Boiler Basics Workshop

Boiler Basics Workshop
November 13th, 2014

Trevor Van Eerde, P. Eng., CEM
Industrial Energy Solutions Consultant
Enbridge Gas Distribution Inc.
647-408-6743
trevor.vaneerde@enbridge.com
Todays Workshop Will Cover:
Enbridge Programs
Boiler Basics
Energy Savings Opportunities in Boilers
Limited Time Campaign
Enbridge Programs
Boiler Basics
Industrial Program
Enbridge DSM program :
In existence for 20 years;

Gained Customer trust through
experience and involvement;
Auditing process in place to
ensure calculated savings are
realistic.
4
Knowledge
Development : Arming
our customers with
information.
Action and
Implementation
Engineering
Analysis : Analyzing
and interpreting data
to
monetize savings
opportunities.
Opportunity
Identification
: Testing and
energy use
analysis.
Measurement :
Choosing the right
metering methods
to quantify key
energy inputs.
Industrial Program
Helped our customers save :
Approx. 110,000,000 m3 of natural gas
More than 20,000,000 KWh of electricity
Over 800,000 m3 of water
In three year period ALONE
Participating in our programs helps YOU :
Reduce C02 emissions
Improve BOTTOM LINE
Approach to Energy Savings

Energy Flow
Meter
Energy
Converter
Distribution
System
End User
Need /
Requirement
Energy Savings Strategy
Enbridge Programs
Boiler Basics
Energy in a boiler room

Energy can be defined as the ability to do work
In the boiler room energy is typically measured in

British Thermal Units or BTUs
1 BTU is the energy required to raise 1lb of water 1F
M in front of BTUs = x 1000, MM = x 1,000,000
Power, the rate at which energy is transferred, is

typically measured in BTU/hr
How many BTUs the boiler can generate in 1 hour
Specific Energy Content BTU/lb

How many BTUs are in 1lb of water, or 1lb of steam
Reference card included in your information package

9
Steam Basics
10
Steam Basics
Water as we know it can exist in 3 states
Solid Liquid Gas (Vapour)
Steam, water vapour, is generated by adding heat energy to

water to bring it to its boiling temperature (sensible heat)
Adding more energy transforms water from liquid to vapor

(latent heat)
Steam is used to carry heat energy from one location to
another
Steam is an excellent energy transporter
Heat Energy is also called Enthalpy (h):

Energy due to both Temp. and Pressure
11
Temperature
100C for Water
Steam Only
0C for Water
Ice & Water
Ice
Sensible
Heat
Latent Heat
Water Only
Water & Steam
Sensible
Heat
Latent Heat
Energy Added (BTUs)
Energy in Water vs. Temperature
Sensible
Heat
Energy Added
Energy Removed
ENERGY
12
Steam Basics Sensible vs. Latent Heat

Heat energy required to make steam has two components:
Sensible heat (Btu/lb)
Latent heat (Btu/lb)
Sensible Heat
Amount of heat required to raise the temperature of water from 32F
to its boiling point (saturated water)
Adding sensible heat raises the temperature
It can be detected with a thermometer
Sensible heat, or enthalpy of water at 32F, is taken as 0 BTU/lb
13
Steam Basics Latent Heat

Amount of heat required to change saturated water to steam
Adding Latent Heat does not raise the temperature: the boiling water and
steam has the same temperature for a given pressure
Latent heat added to the boiler is what is transferred to the load
Removing latent heat at the load creates condensate
Returning maximum amount of condensate reduces heat energy required
by the boiler
14
Steam Basics Pressure Dependency

Increasing Pressure increases Boiling Point (saturated water temp.)
Saturation Temperature vs. Pressure
0 psig
450
212F
Saturation Temp (F)
400
350
300
250
100 psig
200
150
100
0
50
100
150
200
338F
Pressure (psig)
15
Steam Basics Total Heat of Steam

