Energy Saving Solutions. Bob Montgomery Technical Solutions Specialist Waterloo Manufacturing

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1 Energy Saving Solutions Bob Montgomery Technical Solutions Specialist Waterloo Manufacturing

2 Combustion Efficiency Measure Heat Recovery Energy Saving Solutions Upgrade Repair Replace Audits Financial Assistance

3 Fuel Costs Boiler Size Fuel cost/yr ($) (HP) 50% FR/12 hrs day 100% FR/24 hrs day 300 $ 334,934 $ 1,339, $ 446,580 $ 1,786, $ 558,225 $ 2,232, $ 669,871 $ 2,679, $ 781,516 $ 3,126, $ 893,160 $ 3,572, $ 1,004,805 $ 4,019, $ 1,116,450 $ $12.49/MM BTU 600 HP boiler can save $6000-$26,000 for EVERY 1% change in efficiency Every year! 3 3

4 Emissions Greenhouse effect Gases that reduce heat loss into space Water vapor Carbon dioxide Methane Nitrous oxide Ozone Carbon footprint A measure of the impact human activities have on the environment in terms greenhouse gases, in units of CO HP boiler can reduce CO 2 emission by tons/yr for every 1% change in efficiency

5 Boiler vs. System Efficiency Boiler efficiency Typically 75-83% Fuel to steam method System Typically 60-80% No standardized method System Efficiency allows 20-40% improvement!

6 Energy Saving Solutions Opportunities Off the shelf solutions Combustion Parallel positioning O2 trim VSD / VFD High turn down burners Stack dampers 6

7 Energy Saving Solutions Opportunities Off the shelf solutions Heat Reclamation Economizers Blow down heat recovery 7

8 Energy Saving Solutions Off the shelf solutions Opportunities System Efficiency Lead Lag (steam) Condensing boilers (Hot Water) Hybrid Hydronic Systems (Hot Water) 8

9 Energy Saving Solutions Opportunities Off the shelf solutions Measure, Analyze, Perform, Predict Communications Data Logging Report Generation 9

10 Energy Saving Solutions Thought Starters Think outside the box Application of existing technologies in new roles Training 10

11 Energy Saving Solutions Parallel Positioning Otherwise known as Linkageless Control Replaces Jack shaft or single point positioning to reduce or eliminate linkages and improve repeatability Available for use on almost any boiler Multiple fuels, FGR and input air control Typical 3% savings 11

12 Control Linkages

13 Control Linkages AIR CONTROL DAMPER FUEL AIR CONTROL DRIVE MOTOR HYSTERESIS FUEL CONTROL VALVE

14 Control Linkages AIR CONTROL DAMPER FUEL AIR CONTROL DRIVE MOVES 5 TOWARD HIGHER FIRING RATE 5 AIR CONTROL DAMPER MOVES OPEN 5 FUEL CONTROL VALVE REMAINS IN SAME POSITION BECAUSE OF HYSTERESIS HYSTERESIS 5 BURNER OPERATES WITH LEAN MIXTURE

15 Control Linkages AIR CONTROL DAMPER 5 HYSTERESIS FUEL AIR CONTROL DRIVE MOVES 5 TOWARD LOWER FIRING RATE AIR CONTROL DAMPER MOVES CLOSED 5 FUEL CONTROL VALVE REMAINS IN SAME POSITION BECAUSE OF HYSTERESIS 5 BURNER OPERATES WITH RICH MIXTURE

16 16 Firing Rate Signal From Boiler Controls Fuel Air Ratio Controller Parallel Positioning Independent Control of Air Dampers and Fuel Valves with Servo Motors eliminates hysteresis & has greater repeatability Fuel Valves Shielded Cable Servo Servo Servo FGR Valve (If Used) Combustion Air Fan Damper

17 17 Stand Alone Fuel Air Ratio Control Provides Parallel Positioning of Fuel Valves And Combustion Air Dampers Communicates through BMC Programmable Firing Rate Modulation Set Points Full visual performance on PC or operator interface Works Independently or with other boiler control systems on new or retrofit applications

