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UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation 31-35 South St. Danbury CT www.preferred-mfg.com UtilitySaver.

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Presentation on theme: "UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation 31-35 South St. Danbury CT www.preferred-mfg.com UtilitySaver."— Presentation transcript:

1 UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation South St. Danbury CT UtilitySaver Overview

2 UtilitySaver UtilitySaver Burner Control q Introduction q Energy Savings n Fuel Savings n Electrical Savings q System Composition n UtilitySaver Panel n Oxygen Analyzer n Actuators n Variable Frequency Drive q Installation q Summary

3 UtilitySaver UtilitySaver Burner Control The UtilitySaver tm 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.

4 UtilitySaver UtilitySaver Burner Control

5 UtilitySaver Includes: q UtilitySaver Panel q Oxygen Analyzer Kit q Boiler Efficiency Kit q Actuator Kit n Jackshaft and UtilitySaver Damper q Variable Frequency Drive (VFD) Kit q Installation Materials and Supervision! UtilitySaver Burner Control

6 UtilitySaver UtilitySaver Burner Control q Introduction q Energy Savings n Fuel Savings n Electrical Savings q System Composition n UtilitySaver Panel n Oxygen Analyzer n Actuators n Variable Frequency Drive q Installation q Summary

7 UtilitySaver Energy Savings Fuel Savings Electrical Savings +

8 UtilitySaver q Fuel Savings: n Seasonal Air Density and Humidity Changes n Fuel Pressure and Temperature Changes n Fuel Btu and Viscosity Variations n Worn Linkage Components (Hysteresis) q Electrical Savings: n Minimizing Damper Pressure Drop - damper is 100% open for maximum kWh savings, (Partially closed at low fire to maximize burner turndown) n Oversized Fans n Oversized Motors n Partially Loaded Boilers Energy Savings

9 UtilitySaver q Natural gas fired q Operating 365 days / year & 24 hours / day q Electric Cost cents / kWh q Fuel Cost - $4.5/k ft3 q Oxygen Reduction - 1.5% Wet Based on: q ASME by losses boiler efficiency calculations. q Industry leading manufacturer motor energy data. q 600 Bhp Boiler q 125 psi Steam Energy Savings Conservative $13,700 per Year

10 UtilitySaver Unique Energy Savings Tool q Savings Estimate Based on: n Boiler size n Motor HP n Air Damper Type n Current O2 Level n Projected O2 Level n Flue Gas Temperature n Seasonal Loading Data n Fuel Cost n Electrical Cost

11 UtilitySaver Fuel Savings

12 UtilitySaver Variations in Air Composition q Standard air has LB. O 2 per FT 3 q Hot, humid air has less O 2 per cubic ft n 20% less at 95% RH, 120 O F, and 29.9 mm Hg q Dry, cold air has more O 2 per cubic ft n 10% more at 0% RH, 32 O F, and 30.5 mm Hg q Standard Combustion controls must: n Allow at least 20% extra excess air because of the change in air density.

13 UtilitySaver Variations in Air Composition

14 UtilitySaver Variations in Air Composition At these ambient conditions the burner has extra O 2 & N 2

15 UtilitySaver Combustion Air Fan Hp Savings Reference 1 Combustion Air Flow, %Full Load Motor Power(HP) Input, % Full Load Variable Speed Control Damper Control HP Savings

16 UtilitySaver UtilitySaver Burner Control q Introduction q Energy Savings n Fuel Savings n Electrical Savings q System Composition n UtilitySaver Panel n Oxygen Analyzer n Actuators n Variable Frequency Drive q Installation q Summary

17 UtilitySaver UtilitySaver Burner Control

18 UtilitySaver The UtilitySaver Controller Right For the Job...

19 UtilitySaver The UtilitySaver Panel Measured Flue Gas Oxygen Setpoint Organized, simple and to the point local operation Firing Rate % (shown) Steam PSIG Steam PSIG SP Oxygen % Oxygen SP Oxygen Trim % VFD Speed Fuel Valve Position Air Damper Position Boiler Efficiency Firing Rate

20 UtilitySaver The UtilitySaver Panel q Enclosure - n Nema 12, 16 H x 14 W x 10 D Controller - n PCC-III with Z, and G Option Boards. q Components - n VFD / Flame Safeguard interface relays n 24Vac power supply transformer for DM-1E Actuators n Shielded cable for field wiring

21 UtilitySaver The UtilitySaver Controller q PCC-III-ZG00 n Z Option Board, Oxygen Analyzer n G Triac Outputs to Drive Electric Actuators q Constructed For Boiler Front Mounting q Intuitive Operation q Flexible, powerful blockware control logic q Built In Boiler Efficiency q F(x) Characterizers with Learn Mode q Commissioning Tools

22 UtilitySaver q Minimizing Damper Pressure Drop n Damper is 100% open for maximum kWh savings, (Partially closed at low fire to maximize burner turndown) q Fuel-Air Lead-Lag With Cross-Limiting n On a load increase, Air increases first. On a load decrease, Fuel decreases first. n Minimizes excess air during normal firing, and increases excess air during a load change for safety. n Excess air is limited during load changes for flame stability. UtilitySaver Features

23 UtilitySaver q Independent Fuel-Air Ratio Curves q PCC-III "Learn" mode n Rapid, error free burner fuel-air ratio curve setup, with easy "Store" pushbutton operation. q Safety n Low flue gas oxygen trips the burner after an adjustable time delay. n VFD speed and actuator position feedbacks are continuously monitored. Burner trips after an adjustable time delay if any are out of position. q Real Time Boiler Efficiency q Continuous Oxygen Analyzer Diagnostics UtilitySaver Features

24 UtilitySaver 10 inch Touch Screen Options

25 UtilitySaver In-Situ Oxygen Analyzer No separate analyzer, one less item to mount Field replaceable detector Only one conduit to stack.

