UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation...

UtilitySaver

Preferred Utilities Manufacturing Corp

Preferred Utilities Manufacturing Corporation31-35 South St. • Danbury • CT

www.preferred-mfg.com

UtilitySaver

Overview

UtilitySaver

UtilitySaver Burner Control

Introduction Energy Savings

Fuel Savings Electrical Savings

System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive

Installation Summary

UtilitySaver


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

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

Energy Savings

$0

$500

$1,000

$1,500

$2,000

$2,500

$3,000

$3,500

20% 40% 60% 80% 100%Boiler Load (%)

Op

erat

ing

Co

st S

avin

gs

Fuel Savings

Electrical Savings

Fuel Savings

Electrical Savings

+

UtilitySaver

Fuel Savings: Seasonal Air Density

and Humidity Changes Fuel Pressure and

Temperature Changes Fuel Btu and Viscosity

Variations Worn 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 Fans Oversized Motors Partially Loaded Boilers

Energy Savings

UtilitySaver

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

Based on: ASME “by losses”

boiler efficiency calculations.

Industry leading manufacturer motor energy data.

600 Bhp Boiler 125 psi Steam

Energy Savings

Conservative $13,700 per Year

UtilitySaver

Unique Energy Savings Tool Savings Estimate

Based on: 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


Burner

Temperature = 120 FRelative Humidity = 95%Pressure = 29.9 in HgLess lbs of O2 + N2 per cu ft

Fuel Flow( C + H )

H2O

H2O

Forced Draft Fan(Constant Volume)*

Combustion Air( O2 + N2 )

H2O

H2O

N2

N2N2

N2

N2

N2

N2

N2

N2N2

N2

N2

N2N2

N2

N2N2N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2N2

N2N2N2

N2

N2

N2

N2

N2O2 O2

O2

O2

O2

O2

O2

O2

O2

O2

O2O2

O2

H2O

UtilitySaver


Burner

Combustion Air( O2 + N2 )

Temperature = 32 FRelative Humidity = 0%Pressure = 30.5 in HgMore lbs of O2 + N2 per cu ft

N2N2

Fuel Flow( C + H )

N2

N2

N2

N2N2N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2N2

N2

N2

N2

N2

N2

N2

N2N2

N2

N2

N2

N2

N2N2

N2

N2

N2

N2

N2

N2

N2

N2

N2N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2 N2

N2

N2

N2

N2 N2N2

N2

N2

N2

N2

N2N2N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

N2

O2

O2

O2

O2

O2

O2

O2

O2

O2O2

O2

O2

O2

O2

O2O2

O2

O2O2

O2

O2

O2

O2

Forced Draft Fan(Constant Volume)*

At these ambient conditions the burner has extra O2 & N2

UtilitySaver

Combustion Air Fan Hp Savings

Reference 1

Combustion Air Flow, %Full Load

Mo

tor

Po

we

r(H

P)

Inp

ut,

% F

ull

Lo

ad

Variable Speed Control

Damper Control HP Savings

UtilitySaver






UtilitySaver


Fuel Gas

PI

PTTT

(PSI or F)Setpoint

MJackshaftActuator

FuelLead Lag

Full SpeedFuel / Air

Ratio

H/A

f(x)

M

SP

H/A

Firing RateHand / AutoH/A

Fuel Oil

AT

Oxygen TrimHand/Auto

f(x) PI

f(x)

T Full Speed BypassSelection

VFDFuel / Air

Ratio

H/A

Air DamperSetup Station

Fan SpeedSetup Station

OxygenSetpoint

AirLead Lag

PositionFeedback

SpeedFeedback

Air DamperActuator

f(x)

Model ZPOxygen Sensor

Pressure orTemperatureTransmitter

PCC-III Controller

PositionFeedback

VFDDamperPosition

PCTC

Optional

Pressure orTemperatureController

(4-20mA or135 ohm)

Combustion Air

3 Phase

FanVariable

FrequencyDrive

1

2 2

3 3 3

3

Power Supply

UtilitySaver

The UtilitySaver Controller

Right For the Job...

UtilitySaver

The UtilitySaver Panel

MeasuredFlue Gas Oxygen

Flue Gas OxygenSetpoint

Organized, simple and to the point local operation

Firing Rate % (shown)Steam PSIGSteam PSIG SPOxygen %Oxygen SPOxygen Trim %VFD SpeedFuel Valve PositionAir Damper PositionBoiler Efficiency

Firing Rate

UtilitySaver

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

UtilitySaver

The UtilitySaver Controller

PCC-III-ZG00 “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

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

UtilitySaver

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 Features

UtilitySaver

10 inch

Touch Screen Options

UtilitySaver

In-Situ Oxygen Analyzer

No separate analyzer, one less item to mount

Field replaceable detector

Only one conduit to stack.

UtilitySaver

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

In-Situ Oxygen Analyzer

UtilitySaver

Oxygen Analyzer Kit

Model ZP Oxygen Sensor, 20” Standard

Reliable Zirconia Oxide Cell 60 ft ZP Cable Mounting Hardware included

PCC-III Controllerwith

"Z" Option Board

190130Connecting Cable

Probe

Calibration Gas Connectionat Grade Level

Power Supply

Model ZPOxygen Sensor

Detector

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

Torque: 150 in-lbs Rotation: 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 Rectifier DC “Link” line reactor Intermediate Circuit Inverter

(IGBT = Insulated Gate Bipolar Transistor)

Control & Regulation

UtilitySaver

Motor Speed Control

UtilitySaver

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

UtilitySaver

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

“Soft Turn On” IGBTs

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




System Composition UtilitySaver Panel Oxygen Analyzer Variable Frequency Drive Actuators


UtilitySaver

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

UtilitySaver Installation

Air FlowAir Flow

ExistingMotorStarter

ExistingControlCabinet

OxygenSensor

VFD UtilitySaver

JackshaftActuator

DamperActuator

Motor_______Hp_______ V

AUTOMAN

PCC - III

FIRING RATE

DIS

T/CAssembly

1/4" calibrationgas copper tubingand shutoff ballvalve

Wiring Legend

DC Signal Wiring

AC Signal Wiring3 Ph Power Wiring

UtilitySaver






UtilitySaver

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

UtilitySaver

Compatible with other products from Preferred Instruments...

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

Experience

UtilitySaver

SummaryUtilitySaver …... 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 Corporation31-35 South St. • Danbury • CT

T: (203) 743-6741 • F: (203) 798-7313www.preferred-mfg.com • [email protected]

UtilitySaver Preferred Utilities Manufacturing Corp Preferred Utilities Manufacturing Corporation...

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