peter larro mechanical sales
TRANSCRIPT
APEM APEM –– Fall 2011 ForumFall 2011 Forum
High Efficiency Burners and High Efficiency Burners and
Linkageless Combustion ControlsLinkageless Combustion ControlsPresented By: Mechanical Sales, Inc.Presented By: Mechanical Sales, Inc.
Peter Larro and Barry JostolPeter Larro and Barry Jostol
•Optimization strategies using high efficiency burners and combustion controls
•Burners and burner controls options
•Linkageless Combustion Controls
Topics weTopics we’’ll discussll discuss………………....
In all cases, what are we trying In all cases, what are we trying to doto do…………………………..
�� Improve thermal or combustion efficiency to Improve thermal or combustion efficiency to the best level availablethe best level available
�� Maintain reliable operationMaintain reliable operation
�� Maintain absolute level of safety in operationMaintain absolute level of safety in operation
�� Attempt to minimize maintenance requirements Attempt to minimize maintenance requirements if possibleif possible
�� Extend operational life of existing equipmentExtend operational life of existing equipment
Perfect Combustion
Fuel (C, H2)
Air (O2, N2)Air (O2,N2)
Burner
CO2
N2
H2O
Complete Combustion by todays standards……
Fuel (C, H2)
Air (O2, N2)Air (O2,N2)
Burner
CO2 CO (< 50 PPM)
NO (as low as possible)
H2O
O2 (as low as 3%)
0
2
4
6
8
10
12
14
16
0 50 100 150 200 250
% B
y V
loum
e in
dry
flue
gas
% Theoretical Air
Stoichiometric
Fuel Rich Excess Air
%CO
%CO2 %CO2
%O2
O2 Effect on EfficiencyEffect on Efficiency
The graph below shows the savings realized with a 100 horsepower load at various efficiencies caused by different excess air levels.
Burner Controls Burner Controls –– Where is Where is the industry now ?the industry now ?
Microprocessor based, Microprocessor based, linkageless combustion linkageless combustion
controls, often utilizing VFDcontrols, often utilizing VFD’’s s on blower motorson blower motors
HereHere’’s the type of system we s the type of system we are used to..are used to..
Modulating BurnerModulating BurnerWith Single Point PositioningWith Single Point Positioning
Single modulating motor, driving fuel and air, through a system of mechanical linkages, user adjustable for fuel / air ratio control
Linkageless ControlsLinkageless Controls………………....
Individual servo motors attached to fuel valves and air damper, no linkage…infinite adjustability – parallel positioning
PARALLEL PARALLEL
POSITIONINGPOSITIONING
LINKAGELESS BURNER CONTROLLINKAGELESS BURNER CONTROL
What is Parallel PositioningWhat is Parallel Positioning
�� Parallel positioning is the use of Parallel positioning is the use of
multiple positioning motors to set the multiple positioning motors to set the
position of the fuel valves and air position of the fuel valves and air
damper throughout the firing range.damper throughout the firing range.
�� Traditional modulating burners use Traditional modulating burners use
single point positioning. Using one single point positioning. Using one
motor and linkage to position the fuel motor and linkage to position the fuel
valves and air damper.valves and air damper.
Advantages of Parallel Advantages of Parallel
PositioningPositioning
�� No HysterisisNo Hysterisis
�� Accurate Characterization of Fuel/Air Accurate Characterization of Fuel/Air
RatioRatio
�� Optimal Firing of Each FuelOptimal Firing of Each Fuel
�� Accurate Control of Firing RateAccurate Control of Firing Rate
�� TamperTamper--resistant Burner Settingsresistant Burner Settings
�� Remote Monitoring of Burner Remote Monitoring of Burner
PerformancePerformance
Typical Fuel CurveTypical Fuel Curve
Parallel Positioning
0
10
20
30
40
50
60
0 10 20 30 40 50 60 70 80 80 90
Fuel/Air
Fuel
Air
Many manufacturers now sell Many manufacturers now sell linkageless controlslinkageless controls……..
--Siemans CorporationSiemans Corporation--Fireye Fireye ““NexusNexus”” systemsystem
--HoneywellHoneywell--Autoflame MM ControlsAutoflame MM Controls--Custom systems locallyCustom systems locally
Do they work well and are they Do they work well and are they reliable ?reliable ?