Total Heat of Steam = Sensible Heat + Latent Heat
= hg
Sensible Heat
= hf
Latent Heat
= hfg
For 100 psig steam:
Total heat of Steam at 100 psig

1400
Heat (Btu/lb)
Total Heat of Steam
1200
1000
880
800
hf (saturated liq. Enthalpy)
= 309 Btu/lb
600
hfg (latent heat)
= 880 Btu/lb
400
hg (saturated vapour enthalpy) = 1189 Btu/lb
338F
Sensible Heat
338F
200
0
Latent Heat
309
32F
100 psig
Pressure (psig)
16
Steam Table Example

Properties for
100psig?
Saturation
Temperature =
338F
hf = 309
BTU/lb
hfg = 880
BTU/lb
hg = 1180
BTU/lb
17
What is a boiler?
Closed pressure vessel
Used to convert potential energy from a fuel into thermal
energy
Combustion process
Thermal energy released from the fuel is then transferred

into a medium (water, oil, etc.)
Heat transfer tubes, coil tubes
Energy in the medium is then sent to the distribution

system to be used in the load
Steam headers, pipes, etc.
18
Workshop Steam Plant

Boiler: 300BHP (10 MMBTU/hr)
Average Loading: 50%
Plant Operating Hours: 6,000 hrs.

Annual Fuel: 1,000,000m3/yr ($280,000/yr)
Stack Flue Gas
Sat. Steam @ 100 psig
Process Steam
Natural Gas
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Blowdown
Cond.
Tank
Condensate
Return 50%
180 F
Make-Up
Water 50%
19
Energy Losses in Boilers

Qsl
Stack Loss
Improvement in Boiler Efficiency is

achieved by reducing losses
Three main boiler losses

Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Focus on Stack losses and Blowdown

losses
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
20

Qsl
Stack Loss


Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
21
Stack Losses
Stack losses are typically the largest boiler system loss
Result of:
Combustion process
Poor conversion of fuel into thermal energy
Water generated during combustions process
Insufficient heat transfer

Poor transfer of thermal energy from fuel into boiler feedwater
Energy that is not transferred into the feedwater leaves

through the stack
22
Perfect Combustion: Ideal Air:Fuel Ratio

CO2 + 2H2O + 7.52 N2
Heat Released =1012 Btu/ft3
= 23,000 Btu/lb
Natural Gas (CH4 )

1 ft3
16 lbs.
Air( 2O2 + 7.52 N2)

9.52 ft3
275 lbs.
O2 contributes to
combustion, while
N2 absorbs heat.
Air : Fuel Ratio (by vol.) = 9.5 : 1 or 10:1

(approx.)
23
Flue Gas Loss
Air Fuel Mixture

Maximum
Efficiency Zone
Unburned
Fuel
(CO)
rich
Excess Air
( High O2)
stoich
lean
Total Air
24
Example # 1 Reading a combustion test strip
Flue Gas Temperature

%O2
Carbon Monoxide
Combustion Efficiency
% Excess Air
25
Combustion Efficiency Chart
26
Decreasing Efficiency
27
Decreasing Efficiency
28
Example #2 Reading a combustion efficiency chart

Use the Combustion Efficiency Chart to determine the combustion
efficiency based on the following parameters:
Parameters
Excess O2
= 8%
Flue Gas Temp. Tfg
= 460 F
Combustion Air Temp. Tair = 80 F
Calculate Delta T = (460 80) F
= 380 F
Excess, % FG Temperature - Combustion Air

O2
340
360
380
400
420
7.00
7.50
8.00
8.50
80.6
80.4
80.0
79.7
80.1
79.8
79.4
79.1
79.5
79.2
78.9
78.5
79.0
78.6
78.3
77.9
78.4
78.0
77.7
77.2
29
Combustion test strip
30
Flue Gas Analyzers Are Used To Measure Combustion Efficiency
Enbridge Can Help!
31
Typical Readings
Flue gas temperature
Approximately 115F above saturation temperature of steam
Ex. 100psig, Saturation temperature 338F, would expect 453F stack

temperature
If there is a feedwater economizer, closer to saturation temperature, 353F
Oxygen (O2%)
4-6%
Likely higher percentages at low fire, this is normal
Carbon Monoxide (CO%)

