Product category:
Energy management; Boiler control
News Release from: Maxsys | Subject: Ford tests
Edited by the Processingtalk Editorial
Team on 09 April 2007
Boiler fuel savings using Maxsys Fuel+
verified
Ford Motor Co have reduced emissions by 5.1% on gas fired boiler plant using Maxsys Fuel+ systems, as monitored by an independent ABB Engineering Services monitoring exercise
As part of an on-going objective to reduce emissions and conserve energy at the Ford Motor Company Dunton Technical Centre, Maxsys Fuel+ systems have been fitted to the boiler plant, helping the company to achieve over a 5 per cent reduction in gas usage with a commensurate reduction in emissions The Energy Committee at Dunton decided to investigate ways of reducing gas usage by improving efficiency
This article was originally published on Processingtalk on 24 May 2006 at 8.00am (UK)
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As part of this review, the committee focused on potential for energy savings at the Dunton Technical Centre which houses a substantial boiler house.
Rated at 25MW, the boiler house is used to supply high pressure hot water to the many laboratory and engineering facilities at the site along with general space heating.
Following a review of available technologies, the Committee decided to work with Walsall based Maxsys to integrate their innovative Fuel+ system on to the boiler plant.
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The Fuel+ systems are proven to achieve a minimum of a 5% reduction in gas usage - a figure which Maxsys guaranteed to Ford, or their money back.
Technical Performance Evaluation.
The Dunton boiler plant contains 3 boilers - boilers 1 and 2 are Ruston Hornsby twin shell boilers rated at 10.26 MW each whilst 3 is a BIB Minster boiler rated at 5.28MW.
All boilers are fired with Hamworthy dual fuel burner systems.
With the seasonal variation in load, B3 is used as lead boiler from May to September before a changeover to the larger boilers B1 or B2 for the winter period.
The Fuel+ systems were fitted to all the boilers.
Test Protocol.
The Ford Dunton Energy Committee formulated a 6 Sigma project for the integration and evaluation of the Fuel+ systems.
Working closely with Ford's own engineering team, ABB Engineering Services were involved in the project to provide a Test Protocol and to carry out an independent evaluation of pre and post-installation performance.
ABB assessed the current metering and monitoring available on the plant and following an analysis of a sample of data produced a Test Protocol outlining the requirements for the successful assessment of boiler performance.
This was based on the monitoring and recording of a range of variables.
Data points were to be gathered 10 times per day and supplemented by a daily flue gas and efficiency check.
To provide a robust evaluation of the project, ABB stated that a minimum of 30 days data would be required (300 data points) before and after installation of the Fuel+ systems.
The Test Protocol was agreed and signed off by Ford, ABB and Maxsys and formed the basis of the 5% performance guarantee.
Evaluation Technique.
ABB based their evaluation on the established CUSUM statistical model with regenerative analysis.
The sensitivity to small changes can be clearly identified with the CUSUM technique.
Working alongside the 6 Sigma team, ABB "benchmarked" boiler performance prior to installation and then compared predicted and actual data after installation.
Pre Installation Data Analysis.
With the Test Protocol agreed and signed off, pre-installation data collection was started by Ford in June 2006.
Analysis of the 'Pre' data by both the Ford 6 Sigma team and ABB concluded that a robust analysis of predictive and comparative boiler performance after installation of the systems was possible.
Following completion of the 'Pre' data collection exercise by Ford and data analysis by ABB, Maxsys installed the Fuel+ systems on the 15th August 06.
Post Installation Data Analysis.
Analysis of the 'Post' data gathered for August and September 2006 has proven that average gas consumption was 5.1% lower, with a commensurate reduction in emissions, following the installation of Fuel+ systems.
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