18 18 Same features but is integrated into the same controller that provides firing rate, safety, O2 trim, VFD etc. providing a cohesive control package Integrated Fuel Air Ratio Control

19 Fuel Air Ratio Control 19

20 Energy Savings Solutions O2 Trim Available stand alone or integrated packages Automatically adjusts air damper, VFD, or Fuel valve to trim O2 content in exhaust (flue gas) Available for use on almost any boiler Primarily used on Natural Gas, limitations on some fuel types due to possible fouling of the sensor or sensing lines Typical 1% savings 20

21 21 Why do you want to trim to a specific O2 level Fuel Savings Too much air results in high heat losses due to increase in flue gas volume. Not enough combustion air leads to incomplete combustion and decrease in boiler efficiency Burner setting will remain at optimum only if burner operating conditions are exactly the same as at the time of burner set up. Fuel quality, (i.e. heating value and specific gravity) Combustion air quality, (i.e. temperature, barometric pressure, and temperature) Oxygen trim provides compensation for these variances and keeps fuel air ratio at the optimum setting. This results in optimum combustion regardless of changes in combustion air which in turn maintains boiler efficiency that translates to typically 1% fuel savings.

22 22 O2 Trim Savings Example of estimated savings with O2 Trim Assume the following Boiler load 75% of maximum. Hours of operation 8000 Hours/Year Fuel Natural Gas Fuel Cost 1 $/therm Boiler Size Efficiency without O2 Trim % Efficiency with O2 Trim % Fuel Cost without O2 Trim $/Year Fuel Cost with O2 Trim $/Year Annual Savings $/Year $1,016, $1,001, $15, $1,270, $1,253, $17, $1,524, $1,505, $19, $1,778, $1,756, $22, $2,032, $2,007, $25,379.15

23 Energy Savings Solutions Variable Frequency Drive Used to vary the speed of the combustion fan and or pumps Cubic relationship between change of speed and savings. For example, a change in speed from 60 Hz to 45 Hz is a reduction of 25%, through the cubic relationship, that translates to a 42% reduction in energy (kw/hr) used. BUT there are limitations. 23

24 VFD Process Relationship Motor speed and output for a device like a conveyor is a linear relationship. VFD Driven Pump Curve Motor speed and pump output are not. VFD Driven Power Curve 24 24

25 VSD ROI Things to remember Energy savings will accumulate year after year and will increase as the cost of electricity continues to increase. Include in your kwh cost, delivery and demand charges. Check with your electricity provider and government agencies for rebates and incentives The soft start function reduces mechanical shock on pumps and downstream plumbing as well as avoiding peak demand charges. VFD control provides precise pressure and flow control for a more stable system. BUT we have to maintain a static pressure which limits how slow we can run the blower or pump. On a multi-pump common discharge header system, pumps can lead lag as required and all running pumps run in unison to be able to run at as low a speed as possible to maximize savings

26 Packaged Drive Wiring with 3 contactor bypass 26

27 Packaged Drive Panel Layout 27

28 VSD Free Air vrs Packaged Drives 28

29 Energy Savings Solutions High Turndown / Efficiency Burners Advances in burner design and controls have produced new generations of burners with increased efficiency and lower emissions One of these benefits can be a Higher turndown which prevents short cycling and heat losses due to post and pre-purge events. Another is standing pilot or revert to pilot which avoids post and pre-purge by reverting back to pilot after a boiler has reached low fire. Not only do you avoid those purge losses, you also have a much faster response time when load picks back up 29

30 New Mantle Technologies Capable of single digit NOx and CO emissions Natural and LP gas Digester gas as secondary fuel is possible No oil fire capabilities Typical combustion savings on a retrofit design is between 3-5%

