Honeywell CommercialHoneywell Commercial Combustion Products

Opportunity in the Boiler Room

B il C t l S l tiBoiler Control SolutionsABC900 / Delphi / Controlinks

Boiler Control / Energy Cost Savings

Ethernet

Steam – Conventional

FlameSafeguard

Control

FlameDetector

Mod Ctl Hi Limit Op Ctl

CommunicationModbus

Boiler

Mod

Airflow Switch

BurnerMotor

Low WaterCutoff Ign.

Xfmr.

ModMotor

VPS (Valve Proving System)

P

High GasP S

Low GasPress Sw

ManualShut Off

Valve

ManualShut Off

Valve

PressureRegulator

232

Press SwPress Sw SafetyShut OffValve 1

SafetyShut OffValve 2

Pilot Valve

ModulatingValveManual

Shut OffValve

PressureRegulator

%%

What happens over time?

FuelFuel

$

$ $

$ $$ $

$ $ $ $$ $ $$ $ $$ $ $

$ $ $$ $ $

$$

$ $$ $

$ $ $ $$ $ $

$ $ $$

$ $

$ $$ $ $ $$

$ $

$ $$ $

$ $ $ $$ $ $$ $ $$ $

$ $ $$ $ $

$$

$ $$ $

$ $ $$ $ $

$ $ $$

$ $

$ $$ $ $ $$$$

$

$ $ $ $$ $ $$ $ $$ $

$ $ $$ $ $$

$

$ $ $$ $ $

$ $ $$

$ $

$ $$ $ $ $$

$$

$$ $

$ $ $$ $ $$ $ $$ $

$ $ $$ $ $

$ $

$ $ $$ $ $

$ $$

$ $

$ $$ $ $ $$

$ $$$$ $ $

$

$ $$$ $

$$

$$$

$ $$ $$ $$

$$ $$$$ $$$$ $

$

$

$$$$

$$$$$

$

$

$

$$

$$ $ $$ $ $

$ $$ $ $

$$$ $

$ $$ $ $

$ $$ $$

$ $$

$

$

$

$$

$$ $ $$ $ $

$ $$ $ $

$ $$ $

$ $$ $ $

$ $$ $$

$ $$$

$

$

$$

$

$

$

$$ $$ $ $

$ $$ $

$$ $

$$ $$ $$

$ $$

$ $$

$$

$

$

$ $$ $ $

$ $$ $

$$

$

$$ $$ $$

$ $$

$ $$$

$$$$ $$ $

$ $$ $$ $$ $ $$

$$ $

$$

$

$$ $

$$$

$Typical mechanical

curve

% %

Ideal Curve

233

AireAire

Delphi O2 Combustion

Steam - Delphi O2 Panele p O2 Co bust o

Efficiency Panel

FGR Damper

O2 Trim Sensor

4-20mProcess Variable

Transmitter

FlameDetector

Fuel Air Ratio Control, Burner Management, O2 Trim, Display

Mod Ctl Hi Limit Op Ctl

Boiler

Air D

Airflow Switch

BurnerMotor

Low WaterCutoff Ign.

Xfmr.

VFDS dDamper

MotorVPS (Valve Proving System)

P

Speed Sensor

High GasP S

Low GasPress Sw

ManualShut Off

Valve

ManualShut Off

Valve

PressureRegulator

234

Press SwPress Sw SafetyShut OffValve 1

SafetyShut OffValve 2

Pilot Valve

ModulatingValveManual

Shut OffValve

PressureRegulator

235

Why Boiler FA Upgrade?E i t l d i f tEnvironmental and energy saving features

save money

- Drives efficiency to new level by improving the fuelDrives efficiency to new level by improving the fuel air ratio and improving turndown

- Electronic fuel air ratio control maximizes b ti ffi i i th 4combustion efficiency, saving the average user 4-

6% in fuel savings per year

Optimize fuel/air mixture

Accuracy of actuators to 0.1 degree

Accuracy over life

236

Why Boiler FA Upgrade?

