From Retro to Renewable: A Partnership for Carbon Reduction & More

Decades of Preferred Excellence:

Preferred equipment and personnel have been fixtures in this boiler room since the 1950s with a rich history of service and supporting their high standard of maintenance and operation. Leveraging our strong relationship with Analytical & Combustion Systems (ACS), the team orchestrated the necessary changes to usher in a new era of modernization and carbon footprint reduction at this site.

Transforming a Time-Honored Boiler:

In a school in Queens, New York, Preferred joined forces with ACS to undertake a transformative project. The focal point of this endeavor was the conversion of a vintage 1954 boiler and burner, originally crafted by Preferred Utilities. While these stalwart components continued to function adequately in a meticulously maintained boiler room, the time had come for crucial upgrades.

Seizing the opportunity, the facility began a comprehensive modernization initiative for not only the mechanical elements but also the controls. In this important juncture, they chose ACS and Preferred’s expertise to effectively fire renewable B20 biodiesel, a liquid biodiesel that aligned perfectly with their carbon reduction objectives in New York City. These conversions to B20 represent the initial strides in a broader movement of boiler room transformations across New York City, ultimately transitioning to renewable B100 biodiesel.

Preferred and ACS offer sustainable solutions to boiler rooms seeking enhanced efficiency and a resolute commitment to significantly curbing their carbon footprint. Together, they pave the way for a greener and more environmentally conscious future.

The History:

Over the years, we’ve made strategic enhancements to the Preferred burner and boiler system at this school, its associated balance of plant components, and combustion controls. These upgrades have not only maintained the system’s exceptional performance but have also spared our customer from the costly path of total system replacements, a route that often proves financially burdensome in the long term. The exceptional quality of Preferred equipment and their unwavering commitment to service support have yielded substantial savings for this customer.

These savings extend across various fronts, including:

  1. Fuel Efficiency: The improvements have led to significant fuel efficiency gains, resulting in substantial cost savings over time.
  2. Electrical Efficiency: Electrical efficiency has seen marked improvements, translating to reduced energy costs and a more sustainable operation.
  3. Maintenance Costs: The reliability and durability of Preferred equipment have substantially lowered maintenance expenses, sparing them from frequent and costly repairs.
  4. Reduced Burner Retrofits: Perhaps the most remarkable benefit has been the longevity and performance of the Preferred Burner. Over its operational life, it has negated the need for multiple burner retrofits, each of which would have incurred significant expenses in NYC Permitting, Engineering, and Installation costs.

In essence, the investment in Preferred equipment and services has translated into hundreds of thousands of dollars in savings, all while maintaining the operational excellence of our heating system.

The Problem:

In response to various challenges, ACS undertook an assessment of an aging boiler room. Their mission was clear: devise a comprehensive solution that would not only retrofit outdated controls but also introduce new safety measures, ushering in a modernized era for the facility. Additionally, the objective was to enable the use of renewable B20 biodiesel, with key priorities including:

  1. Enhancing Energy Efficiency: The need to upgrade the facility’s overall energy efficiency with boiler and burner controls was paramount.
  2. Integrating Biodiesel Compatibility: ACS aimed to implement a solution that allowed the facility to seamlessly transition to firing 20% biodiesel without necessitating burner replacement.
  3. UL Listing Upgrade: Ensuring compliance and safety, ACS moved to upgrade the facility’s UL Listing to encompass B20 biodiesel usage.
  4. Optimizing Fuel Oil System: Recognizing the importance of effective fuel oil storage and handling, ACS also set out to enhance the facility’s fuel oil system.

Before Pictures

This multifaceted approach addressed both the immediate concerns of the boiler room’s functionality and its long-term sustainability goals, particularly in reducing carbon emissions.

Solution:

ACS was not only up for the challenge but exceeded expectations in retrofitting the aging boiler room for enhanced safety, efficiency, and sustainability. Here’s a closer look at the solutions they implemented:

  1. Flexfit Controller for Enhanced Control: ACS chose to install the Preferred’s Flexfit Controller, seamlessly integrating it into the existing wiring base of the Fireye E110. This upgrade brought advanced control capabilities to the system, allowing for precise adjustments and efficient operation.
  2. Accurate Actuators for Valve and Damper Control: To further improve control over the boiler’s operation, ACS installed highly accurate actuators on all moving valves and dampers. This precise control ensured optimal combustion and energy utilization.
  3. Variable Frequency Drive (VFD) with Oxygen Trim: The addition of a Variable Frequency Drive on the forced draft motor, equipped with Oxygen Trim functionality, allowed for continuous adjustments to maintain optimal oxygen levels in the combustion process. This not only improved efficiency but also contributed to reduced emissions.
  4. Upgraded Electrical Utilities: Bringing all electrical utilities up to code was a crucial step in ensuring the safety and reliability of the boiler room. ACS left no stone unturned in modernizing the electrical infrastructure to meet the highest industry standards.
  5. Advanced Biodiesel Filtration and Transfer System: Recognizing the importance of firing renewable B20 biofuel for carbon emission reduction, ACS installed a new Preferred Fuel Oil Filtration System and Fuel Oil Transfer Pump Set compatible with biodiesels. This upgrade not only supported sustainability goals but also ensured the smooth flow of current and future biofuel into the system.
  6. Plant Master Controller for Efficiency Optimization: To automate and optimize boiler operation, ACS introduced a new Plant Master Controller. This controller intelligently managed the boilers based on parameters such as run-time and steam load, ensuring they operated efficiently and in sync.
  7. UL Certification for B20 Compatibility: ACS secured a new UL Label certifying the system’s compatibility with B20 biodiesel. This certification provided peace of mind, assuring compliance with environmental standards.

After Pictures


In conclusion, Preferred Utilities and Analytical & Combustion Systems (ACS) demonstrated their expertise and commitment to transforming an outdated boiler room into a modern, safe, and sustainable facility. By implementing a comprehensive suite of solutions, they not only improved energy efficiency but also enabled the use of renewable B20 biodiesel, contributing to carbon emission reduction.

The success of this project underscores the importance of proactive maintenance and upgrades in industrial settings. Preferred and ACS’s dedication to excellence and their ability to find innovative solutions are a testament to their position as leaders in the industrial boileroom market. As industries continue to prioritize sustainability and efficiency, companies like ACS and Preferred will play a pivotal role in shaping a greener and more cost-effective future for industrial operations.

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