05/14/2012 BOILER TUNE UPS & REPLACEMENTS PRESENTATION BOILER BASICS FOR LARGE INDUSTRIAL FACILITIES. Mark Bergum, P.E.

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1 BOILER TUNE UPS & REPLACEMENTS FOR LARGE INDUSTRIAL FACILITIES Mark Bergum, P.E. PRESENTATION BOILER BASICS 1

2 BASE ASSUMPTION BOILER Steam Heat Output Exhaust Heat Losses 70% 20% Other Heat Losses 3% Blowdown Heat Losses 5% Radiation and Convection Heat Losses 2% 1% Boiler Efficiency Increase 1% Load Reduction at End Use 6,250 MMBtu boiler savings 3,634 MMBtu reduced load $31,250 $25,000 5,000 MMBtu boiler savings Boiler Tune Ups & Replacements for Large Industrial Facilities 4 BASE ASSUMPTION BOILER Various Steam volumes and pressures 500,000 MMBtu annual consumption of Natural = $2.5 = $4.0 Million/year 79% Combustion Efficiency Boiler Tune Ups & Replacements for Large Industrial Facilities 5 BOILER TUNE UP 2

3 TUNE UP OPPORTUNITY Rule of thumb: boiler efficiency can be increased 1% for each 15% reduction in excess air or 40 F reduction in stack gas temperature Boiler Tune Ups & Replacements for Large Industrial Facilities 7 TUNE UP EFFICIENCY OPPORTUNITY Use Hand-Held or permanent sensor computer-based analyzer Combustion Efficiency for Natural Gas Excess % Combustion Efficiency Flue Gas Temperature Minus Combustion Air Air Oxygen % 2.0% 85.4% 83.1% 80.8% 78.4% 76.0% 15.0% 3.0% 85.2% 82.8% 80.4% 77.9% 75.4% 28.1% 5.0% 84.7% 82.1% 79.5% 76.7% 74.0% 44.9% 7.0% 84.1% 81.2% 78.2% 75.2% 72.1% 81.6% 10.0% 82.8% 79.3% 75.6% 71.9% 68.2% Assumes complete combustion with no water vapor in combustion air 21,661 MMBtu/Year = = $173,285 Boiler Tune Ups & Replacements for Large Industrial Facilities 8 CONTROL TUNE UP Install Linkage less Controls Motors with elec. control Solid State Sensors Track Efficiency Benchmark costs ($/1,000LB) Tune ups on electronic control is more consistent and long-lasting. Boiler Tune Ups & Replacements for Large Industrial Facilities 9 3

4 BURNER MAINTENANCE Analysis: Visually inspect wear on Firing Head Diffusers Igniters Action: Consider Replacement if: Worn out (visual or operating inconsistency) Cycling too often (inadequate turn down ratio) Converted from oil burning Boiler Tune Ups & Replacements for Large Industrial Facilities 10 WATERSIDE HEAT TRANSFER SURFACE Analysis: Visually Inspect scale on water side heat transfer surface of firetube boilers. Scale is an insulator and prevents heat transfer. Scale increases Flue Gas temperature Alternate: Monitor Flue Gas Temperature Match firing rate and excess oxygen content Action: Mechanical or Acid Clean Consult water treatment specialist is consistent problem Boiler Tune Ups & Replacements for Large Industrial Facilities 11 MULTI-BOILER SCHEDULING Analysis: Review boiler set points to ensure most efficient system operation. Lead boiler determination Partial firing rate set points Action: Revise set points Boiler Tune Ups & Replacements for Large Industrial Facilities 12 4

5 BOILER REPLACEMENT NATURAL GAS BOILER REPLACEMENT Typical reasons Equipment at End-of-Life Significant load reduction (Oversized Boiler) Decentralizing boiler load (multiple small boiler plants) Environmental regulations For Decision use the following: Cost Benchmarks Combustion Efficiencies Repair Costs Life of Ex. Equipment Life Cycle Costs Boiler Tune Ups & Replacements for Large Industrial Facilities 14 SOLID FUEL BOILER REPLACEMENT Opportunity Fuel Wastes Compare Operating Costs Heat Load/Efficiency x Cost to compare gas and solid fuels Fuel Handling Maintenance Hurst Boiler Boiler Tune Ups & Replacements for Large Industrial Facilities 15 5

6 WASTE HEAT RECOVERY Higher Temperature = Higher Quality Multi-Stage recovery makes for most efficient use of excess heat Sample Waste Heat Temperatures Uses for heat recovered from various sources Type of Device Pre-Heating water or air Steam boiler exhausts Generally to transfer heat Heat treating furnaces Drying and baking ovens to other places of need Catalytic crackers Process steam condensate Space heating Cooling water from: Product heating Furnace doors Forming dies Steam generation Temperature, o C Hot processed liquids Hot processed solids Boiler Tune Ups & Replacements for Large Industrial Facilities 16 INCENTIVES AVAILABLE The boilers up to 2000 kbtuh (2,000,000 btu capacity input) can be found on the HVAC application for tuneup incentives and replacement incentives. Over this size are to use the CUSTOM application. If you have a steam boiler please remember your boiler is likely referred to in HP (horsepower). 1 HP is equal to approximately 33,340 btu or 60hp and bigger will use a custom application under the current program year applications. All Custom applications need to be pre-approved. Not all standard HVAC applications need pre-approval. BOILER RELATED INCENTIVES HVAC tune-ups (no service contract in past 12 months) AC, Chillers: air and water cooled: $25, 8, or 4 per ton AC* *up to 50% of tune-up cost (no parts included) Gas boilers under 2,000 kbtuh: $150-1,200 per boiler Over this size are custom application based on the therms saved. The bigger boilers show an average of 1 to10% improvement in energy use. Pre-combustion & post analysis required HVAC equipment replacement Boiler for HW under 300 kbtuh or 85% AFUE: $400-3,000 per Boiler HW project over 300 kbtuh & 90%AFUE: $800-6,000 per 6

7 STEAM TRAP PROGRAM The average steam trap last 7 years The steam trap survey will help find the bad ones and pay to help do so Incentive of $30-50 per trap based on psig Capped at the survey cost Replace or repair of the failed OPEN traps: Incentive of $ based on the pressure psig Capped at replacement cost. ADDITIONAL RESOURCES Steam Source Book: Tip Sheets: U.S. Department of Energy Industrial Technologies Program Technical Fact Sheets: Boiler Tune Ups & Replacements for Large Industrial Facilities 20 7

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