Clyde Bergemann has installed more than 70 water cannon cleaning systems in the US. The major elements of a Water Cleaning system are:
- SmartCannon: Model WLB100 opposed wall water cannon located in strategic positions on the furnace wall. From their vantage points each SmartCannon is pre-set to clean many individual zones on their opposing and adjacent walls. A typical system consists of 4 SmartCannons.
- SmartSensor: heat flux and tube metal temperature sensors imbedded in strategic locations throughout the furnace wall providing live data regarding spatial variations in deposition location and tenacity as well as tube metal temperature changes during cleaning events. A typical system includes 24 to 36 SmartSensors.
- AnySpeed Pump: The variable speed pump supplies instantaneous, on-demand, variable water pressure as dictated by the individual zone cleaning needs. One for each system.
- SmartClean Control System: this control system provides the centralized command and control link between the SmartSensor data acquisition devices and the various SmartCannon cleaning devices through an integral Furnace Fouling Monitor and is inclusive of the local PLC cabinets and the control room HMI, which can support the DCS interface using industry standard communication protocols 9Ethernet, Modbus, DH+,... SmartClean also automatically adjust the water jet pressure and progress velocity to minimize the tube thermal impact, on the basis of the feedback from SmartSensors. If desired. Also integral to the SmartClean Control platform is the Thermal Impact Monitor , which constantly reports tube metal temperatures during cleaning events and modifies cleaning intensities accordingly.
The Water Cannon Integral Control system allows intuitive PC based system control. The control MMI, Wonderware, is integrated with the above SmartControls system. All boiler geometry comes preprogrammed in the system. This will include all target cleaning zones, and all prohibited no-go zones such as burners and ducts. The furnace surface area is systematically segregated into a number of cleaning zones. The cleaning cycle for each zone can be initiated manually and individually, or in a sequence of several zones, or sequences of sequences or in automatic mode.
The PC controls interface allows complete configuration and adjustment of the given system, allowing, amongst other things: zone locations and sizes relative to a given reference point; zone specific cleaning intensity / speed individual cannon settings including nozzle sizes, gearbox ratios, spindle pitch size etc.
The system is auto-adaptive in that all zone parameters are automatically and intelligently modified based on the requirements dictated by SmartClean. One NEMA 4 PLC cabinet is provided for four (4) water cannons. This cabinet is to be mounted in the vicinity of the water cannons (max 300'). Each cabinet includes an Allen Bradley ControlLogix series PLC with Allen Bradley I/O, 2 motor amplifiers, line filters, and all termination strips. The local PLC cabinets communicate with the controls PC via an Ethernet highway utilizing a CAT5e cable less than 100 meters in length. For installations over this distance a hub or fiber optic cable is required.