Boiler plant automation description, device and scheme

Greetings and welcome to our boiler plant automation guide! We will examine the fundamentals of automating a boiler system in this post so that your home is properly insulated and heated. Boiler plant automation is the application of cutting-edge technology to maximize energy efficiency and improve boiler performance, providing greater control over heating processes.

Important parts of heating systems are boilers, which burn fuel like gas, oil, or biomass to produce heat. Boiler plant automation entails the integration of multiple controls and sensors to automatically regulate water temperature, air intake, and fuel supply. This automation greatly reduces costs and promotes environmental sustainability in addition to improving convenience.

Gaining an understanding of the boiler plant automation system’s major components and how they work is necessary. An automated boiler system usually has sensors to keep an eye on things like fuel levels, pressure, and temperature. A central control unit receives real-time data from these sensors, processes it, and modifies the settings to maintain peak performance.

Precise control over the heating process is the main goal of boiler plant automation. Automating processes like fuel modulation, water flow regulation, and ignition allows the system to adjust dynamically to fluctuating heating demands. This adaptability minimizes energy waste while guaranteeing constant comfort levels throughout your home.

Complex control strategies are necessary for boiler plant automation to operate efficiently. Microprocessor-based controllers or programmable logic controllers (PLCs) are frequently used in modern systems to control operations. These controllers ensure that the boiler runs effectively in a variety of conditions by enforcing predefined algorithms to regulate heating cycles.

Boiler automation advancements have completely changed heating systems, providing homeowners with never-before-seen levels of convenience and energy savings. Smart home technologies can be integrated with automated boilers to enable remote computer or smartphone monitoring and control. In addition to improving user experience, this connectivity makes proactive maintenance and troubleshooting possible.

To sum up, boiler plant automation is a critical development in contemporary heating technology. Through the implementation of smart controls and automation of critical processes, homeowners can experience increased comfort, lower energy expenses, and less environmental impact. We will go into great detail about boiler plant automation in the sections that follow, going over device configurations, operating principles, and real-world implementation considerations.

Construction of the installation scheme

There are various levels of boiler automation. These are attributable to:

• І level – there are thermostats and regulators that maintain the air temperature, as well as the possibility of heating schedule.
• ІІ level- to all the functions of the first category are added more equipment power regulators, as well as its controllers and the possibility of cascade connection and its regulators.
• ІІІІ level – has a control panel, which displays all the readings of sensors and regulators on the screen.

Fig. 2: An automatic metal cabinet

The automatic boiler station should be installed in a unique metal cabinet.

This plan consists of:

• Controllers that are programmable;
• Secondary power supplies;
• Uninterrupted power supply of the scheme;
• Concentrator;
• Operator panel;
• Switching equipment;
• Computer.

The operator’s automation panel for rice.

Electric boiler for a private boiler room

The electric boiler is the safest type of boiler to use in a private residence. It does not require the equipment of a separate boiler room. The coolant doesn’t require ventilation during heating because it doesn’t release any combustion products.

These boilers are easy to install, quiet when operating, and require little maintenance. Electric boilers are very efficient—up to 99% in certain situations. The drawbacks include the network’s high power requirements and reliance on steady operation.

As long as it is convenient, the electric boiler can be positioned in any corner of the house. It is mostly used as an extra source of heat and uses a lot of electricity.

The electric boiler is connected using various schemes: radiators are connected to it, and a cascade installation option is provided in case you need to heat a large area. Two schemes are used for the piping: the mixing scheme and the direct scheme. A burner controls the temperature in the first scenario, whereas a mixer with a servo drive controls the temperature in the second.

Requirements for rooms with a solid fuel boiler

There are several requirements for the premises that have boilers installed, which are outlined in normative documents.

What is needed in the boiler room:

• the volume of the boiler room depends on the boiler capacity: for a boiler with a capacity of up to 30 kW requires a room area of 7.5 m2, with a capacity of 60 kW – 13.5 m2, with a capacity of up to 200 kW – 15 m2;
• a boiler with an output greater than 30 kW must be located in the center of the prepared room for better air circulation and maximum working efficiency;
• The floor, walls, partitions and ceilings in the boiler room must be made of non-combustible and fire-resistant materials, using waterproofing coatings;
• the boiler drum is installed on a foundation or a special pedestal made of non-combustible materials;
• For boilers with a capacity of less than 30 kW it is possible to use a pedestal made of combustible materials, but using a steel sheet on it;
• the main fuel reserve must be stored in a neighboring room;
• daily fuel supply can be stored at a distance of 1 meter or more from the boiler;
• ventilation.

Operation and device of the hot water boiler

All equipment functions in the same way, regardless of the model: heat is transferred to the heating system by heating the coolant to the necessary temperature.

Differentiate between the following kinds of hot water units:

• Gas.
• Liquid-fuel
• Electric
• Solid fuel.

Depending on the boiler type chosen, the hot water boiler’s device has a different structural makeup. Consequently, different burners are used for different types of fuel. They can be replaceable supercharged ones or built-in atmospheric ones. Exclusive fuel types can be used with built-in burners. Convenient interchangeable burners make it simple to transition between different fuel types when needed.

What is a smart boiler

More money needs to be invested in order to implement the private boiler room automation plan. While programmable systems are far more expensive, a basic thermostatic valve can be purchased for relatively little money. A traditional boiler operating continuously in one mode requires significant energy and financial resources to operate. As a result, the cost of buying an automation unit is swiftly recovered during use.

A private boiler room’s automation ensures that the heating system will operate as efficiently as possible, allowing for the maintenance of comfortable living conditions for the occupants.

The homeowner can modify the heating process to suit his needs by installing automation. Energy bills will be halved as a result of this. It is feasible when boiler control is in automatic mode:

1. Shut down the boiler in the event of a non-standard situation. Carry out automatic starting or stopping of the boiler in the operating mode. Depending on the outside temperature to set the heating temperature.
2. Control the heating and water heating branches of the boiler having 1 combustion chamber.
3. Regulate the temperature of water or other heat transfer medium.
4. To make adjustments in the operation of circulation or recirculation pumps, if the heating of heating in the house is arranged according to the closed scheme. In this case, without automation, the functioning of the system is impossible.

