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BurnerMate TS Overview

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Overview

Introduction Components Control Strategies Auxiliary Controllers / Flame Safeguard SCADA System Integration Competitive Comparison Summary

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Introduction

The BurnerMate® TS is a combined boiler control, flame safeguard, and monitoring system with a touch screen operator interface.

BurnerMate is a full scope control package that assures safe and efficient control with undivided system integration responsibility.

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Preferred Instruments has 35 years of Combustion Control Experience with…

A Third Generation Digital Controller Over 3000 Boiler Control System Installations Over 2400 PCC II/III Controllers Installed

Exclusively in Combustion Control Applications Over 45 SCADA/Flex Projects 640 Rotary Cup Burner Projects

Experience

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BurnerMate TS Components

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10” Touch Screen Operator Interface

Accurate Servo Actuator

Integrated Oxygen Analyzer!

System Composition

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Touch Screen Operator Interface

Fully Integrated Touch Screen…

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Touch Screen Operator Interface

Monitor and control boiler operation, setpoints, and process data from one convenient display

Commissioning activities are laid out in an easy to follow step-by-step procedure, eliminating the need for knowledge of controller menus and programming languages

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Touch Screen Operator Interface

Alarm banner, Silence button, and Navigation

Auto/Manual Control

Real time boiler management data

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DCS-III Programmable Control

DCS-III Controller…

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DCS-III Programmable Control

The DCS-III is a state-of-the-art, boiler-focused programmable logic controller

The large I/O quantity, small sub-panel foot print, intuitive “Blockware”, redundant memories, and built-in industry standard communication allows the DCS-III to be integrated into complex boiler control systems with a minimum number of external components

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Easy Commissioning

The “Learn Mode” feature allows multiple F(x) block input vs. output profiles to be entered simultaneously with a push of a button!

“Store” button to simultaneously store the firing rate, oxygen and burner air flow rate value into the appropriate F(x) blocks

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BurnerMate TS

Advanced

Communication…

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Internet, Web Site Access

A standard WEB Browser provides remote monitoring and operation

Custom software is not required Historical Alarm and event data can be imported to

spreadsheet applications such as MS Excel

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Intranet Communication

The ethernet communication port is easily assigned an IP address and connected to a facility wide network

Remote monitoring, control and data collection is available via a standard WEB Browser

Building Automation Systems and SCADA Systems are interfaced via industry standard MODBUS Ethernet communication

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Integral Oxygen Analyzer

DCS-III with"Z" Option Board

190130Connecting Cable

ZP-xxOxygen Probe

Calibration Gas InputGrade Level Connection By Others

Power Supply

No separate analyzer, one less item to mount

Field replaceable probe

Only one conduit to stack.

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Proven Reliable Sensing element has been proven reliable in 100s

of installation over the last 10 years 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. Fully automatic calibration package available.

Integral Oxygen Analyzer

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Thick cell Avoids premature cell failures

Ceramic heater provides reliable long life

Complete detailed diagnostics Automatic impedance checking

Alarms when time to recalibrate Alarms when reaching end of cell life

Optional fuel gas temperature element T/C input

Integral Oxygen Analyzer

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BurnerMate TSControl Strategies

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Fully Metered System

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Fully Metered System

This control strategy with oxygen trim and variable speed fan control offers the best opportunity to save fuel and electrical cost with a control system upgrade

This strategy measures both the fuel flow and the combustion air flow

PID control is used for both fuel and air flow control, assuring the accurate maintenance of fuel and air flow setpoints

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Parallel Positioning System

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Parallel Positioning System

This control strategy includes up to five (5) servo channels, allowing independent control of fuel valves, air and fuel gas re-circulation dampers

The fuel-air ratio is established and adjusted by use of a “soft” function curve of fuel valve vs. damper position

Parallel positioning enables “tighter” fuel-air ratio control, which improves boiler efficiency

Combining this control method with oxygen trim and variable speed fan control offers substantial cost savings for a fast payback

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Single Point Positioning System

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Single Point Positioning System

This control strategy mechanically links the fuel valve, air and flue gas control dampers to a single actuator

Generally, the fuel valve has a characterizable flow versus position relationship that is used to establish the fuel-air ratio over the range of modulation

This method is recommended when the boiler size or service hours do not justify addition of a VSD

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BurnerMate TSAuxiliary Controller /

Flame Safeguard

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Integrated Auxiliary Controller

Draft Control – Stable & repeatable draft control is essential for efficient boiler operation. This is especially important for boilers with induced Flue Gas Recirculation (FGR) Nox reduction.

Feedwater Control – Single element, two element or three element feedwater control may be provided. Water column blowdown is prompted and logged to ensure proper maintenance.

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Features The Flame Safeguard System provides the proper burner

sequencing, ignition and flame monitoring protection on single burner, automatically ignited oil or gas fired boilers.

The system uses a fail-safe, “de-energize” to trip design. Upon the loss of system power the fuel safety shutoff valves are automatically closed and ignition components are de-energized.

Flame Safeguard

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Features (continued) On a safety shutdown, the message display will advise

the operator that the control is in “Lockout” and will indicate the specific cause and the state in the operating sequence where the shutdown occurred.

