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Monday, August 12, 2019

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WASHINGTON – U.S. Senator Chris Murphy (D-Conn.) announced on Monday that Preferred Utilities Manufacturing Corporation in Danbury is this week’s “Murphy’s Monday Manufacturer.” Founded in 1920, Preferred Utilities specializes in the manufacturing of burners, instruments and controls, and fuel oil handling equipment for industrial, commercial, and missions critical applications. The company does work for government and municipal buildings, hospitals, colleges and universities, data centers, pharmaceutical companies, waste management plants, and nuclear facilities. Preferred Utilities became the first company in the Northeast to convert its boilers to Bio-Residual Oil, which is produced from vegetable grease and animal fat, to power its 50,000 square foot facility in Danbury. They are also one of the first companies in Connecticut to convert its boilers to renewable fuel.

“Preferred Utilities is leading the way in combating climate change by using alternative and renewable fuels to run their business and companies around the world are noticing. They are committed to the Danbury community through partnerships with local schools and charitable organizations. I’m happy to highlight them,” said Murphy.

“Although founded in 1920, we moved to Danbury in 1946 and made it our home. Preferred is very attached and dedicated to the greater Danbury community and we employ some of the top people in our industry, born and raised in Connecticut. Because we are a family company, Preferred employs several generations of the same family, all Connecticut residents and members of the community,” said David Bohn, President and CEO of Preferred Utilities Manufacturing Company.

Preferred Utilities is committed to addressing climate change and carbon emissions with new, carbon neutral innovations and development of existing alternate fuels in partnership with other companies. They are contributing to sustainable alternative solutions to fossil fuels with low carbon emissions and high energy efficiency. They are active in the Danbury community, routinely offering internships to high school and college students in the area, and working with organizations like Danbury Hospital, St. Jude Children’s Cancer Hospital, New Pond Farm, and Danbury Music Center. Preferred Utilities is headquartered in Danbury with facilities around the United States employing 90 people.

The manufacturing industry plays a crucial role throughout Connecticut communities, creating new jobs and accelerating the state’s economic recovery. Today, Connecticut’s thousands of manufacturers account for 10% of the state’s jobs and 87% of the state’s total exports. In order to protect and grow manufacturing jobs in Connecticut, Murphy has introduced two pieces of legislation that aim to strengthen existing standards and prioritize the purchase of American-made goods, theBuyAmerican.gov Act and the American Jobs Matter Act.

 

Made in the U.S.A., one of two new API-Ranger burners and BurnerMate Universal controls upgrade for existing boilers on factory fire test chamber. This burner and controls package is capable of burning three (3) fuels like ENSYN Renewable Fuel oil, an 85% carbon neutral fuel, along with natural gas and #2 oil. On fire test the Ranger API easily achieved <9 PPM NOx on natural gas.

This innovative and Low-Cost combustion solution is designed to meet sustainability goals, emission reduction requirements, and efficiency improvements for Colleges, Universities, Hospitals, Office Campuses, Apartment Complexes, Manufacturing Facilities and more.

For your Aggressive Sustainability Goals, choose a Preferred burner/controls upgrade to achieve emission / carbon reduction milestones while increasing combustion turn down, efficiency, and reducing electric consumption.

Features: 10:1 turn down on NG, 8:1 turn down on oil, <2.5% O2, 50-100% firing rate, <3.5% O2, 10-40% firing rate. <9 PMM NOx with <26% FGR.

Now that is a lot to be Joyful about!

 

Diesel Exhaust Fluid (DEF) was developed to help keep heavy-duty diesel fueled machinery like boilers operating within federal emissions standards. At the chemical level, DEF is a combination of 67.5% de-ionized water and 32.5% urea that transforms harmful nitrous oxide emissions into harmless water and gas.

Urea is an organic chemical compound produced as waste by the body after metabolizing protein—but the urea used in DEF is not (despite some confusion on the subject) derived from human or animal urine. For nearly two centuries, scientists have been able to create synthetic urea, which is much more appropriate for the DEF application.

DEF isn’t actually a fuel additive, and it never comes in contact with diesel. Rather, it is stored in a separate tank and is pumped into the exhaust stream of diesel machinery to break down dangerous NOx emissions into safe nitrogen and water. This process is called Selective Catalytic Reduction (SCR).

Changes in EPA emission standards have required diesel burning machines to reduce their output, and SCR is the technology of choice for this purpose. As emission standards have continued to expand to include off-road vehicles, generators, and a variety of engines, the use of DEF is becoming more and more widespread.

