CompleteAutomationSolutions for theControl andSupervision ofCombustionProcesses

Rockwell Automation's IndustrialCombustion & Power Generation Teamis ready to work with you. Our team has a track record of successfulprojects ranging from burnermanagement to complete plant controlsystems. Working with us, you can beconfident your system will be built toyour specifications, optimized forperformance, and managed by results-oriented engineering professionals – people dedicated to completing your project on time and on budget.

Publication GMSE00-BR010B-EN-P – September 2003Supersedes Publication GMSE00-BR010A-EN-P – May 2001

Copyright © 2003 Rockwell Automation, Inc. All rights reserved. Printed in USA.

One of the most important decisions made at the start of an automation project is the selection

of the engineering team responsible for systems integration. The success of an automation project

is frequently determined by the performance of the engineering team. Extensive product knowledge

and process expertise is paramount, as well as the integrator’s ability to work efficiently and effectively

with your organization and consultants.

Rockwell Automation has helpedcustomers achieve their automation objectives on time

and within budget. We have designed and built thousands of systems for applications

spanning multiple industries. We offer the resourcesand technology you need to stay ahead of

your competition.

This overview brochure illustrates why we believe we are the integrators of choice for automating

combustion processes. We have a great story to tell and are eager to explore working with

you on your next automation project.

Thank you for your interest.

One of the most important decisions made at the start of an automation project is the selection

of the engineering team responsible for systems integration. The success of an automation project

is frequently determined by the performance of the engineering team. Extensive product knowledge

and process expertise is paramount, as well as the integrator’s ability to work efficiently and effectively

with your organization and consultants.

Rockwell Automation has helpedcustomers achieve their automation objectives on time

and within budget. We have designed and built thousands of systems for applications

spanning multiple industries. We offer the resourcesand technology you need to stay ahead of

your competition.

This overview brochure illustrates why we believe we are the integrators of choice for automating

combustion processes. We have a great story to tell and are eager to explore working with

you on your next automation project.

Thank you for your interest.

exp

Results–Oriented EngineeringThe success of your automation project ultimately rests on

the strength of the technical and project management

skills of your system integrator’s project team. Rockwell

Automation offers project management and system integration

expertise to ensure success. Our team of experts includes project

leaders, application engineers, system engineers, field service

engineers and hardware designers. The combined experience for

burner management, industrial combustion and related processes

is over 350 years and over 800 systems. We deliver unparalleled

expertise for your project and its unique system requirements.

Every system is assigned to an experienced project

leader who assumes overall Rockwell Automation

responsibility for the project and is empowered to

take action.

The project leader serves as your single point of formal

contact, although communication with other project team

members is encouraged. The project leader coordinates

the team’s activities and interacts with our centralized

purchasing, panel assembly and quality control department to

ensure timely completion of your project. Under the direction of a

project leader, each team is capable of providing a broad range

of services to meet the varying needs of our customers.

Our approach to managing your project leaves nothing

to chance. All project activity is governed by our total quality

control system which is registered to ISO9001. Our panel

assembly facility is certified for assembling UL 508A general

purpose enclosures.

Rockwell Automation offers a broad spectrum of control and information solutions

Our engineers understand the inherent challenges

in automating combustion processes. Each of our system

platforms offers unique advantages in processing power,

connectivity, expandability and value. Using our product

knowledge and application

expertise, our engineers can

give you the confidence that the

proper technology, products and

system architecture have

been applied to meet your

automation challenges.

Your most

valued global

source of

Complete

Automation™

solutions.

Your most

valued global

source of

Complete

Automation™

solutions.

results-orientedperienced project management

application focusA key feature of

our systemplatforms is opencommunications,

which allows for seamless

integration among Allen-Bradleyplatforms or

with third party systems.

engineering expertisesystem platforms

Combustion & Temperature Controls Help Improve Unit Efficiency

Our combustion control systems can provide coordinated

control of firing-rate, fuel, air and feedwater demand for

industrial and utility boilers. For industrial/process heating

applications, our control systems help maintain tight zone

temperature control, and can be expanded to include

pre-programmed cycle periods (e.g., heating, ramp soak,

cooling), recipe management and material handling of product.

Our field proven control strategies help:

• Enhance combustion efficiency.

• Simplify boiler/furnace operation.

• Reduce start-up time.

• Improve operator understanding of the combustion process.

Our combustion control offerings feature:

CombustionMaster™– a programmable

controller-based combustion/temperature control system.

CombustionMaster provides dynamic, graphic displays via

Rockwell Automation’s family of ViewAnyWare products, or third

party software which allows the operator to easily interact with

the combustion process. Password protected loop tuning displays

and combustion/firing curve displays allow engineers to access

controller gains, alarm limits and other tunable parameters

without the need of an engineering workstation or programming

software.

Combustion/Temperature Control Systems –

in addition to our CombustionMaster solutions, Rockwell

Automation’s team of experts builds combustion/temperature

control systems employing many of the Allen-Bradley control and

I/O platforms available today. An experienced Rockwell

Automation engineer is ready to assist you in selecting the best

control and I/O platform for your specific project.

Automated Balance of Plant Controls HelpSimplify/Centralize Plant Operations

Rockwell Automation provides control for process

related auxiliary equipment integrated with our

combustion/temperature control or as separate stand-alone

systems. Our automated balance of plant controls can help:

• Centralize control room operations.

