Jan. 13, 2025
Whether managing hydronic or steam boilers, there are various approaches to minimize operational expenses throughout their lifecycles.
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The initial costs when selecting new equipment can be overwhelming. However, while there is a tempting desire to cut costs at every turn, the long-term implications of the choices made should be considered as part of the purchasing decision.
A boiler represents a long-term investment, with a lifespan that extends over many years. During this period, its highest expense will be the operating cost. Although fuel prices can fluctuate due to various external factors, efficiency upgrades can lead to significant savings over time. Evaluating the duration to recuperate the additional investment through energy savings can guide this decision.
When operated efficiently, condensing boilers can reach energy efficiency levels of up to 98%. These boilers are specifically designed to handle lower stack temperatures without resulting in damage and perform optimally with the lowest return water temperatures.
To see a marked improvement in efficiency over noncondensing boilers, there must be a significant difference between the return and operating temperatures. Maximum efficiency is achieved with a return temperature of 80°F or less.
Facilities often switch from noncondensing to condensing boilers without adjusting their operation. Without a low return-water temperature, the condensing boiler's efficiency does not surpass that of a noncondensing one.
Given that steam boilers are constructed from steel, it's crucial to consider the thermal properties of this material, as steel is sensitive to rapid temperature changes. Such changes can cause fatigue and potential failure points in the steel. Therefore, during operation, it's essential to ensure that any adjustment in temperature occurs gradually.
Steam boilers operate by cycling on and off to maintain a preset pressure. If the boiler has been inactive for an extended time, the water within can cool significantly, resulting in a drastic temperature difference between the water and burner output, which can induce thermal shock.
Incorporating a temperature sensor can facilitate a smooth increase in the firing rate of the boiler as it warms up. Relying solely on steam pressure monitoring does not provide an accurate indication of water temperature, making such thermal shock defenses impossible.
VFDs are widely prevalent in modern boiler setups. Beyond offering enhanced control, understanding the affinity laws that illustrate the connections between flow, power, and various operational parameters can lead to notable energy savings when applied correctly.
The affinity laws dictate that flow is directly proportional to speed, while power consumption increases exponentially as the cubic function of speed. This means that running a fan or pump at 80% speed utilizes roughly half the energy compared to operating at full capacity. This principle can be quantitatively confirmed by calculating the motor speed cubed (0.8 x 0.8 x 0.8 = 0.512).
When multiple boilers are linked to the same water loop or steam header, they can function independently, leading to increased cycling and inefficiencies. A practical solution is the introduction of a host sequencing panel.
This panel synchronizes numerous boilers, regulating their cycling and modulation effectively. One temperature or pressure sensor oversees the output, and an algorithm, fine-tuned by a qualified technician, ensures the set points are met in the most cost-effective manner. Advanced features can also provide remote access, pump control, and additional boiler-specific functions.
Investing in an Internet of Things (IoT) monitoring system is one of the best ways to keep tabs on a boiler's performance. These systems provide critical operational data and alerts at any time, from anywhere.
Users can remotely access their boiler systems, track performance metrics, receive notifications, utilize diagnostic tools, and analyze trend reports, thereby transitioning from a reactive to a predictive maintenance approach to lower costs and enhance uptime. Partedon Group
An oxygen trim system integrates a sensor into the combustion stack, continuously monitoring oxygen levels during boiler operation. This system can trigger alarms if oxygen levels or stack temperatures deviate from predetermined zones. Algorithms manage the oxygen levels, automatically adjusting one aspect of combustion—usually air—to maintain optimal levels.
Without this system, fluctuations in ambient temperature can adversely affect combustion efficiency, leading to higher energy costs and potentially necessitating a retuning of the boiler during significant temperature shifts.
Utility providers are continuously searching for innovative ways to enhance capacity within their service areas to cater to the increasing energy demands of customers.
One strategy employed by natural gas utilities to manage customer consumption is curtailment, allowing customers to reduce natural gas usage in exchange for lower supply costs. This arrangement requires customers to have versatile burners capable of running on multiple fuels.
Rebates are often provided for customers upgrading to more energy-efficient boiler models or implementing VFDs in existing motor systems.
The efficacy of a boiler following its commissioning is directly linked to the attention and effort invested during the process. Selecting professionally trained technicians who grasp the essentials is crucial for achieving proficient results.
In the case of modulating boilers, it’s vital that the firing rates from low to high fire yield linear heat outputs. Employing instrumentation to validate fuel flow rates during this process is also imperative—confirm maximum outputs during peak firing and make sure the advertised turndown ratios are achieved.
Utilizing a calibrated combustion analyzer while tuning the burner is essential. Be sure to set target oxygen levels for both high and low firing as recommended by the burner manufacturer and never modify combustion settings without appropriate monitoring.
When upgrading or replacing a boiler, take advantage of the opportunity to assess additional improvements in the boiler room. View the boiler room and its components as an interconnected system rather than a collection of individual elements.
Choose controls with capabilities to link all necessary devices, allowing centralized management of the boiler and accessories through one system, thereby enhancing efficiency and saving costs. Consider upgrading related systems such as deaerators, water levels, draft mechanisms, as well as chemical feed and make-up water systems to streamline operations.
By Carlo Zaskorski, Corporate Director of Controls, Cleaver-Brooks
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