26 UtilitySaver q Proven Reliable n Zirconia Oxide Sensor q No Reference Air n The probe uses ambient air as a reference. n Competitors use instrument air and run the risk of element cracking due to water q Automated, menu driven pushbutton calibration. q Automatic impedance checking n Alarms when time to recalibrate In-Situ Oxygen Analyzer

27 UtilitySaver Oxygen Analyzer Kit q Model ZP Oxygen Sensor, 20 Standard q Reliable Zirconia Oxide Cell q 60 ft ZP Cable q Mounting Hardware included

28 UtilitySaver Boiler Efficiency Kit q PCC-III Controller calculates the ASME by losses method efficiency in real time. Kit Includes: n Flue Gas Temperature Assembly, Type J, p/n C, with mounting flange n 60 feet of shielded type J T/C extension cable

29 UtilitySaver Actuator Kit q Two (2) DM-1E Actuators are Included: Jackshaft & Damper n Torque: 150 in-lbs n Rotation:90° travel in 30 seconds n Aux. Switches:Integral 2 SPDT n Position Feedback: 600 ohm n Power Supply:24 Vac n (2)Linkages, (3)Lever Arms, (1)Mounting Bracket

30 UtilitySaver Alternate Actuators q R-AL : 100 lb Linear Thrust q 1730: 1000 in-lb Torque q UP10 Pneumatic: 1080 in-lb Torque q I/P Kit to interface to Existing Pneumatic Jackshaft Actuator q Pot Box, if Existing Actuator doesnt have Feedback

31 UtilitySaver Variable Speed Fan Air Flow Control q Variable Speed Drive (VSD) - The UtilitySaver package includes a full featured, quality drive. q Nema 12 Packaging - for worry free boiler room installation q Built in DC Link line reactor - for reduced electrical system harmonics distortion q Soft Turn On IGBT transistors - for reduced motor stress (lower peak voltages)

32 UtilitySaver VSD Parts & Theory q 5 Parts to a VSD n Rectifier n DC Link line reactor n Intermediate Circuit n Inverter (IGBT = Insulated Gate Bipolar Transistor) n Control & Regulation

33 UtilitySaver Motor Speed Control

34 UtilitySaver Pulse Width Modulation (PWM) q On or Off, voltage does NOT modulate. q PWM allows IGBTs to run cool for long life, so better VSDs use PWM. q However, PWM dV/dt causes spike voltages

35 UtilitySaver q dv/dt - Change in Voltage over Time n Competitors Drives - up to 3500V/us n UtilitySaver Drive - 900V/us n Due to Patented Soft Turn On IGBTs q Lower Peak Voltages Extend Motor Insulation Life n 460V, 75 Hp motor: 815V peak for 50 ft cable Soft Turn On IGBTs

36 UtilitySaver Automatic Over Ramp Protection q The UtilitySaver VFD will not trip when given a STEP speed increase of 0 to 100 % n The drive automatically limits the rate of fan speed increase to that which will prevent an over current trip. n Other drives do not have this feature. Other drives may trip if the speed is increased too quickly.

37 UtilitySaver UtilitySaver Burner Control q Introduction q Energy Savings n Fuel Savings n Electrical Savings q System Composition n UtilitySaver Panel n Oxygen Analyzer n Variable Frequency Drive n Actuators q Installation q Summary

38 UtilitySaver UtilitySaver Installation q Sole Source Responsibility n Locate all device mounting locations n Install Oxygen Sensor & Flue Gas T/C. n Install and adjust damper linkage, and stroke actuators. n Run conduit and wire to field devices, existing motor starter, motor and control panels. n Commission UtilitySaver package for optimum burner performance n Train Owners Operators for proper operation

39 UtilitySaver UtilitySaver Installation

40 UtilitySaver UtilitySaver Burner Control q Introduction q Energy Savings n Fuel Savings n Electrical Savings q System Composition n UtilitySaver Panel n Oxygen Analyzer n Actuators n Variable Frequency Drive q Installation q Summary

41 UtilitySaver Preferred Instruments has 25 years of Combustion Control Experience with… 4 A Third Generation Digital Controller 4 Over 1000 Boiler Control System Installations PCC II/III Controllers Installed Exclusively in Combustion Control Applications 4 45 SCADA/Flex Projects Burner Projects Experience

42 UtilitySaver Compatible with other products from Preferred Instruments... 4 SCADA/Flex Remote Operator Stations 4 BMS Logic+ Burner Management Systems 4 Boiler Sequencing, Lead / Lag Systems 4 Feedwater Control Systems 4 Draft Control Systems 4 Balance Of Plant (BOP) Systems Experience

43 UtilitySaver Summary UtilitySaver …... 4 Excellent Annual Savings 4 Savings from Both oxygen trim and variable speed fan combustion air flow control 4 Field proven and feature rich PCC-III Controller 4 Backed by over a thousand package boiler control installations 4 Single Source Responsibility 4 Complete Material and Installation

44 UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation South St. Danbury CT T: (203) F: (203)


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