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The Integrated Boiler RoomGerry Cellucci Yorkland Controls
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Control Objectives for Hydronic systems
Maximize Occupant ComfortMaintain Constant Space Temperature
Minimize Energy ConsumptionMinimize boiler temperatureMinimize Boiler Cycling (on/off)
ProtectionMinimum Boiler Temperature MaintainedBoilers NOT to be Cycled on Limits
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Boiler Room Control TrendsAway from individual control of various heating loops:
Main Heating LoopSecondary Heating LoopsDomestic Hot WaterSnow Melting
Owners requesting operational informationTrendsStatusAlarms
Reduce operating costs and increase efficiency
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Typical Boiler Room ControlsControl for Boiler sequencingControl(s) for “resetting” Hotwater based on outside air temperatureDomestic Hotwater Air Handler Heating Coil LoopsRadiant Heating LoopsDifferential Pressure Time clocks for setback
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Boiler 1 Boiler 2
MIX
ING
VAL
VE
P1
P2
BP1
BP2
HWS MAIN BOILER LOOP
HWR
HWR
HWS TO ZONES
T
T-360
OA-T
P3
T
T
HEX P4
DHW TANK
T
T
N 0
CNC
DHW-VLV
Sequencer
Reset MainReset
DHW
Pump
Circ Pumps
DHW
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Current ControlDifferent controls for the various loopsDuplicate Sensors for the same function (Outdoor Air temp)Difficult to coordinate setpointsLimited Control LogicLimited DiagnosticLimited AlarmingMinimal Energy Savings
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Boiler Reset - What is it?
Water temperature is varied based on outside temperatureHeat loss from building changes continuously -not on/offControl matches heat loss of building to heat
output of boiler (or mixing valve)
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Boiler Reset - BenefitsReduced heat loss through pipes. (Standby Losses reduced)
Increased boiler efficiency.(Boilers more efficient at lower fire)
Elimination of uncomfortable (and expensive) overheating. Boiler shutoff when it's not needed.
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Boiler ResetHotwater supply temperatures are RESET based on outside air. Goal is to reduce the seasonal average control temperature.Typical reset schedule
OA-T = 0 F HWS-T = 185OA-T = 65 F HWS-T = 135
Savings calculation are often derived from estimates Studies to show minimum 10% to 12 % savings
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Building Reset TypesBoiler Temperature ResetMixing Reset ( Building Loop )
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Typical Reset Products
T775 HoneywellA350R JohnsonTekMarDx9100
Increasing Features
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Typical Reset SchedulesMain Boiler
Radiation
13055
HWS-T
190OA-T
-10
10055
HWS-T
180OA-T
0
Usually expressed as a Ratio
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Outdoor Air Temperature
Hotw
ater Supply
200
-10
130
60
What is the Ratio ?
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Boiler SequencingLead-Lag
Boilers run 1,2,3,4 then 4,3,2,1Switching inputUsually set with a manual or time clock
Rotational Boilers run in logical order on the next firing cycle: 1,2,3,4, then 2,3,4,1 then 3,4,1,2, then 4,3,2,1
Equal Run TimeBoiler with the least amount of “ON” time is first on.
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Integrated Control Benefits(all functions in one common interface)
Multiple Boiler Sequencing:Lead-LagRotationalEqual Run Time
Shared SensorsMultiple Control Loops (PID)Different Reset Ratios for various loadsPump ControlPost-Purge Pump ControlAnti – Condensation ProtectionTrending for Major ParametersOccupied Time schedule common for all the control loops
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Benefits One location for the informationMicroprocessor basedEasy to use customizable displayNetworkableCentralized Alarms
PagerMobile PhoneE-Mail
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Boiler 1 Boiler 2
MIX
ING
VAL
VE
P1
P2
BP1
BP2
HWS MAIN BOILER LOOP
HWR
HWR
HWS TO ZONES
T
T-360
OA-T
P3
T
T
HEX P4
DHW TANK
T
T
N 0
CNC
DHW-VLV
Sequencer
Reset MainReset
DHW
Pump
Circ Pumps
DHW
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Integration withGeneric Controls
Custom Control LoopsSame Controller for different types of heating or cooling systemsEasy to duplicate programs
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Generic ContolUses Software to set up the control loopsSame software is used to commission
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Typical Controllers
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Generic Control Features10 – 12 PID Control Loops with enhanced capabilitiesStart/Stop LoopsLogic LoopsMath FunctionsSequencing functionsPulse inputs for flow meters8 Digital Inputs, 8 Digital Outputs8 Analog Inputs, 6 Analog OutputsExpandable I/O’s
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RESET SCHEDULE TYPICAL
-5 0
65 70
185 185
135 135
-50
0
50
100
150
200
OUTDOOR AIR TEMP DEG F
HO
TWA
TER
SU
PPLY
TEM
PC
ALC
ULA
TED
OUTDOOR AIR -5 0 65 70
HOT WATER SETPOINT(CALCULATED)
185 185 135 135
1 2 3 4
X0
Y0
X1
Y1
X2
Y2
X3
Y3
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Reset Control Strategy
Reset Schedule (ratio) calculates the Hot water temp SETPOINTSETPOINT is compared to ACTUAL Hot water tempDIFFERENCE compared to the “proportional band” (throttling band) parameter determines the amount of heating capacity required (expressed as a %)
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Reset Strategy - Example
Calculated Hotwater Setpoint = 165 FActual Hotwater Temperature = 155 FProportional Band Set = 30 F% Heating Capacity = 33%