To properly deliver DEF, the Diesel Exhaust Fluid Urea Pump system is designed to safely and effectively transfer DEF fluid from a tank to diesel equipment, helping facilities comply with strict NOx emission regulations. Constructed using stainless steel piping and pumps, the DEF system lasts in even the most abusive outdoor environments. We proudly make DEF Urea Pump Systems in the USA. Here are the specifications:

Flow Capacity: 100-300 GPH
Pressure Capacity: 100 PSI
Pump Type: Centrifugal with Stainless construction
Standard Accessories: All Stainless Steel
Inlet Strainer
Outlet Check Valve
Leak Sensor
Inlet Suction Gauges
Outlet Pressure Gauges Flow Switches
High Level Sensor
Level Transmitter and Display
Construction: Stainless Steel Enclosure, Welded Steel Construction

Preferred Utilities is committed to helping facilities meet the most stringent demands for emissions reduction. With innovations such as DEF implementation and SCR, support from Preferred can help you adapt your systems and take advantage of the most efficient and effective ways of reducing emissions.

 
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Given today’s skilled workforce shortage, figuring out how to get the most productivity from the fewest workers has become one of a power sector’s top challenges. How can a plant stay on top of its output requirements when finding and retaining qualified workers is so difficult?

With spare man-hours being a luxury few can afford, two questions are at the top of most plant managers’ minds:

1. How can we avoid downtime?

2. Are we maximizing our workers’ time and capability?

Following are stories of two facilities that found the expertise they needed to address those issues with innovative, “outside-the-box” solutions.

Keeping downtime at bay

Downtime has always been a costly and inconvenient burden, and finding the resources to make up for time lost to equipment failure can be nearly impossible. A well-known North American tissue manufacturer found itself with old boiler equipment that was not up to the job and needed to be replaced—but they had to find a solution that wouldn’t cause downtime, which they simply could not afford.

Their old equipment did not reach full heating capacity as required. The boiler was rated for a certain steam output, but the burner couldn’t provide enough heat to make that steam. They had a second boiler, but switching required a start-and-stop process that added up to higher operating costs. Every stop meant purging the boiler with air and adding additional wear-and-tear on the system. The process also meant lost energy and additional man-hours. It was not a sustainable solution.

They needed a more reliable source of heat, along with ability to meet NOx emission requirements with better fuel efficiency and a safer system. If they didn’t get the NOx emissions into compliance, they risked hefty fines from their home state. So what would work?

A combination of a new burner, new fuel piping train, and a new variable frequency drive (vfd) was proposed to address the heating efficiency problem. This combination saved costs by reusing the existing controls (which had just been put in place a few years earlier). They included Preferred Utilities BurnerMate Universal (BMU) parallel positioning controls, a built-in flame safe guard, and a touch-screen user interface.

The company proposing this solution had been servicing the manufacturer for years, so they had the knowledge to not only source the right equipment but also coordinate the entire project. They provided a highly qualified subcontractor who provided a complete turnkey solution, removing the old boiler and completely replacing it, attaching the new burner and gas lines and wiring the controls. They took just 11 days to install all the equipment and get it fully functional. It met NOx emissions standards and achieved higher efficiency and turn-down. The entire project, from initial analysis to completion, took less than eight weeks.

Working with the right consultants in a case like this is particularly important because they must be experienced with a full range of boiler equipment so they can always utilize the one best suited for the application. Without the right expertise they might recommend ill-suited equipment that will be detrimental to plant staff who will need to deal with the repercussions and possible failure in the future. That’s more risked downtime—something that was simply not an option in this application.

The burner installed in this application burned natural gas, achieved a 10-1 turn-down, and reached 30ppm NOx (the previous level was 50ppm). Additionally, the installation included a 40,000 pounds-per-hour steam boiler and a Cleaver Brooks water tube boiler.

Keeping boilers under control

A mammoth steel processing plant was far behind in a boiler upgrade project. They turned to an outside consultant to help them pinpoint the problems in the application and get the project back on track.

This was the largest project of its kind in the United States at the time. The engineer had to guarantee less than 25.65 PPM NOx and less than 48.60 PPM CO. The project also required 85 dBA noise level at three feet. All of these stringent requirements ended up being met.

An added challenged faced by the consultant concerned the type of controls to be implemented in the application. The management of this facility had traditionally been against Human Machine Interface/Operator Interface Terminals (HMI/OIT) and had not allowed them. Given their experience with these types of controls, the consultant’s challenge was to convince the customer that offering an OIT is an advantage.

In the end, this solution was accepted because the consultant offered a BMU. The LCD screen is standard on the BMU and is a back-up that will provide them with the boiler-burner operation should the OIT fail. To assist in the rollout of these new controls, the consultant also offered a two-day on-site training session.