< 200ppm
High CO levels are a safety concern
Readings outside of these ranges should be investigated further

32

Qsl
Stack Loss


Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
33


Stack Flue Gas
Process Steam
Natural Gas
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Blowdown
Cond.
Tank
Condensate
Return 50%
180 F
Make-Up
Water 50%
34
Water Treatment Issues

Oxygen pitting and corrosion in the boiler can cause boiler
tube failures
Mineral deposits and scale on boiler tubes reduce efficiency

and can ultimately cause boiler tube failures
Boiler water carryover into the steam network reduces
steam system efficiency and can cause equipment damage
Condensate network corrosion can cause piping and steam
control equipment to fail
35
Blowdown Basics
When water is boiled, steam is generated
Solids are left behind:
Suspended solids form sludge which degrades heat transfer
Dissolved solids promote foaming and water carryover
Water is discharged to keep solids within acceptable limits

Bottom blowdown from mud drum removes suspended solids
(once/twice a day)
Surface blowdown removes dissolved solids, concentrated near
liquid surface (continuous)
36
Blowdown Basics
Insufficient BD leads to carryover and deposits
Excessive BD leads to wasted energy, water and chemicals
Blowdown water temp. is same as steam
Typical range is 3% 6% of feedwater
37
Oxygen Pitting
Image courtesy of www.gewater.com
38
Mineral Scale
Image courtesy of http://theapexsolution.files.wordpress.com/2012/11/scaled-boiler.jpg
39
Boiler Water Treatment Report

Test
Hardness (ppm)
Limits
Sodium Sulphite (ppm)

Limits
pH
Limits
Conductivity (umhos)
Limits
Boiler #1
Boiler #2
Feedwater
Condensate
Softener
0-6
0-6
0-2
0-4
0-3
75
75
25
50-100
50-100
6-50
11.5
11.5
9.8-11.8
9.8-11.8
7.5-10.5
3500
3500
20
3000-4000
3000-4000
0-100
250
250
150-700
150-700
200
200
150-700
150-700
Chloride (ppm)
Total Alkalinity (ppm)
Limits
P Alkalinity (ppm)
Limits
Iron (ppm)
0
Limits
0-0.1
40
Additional information in your water report

Make-up water meter readings
How much fresh water you top up to the system
?????
41
Enbridge Programs
Boiler Basics
42
Approach to Energy Savings

Energy Flow
Meter
Energy
Converter
Distribution
System
End User
Need /
Requirement
Energy Savings Strategy
43


Stack Flue Gas
Process Steam
Natural Gas
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Blowdown
Cond.
Tank
Condensate
Return 50%
180 F
Make-Up
Water 50%
44
Steam Distribution and End User Savings

Not the main focus for this workshop
Minimize steam requirements at end user
Lower set points, pressure, less hot water, etc.
Efficient transportation and heat transfer

Fouled heat exchangers
Insulation, steam traps
Condensate return
Enbridge portal can be used

for insulation
See portal card in your portfolio
45
Gas Savings Opportunities in Boilers

Qsl
Stack Loss


Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Focus on Stack losses and Blowdown

losses
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
46

Qsl
Stack Loss


Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
47
Gas Savings Opportunity Stack Loss

Stack loss is a major source of heat loss
Qsl = 21%
Stack
Qng = 100%
Qra = 2.5%
(1% of boiler rating)
Qst
Steam flow
Natural Gas
Qfw
Feedwater
Qbd = 0.7% (4% of FW)

Blowdown
48
Gas Savings Opportunities Stack Loss

Stack loss can be reduced by:
1.
CO2 + 2H2O + X 2O2 + (1 + x) 7.52 N2
Improving combustion
Reduce excess air (O2)
Reduce/eliminate CO and CxHy
Controls
2.
Reducing flue gas temperature

Recover heat from hot flue gases
Air
(40F drop = 1% efficiency improvement)

Economizers
3.
Increasing combustion air temperature
Draw air from a high point in the boiler room
49
Reducing Excess O2
Excess air is required to achieve proper combustion
Excess air wastes heat as air enters at ambient temp. and leaves at stack temp.
o 79% of air goes for a free ride
How much excess air is required?

