Honeywell CommercialHoneywell Commercial Combustion … · Honeywell CommercialHoneywell Commercial...
Transcript of Honeywell CommercialHoneywell Commercial Combustion … · Honeywell CommercialHoneywell Commercial...
Honeywell CommercialHoneywell Commercial Combustion Products
Opportunity in the Boiler Room
B il C t l S l tiBoiler Control SolutionsABC900 / Delphi / Controlinks
Boiler Control / Energy Cost Savings
Ethernet
Steam – Conventional
FlameSafeguard
Control
FlameDetector
Mod Ctl Hi Limit Op Ctl
CommunicationModbus
Boiler
Mod
Airflow Switch
BurnerMotor
Low WaterCutoff Ign.
Xfmr.
ModMotor
VPS (Valve Proving System)
P
High GasP S
Low GasPress Sw
ManualShut Off
Valve
ManualShut Off
Valve
PressureRegulator
232
Press SwPress Sw SafetyShut OffValve 1
SafetyShut OffValve 2
Pilot Valve
ModulatingValveManual
Shut OffValve
PressureRegulator
%%
What happens over time?
FuelFuel
$
$ $
$ $$ $
$ $ $ $$ $ $$ $ $$ $ $
$ $ $$ $ $
$$
$ $$ $
$ $ $ $$ $ $
$ $ $$
$ $
$ $$ $ $ $$
$ $
$ $$ $
$ $ $ $$ $ $$ $ $$ $
$ $ $$ $ $
$$
$ $$ $
$ $ $$ $ $
$ $ $$
$ $
$ $$ $ $ $$$$
$
$ $ $ $$ $ $$ $ $$ $
$ $ $$ $ $$
$
$ $ $$ $ $
$ $ $$
$ $
$ $$ $ $ $$
$$
$$ $
$ $ $$ $ $$ $ $$ $
$ $ $$ $ $
$ $
$ $ $$ $ $
$ $$
$ $
$ $$ $ $ $$
$ $$$$ $ $
$
$ $$$ $
$$
$$$
$ $$ $$ $$
$$ $$$$ $$$$ $
$
$
$$$$
$$$$$
$
$
$
$$
$$ $ $$ $ $
$ $$ $ $
$$$ $
$ $$ $ $
$ $$ $$
$ $$
$
$
$
$$
$$ $ $$ $ $
$ $$ $ $
$ $$ $
$ $$ $ $
$ $$ $$
$ $$$
$
$
$$
$
$
$
$$ $$ $ $
$ $$ $
$$ $
$$ $$ $$
$ $$
$ $$
$$
$
$
$ $$ $ $
$ $$ $
$$
$
$$ $$ $$
$ $$
$ $$$
$$$$ $$ $
$ $$ $$ $$ $ $$
$$ $
$$
$
$$ $
$$$
$Typical mechanical
curve
% %
Ideal Curve
233
AireAire
Delphi O2 Combustion
Steam - Delphi O2 Panele p O2 Co bust o
Efficiency Panel
FGR Damper
O2 Trim Sensor
4-20mProcess Variable
Transmitter
FlameDetector
Fuel Air Ratio Control, Burner Management, O2 Trim, Display
Mod Ctl Hi Limit Op Ctl
Boiler
Air D
Airflow Switch
BurnerMotor
Low WaterCutoff Ign.
Xfmr.
VFDS dDamper
MotorVPS (Valve Proving System)
P
Speed Sensor
High GasP S
Low GasPress Sw
ManualShut Off
Valve
ManualShut Off
Valve
PressureRegulator
234
Press SwPress Sw SafetyShut OffValve 1
SafetyShut OffValve 2
Pilot Valve
ModulatingValveManual
Shut OffValve
PressureRegulator
235
Why Boiler FA Upgrade?E i t l d i f tEnvironmental and energy saving features
save money
- Drives efficiency to new level by improving the fuelDrives efficiency to new level by improving the fuel air ratio and improving turndown
- Electronic fuel air ratio control maximizes b ti ffi i i th 4combustion efficiency, saving the average user 4-
6% in fuel savings per year
Optimize fuel/air mixture
Accuracy of actuators to 0.1 degree
Accuracy over life
236
Why Boiler FA Upgrade?