The thermostat is the most crucial component of the heating system. Its job is to control the temperature in a certain room as well as the entire house. Thermostats come in a variety of forms, ranging from straightforward mechanical to weather-dependent. The latter is the most advantageous in terms of technology, but it is also highly costly.

A temperature controller, an actuator, a coolant temperature sensor, a display for connecting to an external control system, a coolant circulation pump, and consumer circuits make up the heating control system (+)

The type of boiler being used, whether a heated floor is present, whether solar collectors are present, etc., all affect the cost of automation. To avoid wasting money, compare the features of each plan and figure out how much it will cost. Although doing it yourself is pretty challenging, you can always consult experts when you have this kind of issue.

Tasks and objectives

Without the operator’s direct involvement, modern boiler room automation systems can ensure the equipment operates smoothly and efficiently. The only things left for humans to do are monitor the parameters and operation of the entire device complex online. The following tasks are resolved by boiler room automation:

• Automatic start and stop of boiler units.
• Boiler output regulation (cascade control) according to the set primary settings.
• Control of make-up pumps, control of heating medium levels in the working and consumer circuits.
• Emergency stop and activation of signaling devices, in case of the system operating values exceeding the set limits.

Boiler room with solid fuel boiler

Only non-residential buildings are permitted to install solid fuel boilers due to building regulations. If the unit has a large capacity, building a separate boiler room will be necessary. The space needed for a solid fuel boiler must meet a number of requirements:

• the smallest distance between the furnace door and the wall is from 1.2 to 1.5 m;
• minimum distance from the side walls of the boiler to the wall made of non-combustible material or protected by a special screen – 1 m;
• the gap between the rear wall of the boiler with rear connection and the wall made of combustible material with a protective screen – 0,5 m;
• no additional extensions may be built above the boiler room;
• the room must have a supply ventilation in the lower part of the room in the form of a gap between the door and the floor or a hole in the wall.

The pipe behind the boiler may be fastened to the wall using brackets if the wall is constructed of material that complies with fire safety regulations. A CT that has base parameters of 1×0.8 m must be installed in a space that is 2.8 x 2.5 m in order to operate it comfortably. The boiler room’s area increases in proportion to the unit’s size.

To allow for the chimney to be built in advance, the installation of a solid fuel boiler should be planned for during the house’s construction.

The boiler room should be placed against a blank wall if it is designed like an annex. There should be a minimum of one meter between windows and doors on both a vertical and horizontal plane. A door that opens outwards must be installed if the boiler room is situated on the first floor, basement, or both.

Equipment for solid fuel boiler room

A well-designed and functional boiler room layout featuring a solid fuel boiler ought to incorporate several components:

• Heat generator equipped with appropriate bunkers, fuel chambers, etc.д.
• Boiler piping consisting of circulation pump, 3-way valve, safety group.
• Chimney.
• Storage water heater for supplying the house with hot water.
• Automation – weather-dependent or in-house automation.
• Fire extinguishing system.

Firewood, peat, and coal are used as boiler fuel. In a boiler room equipped with a CT unit, the chimney’s diameter needs to match the cross-section of the boiler socket. Exhaust ventilation is required in the room and is calculated so that 1 kW of boiler capacity is present for every 8 cm² of area. This parameter is multiplied by three if the boiler is situated in the basement.

It is necessary to surround the boiler’s base with steel plates. It must protrude by one meter on each side. Plaster on the walls needs to be at least three centimeters thick. There are holes for collecting and removing soot in the chimney itself, which has the same cross-section all the way around. An essential feature is the ability to put out fires.

Any kind of solid fuel can be converted into heat energy by a high-quality solid fuel boiler. This makes financial savings possible.

About 0.08 m² of glazing should be present for every 1 kW that the TT boiler can produce. The largest boiler room area that can be used is 8 m². The electrical wiring needs to be shielded from coal dust if the furnace is to be filled with coal, as coal dust has the potential to explode at a specific concentration.

Influence of soot and scale in the process of operation

The low thermal conductivity of soot will severely impede the transfer of heat from the produced gases to the heating equipment’s walls if a layer of it forms on the surface.

This will inevitably result in an excessive use of fuel mass and a notable decrease in the production of steam and hot water.

The amount of heat transferred from the device wall to the water can be significantly decreased by the presence of scale on the walls, which have a relatively low thermal conductivity.

With a working pressure of 0.8 MPa and a temperature of 175 °C, the MZK steam boiler is engineered to generate saturated steam for use in heating and technology applications.

You can read more about what a steam boiler KP is here.

Because of this, the walls may overheat to a dangerous degree and occasionally burst, leading to boiler appliance malfunctions.

Based on this, it can be said that routine cleaning of this kind of equipment is the only way to achieve the boiler’s optimal performance.

Only by installing a specific dirt filter and regularly blowing the equipment’s main components through the air connections will scale formation be prevented.

It is important to keep in mind that while taking such steps can help to greatly lessen the intensity of scale formation, there is no guarantee that it won’t occur again.

If the equipment is to be operated with hard water, then this approach will not work. This suggests that the water quality that is being used is not worth sacrificing.

Preliminary water treatment will contribute to extending the device’s and the thermal system’s overall service life.

Simultaneously, the hot-water boiler will maintain adequate high efficiency values for the duration of operation. It’s also a great chance to reduce the quantity of fuel used.

Boilers made of oil that are used. Range and categories.

Go here to learn more about how waste oil boilers are built.

Purchasing a hot water boiler from a reputable manufacturer guarantees that the coolant will operate in the best possible speed modes thanks to pumps built into the design. Moreover, it totally removes the chance of scale formation and extreme surface overheating, respectively, preventing system failure.

Warning SMS messages about emergency situations and critical system parameters

Based on signals from sensors and relays, the GSM controller generates and transmits SMS messages (if you have a cellular operator card) alerting you to important system parameters that guarantee the boiler and boiler room operate.

In an emergency, SMS messages are generated automatically. The boiler room status and temperature parameters can also be obtained by calling the numbers linked to the controller. There is a specific SMS message that describes what is happening in the boiler operation system for every scenario and event that occurs during the process of operating boiler equipment.