�� YES YES –– Most burner manufacturers are Most burner manufacturers are going to linkageless as their standardgoing to linkageless as their standard
�� Reliability is very good, systems work as Reliability is very good, systems work as they shouldthey should
�� Case studies have shown fuel savings to as Case studies have shown fuel savings to as much as 20% with the addition of much as 20% with the addition of linkageless control strategieslinkageless control strategies
�� Serviceability of the burner improvesServiceability of the burner improves
Linkageless Control Systems also Linkageless Control Systems also ProvideProvide…………
�� Full PID control of temp / pressure Full PID control of temp / pressure Setpoint by using temp / press Setpoint by using temp / press transmitterstransmitters
�� Setpoint control accurate to within 2 PSI Setpoint control accurate to within 2 PSI or +/or +/-- 22ºº F.F.
�� Enhanced diagnostics, communications, Enhanced diagnostics, communications, data collection and remote monitoring and data collection and remote monitoring and controlcontrol
With a programmable linkageless control system, it is possible to optimize combustion quality for
boiler/burner load requirements. A linkageless combustion-control unit can display positioning data for several individually controlled channels, such as fuel, air, flue-gas recirculation, and atomizing air. Most systems checks the relative positioning of these
channels 50 times per second, ensuring safety and accuracy. This enables the system to achieve “locked-on” near stoichiometric fuel/air mixing throughout a boiler's fuel-input range while maintaining exact
temperature or target pressure values.
Will they work for my boiler Will they work for my boiler ––In most casesIn most cases…….. YES !!.. YES !!
--Initial cost usually limits applicability to Initial cost usually limits applicability to boilers above 100 HP for boilers above 100 HP for ““standardstandard””
systemssystems
--Available as retrofit Available as retrofit ““kitskits”” or as part of or as part of new equipmentnew equipment
-- Applicable to most forced draft burnersApplicable to most forced draft burners
--Even available now on residentially sized Even available now on residentially sized boilersboilers
Major Manufacturers Include:Major Manufacturers Include:
�� Honeywell Honeywell –– ““Control LinksControl Links””
�� Fireye Fireye –– ““NexusNexus””
�� Siemens Siemens –– ““LMVLMV””
�� Autoflame Autoflame –– ““MMMM””
HONEYWELLHONEYWELL
---- The Application The Application ----Fuel Air Ratio Control SystemFuel Air Ratio Control System
Natural GasNatural Gas
Fuel OilFuel Oil
Limits & Operating Control4-20mA Firing Rate Control
WIN 95WIN 95
Limits
Q7999A Wiring SubbaseQ7999A Wiring Subbase
•• Panel mount wiring subbasePanel mount wiring subbase
•• 40 terminal wiring subbase40 terminal wiring subbase
•• Short circuit proof terminalsShort circuit proof terminals
•• 7 terminal grounding strip7 terminal grounding strip
•• Line Voltage & Low VoltageLine Voltage & Low Voltagewiring separationwiring separation
R7999R7999ControllerController
TerminalsTerminalsaccessible foraccessible for
troubleshootingtroubleshooting
Different sizeDifferent sizeterminal pinsterminal pins
prevents improperprevents impropermounting onmounting on
wiring subbasewiring subbase
R7999 ControllerR7999 Controller•• Two Model Numbers :Two Model Numbers :---- R7999AR7999A
100 to 120Vac, 100 to 120Vac, +10% +10% --15%, 15%, 50/60 Hz50/60 Hz---- R7999BR7999B
200 to 240Vac, +10% 200 to 240Vac, +10% --15%, 50/60 Hz15%, 50/60 Hz
•• Four Channel Output Control :Four Channel Output Control :---- Two FuelsTwo Fuels---- Combustion AirCombustion Air---- Flue Gas ReFlue Gas Re--circulationcirculation
•• Operating Temperature :Operating Temperature :-- 4040°°°°°°°°F to +140F to +140°°°°°°°°F F
R7999 ControllerR7999 Controller•• Two Independent Fuel ProfilesTwo Independent Fuel Profiles
-- (950 Positions)(950 Positions)
