Energy Savings: Improving the Energy Efficiency of Steam Boilers, Heating Boilers, Hot Water Heaters and Emissions Reporting

1. CCM Energy Solutions
Uncompromising Excellence in Boiler Room Solutions
Energy Savings: Improving the Energy Efficiency of
Steam Boilers, Heating Boilers, Hot Water Heaters and
Emissions Reporting
Tuesday 4th April, Sydney

2. Company Introduction
Full service boiler room solutions
Boiler room energy audit
Gas & emissions measurement
Data logging & analysis
Proposal, solutions, ROI, NPV calculations
Retrofit applications
Project management
Engineering design
CAD drawings
Complete after-sales service and on-going technical support
Installation, set-up and commissioning support
Staff training
Project reports & analysis
Measurement & verification studies

3. Company Aims
Boiler
Room
Solutions
Fuel
Savings
Greenhouse
Gas
Reductions
Reduced
Maintenance
Costs
Utility Cost
Savings
Overall Plant
Efficiency
Safety &
Reliability
Government
Reporting
Standards

4. Energy Efficiency
Distribute a range of energy efficient technologies
Heating boiler optimisation units (Sabien)
100kW to 2MW
High efficiency burners for hot water and steam (Limpsfield)
220kW to 62MW
Combustion management control systems (Autoflame)
1MW to 62MW
Exhaust gas analysis systems (Autoflame)
Emissions monitoring & logging software (CEMS)
Steam boiler controls (Autoflame)
Technical expertise

5. Limpsfield Burners - Overview

6. Limpsfield Burners - Overview
High efficiency burner range
Low O2 levels (typically 2-3% throughout the range)
Low CO production (sub 10ppm at low O2 levels)
High turndown- at least 6:1
Reduced fuel consumption (typically over 10%)
Improved combustion & thermal efficiency
Improved fuel to steam/heat efficiency
Reduced Greenhouse Gas Emissions (GHG’s)
Lower excess air levels (sub 15%)
Reduced maintenance requirements & operating costs
Improved reliability
Fewer moving parts

7. Limpsfield Burners - Overview
Range from 220kW – 62MW (0.75-106MBtu/hr)
Fuels that can be fired:
Gases- natural gas, LPG, LNG, hydrogen, biogas
Oils- (light to heavy), biofuels, animal fats and by-products, solvents
Dual fuel / multi-fuel applications
Low NOx applications (sub 30ppm or sub 9ppm)
Pre-heat air applications (up to 2800C)
Fuel inlets on both sides of burner housing offering build flexibility to
suit each application
Unique large rear viewing port enabling a clear view of the
combustion process for commissioning, service and maintenance
Simple construction allows easy access to internal components- all
components can be accessed and replaced without the need to
remove the burner from the boiler front

8. Limpsfield- 2MW Natural Gas

9. Case Study- NT Hospital
Mechanical linkage based system
Inefficient and costly
Difficult to maintain and service
Limpsfield LCNO36
Dual fuel (LPG and diesel)
Efficient and economic
Significant reductions in:
Diesel oil usage
CO2 emissions
Electrical consumption

10. Case Study- NT Hospital
Fuel savings of 12.1%, with an annual diesel saving of 125,000 litres
Annual CO2 reduction of 460 tonnes
Electrical consumption reduction of 50,500kWh

11. Autoflame- Overview

12. SWITCH
BOILER
DRAFT
FORCED
MOD. MOTOR
U.V
OIL
AIR
PRESSURE
GAS
FLUE
FLAME
SAFEGUARD
PRESSURE
CONTROL
P.I.D.
CONTROLLER
Pre-Installation Set-Up

13. SENSOR SERVO
SECOND SETPOINTFACILITY
EXTERNALMODULATION
SWITCH
EXTERNAL
BOILER
DRIVECH.5
SPEED
VARIABLE FLAMEOR
DRAFT
FORCED
AUX.
SERVO
CH.4
AIR AUX.
SERVOSERVO
CH.3CH.2
U.V
LOAD OR
OIL
AIR
PRESSURE
PRESSURE
SENSOR
OIL
CH.1
FUEL
PRESSURE
SENSOR
GAS
GAS
HIGH/ LOW GAS
PRESSUREPROVING
VALVEPROVING
SENSOR
PROBE
SAMPLING
CH.6
FLUE
VARIABLE
SPEED DRIVE
EXTERNAL
T.D.S.
PROBE
FEEDWATER
VALVE
STEAM
SENSOR
CAPACITANCE
PROBES
TEMP.
SENSOR
TEMP.
SENSOR
SURFACE
BLOWDOWN
BOTTOM
BLOWDOWN
FEEDWATER
SERVO
OUTSIDE
TEMP. SENSOR 15 XFIRSTOUTANNUNCIATION
Post Installation- Full System