Depends on burner design, boiler configuration, air/fuel control, etc.:
o Older coil-tube boilers without Linkageless Controls (LLC) have high
excess O2 : (5% 12%)
o Fire-tube boilers generally have lower excess O2 :(4% 9%)
o Large water-tube boilers can achieve lower excess O2 : (2% - 6%)
50
Example # 3: Excess O2 Cost Savings

Use the Combustion Efficiency Chart to calculate the cost savings
associated with reducing excess O2 levels from 8% to 5%.
old = 78.9 %
Calculate new
new = 80.6 %
- Minimal Cost
- 300BHP, 50%
loaded
17,000m3/yr
- $4760/yr
Excess, %FG Temperature - Combustion Air

O2
340
360
380
400
420
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
82.0
81.8
81.6
81.4
81.2
80.9
80.6
80.4
80.0
79.7
81.5
81.3
81.1
80.9
80.6
80.4
80.1
79.8
79.4
79.1
81.1
80.8
80.6
80.4
80.1
79.8
79.5
79.2
78.9
78.5
80.6
80.4
80.1
79.9
79.6
79.3
79.0
78.6
78.3
77.9
80.1
79.9
79.6
79.3
79.0
78.7
78.4
78.0
77.7
77.2
51
Linkageless Controls
52
Purpose of Combustion Controls:

Maintain optimum air:fuel ratio at all firing rates to
run boilers safely at optimum combustion efficiency
Monitor process boiler temperature and pressure and
quickly respond to changes in load
53
Linkage Combustion Controls

Mechanical system using cams, linkages and
jackshafts to characterize the air:fuel ratio
A single actuator motor adjusts its jackshaft
arm according to master load (demand)
signal
Linkaged Combustion Control System
As the actuator motor moves the jackshaft,

the arms connected to the fuel valve and air
fan damper move with it
Natural Gas
Valve
Air:fuel ratio is set by adjusting the cam

Calibrating involves combustion tests in
which actuator is positioned to various
settings, usually at least 10, and at each
setting setscrews are adjusted to achieve
the desired O2 level in flue gas
Linkage
Primary Actuator
Motor
Valve
Microprocessor
Controller
Combustion
Air Blower
54
Issues with Linkage Controls:

Hysteresis or drift caused by wear, tear and slop in linkages
Control devices do not return to the same position during boiler ramp-up
or turn-down
Air : fuel ratio is typically set high to compensate for hysteresis
Air : fuel ratio generally drifts after tune-up
Boiler 2 Combustion
10
9
8
Oxygen %
6
5
4
Oxygen
3
2
1
0
20
40
60
80
100
120
Firing Rate %
55
Linkageless Combustion Controls

Obviously no linkages
Linkageless Combustion Control System
Individual servomotors attached to

gas valve and air damper. Position of
each motor is programmed
independently
Servo
Driven
Valve
Natural Gas
A programmable control unit provides

precise air:fuel ratio over entire range
No hysteresis for a properly tuned and

maintained LLC system
Additional controller can be added to
provide O2 trim
New
Microprocessor
Controller
Servo
Driven
Valve
Combustion
Air Blower
56
Power Flame Boiler Burner
Linkages
Linkageless with Honeywell LLC
57
Gas Savings Opportunity: Linkageless Controls

1.
No hysteresis
o Function of Base Case burner age
2.
Improved combustion efficiency due to:

o Reduced excess air
o Accurate characterization of air:fuel ratio
o Accurate control of firing rate
o Depends on how much excess O2 can be reduced
3.
Reduced cycling due to improved turn-down

o Savings are a function of Base Case burner turndown
4.
Additional savings due to O2 trim

