Presentation on theme: "Preferred Utilities Manufacturing Corp"— Presentation transcript:
1 Preferred Utilities Manufacturing Corp UtilitySaverOverviewPreferred Utilities Manufacturing Corporation31-35 South St. • Danbury • CT
2 UtilitySaver Burner Control IntroductionEnergy SavingsFuel SavingsElectrical SavingsSystem CompositionUtilitySaver PanelOxygen AnalyzerActuatorsVariable Frequency DriveInstallationSummary
3 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.
8 Energy Savings Fuel Savings: Electrical Savings: Seasonal Air Density and Humidity ChangesFuel Pressure and Temperature ChangesFuel Btu and Viscosity VariationsWorn Linkage Components (Hysteresis)Electrical Savings:Minimizing Damper Pressure Drop - damper is 100% open for maximum kWh savings, (Partially closed at low fire to maximize burner turndown)Oversized FansOversized MotorsPartially Loaded Boilers
9 Conservative $13,700 per Year Energy SavingsConservative $13,700 per YearBased on:ASME “by losses” boiler efficiency calculations.Industry leading manufacturer motor energy data.600 Bhp Boiler125 psi SteamNatural gas firedOperating 365 days / year & 24 hours / dayElectric Cost cents / kWhFuel Cost - $4.5/k ft3Oxygen Reduction - 1.5% Wet
10 Unique Energy Savings Tool Savings Estimate Based on:Boiler sizeMotor HPAir Damper TypeCurrent O2 LevelProjected O2 LevelFlue Gas TemperatureSeasonal Loading DataFuel CostElectrical Cost
12 Variations in Air Composition “Standard” air has LB. O2 per FT3Hot, humid air has less O2 per cubic ft20% less at 95% RH, 120OF, and 29.9 mm HgDry, cold air has more O2 per cubic ft10% more at 0% RH, 32OF, and 30.5 mm HgStandard Combustion controls must:Allow at least 20% extra excess air because of the change in air density.
18 The UtilitySaver Controller Right For the Job...
19 The UtilitySaver Panel MeasuredFlue Gas OxygenFiring Rate % (shown)Steam PSIGSteam PSIG SPOxygen %Oxygen SPOxygen Trim %VFD SpeedFuel Valve PositionAir Damper PositionBoiler EfficiencyFlue Gas OxygenSetpointFiring RateLarge Displays & Pushbuttons16 character process variable and alarm description messages10 point first out alarm annunciatorIntuitive BargraphsUser Configurable PushbuttonsOrganized, simple and to the point local operation
20 The UtilitySaver Panel Enclosure -Nema 12, 16 H x 14 W x 10 DController -PCC-III with “Z”, and “G” Option Boards.Components -VFD / Flame Safeguard interface relays24Vac power supply transformer for DM-1E ActuatorsShielded cable for field wiring
21 The UtilitySaver Controller PCC-III-ZG00“Z” Option Board, Oxygen Analyzer“G” Triac Outputs to Drive Electric ActuatorsConstructed For Boiler Front MountingIntuitive OperationFlexible, powerful blockware control logicBuilt In Boiler EfficiencyF(x) Characterizers with “Learn” ModeCommissioning Tools
22 UtilitySaver Features Minimizing Damper Pressure DropDamper is 100% open for maximum kWh savings, (Partially closed at low fire to maximize burner turndown)Fuel-Air Lead-Lag With Cross-LimitingOn 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.Fully metered control systems modulate air and fuel flow by actually measuring the air and fuel flow. For each boiler load the commissioning engineer establishes a fuel / air ratio that will provide the desired burner performance. The fuel controller and air controller modulate the fuel and air control devices until the fuel flow and air flow produce the commissioned fuel / air ratio. Changes in fuel pressure, ambient air pressure or temperature and control device hysteresis do not effect this system.As a result the commissioning engineer can set the fuel / air ratio closer to the optimal setting and allow better fuel economy and lower emissions!
23 UtilitySaver Features Independent Fuel-Air Ratio CurvesPCC-III "Learn" modeRapid, error free burner fuel-air ratio curve setup, with easy "Store" pushbutton operation.SafetyLow 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 EfficiencyContinuous Oxygen Analyzer DiagnosticsFully metered control systems modulate air and fuel flow by actually measuring the air and fuel flow. For each boiler load the commissioning engineer establishes a fuel / air ratio that will provide the desired burner performance. The fuel controller and air controller modulate the fuel and air control devices until the fuel flow and air flow produce the commissioned fuel / air ratio. Changes in fuel pressure, ambient air pressure or temperature and control device hysteresis do not effect this system.As a result the commissioning engineer can set the fuel / air ratio closer to the optimal setting and allow better fuel economy and lower emissions!