14. Post Installation- Full System
NEW
2016

15. Mk.8 Micro Modulation Controller
12.1” multi-touch screen display
Micro Modulation- Fuel/Air ratio control
UV and IR self check flame safeguard
Burner safety control
Gas Valve Proving- leakage detection
Gas, oil and air pressure proving
Precise target set point control
Online data logging
Historical trending
FGR Management
Lead lag control for both steam and hot water (I.B.S.)
5 Parameter Trim, O2, CO2, CO, Ambient Temperature & Pressure
Expansion PCB for Water Level Control, Flow Metering and First-Out
Annunciation

16. Micro Modulation- Fuel/Air Ratio
Independently controlled fuel and air positioning motors with an accuracy of
0.1 of an angular degree
4 separate fuel curves
4 dedicated servo drives
2 dedicated variable speed drives
Selectable trim channel (damper of VSD)
Error diagnostic codes displayed
Single point change facility for commissioned fuel/air ratio
User definable optimum ignition position (golden start)
Cold start routine to protect the boiler from cold shock

17. Burner Control Box Functions
Full flame supervision with UV self-check for continuous operation, patented
self adaptive UV amplification
IR self-check
Burner control functions with user configurable timings (ignition, purge, pilot
and main flame proving)
Gas valve proving system with on-line pressure supervision
Oil pressure monitoring and display with limit checks
Air windbox pressure proving- display and supervision
Lockout history of last 128 incidents with date, time, function and reset
Burner control functions (Flame Safeguard) selectable

18. Setpoint Control Features (PID)
Internal 3 term PID control to required setpoint for both pressure and
temperature
Software adjustable thermostat/pressure stat facility
Second setpoint user adjustable
Time clock facility, reduced setpoint and off modes
Outside temperature compensation
Intelligent boiler sequencing for both steam and hot water
Intelligent boiler sequencing for low pressure steam applications
Fuel flow metering- instantaneous and totalised
Hand/Auto/Low flame hold facilities
4-20mA input for external load control
4-20mA output of firing rate
Twin burner and multi-burner control capability

19. Expansion PCB Features
Water level control (digital or analogue)
Steam flow metering through temperature sensors (no meter required)
Surface blowdown
Timed or continuous through modulating valve
Bottom blowdown
Blowdown based on boiler usage and firing rate
Draft control
Balanced flue conditions for tall stacks
First Out Annunciation
15 safety inputs for additional control
Fully metered combustion and cross limiting control
Simultaneous firing of two fuels
Economiser inlet & outlet temperature analysis

20. Case Study- Laundry
3MW Cleaver Brooks- LPG
Electronic fuel / air ratio system
2:1 gear ratio for the air damper
No mechanical linkages, 90 degree servomotor movement for 45 degree air damper
movement (first in Australia)
Fully modulating water level control system to maintain optimum steam
output

21. Case Study- Laundry
Savings
Overall LPG savings approx. 13%, leading to a sub 6 month ROI
Reduced peak gas usage from 58m3/hr to under 50m3/hr
Better steam quality improving production

22. Exhaust Gas Analyser to report flue gas emissions
Continuous and on-going measurement of flue gases
O2, CO2, CO, NO (& SO2 & NO2)
Real time analysis of emissions at your finger tips
Display of efficiency, fuel usage and calculated carbon foot print
Full CEMS package (Continuous Emissions Monitoring Software)
Micro Processor controlled
Complete diagnostic information including cell depletion
Low maintenance, cost and easy installation
Six 4-20mA analogue output signals
Integration with combustion management system for additional savings
Five parameter trim (O2, CO2, CO, Ambient Temperature & Pressure)
Upper and lower limits of control on five measured parameters
O2, CO, CO2, NO & Exhaust Gas Temperature
2 years of data storage
Emissions Logging & Reporting

23. Exhaust Gas Analyser (EGA)
User-definable time periods
for analysis (hourly, daily,
quarterly, annually)
View cell degradation
Anticipate cell replacement requirements
Plug and play cell changeover

24. Exhaust Gas Analyser (EGA)
Total weight & volumetric emissions
Per gaseous emission
Input from fuel flow meter
Specify fuel characteristics
Total cost of fuel

25. Data Transfer Interface to collate information from multiple boilers on a
single site
Set point control and on/off functionality through the BMS
Transfer information from multiple sites back to a single point (board room)
View CO2 emissions at all sites (instantaneous and totalised)
On-going review of burner/boiler performance
Set parameters / limits for efficiencies of each appliance
Ability to add I/O boards to integrate further devices and information
Access through EtherNet allowing global analysis
Remote Monitoring & Control