E i t l d i f tEnvironmental and energy saving features save money continued- Reduced fuel generated gas emissions: CO2, COg g 2,

- Addition of O2 trim provides an additional 1-2% in savings per year

Compensates for variable combustion air

Provides consistent excess air reduction

Keeps excess air CO and CO2 output a minimumKeeps excess air, CO and CO2 output a minimum

Trims air damper and/or VFD

- The Variable Frequency Drive (VFD) for q y ( )Combustion air control delivering electrical savings of 30%-60% per year

237

Typical Applications

• Target Market- Typically boilers > 100hp

Depending on ROI requirements and current equipment efficiency may beDepending on ROI requirements and current equipment efficiency, may be employed on smaller boilers

- Minimal customer down time is required

A packaged sol tion is desirable- A packaged solution is desirable

- Oxygen trim is desired- Control Systems may have older, electro-mechanical controls

Upgrade to new 7800 SERIES ControlsUpgrade to new 7800 SERIES Controls• Longer life• Eliminate potential leaking fuel vent valves and still comply with safety

codes and not waste natural gas • Diagnostics tools make troubleshooting easy!

• Many states offer rebates for linkage-less fuel air ratio controls andO2 trim

238

Verticals MarketsABC900/DelphiControLinks™ ABC900/Delphi

w/ O2 Trim

▪ Hospitals X X

▪ Schools X

▪ Office Buildings Xg

▪ Government Buildings X X

Multi Unit Dwellings /▪ Multi-Unit Dwellings / Condos & Apartments X X

▪ Universities / Campus X X

▪Industrial Process/ Pharmaceutical/ Food Processing / PP

X

Laundries / Dry

239

▪ Laundries / Dry Cleaning X X

Opportunity for Boiler Upgrades

• Installed base of Boilers in U.S. and Canada: 571,000*• 43K in industrial applications• 528K in commercial applications

• Less than 5%, or ,approximately 29,000 boilers, have linkage-less fuel air ratio controlfuel air ratio control installed

O t it t d• Opportunity to upgrade over 500K boilers!

240

* ABMA Data

S t e a m

Boiler Types, Steaming Capacities S t e a m F l o w K l b s / h r H P T Y P E

C o m m e r -0 0 c i a l

F i r e B o i l e r s Controlinks2 5 8 t u b e B o i l e r s

1 0 2 9 0

2 5 7 2 5 P a c k a g e

ControlinksTarget

B o i l e r s I n d u s t r i a lB o i l e r s

1 0 0 2 9 0 0

2 0 0 5 8 0 0 W a t e r

ABC900/HC900DelphiTarget

T u b e5 0 0 B o i l e r s

F i e l d1 0 0 0 E r e c t e d U t i l i t y

B i l B i l B o i l e r s B o i l e r s

6 5 0 0

241

Why Boiler FA Upgrade?

T h d G C i i iTouch and Go; Commissioning done via PC Touchscreen

- No external PC requiredNo external PC required

- No complex programming needed; touch and go

- Embedded software powered by Niagara AX framework; no software to purchase

CHANNEL 4 DISABLED

- Intuitive user screens make burner management a snap

- Easy to access diagnosticEasy to access diagnostic information, system status and alarms

- Immediate access to make any adjustments, reset alarm functions and

242

Immediate access to make any adjustments, reset alarm functions and utilize reporting features

Limits & Operating Control4-20mA Firing Rate Control

WIN XPWIN XPWIN XPWIN XP

Option: PCOption: PC

OROROROR

System DisplaySystem Display

Fuel OilFuel Oil

Limits

Natural GasNatural Gas

Limits

ControLinks ControLinks ---- The Application The Application ----

S7999 S Di lControlinks

S7999 System DisplayFuel/Air Curve CommissioningFuel/Air Curve Commissioning

244

S7999 System Display

Burner Control StatusBurner Control Status

245

S7999 System Display

Expanded Annunciator StatusExpanded Annunciator Status

246

Delphi Combustion Efficiency Panel

Touch and Go

Delphi – Touch and GoThe Delphi CombustionThe Delphi Combustion

Efficiency Panel Integrates• Flame Safeguard Control

F l Ai R ti C t l• Fuel Air Ratio Control• O2 Trim• VFD Control• PID Control• Loop and Logic Algorithms• Multiple Self Check Features

Into a single, pre-wired panel with a

Multiple Self Check Features

g p pPC touchscreen used for easy, user friendly commissioning

248

Delphi ComponentsIndustrial Cooling fan ABC900A1000 RM7840L1075Industrial panel PC TB0 VFD

