Boiler Blog Archive | Nationwide Boiler Inc.

It's that time of year again for our annual freeze protection reminders. As you know, winter can bring extremely cold weather conditions, especially in Canada, the Northeast, Midwest, and Upper Midwest. To reiterate what we have been saying for years, here are a few things to consider to protect your rental boiler and auxiliary equipment (deaerators, water softeners, etc.) from damage due to freezing temperatures this winter.

1. If you are renting a trailer or skid-mounted firetube or watertube boiler and installing the unit outdoors, these systems are completely exposed to the environment. User's should consider enclosing the front and/or the rear end of the boiler, or build a temporary enclosure around the entire system. An external heating source should also be used. 

2. Install the proper heat tracing (steam or electric) and insulation on all main lines and piping components, regardless of whether the boiler (or auxiliary equipment) is in operation or sitting as stand-by. This should include the following lines: 
      - Sensing lines for all transmitters
      - Primary and auxiliary low-water cut-offs
      - Water column and connected piping
      - Bottom blowdown and surface blow-off piping, depending on the length of the piping runs. These valves should also be left open. 

Tomato season is here, and we already have a 70,000 lb/hr, 400 psi design trailer-mounted rental boiler on location at one of our customer sites to support peak season steam demand. This boiler is rented annually in the Central Valley of California for three to four months during the tomato processor’s short but critical production season. To meet the requirement of 5 ppm NOx, the boiler is supplied with an ultra-low NOx CataStak SCR System. This solution allows the facility to operate their own boilers without overworking them, while complying with local air regulations and satisfying seasonal demand.

Some years ago, the company identified a bottleneck in its evaporation system that hindered peak production capacities. The bottleneck was easily resolved; however, it would take more steam to fully realize the increase in production. Although the existing boilers were capable of running the newly found evaporation capacity, the increased production required the existing boilers to operate at 100% output continuously, leaving no room for margin and no buffer against any process anomalies. After evaluating the cost of investing in a new boiler, the detrimental effects of operating the existing boilers at 100 percent output, and the process vulnerabilities of having no excess steam capacity, the decision was made to rent a supplementary steam boiler on an annual basis.  

Many industries face periods of increased process steam requirements and to satisfy demand, steam can be supplemented with a temporary rental boiler. This practical solution allows facilities to maximize the resources needed to meet current, short-term and long-term steam needs. A short-term or long-term rental solution can save time, conserve capital, minimize risk and maximize available resources.

Check out our past article from Today’s Boiler Magazine to learn more about how temporary boilers can support seasonal steam demand, and contact us today if a rental boiler may be the solution to your peak season needs!

Last month on the Boiler Blog, we focused on increased efficiency through the use of O2 trim. This is an easy, cost-effective addition to a boiler system with multiple added benefits. There are, however, additional ways to increase the efficiency of your steam plant even further. A Variable Frequency Drive (VFD) controls a motor’s speed by varying the frequency supplied to it, and VFD’s can help achieve significant electrical power savings when added to your boiler.

To illustrate the benefits of VFDs, take the power usage of the fan. A combustion air fan on a boiler typically uses a large amount of energy. For example, a 125,000 pph boiler can have a fan motor as large as 300 hp. While the actual power usage would typically be less than the rated size of the motor, when operating 24/7/365 at full load and assuming an electricity cost of 8 cents/KW, the cost of electricity can be upwards of $150,000 - just for the combustion air fan! 

The use of VFDs will provide the most savings for boilers that have an average annual operational load of less than 100%. In fact, if your average boiler load throughout the year is 50%, or half load, you could save ⅞ ^th the fan power. This means that with the use of a VFD, the fan would require a fraction of the typical amount of energy used when running your boiler at full load. Generally speaking, if your boiler is operating at half load the fan will also operate at half speed.  According to the fan laws, fan power is related to change in fan speed to the 3^rd power.  When operating the fan at half speed, the change in power is (½)³ or ¹/₈^th the power!  This is where the power savings would come from and why it would be most beneficial to utilize a VFD for scenarios where the boiler system operates more consistently at half load.