A word to the buyer Our article """ presents the options for sending alarm SMS messages, the creation of messages in the event that errors and alarms are eliminated, SMS requests, and other aspects of the warning system’s operation.

The module’s GSM antenna should be positioned where it will receive the strongest GSM signal and away from any metal objects that could impede the signal. Any metal surface should be at least 5 cm away.

Should a GSM module be present in the boiler room, it is imperative to consistently verify its functionality, i.e., sending SMS messages to its number in the A?" The manager in charge of this equipment at the location decides how frequently to request information about the current status of the GSM module and any connected equipment (there are no limits on the number of requests).

Prior to installing the major equipment, the boiler room’s cable channel layout under the automation lines must be coordinated with the commissioning organization. Additionally, the required clearance between walls, pipelines, and collectors must be provided where appropriate.

How to make heating with two boilers

It makes sense to design a circuit to accommodate two heating boilers in order to optimize the performance of various kinds of residential heating systems. Currently, a number of connection choices are available:

• gas boiler and electric;
• solid fuel and electric boilers;
• Solid fuel boiler and gas boiler.

It is advisable that you become acquainted with the basic features of joint boiler operation before moving forward with the selection and installation of a new heating system.

Connection of electric and gas boilers

Combining an electric boiler with a gas boiler is one of the most straightforward heating systems to operate. There are two ways to connect: parallel and serial. Parallel is thought to be better since it allows you to replace, repair, and disconnect one boiler while leaving the other one operating in minimum mode.

This connection can also be fully closed, in which case regular water or ethylene glycol should be used as a coolant for heating systems.

Connection of gas and solid fuel boilers

The most challenging option in terms of technology because it necessitates meticulous ventilation system and space preparation for large, potentially fire-prone installations. Prior to installation, become knowledgeable about the regulations pertaining to gas and solid fuel boiler installation, making the appropriate choice. Furthermore, an open system, where the overpressure is lowered in an expansion tank, is needed to compensate for overheating because the heating medium in a solid fuel boiler is difficult to regulate.

Important: it is not permitted to connect gas and solid fuel boilers using a closed system; doing so is a major fire safety hazard. With a multi-circuit heating system, which has two independent of each other contours, two boilers can operate at their best.

Two independent circuits in a multi-circuit heating system can provide the best performance for two boilers.

Connection of solid fuel and electric boilers

Examine the selected one’s technical features and read the instructions before attempting to connect. Models for both closed and open heating systems are made by manufacturers. The best course of action in the first scenario is to concentrate on the operation of two boilers sharing a heat exchanger; in the second scenario, connecting to an already operational open circuit is simple.

Safety of automatic installation

Ensuring the safety of users and boiler equipment is one of the primary purposes of automatic units.

The alarm signals the occurrence of an unexpected circumstance within the installation and notifies the following parties:

• Leakage of gas or other fuel;
• Increasing or decreasing pressure (gas, water, steam) in the system;
• Boiler breakdowns;
• Carbon monoxide emissions;
• Fire safety violations.

The configuration of the boiler automation system allows for remote control by the operator. It can simultaneously view the fault diary, which helps the service center staff quickly identify every system failure. The installation can also be managed over the phone. To achieve this, a unique code is used, which, when dialed, causes the automation to transition to a different (pre-set) mode of operation.

Block-modular hot water boilers

Block modular hot-water boiler rooms are useful when a continuous hot water supply is required but there are no facilities for setting up a backup boiler.

All of the pieces are assembled and stored in a metal box. Such a box can be installed on any area of the business or in private homes and doesn’t require the pouring of additional foundations.

It is also possible to utilize these systems to provide total heating. Simultaneously, the inside is equipped with heat-supplying equipment rather than hot-water equipment.

Heat and hot water are supplied to the home via water boilers. For this reason, installing hot water boilers is one of the most in-demand services nowadays.

Go here to learn more about hot water boilers.

To completely satisfy the comfort requirements of the staff and/or the technological requirements of an organization or multiple buildings, including apartment buildings, hot water boilers and heating boilers can be combined.

These systems, which completely supply hot water and steam heating for the entire house, can be built from the ground up on the rooftops of multi-story buildings. Installation and modifications to a single apartment building’s gas supply only require permits.

Installation is practical for homes or businesses whose property prohibits indoor boiler installation.

Any type of heat carrier can be used as the heating medium. If the technology plan for the supply of secondary production gases allows, block-modular systems for gas, electricity, coal, fuel oil, and even waste heat recovery boilers can be installed.

You must account for pipe wiring to the premises and the necessary heating medium supply capacity when calculating a hot water boiler room. Everything else is installed in a handy box as a single unit.

It is not required to invest time in calculating the need for a separate room for installation; instead, consider all operational safety requirements. For instance, a small production needs to be operated in a sterile manner.

Contemporary boilers are outfitted with automated control systems that range in complexity and are intended to guarantee the boiler’s safe operation even in the absence of human intervention.

See this page to learn about the different brands of hot-water boilers.

Its range is constrained, and using coal to provide heat and hot water is more cost-effective. Installing the block-modular system outside the workshop premises will be highly convenient at this point.

Professionals should design and calculate the hot-water boiler room, taking into consideration all relevant parameters related to the space, machinery, and required features.

Accurate computation is necessary to guarantee both service staff safety and the equipment’s seamless functioning.

Automation of boiler equipment

The modern market is well-represented by standalone devices, sets of imported and domestic automation for steam and hot-water boilers, and other devices. Among the automation tools are:

• ignition control equipment and the presence of flame, starting and controlling the process of combustion of fuel in the furnace chamber of the boiler unit;
• Specialized sensors (draft gauges, temperature sensors, pressure sensors, gas analyzers, etc.) can be used in the pipeline. д.);
• actuators (solenoid valves, relays, servo drives, frequency converters);
• control panels for boilers and general boiler equipment (consoles, touch screen mnemonic diagrams);
• switching cabinets, communication and power supply lines.

With the exception of unusual and emergency circumstances, the safety automatics should receive the utmost consideration when choosing the control and monitoring.