58
Example # 4 : Linkageless Controls

Reduce O2,Maintain optimum air/fuel all the time
Improvement
Savings
Removal of hysteresis
0.50 %
Improved combustion
2.19 %
Increased turndown
0.13 %
Total
2.82 %
Annual gas savings
29,720 m3/yr
Annual savings
$8,322
Estimated installed cost
$15,000
Simple payback period
1.8 years
Enbridge incentive
$5,944
Revised simple payback period
1.1 years
59
Personal experiences with LLC

Some vendors claim 10 - 15% savings, based on unrealistic
assumptions
Typical 2.5% - 4%
Savings possible if burner is in very bad condition with very

high O2, CO, Combustibles, Cycling etc.
Need to establish base case performance

Important to estimate savings based on a real base case
Your ESC will help you establish a base line to calculate
realistic savings
60
Flue Gas Heat Recovery with

Feedwater Economizers
61


Stack Flue Gas
Process Steam
Natural Gas
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Blowdown
Cond.
Tank
Condensate
Return 50%
180 F
Make-Up
Water 50%
62
Gas Savings Opportunity: Feedwater Economizers

Stack Flue Gas
320F
Feedwater
Economizer
267F
450F
Natural Gas
Boiler
Feedwater
230F
8 psig
DEAERATOR
63
Feedwater Economizer
Parameters
w/o econo. = 80.6 %
O2
= 5%
Tout
= 320 F
Tair
= 70 F
Delta T = 250 F
Heat recovery from flue gases

reduces stack temperature
Sensible heat recovery
Efficiency gain can be read from

combustion chart
320 F
230 F
267 F
new
= 83.9 %
FG Temperature - Combustion Air Temp, F
Excess, %
O2
200
220
240
260
280
300
320
340
360
380
4.50
5.00
5.50
85.3
85.1
85.0
84.8
84.6
84.5
84.3
84.1
84.0
83.8
83.6
83.5
83.3
83.1
82.9
82.8
82.6
82.4
82.3
82.1
81.9
81.8
81.6
81.4
81.3
81.1
80.9
80.8
80.6
80.4
450 F
64
Example 5 : Installing a Feedwater Economizer

300BHP Boiler, 50% average loading, 6000hrs/yr
Reduction of Flue Gas temperature from 450F to 320F

Parameter
Savings
Average Hourly Heat Recovery
208,259 BTU/hr
Annual gas savings
44,725 m3/yr
Annual savings
$12,523 /yr
Percentage of total load
4.2%
$25,000
2.0 years
Enbridge incentive
$8,945
1.3 years
Typical savings of 3-6%

65
Flue Gas Heat Recovery with

Condensing Economizers
66
Basic Concept of Condensing Heat Recovery

When 1 molecule of CH4 is burned, it produces 2 molecules
of H2O
CH4 + 2O2 + 7.52 N2
CO2 + 2H2O + 7.52 N2
1 lb
2.25 lb
1 lb of CH4 produces 2.25 lb of water

1 lb of Natural Gas produces 2.14 lb of water
67
Basic Concepts of Condensing Heat Recovery

Water in products of combustion is vaporized due to
heat of combustion
CO2 + 2H2O + 7.52 N2
Water vapours absorb about 10% of fuel input

Energy is lost to atmosphere with exhaust gases
through stack
NG
Heat of vaporization can be recovered if flue gases are

cooled below water dew point
When water vapour condenses, it releases heat of
vaporization
Air
Latent heat recovery
Condensing economizer recovers both:

1. Heat of condensation (latent heat)
2. Sensible heat
68
Sensible and
latent heat
As flue gas
temperature
decreases,
efficiency increases
Condensation starts
below dew point at
about 137 F
Sensible
heat only
Excess O2 = 5%
69
Available Heat Varies with FG Temp. leaving Economizer

