Brady Blog- Trends and Talk

Is Maintaining A Full Steam Load Critical To Running Your Facility?

Thursday, July 16, 2015

How much does your organization depend on your boilers to run day-to-day operations?

Limpsfield Burner with Autoflame ControlsAre your boilers and burners reliable? Or do they frequently need repairs?

Maybe you are considering adding another boiler to help support your needs. Your existing equipment is aging and this could look like a possible solution.

It may not be your only solution.

A North Carolina hospital found themselves in this very situation. After a review of existing equipment and facility set up, they found better solution to meet their needs.

This 117 bed acute care hospital had issues maintaining a full steam load to support day-to-day operations that included everything from maintaining optimal operating room conditions to supporting the laundry facilities.

The hospital had two boilers that had to be operating 24 hours a day, seven days a week, just to meet the basic needs of the hospital. Their existing boilers and burners were not reliable and frequently in need of repair. Suffering from incomplete combustion, their equipment was also producing over 2000 PPM CO.

Facilities personnel had considered buying a third boiler to solve their problem. They quickly discovered that installation of a third boiler would require a new boiler room and extensive piping to tie the system together. This was not an option.

The hospital needed a better solution. The answer came in the form of burner retrofits and controls upgrades for their existing boilers. The hospital chose to convert the burners on the existing two boilers to high efficiency Limpsfield Burners with Autoflame controls.

The upgrades gave the hospital more precise control over their boilers and burners with a 3% O2 guarantee across the firing range with less than 10 PPM CO.

After the first burner retrofit work was complete the entire hospital was able to run off of one boiler when necessary.

The second burner retrofit was implemented a year later resulting in even more energy efficiency and reliability for the hospital.

This hospital found a solution that helped them be good stewards of the environment while saving money. Their emissions were reduced 30% and initial savings were estimated at 10%.

Considering various scenarios for needed work often can help identify ways to improve efficiency and save money for your organization. What system issues are you facing that need to be looked at from a different perspective? 

Saving Money By Improving Boiler Efficiency

Thursday, July 09, 2015

Curious how a small improvement in efficiency would impact your bottom line? Check out these estimates from just a 5% improvement in boiler efficiency. 


Why Perform Combustion Analysis?

Tuesday, July 07, 2015

Why perform combustion analysis?

Improved Efficiency The largest source of boiler heat loss is from heat energy leaving the system exhaust flue or stack. This loss is composed of Dry Gas loss and Latent Heat Loss. To reduce the sources of heat loss and save fuel costs by improving fuel efficiency, an equipment tune-up using combustion analysis is performed.

Reduced Emissions Undesirable emissions associated with burning fossil fuels include carbon monoxide, sulfur dioxide and nitrogen oxides. These emissions are toxic, contribute to pollution and cause health problems. Federal and state laws govern the permissible emission rates under the Clean Air Act. The EPA and other local agencies also regulate the emissions of these pollutants.

Improved Safety Combustion analysis along with a good preventative maintenance program allow technicians to maintain boiler operating specifications for safe and efficient operation. Safety concerns can include: a reduction in excess air which results in an increase of carbon monoxide and other gasses, low draft pressures contribute to a build up of combustion gases in the combustion chamber or into the building and draft pressures in the flue can cause turbulence in the flue which can lead to damage to the combustion chamber or heat exchanger material.

Combustion analysis is an EarthWise solution. Efficiencies are raised. Emissions are reduced. Documentation is provided. Life cycle and sustainability is enhanced. 


Understanding Combustion Analysis

Wednesday, July 01, 2015

First let's start with combustion. Exactly what is combustion? 

Combustion occurs when fossil fuels react with oxygen in the air to produce heat. The heat from burning fossil fuels can be used for heating applications or industrial processes. The combustion process is complex; requiring the right mixing turbulence, activation temperature and enough time for the reactants to come into contact and combine.During this process other products are often formed as a result of the reaction. If the combustion is not properly controlled, high concentrations of products, often undesirable, are formed. Carbon monoxide, soot, nitrogen oxides, sulfur and sulfur dioxide are byproduct examples of uncontrolled combustion.

Understanding combustion analysis

Combustion analysis is an important part of the process to improve fuel economy, reduce emissions and improve the safety of fuel burning equipment. During combustion, analysis measurements are obtained of gas concentrations, temperatures and pressures. This often includes measurements for Oxygen (O2), Carbon Monoxide (CO), Carbon Dioxide (CO2), exhaust gas temperature, supplied combustion air temperature, draft, nitric oxide (NO), Nitrogen Dioxide (NO2) and Sulfur Dioxide (SO2).

These measurements are then interpreted using calculations for combustion efficiency and excess air. A more detailed analysis can examine the concentration of products produced as a result of the combustion.