E i t l d i f tEnvironmental and energy saving features save money continued- Reduced fuel generated gas emissions: CO2, COg g 2,
- Addition of O2 trim provides an additional 1-2% in savings per year
Compensates for variable combustion air
Provides consistent excess air reduction
Keeps excess air CO and CO2 output a minimumKeeps excess air, CO and CO2 output a minimum
Trims air damper and/or VFD
- The Variable Frequency Drive (VFD) for q y ( )Combustion air control delivering electrical savings of 30%-60% per year
237
Typical Applications
• Target Market- Typically boilers > 100hp
Depending on ROI requirements and current equipment efficiency may beDepending on ROI requirements and current equipment efficiency, may be employed on smaller boilers
- Minimal customer down time is required
A packaged sol tion is desirable- A packaged solution is desirable
- Oxygen trim is desired- Control Systems may have older, electro-mechanical controls
Upgrade to new 7800 SERIES ControlsUpgrade to new 7800 SERIES Controls• Longer life• Eliminate potential leaking fuel vent valves and still comply with safety
codes and not waste natural gas • Diagnostics tools make troubleshooting easy!
• Many states offer rebates for linkage-less fuel air ratio controls andO2 trim
238
Verticals MarketsABC900/DelphiControLinks™ ABC900/Delphi
w/ O2 Trim
▪ Hospitals X X
▪ Schools X
▪ Office Buildings Xg
▪ Government Buildings X X
Multi Unit Dwellings /▪ Multi-Unit Dwellings / Condos & Apartments X X
▪ Universities / Campus X X
▪Industrial Process/ Pharmaceutical/ Food Processing / PP
X
Laundries / Dry
239
▪ Laundries / Dry Cleaning X X
Opportunity for Boiler Upgrades
• Installed base of Boilers in U.S. and Canada: 571,000*• 43K in industrial applications• 528K in commercial applications
• Less than 5%, or ,approximately 29,000 boilers, have linkage-less fuel air ratio controlfuel air ratio control installed
O t it t d• Opportunity to upgrade over 500K boilers!
240
* ABMA Data
S t e a m
Boiler Types, Steaming Capacities S t e a m F l o w K l b s / h r H P T Y P E
C o m m e r -0 0 c i a l
F i r e B o i l e r s Controlinks2 5 8 t u b e B o i l e r s
1 0 2 9 0
2 5 7 2 5 P a c k a g e
ControlinksTarget
B o i l e r s I n d u s t r i a lB o i l e r s
1 0 0 2 9 0 0
2 0 0 5 8 0 0 W a t e r
ABC900/HC900DelphiTarget
T u b e5 0 0 B o i l e r s
F i e l d1 0 0 0 E r e c t e d U t i l i t y
B i l B i l B o i l e r s B o i l e r s
6 5 0 0
241
Why Boiler FA Upgrade?
T h d G C i i iTouch and Go; Commissioning done via PC Touchscreen
- No external PC requiredNo external PC required
- No complex programming needed; touch and go
- Embedded software powered by Niagara AX framework; no software to purchase
CHANNEL 4 DISABLED
- Intuitive user screens make burner management a snap
- Easy to access diagnosticEasy to access diagnostic information, system status and alarms
- Immediate access to make any adjustments, reset alarm functions and
242
Immediate access to make any adjustments, reset alarm functions and utilize reporting features
Limits & Operating Control4-20mA Firing Rate Control
WIN XPWIN XPWIN XPWIN XP
Option: PCOption: PC
OROROROR
System DisplaySystem Display
Fuel OilFuel Oil
Limits
Natural GasNatural Gas
Limits
ControLinks ControLinks ---- The Application The Application ----
S7999 S Di lControlinks
S7999 System DisplayFuel/Air Curve CommissioningFuel/Air Curve Commissioning
244
S7999 System Display
Burner Control StatusBurner Control Status
245
S7999 System Display
Expanded Annunciator StatusExpanded Annunciator Status
246
Delphi Combustion Efficiency Panel
Touch and Go
Delphi – Touch and GoThe Delphi CombustionThe Delphi Combustion
Efficiency Panel Integrates• Flame Safeguard Control
F l Ai R ti C t l• Fuel Air Ratio Control• O2 Trim• VFD Control• PID Control• Loop and Logic Algorithms• Multiple Self Check Features
Into a single, pre-wired panel with a
Multiple Self Check Features
g p pPC touchscreen used for easy, user friendly commissioning
248
Delphi ComponentsIndustrial Cooling fan ABC900A1000 RM7840L1075Industrial panel PC TB0 VFD
