EVALUATING SCHOOL BOILERS: BEST REPLACEMENT OPTIONS

transcript

Integrated Design Solutions Architecture, Engineering, Interiors & Technology

EVALUATING SCHOOL BOILERS:

Bruce Snyder, CEM, LEED AP BD+C

October 8, 2013

BEST REPLACEMENT OPTIONS

Agenda

Background

Common Types of Boilers

Evaluating Existing Boilers

Boiler Efficiencies

To Condense or Not to Condense

Replacement Considerations/Options

Boiler Room Safety Features/Requirements

Utility Incentives

Q & A

Background

Current boiler designs go back well over 150 years.

Fire tube or “Scotch Marine” type boilers once powered

trains and ships.

Fire-tube boilers were one of the main engines behind

the industrial revolution, providing high pressure steam

to power factories.

Late 19th, early 20th century- 50,000 people per year

died from boiler and pressure vessel related accidents

in North America.

Background

ASME, ABMA, and NBBI helped develop codes and

standards to improve safety.

Once safety improved, boiler life, reliability and

efficiency became priorities.

Many different types of boilers began to be

developed.

Background

Cleaning the fire side

Cleaning the water side

Deteriorating refractory bricks

Addressing “thermal shock” or thermal stress cycling

Background

The advent of the flex tube boiler

Classic Fire Tube Boiler

Cast Iron/Cast Aluminum Boiler

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=KfUdChJUlGezzM&tbnid=NflQ0ckJ8G5dTM:&ved=0CAUQjRw&url=http://constructionmanuals.tpub.com/14279/css/14279_141.htm&ei=_LNuUfyfJcfuyQHKvoGgDQ&psig=AFQjCNG55mfbwnJ5l7LoRZ-RRogSvSlPOg&ust=1366295894849558

Flex Tube Boiler

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=-cWzpR9a-K2slM&tbnid=lvHl-uhB2RRDXM:&ved=0CAUQjRw&url=http://www.foodtechinfo.com/FoodPro/GasTechnologies/boilers.htm&ei=SsduUYTJGoWMyQHDwICICg&bvm=bv.45368065,d.aWc&psig=AFQjCNGUrm7o-Ln99aVxoRp7cybrxr5bEQ&ust=1366300869899495

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=mgeGec0zy9sblM&tbnid=RiJ1xmjB7u-0yM:&ved=0CAUQjRw&url=http://www.ejwalsh.com/products/bryanBoilers.htm&ei=NchuUYm-F-KLywGLnoGQDg&psig=AFQjCNFvdpsAZF7qaDP2Nb_qAYVlzXNMEg&ust=1366301049373913

Horizontal Copper Finned Boiler

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=aV9TC0YjVYgo_M&tbnid=sCequdjQy3YIOM:&ved=0CAUQjRw&url=http://www.lochinvar.com/news.aspx?mode=singleArticle&articleid=62&ei=e5puUYTDGqaoywGIuYCQDg&bvm=bv.45368065,d.aWc&psig=AFQjCNGzh9hQvsUC00sV0VNlEfHKmskiZQ&ust=1366289335980172

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=Ok3ZIxQzR9GxjM&tbnid=Kz3TFGQ5dtnryM:&ved=0CAUQjRw&url=http://www.made-in-china.com/showroom/olieve/product-detailIoMxapruFmhn/China-Copper-Finned-Tube.html&ei=JpxuUd3PFbPNywGjrIDIBQ&bvm=bv.45368065,d.aWc&psig=AFQjCNGzh9hQvsUC00sV0VNlEfHKmskiZQ&ust=1366289335980172

Condensing Boilers

Type and manufacturer of the boiler

Number of boilers in the rotation

Maintenance history, water treatment

and air removal

Age of the boilers

Frequency of use/ Seasonal

Frequency of repair service

Video scope the interior

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=ymtO4bL46obd9M&tbnid=7UoeappQFAN8cM:&ved=0CAUQjRw&url=http://www.marineinsight.com/tech/proceduresmaintenance/important-points-for-boiler-cleaning-on-a-ship/&ei=qdluUej5I4iZyAGu74Ag&psig=AFQjCNGr-cd-TjgouFqZ61ZNXEk9JO0u-Q&ust=1366305551670185