•• Programmable Positioning for :Programmable Positioning for :-- StandbyStandby-- PurgePurge-- NonNon--Selected FuelSelected Fuel-- Light OffLight Off-- Minimum ModulationMinimum Modulation
•• Auto / Manual Firing Rate InputAuto / Manual Firing Rate Input
•• 7 to 24 Point Profiles7 to 24 Point Profiles
•• Floating Control OutputFloating Control Output
R7999 ControllerR7999 Controller•• Fast Burner Setup via PC or LaptopFast Burner Setup via PC or Laptop
•• Step by Step, Menu DrivenStep by Step, Menu DrivenCommissioning ProcessCommissioning Process
•• File Backup of Commissioning DataFile Backup of Commissioning Data
•• Diagnostic / Historical DataDiagnostic / Historical Data
•• Password ProtectedPassword Protected
•• Remote Reset CapabilityRemote Reset Capability
•• Alarm OutputAlarm Output
R7999 ControllerR7999 Controller•• Configurable Sensor Interface Configurable Sensor Interface (4(4--20mA):20mA):
-- Low Fire HoldLow Fire Hold-- FGR HoldFGR Hold-- FGR & Low Fire HoldFGR & Low Fire Hold
•• Maximum Modulation Limit InputMaximum Modulation Limit Input
•• Dynamic Safety Checks:Dynamic Safety Checks:-- Fail Safe Potentiometer ChecksFail Safe Potentiometer Checks-- Anti Swap of ActuatorsAnti Swap of Actuators-- Curve Tracking TestsCurve Tracking Tests
•• Global Approval Body CompliantGlobal Approval Body Compliant
Universal Parallel Positioning ActuatorUniversal Parallel Positioning Actuator
ML7999ML7999•• External Indication of PositionExternal Indication of Position
•• Floating Control InputFloating Control Input
•• I.D. Number ProtectedI.D. Number Protected
•• Power IndicatorPower Indicator
•• Operating Temperature:Operating Temperature:
-- 4400°°°°°°°°F to +140F to +140°°°°°°°°FF
•• Universal Power Input:Universal Power Input:
100 to 240Vac, +10%, 100 to 240Vac, +10%, --15%, 50/60Hz15%, 50/60Hz
ML7999ML7999•• Direct Coupled OutputDirect Coupled Output
•• High Torque & Fast Speed:High Torque & Fast Speed:-- 100 in. lb.,100 in. lb.,-- 30 Sec,30 Sec,-- 9595°°°°°°°° StrokeStroke
•• Compact Size Compact Size
•• NEMA 3 / IP54NEMA 3 / IP54-- Requires Weatherproofing KitRequires Weatherproofing Kit
Universal Parallel Positioning ActuatorUniversal Parallel Positioning Actuator
Honeywell S7999Honeywell S7999Honeywell S7999
Controlinks ™ Displayand commissioning
interface
Allows you to set up Controlinks ™ system
without a laptop computer.
• 3.5” x 4.625” Color Touch Screen• RS-485 Communication port• Audio feed back• Flush mounts on panel See Sales Release # 610
Install Commissioning SoftwareInstall Commissioning Software
ZM7999AZM7999A
R7999R7999 -- System SetupSystem Setup
Activate & Setup ZM7999AActivate & Setup ZM7999ADefine Burner System ParametersDefine Burner System ParametersEstablish End PointsEstablish End PointsConfigure Profile CurveConfigure Profile CurveVerify (walk) the Profile CurveVerify (walk) the Profile CurveSave the Profile CurveSave the Profile Curve
WIN 95WIN 95
3 conductor shielded cable3 conductor shielded cable
RS485 to RS232 converterRS485 to RS232 converter
FIREYEFIREYE
Nexus OverviewNexus Overview
Servo Motors
Controller and Base
Flame ScannerMMI/ Display
Remote Station
ControllerController
NX 3000 / 4000
Contains the CPU and PSU Boards
LED Indication of Status/Fault ConditionAuto, Boiler Status, Pre-Purge,Ignition, Normal Run, Flame, Air Pressure, Fault
Nexus Flame SafeguardNexus Flame Safeguard
Timing Sequences Similar to E110 / E210
Non-Recycling Running Interlocks
Supervised Purge
Open Damper Purge Position Proving, Ignition Low Fire Start Position Proving
Proof of Closure - Main Fuel Valve orValve Gas Pressure Test Proving Sequence Available
Nexus Combustion ControlNexus Combustion Control
Parallel Positioning
Individual Servo Positioning MotorsDrive shaft mounted Feedback Potentiometers
24 Programming Positions for each motor
Approved Safety Checking on all Electronics
Three, Four Channel Options
Accuracy to 0.1 angular degrees
Nexus Wiring BaseNexus Wiring Base