26. Remote Monitoring & Control

27. Sabien Technology: M2G System
Sabien Technology is the manufacturer of the patented M2G boiler
load optimisation control system
A system designed to improve the efficiency of commercial heating
boilers and direct fired hot water heaters
Improved boiler room efficiency leads to:
Fuel Savings – typically in range of 5-25%
Reduced Carbon Dioxide Emissions
Typical paybacks between 6 months and 2 years
Proven technology with numerous successful case studies from the
UK & USA, and recently in Australia
Over 10,000 units installed worldwide
CCM is an authorised distributor for Australia – new technology for
this market

28. Sabien Technology Customers

29. Behavioural
Changes
Regular boiler
maintenance
BMS
Weather
Compensation
Boiler
Sequencing
Boiler Load
Optimisation
Boiler Optimisation

30. Boiler Load Optimisation
Specifically designed to overcome the inherent problems
of excessive cycling
Retrofitted onto existing boilers with no impacts to
building temperatures or existing control strategies
Integrates with and complements existing boiler controls
(e.g. Building Management System, sequencing,
Outdoor Temperature Compensation)
Uses flow and return temperature sensors and
proprietary software to regulate boiler cycling
Prevents boilers cycling on to recover standing losses;
only respond to genuine calls for heat
Is widely overlooked – leaving untapped energy savings

31. Red sections show sporadic firing
periods of <15 minutes
Pink sections show boiler firing
continuously
Initial Site Analysis

32. Sabien- How Does it Work?
Flow and return temperatures are analysed independently every 10
seconds by two digital probes (measuring every second)
Intelligent and self adapting software monitors the boiler’s thermodynamic
profile in real time
Boiler temperature decay is monitored to distinguish dry cycling from
genuine calls for heat
Should the temperature decay
be more rapid from the boiler’s
set point - this will indicate a
genuine call for heat from the
building load, rather than just
standing losses
Temp
Time
Temperature over time
Boiler Temperature

33. The M2G measures a reference point of the flow and return temperatures when
the boiler reaches the required set point and creates 2 temperature gradients
The M2G measures the temperature decay of the flow and return every second
to identify the true load profile of the individual boiler
The M2G will prevent the boiler from firing due to dry cycling, i.e. within the
deadband values.
Identifying Boiler Dry Cycling
Boiler thermostat set point
Minutes
TempoC
Deadband 8oC
Boiler Flow
150 Minutes
TempoC Deadband 3oC
Boiler Return
Boiler T
0 15
Boiler would normally fire
at this point i.e. dry cycle.
However, the M2G will
prevent the boiler firing

34. Boiler thermostat set point
Minutes
TempoC
Deadband 8oC
Boiler Flow
150 Minutes
TempoC Deadband 3oC
Boiler Return
Boiler T
0 15
Identifying a Genuine Call for Heat
If the flow or return temperature decay is outside of the deadband values, the
M2G allows the boiler to fire to meet with the genuine heating demand
The M2G re-calculates these values each time the boiler reaches the required
variable set point temperature
This ensures the required ambient temperatures and hot water within the
building are not compromised

35. Common Return / Flow Temperature
Variable Temp
Boiler 1
82o
Boiler 2
70o
Boiler 3
60o
BMS
Outstations
Lighting etc
Air conditioning / ventilation
x 3 Boiler enable / disable
Outside Temperature
82o
60o
70o
60o
60o
60o
72o
Blended
temperature
60o
Individual Boiler Analysis
Dry cycling cannot be identified by measuring the blended
temperatures of all the boilers connected into a common
header- this must be identified at each boiler

36. Case Studies
University in Sydney
700kW leisure complex heating boiler
Boiler off less than 15mins- 356 -> 66 /week
Cycling reduction- 68.1 -> 31.9 /day
Nominal year-on-year reduction- 18%
Degree Day adjusted savings- 9.5%
Reduction in CO2 emissions- 43 tons
Payback period- 1 year
Sydney Hotel
2*1MW heating boilers
Nominal year-on-year reduction- 11%
Reduction in CO2 emissions- 173 tons
Payback period- 0.62 years
-200,000
-150,000
-100,000
-50,000
0
50,000
100,000
1-Aug
8-Aug
15-Aug
22-Aug
29-Aug
5-Sep
12-Sep
19-Sep
26-Sep
3-Aug
10-Aug
17-Aug
24-Aug
31-Aug
7-Sep
14-Sep
21-Sep
28-Sep
CumulativeFuelSaved(MJ)
CUSUM Analysis 2012 - 2013
M2G installed.
Significant drop in gas
consumption following
installation

37. Thank you
Any Questions?