Let’s look further into the reason behind using 50% fan speed for 50% boiler load. When running your boiler at half load, the air flow requirement will also be reduced by half (assuming the burner excess air stays the same).  Since the fan laws state that air flow changes linearly with fan speed, that means that at 50% fan speed (or RPM), the flow would be 50% of full load.  For the static pressure requirement, the fan pressure is closely related to the square of the change in boiler load.  So, at 50% load, the static pressure change would be (½)² which also matches the fan laws which state change in fan speed changes fan static by the square.  You’ll notice that if you multiply the flow and static changes together (i.e. ½ * (½)²) you get ⅛ ^th which is the same number for the power savings.

If a VFD is not being used, the alternate device is likely a line motor starter. With a motor starter, the fan is always running at full speed. At 50% load, the air flow is about half but the static pressure requirement typically increases due to the closing of the air dampers (which are used instead of a VFD to control the flow).  That said, with a standard motor started, the overall fan power requirement stays about the same regardless of whether the boiler is operating at half or full load.

Given today’s awareness to the advantages of minimizing energy usage and carbon footprint, boiler operators and plant managers are always on the lookout for ways to improve boiler efficiency and ensure emissions compliance. With improved efficiency, fuel usage is minimized which in turn reduces the carbon footprint (i.e. reduces CO2 emissions from the boiler) and reduces issues around emissions compliance. One way to increase boiler efficiency is to use oxygen trimming, or O2 Trim, at the stack.

A typical burner will operate from 3 to 4% O2 at 50% boiler load and higher. This stack O2 concentration corresponds to the amount of excess air at the burner, and excess air is required for burner operation to assure complete combustion of the fuel.  For example, for natural gas firing, 3% O2 corresponds to 15% excess air. During commissioning, the burner service engineer will set the fuel / air ratio so that there is always excess air over the firing range of the burner.  The service engineer must also keep in mind that ambient conditions (mainly air temperature changes) will affect air density which will affect the burner fan air flow output.  On cold days the fan will flow more air due to a higher air density, and on hotter days the flow will be less. Varying air flow conditions can adversely affect burner operation.

Boiler efficiency is affected by the excess air concentration in the flue gas. The rule of thumb is that for every 5% more excess air, boiler efficiency decreases by 0.5%. If not adjusted, the boiler stack can vary by at least 2% O2 (i.e., if normal operation is 3% O2, it can increase to 5% O2 on a cold day). That corresponds to about 1% boiler efficiency loss. Saving 1% efficiency over a year operation can save big on fuel costs. If the normal fuel bill is $10,000,000 per year, you would save $100,000. Adding an O2 Trim system would cost a fraction of that amount (assuming a 150,000 lb/hr steam boiler or smaller), providing a quick and worthwhile ROI. So, what exactly is an O2 Trim System?

Many burners use a control system where the fan air flow does not vary based on air temperature.  As explained above, the air flow can vary based on ambient conditions causing the stack O2 to vary; this can be solved by adding O2 Trim to the control system. O2 Trim is an air flow trimming system where stack O2 is measured (using an O2 probe) and the air flow is adjusted (trimmed) based on the reading. It’s a closed loop control system since changes in air flow will directly affect the stack O2 reading (assuming fuel flow is the same). By maintaining a consistent air flow rate, O2 trim reduces fuel usage in turn increasing boiler efficiency.

In addition to increased boiler efficiency, utilizing O2 Trim will ensure stable and safe O2 levels. On hot days with reduced fan air flow, the stack O2 level can drop to dangerously low levels and boiler emissions can go out of compliance. With O2 monitoring, alarms can be created to alert the boiler operator to either reduce fuel flow or increase air flow, to return to safe operating conditions.