Transcript Boiler Efficiency and Combustion Control

BurnerMate TS Overview
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Overview
 Introduction
 Components
 Control
Strategies
 Auxiliary Controllers / Flame Safeguard
 SCADA System Integration
 Competitive Comparison
 Summary
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Introduction
The BurnerMate® TS is a combined boiler control,
flame safeguard, and monitoring system with a touch
screen operator interface.
BurnerMate is a full scope control package that
assures safe and efficient control with undivided
system integration responsibility.
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Experience
Preferred Instruments has 35 years
Combustion Control Experience with…
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of
A Third Generation Digital Controller
Over 3000 Boiler Control System Installations
Over 2400 PCC II/III Controllers Installed
Exclusively in Combustion Control Applications
Over 45 SCADA/Flex Projects
640 Rotary Cup Burner Projects
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BurnerMate TS
Components
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System Composition
10” Touch Screen Operator Interface
Accurate Servo
Actuator
Integrated Oxygen Analyzer!
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Touch Screen Operator Interface
Fully Integrated Touch Screen…
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Touch Screen Operator Interface
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Monitor and control boiler operation, setpoints, and
process data from one convenient display
Commissioning activities are laid out in an easy to
follow step-by-step procedure, eliminating the need
for knowledge of controller menus and programming
languages
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Touch Screen Operator Interface
Real time boiler
management data
Auto/Manual
Control
Alarm banner, Silence
button, and Navigation
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DCS-III Programmable Control
DCS-III Controller…
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DCS-III Programmable Control
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The DCS-III is a state-of-the-art, boiler-focused
programmable logic controller
The large I/O quantity, small sub-panel foot print,
intuitive “Blockware”, redundant memories, and
built-in industry standard communication allows the
DCS-III to be integrated into complex boiler control
systems with a minimum number of external
components
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Easy Commissioning
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The “Learn Mode” feature allows multiple F(x)
block input vs. output profiles to be entered
simultaneously with a push of a button!
“Store” button to simultaneously
store the firing rate, oxygen and
burner air flow rate value into the
appropriate F(x) blocks
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BurnerMate TS
Advanced
Communication…
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Internet, Web Site Access
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A standard WEB Browser provides remote
monitoring and operation
Custom software is not required
Historical Alarm and event data can be imported to
spreadsheet applications such as MS Excel
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Intranet Communication
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The ethernet communication port is easily assigned
an IP address and connected to a facility wide
network
Remote monitoring, control and data collection is
available via a standard WEB Browser
Building Automation Systems and SCADA Systems
are interfaced via industry standard MODBUS
Ethernet communication
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Integral Oxygen Analyzer
ZP-xx
Oxygen Probe
Field replaceable probe
Only one conduit to stack.
DCS-III with
"Z" Option Board
190130
Connecting Cable
Power Supply
Calibration Gas Input
Grade Level Connection By Others
No separate analyzer, one less item to mount
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Integral Oxygen Analyzer
 Proven
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Sensing element has been proven reliable in 100s
of installation over the last 10 years
 No
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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
 Automated,
menu driven pushbutton
calibration.
 Fully automatic calibration package available.
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Integral Oxygen Analyzer
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Thick cell
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Avoids premature cell failures
Ceramic heater
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provides reliable long life
Complete detailed diagnostics
 Automatic impedance checking
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Alarms when time to recalibrate
Alarms when reaching end of cell life
Optional fuel gas temperature element T/C input
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BurnerMate TS
Control Strategies
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Fully Metered System
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Fully Metered System
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This control strategy with oxygen trim and variable
speed fan control offers the best opportunity to save
fuel and electrical cost with a control system
upgrade
This strategy measures both the fuel flow and the
combustion air flow
PID control is used for both fuel and air flow
control, assuring the accurate maintenance of fuel
and air flow setpoints
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Parallel Positioning System
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Parallel Positioning System
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This control strategy includes up to five (5) servo
channels, allowing independent control of fuel
valves, air and fuel gas re-circulation dampers
The fuel-air ratio is established and adjusted by use
of a “soft” function curve of fuel valve vs. damper
position
Parallel positioning enables “tighter” fuel-air ratio
control, which improves boiler efficiency
Combining this control method with oxygen trim
and variable speed fan control offers substantial cost
savings for a fast payback
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Single Point Positioning System
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Single Point Positioning System
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This control strategy mechanically links the fuel
valve, air and flue gas control dampers to a single
actuator
Generally, the fuel valve has a characterizable flow
versus position relationship that is used to establish
the fuel-air ratio over the range of modulation
This method is recommended when the boiler size or
service hours do not justify addition of a VSD
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BurnerMate TS
Auxiliary Controller /
Flame Safeguard
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Integrated Auxiliary Controller
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Draft Control – Stable & repeatable draft control is
essential for efficient boiler operation. This is
especially important for boilers with induced Flue
Gas Recirculation (FGR)
Nox
reduction.
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Feedwater Control – Single element, two element
or three element feedwater control may be provided.
Water column blowdown is prompted and logged to
ensure proper maintenance.
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Flame Safeguard
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Features
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The Flame Safeguard System provides the proper burner
sequencing, ignition and flame monitoring protection on
single burner, automatically ignited oil or gas fired
boilers.
The system uses a fail-safe, “de-energize” to trip design.
Upon the loss of system power the fuel safety shutoff
valves are automatically closed and ignition components
are de-energized.
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Flame Safeguard
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Features (continued)
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On a safety shutdown, the message display will advise
the operator that the control is in “Lockout” and will
indicate the specific cause and the state in the operating
sequence where the shutdown occurred.
