Ontario. Four existing relay/DCS based BMS’ were replaced with four new Allen Bradley ControlLogix PLC based systems.  Fuel and oxygen headers were modified in order to achieve compliance with the CSA B149.3 and NFPA 86.  Existing Foxboro DCS graphics were updated in order to reflect the new system design.  A new PLC/DCS gateway was designed and installed to provide communication between the new PLC’s and the existing DCS.  KMH also provided construction management support and completed the commissioning and start-up of the new system.  KMH completed the Field Approval Application to the TSSA and acted as the technical liaison to the TSSA for final field approval. The four PLC cabinets were manufactured at the KMH CSA certified panel shop. A detailed operations and maintenance manual was also provided.  CSA B149.3, CSA B149.1, and NFPA 86 codes were applied in the design in order to obtain field approval from the TSSA.

#1 and #2 Flash Furnaces Vale Copper Cliff Smelter Complex - BMS Upgrade

Currently in the design phase, this project will upgrade the burner management systems (BMS’) on both No. 1 and No. 2 Flash Furnaces in the Smelter Complex. The upgrades were driven by the requirement to meet the Technical Standards and Safety Authorities (TSSA) order to comply with CSA B149.3, the TSSA is the governing body for fuels safety in Ontario. The existing relay/Foxboro DCS based BMS’ are not compliant and will be replaced with new Allen Bradley ControlLogix PLC based systems.  Fuel and oxygen headers will be modified in order to achieve compliance.  The existing Foxboro DCS graphics will be updated in order to reflect the new system design.  A new PLC/DCS gateway will be designed and installed to provide communication with the new PLC’s and the existing DCS for burner controls and status display including first in first out trip capture. KMH will also provide construction management support and will be responsible for the commissioning and start-up of the new system. KMH will also complete the Field Approval Application to the TSSA and act as the technical liaison to the TSSA for final field approval. A detailed operations and maintenance manual will also provided by KMH.  CSA B149.3, CSA B149.1, and NFPA 86 codes will be applied in the design in order to obtain field approval from the TSSA. 

#2 Flash Furnaces Vale Copper Cliff Smelter Complex -  O2 Afterburners

Production downtime in the Flash Furnaces has been attributed to sulphide formations in the uptake of the furnace.  These formations occur at the transition in the uptake to the gas cleaning stage of the process and eventually restrict the flow of furnace off gas to the gas cleaning process.  The resulting formations in the furnace uptake require the furnace to be shut down for removal of the solids.  Vale along with PraxAir undertook a research and development project to mitigate the formation of the solids.  The project involved the design for the electrical, control, and mechanical installation of two new PraxAir oxygen/natural gas afterburners (lances) in the furnace uptake.  KMH designed a new Allen Bradley ControlLogix based burner management system (BMS) for the afterburners and designed the new natural gas, oxygen, and nitrogen header skids.  Control and monitoring of the afterburners will be integrated in the existing plant Foxboro I/A DCS with KMH completing all programming and configuration.  This project has not entered the construction phase as of yet.  CSA B149.3, CSA B149.1, and NFPA 86 codes were applied in the design in order to obtain field approval from the TSSA.

Walking Beam Reheat Furnace-Evraz Regina Saskatchewan