ModbusCooling fan ABC900A1000 RM7840L1075
with S7800A1142
RelaysRelays
TB2TB2:T40-T101Line Voltage
TB3: 120Vac
24Vd Power Grounding
TB3: 120Vac Power Input
249
Ethernet switch
24Vdc power supplies
Power conditioner
Grounding barTB1:
T1-T38Low Voltage
Tachometer
Delphi Robust and Field Proven S t R li bilit d Q litSystem Reliability and Quality
- Trusted name in reliable Flame Safeguard ControlHoneywell RM7840 with Valve ProvingHoneywell RM7840 with Valve Proving
Keyboard Display Module included for programming of VPS
R b t O2 S- Robust O2 Sensor
Long life
No replacement filters; no moving parts to wear outNo replacement filters; no moving parts to wear out
Auto-calibration feature; no manual calibration required
- Industrial Hybrid ControllerIndustrial Hybrid Controller
ABC900
Robust programming
250
Multiple safety checks
Delphi Robust and Field ProvenS t R li bilit d Q litSystem Reliability and Quality
- Maximum flexibility with actuators
ML7999B H li t t (100 200 d 400 i lb )ML7999B or Herculine actuators (100, 200 and 400 in. lbs)
Feedback to system for enhanced safety
Actuators can be mixed and matchedActuators can be mixed and matched
- Honeywell NXS or NXL Series VFD
Keypad for easy programmingKeypad for easy programming
Modbus communication
Feedback to system for enhanced safetyy y
251
Delphi Robust and Field ProvenS t R li bilit d Q litSystem Reliability and Quality
- Tachometer and Hall Effect Sensor
U d t id f db k d l t dUsed to provide feedback on modulated blower speed
- User friendly programming in PC Use e d y p og a g CTouchscreen
Industrial PC
P d b Ni dditi lPowered by Niagara; no additional software required
Easy to navigate for commissioning
Touch and Go
252
Competitive Advantage
• Proven Reliability backed by HoneywellHoneywell Combustion Safety Approval• Honeywell Combustion Safety Approval
• Total Combustion Solution• Global SupportGlobal Support
- Direct Honeywell - Network of Reps/ Distributors
Integrated Burner Management• Integrated Burner Management• Thousands of Installations
253
Honeywell Boiler Case Studies
Case Studies• Controlinks 100 - 600HP
- Space Coast Hospital ServicesSpace Coast Hospital Services www.customer.honeywell.com search Controlinks case studies
- 1000’s of installationsABC900/HC900 200HP• ABC900/HC900 >200HP- Hospitals- Home Products manufacturer - http://hpsweb.honeywell.com/Cultures/en-
US/Products/Instrumentation/default.htm• Delphi >100hp
Ph ti l 5 t- Pharmaceutical – 5 systems- Aircraft manufacturer - 14 systems- Manufacturing
254
ControLinks™ Energy Savings: Case Study
• Application: Hospital Laundry FacilityApplication: Hospital Laundry Facility- Site: Space Coast Hospital Services, Rockledge, FL- Distributor: Thermal Tech, Inc., Orlando, FL
• Situation:2002 2003; 38% increased production (7 12 million pounds to 9 million- 2002-2003; 38% increased production (7.12 million pounds to 9 million pounds laundry annually)
- 35% increased steam usage- Rising fuel costs
• Results following plant upgrade:• Results following plant upgrade:- 1.6% increased fuel consumption
• Energy Savings by Technology:- ControLinks™: 8.6%- High Turndown Burner: 7.5%- Pressurized Deaerator: 11.5%
• Calculated Annual Fuel Cost Savings (USD): (based on: 250 hp• Calculated Annual Fuel Cost Savings (USD): (based on: 250 hp boiler, operating at 50% firing rate for 16 hrs/day, 5 days/wk, 50 wks/yr and $0.75 (USD) per Therm (100 cubic feet) fuel cost)- ControLinks™: $12,900- High Turndown Burner: $11 300
255
- High Turndown Burner: $11,300- Pressurized Deaerator: $17,300
• Total Facility Energy Reduction: 27.3%
Boiler upgrade Savings Estimator
Job Site Details Definitions for Input VariablesDistributor: Boiler Output Rating as stated in horsepower from data plate.Sales Rep: Boiler Average Firing Rate as determined by boiler operation/load. Customer: Boiler Efficiency as determined by combustion analyzer.Customer Contact: Boiler Annual Run Hours as determined by boiler on time/usage.Customer Address: Fuel Cost as determined by supplier.
