westbrook apartments boiler replacement assessment and proposal august 2007
TRANSCRIPT
Westbrook Westbrook ApartmentsApartmentsWestbrook Westbrook ApartmentsApartments
BOILER REPLACEMENT ASSESSMENT AND
PROPOSAL
AUGUST 2007
Westbrook Boiler Westbrook Boiler RoomsRooms
Westbrook Boiler Westbrook Boiler RoomsRooms
Very large breeching / square / very tall chimney (70’+)
B-1 B-2 B-3
E-1
E-2
E-3
DHX
DP-1
DP-2
CAD
• Large single wall breeching with tall Chimney.
• Atmospheric boilers.
• System Expansion Tanks (Bladder).
• Domestic Heat Exchanger System.
• Domestic Storage Tank.
• Combustion Air Damper.
Westbrook Boiler Westbrook Boiler and Breechingand Breeching
Westbrook Boiler Westbrook Boiler and Breechingand Breeching
Very large breeching / square / very tall chimney (70’+)
B-1 B-2 B-3
• Atmospheric efficiencies UNDER 65%.
• Chimney barely meets an ANSI category I rating.
• Room is tremendously hot indicating horrific losses.
• Vents are very large. Stand by losses are huge. Concern with hot floor.
• Maintenance intensive with 60+ tubes per boiler and state inspections due.
• BTU output isn’t nearly what it should be. Each boiler is 2100 MBH IN but nets less than 1365 MBH of heat value.
• Load matching is very poor. Boiler Type can’t be turned down effectively.
Westbrook Westbrook Domestic SystemDomestic System
Westbrook Westbrook Domestic SystemDomestic System
DHX
DP-1
DP-2
• Domestic Hot water System uses a plate and frame heat exchanger.
• Additional 4 HP in electrical losses from two pumps.
• Boilers are oversized to match this load and summer operation is expensive.
• Condition of the tank is unknown
• Entire system should be removed and water should be heated directly by water heaters.
Westbrook Westbrook Expansion TanksExpansion Tanks
Westbrook Westbrook Expansion TanksExpansion Tanks
E-1
E-2
E-3
• Expansion tanks are fairly new. Bladders should be checked.
• Size is sufficient for new boiler plant as volume will be lower.
• Note there is NO expansion on the domestic side. This violates current plumbing codes.
Westbrook Westbrook Combustion AirCombustion Air
Westbrook Westbrook Combustion AirCombustion Air
CAD
• Opening in wall may be too small for 6000 MBH.
• Infiltration is expensive / lack of air hurts efficiency.
• Louvers are rated around 60% blocked by screen and louver.
• Atmospheric boiler intensify losses with constant flow.
• No consideration for a variable rate of fire.
• Sizing properly is a minimum requirement for new or old plant.
Simple Combustion Simple Combustion EfficiencyEfficiency
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.
Simple Combustion Simple Combustion EfficiencyEfficiency
Simple Combustion Simple Combustion EfficiencyEfficiency
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!
Simple Combustion Simple Combustion EfficiencyEfficiency
Simple Combustion Simple Combustion EfficiencyEfficiency
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%.
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
Atmospheric TypeAtmospheric TypeAtmospheric TypeAtmospheric Type
Atmospheric Boilers
• Atmospheric (Flame at the bottom) boilers are OPEN flame boilers with the
largest in stand by losses.
• Room air continually passes through the boiler cooling it down and stealing
conditioned air on the off cycles.
• No air control, typical O2 around 10% (4% optimum)
• Negative room dangerous as Flames roll out, combustion enters room.
• Great Heat loss at the bottom of the boiler, you can almost burn your feet!
Forced DraftForced DraftForced DraftForced Draft
Forced Draft
• Forced draft uses a fan to add air to the ignited gas in
a controlled way.
• Combustion air as needed (Fan may require more than
natural)
• Good air control, typical O2 around 4% about 3:1 TD.
