{"id":1699,"date":"2021-07-21T17:00:44","date_gmt":"2021-07-21T17:00:44","guid":{"rendered":"https:\/\/www.thepyroscope.com\/blog\/?p=1699"},"modified":"2024-05-29T02:06:35","modified_gmt":"2024-05-29T02:06:35","slug":"boiler-system-101-the-advantages-of-full-system-integration","status":"publish","type":"post","link":"https:\/\/www.thepyroscope.com\/blog\/boiler-system-101-the-advantages-of-full-system-integration\/","title":{"rendered":"Boiler System 101: The Advantages of Full System Integration"},"content":{"rendered":"\n

Danbury, CT \u2013 A boiler system functions as a critical\ncomponent to the continuous operation of a facility.  It is\nimportant to maintain safe, reliable, and efficient operation while minimizing\nany downtime of the boiler system to prevent disruption of operation and\nsignificant loss.<\/p>\n\n\n\n

A boiler system consists of many sub-systems working in harmony \u2013\nthe boiler, the burner and its controls, boiler controls including feed water\nand draft control, fuel oil handling system (if burning oil), water treatment,\nfuel gas booster system (for areas with low supply gas pressure) etc. <\/p>\n\n\n\n

With so many different options in the marketplace, and a common lack\nof emphasis on how each component interfaces with another (or doesn\u2019t), these\nsub-systems are sometimes cobbled together from multiple manufacturers \u2013to the facility\u2019s\ndetriment. To deliver the safe, reliable, and efficient service that the\nend user expects and the facility manager can optimally maintain, a \u201cfull\nsystem integration\u201d provides clear advantages.<\/p>\n\n\n\n

\"\"<\/figure><\/div>\n\n\n\n

Possible Problems<\/strong><\/p>\n\n\n\n

A boiler system in general could have many modes of failures. \nFailures in water level control have serious implications on the longevity of\nthe boiler and in safety\u2014the sudden inrush of feedwater to a baked-dry boiler\ncould lead to a steam burst. Water treatment failures can decrease the\nlongevity and efficiency of the boiler. Boiler operators need to understand\nthese dangers. <\/p>\n\n\n\n

Among all sub-systems, the burner system is by far the most\nsophisticated sub-system in a boiler system. The burner system has many modes\nof failure that require training and\/or experience for the boiler operators to\nfully understand.<\/p>\n\n\n\n

When a boiler system is not delivering satisfactory performance to\nthe end user, it\u2019s often difficult to pinpoint the exact cause of the problem.\nThe following example illustrates this difficulty. Sometimes a burner makes a\nlow frequency noise, or a combustion \u201crumble.\u201d The rumble could be a nuisance\nor discomfort to the operators and residents nearby, or could even cause damage\nto property. Potential causes of the rumble include, but are not limited to:<\/p>\n\n\n\n

  1. The burner has poor stability at certain firing\n rates; or the burner\u2019s window of operation is too narrow. This could be\n related to the design or manufacturing of the burner.<\/li>
  2. The air\/ fuel ratio is improper due to poor\n commissioning or lack of maintenance.<\/li>
  3. The servos used by the burner control may have\n poor accuracy or repeatability.<\/li>
  4. The linkage between servos and dampers may be\n loose.<\/li>
  5. The system does not have oxygen trim to ensure\n consistent excess air levels. Any variation in draft, ambient temperature,\n fuel gas composition, building ventilation (affecting building inside\n pressure vs. outside ambient pressure), or wind speed blowing on outlet of\n chimney, can affect the amount of combustion air supplied by the fan.<\/li>
  6. Lack of draft control. Severe draft variation may\n cause the air\/fuel ratio to go out of range. This is a challenge if the\n system does not have an oxygen trim system; it can be a problem even with\n an oxygen trim if the draft variation is too severe for the oxygen trim to\n compensate.<\/li>
  7. The \u201cacoustic coupling\u201d between the burner and\n the boiler\u2019s fire chamber and the subsequent space the flue gas flows\n through.<\/li>
  8. The fuel gas booster could surge and cause the\n gas pressure to oscillate, beyond the pressure regulator\u2019s ability to\n regulate.<\/li>
  9. The boiler room\u2019s ventilation system could be\n improperly designed. When windows and doors are shut, a significant\n negative pressure can develop in the boiler room, causing a drop in\n combustion air supply and air\/fuel ratio.<\/li>
  10. Fuel gas supply pressure and composition can\n fluctuate, especially if the fuel gas is from an alternative fuel source,\n such as land fill gas or, to a lesser degree, digester gas.<\/li>
  11. Burner components may not work well together. For\n example, the gas regulator may be over-sized for the flow rates of the\n burner.<\/li><\/ol>\n\n\n\n
    • \"\"<\/figure><\/li>
    • \"\"<\/figure><\/li><\/ul><\/figure>\n\n\n\n