Heat available from one boiler
1.6
Heat Available (MMBTU/hr)
1.4
1.39
0.82
1.2
1.11
0.61
0.8
Latent Heat
0.61
Sensible Heat
0.6
0.4
0.56
0.17
0.50
0.44
0.38
0.38
0.2
0
75 F
100 F
125 F
150 F
Flue Gas Temp. Leaving Condensing Economizer (F)
70
Gas Savings Opportunity: Condensing Economizer (In-line)

Stack Flue Gas
100F
Make-Up
Water 75%
50F
Condensing
Economizer
190F
450F
Process Steam
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Make-Up
Water 75%
Cond.
Tank
Condensate
Return 25%
180 F
71
Gas Savings Opportunity: Condensing Economizer (In-line)

Stack Flue Gas
100F
Make-Up
Water 75%
50F
Condensing
Economizer
190F
450F
Process Steam
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Cond.
Tank
Condensate
Return 25%
180 F
72
Gas Savings Opportunity: Feedwater Economizers (Offline)

Stack Flue Gas
320F
Make-Up
Water 75%
50F
Condensing
Economizer
Feedwater
Economizer
267F
190F
450F
New Stack
Process Steam
Boiler
Feedwater
DA Steam
230F
8 psig
DEAERATOR
Condensate
Return 25%
180 F
Cond.
Tank
73
Key Considerations
Establish how much heat is available, Heat Source
o Existing FW economizer, Flue gas temp., excess O2, steam production, gas
consumption, hours of operation, etc.
Is there sufficient Heat Sink available?

o Boiler make-up water
o Domestic hot water
o Process water
Heat sink temp must be low enough to bring FG temp below dew
point (137 F) to cause condensation
Your ESC can help you evaluate your opportunity for a condensing
economizer
74
Example 6 : Installing an Inline Condensing Economizer

300BHP Boiler, 50% average loading, 6000hrs/yr, 75% Make-up
Total Available Heat in Exhaust (no feedwater economizer):

1,145,417 BTU/hr ( > 50% Latent)
Parameter
Savings
Average make-up water flow rate
7.4gpm (3,700lbs/hr)
Average Hourly Heat Recovery
554,825 BTU/hr
Annual gas savings
121,584 m3/yr
Annual savings
$34,044 /yr
11.5%
$60,000
1.8 years
Enbridge incentive
$13,579
1.36 years
75
Typical Applications
Industries with steam boilers, requiring a large amount of hot water
such as make-up, washing, process, DHW
Best Candidates:
o Food and beverage
o Breweries
o Textile, commercial laundries
o Non-integrated paper mills
o Chemicals
o District heating
o Large hospitals
o Greenhouses
76

Qsl
Stack Loss


Stack Losses
Blowdown Losses
Radiation Losses
Qng
Natural
Gas
Qra
Radiation
Loss
Qst
Steam
Qfw
Feedwater
Qbd
Blowdown
Loss
77
Blowdown Heat Recovery
78


Stack Flue Gas
Process Steam
Natural Gas
DA Steam
Boiler
Feedwater
8 psig
DEAERATOR
Blowdown
Cond.
Tank
Condensate
Return 50%
180 F
Make-Up
Water 50%
79
Gas Savings Opportunity: Blowdown (BD) Loss

Blowdown loss can be reduced by:
1.
Reducing amount of BD
2.
TDS Controller
Recovering BD heat
Flash tank
Heat exchanger
80
Blowdown Heat Recovery

Utilize energy in blowdown for:
Generating flash steam for DA (or
condensate receiver)
Preheating make-up water
Typically sold as skid type package
Additional benefit eliminates the

need to use fresh water for cooling
of blowdown liquid before going to
drain
Blow Down
Flash Steam to DA or Receiver
10 psig
Flash Tank
Heat Exchanger
Make-Up
Water 50%
1.5%-3% average savings (fuel input)