Automation of boiler equipment operation

Ignoring the features that simplify the operation of heating systems would be a mistake. Automation enables the use of a number of programs that regulate heat flows based on the time of day, the weather, and other factors. It can also help heat different rooms, like a nursery or a swimming pool.

An illustration of a principal automated scheme is the boiler room’s automatic mode of operation, which regulates the water heating, ventilation, heat exchanger, two floor heating circuits, four building heating circuits, and water recirculation circuits.

A number of customized features adjust how the equipment operates based on the way the residents of the home live. For example, there are a number of stand-alone solutions that are more practical and cost-effective for the residents in addition to the standard hot water program. Because of this, a boiler room automation scheme that selects one of the common modes can be created.

The "Good Night" program

It has been demonstrated that the ideal room temperature at night should be a few degrees colder than the daytime temperature; that is, it is best to reduce the bedroom’s temperature by roughly 4°C while you are sleeping. A person finds it uncomfortable to wake up in an abnormally cold room, so the temperature needs to be adjusted early in the morning. Automating the heating system’s transition from day mode to night mode and back again is a simple way to alleviate this inconvenience. DE DIETRICH and BUDERUS are the controllers that control the nighttime hours.

Hot water supply prioritization system

One more use of general equipment automation is the automatic regulation of hot water flows. It is separated into three categories:

• priority, in which the heating system is completely switched off during hot water use;
• mixed, when the boiler capacity is differentiated for water heating and house heating service;

Non-priority, in which the building’s heating comes first but both systems work together.

The automated system consists of the following components: a hot water boiler; a network pump;a source water pump;a heater; a water treatment unit; a make-up pump; Unit 7: Deaeration; Eight coolers, nine heaters, ten deaerators, eleven condensate coolers, and twelve recirculation pumps

Low temperature operating modes

Manufacturers of boilers are focusing their most recent developments on the shift to low-temperature programs. This strategy has the benefit of being more economical due to its lower fuel usage. Simply using automatics enables you to select the appropriate mode, control the temperature, and lower the heating intensity. The aforementioned considerations should be made when designing the hot-water boiler room’s thermal scheme.

Gas boiler room for your home

Since gas is an explosive material, there are stringent regulations for gas boiler rooms. A separate boiler room is not necessary if a boiler with a capacity of up to 30 kW is adequate to heat the house. If the kitchen is well-ventilated, has a floor-to-ceiling height of 2.5 meters, and a floor area of at least 6 meters square, the boiler may be placed on a wall composed of non-combustible materials.

If the kitchen does not have any non-combustible walls, the boiler is placed on an insulated, plastered surface that is protected with a special screen.

The goal of all gas boiler room regulations is to avoid any potential gas leaks and their aftermath. For this reason, the door width starts at 0.8 m and the window area in the room where the gas equipment is installed starts at 0.5 m².

Such a boiler room’s chimney needs to have an extra cleaning channel and be at least 500 cm above the roof ridge. Installation of condensate collectors on the chimney and ventilation systems is required.

The electronic or piezo ignition is turned on when the boiler receives gas. A spark is produced, lighting the igniter and the main burner, which raises the coolant’s temperature to the desired level. Additionally, the automation turns off the burner.

When a gas boiler’s capacity surpasses 30 kW, it needs its own building. The following specifications are included in the building regulations for a freestanding boiler room:

• the foundation of the boiler room building must be separated from the foundation of the house;
• In the concrete mortar used in the construction of the building, there must be a certain percentage of sand;
• a separate foundation should be built for the boiler, raising it above the floor finish by 0.2 m;
• the boiler must be covered with a flat slate or tile substrate extending 0.1 m beyond the boiler perimeter;
• in case of emergency, the boiler room must be equipped with a sewage system to drain the heat carrier;
• the space around the boiler must be free within a radius of 0.7 m;
• the interior finish must have a fire resistance coefficient of 0,75 h.

Since the boiler is a type of sophisticated engineering equipment rather than a home appliance, it must adhere to specific regulatory standards. All boilers used in the residential sector, including gas boilers, need to have a certificate proving they’ve passed a safety inspection. If a boiler room does not have a gas alarm system, control services will never approve the commissioning of a boiler room with a gas boiler.

Notification of the boiler room operation by means of GSM module

With the use of a GSM module, an external notification system for boiler room equipment operation can be installed.

A controller with a GSM module is used to monitor boiler room operation. This controller, also referred to as a GSM controller, is connected to a cellular operator and receives and processes signals from sensors and relays that regulate the boiler, boiler room, and related systems’ fundamental parameters. It then provides control over:

• availability of voltage in the electrical network (line to the UPS);
• the operating time of the boiler room from the UPS;
• the minimum water pressure in the heating system;
• of maximum water pressure in the heating system;
• the gas pressure after the down-pressure valve;
• leaks in the boiler room;
• cold water pressure at the inlet to the house;
• reserve or triggering of the boiler room security system;
• the surface temperature of the supply line of the heating system (+15 °C);
• air temperature in the water treatment room (+5 °C).

Diagram showing how the boiler room’s GSM module is connected to sensors

Diagram showing how to connect the GSM module to the minimum and maximum pressure gauge

Overpressure regulation in the heating system

A considerable rise in system pressure brought on by an uncontrollably high temperature is a phenomenon that occurs when a solid fuel boiler operates. An open expansion tank that is connected to the atmosphere is used to protect the system in these situations. This allows the heat carrier, which is water, to expand without raising the pressure inside the pipes. The extra heated water just drains into the sewer system through the hole in the tank when the temperature rises above average.

The primary distinction between a gas boiler and a solid fuel boiler is the open expansion tank. The latter has an automated system that regulates the system’s pressure and temperature to keep the coolant from overheating. One benefit of having a closed self-regulating system is that it receives very little oxygen from the outside, which lowers the possibility of metal parts corroding. However, like with solid fuel boilers, this type of system also has a certain amount of overpressure, which is controlled by an expansion tank and safety valve that are installed inside the boiler drum itself.

Thermal control

The following guidelines should be followed when choosing instruments and conducting organization thermal monitoring:

– parameters, controlled display devices, whose observation is required for boiler room operation;

Parameters, which are monitored by signaling indicating devices and a change in which may result in a change in the ventilation system’s temperature or an emergency condition of the equipment;

Recording instruments or summing devices keep an eye on parameters that are required to analyze how household calculations or equipment operate.

