Boiler Efficiency and Combustion Control

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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 of Combustion
  Control Experience with
• 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
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Touch Screen Operator Interface
Fully Integrated Touch Screen
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Touch Screen Operator Interface

• 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

• 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

• 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

• 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

• 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
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 Reliable
• Sensing element has been proven reliable in 100s
  of installation over the last 10 years
• 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.
• Fully automatic calibration package available.

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Integral Oxygen Analyzer

• Thick cell
• Avoids premature cell failures
• Ceramic heater
• provides reliable long life
• Complete detailed diagnostics
• Automatic impedance checking
• 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 TSControl Strategies
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Fully Metered System
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Fully Metered System

• 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

• 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

• 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 TSAuxiliary Controller / Flame
Safeguard
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Integrated Auxiliary Controller

• 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.
• 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

• Features
• 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

• Features (continued)
• 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 TSSCADA 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 TSCompetitive Comparison
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Comparison
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Comparison
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Comparison
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Comparison
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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
[phone] F [phone] www.preferred-m
fg.com