CT556 Boiler Efficiency Modern Controls for Package Boiler Operations Marc L Hunter Vice President 25 & 26 March 2015 PUBLIC www.rockwellautomation.com www.us.endress.com
2 Agenda Boiler Operations Overview Sub-Systems Solution Return on Investment Calculation Support Conclusion
Synergy Process, Combustion, & DCS PUBLIC 3
Boiler Overview PUBLIC 4
5 Fuel System Synergy has experience with solid, liquid, gaseous, and alternative fuel sources New fuels are being explored by business management Current fuel valve train not in compliance with NFPA 85 Valve train components mechanical failures Replace valve train as total assembly Work with new/modern components Convert fuel type
6 Burner Management System Synergy has decades of experience working with BMS and compliance with NFPA 85/86 standards, along with representation on NFPA 85 committees Risk Management and insurance evaluation questions safety system compliance Current system gives false trips Current system doesn t trip appropriately Simple BMS replacement Error checking BMS SIL2 Level BMS SIL3 Level BMS
7 Combustion Air Fan Most combustion air applications are set up with dampers and full speed motor driving your car with gas pedal to the floor and speed control with brakes. Boiler cannot turn down to firing rate that is plant demand Boiler doesn t ramp quickly enough Issues with burner pulsing/drumming Variable Frequency Drive Cascaded with damper actuation Flue Gas Recirculation intake
8 Burner Burners are the most critical design component within combustion systems for complete combustion and reduction in emissions Burner(s) mechanically degraded due to over firing Burner(s) not able to fire in low range without furnace rumble Burner(s) not capable of adequate mixing for low NOx requirements Burner replacement Flue Gas Recirculation can be added for lower emissions Re-characterization of boiler is required
9 Combustion Control Combustion control strategy is the place to make the largest bottom line impact with controls only solution. Pneumatic Loops Single Loop controllers Fixed ratio with mechanical linkage (jack shaft) Modern controls provide ratio adjustment throughout the entire firing range for complete combustion Automation platform for boilers on same platform as production plant
Economizers are susceptible to quick corrosion especially in formation of acid and incorrect condensate handling Economizer Economizer implementation is the fastest return on investment that can be made typical returns on economizer can fund itself and controls upgrade Reduction in stack gas temperature directly improves the total system efficiency Reduction in stack gas temperature also will reduce CO2 emissions PUBLIC 10
11 Water System Water treatment is critical to maintaining tube life and the highest consumable cost in the entire operation of the boiler plant Water quality is unknown or over-treated with expensive chemicals Can boiler operation be switched from a continuous blow down to an on-demand automated process Monitoring/integration of water treatment process Tracking of chemical cost into the steam production cost Monitor blow down flow quantities Reclaim condensate
12 Emissions Emissions controls on combustion account for the largest capital spending in recent years. Different technologies exist for dealing with stack emissions what technology is correct Current stack analytics are broken, out of date, or out of calibration Replace Oxygen and Total Combustibles analytics and tie into control scheme Investigate/automate flue gas recirculation, urea injection, activated carbon injection or wet flue gas desulfurization technologies
13 Energy Usage The steam plant within a production facility can move from being overhead cost to a P/L center for business if the metrics are in place for operations to drive out inefficiencies Energy Usage custody transfer points are not measured steam flow and electricity at the production unit Steam plant operations staff overhead cost and don t qualify for capital spending Energy management plans are becoming the expectation Measurement is the first step to management
14 Synergy Evaluation w/ Pro Forma Analysis ENERGY PATRIOT PROGRAM Summary Report Energy Savings Project Overview Project name: Sample Project Project Mngr: Marc L. Hunter Project sponsor: Joe DeRoches Phone: 888-888-8585 Reviewed by: Marc L. Hunter Date of request: 1/31/2013 Email: joe@comcast.net Client Name: YYZ Incorporated Client Address: 123 State Street West Chicago Energy Audit Contents Improved Turndown Water Pump Return Economizer Implementation Fan Return Controls Implementation Energy Distribution Provider Rebate Cash Flow and Return on Investment statement BENEFIT DRIVERS YEAR 1 2 3 4 5 Greater margin driven by higher production capacity $0 $0 $0 $0 $0 Improved cycle time benefits: Reduced energy cost $515,908 $515,908 $515,908 $515,908 $515,908 Reduced labor cost 0 0 0 0 0 Fewer accidents, resulting in less workers' compensation 0 0 0 0 0 Improved quality benefits: Fewer defects, resulting in less 0 0 0 0 0 Fewer customer returns, 0 0 0 0 0 Reduced time spent handling 0 0 0 0 0 Total annual benefits $515,908 $515,908 $515,908 $515,908 $515,908 Implementation filter 90% 90% 95% 95% 95% Total benefits realized $464,317 $464,317 $490,112 $490,112 $490,112 Costs Year 1 Year 2 Year 3 Year 4 Year 5 Capital Outlay $787,510 $27,200 $27,200 $27,200 $27,200 Energy Distribution Provider Rebate (50% of energy saved up to $0.5MM) $0 $0 $0 $0 $0 Total $787,510 $27,200 $27,200 $27,200 $27,200 Benefits Year 1 Year 2 Year 3 Year 4 Year 5 Annual benefit flow (323,193) 437,117 462,912 462,912 462,912 Cumulative benefit flow (323,193) 113,924 576,836 1,039,748 462,912 Discounted benefit flow Year 1 Year 2 Year 3 Year 4 Year 5 Discounted costs 684,791 20,567 17,884 15,552 13,523 Discounted benefits 464,317 351,090 322,257 280,223 243,672 Total discounted benefit flow (220,474) 330,523 304,372 264,672 230,149 Total cumulative discounted benefit flow (220,474) 110,049 414,421 679,093 909,242 Initial investment Year 1 Year 2 Year 3 Year 4 Year 5 Capitalized Costs 210,010 0 0 0 0 Engineering Services 235,000 0 0 0 0 Installation Services 285,000 0 0 0 0 Training and Documentation Costs 57,500 0 0 0 0 Technical Support and Maintenance 0 27,200 27,200 27,200 27,200 Total costs $787,510 $27,200 $27,200 $27,200 $27,200 ROI measures Cost of capital 15% Net present value $711,309 Return on investment 50% 93% 129% 129% Payback (in years) 0.74
Synergy Values: Safety, Reliability, Efficiency PUBLIC www.rockwellautomation.com www.us.endress.com