ModbusCooling fan ABC900A1000 RM7840L1075

with S7800A1142

RelaysRelays

TB2TB2:T40-T101Line Voltage

TB3: 120Vac

24Vd Power Grounding

TB3: 120Vac Power Input

249

Ethernet switch

24Vdc power supplies

Power conditioner

Grounding barTB1:

T1-T38Low Voltage

Tachometer

Delphi Robust and Field Proven S t R li bilit d Q litSystem Reliability and Quality

- Trusted name in reliable Flame Safeguard ControlHoneywell RM7840 with Valve ProvingHoneywell RM7840 with Valve Proving

Keyboard Display Module included for programming of VPS

R b t O2 S- Robust O2 Sensor

Long life

No replacement filters; no moving parts to wear outNo replacement filters; no moving parts to wear out

Auto-calibration feature; no manual calibration required

- Industrial Hybrid ControllerIndustrial Hybrid Controller

ABC900

Robust programming

250

Multiple safety checks

Delphi Robust and Field ProvenS t R li bilit d Q litSystem Reliability and Quality

- Maximum flexibility with actuators

ML7999B H li t t (100 200 d 400 i lb )ML7999B or Herculine actuators (100, 200 and 400 in. lbs)

Feedback to system for enhanced safety

Actuators can be mixed and matchedActuators can be mixed and matched

- Honeywell NXS or NXL Series VFD

Keypad for easy programmingKeypad for easy programming

Modbus communication

Feedback to system for enhanced safetyy y

251

Delphi Robust and Field ProvenS t R li bilit d Q litSystem Reliability and Quality

- Tachometer and Hall Effect Sensor

U d t id f db k d l t dUsed to provide feedback on modulated blower speed

- User friendly programming in PC Use e d y p og a g CTouchscreen

Industrial PC

P d b Ni dditi lPowered by Niagara; no additional software required

Easy to navigate for commissioning

Touch and Go

252

Competitive Advantage

• Proven Reliability backed by HoneywellHoneywell Combustion Safety Approval• Honeywell Combustion Safety Approval

• Total Combustion Solution• Global SupportGlobal Support

- Direct Honeywell - Network of Reps/ Distributors

Integrated Burner Management• Integrated Burner Management• Thousands of Installations

253

Honeywell Boiler Case Studies

Case Studies• Controlinks 100 - 600HP

- Space Coast Hospital ServicesSpace Coast Hospital Services www.customer.honeywell.com search Controlinks case studies

- 1000’s of installationsABC900/HC900 200HP• ABC900/HC900 >200HP- Hospitals- Home Products manufacturer - http://hpsweb.honeywell.com/Cultures/en-

US/Products/Instrumentation/default.htm• Delphi >100hp

Ph ti l 5 t- Pharmaceutical – 5 systems- Aircraft manufacturer - 14 systems- Manufacturing

254

ControLinks™ Energy Savings: Case Study

• Application: Hospital Laundry FacilityApplication: Hospital Laundry Facility- Site: Space Coast Hospital Services, Rockledge, FL- Distributor: Thermal Tech, Inc., Orlando, FL

• Situation:2002 2003; 38% increased production (7 12 million pounds to 9 million- 2002-2003; 38% increased production (7.12 million pounds to 9 million pounds laundry annually)

- 35% increased steam usage- Rising fuel costs

• Results following plant upgrade:• Results following plant upgrade:- 1.6% increased fuel consumption

• Energy Savings by Technology:- ControLinks™: 8.6%- High Turndown Burner: 7.5%- Pressurized Deaerator: 11.5%

• Calculated Annual Fuel Cost Savings (USD): (based on: 250 hp• Calculated Annual Fuel Cost Savings (USD): (based on: 250 hp boiler, operating at 50% firing rate for 16 hrs/day, 5 days/wk, 50 wks/yr and $0.75 (USD) per Therm (100 cubic feet) fuel cost)- ControLinks™: $12,900- High Turndown Burner: $11 300

255

- High Turndown Burner: $11,300- Pressurized Deaerator: $17,300

• Total Facility Energy Reduction: 27.3%

Boiler upgrade Savings Estimator

Job Site Details Definitions for Input VariablesDistributor: Boiler Output Rating as stated in horsepower from data plate.Sales Rep: Boiler Average Firing Rate as determined by boiler operation/load. Customer: Boiler Efficiency as determined by combustion analyzer.Customer Contact: Boiler Annual Run Hours as determined by boiler on time/usage.Customer Address: Fuel Cost as determined by supplier.

