Tag Archives: FlexFit

 

Linkageless control technology makes boiler rooms more efficient and easier to operate 

In order to cut boiler room costs and solve end-user headaches, many boiler professionals are making the move to “linkageless” control systems. A linkageless system uses a burner with individual servos to control fuel and air ratios, and this in turn provides more savings to the end user. Some of the biggest benefits of linkageless systems include:

1)      Higher efficiency: O2 levels may fluctuate but will always return to position of highest fuel and electrical efficiency. In addition, turndown is often improved resulting in less cycling of the burner.

2)      Monitoring and communication: The system communicates via Modbus and reports on all functions. The main module monitors the positions of all fuel- and air-control devices. Any positioning error shuts the burner down safely.

3)      Automatic adjustments for ambient air and fuel changes: Linkage systems can cause major problems for technicians. Once all the linkage is set, the ambient air density may change, throwing the system off. In addition, instead of system readjustment every time there is a fuel switch, the positions of all servos are programmed and independent. This means that the system adjusts automatically to fuel/air ratio changes as well as fuel changes.

The new FlexFit system is an innovation in linkageless technology now being offered by Preferred Utilities Manufacturing Corporation. The FlexFit solution offers a less costly, less time-consuming retrofit to modern linkageless controls in the boiler room. Leveraging the industry-leading BMU (Burner Mate Universal) platform, the FlexFit can be used in new installations or be easily retrofitted into existing jackshaft control panels that use supported common flame safe guards. This solution is half the price of the BMU (with the same benefits), and a trained technical can install the FlexFit in one day.

Fuel savings are accomplished with parallel positioning combustion control with optional oxygen trim. Electricity savings are provided by the ability to control a Variable Speed Drive for the FD Fan. In addition to flame safeguard and combustion control, the FlexFit also includes optional draft control.

The FlexFit communicates to Building Automation Systems by Modbus or optional Ethernet. And because it is microprocessor-based and pre-engineered, the FlexFit is an economical alternative to more expensive PLC-based boiler controllers. The parts are in stock for immediate delivery and require no programming.

This is a control solution that delivers benefits for all members of your team. Owners will see savings through electrical and fuel efficiency, and they’ll have tighter control of boiler room functions. Managers will be able to get ahead of emergencies before they happen, and technicians will enjoy easy installation, in-and-out maintenance, and local support.

With a flexible design that is more affordable, more accessible, and more accurate, FlexFit is the retrofit solution you’ve been waiting for.

About Preferred Utilities Manufacturing Corporation:

Preferred Utilities Manufacturing Corporation is an engineering-based manufacturer of products for commercial, institutional, industrial and nuclear power facilities. Our products include fuel oil handling systems and components, boiler instrumentation and controllers, high quality burners, and nuclear power plant outage reduction tools and component parts. Continuous research and development are applied to our existing products and help us to lead the industry with new and innovative power plant solutions. Our manufacturing, engineering, and administrative headquarters is located in Danbury, Connecticut, and regional sales and service offices are located throughout the United States.

 

Wondering how to reduce GHG emissions by 30% by 2025 or 80% by 2050?

If you’re thinking you need to completely retrofit your entire boiler room, you’re wrong. There’s more than one way to meet your goals AND stay within your budget.

Preferred’s FlexFit Controller Retrofit Package, is the easiest, least expensive, most efficient way to go linkageless. This controller adds O2 trim, draft control, VFD and valve-proving capabilities as a standard and helps you meet your emission reduction goals too!

See the NYSERDA funded study by Steven Winters Associates that recommends linkageless retrofits!

Bring some Combustion Joy home for your operators, custodians, and superintendents this Fall.

 

by Joe Wallace

Oxygen trim (O2 Trim) is a system that constantly monitors your boiler’s combustion. Unlike your car, your boiler has the ability to run properly without it, so what are the upsides to it? This system can adjust your air fuel ratio based on what it’s supposed to be and triggers alarms or lockouts should the combustion deviate from proper levels. It also helps end users save on operational and maintenance costs.

