APEM Fall 2011 Forum

High Efficiency Burners and Linkageless Combustion Controls

Presented By: Mechanical Sales, Inc. Peter Larro and Barry Jostol

Topics well discuss..

Optimization strategies using high efficiency burners and combustion controls Burners and burner controls options Linkageless Combustion Controls

In all cases, what are we trying to do.

Improve thermal or combustion efficiency to the best level available Maintain reliable operation Maintain absolute level of safety in operation Attempt to minimize maintenance requirements if possible Extend operational life of existing equipment

Perfect Combustion
Fuel (C, H2) Burner Air (O2,N ,N )) 22

CO2 N2 H2O

Complete Combustion by todays standards

Fuel (C, H2) Burner Air (O2,N ,N )) 22 CO2 CO (< 50 PPM)

NO (as low as possible) H2O O2 (as low as 3%)

16 14
% By Vloume in dry flue gas

Stoichiometric

12 10 8 6 4 2 0
Fuel Rich %CO %O2 %CO2 %CO2

50

100

150

200
Excess Air

250

% Theoretical Air

O2 Effect 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 Where is the industry now ?

Microprocessor based, linkageless combustion controls, often utilizing VFDs on blower motors

Heres the type of system we are used to..

Modulating Burner With Single Point Positioning

Single modulating motor, driving fuel and air, through a system of mechanical linkages, user adjustable for fuel / air ratio control

Linkageless Controls..

Individual servo motors attached to fuel valves and air damper, no linkageinfinite adjustability parallel positioning

PARALLEL POSITIONING

LINKAGELESS BURNER CONTROL

What is Parallel Positioning

Parallel positioning is the use of multiple positioning motors to set the position of the fuel valves and air damper throughout the firing range. Traditional modulating burners use single point positioning. Using one motor and linkage to position the fuel valves and air damper.

Advantages of Parallel Positioning

No Hysterisis Accurate Characterization of Fuel/Air Ratio Optimal Firing of Each Fuel Accurate Control of Firing Rate Tamper-resistant Burner Settings Remote Monitoring of Burner Performance

Typical Fuel Curve

Parallel Positioning
60

Air

50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 80 90 Fuel/Air

Fuel

Many manufacturers now sell linkageless controls.

Corporation -Fireye Nexus system -Honeywell -Autoflame MM Controls -Custom systems locally

-Siemans

Do they work well and are they reliable ?

YES Most burner manufacturers are going to linkageless as their standard Reliability is very good, systems work as they should Case studies have shown fuel savings to as much as 20% with the addition of linkageless control strategies Serviceability of the burner improves

Linkageless Control Systems also Provide

Full PID control of temp / pressure Setpoint by using temp / press transmitters Setpoint control accurate to within 2 PSI or +/- 2 F. Enhanced diagnostics, communications, data collection and remote monitoring and control

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 lockedon 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 In most cases.. YES !!

-Initial cost usually limits applicability to boilers above 100 HP for standard systems -Available as retrofit kits or as part of new equipment - Applicable to most forced draft burners -Even available now on residentially sized boilers

Major Manufacturers Include:

Honeywell Control Links Fireye Nexus Siemens LMV Autoflame MM

HONEYWELL

4-20mA Firing Rate Control Limits & Operating Control

WIN 95

Fuel Oil
Limits

Natural Gas

-- The Application -Fuel Air Ratio Control System

Q7999A Wiring Subbase

Panel mount wiring subbase 40 terminal wiring subbase Short circuit proof terminals 7 terminal grounding strip Line Voltage & Low Voltage wiring separation

R7999 Controller

Different size terminal pins prevents improper mounting on wiring subbase

Terminals accessible for troubleshooting

R7999 Controller
Two Model Numbers :
-- R7999A 100 to 120Vac, +10% -15%, 50/60 Hz -- R7999B 200 to 240Vac, +10% -15%, 50/60 Hz

Operating Temperature :
- 40F to +140F

Four Channel Output Control :

-- Two Fuels -- Combustion Air -- Flue Gas Re-circulation

R7999 Controller
Two Independent Fuel Profiles 7 to 24 Point Profiles Floating Control Output
- (950 Positions)