The operating steam pressure and the calculated steam capacity of steam boilers determine the requirements for thermal parameter monitoring. As an illustration, the steam gas oil boilers DE-25-14GM (Figs. 4.1 и 4.2) have indicating measuring devices installed.

– feed water temperatures before and after type 1 Δ or Σ economizer technical thermometers;

– steam temperatures from the superheater up to the main steam gate valve, measured by three different types of technical thermometers, μ or Σ;

– flue gas temperature measured with a millivoltmeter (Δ4 type Ψ4540/1);

– temperatures using a type 2 μ or Σ fuel oil thermometer;

Steam pressure in the drum is indicated by a self-describing secondary device 20 type CCU1-003 and a manometer 25 type MP4-Σ;

– oil injector pressure vapor using manometer 15 type MP-4Σ;

-pressures measured by manometers 25 type MF-4Σ at the economizer inlet after the regulator; air pressure measured by differential thrust gauge liquid 26 type TJ16300 and diaphragm pressure gauge type NML-52 after blowing air fan;

– uses pressure gauges 16 type MP-4κ to pressurize fuel oil into the boiler, indicating a secondary device 13 type CSU1-003;

– uses diaphragm pressure gauges with self-describing secondary indicating instrument 12 type CCU1-003 and type NML-100 to pressure gas into the boiler;

– uses a type 34 MF-4Σ manometer to pressurize gas to the igniter;

– rarefaction detected by a diaphragm thrust gauge in the boiler furnace, indicating type 14 TNMP-52;

– rarefactions using a draught gauge differential liquid type 18 TJ24000 upstream of the smoke evacuator;

– steam diffmanometer type 33 DSS-711In-Μ1 flow rate;

– gas pressure flow rate using difmanometer 31 type DSS-711In-Μ1;

– fuel oil counter 32 type SMO-200 with flow rate fuel oil meter;

The CO2 content of flue gases measured with a portable gas analyzer 30 of type CGA-1-1;

Water level in the drum is indicated by the water measuring glass (28), which also serves as a self-describing secondary device (29), model CSU1-003.

The following are monitored by signaling devices: difmanometer Е35 – type BSP-4СГ-Μ1, pressure and draught control sensor Ε22 type DNT-1, head sensor-relay Ε19 type DN-40, electric contact pressure gauge indicating Ε23 type ECM-IV, pressure switch sensor Ε21 type DN-40, and signal lamps HLΗ – HL7. Level of water in the boiler drum, rarefaction in the boiler drum furnace, gas pressure to the boiler, pressure fuel oil pressure to the boiler, and air pressure after the blower fan are monitored by signaling devices.

2.4. Temperature regulation in heating and ventilation systems.

The function module FM 441 controls the temperature in the heating circuit in accordance with the temperature schedule with weather compensation. The temperature sensors in the supply pipe of the heating circuit and the outdoor temperature sensor are examples of sensing elements. The regulator is a three-way valve with an electric actuator that shifts in response to signals from the module, altering the rate at which heated water flows and preserving the water’s predetermined temperature.

The FM 442 function module is used to adjust the ventilation circuits’ temperature in accordance with the two separately defined temperature schedules (60/50 and 95/70), taking weather into account. The temperature sensors in the supply pipes of ventilation circuits and the outside air temperature sensor are sensitive components. The regulators are three-way valves with electric actuators that shift in response to signals from the module. This allows the regulators to alter the rate at which heated water flows while preserving the desired water temperature.

How to use the thermal scheme of the boiler room

The boiler room’s condition and operation can be kept an eye on with the aid of the thermal scheme. Sulfuric acid or low-temperature metal coatings are not immune to corrosion from flue gases. Additionally, you should regulate the water’s temperature to stop it from happening. Notably, the ideal temperature for the boiler inlet will be between 60 and 70 degrees.

In order to achieve the necessary temperature, a recirculation pump is also installed. In order to maintain a reasonable service life and regulate the water flow rate consistency, hot water boilers must be closely observed. Typically, this indicator’s minimum data is set by the manufacturer.

Vacuum deaerators are essential for boiler room operation. Typically, a water jet ejector will produce a vacuum, and deaeration is accomplished using the steam that is produced. However, the biggest concern when building a boiler room is that it will become a permanent part of the property. Many processes are made simpler by modern automation.

How to make heating with two boilers

Thus, there are two boilers that have several design elements that set them apart from one another. How can they be integrated into a single system? Using a heat exchanger to split the system into two separate circuits is the most efficient solution. One circuit is open and has a solid fuel boiler; the other has a gas boiler along with radiators. One heat exchanger is used to load both circuits.

The positioning of all major and connecting components must be considered when designing such a system in order to facilitate their easy finding, inspection, and replacement as needed during operation, maintenance, or repair. As a result, it is preferable to create a diagram before beginning the installation, place the equipment on it, indicate where the pipes will be laid, and indicate where other components will be installed.

In the realm of heating and insulating homes, understanding boiler plant automation is key to efficient and effective heating systems. This article dives into the description, workings, and schematic layout of boiler plant automation. Essentially, automation streamlines the process of heating by regulating the boiler"s operation automatically. It utilizes sensors to monitor temperature and pressure, adjusting fuel and air supply accordingly. The device employs a control system that interprets sensor data and operates valves, pumps, and igniters to optimize performance. A typical scheme involves connecting sensors to a central controller, which then communicates with the boiler and associated components. This automation not only enhances convenience but also maximizes energy efficiency and reduces operational costs, making it a cornerstone of modern home heating solutions. Understanding this automation is vital for anyone seeking a more efficient and cost-effective heating system for their home.

Energy-saving and social effects of automation

Boiler room automation eliminates all chance of accidents resulting in capital building destruction or service personnel deaths. With ACS, you can be sure that the equipment is operating normally around-the-clock while reducing the impact of human error.

