TS BurnerMate TS Overview. TS Overview q Introduction q Components q Control Strategies q Auxiliary Controllers / Flame Safeguard q SCADA System Integration.
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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
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