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Boiler Capacity & Proportional Band Relationship
% Heating Capacity Required
100 %
50 %
Calculated Setpoint
Proportional Band = 30 F
15 F
165 F
Actual HW Temp155 F
33 %
Hot Water Temperature
One Boiler - 3 Stages each stage having equal capacity
One stage is ON
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Boiler Reset –Load Compensation
Direct Feedback of Buildings’ Heat LoadBoiler Capacity is adjusted by using Return Water or Space Temperature as Feedback
Capacity is reduced as Space temperature approaches space comfort (72F)Capacity is reduced as Return Water approaches Supply Water
New Effective Set point is used to determine Capacity
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Boiler Capacity & Proportional Band Relationship
% Heating Capacity Required
100 %
50 %
ReferenceSetpoint 165 F
Proportional Band = 30 F
15 F
Effective Setpoint163.5 F
Actual HW Temp155 F
33 %
Hot Water Temperature
25 %
One Boiler - 3 Stages each stage having equal capacity
One stage is OFF
Proportional Band Increased = 40 F
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Simply…………Load Compensation accounts for internal heat load by staging boilers -“OFF” SOONER & “ON” LATER…...….in a smooth controlled manner. (no cycling of the boilers)
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Estimated Reset SavingsAverage reduction in boiler temp 25 F with basic reset
10% to 15% SavingsAverage reduction in boiler temp 30 F with load compensation additional
7% to 15%Utilities offering Rebates
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Other Control System Features
Variable Stage CyclingEqual wearLow-Med-High or Low-Low-Low Firing
Season “Soft-Start” of Building Loop ValveBoiler Circulating Pump Run TimeCharacterized Reset Schedule
Match radiation equipmentFinned TubeFan CoilsDHW Production
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Boilers Efficient at Low to Mid Load
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Firing Sequence• Low - Medium - High (3 to 4 stages per boiler)
•Low – Low – Low
•Equal Run Time
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Characterized Heating Curve
• Different types of terminal units transfer heat to the space at different proportions of radiation, and convection
• Water supply temperature is controlled by the type of terminal unit
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Terminal Unit Types
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RESET SCHEDULE "Characterized"
-10 -5 0 10
55 60 70
190 187 185170
140 130 130
-50
0
50
100
150
200
OUTDOOR AIR TEMP DEG F
HO
TWA
TER
SU
PPLY
TE
MP
CA
LCU
LATE
D
OUTDOOR AIR -10 -5 0 10 55 60 70
HOT WATER SETPOINT(CALCULATED)
190 187 185 170 140 130 130
1 2 3 4 5 6 7
X0
Y0
X1
Y1
X2
Y2
X3
Y3
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Dx9100 Generic ControllerExample
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Boiler Product for Intergrated Heating Plants
Johnson Dx9100 Configurable ControllerAllows for Flexibility in Control Strategy
Standard Reset CurveCharacterized curve
Integral Boiler ControlMain Hot waterBuilding LoopDomestic Hot water
Allows for Load Compensation Strategy ChangeSpace sensing for small facilitiesReturn Water sensing for larger systems
Maybe networked and monitoredOver 90 contractor individuals trainedProduct Stocked and supported
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Typical Projects MTHA
P5-CP5-STS
P7-CP7-STS
P6-CP6-STS
P10-CP10-STS
P3-CP3-STS
P2-CP2-STS
P4-CP4-STS
B3HI-CB3LO-C
B2HI-CB2LO-C
TAN
K-T
HIG
H
B1HI-CB1LO-C
BP 4
B4 BP 3
B3 BP 2
B2 BP 1
B1
P1
P4
LOO
P 3-T
P10
TAN
K-T
LOW
P9
P2
LOO
P 1-T
V2
P3
LOO
P 2-T
DHW LOWPRESSURE
HW
S-T H
WR
-T
B4HI-CB4LO-C
HWR HWR
DHW HIGHPRESSURE
HEX 2 HEX 1
V4P5
P8
V5
P6
V3
P7
V1
HWS HWS
BP 1-STSBP 2-STSBP 3-STSBP 4-STS
P1-CP1-STS
P9-CP9-STS
P8-CP8-STS
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Intergrated Boiler Control Room
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Diagnostic Exercise 1HWS -T = 178FHWR -T = 172FWhat assumptions can you make?
Load ?
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Diagnostic Exercise 2HWS-T = 170 (current reading)HWR-T = 160 (current reading)Setpoint = 185Trend showed:
HWS-T = 198FHWR-T = 180F
2 out of 4 Boilers not firing ????
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Diagnostic Exercise 3HWS-T = 170HWR-T = 175
???
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Diagnostic Example 4OA-T = 0 FHWS-T = 185HWR-T = 160All boilers on and firing
????
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Service TipsFamiliarize yourself with the systemReview diagnostic information Check Trending info (if available)Make sure equipment is functioningCheck sensors and relays
Most outputs from controllers are TRIAC with Pilot Relays
Software would be nice to have – BUT NOT necessary – use the display?
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Tools of the Controls Trade ?Supplier Commissioning Software
Allows you to verify operation and get all parameters
Laptop or Display DeviceControl Logic ExperienceUnderstand the control terms
PIDDead Bands
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Typical Cost - Conventional8 Stage Boiler Control $ 1890
Lead/Lag / PumpReset Control w/Pump $ 750 (250x3)Lead/Lag Pump Control $ 400Domestic w/ VLV output $ 400Time Clock $ 60
Total $ 3,500.00
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Integrated Controller System
Controller $ 1400Sensors $ 400Panel $ 250Programming $ 500TOTAL $ 2550.00
Display(optional) 750.00 Software 500.00Hardware 100.00
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Questions
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Thank You