The impact of automation on energy savings is not insignificant, given the ongoing rise in the cost of fuel resources. During the heating season, natural gas savings of up to 25% are guaranteed:

• optimal "gas/air" ratio in the fuel mixture in all modes of boiler operation, correction for the level of oxygen content in the combustion products;
• Possibility of individual adjustment not only of boilers, but also of ;
• regulation not only according to the temperature and pressure of the heat carrier at the inlet and outlet of the boilers, but also taking into account the environmental parameters (weather-dependent technologies).

Furthermore, the automation enables the realization of an energy-efficient heating algorithm for buildings or non-residential spaces that are not occupied on weekends or holidays.

Heat supply source is two Viessmann floor standing gas boilers

Heat supply is provided by two floor-standing gas boilers (Viessmann Vitoplex 100 PV1-250) equipped with Weishaupt WG30/1-N version ZM-LN burners.

The boiler room’s nominal heat capacity is 500 kW.

The restaurant’s heat supply is taken into consideration when choosing the boiler capacity.

The boilers’ combustion products are removed via individual, heat-insulated chimneys.

A polar distribution comb is used to distribute the heating medium. Pump-mixing groups with "Grundfos" company pumping equipment are recommended for circuit connection. The boiler room houses the comb, pumping apparatus, shut-off, and control-measuring valves.

It is advised to use treated (or prepared) water that has undergone water treatment to fill the heat supply system. The process of treating water involves desalinating it to a concentration of less than 10 μS/cm. In this project, mobile (portable) purification systems are intended to be used in place of the undeveloped water treatment system equipment for the heat supply system.

When the system’s heat carrier pressure drops (as indicated visually by the manometer), the heat supply system must be manually made up. It is offered for use as a regulating valve with the manufacturer "Danfoss" equipment.

The project includes pre-boiler water treatment equipment installation.

The heat supply system’s heat carrier parameters are +80/+60 °Ρ.

All of the boiler room’s engineering equipment gets its power from a separate electrical panel that is linked to the UPS system. The boiler room is where you should find the switchboard.

Selection of the make-up pump for the boiler room

At a relatively low flow rate, the make-up pump needs to develop a higher pressure than in the heating circuit. But large volumes of liquid don’t need to be pumped for makeup. The selection of a pump of this type is done based on multiple criteria.

Choosing a makeup pump:

• It must create a pressure that exceeds the pressure in the return of the CO;
• Also the pressure head should be able to push through the hydraulic resistance of the pressure sensor and piping;
• Another important criterion is the flow rate, in particular for closed COs the leakage rate is half a percent of the volume of the heating medium in the boiler and heating circuit.

Simultaneously, we would like to point out that buying such a pump for use is not very practical. in the sense that it ought to be used for more than just makeup. It can also be used to pump and drain water into the circuit, serving as a backup circulation pump, among other things.

Boiler room automation functions

The automation system is capable of executing the subsequent functions:

• automatic detection and adaptation of heating curves, t.е. the system automatically determines the heating curve based on a small number of input data and measurement results (the data can also be entered manually). Thanks to this function, the control system in conjunction with the remote control in the control room brings the heating curve in line with the thermal performance of the building;
• automatic switching of summer/winter modes, t. е. the system automatically switches from summer mode to winter mode and vice versa according to the available conditions
  heating circuits (can be separately configured for each circuit);
• economical control of circulation pumps, t. е. The circulation pumps are controlled via their own time channels, and the pumps are controlled by their own time channels
  are switched on several times per hour and run for 3 minutes at a time. This only occurs if the heating circuits or the own timer program is running in daytime mode. This mode maintains comfortable conditions and saves energy, which is wasted when the circulation pump is constantly running. This control principle ensures that hot water is always available at the water points;
• optimized switching on and off. Optimized switching on means that the room temperature must already be reached by the set time, i.e. the circulation pumps are controlled via their own time channels. е. the automation system calculates the time when the heating should be switched on, taking into account the room and outdoor temperature. As a result, a comfortable temperature is reached and energy savings are realized. Optimized shutdown is possible with remote control in the control room and allows the heating to be switched off without compromising comfort;
• automatic kit recognition, t. е. the system automatically recognizes which modules are installed and adjusts itself according to the set configuration;
• intelligent power control in a multi-boiler plant with small setpoint jumps. This function guarantees a fully modulated power range of the boiler cascade, minimizing emissions and economical operation;
• intelligent power control on an installation with several boilers at large jumps in the set parameters. This function guarantees a complete
  modulated power range of a cascade of boilers, minimizing emissions and economical operation mode.

Boiler room automation electrical diagram

Part numbers on the boiler automation circuit diagram in three dimensions

Design

Boiler rooms ought to be designed by an organization that possesses an extensive list of certifications and work permits.

Selecting the designer and project for the hot-water boiler room requires careful consideration because safety is just as important as cost. The operating characteristics of specific equipment or the peculiarities of the room may not have been considered by dishonest designers, which can result in emergencies:

• gas leaks with subsequent ignition;
• hydrostatic shocks, which are dangerous for pumps and can rupture the water system;
• electric shocks if the earthing is not correctly calculated;
• malfunction of the electronics controlling the process (almost all equipment may fail) and many other dangerous consequences.

The boiler output determines the autonomous heating system’s efficiency. To prevent unforeseen expenses, it is therefore essential to be able to compute it before purchasing a hot water boiler.

See How to Maintain a Hot Water Boiler.

It is advisable to select a design firm that will handle the commissioning process afterward and have complete control over the equipment installation in the space in order to prevent this.

It is reasonable to use automatic and manual switching between the two boilers

Together with an electric boiler that is required to turn on at the appropriate time and is in reserve, take into consideration the following five options using various units:

• gas + electric
• Wood + Electric
• Liquefied Gas + Electric
• Solar + Electric
• Pellet (pellet) + Electric

Pellet and electric boiler

The optimal configuration for automatic on/off switching is when two boilers—pellet and electric boilers—are connected together; manual on/off switching is also permitted.

When a pellet boiler runs out of fuel pellets, it may shut down. It hasn’t been cleaned and has grown soiled. Electricity should be kept ready to turn on in case the boiler stops. Only with an automated connection is this feasible. This variant’s manual connection is only appropriate if you live in a home with an installed heating system on a permanent basis.