25 In-Situ Oxygen Analyzer Field replaceable detectorOnly one conduit to stack.No separate analyzer, one less item to mount
26 In-Situ Oxygen Analyzer Proven ReliableZirconia Oxide SensorNo Reference AirThe probe uses ambient air as a reference.Competitors use instrument air and run the risk of element cracking due to waterAutomated, menu driven pushbutton calibration.Automatic impedance checkingAlarms when time to recalibrate
27 Oxygen Analyzer Kit Model ZP Oxygen Sensor, 20” Standard Reliable Zirconia Oxide Cell60 ft ZP CableMounting Hardware included
28 Boiler Efficiency KitPCC-III Controller calculates the ASME “by losses” method efficiency in real time. Kit Includes:Flue Gas Temperature Assembly, Type J, p/n C, with mounting flange60 feet of shielded type J T/C extension cable
29 Actuator Kit Two (2) DM-1E Actuators are Included: Jackshaft & Damper Torque: in-lbsRotation: 90° travel in secondsAux. Switches: Integral 2 SPDTPosition Feedback: 600 ohmPower Supply: 24 Vac(2)Linkages, (3)Lever Arms, (1)Mounting Bracket
30 Alternate Actuators R-AL : 100 lb Linear Thrust 1730: in-lb TorqueUP10 Pneumatic: 1080 in-lb TorqueI/P Kit to interface to Existing Pneumatic Jackshaft ActuatorPot Box, if Existing Actuator doesn’t have Feedback
31 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 installationBuilt in “DC Link” line reactor - for reduced electrical system harmonics distortion“Soft Turn On” IGBT transistors - for reduced motor stress (lower peak voltages)
32 VSD Parts & Theory 5 Parts to a VSD Rectifier DC “Link” line reactor Intermediate CircuitInverter(IGBT = Insulated Gate Bipolar Transistor)Control & Regulation
34 Pulse Width Modulation (PWM) 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
35 “Soft Turn On” IGBTs dv/dt - Change in Voltage over Time Competitor’s Drives - up to 3500V/usUtilitySaver Drive - 900V/usDue to Patented “Soft Turn On” IGBT’sLower Peak Voltages Extend Motor Insulation Life460V, 75 Hp motor:815V peak for 50 ft cable
36 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.
37 UtilitySaver Burner Control IntroductionEnergy SavingsFuel SavingsElectrical SavingsSystem CompositionUtilitySaver PanelOxygen AnalyzerVariable Frequency DriveActuatorsInstallationSummary
38 UtilitySaver Installation Sole Source ResponsibilityLocate all device mounting locationsInstall 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 performanceTrain Owners Operators for proper operation
40 UtilitySaver Burner Control IntroductionEnergy SavingsFuel SavingsElectrical SavingsSystem CompositionUtilitySaver PanelOxygen AnalyzerActuatorsVariable Frequency DriveInstallationSummary
41 ExperiencePreferred Instruments has 25 years of Combustion Control Experience with…A Third Generation Digital ControllerOver 1000 Boiler Control System Installations2400 PCC II/III Controllers Installed Exclusively in Combustion Control Applications45 SCADA/Flex Projects640 Burner ProjectsPreferred Instruments has the experience and know how to design and integrate complete combustion systems……..PCC II/III Combustion Control Projects....> 1000 Boilers624 Jackshaft Controlled Boilers127 Parallel Positioning Controlled Boilers103 Metering Controlled Boilers351 Oxygen Trim Systems13 EPA Compliant Opacity Monitors
42 ExperienceCompatible with other products from Preferred Instruments...SCADA/Flex Remote Operator StationsBMS Logic+ Burner Management SystemsBoiler Sequencing, Lead / Lag SystemsFeedwater Control SystemsDraft Control SystemsBalance Of Plant (BOP) SystemsPreferred Instruments has the experience and know how to design and integrate complete combustion systems……..PCC II/III Combustion Control Projects....> 1000 Boilers624 Jackshaft Controlled Boilers127 Parallel Positioning Controlled Boilers103 Metering Controlled Boilers351 Oxygen Trim Systems13 EPA Compliant Opacity Monitors
43 Summary UtilitySaver …... Excellent Annual Savings Savings from Both oxygen trim and variable speed fan combustion air flow controlField proven and feature rich PCC-III ControllerBacked by over a thousand package boiler control installationsSingle Source ResponsibilityComplete Material and InstallationUnit responsibility for controls, BMS and SCADA assures proper interface between the parts with no division of responsibility!
44 Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation31-35 South St. • Danbury • CTT: (203) • F: (203)•
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