Modernization of the control system for WLM 2.5 boilers
In 2020, we were tasked with modernizing the control system for WLM 2.5 boilers. The greatest challenge was not the scope of work itself, but the extremely short execution time — the heating season was approaching rapidly, and the system had to be commissioned in compliance with all technical and safety requirements.
Goals
- Adapting the I&C (Instrumentation and Control) system to current UDT requirements
- Elimination of failures and unplanned downtime
- Improved safety and reliability of boiler operation
Challenges
- Selection of instrumentation and development of a control algorithm in accordance with UDT requirements
- Very short execution deadline due to the approaching heating season
- Development of a new, highly reliable control algorithm
Solutions
- Use of instrumentation compliant with UDT standards
- Implementation of a Siemens Fail-Safe controller
- Parallel execution of project phases: electrical design, UDT approvals, and control algorithm development
- Replacement of power and control cabinets
Benefits
- High safety level confirmed by compliance with UDT regulations
- Delivery, commissioning, and UDT certification completed several weeks ahead of schedule
- Elimination of failures and downtime caused by outdated equipment
- Uninterrupted production and heat supply
The heating season is a particularly demanding period for the energy sector. Our client decided to modernize the control system of WLM 2.5 boilers in order to comply with current UDT (Office of Technical Inspection) requirements and reduce the risk of failures and unplanned downtime.
Aged control cabinets were causing frequent breakdowns that could disrupt heat supply to end users. During the heating season, such situations are especially critical, which made the rapid implementation of a stable and safe solution essential. We delivered new control cabinets based on high-efficiency Danfoss drives and Siemens switching and protection equipment, eliminating downtime caused by failures of outdated components.
A key part of the modernization was the development of a simple yet reliable control algorithm for the Siemens controller. This solution simplified system operation, improved installation safety, and ensured compliance with requirements for this type of energy systems.
Compliance with safety requirements was confirmed by the Office of Technical Inspection (UDT) through appropriate certifications. The entire project was completed several weeks ahead of schedule, allowing operators to become familiar with the new control system before the start of the heating season.