Boilers on diesel. fuel and electricity

You are well suited for a manual connection if your home has a system in place for connecting two heating boilers. In the event that the boilers malfunction for any reason, the electric boiler will function as an emergency boiler. Not only has it stopped, but it’s broken and requires fixing. It is also possible for the device to turn on automatically based on time. Solar boilers can operate on a night tariff and electric boilers can operate in pairs on liquefied gas. because a kWh on the night tariff costs less than a liter of diesel fuel.

Combination of electric boiler and wood boiler

When two boilers are connected together, there is less of a manual connection and more of an automatic connection. The primary boiler is a wood boiler. The room is heated during the day by it, and at night the electric boiler is turned on to continue the heating. Alternatively, the electric boiler keeps the house warm enough to prevent freezing over during extended periods of non-residence. It is also possible to save electricity manually. When you leave, the electric boiler will be manually turned on; when you return, the wood-fired boiler will take over and heat the house.

Combination of gas and electric boilers

The electric boiler in this setup of two boilers can function as the primary boiler as well as a backup. Compared to an automatic connection scheme, a manual connection scheme makes more sense in this scenario. A gas boiler is a tried-and-true appliance that operates without issue for an extended period of time. Connecting an electric boiler in parallel to the automatic backup system is not a logical configuration. Manually turning on the second unit is always an option in the event that the gas boiler fails.

Levels of automation

When designing the boiler room or replacing or overhauling the equipment, the level of automation is predetermined. It can vary from fully automatic control based on weather-dependent algorithms to manual regulation based on instrumentation readings. The main factors influencing the degree of automation are the equipment’s functionality, capacity, and intended use.

A comprehensive approach is implied by modern boiler room automation, wherein subsystems for the regulation and control of distinct technological processes are integrated into a single network that has functional group control.

1. The basic principles of boiler plant automation

Only when thermal control, automatic regulation and process control systems, signaling, and equipment protection are available can the boiler house operate in a dependable, cost-effective, and safe manner with the fewest number of employees [8].

The process of developing automation schemes involves the adoption of primary boiler plant automation solutions (functional diagrams). Automation plans will be created after thermal engineering plans are designed and selections are made. boiler house, its mechanization, and the communications related to heat engineering for main and auxiliary equipment. Boiler unit, smoke exhausters and fans, installation of auxiliary pumping and deaerator plant, chemical water treatment, heat recovery plant, condensate pumping station, GDS, fuel oil (coal) storage, and fuel supply are some of the main equipment.

Volume automation is permitted in accordance with manufacturers’ specifications for heat and mechanical equipment as well as SNiP II-35-76 (section 15 – "Automation").

Boiler plant automation levels are determined by the primary technical factors listed below:

– type of boiler (combination, steam and hot water, steam and hot water);

– the type of fuel (solid, liquid, gaseous, combined – gas-fueled, dust-fueled), the fuel combustion unit type (FCU), and the boiler’s equipment (drum, straight-flow, cast-iron, sectional supercharged, etc.);

The nature of heat loads (production, heating, etc.);-offer the primary technological protection systems, both personal and t.ο.);

Boiler room number of boilers.

Provide for the primary subsystems’ automatic regulation, technological protection, remote control, thermal control, technological interlocking, and signaling when drafting the automation scheme.

General structure

The automation of boiler houses is constructed using a two-level control scheme. Local automation devices based on programmable microcontrollers, which realize technical protection and blocking, regulation and parameter changes, and primary converters of physical quantities, are included in the lower (field) level. This also includes data conversion, coding, and transmission equipment.

An automated operator’s workstation powered by a personal computer or a graphic terminal integrated into the control cabinet can serve as representations of the upper level. Here, all data gathered by the system’s lower-level microcontrollers and sensors is shown, and setpoints, adjustments, and operational commands are input. Process dispatching is complemented by the resolution of tasks related to mode optimization, technical diagnostics, economic indicator analysis, data archiving, and storage. The data is sent, if required, to the municipality or the general enterprise management system (MRP/ERP).

Wiring diagram for two manually controlled boilers

Nothing is required here except shut-off valves. Switching between boilers is carried out by manual opening/closing of two taps located on the heat transfer medium. It is not four to completely cut off the inoperative boiler from the system. Both boilers most often have built-in boilers and it is more advantageous to use them both simultaneously, because the volume of the heating system very often exceeds the capacity of one expansion tank taken separately. In order to avoid useless installation of an additional (external) expansion tank, it is not necessary to cut off the boilers from the system completely. It is necessary to close them on the flow of the heating medium and leave them simultaneously connected to the expansion system.

Types of boiler rooms for private sector

Boiler room requirements are outlined in SNiP under the nomenclature II-35-76. Boiler rooms can be classified into one of the following types based on where the heating equipment is located within the room:

• built-in;
• freestanding;
• attached.

The type of fuel and boiler design are taken into consideration when determining the boiler room’s size.

A mini-boiler room is an additional choice in cases where setting up a dedicated space for a boiler room proves to be challenging. It is put in a container that is put together using the principles of metal structures and is usually found in the home’s yard. All that’s left to do is connect the utilities to the mini-boiler house.

Selecting a boiler room based on its location

Separate boiler room

Where the private boiler room is located

Removal system for combustion products

The reason for the relatively low popularity of these modules is their relatively high cost. You can purchase the equipment individually if you plan to set aside space in the basement for the boiler room. The heating system will then be substantially less expensive.

The mansion’s backyard mini-boiler room eliminates the need for ventilation equipment, separate room construction and arrangement, and design work. Everything required for the heating system to operate effectively is already present in the container.

Thermal scheme of the boiler house with two boilers

The boiler house’s thermal plan is implemented by means of a heat exchanger, which connects the building complex’s heating and ventilation systems to the boilers and the hot water supply. Every boiler has a recirculation pump installed in order to keep the return water temperature at the boiler’s inlet at least 50 °C when using gas and 70 °C when using liquid fuel.

Dual circulation pumps that function in both working and standby modes supply the coolant (water) to the three branches of the building complex’s HVAC system. The DHW heat exchanger’s own circulation pump provides the heating medium from the boilers. By turning on and off the boilers, as well as the regulators in the burner devices, the boiler room’s heat load is automatically controlled based on heat consumption.