Error messages will disappear when data is enteredCustomer Phone:Customer Fax:
BURNER/BOILER EFFICIENCY CALCULATIONS
Burner/Boiler Operating Values - Present Burner/Boiler Operating Values - ProjectedBurner/Boiler Output Rating: HP Burner/Boiler Output Rating: 0 HPBurner/Boiler Average Load: % Burner/Boiler Average Load: 0 %Burner/Boiler Average Output: 0 HP Burner/Boiler Average Output: 0 HPBurner/Boiler Average BTU Output 0 BTU/Hr Burner/Boiler Average BTU Output 0 BTU/HrPresentBurner/Boiler Efficiency % Projected Burner/Boiler Efficiency # 0.0 %Burner/Boiler Average BTU Input #DIV/0! BTU/Hr Burner/Boiler Average BTU Input #DIV/0! BTU/HrBurner/Boiler Annual Run Hours: Hours Burner/Boiler Annual Run Hours: 0 HoursFuel Cost: $ per Therm Fuel Cost: $0.00 $ per ThermAnnual Fuel Cost: #DIV/0! Annual Fuel Cost: #DIV/0!
Projected Annual Fuel Savings #DIV/0!# Projected Burner/Boiler Efficiency Savings Removal of Linkage Wear* (0 to 1.0) % Projected Installation CostI d C b ti ** ( 5 t 3 0) %Improved Combustion** (.5 to 3.0) %Increased Turndown*** (.5 to 1.5) % Projected Return on Investment #DIV/0! year(s)O2 savings 0.0 %Total Efficiency Savings NOTE: These are estimated savings. For dual fuel systems, calculate savings for each fuel for a total savings.
Footnotes*Linkage systems have wear over time.*Linkage less systems have no hysteresis across actuator stroke, 0.1% accuracy.**Linkage systems can not maintain consistent excess air across the firing curve.**Linkage less systems can maintain consistent excess air across the firing curve, reducing stack temperature and emmissions.**Some installations may realize greater improvements in efficiency.***Linkage systems lite-off and minimum modulation positions are typically the same.***Linkage less system lite-off and minimum modulation positions are independant, increased turndown.
"H ll ill b ibl f i f il hi h i "
256
"Honeywell will not be responsible for any savings or failure to achieve the savings."
Marketing Assistance
• Marketing to Commercial / Industrial Users – help in understanding their carbon footprint to meet governmental requirements e.g. CEMs and PEMs g q gfor larger users
• Education and Rebate programs for Energy Efficiency upgrades i.e. Can the customer pay forEfficiency upgrades i.e. Can the customer pay for the upgrade through their monthly utility bill?
• Leads – for larger companies teaming with Utilities / End Users to offer comprehensive plant wide /End Users to offer comprehensive plant wide / facility energy solutions
• Joint Customer workshops / tradeshows
257
Honeywell Contacts
• Honeywell Contacts / Information - Commercial/Industrial Combustion Control Product
Specialist N th t Mi h l H dl i h l h dl @h llNortheast – Michael Handler [email protected] Atlantic – Robert Thomas [email protected] – David Krause [email protected] Lakes – Carl Manoogian [email protected] Lakes Carl Manoogian [email protected] Midwest – Steve Young [email protected] – Rick Boers [email protected] Coast – Aaron Contente [email protected]
- Local Honeywell Combustion Solution Distributors - Local Honeywell Sales representatives - Environmental Controls and Combustion
www customer honeywell comwww.customer.honeywell.com- Industrial/ Process Control Group
http://hpsweb.honeywell.com/cultures/en-us/default.htm
258