The consultant matched the proper controls to the boilers and fast-tracked the resulting installation. A four-week submittal, proposed to the consulting engineers, got approval for both boilers and burners to proceed with manufacturing and meet the schedule.

The final application included three X-Plus burners on three B&W 60,000 PPH boilers with BMU controls. The control system and VFD was located on a high ambient temperature environment of 139°F and in corrosive atmosphere. All controls, hardware, and VFD were rated for 122°F. NEMA 4X requirement encloses the heat from the temperature rise and will exceed all temperature rating of the electrical components. In order to meet the reliability requirements, the consultant provided a NEMA 4X enclosure with NEMA 4 rated air conditioning system.

In both these applications, timing was critical. They could not allow the boiler system to fail, but they also could not afford a lengthy downtime for upgrades. Overcoming a pre-conceived mindset and looking for creative solutions allowed the facilities to resolve their problems and stay productive. In the end, an outside perspective gave them access to both the knowledge and technology they needed to conserve workforce time and talent.

About the author: David Bohn is President and CEO at Preferred Utilities Manufacturing Corporation, an engineering-based manufacturer of products for commercial, institutional, industrial and nuclear power facilities.

 

With the NEW and improved Opacity Monitor model JC-30D with Automatic Calibration, LED light source, and light detector, no onsite operator is required to calibrate the system. When the system receives a signal from the burner fan, it auto calibrates opacity by itself, compensating for dirty lenses.

Auto-Calibrate coupled with the new brighter LED light source allows the lenses to go without cleaning for up to 9 times as long as previous versions. This saves on labor cost for unmanned boiler rooms and operators can focus on other tasks in their boiler room. The improved light sensor now directs light only from the light source and eliminates misreading from tramp light, which can cause problems in the boiler room.

The new JC-30D is an easy retrofit for older JC-30D models, as well as other opacity monitors. Durable quality and made in the U.S.A.!

 

A New York City Public School central heating plant and their consulting engineer made the decision to install 3 new low emissions burners with state of the art combustion control systems to meet Local Law 87 initiatives.

Compliant with Local Law 87, NO FIBER METAL MESH HEADS OR AIR FILTERS REQUIRED.

For sub 35 PPM NOx, low O2 performance without FGR and ability to go to sub 9 PPM NOx with FGR  all without fiber metal mesh heads or air filters.

If dual fuel capabilities are added they can have a sub 5-minute change over from natural gas to oil firing. Their new controls packages includes: BurnerMate Universal O2 Trim, Draft Indication & Control, Fuel Air Ratio Control, Flu Gas Temperature indication and alarm, Smoke Opacity, Flame Safeguard control, with VFDs.

These burners will reduce electricity consumption by 60% or more and allow for 8:1 turn down on oil firing. O2 ranges from sub 1.5% at 50-100% firing rate, to sub 3.5% 10-40% firing rate. The burners and controls package are made by skilled American tradesmen in our Danbury, CT, UL 508 / IBEW shop, and started up by our combustion field engineers.

Made in the U.S.A. for a Greener, more Sustainable and Fuel Efficient future for NYC.

 

Our SECOND burner and controls retrofit for Bates College on one of their existing 700 HP Cleaver-Brooks™ boilers so they can burn ENSYN Renewable Fuel Oil (100% renewable fuel source derived from trees) as their primary heating source! With our help, Bates is on the verge of reaching their 2020 emissions and carbon reduction milestones while increasing combustion efficiency and reducing electric consumption.

Read the full story here.

 

 

An innovative, low-cost combustion solution to meet sustainability goals, emission reduction requirements, and extreme efficiency improvements.

This installation is at an American college with aggressive sustainability goals. Our solution for them–a burner and controls upgrade on one of their existing 700 HP Cleaver Brooks boilers to achieve their emission and carbon reduction milestones, while increasing combustion efficiency and reducing electric consumption. This upgrade will NOT require the removal of the Cleaver Brooks front or rear doors, but acts as a direct replacement “insert” for the existing Cleaver Brooks burner, while reusing the existing Cleaver Brooks combustion fan and making no cuts or modifications in the original front door.

This specialized API-Ranger burner and controls upgrade will allow the college to burn ENSYN Renewable Fuel Oil, an 85% carbon neutral renewable fuel, along with natural gas or #2 oil.

American made and supported, our technological advancements continue to out-pace the competition.

 

For reliability, longevity and unmatched service, choose Preferred!

This Preferred JC-CDDF2 chief dispatcher model has been in service since the 1970’s in a Newport, RI facility. When one of the relay sockets finally broke, they called Preferred.

Although this unit has been out of production for nearly 20 years, we still had replacement parts in stock and original wiring diagrams for the installation of the new parts.

Built in the USA and built to last!