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

UtilitySaver Burner Control Introduction Energy Savings Fuel Savings Electrical Savings System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive Installation Summary

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 Burner Control

UtilitySaver Burner Control 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 Introduction Energy Savings Fuel Savings Electrical Savings System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive Installation Summary

Energy Savings Fuel Savings + Electrical Savings

Energy Savings Fuel Savings: Electrical 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

Conservative $13,700 per Year Energy Savings Conservative $13,700 per Year Based on: ASME “by losses” boiler efficiency calculations. Industry leading manufacturer motor energy data. 600 Bhp Boiler 125 psi Steam 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

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

Fuel Savings

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.

Variations in Air Composition

Variations in Air Composition At these ambient conditions the burner has extra O2 & N2

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

UtilitySaver Burner Control Introduction Energy Savings Fuel Savings Electrical Savings System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive Installation Summary

UtilitySaver Burner Control

The UtilitySaver Controller Right For the Job...

The UtilitySaver Panel Measured Flue Gas Oxygen Firing Rate % (shown) Steam PSIG Steam PSIG SP Oxygen % Oxygen SP Oxygen Trim % VFD Speed Fuel Valve Position Air Damper Position Boiler Efficiency Flue Gas Oxygen Setpoint Firing Rate Large Displays & Pushbuttons 16 character process variable and alarm description messages 10 point first out alarm annunciator Intuitive Bargraphs User Configurable Pushbuttons Organized, simple and to the point local operation

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

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 Features 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. Fully metered control systems modulate air and fuel flow by actually measuring the air and fuel flow. For each boiler load the commissioning engineer establishes a fuel / air ratio that will provide the desired burner performance. The fuel controller and air controller modulate the fuel and air control devices until the fuel flow and air flow produce the commissioned fuel / air ratio. Changes in fuel pressure, ambient air pressure or temperature and control device hysteresis do not effect this system. As a result the commissioning engineer can set the fuel / air ratio closer to the optimal setting and allow better fuel economy and lower emissions!

UtilitySaver Features 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 Fully metered control systems modulate air and fuel flow by actually measuring the air and fuel flow. For each boiler load the commissioning engineer establishes a fuel / air ratio that will provide the desired burner performance. The fuel controller and air controller modulate the fuel and air control devices until the fuel flow and air flow produce the commissioned fuel / air ratio. Changes in fuel pressure, ambient air pressure or temperature and control device hysteresis do not effect this system. As a result the commissioning engineer can set the fuel / air ratio closer to the optimal setting and allow better fuel economy and lower emissions!

Touch Screen Options 10 inch

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

In-Situ Oxygen Analyzer 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

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

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

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

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

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)

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

Motor Speed Control

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

“Soft Turn On” IGBTs 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

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 Burner Control Introduction Energy Savings Fuel Savings Electrical Savings System Composition UtilitySaver Panel Oxygen Analyzer Variable Frequency Drive Actuators Installation Summary

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 Installation

UtilitySaver Burner Control Introduction Energy Savings Fuel Savings Electrical Savings System Composition UtilitySaver Panel Oxygen Analyzer Actuators Variable Frequency Drive Installation Summary

Experience 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 Preferred Instruments has the experience and know how to design and integrate complete combustion systems…….. PCC II/III Combustion Control Projects.... > 1000 Boilers 624 Jackshaft Controlled Boilers 127 Parallel Positioning Controlled Boilers 103 Metering Controlled Boilers 351 Oxygen Trim Systems 13 EPA Compliant Opacity Monitors

Experience 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 Preferred Instruments has the experience and know how to design and integrate complete combustion systems…….. PCC II/III Combustion Control Projects.... > 1000 Boilers 624 Jackshaft Controlled Boilers 127 Parallel Positioning Controlled Boilers 103 Metering Controlled Boilers 351 Oxygen Trim Systems 13 EPA Compliant Opacity Monitors

Summary UtilitySaver …... 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 Unit responsibility for controls, BMS and SCADA assures proper interface between the parts with no division of responsibility!

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 • info@preferred-mfg.com