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
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.
UtilitySaver
UtilitySaver Burner Control
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 Burner Control
UtilitySaver
UtilitySaver Burner Control
Introduction Energy Savings
Fuel Savings Electrical Savings
System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive
Installation Summary
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
Variations in Air Composition
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
Variations in Air Composition
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 Burner Control
Introduction Energy Savings
Fuel Savings Electrical Savings
System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive
Installation Summary
UtilitySaver
UtilitySaver Burner Control
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
UtilitySaver Burner Control
Introduction Energy Savings
Fuel Savings Electrical Savings
System Composition UtilitySaver Panel Oxygen Analyzer Variable Frequency Drive Actuators
Installation Summary
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 Burner Control
Introduction Energy Savings
Fuel Savings Electrical Savings
System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive
Installation Summary
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]