charleston towers west virginia boiler replacement assessment and proposal august 2007

Charleston Towers Charleston Towers West VirginiaWest Virginia

Charleston Towers Charleston Towers West VirginiaWest Virginia

BOILER REPLACEMENT ASSESSMENT AND

PROPOSAL

AUGUST 2007

Simple Combustion Simple Combustion EfficiencyEfficiency


1000

Fuel In

Cooler Water Back

800 In

Heat Out

20% of fuel Wasted

80% Efficient

Boiler

• Fuel is the energy the boiler is provided. (What you pay for)

• Heat out is how much you get out of that fuel. (What you actually get)

• Wasted is the Fuel you couldn’t use. (What went up the stack and outside)

• Cooler water is what you get back AFTER your building used the heat you provided it. Obviously, it needs to be heated again.



1000

Fuel In

Cooler Water Back

800 In

Heat Out

20% of fuel Wasted

80% Efficient

Boiler

80% =

$1.00 SPENT TO GET

$ 0.80 IN HEAT

You’ll have to spend

$10,000.00 to get $8,000 in

Heat!



1000

Fuel In

Cooler Water Back

800 In

Heat Out

20% of fuel Wasted

80% Efficient

Boiler

Put $500 back in your pocket by making the boiler fire 85%

or $1000 @ 90%.

Water Temperature Water Temperature and Efficiencyand Efficiency

Water Temperature Water Temperature and Efficiencyand Efficiency

1801804040 130130

inlet water temperature

boi

ler

effi

cien

cy, %

8080

100100

8686

9494

condensing boilercondensing boiler non-condensing boilernon-condensing boiler

dew pointdew point

natural gas = 1050 Btu/ft33

8080

Solving Waste by Solving Waste by Boiler TypeBoiler Type

Solving Waste by Solving Waste by Boiler TypeBoiler Type

Boiler Type Condensing Copper Steel Firetube

Steel Water Tube

Cast Iron

Typ. Efficiency

85% - 98% 85% - 88% 78% - 82% 80% - 85% 80% - 84%

Minimum Return Temp

60F or below

120F 140F 130F 135F – 140F

2000 MBH Typ. Price

$25,000 $15,000 V: $16,000

H: $20,000

$16,000 $13,500 (Must assemble)

Which is best for Which is best for you?you?

Which is best for Which is best for you?you?

Boiler Type Condensing Copper Steel Firetube

Steel Water Tube

Cast Iron

Typ. Efficiency 85% - 98% 85% - 88% 78% - 82% 80% - 85% 80% - 84%

Minimum Return Temp

60F or below 120F 140F 130F 135F – 140F

2000 MBH Typ. Price $25,000 $15,000 V: $16,000

H: $20,000

$16,000 $13,500 (Must assemble)

Low Temperature System – Use Condensing

(Return at 80F or below)

Mid Temperature System – Use Copper

(Return at least part of the season at 120F or above)

High Temp System – Use Steel Fire or Water Tube/Cast Iron.

(Return at 140F – 160F – Usually 180F – 200F supply)

Other Waste?Other Waste?Other Waste?Other Waste?

• Electrical Losses from Pumps or large blowers.

• Jacket losses amplified by larger volumes and

steel designs.

• Temperature Control Limitations.

• Purge Losses.

• Vent Losses.

• Maintenance or Life Cycle costs.

80% Efficient

Boiler

Thermal Efficiency Thermal Efficiency Life Cycle CostLife Cycle Cost

Thermal Efficiency Thermal Efficiency Life Cycle CostLife Cycle Cost

Decrease inThermalEfficiency

Decrease inThermalEfficiency

5%5%

10%10%

7.5%7.5%

6%6% 9.3%9.3% 12.8%12.8%

Increase in Fuel Cost for Life of Product Increase in Fuel Cost for Life of Product

Load MatchingLoad MatchingLoad MatchingLoad Matching

• SOLID SIZING DONE BY EXPERIENCED AND ACCREDITED ENGINEERING

• BOILER TURNDOWN

• MODULAR BOILER PLANT.

