We Audit You Decide. - Netfirms...he construction of the Limpseld burner allows it to be easily...

We Audit...

You Decide.

Computational Fluid Dynamics (CFD) study

Providing boiler room emissions calculations

http://www.limpsfield.co.uk

http://www.autoflame.com

Contents

www.GaryAndersonHVAC.com 410.257.7277

Why Audit?…Why us?………………………………………… 2

Technological Advances…………………………..…………… 3

Going Green…………………………………….……………… 4

Retrofit........................………………….……………….………….. 5

o Cleaver Brooks

Limpsfield and Autoflame..…………………………………… 6

Meeting Mandates……………………………………………… 7

o Title I, Titile IV, Clean Air Act

Energy Efficiency / Cost Reduction…………………….……….. 8

Testimonies……………………………………………………… 9

Testimonies……………………………………………........……. 10

Gary Anderson Mechanical Services, LLC……………………Back

http://www.garyandersonhvac.com

Why Audit?. . . Why Us?

Gary Anderson Mechanical Services, LLC is a full service Heating Ventilation Air Conditioning (HVAC) company with the emphasis on SERVICE. Everything we do establishes a sustainable relationship where quality workmanship, technical expertise and professionalism combine to bring you services delivered with expectations exceeded.

• We specialize in performing boiler room energy audits to determine if there are opportunities to reduce fuel consumption.

• Our technicians are factory trained specialists capable of problem solving.

• We are the only local company authorized to maintain and install the most up-to-date, technoligically advanced units in the industry.

• Let our knowledge and expertise work for you.

• We hire only those we would trust in our own homes.

An audit establishes a fundamental assessment Is your current system efficient or inefficient? What is currently being serviced and what needs serviced? Should you invest in an upgrade to newer technology or would a maintenance plan bring about sustained efficiencies? The boiler and burner industry has seen significant technological advances. Advances can save you money in the long run and meet mandates for going green. Are you current on EPA mandates and meeting the reduced carbon footprint requirements? Are you positioned to take advantage of grants and subsidies for going green? Our audit will answer these questions and more.

This audit is free There is no obligation to follow our recommendations.

How to begin:

• Schedule an appointment – the audit usually takes about one hour and then we will issue a report, audit summary and do a walk through with you if desired.

• The audit and report will contain recommendations which we can contract for or you can determine another path forward.

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• There’s a lot of technology out there that might not have been available when your boiler room was originally designed.

• These audits have been performed all over the country for industrial process clients and hospitals. Hershey Foods, Frito-Lay, and several hospitals are among those companies who have been helped.

• The energy audit is free of charge, takes about an hour of a boiler operator’s time, and usually show a 5% minimum to 15% reduction in fuel consumption.

• Paybacks are usually 1 to 2 years.


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Technological Advances

SOUNDS GOOD, RIGHT? CATCH UP ON WHAT THE LATEST ANALYZERS CAN DO, AND VISIT A LARGE COMPANY WHO EXPANDED ITS STEAM CAPACITY BY 50% IN CALIFORNIA’S TOUGH REGULATORY ENVIRONMENT.

Reducing NOxwhile keeping expenses and emissions down.

A RECENT SOLUTION AND CASE STUDY In 2005, a leading health care company in California decided to expand their steam capacity by 50%. A new 1,000 hp, four-pass steam boiler was specified and selected for the expansion, along with a sub-9 ppm low NOx burner and control system. By the end of 2006, the new boiler was installed and the sub-9 ppm low NOx target had been achieved. However, the residual oxygen levels were in the range of 8% to 8.5%. In addition, maintaining this low NOx level was causing many problems, such as excessive vibration from the 125-hp blower motor running at 3,600 rpm, flame failures, and material and refractory failures. Reliability was a serious issue with the existing system, and further to this the boiler could not reach the rated steam capacity. In 2010, a steam reliability study was conducted on site and commissioned by the Autofl ame Technology Centre.

“High performance industrial/commercial dual and single fuel burners are manufactured in house. We offer extensive experience in commissioning and reducing O2 levels in combustion in firetube, watertube and furnace applications. The burner is designed to maximize efficiency and reduce fuel usage and the carbon footprint.” Limpsfield.co.uk



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Going Green

“Whether it’s better controls, smart use of analyzers, or new boiler offerings, several ways to boost performance and cut emissions today are worth discussing.” Today’s Boiler, Spring 2012 issue.

Reliability was a priority given the existing conditions and, therefore, replacing the burner and offering an SCR system was the best longterm solution for the client. This would not only offer the client improved functionality and reliability, but would also provide a high efficiency burner complete with low NOx and low carbon production.