Safety:

We have all seen slipping couplings, broken shafts, blocked intakes or other things that have created improper combustion and unsafe conditions. Oxygen trim can prevent those situations from turning into something far worse. When a burner is tuned with O2 Trim, an oxygen level is assigned to each curve point and is stored with that point as a safe oxygen level. While the oxygen sensor continually monitors your burner’s combustion, it can detect any “off-curve” oxygen readings during combustion and adjust for them within reason. Should the oxygen level have a large deviation from setpoint, the control system will alarm and/or shut down the burner before something bad happens. Another safety function of O2 trim is if a very high CO condition is present, the CO will also make the O2 cell read a lower oxygen level and alarm/lockout the boiler.

Maintenance Savings:

Preventative maintenance should always be done in your boiler room including boiler tuning, but O2 trim may help save you some money on these visits. Since O2 trim constantly monitors your burner’s emissions and makes small adjustments to ensure proper and safe combustion, some areas have only required tuning bi-annually or less. Your system still needs to be set up by a professional and is certainly not a replacement for your service company, but is a great way to ensure your boiler is running properly between their visits. Due to this continually monitoring, the burner is much less likely to be damaged during operation. Improper combustion can lead to very expensive repairs to your system such as burner component replacement due to being burned up, refractory repairs do to instability and impingement, or a catastrophic boiler explosion. Having oxygen trim drastically decreases the risk of these events for a small fraction of the cost.

Operational Savings:

While one can tune a boiler for the conditions that exist while they are on site, what happens when the conditions change? The temperature in your boiler room, the fuel quality, hysteresis of control valves or dampers, etc. can cause a variation in your combustion. Often a boiler is tuned with a safety factor to accommodate for these variations which leaves some efficiency on the table. With O2 trim, you don’t have to accommodate for these future variations, therefore allowing you to run your boiler more efficiently. Your return on investment is contingent on your fuel usage and there are several utilities incentivizing the installation of this equipment with rebates as it has been proven to reduce fuel usage.

Oxygen trim is best coupled with a linkageless control strategy. If you have a Preferred Utilities FlexFit or BurnerMate Universal system already installed, oxygen trim is easily added. The return on investment is dependent on your usage and incentive programs in your area and can often pay for itself within a single heating season.

Ask us how you can improve your boiler efficiency and start saving today.

 

FlexFit and flame safeguard installed in existing panel using existing wiring

Preferred is bringing something BIG to the industry! 

Tired of fuel and electric waste? Want a more reliable system that also meets strict emissions standards? You know you need to upgrade, but the installation time and expense of a modern linkageless control system often just isn’t plausible…Until now.

Preferred’s new flexible solution dramatically cuts the cost and time for a linkage to linkageless control system retrofit. Now, you don’t have to upgrade your whole boiler room in order to have modern linkageless control. 

So, what do you get? A deal on a modern efficient system, significant fuel and electric savings and rebates, and an intuitive system that will keep you ahead of any emergencies.

 

It’s the flexible retrofit solution…It’s the FlexFit.

 

 

A linkageless control system uses a burner with individual servos to control fuel and air ratios, and provide more savings to the end user. This technology can cut boiler room costs and solve end-user headaches. Here are three reasons to choose linkageless controls:

  1. Higher efficiency: O2 levels may fluctuate, but will always return to position of highest fuel and electrical efficiency. In addition, turndown is often improved resulting in less cycling of the burner.
  2. Monitoring and communication: the system communicates via Modbus and reports on all functions. The main module monitors the positions of all fuel- and air-control devices. Any positioning error shuts the burner down safely.
  3. Automatic adjustments for ambient air and fuel changes: Linkage systems can cause major problems for technicians. Once all the linkage is set, the ambient air density may change, throwing the system off. In addition, instead of system readjustment every time there is a fuel switch, the positions of all servos are programmed and independent. This means that the system adjusts automatically to fuel/air ratio changes as well as fuel changes.

In a world of high electric and fuel costs, this technology is indispensable to the modern boiler room.

Our Solution: The Preferred FlexFit Linkageless Controller can be used in new installations OR be easily retrofitted into existing jackshaft control panels that use supported common flame safe guards.