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=ZM5oqylkAGIkYM&tbnid=XE1eSMnc8MM6GM:&ved=0CAUQjRw&url=http://www.spirotherm.com/combination/&ei=BlZxUciAH_er4AOS-oDIDw&bvm=bv.45373924,d.dmg&psig=AFQjCNE0RZC5ujkj0LDXj0g6zJybfspVHg&ust=1366462554363500

Fire Tube = 40+ Yrs

Cast Iron = 35 Yrs

Flex Tube = 30 Yrs

Copper Fin =15 Yrs

Condensing, depends

on type and usage

Boiler Efficiency

Thermal Efficiency

Combustion Efficiency

AFUE (Annual Fuel Utilization Efficiency)

Boiler Efficiency

Determine your boiler

efficiency

Check boiler name plate

for input and output

i.e. INPUT: 5,000 MBH

OUTPUT: 4,000 MBH

equals 80% Thermal Eff.

Boiler Efficiency

How a condensing boiler works

Boiler Efficiency

Phase change captures a large amount of energy

Stack Economizer

Condensing HX

Boiler Efficiency

A stack economizer which preheats the boiler feed

water increases thermal efficiency by 1.5-2%

Boiler Efficiency

Visual depiction of the amount latent heat exhausted

and the damaging effects on metal.

Boiler Efficiency

Combustion efficiency

Boiler Efficiency

When fuel and oxygen in the air are in balance

the combustion is said to be Stoichiometric

Boiler Efficiency

Efficiency losses due to water side scale build up

To Condense or Not to Condense

New design

Off season requirements

Pool boilers

Year round operation

Does the amount of time the boiler “may” operate in the condensing mode save enough energy/money to justify the added cost of the boiler?

Run a computer model

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=EqHEijtVrGpAFM&tbnid=Q3Yn68y00UZ4bM:&ved=0CAUQjRw&url=http://www.empowernetwork.com/3djohnboy/blog/empower-network-chicago-event-ticket-to-get-money/&ei=ghhwUZCPCIbmyQHLj4DYDg&bvm=bv.45368065,d.aWc&psig=AFQjCNF_xpJyxWaoXHC2AERaQzQn70RlNQ&ust=1366387169077568

Replacement Considerations/Options

Like and kind

Physical constraints

Thermal load verification

Degree of redundancy

Maintenance issues

Stack arrangement

Combustion air intake arrangement

Boiler Room Safety Requirements

Submit all plans to the State Bureau of Construction

Code for Plan Review

A multitude of safeties intrinsic to each boiler itself

Gas regulators- always vented to the outdoors

Temperature and pressure relief valves vented safely to

the floor

ASME code CSD-1 Rule 27 Annual Safety Testing

Do not use the results of the CSD-1 test as a

indication of the overall condition of your boiler

Boiler service clearances as

required by the boiler

manufacturer

Electrical clearances as

required by NEC and the

Michigan Electrical Code

Emergency off buttons for all

gas fired appliances

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=DRpLo31xySbz7M&tbnid=MCmRLCsNCquBoM:&ved=0CAUQjRw&url=http://pillaelectricalproducts.com/proba164AB8.htm&ei=b2BwUcKAGPaw4APKooDwCA&bvm=bv.45373924,d.dmg&psig=AFQjCNGjW9TAOMlI9I2f5pSbY3JHgDyq5A&ust=1366405593001346

Meet combustion air requirements for all

appliances in the room

Create separation or add a refrigeration purge

system for a combined use space

Independently support boiler stacks, economizers,

combustion air intake ducts, inline pumps, etc.

Provide ample light not obscured by equipment

Eye wash or shower when chemicals are present

Utility Incentives

Consumers Energy

Gas Measure Incentive Changes The new incentives listed below are effective with all new applications submitted April 2, 2013 or later.

Contact Information:

Bruce Snyder

1441 W. Long Lake, Ste. 200

Troy, MI 48098

Phone: 248-823-2174

Email: bsnyder@ids-troy.com

Questions???

Integrated Design Solutions Architecture, Engineering, Interiors & Technology

EVALUATING SCHOOL BOILERS: BEST REPLACEMENT OPTIONS

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