There were several requirements that any potential new burner had to meet:the selected burner had to be robust incorporating a standard low NOx design (sub-30 ppm), as well as being able to perform with a reasonable turndown ratio (5:1). The dampers and bearing assembly, combustion air system, burner head, and igniter system all needed to demonstrate high quality engineering and craftsmanship. It was important to the client that the entire burner package had the appearance and design of a quality engineered product. After reviewing the available burners on the market today, they chose Limpsfield Combustion Engineering Ltd. to supply the burner, as theirs was a package that met all of these customer specific requirements and would guarantee the necessary efficiency levels. The next stage was to review the SCR system. Again, they chose a supplier that had vast experience in this technology, including many installations and successful case studies, and was also a local manufacturer. The Nationwide Environmental Solutions CataStak™ system was chosen. SYSTEM PERFORMANCE Installation of the specified equipment began in November 2011. The Limpsfield burner was commissioned in January 2012, achieving a 5:1 turndown, sub-30 ppm NOx, corrected to 3% O2, CO was zero throughout the firing range, and the O2 level was 2% to 3% from low to high fire. The split head design manufactured by Limpsfield mixes the fuel and air in the highpressure zone in the burner head offering superb stability and flame retention, which is essential for this type of application. Boiler capacity was also achieved for the first time ever. In February 2012, the SCR was commissioned and the NOx was reduced from sub-30 ppm to 1 ppm throughout the firing range. The contractual NOx emission guarantee to the client was sub-5 ppm and below the required air permit level of sub-9 ppm NOx. Over time, the NOx will be adjusted to approximately 4 to 5 ppm, corrected to 3% O2, by reducing the ammonia fl ow. The installation has been a great success and since commissioning the new Limpsfield LCN123 burner and CataStakTM SCR system have been operating without issue, with no faults, lockouts, or problems that were inherent before the upgrade. Most importantly, the system has retained its commissioned values operating at high effi ciency, low excess air levels, low carbon production and ultra-low NOx. TB Autofl ame Engineering Ltd. can be contacted through email at [email protected]. Autoflame manufactures combustion management systems and solutions for the boiler industry having pioneered the first Micro Modulation fuel/air ratio controller. Autoflame works with a worldwide distribution network of technology centers.


Retrofit package Limpseld’s engineered solutions enables all burners to be fitted to both new boilers as well as being retro fitted to existing boilers allowing fuel savings of up to 35% to be made by replacing an existing burner with this high efficiency burner. The construction of the Limpseld burner allows it to be easily retro tted to the Cleaver Brooks boiler. A transitional duct is sized and designed to transfer combustion air using the original boiler front door fan impeller and motor assembly. Typical turndown ratios of 5:1 and 6:1 on gas ring with O2 levels less than 3%throughout the ring range make this retro t have a very quick and realistic return on investment. Many customers have realised savings of 10% -35% when retrofitting their existing burner with a Limpseld burner.

At a major Semiconductor manufacturer in Texas, USA further savings were made by data linking all burner controllers and sequencing the boilers. With the reliability of the Limpseld burners and the gained confidence from the site operators, only one burner/boiler fires at any one time with the other two boilers in a warming status ready to produce steam when the demand dictates. Previously all three boilers would be in operation all the time as the boiler house operators did not have the confidence to leave only one boiler dealing with the demand as they had experienced many start up failures in the past.

Retrofitting is a unique engineering capability which saves you money upfront and allows for more varied and integrated options.

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Retrofit

Cleaver Brooks retrofit installation 3D Cleaver Brooks conversion

Touch Screen Mk7 E.G.A

Due to the autonomy of the components the options for upgrades and replacements can vary.• Add AutoFlame controls to current system• Change over current system with a retrofit

and keep current or change over controls.• Replace burner and keep or change controls.• Replace entire system.• Or any other possible combination - we can

walk you through the pros and cons and help you determine what is best for metting both your long and short-term goals.

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Limpsfield and Autoflame


With the premix technology, refractoring are removed. This allows for more surface area to be used. Swirl types of burners rely on the refractoring for the process.

“Low-NOx Burners (LNBs) are designed to control the mixing of fuel and air to achieve what amounts to staged combustion. This staged combustion reduces both flame temperature and oxygen concentration during some phases of combustion, in turn, reduces both lower thermal NOx and fuel NOx production.” United States Department of Energy.www.netl.doe.gov/technologies/coalpower/ewr/nox/NOx-reduct.html

1.1 New Burners/Upgrades “Older, wrongly sized, or mechanically deteriorated burners are typically inefficient. Inoperable dampers, broken registers, or clogged nozzles will render an otherwise good burner into a poor performer. These inefficiencies result in incomplete combustion (high carbon monoxide (CO) emissions and unburned carbon) and the need for high excess air. Burner maintenance, discussed above, is important because it can improve efficiency. Burner upgrades will often need to consider controlling conventional emissions and multiple burners where the ability to maintain ideal air/fuel conditions is much more challenging. More sophisticated combustion monitoring and controls may be an integral part of an upgrade and are described as a separate measure in the section on tuning and optimization. Burner replacement and retrofits can be considered on any burner. New burners for all types of boilers and fuels are commercially available. Burners with single and multiple fuel capability, low- and ultra low-NOX models, and sizes ranging from very small to very large are widely deployed in industry. In addition, many suppliers (original equipment manufacturer (OEM) and non-OEM) offer burner retrofit parts for modifying burners rather than fully replacing them; this often can achieve significant improvements at lower cost than a full replacement. Site-specific conditions and objectives may favor one model over the other. The potential for efficiency gains from new burners is a function of the difference between the old and new technologies. Levels of CO/UBC (incomplete combustion) and excess air between the new and old will dictate the performance improvement potential. Further, the burner size and turndown capability (i.e., ability to operate and/or efficiency of operation at less than full load) will impact the losses associated with inefficient low load and on/off cycling duty. “ United States Environmental Protection Agency. www.epa.gov/nsr/ghgdocs/iciboilers.pdf