• CONTROL WITH INTER-BOILER COMMUNICATION

• TAKE FULL ADVANTAGE OF SEASONAL OR WATER TEMPERATURE OPPORTUNITIES.

Load MatchingLoad MatchingLoad MatchingLoad Matching

• When loads vary, the boilers need to match the load.

• Proper sizing of the boilers and sufficient turndown (not excessive) adds to efficiency.

• Offset first cost quickly with proper evaluation of system demands.

• Eliminate short cycling while firing boilers at the most efficient rate (low fire) most of the season.

based on Windsor Locks, CT 5656 degree days

months

10

jan

deg

ree

day

s

20

30

40

50dec

Identify Your Identify Your SystemSystem


HOT WATER HEATING LOOP

(Basic main loop, radiation, air handlers, etc.. May be cut into or flow off of this loop.)

STEP ONE:

Determine the water temperature required for the system and roughly how many degrees the system will remove from the water (system delta tee)

100F

80F



HOT WATER HEATING LOOP

(Basic main loop, radiation, air handlers, etc.. May be cut into or flow off of this loop.)

STEP TWO:

• Begin to weigh first cost vs. long term savings.

• Look closely at the cost of maintaining and operating your plant.

• Proper boiler selection OR system piping becomes CRITICAL!

SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS

SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS

LOW TEMPERATURE HEATING LOOP RUNNING YEAR ROUND.

STANDARD EFFICIENCY BOILERS (STEEL or CAST):

• Special piping required.

• Special flow requirements.

• Added pumps and equipment will be needed.

• Firetube is not typically applied to a low temp system based on temperature requirements.

STANDARD STANDARD EFFICIENCYEFFICIENCYSTANDARD STANDARD EFFICIENCYEFFICIENCY

STEEL FIRETUBE WILL REQUIRE YOU SEPARATE THE COLD SYSTEM WATER FROM THE BOILER. ONE OF TWO OPTIONS ARE AVAILABLE.

STANDARD STANDARD EFFICIENCYEFFICIENCYSTANDARD STANDARD EFFICIENCYEFFICIENCY

HEAT EXCHANGER OPTION:

(YOUR CURRENT CONFIGURATION)

80F SYSTEM

STEEL / CAST STEEL / CAST DISADVANTAGESDISADVANTAGES


SYSTEM REDUNDANCY?

MUST RUN HOT. 140F OR ABOVE.

TOO MUCH PIPE IF DONE RIGHT!



EXTRA PUMPS NEEDED

•8HP IN ADDED OPERATIONAL

COST

•9 COUPLINGS

•9 BEARING ASSEMBLIES

•9 PUMPS TO OIL AND

MAINTAIN

1 2 3 4

57 68

9

STEEL / CAST STEEL / CAST CONCERNSCONCERNS

STEEL / CAST STEEL / CAST CONCERNSCONCERNS

• FAILED HEAT X COULD SHOCK THE BOILERS (NOT GUARANTEED)

• VERY DIFFICULT TO CONTROL

• INSUFFICIENT SIZES AVAILABLE

• LIMITED TURNDOWN OR LOAD MATCHING

• COMBUSTION AIR / VENTING

• HUGE LOSS IN COMBUSTION EFFICIENCY 365 DAYS PER YEAR.

• MAINTENANCE SETTINGS, ADJUSTMENTS, AND INSPECTIONS.

INTERNAL COIL INTERNAL COIL DESIGNDESIGN


Option 2 puts the separation on board the boiler with a coil around the firetube bundle.



• COIL WILL WRAP THE FIRETUBES

• COIL IS NOT REPAIRABLE.

• FLOW WILL BE A CERTAIN CONCERN AS COPPER SHOULD NEVER EXCEED 7’ PER SECOND. 35GPM WILL BE A 50F DELTA T.

• SYSTEM VOLUME IS A CONCERN

CONDENSING CONDENSING SOLUTIONSOLUTION


Selecting the properly configured condensing boiler is a long term solution that will make up the first cost quickly and continue to pay back.



