Preferred Utilities Manufacturing Corp Utility Saver Overview Preferred

Preferred Utilities Manufacturing Corp Utility. Saver Overview Preferred Utilities Manufacturing Corporation 31 -35 South St. • Danbury • CT www. preferred-mfg. com Utility. Saver

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

Utility. Saver Burner Control The Utility. Savertm 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. Utility. Saver fuel and electrical savings can pay for the installed system in two years or less. Utility. Saver

Utility. Saver Burner Control Utility. Saver

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

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

Energy Savings Fuel Savings + Electrical Savings Utility. Saver

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

Energy Savings Conservative $13, 700 per Year Based on: q ASME “by losses” boiler efficiency calculations. q Industry leading manufacturer motor energy data. q 600 Bhp Boiler q 125 psi Steam Natural gas fired q Operating 365 days / year & 24 hours / day q Electric Cost - 7. 5 cents / k. Wh q Fuel Cost - $4. 5/k ft 3 q Oxygen Reduction 1. 5% Wet q Utility. Saver

Unique Energy Savings Tool q Savings Estimate Based on: n n n n n Boiler size Motor HP Air Damper Type Current O 2 Level Projected O 2 Level Flue Gas Temperature Seasonal Loading Data Fuel Cost Electrical Cost Utility. Saver

Fuel Savings Utility. Saver

Variations in Air Composition q “Standard” air has 0. 0177 LB. O 2 per FT 3 q Hot, humid air has less O 2 per cubic ft n 20% less at 95% RH, 120 OF, and 29. 9 mm Hg q Dry, n cold air has more O 2 per cubic ft 10% more at 0% RH, 32 OF, and 30. 5 mm Hg q Standard n Combustion controls must: Allow at least 20% extra excess air because of the change in air density. Utility. Saver

Variations in Air Composition Utility. Saver

Variations in Air Composition At these ambient conditions the burner has extra O 2 & N 2 Utility. Saver

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

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

Utility. Saver Burner Control Utility. Saver

The Utility. Saver Controller Right For the Job. . . Utility. Saver

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

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

The Utility. Saver Controller q PCC-III-ZG 00 n n “Z” Option Board, Oxygen Analyzer “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 Utility. Saver

Utility. Saver Features q Minimizing n Damper Pressure Drop Damper is 100% open for maximum k. Wh 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. Utility. Saver

Utility. Saver Features 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 n 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. q Real Time Boiler Efficiency q Continuous Oxygen Analyzer Diagnostics Utility. Saver

Touch Screen Options 10 inch Utility. Saver

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

In-Situ Oxygen Analyzer q Proven n Zirconia Oxide Sensor q No n n Reliable Reference Air The probe uses ambient air as a reference. 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 Utility. Saver

Oxygen Analyzer Kit q q Model ZP Oxygen Sensor, 20” Standard Reliable Zirconia Oxide Cell 60 ft ZP Cable Mounting Hardware included Utility. Saver

Boiler Efficiency Kit q PCC-III Controller calculates the ASME “by losses” method efficiency in real time. Kit Includes: n n Flue Gas Temperature Assembly, Type J, p/n 104087 C, with mounting flange 60 feet of shielded type J T/C extension cable Utility. Saver

Actuator Kit q Two (2) DM-1 E Actuators are Included: Jackshaft & Damper n n n Torque: Rotation: 150 in-lbs 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 Utility. Saver

Alternate Actuators q R-AL : 100 lb Linear Thrust q 1730: 1000 in-lb Torque q UP 10 Pneumatic: 1080 in-lb Torque q I/P Kit to interface to Existing Pneumatic Jackshaft Actuator q Pot Box, if Existing Actuator doesn’t have Feedback Utility. Saver

Variable Speed Fan Air Flow Control q Variable Speed Drive (VSD) - The Utility. Saver 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) Utility. Saver

VSD Parts & Theory q 5 Parts to a VSD n n Rectifier DC “Link” line reactor Intermediate Circuit Inverter (IGBT = Insulated Gate Bipolar Transistor) n Control & Regulation Utility. Saver

Motor Speed Control Utility. Saver

Pulse Width Modulation (PWM) q q q 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 d. V/dt causes spike voltages Utility. Saver

“Soft Turn On” IGBTs q dv/dt - Change in Voltage over Time n n Utility. Saver Drive - 900 V/us n q Competitor’s Drives - up to 3500 V/us Due to Patented “Soft Turn On” IGBT’s Lower Peak Voltages Extend Motor Insulation Life n 460 V, 75 Hp motor: 815 V peak for 50 ft cable Utility. Saver

Automatic Over Ramp Protection q The Utility. Saver VFD will not trip when given a “STEP” speed increase of 0 to 100 % n n 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. Utility. Saver

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

Utility. Saver Installation q Sole n n n 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 Utility. Saver package for optimum burner performance Train Owners Operators for properation Utility. Saver

Utility. Saver Installation Utility. Saver

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

Experience Preferred Instruments has 25 years of Combustion Control Experience with… 4 4 4 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 Utility. Saver

Experience Compatible with other Preferred Instruments. . . 4 4 4 products from 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 Utility. Saver

Summary Utility. Saver …. . . 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 Utility. Saver

Preferred Utilities Manufacturing Corporation 31 -35 South St. • Danbury • CT T: (203) 743 -6741 • F: (203) 798 -7313 www. preferred-mfg. com • info@preferred-mfg. com Utility. Saver