To Drain
81
Example 7 : Installing a blowdown heat recovery package

300 BHP boiler with 50% make-up and
8% blowdown rate
Parameter
Savings
Annual gas savings
24,532 m3/yr
Annual savings
$6,869 /yr
2.3%
$14,000
2.0 years
Enbridge incentive
$4,906
Revised simple payback

period
1.3 years
Flash Steam to DA or Receiver
Flash Tank
Heat Exchanger
Make-Up
Water 50%
To Drain
82
Enbridge Programs
Boiler Basics
83
Limited Double Incentive Boiler Campaign

Enbridge is offering industrial customers
double the financial incentive towards an
energy retrofit to your boiler system!
Thats a maximum of $25,000 or 50% of the
project cost!
A
limited
time
offer!
The incentive can be used towards

linkageless controls, economizers and blow
down heat recovery system
See your ESC for details
84
Example 5 : Installing a Feedwater Economizer

300BHP Boiler, 50% average loading, 6000hrs/yr
Reduction of Flue Gas temperature from 450F to 320F

Parameter
Savings
Annual gas savings
44,725 m3/yr
Annual savings
$12,523 /yr
$25,000
2.0 years
Enbridge incentive
$8,945
1.3 years
Limited time incentive
$12,500
1.0 years
85
Summary
Energy savings starts by understanding the need, then
proceed upstream
Boiler Savings:
Target stack losses and blowdown losses
Look at combustion efficiency
Heat recovery
Your ESC can help you better understand your boiler system
and the savings opportunities
Act now to take advantage of this limited time offer!
86
Knowledge
Development
Action and
Implementation
THANK YOU!
Opportunity
Identification
QUESTIONS?
Engineering
Analysis
Measurement
87

Boiler Basics Workshop - FINAL

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Boiler Basics Workshop - FINAL

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November 13th, 2014

Todays Workshop Will Cover:

Todays Workshop Will Cover:

In existence for 20 years;

Approx. 110,000,000 m3 of natural gas

More than 20,000,000 KWh of electricity

Over 800,000 m3 of water

In three year period ALONE

Participating in our programs helps YOU :

Reduce C02 emissions

Improve BOTTOM LINE

Approach to Energy Savings

Energy Savings Strategy

Todays Workshop Will Cover:

Energy in a boiler room

In the boiler room energy is typically measured in

Power, the rate at which energy is transferred, is

Specific Energy Content BTU/lb

Reference card included in your information package

Steam, water vapour, is generated by adding heat energy to

Adding more energy transforms water from liquid to vapor

Heat Energy is also called Enthalpy (h):

100C for Water

Water & Steam

Energy Added (BTUs)

Energy in Water vs. Temperature

Steam Basics Sensible vs. Latent Heat

Latent heat (Btu/lb)

Steam Basics Latent Heat

Steam Basics Pressure Dependency

Saturation Temp (F)

Steam Basics Total Heat of Steam

For 100 psig steam:

Total heat of Steam at 100 psig

Total Heat of Steam

hf (saturated liq. Enthalpy)

hfg (latent heat)

hg (saturated vapour enthalpy) = 1189 Btu/lb

Steam Table Example

Thermal energy released from the fuel is then transferred

Energy in the medium is then sent to the distribution

Workshop Steam Plant

Plant Operating Hours: 6,000 hrs.

Stack Flue Gas

Sat. Steam @ 100 psig

Energy Losses in Boilers

Improvement in Boiler Efficiency is

Three main boiler losses

Focus on Stack losses and Blowdown

Energy Losses in Boilers

Improvement in Boiler Efficiency is

Three main boiler losses

Insufficient heat transfer

Energy that is not transferred into the feedwater leaves

Perfect Combustion: Ideal Air:Fuel Ratio

Natural Gas (CH4 )

Air( 2O2 + 7.52 N2)

Air : Fuel Ratio (by vol.) = 9.5 : 1 or 10:1

Flue Gas Loss

Air Fuel Mixture

Example # 1 Reading a combustion test strip