Wiring Module NX1386, NX1466
Two Versions : Open and Enclosed UL & UL RecognizedContains Terminal StripsMain FuseVoltage Selection LinksPressure / Temperature Selection LinksPotentiometer Voltage Selection LinksRS485 Communications Selection Link
Nexus MMI / DisplayNexus MMI / Display
Display NX550
Two Line 20 Character Vacuum Fluorescent Display
Key Pad w/ Multi Purpose Keys
Engineer’s Key
Nexus Servo Motors Nexus Servo Motors
Three Servo Configurations
36 in. lbs. 4 Nm
180 in. lbs. 20Nm
420 in. lbs. 50Nm
Nexus Servo Motor RequirementsNexus Servo Motor Requirements
Servo Motor Control
Type of Motor - AC Up/Down with Feedback PotentiometerNumber of Motors - 3 or 4 Depending on Controller24 Setpoints per ProfilePosition Accuracy 0.1°Response time to Positioning Error
15s for +/- 1.0°1s for +/- 5.0 °
Number of Fuel Motors 1 or 2Number of Air Motors 1 or 2
Optional EquipmentOptional Equipment
–– Pressure SensorsPressure Sensors
–– Temperature SensorTemperature Sensor
–– SequencingSequencing
–– Communication SoftwareCommunication Software
–– O2 TrimO2 Trim
AUTOFLAMEAUTOFLAME
AUTOFLAME FEATURESAUTOFLAME FEATURES
�� Fuel/Air Ratio Controller Fuel/Air Ratio Controller
–– Controls Servo Motors for up to 3 FuelsControls Servo Motors for up to 3 Fuels
–– P.I.D. Load ControllerP.I.D. Load Controller
–– Intelligent Boiler SequencingIntelligent Boiler Sequencing
–– Computer CompatibleComputer Compatible
�� Exhaust Gas AnalysisExhaust Gas Analysis
–– 3 Parameter Trim of O2, CO, CO23 Parameter Trim of O2, CO, CO2
–– Displays O2, CO, CO2, Efficiency, Exhaust Displays O2, CO, CO2, Efficiency, Exhaust
Temp (NO and SO are optional)Temp (NO and SO are optional)
Mini M.M. Facia
AUTOFLAMEM.M./E.G.A. Technical Manual
Multiple Systems OptionsMultiple Systems Options
�� ““MMMM”” –– Mark SeriesMark Series
�� Mini Mark V Mini Mark V –– Two fuel channels and FGRTwo fuel channels and FGR
�� Mark VI Evolution Mark VI Evolution –– Six dedicated channelsSix dedicated channels
�� Mini Mark VII Mini Mark VII –– Three channels Three channels –– two fuel and one two fuel and one
VFDVFD
�� Mark VII Evolution Mark VII Evolution –– Six dedicated channels Six dedicated channels –– four four
fuels and two VFDfuels and two VFD
AUTOFLAME MK.6 FEATURESAUTOFLAME MK.6 FEATURES
�� 4 Fuel Curves 4 Fuel Curves
�� Integral Flame SafeguardIntegral Flame Safeguard
�� Gas and Oil Pressure SupervisionGas and Oil Pressure Supervision
�� Combustion Air SupervisionCombustion Air Supervision
�� Integral VFD InterfaceIntegral VFD Interface
�� Quarter VGA ScreenQuarter VGA Screen
AUTOFLAMEM.M./E.G.A. Technical Manual
Optional Exhaust Gas AnalyzerOptional Exhaust Gas Analyzer
Use of an exhaustUse of an exhaust--gas analyzer expands the benefits of gas analyzer expands the benefits of linkageless combustion control. An exhaustlinkageless combustion control. An exhaust--gas gas analyzer measures and displays O2, CO2, carbonanalyzer measures and displays O2, CO2, carbon--monoxide (CO), nitricmonoxide (CO), nitric--oxide (NO), nitrogenoxide (NO), nitrogen--dioxide dioxide (NO2), NOx, and sulfur(NO2), NOx, and sulfur--dioxide (SO2) exhaust dioxide (SO2) exhaust
temperature and combustion efficiency. An exhausttemperature and combustion efficiency. An exhaust--gas analyzer's builtgas analyzer's built--in continuousin continuous--emissionsemissions--monitoring monitoring
software monitors instantaneous and totalized software monitors instantaneous and totalized emission output for each fuel as a weight (cubic feet) emission output for each fuel as a weight (cubic feet) and mass (pounds or tons). Because of the software, and mass (pounds or tons). Because of the software, data collected from the exhaustdata collected from the exhaust--gas analyzer can be gas analyzer can be submitted as an emissions report for a boiler and/or submitted as an emissions report for a boiler and/or
plant annually, quarterly, or monthly.plant annually, quarterly, or monthly.