Proof of purge, low fire position interlocks, and fuel valve end switch safety checks are also included.

A drum level conductivity probe relay is incorporated for an auxiliary Low Water Cutout safety interlock.

Flame Safeguard

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BurnerMate TSSCADA System Integration

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Supervisory Control And Data Acquisition: Windows XP based workstations Programmable Controller based combustion

control hardware Up to 31 I/O per controller Touch Screen interface can be used as backup

control station if the workstation, or communication network breaks down

“Service Manual” mode can be used as backup control station if the Loop Controller fails

SCADA System

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Expanded Remote Systems

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Process Style Boiler Overview

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Flame Safeguard Overview

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Store Data for Analysis Later

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BurnerMate TSCompetitive Comparison

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Comparison

BurnerMate TS

Hawk ICS Comment

Basic Hardware

Boiler Front Display 10” Touch Screen 10” Touch Screen

Remote Monitoring Web Based RS-View BurnerMate offers true “plug and play” remote operation and monitoring via a standard web browser

Fuel-Air Ratio Control (Parallel Positioning)

DCS-III Controller Allen Bradley Control Logixs

Hawk system requires the fuel air ratio to be controlled by a separate Honeywell control product for some Parallel Positioning control systems

Flame Safeguard Honeywell or Fireye

Honeywell

Flue Gas Oxygen Trim with Sensor

YES YES

Operator Interface

Boiler Overview YES YES

Alarm / Event Summary Display

YES YES

Burner Hours/Cycles YES YES

Efficiency Calculation based using ASME “By Losses” Method

YES YES

Real Time & Historical Trending

YES NO Easy to use multiple pen charts allow quick system assessment and maintenance monitoring.

Real Time X/Y Plots YES NO

BurnerMate x/y plots graphically display fuel vs. air curve data for intuitive burner setup and to store commissioning data into multiple characterizer curves for a particular load point.

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Comparison

BurnerMate TS

Hawk ICS Comment

Hardware Options

Shipped Loose for Field Installation

YES NO

This is a major advantage when field

upgrading obsolete existing equipment

6 inch Color Display

Optional Optional

Expansion and connection to existing Equipment

Optional NO BurnerMate TS may be integrated with existing Preferred, Fireye or Honeywell

equipment

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Comparison

BurnerMate TS

Hawk ICS

Comment

Controller

Redundant Memory Module, “Hot stand by”

YES NO

Plug In Configuration Memory Module is useful for copying, transferring applications from first to second boiler and service as a level of redundancy in the event of a memory corruption.

Integrated Flue Gas Oxygen Transmitter

Qty: 1 to 2 NO

The BurnerMate TS uses an integrated flue gas oxygen analyzer, separate analyzer electronics is not required. All analyzer status and diagnostic information is available to touch screen and web based monitoring

Analog Inputs YES YES 4-20mAdc/ Thermocouple Analog Outputs

YES YES 4-20mAdc

Discrete Inputs,

YES YES 120Vac

Relay Outputs YES YES

Triac Outputs

YES NONE

BurnerMate Triac outputs allow direct control of electric servo actuators. The Hawk ICS uses standard solid state relay outputs that cause low mean time between failures.

Special Features

Thermal Shock Protection YES YES Economizer Monitoring Optional Optional

Fuel Flow metering Optional Optional

Level Control / Monitoring Optional Optional BurnerMate offers one, two & three element feedwater control as standard options

Draft Control Optional NO Standard BurnerMate Option

Opacity Monitoring JC-30D NO JC30D has unique Auto Cal, Lowest Cost instrument available

Custom Engineering and field support

Optional Optional

Preferred has a company focus on boiler control systems. This focus backs each product and project by an experienced staff of boiler control application, field service and sales people. Preferred offers 24 hours a day/ seven day a week expert support.

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Comparison

BurnerMate TS

Hawk ICS Comment

Modulating Lead/Lag Optional Optional

Number of Boilers Chief Dispatcher

2 to 10 2 to 8

Preferred offers flexible and unique Lead/Lag Sequences that meet individual plant requirements.

Hardwired control switches and lights

YES NO Important feature that provides ease of use to every type of operator.

Warm Standby

YES YES

Outdoor Reset

YES YES

Setback, day, week and holidays

YES NO

Domestic Hot Water Priority

YES NO

“Smart” Sequencing

YES NO Both “LIMITS” and “LOCKOUT” conditions are monitored. Sequencing is fast and efficient.

Blend Valve Control

YES NO True thermal shock protection. Cold return water is blended with boiler outlet water to prevent unnecessary boiler wear.

Condensing Boiler Logic

YES NO

Independent primary Pump Control

YES NO

Header Pump Control

YES NO

Secondary Pump VSD Control

YES NO

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Summary

BurnerMate TS has…. Integrated fuel-air ratio, flame safeguard,

draft, and feedwater controls Single Point Positioning, Parallel

Positioning, and Fully Metered Combustion Control

Single or Dual Fuel Flame Safeguard with easy trouble shooting.

Low Cost Full Scope Package.

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Preferred Utilities Manufacturing Corp

Preferred Utilities Manufacturing Corporation31-35 South St. • Danbury • CT

T: (203) 743-6741 • F: (203) 798-7313www.preferred-mfg.com