Whether running hydronic or steam boilers, there are many ways to reduce operational costs throughout their life cycles. 

You can find more information on our web, so please take a look.

1. Select new equipment with lower operating costs &#; When choosing new equipment, initial costs can be daunting. While there may be a natural inclination to try to save money at every step, the long-term consequences of the selection should be factored into the purchase decision. 

A boiler is a long-term asset that will be in service for many years. During that time, the greatest expense will be its operating cost. This expense can be difficult to plan for, as there are many external influences on the cost of fuel, but efficiency upgrades will reduce it over time. Estimating how long it will take to recover the extra cost of upgrades via energy savings can also help influence this decision.

2. Properly operate condensing boilers &#; A condensing boiler can achieve energy efficiency of up to 98% when operated properly. These boilers are engineered to withstand lower stack temperatures without damage and are designed to work best with the lowest possible return temperature. 

Condensing boilers begin to increase efficiency over noncondensing boilers only when there is a large delta between the return temperature and the operating temperature. Efficiency reaches its peak with a return temperature of 80°F or less. 

Facilities often replace noncondensing boilers with condensing ones without changing how they are operated. Without a low return-water temperature, a condensing boiler is no more efficient than a noncondensing one. 

3. Monitor the water temperature on a steam boiler &#; Being that a steam boiler is made of steel, consider the thermal characteristics of the material. Steel does not react well to rapid changes in temperature; the expansion and contraction cycles can fatigue the steel and cause failure points to develop. So, during boiler operation, it&#;s important to ensure any temperature change is gradual. 

A steam boiler will cycle on and off to maintain a set pressure. When the boiler has been off for an extended period, the water inside it becomes cold, and the delta between the water temperature and the burner output can be extreme, leading to thermal shock. 

Adding a temperature sensor allows the firing rate to gradually increase as the boiler warms. Without monitoring the water temperature, this type of thermal shock protection is not possible, since simply monitoring steam pressure does not accurately indicate a warm vessel.

4. Connect VFDs to fans and pumps &#; Variable frequency drives (VFDs) are common in today&#;s boiler rooms. In addition to providing controllability, understanding the affinity laws that dictate the relationship between flow, power, and other characteristics of operation can lead to energy savings when properly applied.

The affinity laws define flow as being linear to the speed, changing together in proportion. The power used is the cube of the speed. What this means is that as you increase the speed of a fan or pump, the energy usage increases exponentially by a factor of eight. This can be used to save energy, as a motor operating at 80% uses about half of the electricity as a motor operating at 100%. This can be confirmed by calculating the multiplier, which is the motor speed cubed (0.8 x 0.8 x 0.8 = 0.512). 

5. Add a host sequencing panel &#; When there are multiple boilers connected to the same water loop or steam header, each will act independently to satisfy the load. This can result in excessive cycling and inefficiency. One solution is to connect the boilers together with a host sequencing panel. 

A host sequencing panel manages multiple boilers by controlling the cycling and modulation of each unit. A single temperature or pressure sensor monitors the output, and an algorithm, tuned by a qualified service technician, ensures that the set point is satisfied in the most economical way. Advanced options may be available for remote connectivity, pump control, or other boiler-specific functionality. 

6. Take advantage of monitoring options &#; The best way to monitor a boiler is to ask about an Internet of Things (IoT) monitoring solution. These systems are designed to offer the most important operating and notification data for a boiler at anytime from anywhere.

Users can remotely monitor their boiler systems, view key performance indicators, receive alerts, utilize an asset diagnostic tool, and review trend reports, moving from a reactive approach to a predictive stance in order to reduce boiler maintenance costs and improve uptime. 

7. Incorporate oxygen trim &#; An oxygen trim system adds a sensor into the combustion stack to continuously monitor the level of oxygen during boiler operation. The oxygen level or stack temperature can be monitored to create an alarm if either one falls outside of a defined range. Algorithms monitor the oxygen level and make controlled adjustments to one of the channels of combustion (typically air) to keep the level at a target set point. This action has many safeguards to ensure these adjustments keep combustion safe. 

Without oxygen trim, variations in ambient temperature will result in changes to combustion efficiency. This will lead to higher energy costs, and it may be necessary to retune the boiler if there is a significant temperature change. 

8. Seek out utility rebates and incentives &#; Utility providers are always looking for ways to increase capacity in their service areas. They need to find ways to satisfy the constantly growing energy requirements of their customers. 

One method natural gas utilities use to reduce customer usage is the policy of curtailment. In this case, a customer stops using natural gas when requested in exchange for a lower fuel price. This requires customers to utilize burners that can run on multiple fuels. 

Rebates may be offered when equipment is upgraded to more energy-efficient models. It is also common for electric utilities to provide rebates when VFDs are added to existing motor-driven devices. 

9. Apply proper instrumentation and technique during commissioning &#; The performance of a boiler after commissioning is only as good as the amount of time and effort that is put into the task. It is imperative to select qualified, trained technicians who understand what is required for a professional outcome. 

With a modulating boiler, it is critical that the firing rate from low to high fire has linear heat output. To do so, it is also important to use instrumentation to verify fuel flow rates. Make sure the maximum output is reached during high fire and the turndown is exactly as advertised. 

Always use a calibrated combustion analyzer when tuning the burner. Determine the target oxygen levels for both high and low fire from the burner manufacturer. Never adjust combustion without monitoring the analyzer.

The last step is to properly tune the PID parameters to maintain the desired set point. If commissioning is done well, tuning the PID loop should not be difficult and will result in good performance. 

10. Conduct a boiler plant optimization &#; When replacing or upgrading a boiler, use the opportunity to see what other upgrades you can make in the boiler room. Consider the boiler room and its components as one integrated system rather than as a collection of separate components. 