VI. Energy Efficiency Improvements “This section presents the efficiency improvement measures identified for ICI boilers. The majority of the identified options focus on measures that are common from the perspective of applicability, availability, and owner/operator experience. Some options that may require project or site reconfiguration and process modifications, such as combined heat and power (CHP) and repowering, are also included in this section. Additional costs and complexities would need to be considered with these options. Options will vary for each unit and multiple options may be applied to save energy. Efficiency gains derived from the various techniques or measures as well as the CO2 benefit associated with such gains are summarized for each measure in the summary table. In many cases the impacts of these measures are highly site specific and benefits will vary. Ranges for potential benefits are listed when appropriate. Because boilers have different baseline efficiencies, it is easier to state efficiency gains in percentage points (e.g., from 78 to 83 % = 5 percentage points) rather than the actual efficiency gain as a percent improvement (e.g. from 78 to 83% = 1-78/83 = 6 %). Of course it is the actual percent efficiency gain that translates directly to CO2 reduction. For purposes of providing nominal values in the summary tables, a baseline efficiency of about 78 % was used to relate efficiency gains in “percentage points” to CO2 reduction potential as a fractional improvement as in the example above.


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Meeting MandatesExceeding current mandates protects you into the future


Emissions

[email protected]+44 (0)1959 576633

Limps�eld burners have been designed to ensure minimal emissions are released into the atmosphere. This means less harmful emissions are created, but also means greater e�ciency of the burner due to good combustion which in turn creates great fuel savings. Typically Limps�eld standard burners operate at <3% O2 and <10ppm of CO. These �gures continue throughout the �ring range, from low �re to high �re.

Detailed research and experiments have taken place during the design process of the Limps�eld burner to ensure the lowest emissions are achieved. Many CFD ‘computational �uid dynamics’ projects have been completed to gain an accurate representation of the �ow and mixing of the gases in the burner.

8

Ignition Point

Gas Inlet

Recirculating Eddy

Typical emission values throughout the burner �ring range


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Energy Efficiency / Cost Reduction

EXCEED THE STANDARDS SET FOR TODAY AND SAVE FOR THE FUTURE

1. O&M Practices Operating and maintenance (O&M) practices have a significant impact on plant performance, including its efficiency, reliability, and operating costs. Each of these parameters change over the life of the plant, and some deterioration of equipment is unavoidable. Boiler efficiency will decreases over time. The rate of deterioration can be curbed by good O&M practices. A well operated and maintained plant will experience less deterioration of boiler efficiency. Deterioration results in higher heat rate, CO2 emissions, and operating costs; in lower reliability; and in some cases, reduced output. After a few years of neglect, it may reach the point where significant investment is required to rehabilitate the plant and bring it as close as possible to the design performance. Such rehabilitation programs are capital intensive and typically O&M is covered in the budget of the plant for this reason. Rehabilitation may focus on life extension and reliability improvement of the plant or may include additional measures that improve plant efficiency, occasionally above the original design efficiency. The efficiency can be improved by retrofitting combustion control technologies such as: heat recovery systems, control technology, and upgraded burners. Additional GHG reductions can be achieved through energy improvements in the steam/hot water distribution system, the boiler auxiliaries, or in process efficiency improvements. (U.S. EPA, 2008).”United States Environmental Protection Agency.www.epa.gov/nsr/ghgdocs/iciboilers.pdf

Several provisions of the Clean Air Act Amendments of 1990 will require “deep” NOx control on a large number of large utility and industrial boilers in the eastern United States. site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/ger4192.pdf

Overview of compliance alternatives for U.S. coal-fired utility boilers facing requirements for deep NOx control under Title I (Attainment of National Ambient Air Quality Standards for ozone) of the Clean Air Act Amendments of 1990. site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/ger4192.pdf

Since the compliance dates for the Title I NOx regulations discussed above are in the 2003- 2005 time frame, plant owners must provide additional control beyond the Title IV target levels over a 3-5 year period to meet the ozone sea-son NOx regulations. site.ge-energy.com/prod_serv/products/tech_docs/en/downloads/ger4192.pdf



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Testimonies



Testimonies

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mechanical servicesarynderson LLC






• Commercial Service Contracts• Maintenance Agreements• 24 Hour Priority Emergency Response• Account Access Online• Equipment Servicing and Replacement• Complete HVAC Services• Boilers/Burners all brands serviced• All heating and cooling systems• Ventillation systems• Factory certified technicians• Government Contracts• State Certifications• Background checks and clearances

Contact:Gary Anderson 443-926-2150 (cell)410-257-7277 (office)155 Prospect, Suite 102,Huntingtown, MD 20639

[email protected]/AutoFlame Territory Manager D.C. & Maryland


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