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1 Cleaver-Brooks Webinars Today s Topic: Six Steps for Proper Industrial Watertube Boiler Selection If you ve missed any of our previous live webinars You can view our archived webinars by going to Past topics include: Stacks, Hydronics, Energy Recovery, Annual Shutdowns & Much More Coming Up January 22, 2013 at 2:00 PM ET: Routine Boiler Maintenance Ensures Reliability, Efficiency & Safety

2 Boiler Room Essentials Boiler Room Essentials is an online, self-paced learning course designed to educate individuals that are looking for a career in the steam boiler operations field or just to gain an understanding of the high pressure steam boiler industry. The course is geared for various levels of knowledge bases; whether you are just starting out, or you have been in the industry for many years this course is for you. Learn more or register at: Topics Covered: Steam Boilers Boiler Systems Steam System Fittings Steam System Accessories Feedwater Systems Water Treatment Combustion Equipment Combustion & Boiler Controls Draft Controls Instrumentation & Control Systems Steam Boiler Operation Licensing

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4 Six Steps for Proper Industrial Watertube Boiler Selection November 20, 2013, 2:00 PM ET Presented by: Steve Connor & Jason Jacobi

5 Scenario Midwest vegetable & specialty canner Boiler replacement; Coal to natural gas & #2 oil standby Max load: 200, psi Load increases during the pack from 160,000 lb/hr to 200,000 lb/hr Load swings and pressure decays rapidly 5

6 Other Factors for Consideration 6

7 Considerations Old Steam Piping 7

8 Considerations Limited Access Narrow, tree lined streets through local town before getting to the plant s power house 8

9 Considerations Budget Constraints Powerhouse: existing masonry chimney had to stay. 9

10 Considerations Newer Dearator and Chemical Feed Deaerator located in upper mezzanine of steam plant 10

11 Considerations Retiring Personnel Limited and/or inexperienced replacements. 11

12 Considerations Limited Maintenance Budget Reduction in maintenance budget to save on operating costs. 12

13 Considerations Reduce Fuel Costs Reduction in fuel expenses by at least 20%. 13

14 Considerations Lower Stack Emissions Lowering NO x and CO 14

15 15 Six Steps

16 Step 1 Steam & Process Load Needs

17 Step 1 Steam & Process Load Needs NC State University, boiler room, red boiler pic 200, operating psi Steam cycle variations with significant swings

18 Step 1 Steam & Process Load Needs Three Element Control System Monitoring water level, steam flow and feedwater flow 18

19 Step 1 Steam & Process Load Needs 10:1 Turndown Burner Allows for reduction in output before cycling offline. 19

20 Step 1 Steam & Process Load Needs NC State University, boiler room, red boiler pic 200, operating psi Steam cycle variations with significant swings Steam quality of ½% moisture as a minimum

21 Step 1 Steam & Process Load Needs Riser tubes fill the void above the waterline with wet steam Secondary separation is often provided by labyrinth or chevron style internal separators Steam endures a tortuous path as water droplets are knocked off End result is 99.5% dry steam, or < 0.5% moisture to process 21

22 Effects of Water Hammer New York City Midtown Manhattan July 18, 2007 We thought it was another terrorist attack! 22

23 Step 1 Steam & Process Load Needs NC State University, boiler room, red boiler pic 200, operating psi Steam cycle variations with significant swings Steam quality of ½% moisture as a minimum Conductivity Control 23

24 Step 1 Steam & Process Load Needs TDS Control 24

25 Step 2 Footprint & Site Issues

26 Building Access Step 2 Footprint & Site Issues

27 27 Step 2 Footprint & Site Issues

28 Step 2 Footprint & Site Issues Building Access Inside Building Interferences 28

29 Step 2 Footprint & Site Issues Tight Boiler Room with Interferences Early engagement can help minimize unnecessary modifications and movement. 29

30 Step 2 Footprint & Site Issues Soot Blower 30

31 Step 2 Footprint & Site Issues Building Access Inside Building Encumbrances Available Square Footage Ceiling Heights Overhead Restrictions Floor Loading Seismic/Wind Loading Stack and Breeching Location 31

32 Step 2 Footprint & Site Issues Structural Characteristics Draft conditions Too much or too little 32

33 Step 2 Footprint & Site Issues Building Access Inside Building Encumbrances Available Square Footage Ceiling Heights Overhead Restrictions Floor Loading Seismic/Wind Loading Stack and Breeching Location Utilities 33

34 Step 2 Footprint & Site Issues Motor Control Center Closely examined to assure voltages and fusing exists to adequately power the new boiler. 34