Data Transfer and Data Transfer and
CommunicationsCommunications
M.M./E.G.A. Technical Manual AUTOFLAMEAUTOFLAME
SiemensSiemens
LMV51 Application
V1DualDual --fuel burnerfuel burner
LMV Basic Unit
�� Real dual fuel burner Real dual fuel burner control control Separate inputs and Separate inputs and outputs for oil and gasoutputs for oil and gas
�� Adjustable timing and Adjustable timing and programmingprogramming
�� Configurable inputs Configurable inputs and outputsand outputs
�� Continuous operation Continuous operation with IR detectionwith IR detection
�� Flexible test timingFlexible test timing�� No additional wiringNo additional wiring�� Only one additional pressure switchOnly one additional pressure switch�� Accuracy via timing adjustableAccuracy via timing adjustable�� Detectable which valve is leakingDetectable which valve is leaking�� Sequence for the test adjustable Sequence for the test adjustable (pre purge, post purge or during both (pre purge, post purge or during both phases)phases)
Gas valve proving system
Electronic air / fuel ratio Electronic air / fuel ratio
controlcontrol
�� Easy wiring of the actuatorsEasy wiring of the actuators�� Easy adjustment of the burnerEasy adjustment of the burner�� Ignition position independent of the Ignition position independent of the curvescurves
�� High adjustment accuracyHigh adjustment accuracy�� Up to 4 actuators:Up to 4 actuators:air, 2 x fuel, auxiliaryair, 2 x fuel, auxiliary
AZLAZLProgramming
• Burner control
• Electronic air/fuel ratio control
• Gas valve proofing
• Load controller
Display burner operation
Diagnosis
Interface communication
Display and programming unit Display and programming unit
(AZL)(AZL)
�� Separate housing removableSeparate housing removable�� Easy menu structure Easy menu structure �� Clear text display (4 x 16 characters)Clear text display (4 x 16 characters)�� 3 languages / other languages possible3 languages / other languages possible�� Functions protected with passwordsFunctions protected with passwords�� 4 different levels: End4 different levels: End--user, Installer, user, Installer, Burner manufacturer, L&SBurner manufacturer, L&S
�� UpUp--load and download and down--load functionality for load functionality for exchangeexchange
�� CommunicationCommunication
Actuator SQM45 / 48Actuator SQM45 / 48
�� High positioning accuracy High positioning accuracy over over the life time and torquethe life time and torque
�� Easy exchangeabilityEasy exchangeability�� Several torque ratingsSeveral torque ratings
�� 25 in. lb.25 in. lb.
�� 175 in. lb.175 in. lb.
�� 350 in. lb.350 in. lb.
QRI...QRI...
�� Infrared flame Infrared flame detector for gas detector for gas and oiland oil
�� Sensor and Sensor and amplifier are amplifier are integratedintegrated
�� Side or frontal Side or frontal scanningscanning
�� Flame signal Flame signal shown on AZL shown on AZL displaydisplay
Parallel PositioningParallel Positioning
Sales ToolsSales ToolsRun
Efficiency calculator can help you sell the customer on fuel savings.
