Temp A Trim Slides 2009
- 1. www.webster-engineering.com Air Density Trim Control TM
- 2. Webster Engineering, a leader in burner manufacturing and combustion control, now offers a combustion air temperature trim system that should give you a 2-3% savings in your fuel bill. With out the cost and complexity of a conventional O 2 trim system. www.webster-engineering.com
- 3. Combustion Fuel to Air Ratio Burner Set-up A burner is set up to run efficiently by mixing the proper mass of fuel and the proper mass of air. www.webster-engineering.com Air Gas
- 4. Combustion Fuel to Air Ratio Burner Set-up www.webster-engineering.com Air Efficient ratio at 80 o F Results in 3% O 2 Efficient mass of Gas to mass of Air White circle = Volume Yellow circle = Mass This represents a normal set-up @ 80 degrees - trying to make the burner as efficient as possible. Gas
- 5. Combustion Fuel to Air Ratio www.webster-engineering.com Volume of Air @ 80 o Ratio at 120 o F Burner Fans Produce Constant Volume of Air Combustion Air Temperature Changes Volume increases with higher temperature, but mass remains the same Same Air @ 120 o Gas
- 6. Combustion Fuel to Air Ratio www.webster-engineering.com Volume of Air @ 80 o Ratio at 120 o F Results in 1.5% O 2 Burner Fans Produce Constant Volume of Air Combustion Air Temperature Changes Volume stays the same with the burner fan, although the mass is reduced Constant volume - reduced mass Gas
- 7. Combustion Fuel to Air Ratio www.webster-engineering.com Volume of Air @ 80 o Ratio at 120 o F Results in 1.5% O 2 Combustion Air Temperature Changes Volume stays the same with the burner fan, although the mass is reduced Unburned fuel and high CO Constant volume - reduced mass Gas
- 8. Combustion Fuel to Air Ratio Results in 3.0% O 2 www.webster-engineering.com Volume of Air @ 80 o Ratio at 120 o F Efficient operation The Temp A Trim Solution Increase fan RPM to maintain mass Gas
- 9. Combustion Fuel to Air Ratio Results in 4.5% O 2 www.webster-engineering.com Volume of Air @ 80 o Ratio at 40 o F Burner Fans Produce Constant Volume of Air Volume decreases with lower temperature, but mass remains the same Same Air @ 40 o Gas
- 10. Combustion Fuel to Air Ratio Results in 4.5% O 2 www.webster-engineering.com Volume of Air @ 80 o Ratio at 40 o F Volume decreases with lower temperature, but mass remains the same Inefficient operation Same Air @ 40 o Gas
- 11. Combustion Fuel to Air Ratio Results in 4.5% O 2 www.webster-engineering.com Volume of Air @ 80 o Ratio at 40 o F Efficient operation The Temp A Trim Solution Decrease fan RPM to maintain mass Gas
- 12. www.webster-engineering.com That’s what the does. It measures the combustion air temperature and adjusts the fan motor speed to maintain the correct mass of air. Thus allowing you to set and hold an optimum excess air or O 2 level.
- 13. www.webster-engineering.com Typical Combustion Air Temperature Variations Date: 8/2/07 Date: 10/23/07 Site located in Winfield, Kansas Dry Cleaners High Temp. = 121 F. Low Temp. = 58 F. Burner saw a 63 F temperature swing prior to the cold of winter. TEMP A TRIM maintained a consistent O 2 reading.
- 14. www.webster-engineering.com System Layout TAT Circuit Board VFD Control Flame Safeguard (existing) Motor / Blower Wheel (existing) Air Flow Sensor
- 15. www.webster-engineering.com System Layout Retro-Fit Application Components TAT circuit board / slave relay in separate enclosure Sensor (Thermistor) Variable frequency drive VFD display Conduit and wiring by field personnel.
- 16. www.webster-engineering.com System Layout Retro-Fit Application TAT circuit board / slave relay in separate enclosure Original Burner control panel Sensor (thermistor) mounted at Burner air inlet Variable frequency drive VFD display TAT Board, sensor and VFD field wired Flame Safeguard
- 17. www.webster-engineering.com System Layout New Application – Burner Mount Panel Burner Flame Safeguard Variable frequency drive, mounted on outside of panel VFD display TAT circuit board / slave relay in Burner panel
- 18. www.webster-engineering.com System Layout New Application – Burner Mount Panel Sensor (Thermistor) Air Louver Box Air flow Burner panel Burner
- 19. www.webster-engineering.com System Layout New Application – Remote Mount Panel TAT circuit board / slave relay in own junction box TAT circuit board and sensor wiring by Webster Sensor (Thermistor) Variable frequency drive, mounted on outside of panel (mounted in field) VFD display Remote Control Panel Air Louver Box
- 20. www.webster-engineering.com System Layout New Application – Remote Mount Panel TAT circuit board / slave relay in own junction box TAT circuit board and sensor wiring by Webster
- 21. www.webster-engineering.com TEMP A TRIM Circuit Board
- 22. www.webster-engineering.com Thermistor Location Boiler room wall louvers Combustion Air Flow Cooler Air Cold Ambient Air The TEMP A TRIM Sensor should be located within the path between the boiler room louvers and the burner louver box. Sensor Warmer Air Warmer Air
- 23. www.webster-engineering.com Patent Pending Using you get the following…………… An estimated fuel savings of up to 3% An efficiency gain of 1% or greater An electrical savings of up to 30% due to the reduced motor speed Reduced noise level due to reduced motor speed Reduced seasonal tune-ups
- 24. www.webster-engineering.com View a video by visiting the Webster website: www.webster-engineering.com Click on TEMP A TRIM bar Ask your Representative about using the LogTag temperature recorder to measure the temperature swing in your boiler room.
- 25. www.webster-engineering.com LogTag Temperature Recorder Sample Graph from LogTag Readings
- 26. www.webster-engineering.com Payback Analysis TEMP A TRIM savings 2% $5,500 Recalculation of payback in years (with TEMP A TRIM) 1.66 Energy savings rebate (gas & electric company) $1,000 Recalculation of payback in years (with rebate) 1.56 % capacity utilization (average firing rate including off time) 33.7% % capacity utilization (based on running hours only) 60.1% Total savings per year (not including rebate) $15,686 % utilization based on 8760 operating hr/yr (56% on – 44% off) 56% Payback in years 2.36 Cost of new burner & installation $24,000 Percent fuel savings 3.7% Total retrofit burner savings $10,187 Savings from reduced hysteresis & excess air $6,023 Maintenance savings from reduced cycling $887 Savings from On-OFF cycling losses $3,277
- 27. www.webster-engineering.com Air Density Trim Control Thank you for your time TM