Westbrook Apartments BOILER REPLACEMENT ASSESSMENT AND PROPOSAL AUGUST 2007

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


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%.

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)


• 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)


• 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


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



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


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%.




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.




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


REMOVE 2 BOILERS AND SYSTEM PIPING LEAVE DOMESTIC RUNNING

SYSTEM PIPING



CONNECT SYSTEM PIPING AS SHOWN – SYSTEM FLOW IS

UNCHANGED.

SYSTEM PIPING



INSTALL TWO PRIMARY LOOP TEES MAXIMUM 12” APART IN THE SYSTEM. THIS WILL BE THE NEW INLET/OUTLET

SYSTEM PIPING



PLACE NEW MODULAR 85% COPPER FIN BOILERS IN PLACE. CONNECT

EXPANSION TO SYSTEM.

SYSTEM PIPING



CREATE AND PIPE YOUR PRIMARY LOOP TO THE NEW BOILERS.

SYSTEM PIPING



REMOVE HEAT EXCHANGER AND PIPING ASSOCIATED WITH OLD BOILER. PLACE

AND PIPE NEW DIRECT WATER HEATERS.

SYSTEM PIPING



REMOVE LAST OLD BOILER. ENJOY A COOLER ROOM, LOWER BILLS AND

COMPLETE REDUNDANCY.

SYSTEM PIPING



OPTION ONE: REMOVE OLD TANK INSTALL MULTIPLE SMALL TANKS.

SYSTEM PIPING



OPTION 2: REMOVE LARGE AND WASTEFUL LOUVER, ADD MATCHING

COMBUSTION SYSTEM.

SYSTEM PIPING



OPTION 2B: AS PART OF THE COMBUSTION AIR SYSTEM INSTALL A MODS SYSTEM TO CONTROL DRAFT.

SYSTEM PIPING



OPTION 3: USE AT LEAST AN ECONOMICAL STAGING CONTROL TO RESET AND MAXIMIZE EFFICIENCY.

months

10

jan

deg

ree

day

s

20

30

40

50dec

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!

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!

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!

Documents

Westbrook Apartments BOILER REPLACEMENT ASSESSMENT AND PROPOSAL AUGUST 2007