Rotary Furnace Combustion & Controls Upgrade

The client needed to modernize its outdated PLC5 furnace controls for reliability and obsolescence reasons. In addition, they requested to install and commission a new rotary encoder for furnace table position tracking. With rotary furnace upgrades, we complete a thorough audit of the furnace for other upgrades required meet today’s standards. 

To kickoff the project, we sent a CSS auditor to the site to perform a combustion survey. The furnaces were last modernized in 2002, so upgrades were needed to meet today’s code. As such, we provided the results and a combustion schematic detailing upgrades needed and parts required. From this, the client asked us to purchase the materials and manage the installation.

Meanwhile, we designed a controls modernization to update the old PLC5 controls to a new Honeywell HC900 PLC. Next, we programmed the new Honeywell controls to calculate and display furnace position. And we also designed and built a touch screen operator console and remote operator enclosures for each furnace. Furthermore, we selected and configured a new rotary encoder to track furnace position and programmed the logic in the PLC to monitor and control position.

Once the materials arrived and controls were tested, we returned on-site to manage the contractors that performed the installation. Then, we commissioned the new controls. In the end, our combustion survey educated the customer so they could budget and scope a proper rotary furnace upgrade. This allowed them to modernize the furnace and stay compliant with critical NFPA standards.