Three-way control valves automatically regulate the direct water temperature in each branch of the heating and ventilation systems in accordance with a predetermined temperature schedule: 80–60 oÑ for heating, 95–70 oÑ for ventilation, and 60–50 oÑ for the second heating, depending on the outside air temperature.

By turning on and off the heating water circulation pump, the hot water supply water’s temperature is automatically regulated.

Water from the household water supply system, treated in the water treatment plant, is used to fill and top up boilers and heating and ventilation systems.

With a pressure of 10–15 m, tap water enters the boiler room and is supplied to the DHW heat exchanger and make-up system via a booster pump. Boilers and heat supply systems are equipped with closed expansion tanks to guarantee that water expansion is compensated for. Boiler static pressure is typically maintained between 2,0 and 2,5 kgf/cm in order to prevent boiler water from scorching. This pressure is the minimum that the water pressure in the make-up pipeline should be.

A heat meter with a flow converter, sensors for the direct and return water temperatures, an electronic unit, and a calculator are used in the boiler house to measure the heat carrier and heat flow rate on each branch of the boiler house outlet.

There are drainage outlets in the boiler room where water can be drained from safety valves and equipment during repairs.

Rain sewerage and the cooling well are two places where the boiler house’s drainage is accommodated.

Automation object

It is a dynamic, complex system with numerous interconnected input and output parameters that is subject to regulation. Boiler room automation is made more difficult by the rapid technological advancements in steam units. The primary values that are regulated are:

• flow rate and pressure of the heat carrier (water or steam);
• discharge in the furnace;
• the level in the feed tank;
• in recent years, increased environmental requirements are imposed on the quality of the fuel mixture and, as a consequence, on the temperature and composition of smoke exhaust products.

General design provisions

It is advisable to contact experts who have vast experience installing engineering systems for private cottages rather than attempting to design communications and install equipment on your own. Every step of the boiler plant installation should be carefully considered. They will provide a number of helpful pointers, such as assistance in selecting the best boiler model and figuring out where to install it.

For instance, a wall-mounted appliance that is convenient to place in the kitchen is adequate for a small country home. As a result, a two-story cottage requires a special room that must have a window, a chimney, ventilation, and a separate exit. Enough room should be left over to fit the remaining parts, which include the boiler, pumps, pipes, connecting elements, etc.

A private home’s boiler room design process entails the following steps:

• Preparation of the boiler room layout in relation to the location inside the house;
• equipment distribution diagram with indication of the main technical characteristics;
• specification of materials and equipment to be used.

Experts will assist with the completion of the required documentation in addition to purchasing and installing system components and creating graphic works, which include the inclusion of a circuit diagram.

An illustration of the basic layout of a boiler room for hot water: I stands for boiler, II for water evaporator, III for source water heater, IV for heat engine, V for condenser, VI for additional heater, and VII for accumulation tank.

Scheme of the boiler house with hot-water boilers

Following the selection of the boiler room’s essential dimensions and the determination of the priority heat transfer medium, a plan for the equipment’s calculation and installation must be developed in order to account for all relevant details.

The complete list of equipment and pipe wiring should be displayed in multiple graphical drawings that are included in the schematic diagram. Pumps and all boilers (or just one boiler, if there is only one) need to be specified:

• Circulating;
• make-up;
• network;
• recirculation.

In the design process, additional considerations include accumulation and condensing tanks, fuel supply and combustion devices, heat shields, control panels, fans, and deaerators and heat exchangers.

The purpose of solid fuel boilers is to generate hot water for heating systems.

You can read more about gas-fired hot water boilers and their applications here.

Depending on the heat carrier of choice, the cost of the boiler room layout with hot-water boiler drawings will vary. Essentially, though, there ought to be records that highlight the object’s primary attributes:

• thermotechnical (placement of equipment for converting the coolant into hot water);
• energetic (supply of the heat carrier to the inlet and pipe wiring of the received hot water);
• Electrical (providing control, signaling and automation of equipment);
• utilization (reflect the system of removal of fuel combustion products and sewage drainage in case of leaks and emergency situations).

In order to remove combustion products from the chimneys and foundation, boiler rooms also require construction calculations to account for the cumulative load. Large device installations require the construction of ladders and service platforms.

Description	Boiler plant automation involves using controls and sensors to manage heating processes automatically, optimizing efficiency and ensuring safety.
Device	The key components include temperature sensors, control panels, actuators (to regulate valves), and a central processor or controller.
Scheme	The automation scheme typically consists of sensors measuring parameters like temperature and pressure, feeding data to a controller that adjusts boiler operation based on set parameters.

Your home’s heating efficiency and convenience can be significantly increased by automating your boiler plant. You can optimize your heating system’s performance and streamline the heating process by implementing automation. An overview of boiler plant automation has been given in this article, along with information on its parts, uses, and integration with the heating system in your house.

Comprehending the boiler plant automation system and its mechanism facilitates the understanding of its importance. Automation is essentially the integration of sensors, controllers, and actuators to control boiler operation. Together, these parts preserve optimal temperatures and adapt to shifting heating needs while using less energy.

The control system is one important component of boiler plant automation. This system controls every aspect of heating, including fuel consumption and temperature monitoring. The boiler’s sophisticated control algorithms enable it to adjust to changing circumstances, increasing efficiency and lowering energy waste.

In addition, the boiler plant automation scheme makes use of a network of linked devices. Actuators modify dampers and valves in response to temperature variations that are detected by sensors. Your heating system will function flawlessly thanks to this interconnection, giving warmth and comfort to every part of your house.

Adding automation to your boiler plant has observable advantages. By using less fuel, it not only makes heating management simpler but also saves money. Furthermore, automation increases system reliability by lowering the possibility of malfunctions and guaranteeing dependable operation.

In conclusion, for homeowners looking for dependable and efficient heating solutions, boiler plant automation is a wise investment. Using automation technology can help you save energy, improve comfort, and require less maintenance. In the end, a well-automated boiler plant results in a more eco-friendly and comfortable home.

Video on the topic

Boiler room automation scheme

Boiler plant automation

Designs of boiler plants