1. Preferred Utilities Manufacturing Corp
UtilitySaver
Overview
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT

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

3. 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.

4. UtilitySaver Burner Control

5. 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!

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

7. Energy Savings
Fuel
Savings +
Electrical
Savings

8. 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

9. 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 cents / kWh
Fuel Cost - $4.5/k ft3
Oxygen Reduction - 1.5% Wet

10. 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

11. Fuel Savings

12. Variations in Air Composition
“Standard” air has 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.

13. Variations in Air Composition

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

15. 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

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

17. UtilitySaver Burner Control

18. The UtilitySaver Controller
Right For the Job...

19. 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

20. 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

21. 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

22. 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!

23. 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!

24. Touch Screen Options
10 inch

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

26. 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

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

28. 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 C, with mounting flange
60 feet of shielded type J T/C extension cable

29. Actuator Kit Two (2) DM-1E Actuators are Included: Jackshaft & Damper
Torque: in-lbs
Rotation: 90° travel in seconds
Aux. Switches: Integral 2 SPDT
Position Feedback: 600 ohm
Power Supply: 24 Vac
(2)Linkages, (3)Lever Arms, (1)Mounting Bracket

30. Alternate Actuators R-AL : 100 lb Linear Thrust
1730: 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

31. 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)

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

33. Motor Speed Control

34. 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

35. “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

36. 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.

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

38. 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

39. UtilitySaver Installation

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

41. 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

42. 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

43. 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!

44. Preferred Utilities Manufacturing Corp
Preferred Utilities Manufacturing Corporation
31-35 South St. • Danbury • CT
T: (203) • F: (203) •