Error messages will disappear when data is enteredCustomer Phone:Customer Fax:

BURNER/BOILER EFFICIENCY CALCULATIONS

Burner/Boiler Operating Values - Present Burner/Boiler Operating Values - ProjectedBurner/Boiler Output Rating: HP Burner/Boiler Output Rating: 0 HPBurner/Boiler Average Load: % Burner/Boiler Average Load: 0 %Burner/Boiler Average Output: 0 HP Burner/Boiler Average Output: 0 HPBurner/Boiler Average BTU Output 0 BTU/Hr Burner/Boiler Average BTU Output 0 BTU/HrPresentBurner/Boiler Efficiency % Projected Burner/Boiler Efficiency # 0.0 %Burner/Boiler Average BTU Input #DIV/0! BTU/Hr Burner/Boiler Average BTU Input #DIV/0! BTU/HrBurner/Boiler Annual Run Hours: Hours Burner/Boiler Annual Run Hours: 0 HoursFuel Cost: $ per Therm Fuel Cost: $0.00 $ per ThermAnnual Fuel Cost: #DIV/0! Annual Fuel Cost: #DIV/0!

Projected Annual Fuel Savings #DIV/0!# Projected Burner/Boiler Efficiency Savings Removal of Linkage Wear* (0 to 1.0) % Projected Installation CostI d C b ti ** ( 5 t 3 0) %Improved Combustion** (.5 to 3.0) %Increased Turndown*** (.5 to 1.5) % Projected Return on Investment #DIV/0! year(s)O2 savings 0.0 %Total Efficiency Savings NOTE: These are estimated savings. For dual fuel systems, calculate savings for each fuel for a total savings.

Footnotes*Linkage systems have wear over time.*Linkage less systems have no hysteresis across actuator stroke, 0.1% accuracy.**Linkage systems can not maintain consistent excess air across the firing curve.**Linkage less systems can maintain consistent excess air across the firing curve, reducing stack temperature and emmissions.**Some installations may realize greater improvements in efficiency.***Linkage systems lite-off and minimum modulation positions are typically the same.***Linkage less system lite-off and minimum modulation positions are independant, increased turndown.

"H ll ill b ibl f i f il hi h i "

256

"Honeywell will not be responsible for any savings or failure to achieve the savings."

Marketing Assistance

• Marketing to Commercial / Industrial Users – help in understanding their carbon footprint to meet governmental requirements e.g. CEMs and PEMs g q gfor larger users

• Education and Rebate programs for Energy Efficiency upgrades i.e. Can the customer pay forEfficiency upgrades i.e. Can the customer pay for the upgrade through their monthly utility bill?

• Leads – for larger companies teaming with Utilities / End Users to offer comprehensive plant wide /End Users to offer comprehensive plant wide / facility energy solutions

• Joint Customer workshops / tradeshows

257

Honeywell Contacts

• Honeywell Contacts / Information - Commercial/Industrial Combustion Control Product

Specialist N th t Mi h l H dl i h l h dl @h llNortheast – Michael Handler michael.handler@honeywell.comMid Atlantic – Robert Thomas robert.g.thomas@honeywell.comSoutheast – David Krause david.krause@honeywell.comGreat Lakes – Carl Manoogian carl.manoogian@honeywell.comGreat Lakes Carl Manoogian carl.manoogian@honeywell.comUpper Midwest – Steve Young steve.young6@honeywell.comSouthwest – Rick Boers rick.boers@honeywell.comWest Coast – Aaron Contente aaron.contente@honeywell.com

- Local Honeywell Combustion Solution Distributors - Local Honeywell Sales representatives - Environmental Controls and Combustion

www customer honeywell comwww.customer.honeywell.com- Industrial/ Process Control Group

http://hpsweb.honeywell.com/cultures/en-us/default.htm

258