Programmable Positioning for :

- Standby - Purge - Non-Selected Fuel - Light Off - Minimum Modulation

Auto / Manual Firing Rate Input

R7999 Controller
Fast Burner Setup via PC or Laptop Step by Step, Menu Driven Commissioning Process File Backup of Commissioning Data Diagnostic / Historical Data Password Protected Remote Reset Capability Alarm Output

R7999 Controller
Configurable Sensor Interface (4-20mA):
- Low Fire Hold - FGR Hold - FGR & Low Fire Hold

Dynamic Safety Checks:

- Fail Safe Potentiometer Checks - Anti Swap of Actuators - Curve Tracking Tests

Maximum Modulation Limit Input Global Approval Body Compliant

Universal Parallel Positioning Actuator

External Indication of Position

ML7999

Floating Control Input I.D. Number Protected Power Indicator Operating Temperature:
- 40F to +140F

Universal Power Input:

100 to 240Vac, +10%, -15%, 50/60Hz

Universal Parallel Positioning Actuator

ML7999
Direct Coupled Output High Torque & Fast Speed:
100 in. lb., 30 Sec, 95 Stroke

Compact Size NEMA 3 / IP54

- Requires Weatherproofing Kit

Honeywell S7999
Honeywell S7999 Controlinks Display and 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 See Sales Release # 610 Flush mounts on panel

R7999 - System Setup

Install Commissioning Software ZM7999A
3 conductor shielded cable RS485 to RS232 converter
WIN 95

Activate & Setup ZM7999A Define Burner System Parameters Establish End Points Configure Profile Curve Verify (walk) the Profile Curve Save the Profile Curve

FIREYE

Nexus Overview
Remote Station Servo Motors Controller and Base

Flame Scanner MMI/ Display

Controller
NX 3000 / 4000 Contains the CPU and PSU Boards LED Indication of Status/Fault Condition Auto, Boiler Status, Pre-Purge, Ignition, Normal Run, Flame, Air Pressure, Fault

Nexus 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 or Valve Gas Pressure Test Proving Sequence Available

Nexus Combustion Control

Parallel Positioning Individual Servo Positioning Motors Drive 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 Base

Wiring Module NX1386, NX1466 Two Versions : Open and Enclosed UL & UL Recognized Contains Terminal Strips Main Fuse Voltage Selection Links Pressure / Temperature Selection Links Potentiometer Voltage Selection Links RS485 Communications Selection Link

Nexus MMI / Display

Display NX550 Two Line 20 Character Vacuum Fluorescent Display Key Pad w/ Multi Purpose Keys Engineers Key

Nexus Servo Motors

Three Servo Configurations 36 in. lbs. 4 Nm 180 in. lbs. 20Nm 420 in. lbs. 50Nm

Nexus Servo Motor Requirements

Servo Motor Control Type of Motor - AC Up/Down with Feedback Potentiometer Number of Motors - 3 or 4 Depending on Controller 24 Setpoints per Profile Position Accuracy 0.1 Response time to Positioning Error 15s for +/- 1.0 1s for +/- 5.0 Number of Fuel Motors 1 or 2 Number of Air Motors 1 or 2

Optional Equipment
Pressure Sensors Temperature Sensor Sequencing Communication Software O2 Trim

AUTOFLAME

AUTOFLAME FEATURES
Fuel/Air Ratio Controller
Controls Servo Motors for up to 3 Fuels P.I.D. Load Controller Intelligent Boiler Sequencing Computer Compatible

Exhaust Gas Analysis

3 Parameter Trim of O2, CO, CO2 Displays O2, CO, CO2, Efficiency, Exhaust Temp (NO and SO are optional)

M.M./E.G.A. Technical Manual Mini M.M. Facia

AUTOFLAME

Multiple Systems Options

MM Mark Series Mini Mark V Two fuel channels and FGR Mark VI Evolution Six dedicated channels Mini Mark VII Three channels two fuel and one VFD Mark VII Evolution Six dedicated channels four fuels and two VFD

AUTOFLAME MK.6 FEATURES

4 Fuel Curves Integral Flame Safeguard Gas and Oil Pressure Supervision Combustion Air Supervision Integral VFD Interface Quarter VGA Screen