Parallel PositioningParallel Positioning
Possible ApplicationPossible Application
� Hospitals / large health care facilities
� Schools / Institutions
� Prisons
� Federal and State Buildings
� Industrial Steam Generation plants
� Process applications
� Best return on investments for large industrial user
� Any applications that have varying loads
� <20 PPM Low NOx applications
� HTD applications with single fuel and especially on dual fuel
The next optimization stepThe next optimization step……
A burner conversion on A burner conversion on your existing boiler, or the your existing boiler, or the
specification of a specification of a currentcurrent””statestate--ofof--thethe--artart””burner on your new boilerburner on your new boiler
But how are new burners But how are new burners differentdifferent
Integrated burners by the boiler manufacturer…….
• Modulating firing with VFD and air/gas ratio valve
•Maintains same efficiency at all operating points
•Safety and ease of set-up using integral linear air/gas valves (negative ratio)
•Usually not available as a retrofit to other boiler manufacturers
What can new burners do for What can new burners do for meme…………
�� Provide significant fuel savings through better Provide significant fuel savings through better control of combustioncontrol of combustion
�� Provide for reduced emissionsProvide for reduced emissions
�� Offer much better servicabilityOffer much better servicability
�� Run at much more quiet sound levelsRun at much more quiet sound levels
�� Provide for more repeatable operationProvide for more repeatable operation
�� Increase turndown while maintaining incredibly Increase turndown while maintaining incredibly good combustion performancegood combustion performance
�� Enhanced communication ability to DDC systemsEnhanced communication ability to DDC systems
Typical Traditional Burners By:Typical Traditional Burners By:
�� PowerflamePowerflame
�� WebsterWebster
�� RielloRiello
�� WeishauptWeishaupt
Powerflame CPowerflame CMAXMAX BurnerBurner
�� Introduced in 2004Introduced in 2004
�� Over 500 burners sold (All Over 500 burners sold (All Applications)Applications)
�� Capacities from 12 MMBH to Capacities from 12 MMBH to 95 MMBH95 MMBH
�� Fires all gaseous fuels, light Fires all gaseous fuels, light & heavy oil& heavy oil
�� Sub 60 PPM NOx without Sub 60 PPM NOx without IFGR on Natural GasIFGR on Natural Gas
�� Sub 30 PPM with IFGRSub 30 PPM with IFGR
�� Sub 20 PPM on water tubeSub 20 PPM on water tube
�� Energy efficient Energy efficient -- reduced reduced blower motor HPblower motor HP
�� Heavy duty constructionHeavy duty construction
Webster HDRMBWebster HDRMB
RielloRiello
WeishauptWeishaupt
Weishaupt Head DetailWeishaupt Head Detail
New non-traditional burner designs such as:
Ceramic infrared / radiant burner
- Extended warranties
- Minimal moving
parts
- Minimal service
- Ultra low NOx
Alzeda TechnologyAlzeda Technology
PREMIXED SURFACEPREMIXED SURFACE--STABILIZED STABILIZED
COMBUSTIONCOMBUSTION
�� Fully preFully pre--mixed design similar to what we mixed design similar to what we
see on todaysee on today’’s condensing boilers but s condensing boilers but
available for retrofitavailable for retrofit
�� UltraUltra--low NOx of 12 ppm, 9 ppm or even low NOx of 12 ppm, 9 ppm or even
lower without FGRlower without FGR
�� Parallel positioning and fully metered fuelParallel positioning and fully metered fuel--air air
ratio controlratio control available as optionavailable as option
Burners Burners -- Communications Communications –– Major Major
AdvancesAdvances
�� Ability to gather and transmit incredible amounts of Ability to gather and transmit incredible amounts of
datadata
�� Integrated multi boiler and systems controlIntegrated multi boiler and systems control
�� Interface to building management systemsInterface to building management systems
�� Wireless / Smartphone monitoring and controlWireless / Smartphone monitoring and control
QUESTIONS QUESTIONS –– THOUGHTS THOUGHTS ––
COMMENTS ?COMMENTS ?
Thank You For The Opportunity Thank You For The Opportunity
and Good Luck With Your Boiler and Good Luck With Your Boiler
Systems !!Systems !!