31 Stack Dampers Energy Savings Solutions Draft Control improves flame stability by maintaining optimum furnace pressure and improves boiler efficiency by reducing heat loss after boiler shutdown by automatically closing the outlet damper. This type control is ideal in systems where multiple boilers share a common stack and outlet ductwork, or in a single boiler application with high natural draft. 31

32 Heat Recovery Heat Recovery Product Types Economizer Blowdown Heat Recovery 32

33 Heat Recovery Product Types Focus on (2) wasted energy sources Flue Gas Gas exiting the boiler to atmosphere via the stack Surface Blowdown Contaminates (i.e. dissolved solids and particles) on the water surface within the Boiler that must be discarded to effectively operate the boiler 33

34 Energy Savings Solutions Economizers 34

35 Features & Options

36 Applications Preheat Feedwater Increase Make-Up Water Temperature Hot Water Return Increase Heat another water source (Process Water) 1 Water Source or 2 Water Sources (2 Stage) Keys High Flue Gas Temperature Specific Applications / Fuels DON T Condense Continuous Water Flow through Economizer when boiler operational / residue heat present 4-13% gain in efficiency Equipment ROI months Heat Recovery Products Economizer 36

37 Economizer Type Standard (non condensing) Traditional approach to reduce fuel usage Sensible Heat recovery Condensing Latent Heat recovery Optimized Economizer / Optimized Boiler packages Combining Standard & Condensing Economizer into one package 37 37

38 Economizers Standard (non condensing) economizers Capture sensible heat Typically 100 F = 2.5% efficiency gain Outlet gas temp ~ 300 F Preheat boiler feed water 600 HP boiler saves $12,000 - $52,000 each and every year

39 Economizers Non-Condensing economizers How it works 200 F Economizer Cold liquid Deaerator Boiler 400 F

40 Sensible heat Latent vs. Sensible Heat Heat that can be detected by a change in the temperature of a system Latent heat Heat that cannot be detected because there is no change in temperature of the system. e.g. The heat that is used to melt ice or to evaporate water is latent heat

41 Economizers Condensing economizers Capture sensible heat Typically 100 F = 2.5% efficiency gain Outlet gas temp ~ 300 F Preheat boiler feed water Capture latent heat 980 BTU/lb of water Condensing occurs at <130 F Require cold liquid stream to condense Adds ~2.5-9% efficiency gain Total efficiency gain % 600 HP boiler saves $57,000 - $247,000 each and every year

42 Economizers Condensing economizers How it works 150 F Cold liquid Economizer 400 F Boiler

43 Economizers Two Stage Condensing Economizer Applications 1 st Stage Preheat Boiler Feedwater On/Off Feedwater Control Make-Up Water / Process Water Heating Hot Water Return 2 nd Stage Any Cool Liquid Stream ( F) Make-Up Water Process Water Wash Water Hot Water Preheating Rule of thumb: >25% MUW good condensing application 43

44 Economizers Condensing economizers How it works 150 F Deaerator Cold liquid Economizer Upper Coils Economizer Lower Coils Boiler 400 F 300 F

45 Economizers Optimized Boiler Package Condensing / optimized economizer applications Preheating boiler feed water Boiler Efficiency up to 90% 600 HP savings $66,000- $265,000 per year Preheating other liquids Boiler Efficiency up to 91% 600 HP savings $80,000-$321,000 per year Typical Applications Process water Wash/RO water Rule of thumb: >25% MUW good condensing application 45 45

46 Economizers Optimized Boiler Package

47 Economizers Optimized Boiler Package Optimized Package Both Condensing and Standard economizer combined How it works Cold make up 150 F Economizer Upper Coils 300 F Economizer Lower Coils Circulating Loop 400 F Deaerator Boiler Boiler Feedwater 47 47

48 Energy Savings Solutions Blowdown Heat Recovery Opportunities Flash Tanks Blow Down Heat Recover 48

49 Bottom blow TDS Control Blowdown Required TDS Control not recommended for heat recovery Boiler Water TDS Surface Blowdown Time - hrs Boiler Water TDS 49 Time - hrs