M.M./E.G.A. Technical Manual

AUTOFLAME

Optional Exhaust Gas Analyzer

Use of an exhaust-gas analyzer expands the benefits of linkageless combustion control. An exhaust-gas analyzer measures and displays O2, CO2, carbonmonoxide (CO), nitric-oxide (NO), nitrogen-dioxide (NO2), NOx, and sulfur-dioxide (SO2) exhaust temperature and combustion efficiency. An exhaustgas analyzer's built-in continuous-emissions-monitoring software monitors instantaneous and totalized emission output for each fuel as a weight (cubic feet) and mass (pounds or tons). Because of the software, data collected from the exhaust-gas analyzer can be submitted as an emissions report for a boiler and/or plant annually, quarterly, or monthly.

Data Transfer and Communications

M.M./E.G.A. Technical Manual

AUTOFLAME

Siemens

LMV51 Application
Dual-fuel burner
V1

LMV Basic Unit

Real dual fuel burner control Separate inputs and outputs for oil and gas Adjustable timing and programming Configurable inputs and outputs Continuous operation with IR detection

Gas valve proving system

Flexible test timing No additional wiring Only one additional pressure switch Accuracy via timing adjustable Detectable which valve is leaking Sequence for the test adjustable (pre purge, post purge or during both phases)

Electronic air / fuel ratio control

Easy wiring of the actuators Easy adjustment of the burner Ignition position independent of the curves High adjustment accuracy Up to 4 actuators: air, 2 x fuel, auxiliary

AZL
Programming Burner control Electronic air/fuel ratio control Gas valve proofing Load controller Display burner operation Diagnosis Interface communication

Display and programming unit (AZL)

Separate housing removable Easy menu structure Clear text display (4 x 16 characters) 3 languages / other languages possible Functions protected with passwords 4 different levels: End-user, Installer, Burner manufacturer, L&S Up-load and down-load functionality for exchange Communication

Actuator SQM45 / 48
High positioning accuracy over the life time and torque Easy exchangeability Several torque ratings
25 in. lb. 175 in. lb. 350 in. lb.

QRI...
Infrared flame detector for gas and oil Sensor and amplifier are integrated Side or frontal scanning Flame signal shown on AZL display

Parallel Positioning Sales Tools

Run

Efficiency calculator can help you sell the customer on fuel savings.

Parallel Positioning Possible 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 step

A burner conversion on your existing boiler, or the specification of a currentstate-of-the-art burner on your new boiler But how are new burners different

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 me

Provide significant fuel savings through better control of combustion Provide for reduced emissions Offer much better servicability Run at much more quiet sound levels Provide for more repeatable operation Increase turndown while maintaining incredibly good combustion performance Enhanced communication ability to DDC systems

Typical Traditional Burners By:

Powerflame Webster Riello Weishaupt

Powerflame CMAX Burner

Introduced in 2004 Over 500 burners sold (All Applications) Capacities from 12 MMBH to 95 MMBH Fires all gaseous fuels, light & heavy oil Sub 60 PPM NOx without IFGR on Natural Gas Sub 30 PPM with IFGR Sub 20 PPM on water tube Energy efficient - reduced blower motor HP Heavy duty construction

Webster HDRMB

Riello

Weishaupt

Weishaupt Head Detail

New non-traditional burner designs such as: Ceramic infrared / radiant burner
- Extended warranties - Minimal moving parts - Minimal service - Ultra low NOx

Alzeda Technology

PREMIXED SURFACE-STABILIZED COMBUSTION

Fully pre-mixed design similar to what we see on todays condensing boilers but available for retrofit Ultra-low NOx of 12 ppm, 9 ppm or even lower without FGR Parallel positioning and fully metered fuel-air ratio control available as option

Burners - Communications Major Advances

Ability to gather and transmit incredible amounts of data Integrated multi boiler and systems control Interface to building management systems Wireless / Smartphone monitoring and control

QUESTIONS THOUGHTS COMMENTS ?

Thank You For The Opportunity and Good Luck With Your Boiler Systems !!