35 Step 2 Footprint & Site Issues Building Access Inside Building Encumbrances Available Square Footage Ceiling Heights Overhead Restrictions Floor Loading Seismic Stack and Breeching Location Utilities Fuel Storage Old Asset Removal 35

36 36 Step 2 Footprint & Site Issues

37 Step 3 Specification Considerations 37

38 Step 3 Specification Considerations Improve Efficiency by at least 20% 38

39 Step 3 Specification Considerations Combustion Efficiency 39

40 Step 3 Specification Considerations Economizer 40

41 Step 3 Specification Considerations Improve Efficiency by at least 20% Limited Maintenance Budget 41

42 Step 3 Specification Considerations 42

43 Step 3 Specification Considerations Older refractory design Modern maintenance-free design 43

44 Step 3 Specification Considerations 44

45 Step 3 Specification Considerations Improve Efficiency by at least 20% Limited Maintenance Budget Inexperienced Operating Personnel 45

46 Step 3 Specification Considerations Many modern steam plants are controlled from a central control room, with ethernet communication to local PLC control panels located at each boiler 46

47 Step 4 Emission Considerations

48 Step 4 Emission Considerations Low NOx Burner 48

49 Step 4 Emission Considerations Selective Catalytic Reduction 49

50 Step 4 Emission Considerations Volumetric Heat Release: Btu/hr-ft3 Evaluates combustion volume Furnace Heat Absorbed: Btu/hr-ft2 Evaluates tube metal temperature 50

51 Step 5 Shipping Considerations

52 Step 5 Shipping Considerations Packaged Boiler Units Are shippable via truck or railcar (depending on shipping clearances). 52

53 Step 5 Shipping Considerations Heavy, Wide Loads Can significantly impact timing and overall project cost. 53

54 54 Step 5 Shipping Considerations

55 Step 6 Economic Considerations

56 Step 6 Economic Considerations Full Metering/O 2 Trim Economizer High Turndown Burner 56

57 Step 6 Economic Considerations No Refractory PLC Based Control System Boiler Access 57

58 Step 6 Economic Considerations D O A 58

59 Up to 225,000 lb/hr High Pressure and Superheat Boiler Types D-Style BURNER Heating Process Auxiliary Power

60 Boiler Types D-Style The D style boiler is a design with two drums, vertical tube boiler bank, and a water-cooled furnace Capacity range: 10,000 to 225,000 lbs/hr BURNER Advantages: Economical 2-Drum Design Large Drums for Load Swings and High Steam Quality/Purity FURNACE Large Water-Cooled Furnaces Operate with Low Heat Release and Emissions Heating Process Auxiliary Power

61 Boiler Types O-Style Up to 250,000 lb/hr High Pressure BURNER Heating Process Auxiliary Power

62 Boiler Types O-Style The O style boiler is a design with two drums, vertical tube boiler bank, and a water-cooled furnace, but with a symmetrical design and vertical gas outlet BURNER FURNACE Capacity range: 10,000 to 250,000 lbs/hr Advantages: Vertical Gas Outlet Minimizes Footprint Symmetrical Design for Easy Shipment Lower Draft Loss = Lower Fan HP Heating Process Auxiliary Power

63 Boiler Types A-Style Up to 275,000 lb/hr High Pressure and Superheat BURNER Heating Process Auxiliary Power

64 Boiler Types A-Style The A style boiler is a design with two drums, vertical tube boiler bank, and a water-cooled furnace, but with a symmetrical design and vertical gas outlet BURNER FURNACE Capacity range: 10,000 to 275,000 lbs/hr Advantages: Vertical Gas Outlet Minimizes Footprint Symmetrical Design for Easy Shipment Lower Draft Loss = Lower Fan HP Larger Furnace than O-type Heating Process Auxiliary Power

65 Step 6 Economic Considerations 65

66 Step 6 Economic Considerations CBND Boiler Exhaust Stack Steam Outlet FD Fan Heat Recovery (Economizer) BURNER Emissions Scrubber (SCR or CO) D-Type Boiler Pressure Vessel Feedwater Inlet Control Panel 66 Burner & Fuel Inlet

67 Summary 1. Determine Steam and Process load needs. Probe deeply into the operation 2. Footprint & Site Issues. Outside & inside the building. Floor space and loading. Ceiling height and restrictions. Utilities (electrical, fuel, water and discharges) 3. Spec. Considerations. Efficiency expectations. Maintenance issues. Personnel issues 4. Emissions. Local or Federal requirements? 5. Shipping. Clearances. Road and off loading access 6. Economics. Best value fit for the job. Prioritize 67

68 Contact Us Jason Jacobi Product Manager cleaverbrooks.com 68