50 When to Use Blowdown Heat Recovery 50

51 Heat Recovery Products Blowdown Heat Recovery Utilize Wasted Surface Blowdown Energy 51

52 Heat Recovery Products Flash Tank Economizer Applications Increase Make-Up Water Temperature Use Flash Steam for Low Pressure use Keys Adequate MakeUp Flow Consistent Surface Blowdowns Equipment ROI months 52

53 Proportional HX Process Flow Diagram 53

54 Energy Savings Solutions Condensing Boilers Opportunities More efficient at lower firing rates and when in condensing mode. Pre-heat water going to boilers 54 54

55 Premix Gas Burner Condensing Boilers and New Tube technologies Optimized Heat Exchanger True Counter-Flow Arrangement EX Spiral Tubes SS AluFer Tubes

56 Communications Energy Savings Solutions How do I get from here to there and back? How can this be considered as Energy Saving? 56

57 More Than Just Controlling the Boiler Communications Protocol Translation for Seamless Building and Process Systems Integration Remote Monitoring Direct to PC or Web Based Web Server with Data Collection and Remote Alarm Enunciation Firetube Boiler Control Watertube Boiler Control Electric and Electrode Boiler Control DeAeration and Surge Tank Control

58 Data logging Systems Integration Supervisory Control Report Generation Response Time Communications Why? Remote Notification Remote Viewing Operational Analysis Predictive Maintenance Troubleshooting The Bottom Line

59 Communications Typical System Boiler 1 Ethernet HMI Ethernet Boiler 2 Ethernet HMI Ethernet Ethernet Port Cat 5 Ethernet Cable Ethernet Port Serial Port Serial Port Cat 5 Ethernet Cable Serial Cable 5 Port Hub Web Server, Lan/Wan, Internet , Remote Monitoring Cat 5 Ethernet Cable Ethernet I/P OPC BAS Dial Out Paging Modem Boiler 1 Dedicated Telephone Line Dial Out Paging Modem Boiler 2 Bacnet, Modbus, Lonworks, Johnson Metasys N2 BAS Protocol Translator Serial Cable

60 What if my equipment doesn t talk and I don t want to upgrade just for communications and data collection? Burner Management Analog Signals Data Concentrator Steam and Water Flow Gas Flow Oil Flow Web Server Modbus Comm End User Computer System Discrete Signals Temperature Switch Level Switch Manual Control Data concentrators or small PLC s can be used to hardwire to existing or additional controls and instrumentation to then log and share data.

61 What s next for the boiler room? Cloud Based Data Collection Corporate Headquarters Cloud Manager Cloud Platform Prod/Proc Designer 1 Prod/Proc Designer 2 Rep 1 Rep 2 Rep 3 Cloud Gateway Secure, smart efficient transfer of device data to the Cloud Platform Support Customer 1 Customer 2 Customer 3 Supplier 1 Supplier 2 Water Energy Waste Simple, Secure Access for key Stakeholders

62 Energy Saving Solutions Think outside the box Thought Starters Application of existing technologies in new roles Training 62

63 Energy Saving Solutions Training Opportunities Refresh and update operator skill sets Exposure to new and current technologies Energy Savings possible through more efficient utilization and operation of equipment 63

64 The Bottom Line New and Old equipment can have increased efficiency, lower emissions and communications capability added as retrofits. If the Bones are good, upgrading the controls or adding devices may allow you to take advantage of these technologies and increased savings.

65 BENEFITS Reduce steam and hot water generating costs. Reduce maintenance costs. Improve system reliability. Improve uptime and production quality. Improve safety. Reduce environmental footprint. Improve system intelligence. Improve information access locally and remotely.

66 Questions? Visit us on our Web Site at for more information 505 Dotzert Court Unit 1 Waterloo, Ontario - N2L 6A wmc5@watmfg.com