• Schedule required maintenance based on timely

reports and logs of critical parameters.

• Improve process efficiency via coordinated control

of conveyors, pumps and motors.

A few of our auxiliary control solutions include:

Coal yard handling control systems – designed to

accommodate any configuration of coal handling equipment. The

extended range of our communication networks and

the modularity of our input/output subsystem allows us to

offer control from “dumper-to-bunker” economically. Standard

algorithms provide manual and automatic control of feeders,

breakers, crushers, conveyors, trippers and related equipment.

Sequenced starting of conveyors includes “proof of flow path”

prior to starting and “unload logic” prior to conveyor stops.

Access to all tunable parametersis available through tuning and

engineering displays.

Your most

valued global

source of

Complete

Automation™

solutions.

Your most

valued global

source of

Complete

Automation™

solutions.

enhanced efficiencyreduced start-up time

simplify operationsAnalog & sequential control systems – in addition

to the systems mentioned, our engineers have experience

implementing control and monitoring systems for all types

of plant equipment common to unit operations within

the plant.

Data collection systems – feature the Allen-Bradley fully

distributed input/output subsystem which provides for

the timely collection of plant data. Our open communication

architecture allows for the seamless transfer of data to

supervisory workstations. Data collection, trending and archival

storage are implemented on personal computers

running either Rockwell Software’s RSView or third party

software platforms.

For industrial/process heating

applications, our control solutions

help maintain tight temperature

control and can be expanded to include

pre-programmed cycle periods andmaterial handling

of product.

Ash handling/dust emission control systems –

designed to each plant’s specific automation requirements

for bottom ash/fly ash removal. Monitoring and control for all

bottom ash collection points and associated conveyor gates,

crushers, pumps, water levels, and motor start/stops is

implemented and automatically sequenced by the system.

Rockwell Automation also designs systems for monitoring and

controlling fly ash removal for both wet scrubber and fabric

filter baghouse applications. Fly ash removal systems feature

automatic sequencing and manual control of pumps,

recycle pumps and agitators as appropriate.

Sootblower control systems – easily accommodate

any of the boiler tube and wall cleaning technologies in use

today. Our

systems

provide all of

the benefits

associated

with the open

architecture of

an Allen-Bradley platform coupled with the operating

flexibility and maintenance advantages found in dedicated,

proprietary systems. A few of the standard features

designed in our systems include:

• User defined blower sequences

• Group sequences

• Motor current trends

• Blower tag-out reason list

• Alarm annunciation

automation solutions forcombustion processes

and related auxiliaries

Burner management systems control and monitor

the start-up and shutdown ofburners and ignitors associated

with combustion processes.

Our Burner Management solutions include:

BurnerMaster™– a programmable

controller-based, burner management system for

use with multi-burner combustion processes.

BurnerMaster can be designed to accommodate any fuel type

and burner firing arrangement.

BurnerMaster SB™– a pre-engineered, programmable

controller-based, burner management system for use with

single burner combustion processes. Each BurnerMaster

SB system is designed with approximately 100 diagnostic

and alarm messages to help operators start-up, operate

and troubleshoot the combustion process.

Burner management systems – in addition to our

BurnerMaster SB solution. Rockwell Automation builds burner

management systems for multiple burner applications employing

many of the Allen-Bradley control and I/O platforms and

architectures available today.

Rockwell Automation also designs systems to address your

specific control philosophies.

An experienced Rockwell Automation engineer is ready to

assist you in selecting the best control and I/O platform for your

specific project.

Burner Management Systems Enhance theSafety of Start-up and On-line Operations.

Our burner management systems control and monitor the

start-up and shutdown of burners and ignitors associated with

combustion processes. These burner management systems

help you:

• Protect against damage to your combustion process

• Reduce start-up time

• May qualify for lower insurance premiums

Design features used to help improve unit

uptime may include:

• Hardware & software partitioning

• Hardware redundancy

• Input signal voting

• Accommodation of dual system power feeds

Your most

valued global

source of

Complete

Automation™

solutions.

Your most

valued global

source of

Complete

Automation™

solutions.

Rockwell Automation BurnerManagement Systems are

designed in accordance with applicable industry

standards associated withthe combustion process,

whether it involves a boiler,HRSG, furnace, oven, kiln,

dryer, incinerator or process heater.

automation solutions forburner management

detailed diagnosticsoperator help messages

first-out alarms

Your most

valued global

source of

Complete

Automation™

solutions.

Your most

valued global

source of

Complete

Automation™

solutions.

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CompleteAutomationSolutions for theControl andSupervision ofCombustionProcesses

Rockwell Automation's IndustrialCombustion & Power Generation Teamis ready to work with you. Our team has a track record of successfulprojects ranging from burnermanagement to complete plant controlsystems. Working with us, you can beconfident your system will be built toyour specifications, optimized forperformance, and managed by results-oriented engineering professionals – people dedicated to completing your project on time and on budget.

Publication GMSE00-BR010B-EN-P – September 2003Supersedes Publication GMSE00-BR010A-EN-P – May 2001

Copyright © 2003 Rockwell Automation, Inc. All rights reserved. Printed in USA.