Controls & Instrumentation

steam plant controls and instrumentation


Customized instrumentation and boiler control technology.

Taking advantage of new technologies, IB&M created an in-house boiler control panel building shop and testing center dedicated to steam boiler controls and boiler instrumentation systems. Our in-house boiler testing center allows us to create custom instrument panels and provide online troubleshooting of boiler control systems around the world.


Boiler Instrumentation Testing

The boiler combustion control testing center allows IB&M technicians to design boiler instrumentation panels and actually test panels at our location by way of our boiler simulation test center. Customers can come to our facilities and operate their new system and receive training in our panel shop before the new control system is ever delivered. 


Boiler Control Panel Building

Custom-designed boiler control panels are built in-house IB&M.  Upon customer approval, the panels go through rigorous testing and programming before field installation. Since the bulk of testing has already been done at the IB&M center, the customer experiences a faster and smoother installation process with less downtime.


We design, build, and test all control systems, and can build custom control systems for application. All of our systems have Ethernet ability. We provide full electrical drawings, P&ID, loop sheets, recommended parts list.


We have the required test instruments to perform a base line test for burning #2 fuel oil and natural gas 200 HP to 2,000 HP boilers. The results are used to determine if the burner/boiler is efficient enough to request a controls upgrade, and or new burner/boiler. Our controls department also provides complete boiler room survey and base line testing with our own test instruments to show as is results, and burner optimum performance before upgrading controls, burner, or boiler. We always recommend this base line test as this will tell if the burner can perform at lower O2 adjustments, Carbon Monoxide, NOx, SOx, or any other burner and boiler issues.


Contact IB&M today at (855) 753-BOILER and speak to our Controls & Instrumentation division for more information on boiler controller, combustion controls, panel building, and instrumentation.



Fireye Burner Control MB Series


This packaged controller includes a main control system, plug-in flame sensor modules, a UV detection system, and a UV self-check.


  • Control and monitor up to 20 individual gas, oil, or combination gas/oil burners connected to a common valve train
  • Detects responsible boiler in the event of flame failure
  • Optional MB510 remote alpha-numeric display
  • Optional MB-604E or MB608E for systems requiring more than 4 burners per zone


Fireye Nexus Integrated Controller


The Fireye Nexus combustion control unit provides flame safeguarding and parallel positioning for oil, gas, and combination fuel burners using IR, UV, or UV self checking scanners.


  • Control and monitor up to 20 individual gas, oil, or combination gas/oil burners connected to a common valve train
  • Burner sequencing, ignition timing, and flame monitoring protection
  • Compact and user-configurable
  • Independent servo motor control
  • Parallel positioning of up to four channels (2 air, 2 fuel), accurate to 0.1º


Fireye PPC 5000 & PPC 6000


The cost-effective PPC 5000 controls electronic fuel/air ratios and parallel positioning functions for gas and/or liquid fuel-based industrial burners.


  • Compatible with existing flame safeguard controls
  • Controls up to 8 servo motors
  • Fuel/air ratio control


The PPC 6000 is the most compact and efficient parallel positioning system in the Fireye Nexus series. The PPC 6000 is compatible with servo motors ranging from 3 to 37 ft/lbs, and utilizes CanBus communication for reliable servo operation.


  • Controls up to 10 servo motors
  • Four programmable profiles
  • Positional accuracy up to 0.1º
Allen Bradley Controls or Compact Logix (ladder logic, FB, Scripting)
ABB Mod30ML and Modcell multi-loop controller (FB, and scripting)
Modicon M340 or Quantum PLC (ladder logic, FB, Scripting)
GE PLC or MTL Matrix system (ladder logic, FB, Scripting)
Siemens 353 multi-loop controller (FB)
Siemens SIMATIC PLC’s (Ladder logic, FB, Scripting)
Automation Direct PLC Koyo and DoMore CPU’s (Ladder logic)


The above control systems configuration will have PLC or multi-loop controller for CCS and option PLC or YB110 or RM7800 for BMS.


All the below PLC based controls systems have HMI, MMI and SCADA display systems. IB&M provides configurations for full detail of boiler, burner, combustion, all AI/AO, DI/DO and system performance, control, and diagnostics.


The following configurations are available for the above PLC’s and controllers:


  • Single point positioning jackshaft system
  • Single point positioning parallel system
  • Single point positioning parallel with feedback
  • Cross limiting parallel positioning system
  • Full meter cross limiting positioning system
  • O2 trim
  • Single, two and three element drum level control
  • Firstout annunciation
  • FGR control
  • Duel fuel firing
  • Fuel changing on the fly
  • Pressure and level control for Deaerator
  • Water softeners configuration and control
  • Plant master control system for multi – boiler applications. With lead/lag, hot boiler standby, biasing boiler masters, automatic boiler warm up, switching boilers automatically if burner or boiler failure to standby hot boiler
  • VFD control loops for pressure, and level
  • VFD control for combustion air
  • VFD control for fuel oil pump pressure
  • Multi-fuel configurations (gas “natural, hydrogen, propane-air,  propane, Bio-gas), oil (2 to 6, Bio fuel oil)


All of our systems have the ability of remote monitoring and diagnostics via modem, DSL/cable or cellar.


We can install Local/remote PC SCADA systems, local/remote HMI.


  • Indusoft
  • Wonderware
  • Proficy HMI/SCADA- iFIX
  • Allen Bradley RSView
  • C-More
  • Vijeo designer
  • Network, and wireless network controls
  • Modbus RTU, Modbus TCP/IP, Ethernet/IP, Ethernet
  • Remote monitoring for IB&M location and controls service tech laptop
24 / 7 Emergency Service
Count on IB&M's expert service technicians to solve your equipment repair challenges quickly and correctly – today.
With over 13,000 projects completed to date, we are proud of our safety record and boast one of the lowest EMRs in the industry:  .71.




Contact IB&M Today

We are the leaders in innovative steam plant solutions. Contact the IB&M boiler experts.

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IB&M is proud to provide end-to-end boiler service and repair as a fully licensed contractor in 25 states.