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

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

Company Aims

Boiler Room

Solutions

Fuel Savings

Greenhouse Gas

Reductions

Reduced Maintenance

Costs

Utility Cost Savings

Overall Plant Efficiency

Safety & Reliability

Government Reporting Standards

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

Limpsfield Burners - Overview

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

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

Limpsfield- 2MW Natural Gas

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

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

Autoflame- Overview

SWITCH

BOILERDRAFT

FORCED

MOD. MOTOR

U.V

OIL

AIRPRESSURE

GAS

FLUE

FLAMESAFEGUARD

PRESSURECONTROL

P.I.D.CONTROLLER

Pre-Installation Set-Up

SENSOR SERVO

SECOND SETPOINT FACILITYEXTERNAL MODULATION

SWITCH

EXTERNAL

BOILER

DRIVECH.5SPEEDVARIABLE FLAMEOR

DRAFTFORCED AUX.

SERVO

CH.4AIR AUX.

SERVOSERVO

CH.3CH.2 U.V

LOAD OR

OIL

AIRPRESSURE

PRESSURESENSOR

OIL

CH.1FUEL

PRESSURESENSOR

GAS

GAS

HIGH/ LOW GASPRESSURE PROVING

VALVE PROVING

SENSOR

PROBESAMPLING

CH.6

FLUEVARIABLE

SPEED DRIVEEXTERNAL

T.D.S.PROBE

FEEDWATERVALVE

STEAMSENSOR

CAPACITANCEPROBES

TEMP.SENSOR

TEMP.SENSOR

SURFACEBLOWDOWN

BOTTOMBLOWDOWN

FEEDWATERSERVO

OUTSIDETEMP. SENSOR 15 X FIRST OUT ANNUNCIATION

Post Installation- Full System

Post Installation- Full System NEW 2016

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

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

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

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

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

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

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

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

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

Exhaust Gas Analyser (EGA) Total weight & volumetric emissions Per gaseous emission

Input from fuel flow meter Specify fuel characteristics Total cost of fuel

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

Remote Monitoring & Control

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

Sabien Technology Customers

Behavioural Changes

Regular boiler maintenance

BMS Weather Compensation

Boiler Sequencing

Boiler Load Optimisation

Boiler Optimisation

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

Red sections show sporadic firing periods of <15 minutes

Pink sections show boiler firing continuously

Initial Site Analysis

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

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

Tem

p o C

Deadband 8oC

Boiler Flow

15 0 Minutes

Tem

p o C

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

Boiler thermostat set point

Minutes

Tem

p o C

Deadband 8oC

Boiler Flow

15 0 Minutes

Tem

p o C

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

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

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-A

ug8-

Aug

15-A

ug22

-Aug

29-A

ug5-

Sep

12-S

ep19

-Sep

26-S

ep3-

Aug

10-A

ug17

-Aug

24-A

ug31

-Aug

7-S

ep14

-Sep

21-S

ep28

-Sep

Cum

ulat

ive

Fuel

Sav

ed (M

J)

CUSUM Analysis 2012 - 2013

M2G installed. Significant drop in gas consumption following

installation

Thank you Any Questions?