1. 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 1 Automated Recovery Boiler Sootblowing Control System Barbara G. Haley; B.A., Accounting; C.P.A. University of South Alabama; Mobile, AL Floyd I. Lawrence; B.S., Electrical Engineering University of Iowa; Iowa City, IA Brad S. Carlberg, P.E.; B.S., Mechanical Engineering Washington State University; Pullman, WA Ford, Bacon & Davis, LLC Mobile, AL James A. Johnson; B.S. Electrical Engineering James A. Johnson; B.S. Electrical Engineering Louisiana Tech; Ruston, LA Ford, Bacon & Davis, LLC Monroe, LA

2. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 2  The mill’s OTHER Recovery Boiler sootblowers were already controlled by a pair of redundant PLC’s  The existing sootblower panel was beginning to take more maintenance time - “it was wearing out”  Operators wanted “better” control: sootblower sequences, etc.  E&I technicians wanted “better” diagnostics to help find failed field devices  Superintendent wanted better tracking of failed field devices to determine cause of shutdowns

3. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 3  Dynamic Simulation in PLC tested PLC code Prior to Start-up / Commissioning  Team Effort Assured Smooth Start-Up  PLC Code Programming  Backup HMI Programming  DCS Programming  Installing New I/O Cables  Cutover Completed in Two-Week Yearly Shutdown  Recovery Boiler & Sootblowers Started Up On Time  50% of team on-site at startup

4. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 4 Sootblower Control Panel Existing I/O Cables from MCC Field Device’s Intermediate Junction Box in MCC UNEFFECTED UNEFFECTEDUNEFFECTEDREMOVED REDUNDANT PLC’s Existing DCS Back-Up HMI New I/O Cables from MCC NEW Added NEW Screens NEW “Blue Hose”

5. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 5  The Automated Recovery Boiler Sootblower System Operates the Same on Both the DCS Operator Interface and the Redundant, Backup, Plasma Screen Operator Interface  The Operator Interface and the DCS Are Talking to the Same PLC and Reading the Same Points  The PLC Does Not Care Which System Sends It Information, It Will Simply Process the Information As It Is Received  The Automated Recovery Boiler Sootblower System Operates basically the same as the original panel-mounted controller; EXCEPT for greater visibility

6. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 6  Six (6) Display Screens:  Sootblowing Control  Manual Mode Blower Select  Automatic Sequence Blower Out of Service  Limit Switch Monitoring  Help Screens  Alarm screens

7. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 7 Main Display Screen

8. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 8 Steam Mode Continuous Control Mode Steam Mode Continuous Control Mode Sequence Continuous Cycle Mode Sequence Continuous Cycle Mode Sequence Single Cycle Mode Sequence Single Cycle Mode Steam Mode Automatic Control Mode Steam Mode Automatic Control Mode FOUR (4) OPERATING MODES 3 PRE-DETERMINED SOOTBLOWING SEQUENCES ALL Sootblowers in ASCENDING Order ALL Sootblowers in ASCENDING Order Economizer Sequence (1-32, then 1-52) Economizer Sequence (1-32, then 1-52) Generator Plugging Sequence (5-8,15-18,25-28,1-52) Generator Plugging Sequence (5-8,15-18,25-28,1-52)

9. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 9 Manual Mode Blower Select

10. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 10 Automatic Sequence Sootblower Out of Service

11. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 11 Limit Switch Monitoring

12. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 12 Alarm Notification Screen

13. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 13 Help Screens

14. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 14 2 16-slot racks - with single slot addressing with scanner cards in each rack 56 Digital Input - 4 ea 16 point cards (4 for Even/Odd Fwd/Rev & 52 for each Soot Blower) 156 Digital Output - 11 ea 16 point cards (3 limit switches for each of 52 Soot Blowers) I/O Count Only 2 channels used (1A-DH+ & 1B-RIO) Communicates to DCS via Extended PLC Gateway I/O Racks Communication

20. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 20  Pre-Existing, Stand-Alone Sootblower Panel REMOVED  Redundant PLC’s Assure Constant Control  DCS Continuously Collects the Plant’s Real-time Process Data  Operators Have Greater Access to That Real-time Process Data  3 Strategic, Pre-Determined Sootblowing Sequences  E&I Technicians Can Quickly Find and Troubleshoot Failed Field Devices From the Alarm Display  Better Control of Sootblowers  Optimally Operate the Recovery Boiler.  Pre-Existing, Hard-Wired Field Devices UNAFFECTED  DCS and Backup HMI Assure Constant Visibility CONCLUSIONS  ALL Sootblowers in ASCENDING Order  Economizer Sequence (1-32, then 1-52)  Generator Plugging Sequence (5-8,15-18,25-28,1-52)  Easy to implement 15 more sequences by “fill-in-the-blanks”

21. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 21  The Plant Saved Resources (i.e.; Steam) and Reduced Plant Operating Costs Significantly by “Smoothing” Steam Demand  The Plant Only Blows Soot When It Is Needed, and Only in the Necessary Locations (i.e.: Economizer or Generator Tube Banks) H Automated Sootblowing Improves Boiler Heat Rate, Minimizes Soot Accumulation, Improves Overall Boiler Efficiency, and Balances Blowing Sequences  The Plant Is Able to Avoid Unnecessary Steam Usage and Opacity Spikes  Plant Equipment Life Was Extended and the Plant Now Avoids Forced Outages Due to Soot Accumulation MORE CONCLUSIONS  The Operators Can Use the Additional Real-time Process Data and Alarm Management Display to Schedule Sootblowing Sequences and Optimally Operate the Recovery Boiler

22. Automated Recovery Boiler Sootblowing Control System 2001 TAPPI PCE&I / ISA PUPID Joint ConferenceMarch 27, 2001Page 22  Implement Smart Sootblowing By Implementing Advanced Control Software in DCS Utilizing Instrumentation in DCS  Add Additional Sootblowing Sequences By Modifying The PLC Code FUTURE RECOMMENDATIONS