Today's Boiler Spring 2011 : Page 6

CLEAVER-BROOKS > SOFTWARE NAVIGATING THE BOILER UPGRADE AND REPLACEMENT POSSIBILITIES AND PROCESS BY STEVE CONNOR here are several catalysts that spark a discussion expected life cycle. A life-cycle evaluation may reveal addi-within a company about whether to upgrade tional savings when a properly sized and controlled burner is or replace their steam boiler. Among the most ﬁtted to a boiler's furnace for optimum radiant-heat transfer. common reasons are: a need to increase fuel ef-If the pressure vessel inspection determines the useful ﬁciency, a requirement to decrease emissions, a life has been depleted, all of the issues pertaining to boiler-heightened demand for steam, a process load decrease, or es-replacement selection, including operational, physical, and calating maintenance costs on existing equipment. ﬁnancial concerns, need to be assessed. A boiler purchase The age of the boiler system is important to consider, but needs to be evaluated on a true price/value basis. it should not be the key factor in the decisionmaking process. A more critical factor is the condition KNOW THE FINANCIAL of a boiler’s pressure vessel. The shell, IMPACT OF YOUR DECISION furnace, and tubes, which make up a One software program now available “A life-cycle evaluation boiler's body and venous system, are to help aid in the upgrade vs. replace-may reveal additional responsible for delivering heat energy ment decision is BOOST (Boiler Opera-savings when a from the burner into the water. tion Optimization Savings Test). This program, available through Cleaver-If an annual inspection of water-properly sized and Brooks representatives, details the side and ﬁreside surfaces shows mini-controlled burner is annual cost savings to a company for mal signs of heavy scaling, pitting, ﬁtted to a boiler's making certain energy-efﬁcient up-cracking, or stress, then the pres-furnace for optimum grades, retroﬁts or replacements. sure vessel is probably in good shape radiant-heat transfer. “ and could deliver many more years of BOOST generates tailored reports dependable life. that predict the efficiency calcula-After determining the pressure vessel is acceptable, the tion and associated dollar savings of replacing vs. upgrad-next step is calculating the boiler’s efficiency. Using a flue-ing current equipment. The reports also provide detailed gas analyzer, check for the stack temperature over saturated financial analysis that shows a company’s after-tax savings, temperature, the percent of oxygen (O 2 ), carbon monoxide net present value (NPV), internal rate of return (IRR), and (CO), particulate, and nitrogen oxide (NOx) in the exit gas. after-tax payback. If this analysis indicates high excess air (8% to 10% O 2 ) in One company that recently used BOOST to determine the mid-to high-fire ranges and CO in excess of 50 ppm, the whether to repair or replace its equipment is Indian Summer, burner will require a major tune-up, upgrade, or replacement. manufacturer of apple juice and applesauce, located in Lud-The upgrade costs should be evaluated based on a boiler's ington, MI. The company was running three boilers between 6 T O D A Y’S BOI L E R S P R I N G 2 0 11 STEERING WITH T

Steering With Software

Steve Connor

CLEAVER-BROOKS > NAVIGATING THE BOILER UPGRADE AND REPLACEMENT POSSIBILITIES AND PROCESS There are several catalysts that spark a discussion within a company about whether to upgrade or replace their steam boiler. Among the most common reasons are: a need to increase fuel efficiency, a requirement to decrease emissions, a heightened demand for steam, a process load decrease, or escalating maintenance costs on existing equipment. The age of the boiler system is important to consider, but it should not be the key factor in the decisionmaking process. A more critical factor is the condition of a boiler’s pressure vessel. The shell, furnace, and tubes, which make up a boiler's body and venous system, are responsible for delivering heat energy from the burner into the water. If an annual inspection of waterside and fireside surfaces shows minimal signs of heavy scaling, pitting, cracking, or stress, then the pressure vessel is probably in good shape and could deliver many more years of dependable life. After determining the pressure vessel is acceptable, the next step is calculating the boiler’s efficiency. Using a fluegas analyzer, check for the stack temperature over saturated temperature, the percent of oxygen (O2), carbon monoxide (CO), particulate, and nitrogen oxide (NOx) in the exit gas. If this analysis indicates high excess air (8% to 10% O2) in the mid- to high-fire ranges and CO in excess of 50 ppm, the burner will require a major tune-up, upgrade, or replacement. The upgrade costs should be evaluated based on a boiler's Expected life cycle. A life-cycle evaluation may reveal additional savings when a properly sized and controlled burner is fitted to a boiler's furnace for optimum radiant-heat transfer. If the pressure vessel inspection determines the useful life has been depleted, all of the issues pertaining to boilerreplacement selection, including operational, physical, and financial concerns, need to be assessed. A boiler purchase needs to be evaluated on a true price/value basis. KNOW THE FINANCIAL IMPACT OF YOUR DECISION One software program now available to help aid in the upgrade vs. replacement decision is BOOST (Boiler Operation Optimization Savings Test). This program, available through Cleaver- Brooks representatives, details the annual cost savings to a company for making certain energy-efficient upgrades, retrofits or replacements. BOOST generates tailored reports that predict the efficiency calculation and associated dollar savings of replacing vs. upgrading current equipment. The reports also provide detailed financial analysis that shows a company’s after-tax savings, net present value (NPV), internal rate of return (IRR), and after-tax payback. One company that recently used BOOST to determine whether to repair or replace its equipment is Indian Summer, manufacturer of apple juice and applesauce, located in Ludington, MI. The company was running three boilers between 100 to 300 hp, two of which were more than 30 years old. It had added more pasteurizers and filtration equipment to increase production, but according to Larry Morton, maintenance manager for Indian Summer, the boiler system was already maxed out. Indian Summer contacted John Wallish at Dean Boiler in Grand Rapids, MI. Wallish met with executives at Indian Summer to understand the company’s goals and discovered that energy efficiency was top-of-mind for the company along with lowering emissions. The local utility company was offering rebates to manufacturers that made Energy efficient upgrades; however, the decision for Indian Summer to buy new equipment had to be fiscally responsible in the long-run. Dean Boiler ran BOOST reports for a number of upgrade vs. replacement scenarios. After analyzing the reports, Indian Summer purchased a Cleaver- Brooks CBLE 500-hp boiler with economizer, feed system, blow down heat recovery, and separator at a total project cost of $350,000 to $400,000. According to BOOST, the overall savings was projected to be $965,312 over a 10-year Period with an estimated 18.9% reduction in overall energy expense and a 17% reduction in Nox emissions. The BOOST analysis for Indian Summer was conducted with the expectation that the company would have to run one of its older boilers alongside the new system, but that has not been the case. According to Morton, “The new boiler runs the whole plant without any problem at all. We went from running three boilers to running one at ½ to ¾ throttle. It doesn’t even run wide open. It’s a world of difference.” Shutting down the older boilers significantly increased the system’s efficiency and projected payback period. As a result, production has increased 9% and the plant is using 32% less fuel. Whereas, the initial payback period was projected to be 51 months, the company anticipates it will reach this mark in 32 to 37 months. Installing a new boiler system was the right decision for Indian Summer. Today, there are many tools like BOOST available to help guide other companies facing the same decision. Take advantage of them to keep your company headed in the right direction. TB Steve Connor is director of training and marketing services for Cleaver-Brooks. Cleaver-Brooks is a world-renowned provider of boiler room products and systems that helps customers and the industry reduce energy usage, cost and environmental impact. As the pioneer of packaged firetube and watertube boilers, Cleaver-Brooks is the only manufacturer to offer an entirely integrated boiler room solution for any size application. Visit cleaverbrooks.com for more information.

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