Transcript Boiler Efficiency and Combustion Control

Preferred Utilities Manufacturing Corp
UtilitySaver
Overview
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
www.preferred-mfg.com
UtilitySaver
UtilitySaver Burner Control
Introduction
 Energy Savings




Fuel Savings
Electrical Savings
System Composition




UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
 Summary

UtilitySaver
UtilitySaver Burner Control
The UtilitySavertm uses a single PCC-III Controller to
provide state of the art burner control. The package
includes firing rate control with both oxygen trim and
variable speed fan combustion air flow control.
UtilitySaver fuel and electrical savings can pay for the
installed system in two years or less.
UtilitySaver
UtilitySaver Burner Control
UtilitySaver
UtilitySaver Burner Control
Includes:
 UtilitySaver
Panel
 Oxygen Analyzer Kit
 Boiler Efficiency Kit
 Actuator Kit

Jackshaft and UtilitySaver Damper
 Variable
Frequency Drive (VFD) Kit
 Installation Materials and Supervision!
UtilitySaver
UtilitySaver Burner Control
Introduction
 Energy Savings




Fuel Savings
Electrical Savings
System Composition




UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
 Summary

UtilitySaver
Energy Savings
F u e l S a v in g s
E le c tric a l S a v in g s
Fuel
Savings
$3,500
Operating Cost Savings
$3,000
$2,500
+
$2,000
Electrical
Savings
$1,500
$1,000
$500
$0
20%
40%
60%
80%
B oiler Load (%)
100%
UtilitySaver
Energy Savings

Fuel Savings:
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Seasonal Air Density
and Humidity Changes
Fuel Pressure and
Temperature Changes
Fuel Btu and Viscosity
Variations
Worn Linkage
Components
(Hysteresis)

Electrical Savings:


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Minimizing Damper
Pressure Drop - damper
is 100% open for
maximum kWh
savings, (Partially
closed at low fire to
maximize burner
turndown)
Oversized Fans
Oversized Motors
Partially Loaded
Boilers
UtilitySaver
Energy Savings
Conservative $13,700 per Year
Based on:
 ASME “by losses”
boiler efficiency
calculations.
 Industry leading
manufacturer motor
energy data.
 600 Bhp Boiler
 125 psi Steam
Natural gas fired
 Operating 365 days /
year & 24 hours / day
 Electric Cost - 7.5
cents / kWh
 Fuel Cost - $4.5/k ft3
 Oxygen Reduction 1.5% Wet

UtilitySaver
Unique Energy Savings Tool

Savings Estimate
Based on:
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Boiler size
Motor HP
Air Damper Type
Current O2 Level
Projected O2 Level
Flue Gas Temperature
Seasonal Loading Data
Fuel Cost
Electrical Cost
UtilitySaver
Fuel Savings
UtilitySaver
Variations in Air Composition
 “Standard”
air has 0.0177 LB. O2 per FT3
 Hot, humid air has less O2 per cubic ft

20% less at 95% RH, 120OF, and 29.9 mm Hg
 Dry,

cold air has more O2 per cubic ft
10% more at 0% RH, 32OF, and 30.5 mm Hg
 Standard

Combustion controls must:
Allow at least 20% extra excess air
because of the change in air density.
UtilitySaver
Variations in Air Composition
Forced Draft Fan
Combustion Air
(Constant Volume)*
( O 2 + N2 )
Temperature = 120 F
Relative Humidity = 95%
Pressure = 29.9 in Hg
Less lbs of O2 + N2 per cu ft
H2O
N2
N2
N2
N2
N2
H2O
O2
N2
N2
N2 O 2
N2
N2 O 2
N2
Fuel Flow
(C+H)
O2
O2
N2
N2
H2O
N2 N 2
N2
N2
N2
N2
N2
N2
H2O
O2
N2
O2
O 2 N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
O2
N2
O2
N2
N2
N2
N2
N2
N2
N2
N2
O2
N2
O2
N2
O2
H2O
Burner
UtilitySaver
Variations in Air Composition
Forced Draft Fan
Combustion Air
(Constant Volume)*
( O2 + N2 )
Temperature = 32 F
Relative Humidity = 0%
Pressure = 30.5 in Hg
More lbs of O2 + N2 per cu ft
Fuel Flow
(C+H)
O2
N2
O 2 N2
N2
N2
N2
N2
O 2 N2
N2 O 2
N2
N2
N2N2
O 2 O2
N2 O 2
N2
N2
N2
N2
N2
N2
N2 O 2
N2
N2
N2 N 2
N
2
N2
O2
N2
N2
O2
N2 O 2 N2
N2
N 2 N2
O2
N2
N2 N2
N2
O 2 N2
O2
N2
N2
N2 N2
N2
N2 N 2
O2
N2
N2
N2
N2
N2
O2
N2
O2
N2
N2
N2
O 2 N2
N2
N 2 N2
O 2 N2
N2
N2
O 2 N2
N2
N2
N2
N2 N2 N 2
N2
N2
N2
N2
O2
N2
N2
N2
O2
N2
N 2 N2 O 2
N2
Burner
At these ambient conditions the burner has extra O2 & N2
UtilitySaver
Combustion Air Fan Hp Savings
Damper Control
HP Savings
Variable Speed Control
Combustion Air Flow, %Full Load
UtilitySaver
Reference 1
UtilitySaver Burner Control
Introduction
 Energy Savings