Proof of purge, low fire position interlocks, and fuel
valve end switch safety checks are also included.
A drum level conductivity probe relay is incorporated
for an auxiliary Low Water Cutout safety interlock.
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BurnerMate TS
SCADA System Integration
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SCADA System
Supervisory Control And Data Acquisition:
 Windows XP based workstations
 Programmable Controller based combustion
control hardware
 Up to 31 I/O per controller
 Touch Screen interface can be used as backup
control station if the workstation, or
communication network breaks down
 “Service Manual” mode can be used as backup
control station if the Loop Controller fails
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Expanded Remote Systems
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Process Style Boiler Overview
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Flame Safeguard Overview
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Store Data for Analysis Later
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BurnerMate TS
Competitive Comparison
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Comparison
BurnerMate
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Hawk ICS
Boiler Front Display
10” Touch Screen
10” Touch Screen
Remote Monitoring
Web Based
RS-View
DCS-III Controller
Allen Bradley
Control Logixs
Flame Safeguard
Honeywell or
Fireye
Honeywell
Flue Gas Oxygen
Trim with Sensor
YES
YES
Boiler Overview
YES
YES
Alarm / Event
Summary Display
YES
YES
Burner Hours/Cycles
YES
YES
YES
YES
YES
NO
YES
NO
Comment
Basic
Hardware
Fuel-Air Ratio
Control
(Parallel Positioning)
BurnerMate offers true “plug and play” remote
operation and monitoring via a standard web
browser
Hawk system requires the fuel air ratio to be
controlled by a separate Honeywell control
product for some Parallel Positioning control
systems
Operator
Interface
Efficiency
Calculation based
using ASME “By
Losses” Method
Real Time &
Historical Trending
Real Time X/Y Plots
Easy to use multiple pen charts allow quick
system assessment and maintenance monitoring.
BurnerMate x/y plots graphically display fuel vs.
air curve data for intuitive burner setup and to
store commissioning data into multiple
characterizer curves for a particular load point.
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Comparison
BurnerMate
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Hawk ICS
YES
NO
Optional
Optional
Optional
NO
Comment
Hardware
Options
Shipped Loose for
Field Installation
6 inch Color
Display
Expansion and
connection to
existing Equipment
This is a major advantage when field
upgrading obsolete existing equipment
BurnerMate TS may be integrated with
existing Preferred, Fireye or Honeywell
equipment
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Comparison
BurnerMate
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Hawk
ICS
Comment
Controller
Redundant Memory
Module, “Hot stand by”
Integrated Flue Gas
Oxygen Transmitter
Analog Inputs
Analog Outputs
Discrete Inputs,
Relay Outputs
Triac Outputs
YES
NO
Qty: 1 to 2
NO
YES
YES
YES
YES
YES
YES
YES
YES
YES
NONE
Thermal Shock Protection
Economizer Monitoring
YES
Optional
YES
Optional
Fuel Flow metering
Optional
Optional
Level Control / Monitoring
Optional
Optional
Draft Control
Optional
NO
Opacity Monitoring
JC-30D
NO
Custom Engineering and
field support
Optional
Optional
Plug In Configuration Memory Module is useful for
copying, transferring applications from first to second
boiler and service as a level of redundancy in the event
of a memory corruption.
The BurnerMate TS uses an integrated flue gas oxygen
analyzer, separate analyzer electronics is not required.
All analyzer status and diagnostic information is
available to touch screen and web based monitoring
4-20mAdc/ Thermocouple
4-20mAdc
120Vac
BurnerMate Triac outputs allow direct control of electric
servo actuators. The Hawk ICS uses standard solid
state relay outputs that cause low mean time between
failures.
Special
Features
BurnerMate offers one, two & three element feedwater
control as standard options
Standard BurnerMate Option
JC30D has unique Auto Cal, Lowest Cost instrument
available
Preferred has a company focus on boiler control
systems. This focus backs each product and project by
an experienced staff of boiler control application, field
service and sales people. Preferred offers 24 hours a
day/ seven day a week expert support.
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Comparison
Modulating
Lead/Lag
Number of Boilers
Chief Dispatcher
Hardwired control
switches and lights
Warm Standby
Outdoor Reset
Setback, day, week
and holidays
Domestic Hot
Water Priority
“Smart”
Sequencing
Blend Valve
Control
Condensing Boiler
Logic
Independent
primary Pump
Control
Header Pump
Control
Secondary Pump
VSD Control
BurnerMate
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Hawk ICS
Optional
Optional
2 to 10
2 to 8
YES
NO
YES
YES
YES
YES
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
YES
NO
Comment
Preferred offers flexible and unique Lead/Lag
Sequences that meet individual plant
requirements.
Important feature that provides ease of use to
every type of operator.
Both “LIMITS” and “LOCKOUT” conditions are
monitored. Sequencing is fast and efficient.
True thermal shock protection. Cold return water
is blended with boiler outlet water to prevent
unnecessary boiler wear.
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Summary
BurnerMate TS has….
 Integrated fuel-air ratio, flame safeguard,
draft, and feedwater controls
 Single Point Positioning, Parallel
Positioning, and Fully Metered Combustion
Control
 Single or Dual Fuel Flame Safeguard with
easy trouble shooting.
 Low Cost Full Scope Package.
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Preferred Utilities Manufacturing Corp
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
T: (203) 743-6741 • F: (203) 798-7313
www.preferred-mfg.com
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