Transcript UtilitySaver Overview - Preferred Utilities Manufacturing Corporation

UtilitySaver
Overview
PREFERRED UTILITIES MFG CORP
31-35 South St. • Danbury • CT
T: (203) 743-6741 • F: (203) 798-7313
www.PREFERRED-MFG.com
UtilitySaver Burner Control
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Introduction
Energy Savings
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System Composition
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Fuel Savings
Electrical Savings
UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
Summary
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.
UtilitySaver Burner Control
UtilitySaver Burner Control
Includes:
 UtilitySaver Panel
 Oxygen Analyzer Kit
 Boiler Efficiency Kit
 Actuator Kit
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Jackshaft and UtilitySaver Damper
Variable Frequency Drive (VFD) Kit
Installation Materials and Supervision!
UtilitySaver Burner Control
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Introduction
Energy Savings
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
System Composition
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Fuel Savings
Electrical Savings
UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
Summary
F u e l S a v in g s
Energy Savings
E le c tric a l S a v in g s
Fuel
Savings
$3,500
Operating Cost Savings
$3,000
+
$2,500
Electrical
Savings
$2,000
$1,500
$1,000
$500
$0
20%
40%
60%
80%
B oiler Load (%)
100%
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
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
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
Fuel Savings
Variations in Air Composition
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“Standard” air has 0.0177 LB. O2 per FT3
Hot, humid air has less O2 per cubic ft
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Dry, cold air has more O2 per cubic ft
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20% less at 95% RH, 120OF, and 29.9 mm Hg
10% more at 0% RH, 32OF, and 30.5 mm Hg
Standard Combustion controls must:
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Allow at least 20% extra excess air
because of the change in air density.
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
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
O2
N2
O2
Burner
N2
N2
N2
N2
N2
N2
N2
N2
O2
N2
O2
N2
O2
H2O
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
N2
N2
O2
N2
N2
O2
N2 O 2 N2
N2
N 2 N2
O2
N2
N2 N2
N2
O 2 N2
O2
N2
N
2
N2 N2
N
2
N
2
N2
O2
N2
N2
N2
N2
N2
O2
N2
O2
N2
N
2
N
2
N
2
O2
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
O
2
O
2
N2
N 2 N2
N2
Burner
At these ambient conditions the burner has extra O2 & N2
Combustion Air Fan Hp Savings
Damper Control
HP Savings
Variable Speed Control
Combustion Air Flow, %Full Load
UtilitySaver Burner Control

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Introduction
Energy Savings



System Composition






Fuel Savings
Electrical Savings
UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
Summary
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
Power Supply
Fuel Oil
Air Damper
Setup Station
M
Air Damper
Actuator
Fan
Variable
Frequency
Drive
Combustion Air
Fuel Gas
Full Speed Bypass
Selection
H/A
Speed
Feedback
3 Phase
VFD
Damper
Position
The UtilitySaver Controller
Right For the Job...
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
The UtilitySaver Panel
 Enclosure  Nema 12, 16 H x 14 W x 10 D
 Controller  PCC-III with “Z”, and “G” Option Boards.
 Components  VFD / Flame Safeguard interface relays
 24Vac power supply transformer for DM-1E Actuators
 Shielded cable for field wiring
The UtilitySaver Controller
 PCC-III-ZG00
 “Z” Option Board, Oxygen Analyzer
 “G” Triac Outputs to Drive Electric Actuators
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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 Features
 Minimizing Damper Pressure Drop
 Damper is 100% open for maximum kWh savings,
(Partially closed at low fire to maximize burner
turndown)
 Fuel-Air 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 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
Touch Screen Options
10 inch
In-Situ Oxygen Analyzer
Field replaceable detector
Only one conduit to stack.
No separate analyzer, one less item to mount
In-Situ Oxygen Analyzer
 Proven Reliable
 Zirconia Oxide Sensor
 No 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
Oxygen Analyzer Kit
Model ZP
Oxygen Sensor
Probe
Detector
PCC-III Controller
with
"Z" Option Board
190130
Connecting Cable
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Model ZP Oxygen Sensor, 20”
Standard
Reliable Zirconia Oxide Cell
60 ft ZP Cable
Mounting Hardware included
Power Supply
Calibration Gas Connection
at Grade Level
Model ZP Oxygen Analyzer Arrangment
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
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
Alternate Actuators
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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
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)
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)
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Control & Regulation
Motor Speed Control
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
“Soft Turn On” IGBTs
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dv/dt - Change in Voltage over Time
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Competitor’s Drives - up to 3500V/us
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UtilitySaver Drive - 900V/us
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Due to Patented “Soft Turn On” IGBT’s
Lower Peak Voltages Extend Motor Insulation Life
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460V, 75 Hp motor:
815V peak for 50 ft cable
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 Burner Control


Introduction
Energy Savings



System Composition






Fuel Savings
Electrical Savings
UtilitySaver Panel
Oxygen Analyzer
Variable Frequency Drive
Actuators
Installation
Summary
UtilitySaver Installation
Sole 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 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 Burner Control


Introduction
Energy Savings



System Composition






Fuel Savings
Electrical Savings
UtilitySaver Panel
Oxygen Analyzer
Actuators
Variable Frequency Drive
Installation
Summary
Experience
Preferred Instruments has 25 years of Combustion
Control Experience with…
 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
Experience
Compatible with other products from Preferred
Instruments...
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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
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