Fuel Savings
Electrical Savings
System Composition




UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
 Summary

UtilitySaver
UtilitySaver Burner Control
Optional
(4-20mA or
135 ohm)
PC
TC
Pressure or
Temperature
Controller
PT
TT
Pressure or
Temperature
Transmitter
PI
SP
1
AT
Model ZP
Oxygen Sensor
PCC-III Controller
3
(PSI or F)
Setpoint
f(x)
PI
Oxygen
Setpoint
Firing Rate
Hand / Auto
H/A
H/A
Oxygen Trim
Hand/Auto
2
2
Fuel
Lead Lag
Air
Lead Lag
3
f(x)
VFD
Fuel / Air
Ratio
3
Full Speed
Fuel / Air
Ratio
f(x)
3
f(x)
T
H/A
Jackshaft
Actuator
Fan Speed
Setup Station
Position
Feedback
Position
Feedback
M
VFD
Damper
Position
Full Speed Bypass
Selection
H/A
Air Damper
Setup Station
M
Air Damper
Actuator
Speed
Feedback
3 Phase
Power Supply
Fuel Oil
Fan
Variable
Frequency
Drive
Combustion Air
Fuel Gas
UtilitySaver
The UtilitySaver Controller
Right For the Job...
UtilitySaver
The UtilitySaver Panel
Measured
Flue Gas Oxygen
Flue Gas Oxygen
Setpoint
Firing Rate
Firing Rate % (shown)
Steam PSIG
Steam PSIG SP
Oxygen %
Oxygen SP
Oxygen Trim %
VFD Speed
Fuel Valve Position
Air Damper Position
Boiler Efficiency
Organized, simple and to the point local operation
UtilitySaver
The UtilitySaver Panel

Enclosure 

Controller 
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Nema 12, 16 H x 14 W x 10 D
PCC-III with “Z”, and “G” Option Boards.
Components 
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VFD / Flame Safeguard interface relays
24Vac power supply transformer for DM-1E
Actuators
Shielded cable for field wiring
UtilitySaver
The UtilitySaver Controller
 PCC-III-ZG00
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“Z” Option Board, Oxygen Analyzer
“G” Triac Outputs to Drive Electric Actuators
 Constructed
For Boiler Front Mounting
 Intuitive Operation
 Flexible, powerful blockware control logic
 Built In Boiler Efficiency
 F(x) Characterizers with “Learn” Mode
 Commissioning Tools
UtilitySaver
UtilitySaver Features
 Minimizing

Damper is 100% open for maximum kWh savings,
(Partially closed at low fire to maximize burner
turndown)
 Fuel-Air
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Damper Pressure Drop
Lead-Lag With Cross-Limiting
On a load increase, Air increases first. On a load
decrease, Fuel decreases first.
Minimizes excess air during normal firing, and
increases excess air during a load change for safety.
Excess air is limited during load changes for flame
stability.
UtilitySaver
UtilitySaver Features
 Independent
Fuel-Air Ratio Curves
 PCC-III "Learn" mode

Rapid, error free burner fuel-air ratio curve setup, with easy
"Store" pushbutton operation.
 Safety


Low flue gas oxygen trips the burner after an adjustable time
delay.
VFD speed and actuator position feedbacks are continuously
monitored. Burner trips after an adjustable time delay if any are
out of position.
 Real
Time Boiler Efficiency
 Continuous Oxygen Analyzer Diagnostics
UtilitySaver
Touch Screen Options
10 inch
UtilitySaver
In-Situ Oxygen Analyzer
Field replaceable detector
Only one conduit to stack.
No separate analyzer, one less item to mount
UtilitySaver
In-Situ Oxygen Analyzer
 Proven

Zirconia Oxide Sensor
 No

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Reliable
Reference Air
The probe uses ambient air as a reference.
Competitors use instrument air and run the risk of
element cracking due to water
 Automated,
menu driven pushbutton
calibration.
 Automatic impedance checking

Alarms when time to recalibrate
UtilitySaver
Oxygen Analyzer Kit
Model ZP
Oxygen Sensor
Probe
Detector
PCC-III Controller
with
"Z" Option Board
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Model ZP Oxygen Sensor, 20”
Standard
Reliable Zirconia Oxide Cell
60 ft ZP Cable
Mounting Hardware included
190130
Connecting Cable
Power Supply
Calibration Gas Connection
at Grade Level
Model ZP Oxygen Analyzer Arrangment
UtilitySaver
Boiler Efficiency Kit
 PCC-III
Controller calculates the
ASME “by losses” method efficiency in
real time. Kit Includes:


Flue Gas Temperature Assembly, Type J,
p/n 104087C, with mounting flange
60 feet of shielded type J T/C extension
cable
UtilitySaver
Actuator Kit

Two (2) DM-1E Actuators are
Included: Jackshaft & Damper
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Torque:
Rotation:
150 in-lbs
90° travel in 30
seconds
Aux. Switches: Integral 2 SPDT
Position Feedback:
600 ohm
Power Supply: 24 Vac
(2)Linkages, (3)Lever Arms,
(1)Mounting Bracket
UtilitySaver
Alternate Actuators
 R-AL
: 100 lb Linear Thrust
 1730: 1000 in-lb Torque
 UP10 Pneumatic: 1080 in-lb Torque
 I/P Kit to interface to Existing
Pneumatic Jackshaft Actuator
 Pot Box, if Existing Actuator doesn’t
have Feedback
UtilitySaver
Variable Speed Fan Air Flow Control
 Variable
Speed Drive (VSD) - The
UtilitySaver package includes a full featured,
quality drive.
 Nema 12 Packaging - for worry free boiler
room installation
 Built in “DC Link” line reactor - for reduced
electrical system harmonics distortion
 “Soft Turn On” IGBT transistors - for
reduced motor stress (lower peak voltages)
UtilitySaver
VSD Parts & Theory

5 Parts to a VSD
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Rectifier
DC “Link” line reactor
Intermediate Circuit
Inverter
(IGBT = Insulated Gate
Bipolar Transistor)

Control & Regulation
UtilitySaver
Motor Speed Control
UtilitySaver
Pulse Width Modulation (PWM)

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On or Off, voltage does
NOT modulate.
PWM allows IGBT’s to
run cool for long life, so
better VSD’s use PWM.
However, PWM dV/dt
causes spike voltages
UtilitySaver
“Soft Turn On” IGBTs


dv/dt - Change in Voltage over Time

Competitor’s Drives - up to 3500V/us

UtilitySaver Drive - 900V/us

Due to Patented “Soft Turn On” IGBT’s
Lower Peak Voltages Extend Motor Insulation Life

460V, 75 Hp motor:
815V peak for 50 ft cable
UtilitySaver
Automatic Over Ramp Protection
 The
UtilitySaver VFD will not trip when
given a “STEP” speed increase of 0 to 100 %


The drive automatically limits the rate of fan
speed increase to that which will prevent an over
current trip.
Other drives do not have this feature. Other
drives may trip if the speed is increased too
quickly.
UtilitySaver
UtilitySaver Burner Control
Introduction
 Energy Savings




Fuel Savings
Electrical Savings
System Composition




UtilitySaver Panel
Oxygen Analyzer
Variable Frequency Drive
Actuators
Installation
 Summary

UtilitySaver
UtilitySaver Installation
 Sole
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Source Responsibility
Locate all device mounting locations
Install Oxygen Sensor & Flue Gas T/C.
Install and adjust damper linkage, and stroke
actuators.
Run conduit and wire to field devices, existing
motor starter, motor and control panels.
Commission UtilitySaver package for optimum
burner performance
Train Owners Operators for proper operation
UtilitySaver
UtilitySaver Installation
T/C
Assembly
Oxygen
Sensor
Air Flow
Air Flow
Wiring Legend
Motor
_______Hp
_______ V
3 Ph Power Wiring
AC Signal Wiring
DC Signal Wiring
Damper
Actuator
Existing
Control
Cabinet
1/4" calibration
gas copper tubing
and shutoff ball
valve
Existing
Motor
Starter
VFD
UtilitySaver
D
I
S
A
U
T
O
M
A
N
PCC - III
FIRING RATE
Jackshaft
Actuator
UtilitySaver
UtilitySaver Burner Control
Introduction
 Energy Savings




Fuel Savings
Electrical Savings
System Composition




UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
 Summary

UtilitySaver
Experience
Preferred Instruments has 25 years
Combustion Control Experience with…





of
A Third Generation Digital Controller
Over 1000 Boiler Control System Installations
2400 PCC II/III Controllers Installed
Exclusively in Combustion Control Applications
45 SCADA/Flex Projects
640 Burner Projects
UtilitySaver
Experience
Compatible with other
Preferred Instruments...

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



products
from
SCADA/Flex Remote Operator Stations
BMS Logic+ Burner Management Systems
Boiler Sequencing, Lead / Lag Systems
Feedwater Control Systems
Draft Control Systems
Balance Of Plant (BOP) Systems
UtilitySaver
Summary
UtilitySaver …...
 Excellent Annual Savings
 Savings from Both oxygen trim and variable
speed fan combustion air flow control
 Field proven and feature rich PCC-III
Controller
 Backed by over a thousand package boiler
control installations
 Single Source Responsibility
 Complete Material and Installation
UtilitySaver
Preferred Utilities Manufacturing Corp
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
T: (203) 743-6741 • F: (203) 798-7313
www.preferred-mfg.com • [email protected]
UtilitySaver