POWER PLANT APPLICATIONS

Burner Tilt Systems

System Overview
In a Tangentially Fired boiler, a burner tilt mechanism
is one of the systems used to control main steam
and reheat outlet temperatures in boiler. A burner tilt
actuator is used to tilt a burner or group of burners.

Windbox #2

Windbox #3

Primary Air,
Coal and
Secondary Air

A fossil-fueled tangentially fired furnace has burners

in the corners, not in the walls (see figure 1). The
burners aim at points tangent to an imaginary
circle at the center of the furnace for intensive fuel/
air mixing. Flame body spreads out due to vortex
motion, filling out the furnace area. A furnace can
have four or eight corners.
Burners are vertically arranged in each corner in a
windbox arrangement. The windbox arranges
burners alternating with air nozzles, flame scanners
and ignitors. Windboxes span many furnace
elevations. Each furnace typically has a unique
windbox arrangement. Each burner nozzle connects
to a tilt mechanism inside the windbox. Several
nozzles can be grouped together on one internal tilt
mechanism. The internal tilt mechanism connects
to shafts that pass through the windbox wall.
Each shaft connects to external tilt levers. Often
a windbox has two or more external tilt levers. A
connecting rod ties external tilt levers together
vertically in each corner. Typically, there is one tilt
actuator per corner mounted near and connected
to one external tilt lever, called the drive lever. The
burner nozzles commonly tilt inside the furnace 30
degrees from horizontal (60 degrees total rotation)

PWR-BT 04/13

Imaginary
Firing Circle

Windbox #1

Figure 1
Tangentially Fired Boiler

Windbox #4

to raise or lower the fireball in the furnace and often

have different rotation than the tilt lever. Due to
the geometry of internal tilt mechanism, external tilt
levers usually rotate 78 degrees, or 39 degrees.
There is often a tilt travel scale marked +30 UP
to 30 Down by external levers in order to show
nozzle rotation, not lever rotation. One tilt actuator
moves all nozzles in the corner at the same time.
Sometimes, the customer splits the tilts, using
two or more tilt actuators in a corner in order to
individually tilt a nozzle or group of nozzles for more
customized control of combustion.

POWER PLANT APPLICATIONS

The Problem
The nozzles can become coated with combustion
by-products causing them to jam or stick in position
due to build up of slag or molten ash. If the burner
tilt actuator moves the external drive lever responding to the control system but the nozzle is stuck,
damage to the tilt mechanism may occur. To protect
the tilt mechanism, in this scenario, the external
drive lever is really a two-lever assembly where a
shear pin connects the inner and outer lever. The
actuator connects to the inner, longer lever. The
outer, smaller lever connects to the tilt shaft and to
the internal tilt mechanism. If (or when) the shear
pin breaks and disconnects the two external levers,
the actuator continues moving the longer lever. The
actuator position feedback may match signal, but the
actuator is no longer connected to the smaller lever
or nozzles. The nozzles may continue to be stuck
in position, or the nozzles may drop due to weight
of parts. The end result of a sheared pin is loss of
control of the nozzle position.
For emphasis, note two things that happen if a pin
shears: (1) actuator position feedback still matches
instrument signal, (2) there is a drastic reduction in
required torque.
If the plant senses the loss of tilt control via other
signals, they can lock the tilt or drive lever in position
or take reactive measures while running. Some
customers install a limit switch across both levers
to trip when levers spread apart. In extreme cases,
customers say buildup on nozzles causes clogging/
plugging of air flow at a nozzle which changes flame
sculpturecausing damage requiring entire nozzle
replacement.
An additional problem is that burner tilt actuators
are typically installed in hot areas where ambient

temperatures can be greater than 185F (85C).

Electric actuators are subject to overheating motors, overheating grease and lubricant, and wiring
degradation. All these events ultimately result in
more frequent actuator repair or complete replacement. Sometimes, an electric actuator still under
warranty will need repair. However, some manufacturers may deny warranty coverage due to exposure
greater than 185F, maximum allowable ambient
temperature. Air operated actuators with smart
digital current to pressure (I/P) converter positioners or analog I/P positioners also suffer due to high
ambient temperatures. Removing a positioner for
replacement, high up on the windbox in a hot inside
corner while a furnace fires, is not safe or easy.

Burner Tilts
The REXA Solution
REXA linear actuators and drives are widely applied
on burner tilts. Required tilt torque changes due to
build up on nozzles, causing the actuator to increase
its output to overcome the additional load and make
position match the control signal. Using REXA Differential Pressure (DP) cylinder output allows the
customers Distibuted Control Systems (DCS) to
calculate the actual output and directly monitors the
effects of deposit build-up; thus allowing the customer to take corrective action. In addition, monitoring DP increase can infer build-up on nozzles and
resultant nozzle clogging; thereby facilitating the
customer in taking proactive steps to help prevent
nozzle damage due to changing flame sculpture.
REXA actuators have two additional features which
can help protect the burner tilt mechanism: (1) motor
shutoff in stall condition, (2) hydraulic pressure limiting devices to prevent excess pressure build up.

Built into all X2 modules as standard equipment

are pressure limiting devices. These devices protect the cylinder from excessive hydraulic pressure
which protects the tilt lever (and any shear pin) from
excessive output torque. When something restricts
the rotation of the drive lever, the power module
will continue to build hydraulic pressure. In order to
protect from the higher pressure, the pressure limiting devices should be set to a DP cylinder pressure
where actuator output is less than shear pin torque.
At lift pressure the devices open so oil is harmlessly
diverted away from the cylinder and into the thermal
expansion chamber in the power module. REXAs
pressure limiting devices reseat when pressure
drops 500 psig below lift pressure; therefore normal
operating pressure needs to be less than lift pressure 500 psig.

The stall parameter monitors time required for

actuator to travel 1% of calibrated stroke. If the
actuator fails to move 1% of stroke within the defined
stall time, the motor stops and retries five times. If,
after five attempts, the stall condition still exists, the
motor turns off, and REXA sends both an alarm and
warning via relays #3 and #4. If so equipped, REXA
can report a stall via HART or Foundation Fieldbus.

POWER PLANT APPLICATIONS / Burner Tilts

The REXA Advantage
REXAs Electraulic actuators offer accuracy,
repeatability, high temperature capability (for use
up to 250F [121C]), continuous-duty, and rigidity
required for precise control of burner position.
Required torque for burner tilt actuators varies
according to windbox dimensions and arrangement
(i.e.; number, size, and weight of nozzles).
High-temperature capability
For installation up to 250F (121C), REXAs high
temperature construction survives where other
actuators often fail. Typically hot installation is an
inside corner of a windbox.
High output with low weight
REXAs output to weight ratio is best in class.
Lighter actuator means faster easier installation.
Real-time monitoring
Optional pressure transducers and one of REXAs
three optional output boards provide real-time output
of differential pressure across cylinder. Customers
can use DP cylinder output to calculate real-time
actuator torque or thrust to monitor required tilt
torque and associated condition of burner and tilt
mechanism.

REXA
4 Manley Street
W. Bridgewater, MA 02379
(P) 508.584.1199
(F) 508.584.2525
www.rexa.com
REXA Electraulic Actuators & Drives