• 30-300gpm flow turndown. Should not need pumps!

• 5:1 fuel turndown for load matcing.

• On board controls communicating between boilers.

• Completely repairable CAST IRON



• No minimum return temperature

• 6 sections (not 60 tubes) per boiler if repair is needed.

• Automatic combustion correction.

• Sealed combustion approved.

• Quiet! Under 70db.



• Matching seasonal load with maximum turndown and on board energy management controls and communication.

months

10

jan

deg

ree

day

s

20

30

40

50dec

Higher efficiency when running all in low, than a few in high. The

controls know this!



Efficiency charts for condensing boilers are fairly typical. Shown here is an example of how important load

matching is to attain the advertised

efficiency. Second ONLY to return

water temperature.

HYDROTHERM KN HYDROTHERM KN QUALITYQUALITY

HYDROTHERM KN HYDROTHERM KN QUALITYQUALITY

• True cast iron sections pre-assembled and fire-tested in the factory.

• Castings by age old foundry (aka. HB Smith – Boyerstown)

• No push nipples. Milled and sealed with top quality graphite gaskets!

HYDROTHERM KN HYDROTHERM KN MAINTENANCEMAINTENANCE


• Sections are replaceable (only 6 per boiler to worry about).

• Fireside cleaning should not be necessary with self correcting combustion.

• Counter flow design means no minimum water temperature, no thermal shock.



• Set it and forget it combustion. No linkage or moving dampers.

• Ratio controlled auto correcting combustion system.

• Allows for Full Modulation and 5:1 turndown with as low as 2” w.c. of incoming gas pressure.



• Familiar ignition system

• Powerful spark ignition (14K)

• Air dried reliability.

• UV flame sensing (most reliable and accurate).

• Heavy igniters easily accessed for alignment.



• Standard combustion system including RM7800 series FSG.

• Instant response to changes in air (air VFD)

• Sealed combustion can increase your plant efficiency eliminating infiltration of cold air.

HYDROTHERM KN HYDROTHERM KN ADVANTAGEADVANTAGE


• All stainless steel cabinets.

• Easy to rig and fits through standard doors.

• Standard controls such as Honeywell safety stats, relief valve, and low water cut offs mounted and external to easily check.



• Plaque burner design fires in near silence.

• Flame view port at top of boiler.



• Factory visit and training available.

• RME Tech’s factory trained and authorized for start up and warranty work.

• Contractor trained specifically on the KN boiler.

• Local Representatives surrounding you.

• Mestek backed!

WHO OWNS WHO OWNS HYDROTHERM?HYDROTHERM?


•Manufacturer of HVAC & Metal Forming Equipment

•Became a private company once again in 2006.

•Headquartered in Westfield, Massachusetts

•25+ Locations Throughout US and Canada

•Approx. 3000 EmployeesApprox. $375 million in Sales

HVAC

Metal Forming

WHERE MESTEK WHERE MESTEK STARTEDSTARTED

WHERE MESTEK WHERE MESTEK STARTEDSTARTED

• Founded in Westfield, MA in 1946 as Sterling Radiator by John E. Reed

• 4 employees in a rented garage

• Produced only hydronic finned-tube heating element



MESTEK KNOWS THE HVAC INDUSTRY – THEY OWN ALL THESE GUYS!

MESTEK KNOWS THE HVAC INDUSTRY – THEY OWN ALL THESE GUYS!

http://www.appliedair.com/

http://www.kingcompany.com/

http://www.kingcompany.com/

MESTEK NATIONAL MESTEK NATIONAL ACCOUNTSACCOUNTS

MESTEK NATIONAL MESTEK NATIONAL ACCOUNTSACCOUNTS

THESE GUYS TRUST US – SO SHOULD YOU!THESE GUYS TRUST US – SO SHOULD YOU!

charleston towers west virginia boiler replacement assessment and proposal august 2007

Documents

efficient boiler slide

efficient boiler fuel

f supply slide

cooler water

fuel cost

inter boiler communication

simple combustion efficiency

life of product slide