• Usually a category III Appliance. May need to line
chimney.
• Jacket losses exist but stand by losses become
PURGE and electrical losses.
Fan Assisted DraftFan Assisted DraftFan Assisted DraftFan Assisted Draft
Fan Assisted
• Fan assisted uses a small fan to premix the gas and
the air before ignition.
• Combustion air as needed (Typically less HP than FD)
• Good air control, typical O2 around 3% about 4:1 TD.
• Usually a category I Appliance. Depends on
Efficiency.
• Jacket losses and purge losses practically eliminated with design and low volume.
CondensingCondensingCondensingCondensing
Condensing
• Combustion system usually fan assisted (lowest losses).
• Combustion air as needed (Typically less HP than FD)
• Good air control, typical O2 around 3% about 5:1 TD.
• Usually a category II or IV Appliance. AL29.
• Jacket losses and purge losses practically eliminated with design and low volume.
• Low water temperature is a MUST to offer a return.
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)
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
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)
140F-180F
120F-160F
Identify Your Identify Your SystemSystem
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 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
MID TEMPERATURE HEATING LOOP.
STANDARD EFFICIENCY BOILERS (STEEL or CAST):
• Return Temperatures will be limited to 140F to prevent fireside and refractory damage.
• Limitations will prevent top efficiency reset ratios.
• Load matching is much more difficult as standard ratios are 3:1
• Maintenance cost will be higher as turndowns require expert settings and consistent adjustment.
• Efficiency limited to around 83%.
SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS
SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS
MID TEMPERATURE HEATING LOOP.
HIGH EFFICIENCY BOILERS (CONDENSING):
• Must have a very low return temperature to achieve over standard efficiency (60F-100F).
• High return temperatures will net no more than 88% efficiency.
• Cost is 25% greater but when conditions are met, payback can be quick.
• Special venting is required, but typically smaller. Masonry chimneys will need an AL29 liner.
• If tall chimneys 40’ or above are required, first cost may take too long to be recouped.
SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS
SYSTEM SYSTEM REQUIREMENTSREQUIREMENTS
MID TEMPERATURE HEATING LOOP.
MID EFFICIENCY MODULAR BOILERS (COPPER FIN):
• Can handle 120F temperatures.
• Primary / Secondary piping gives great control.
• Depending on model, Category I (85%) can be used in existing chimneys.
• Modular design offers staged firing which works well for load matching.
• System changes are unnecessary. System flow is unchanged.
• Small footprint gives back valuable space.
• Sealed combustion offers maximum boiler plant efficiency and is used ILO refrigeration detection systems.
CURRENT PLANT CURRENT PLANT CONFIGURATIONCONFIGURATIONCURRENT PLANT CURRENT PLANT CONFIGURATIONCONFIGURATION
BOILER PLANT
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
REMOVE 2 BOILERS AND SYSTEM PIPING LEAVE DOMESTIC RUNNING
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
CONNECT SYSTEM PIPING AS SHOWN – SYSTEM FLOW IS
UNCHANGED.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
INSTALL TWO PRIMARY LOOP TEES MAXIMUM 12” APART IN THE SYSTEM. THIS WILL BE THE NEW INLET/OUTLET
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
PLACE NEW MODULAR 85% COPPER FIN BOILERS IN PLACE. CONNECT
EXPANSION TO SYSTEM.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
CREATE AND PIPE YOUR PRIMARY LOOP TO THE NEW BOILERS.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
REMOVE HEAT EXCHANGER AND PIPING ASSOCIATED WITH OLD BOILER. PLACE
AND PIPE NEW DIRECT WATER HEATERS.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
REMOVE LAST OLD BOILER. ENJOY A COOLER ROOM, LOWER BILLS AND
COMPLETE REDUNDANCY.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
OPTION ONE: REMOVE OLD TANK INSTALL MULTIPLE SMALL TANKS.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
OPTION 2: REMOVE LARGE AND WASTEFUL LOUVER, ADD MATCHING
COMBUSTION SYSTEM.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
OPTION 2B: AS PART OF THE COMBUSTION AIR SYSTEM INSTALL A MODS SYSTEM TO CONTROL DRAFT.