When selecting controls, seek out a system with the capacity to connect all the required devices. This enables the boiler and accessories to be controlled by a single piece of equipment, enhancing system efficiency and savings. Also consider updating the deaerator, water level, draft, or other dedicated controls as well as chemical feed and makeup water systems to optimize operations.  

By Carlo Zaskorski, corporate director of controls, Cleaver-Brooks

If you want to learn more, please visit our website Partedon Group.

For more information, visit the Cleaver-Brooks website.

Buying an Industrial Boiler: Critical Features to Consider

Buying a commercial boiler for your industry needs is not something to take lightly. It&#;s an expensive piece of equipment that needs to function properly for many years to come.

The last thing you want to do is buy the wrong boiler and end up having to spend extra money on repairs. You also don&#;t want to have to buy another boiler long before you planned on doing so, wasting even more money. To prevent these from happening, here are the most important factors to consider when selecting a new industrial steam boiler.

Getting More Efficiency for the Price

Obviously, the price of a boiler system has to receive some consideration. Everyone has a budget, and you need to buy a boiler that fits into that budget. However, you may not want to skimp on price when it comes to buying a boiler. If you settle for a cheap, inferior product, you may end up spending more in the long run on repairs or replacing the boiler sooner than expected.

Efficiency is actually a more important factor to consider when it comes to selecting a new boiler. When you buy a steam boiler, you need to look at the overall cost of operation, not just the price of the unit. An inefficient boiler will consume more fuel, causing energy bills to rise. In this sense, it may be better to spend a little more on a boiler with higher thermal efficiency, knowing it will save you money in the long run. Miura boilers have been shown to reduce fuel costs by up to 20%. Over the lifecycle of a boiler, which could be 15 to 20 years, saving that much on energy costs could end up being a significant amount of savings.

Firetube Vs. Watertube Boilers

Another key factor to consider is the type of boiler itself&#;specifically the heat transfer design of the boiler system. Most conventional boiler systems are fire tube boilers, in which hot gases pass through tubes immersed in the water to heat it. Watertube boilers take the opposite approach: the water passes through a tube that is surrounded by hot flue gas. The difference between these designs is that water tube boilers can convert water to steam in a very short period of time, requiring much less startup time and consuming less fuel in the process.

Watertube boilers also take up less space while providing enough steam output to accommodate most industrial processes. Miura specializes in producing high-quality watertube boilers, which many industries find preferable to conventional fire tube boilers.

When Size Matters: Space Considerations

The size of the boiler matters in the sense that you have to be able to fit it in your boiler room. Generally, you&#;ll want a boiler to have as small of a footprint as possible, as it will help to save both space and money. Miura&#;s modular boiler design helps to keep boilers as small as possible without sacrificing output or efficiency. The smaller boiler helps create flexibility with regard to space, as there is no need for tube pull-space or door-swing space like with traditional boilers.

This creates additional space in the boiler room and may even open the door for multiple modular boilers working on the same system to help improve efficiency and cut operating costs even further.

Safety Is a Must

Safety should always be one of the top priorities when buying a new boiler. Conventional steam and hot water boilers sometimes become overheated to the point that the build-up of high-pressure steam can cause a catastrophic explosion. One way to mitigate this risk is with a boiler system specifically designed for low water content operation. With low water content boilers, the amount of steam build-up is not enough to do excessive damage even if the unit malfunctions.

Another risk with conventional boilers is in the physical design itself. Performing maintenance on these units requires opening extremely heavy steel doors, realigning them, and closing them again, all while standing on a ladder &#; an invitation to a variety of injuries ranging from back pain to severe limb injury.

When it comes to safety, Miura boilers have an impeccable track record. Miura&#;s steam boilers are designed with no heavy doors, and their low water content design makes a catastrophic explosion virtually impossible. With over 140,000 units in operation all over the world, Miura has never experienced a pressure vessel explosion in one of its boilers.

Stay Ahead of Emissions Regulations

With growing concerns about air pollution, greenhouse gases, and the environment, manufacturers are under increasing pressure to reduce the amount of harmful emissions caused by their industrial processes. Much of the emissions problems companies face stem from the use of conventional boiler systems. Even when using &#;clean&#; natural gas, these boilers are notorious for expelling large amounts of CO2 and toxic nitrogen oxides (NOx) into the atmosphere, damaging the environment and often causing respiratory issues.

There are, however, alternative boiler designs that can significantly reduce the rate of harmful emissions. Miura boiler systems require far less fuel to operate and can easily power down when not needed. They also are designed for low to no NOx emissions, making it much easier for companies to comply with state and local emissions standards.

Maintenance Made Simple and Seamless

Last, but certainly not least, you need to consider how much long-term maintenance and upkeep your boiler will need in order to function at its best for as long as possible. A low-quality boiler may require frequent repairs, which will not only cost extra but may also force you to replace the boiler sooner than expected. A well-maintained steam system involves more than just the condition of the pressure vessel itself. It also involves having a good water treatment process in place to prevent mineral build-up and ensure proper working of your feedwater tanks, deaerator tanks, and reverse osmosis systems. Having an effective monitoring and control system can also help you identify and fix small problems before they turn into big ones, and you&#;ll also want a robust troubleshooting/maintenance support plan in place for routine maintenance issues.

Miura offers a full array of accessories and support systems designed to cover all aspects of your boiler system maintenance &#; from state of the art remote monitoring to water treatment to troubleshooting support. Miura also offers a boiler maintenance program that only requires a three-hour shutdown for routine inspections. Such inspections, as well as our monitoring system, will help keep your boiler running efficiently and safely for a long time to come.

Contact Miura today to learn more about modular boilers and how they can help your business save money.

Contact us to discuss your requirements of Steam Boiler. Our experienced sales team can help you identify the options that best suit your needs.