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Steve Connor
Technical Services Consultant
• Discuss the operational drivers: • Efficiency, Reliability and Safety
• The impact areas associated with each
• Possible remedies or solutions to consider
• Prioritizing
2
What We are Covering Today
What’s most wrong with my boiler operation?
Efficiency?
Reliability?
Safety?
3
What’s most wrong with my boiler operation?
Efficiency?
Reliability?
Safety?
Where do problems normally lie?
What are most popular solutions?
How do I prioritize them?
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Efficiency
5
Major Market DriversEconomics
6
COST OF
OPERATION
50% +
Impact Areas
7
Popular Fuels
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Hydrogen/Carbon Ratio
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Moisture Losses
10
Hydrogen
OxygenWater Vapor = Moisture losses!!
Fuel/Air Control
11
Single motor & Jackshaft
Combustion Problems
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Stack Losses
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40 Deg. F Rise = 1% Loss
• Operating pressure
• Firing rate
• Ambient temperature
BASED ON:
Excess Air Increases As The Firing
Rate Decreases
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Combustion Efficiency
0%
2%
4%
6%
8%
10%
12%
Burner
Turndown4 To 1
75%LF 50%25%
Percent O2
Firing Rate
Every 2%
Increase
= 1% loss!
100%
Cycling Losses
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Pre & Post
Purge Losses
Excessive Makeup?
Feed water temperature?
Condensate returning?
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Excessive Makeup?
Feed water temperature?
Condensate returning?
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Every 10 Deg. F increase in FW temperature
= 1% increase in efficiency!
Motors
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Reliability
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Impact Areas
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Reliability Issues
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Reliability Issues
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Scanner
Reliability Issues
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Diffuser
Combustion Issue
Reliability Issues
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Fuel/Air Ratio Control
Problems• Slip
• Deflect
• Wear
Reliability Issues
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Unstable water level
Reliability Issues
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Nuisance shutdowns
Pump on
LWCO
Reliability Issues
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Liner tile
Throat tile
Reliability Issues
Burner housing cracks or poor seals
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Safety
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Impact Areas
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Electrical Power
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Low Voltage High Voltage
Hot Surfaces
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Hot Surfaces
34
Hot Surfaces
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Lower half
Sight port w/cooling line
Water Level Controls
Auxiliary
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Main
Gauge glass
Water Side Occurrence
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Confined Spaces
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Firetube Boiler Watertube Boiler
Safety Valve Piping
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Solutions
40
Efficiency Solutions
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Stack Temperature
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Accurate thermometer
Stack Temperature
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+ 40 Deg. F
= 1% Efficiency lost
Reduce Cycling
Losses can reach 10 – 15%!
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High Turndown Burner
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Fuel/Air Ratio Control
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Single point
Fuel/Air Ratio Control
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Parallel Positioning System
Excess Air Losses
OXYGEN TRIM SYSTEM
Compensates for atmospheric changes such as:
• Ambient temperature
• Relative humidity
• Barometric pressure.
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Stack Economizers
• Noncondensing
• Full Condensing
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Stack Economizers
• Noncondensing
• Full Condensing
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Every 40 Degrees Gained = 1% Saved!
Returning Condensate
Deaerator
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Every 10 degree increase = 1% Saved!
High pressure receiver
Electrical Draw
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High Efficiency Motors?
Variable Frequency Drives
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VFD Analysis
No VFD
@ 100% = 100%
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VFD Analysis
No VFD
100% = 100%
W/VFD
@ 70% = 34%
@ 50% = 12.5%
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Reliability Solutions
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Reliability
57
Reliability
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Neat & Clean
Boiler Room Equipment Record Keeping
Dynamic records• Start up and tuning reports
• Repair reports
• Inspection reports
• Chemical analysis reports
• Boiler room log
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Reliability Solutions
Scanner
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Burner
Diffuser BMS
Reliability Solutions
61
Throat Tile
Furnace Liner
Dry Oven
Reliability Issues
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Water Treatment
63
Water Treatment
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Safety
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Hot Surfaces
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Dryback Wetback
Hot Surfaces
67
Dryback Wetback
Hot Surfaces
68
Gun Burner Package Integral Burner Package
Hot Surfaces
69
Hot Surfaces
70
Safety Solutions
72
Electrical Safety
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Safety Valve Piping
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Cleaver-Brooks Boiler Room Log
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Date
Time
Boiler #
Operator
Water visible in gauge glass
Combustion check (visual)
Steam pressure
Feedwater pressure
Feedwater temperature
Flue gas temperature
Burner
Gas pressure
Gas meter reading
Oil pressure (regulated)
Oil temperature
Oil meter reading
Atomizing air pressure
Ambient air temperature
Make-up water
Blowdown water column
Blowdown boiler
Comments/Observations
Chemical analysis
Steam
Note: record water analysis and treatment on separate log
Diligent Monitoring and Recording
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Evaporation Test
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CB Level Master
Features• Low or no float movement
• High and low water alarming
• Column blowdown reminder
• Notes successful or unsuccessful
• LED readout of water level
• Test auxiliary without jumper wire
• Easy tie into PLC platform
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Operator Training
Cleaver-Brooks “Boiler House” Milwaukee, WI
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• On-site Tailored programs
• Regional seminars
• Online
Armstrong International Training Center
Troubleshooting and Repair
80
Prioritizing
• Efficiency
• Reliability
• Safety
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Investing Capital Dollars
82
Everybody is vying for the same bag of
cash…
Normally a simple payback calculation…
Operation’s Guy Facility’s Guy
Investing Capital Dollars
Evaluating Cost & Value• NPV (Net Present Value)
• Time/value of money (opportunity)
• Discounted dollars
• Positive cash flow and/or profitability
• IRR (Internal Rate of Return)• Cost of capital including tax rate
• Hurdle rate
• Competing projects
83
Summary
• Single point positioning systems tend to wear causing poor fuel/air control. A
2% increase in O2 is a 1% loss in efficiency. A parallel positioning system can
remedy this problem.
• Excessive boiler cycling is a huge energy waster. A smaller boiler or high
turndown burner may be the answer.
• Reliability improvement starts with a clean and organized boiler room.
• Burner trips are mainly caused by fouled scanners and bouncing waterlines
due to improper water treatment or condensate fouling.
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Summary
• The biggest contributors to unsafe boiler rooms are poor maintenance
procedures and low water cutoff failures. Operator Training is critical.
• Low voltage can kill!
• Safe boiler rooms have excellent boiler room policies & procedures which are
diligently followed including documentation.
• Justifying a capital spend goes beyond simple payback. Money has a
time/value component as well as various opportunities for its use. NPV and IRR
are critical methods for analyzing the investment for decisions & prioritizing
purposes.
85
Questions?
86
Steve Connor
Technical Services Consultant
262.377.6347
cleaverbrooks.com