SYSTEM PIPING
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
NEW PLANT NEW PLANT CONFIGURATIONCONFIGURATION
OPTION 3: USE AT LEAST AN ECONOMICAL STAGING CONTROL TO RESET AND MAXIMIZE EFFICIENCY.
months
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ABOUT RBI ABOUT RBI FUTERA IIFUTERA II
ABOUT RBI ABOUT RBI FUTERA IIFUTERA II
•85% EFFICIENT
•CATEGORY I APPLIANCE VERTICAL
•TRUE FLAME SAFEGUARD DESIGN
•NON PROPRIETARY CONTROLS
•UV FLAME MONITORING
•SPARK IGNITION
•ALL BRONZE HEADERS
•FULLY DIAGNOSTIC PANEL
•EASY ACCESS / SERVICEABILITY
•STAINLESS STEEL JACKET OPTIONAL
HEAT EXCHANGERHEAT EXCHANGERHEAT EXCHANGERHEAT EXCHANGER
DIAGNOSTIC DIAGNOSTIC PANELPANEL
DIAGNOSTIC DIAGNOSTIC PANELPANEL
Terminal Strips
Jumo 2-Stage
High Limit
HoneywellRM7895C
ELECTRICAL ELECTRICAL PANELPANEL
ELECTRICAL ELECTRICAL PANELPANEL
SIMPLE 2 STAGE SIMPLE 2 STAGE CONTROLCONTROL
SIMPLE 2 STAGE SIMPLE 2 STAGE CONTROLCONTROL
WHO OWNS RBI?WHO OWNS RBI?WHO OWNS RBI?WHO OWNS RBI?
•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
WHO OWNS RBI?WHO OWNS RBI?WHO OWNS RBI?WHO OWNS RBI?
MESTEK KNOWS THE HVAC INDUSTRY – THEY OWN ALL THESE GUYS!
MESTEK KNOWS THE HVAC INDUSTRY – THEY OWN ALL THESE GUYS!
MESTEK NATIONAL MESTEK NATIONAL ACCOUNTSACCOUNTS
MESTEK NATIONAL MESTEK NATIONAL ACCOUNTSACCOUNTS
THESE GUYS TRUST US – SO SHOULD YOU!THESE GUYS TRUST US – SO SHOULD YOU!
LOCAL LOCAL SUPPORT?SUPPORT?
LOCAL LOCAL SUPPORT?SUPPORT?
• ROBERTS MECHANICAL EQUIPMENT COMPANY IS THE DIRECT FACTORY REPRESENTATIVE FOR RBI LOCATED IN GARFIELD HEIGHTS OHIO.
• WE ARE DEDICATED TO THE FULL SUPPORT OF MCPHILLIPS ON THIS PROJECT. MCPHILLIPS WILL BE FULLY FACTORY AUTHORIZED TO SERVICE AND MAINTAIN THIS EQUIPMENT.
• WE ARE OFFERING FULL FACTORY START UP AND COMMISSIONING. FACTORY TRAINING WILL BE OFFERED TO K & D ON SITE OR AT THE FACGTORY.
• WE ARE THE AREA’S LARGEST REPRESENTATIVE FIRM DEDICATED TO THE APPLICATION AND CARE OF BOILERS AND BOILER RELATED EQUIPMENT.
• OVER 100 YEARS OF COMBINED EXPERIENCE INCLUDING SALES, PARTS, WARRANTY SERVICE AND ENGINEERING SUPPORT FOR OUR CONTRACTORS.
THANK YOU FOR YOUR TIME AND FOR YOUR THANK YOU FOR YOUR TIME AND FOR YOUR CONSIDERATION!CONSIDERATION!