      Problems with the Multiple-Vendor Approach<\/strong><\/p>\n\n\n\n

      By cobbling sub-systems from many different vendors piece-meal (by\nthe general contractor or the end user), no engineering firm\ntakes responsibility for integrating these sub-systems, making it\ndifficult to identify the party responsible for correcting the problem. This\noften results in blame shifting among different parties, ultimately frustration\nfor the end user who does not get their equipment tended to.<\/p>\n\n\n\n

      For example: in a piece-meal approach, the burner may be supplied\nby a burner company, the controls may be supplied by a company that is solely\ndedicated to burner controls and knows little about the combustion behaviors of\nthe burner. The specifications do not call for a draft control or oxygen trim,\nwhen one or both of those may be required for the site conditions and\nrequirements. The booster, if there is one for the job, may be supplied by yet\nanother vendor, the commissioning may be done by a contractor who does not know\nthat the ventilation system of the boiler room may not have been designed properly\nto avoid high negative building pressure. <\/p>\n\n\n\n

      The troubleshooting process itself is further complicated by the\ndiverging interests of the different parties involved, none of which are\ndedicated to the specifications of the unique project. <\/p>\n\n\n\n

      Sole Source Responsibility<\/strong><\/p>\n\n\n\n

      The most important advantage of the full system integration approach\nis that the integrator must accept sole source responsibility. If the burner\nsystem does not perform, the integrator is responsible for correcting the\nproblem. There is no blame shifting among different suppliers or vendors.<\/p>\n\n\n\n

      A burner system supplier that adopts the full system integration\napproach is inclined to build a long-term relationship whenever it sells a project.\nThe supplier would look at the specific conditions and requirements of the customer\nand look for the best solution tailored for the job instead of chasing the\nlatest trendy requirement in specifications. <\/p>\n\n\n\n

      For example, it may be tempting to ask for a 12:1 or higher\nturndown from the burner system, but can the non-condensing boiler operate at\n12:1 or higher turndown without condensation and corrosion problems?  Is\n10:1 or 8:1 turndown enough for the job? In another example, does the system\nrequire a draft control device to work? Can the burner deliver satisfactory\nperformance without the draft system?<\/p>\n\n\n\n

      A supplier adopting the full system integration approach would look\nat total costs of ownership (the fixed costs and the operating costs) for the\nboiler system, instead of focusing on the fixed costs. In today\u2019s corporate\nprocurement practices, too often the one responsible for buying the boiler\nsystem is not the one paying the energy bill, hence there is less\nincentive to consider the total costs of ownership.<\/p>\n\n\n\n

      For instance, a burner capable of operating at 1.5-2.5% oxygen can\nlead to significant savings in fuel costs.  If a vendor offers a burner\nsystem without oxygen trim, is the burner operating at consistent excess air\nlevels all year round? Does the lack of oxygen trim mean conservatively high\nexcess air levels? <\/p>\n\n\n\n

      \"\"<\/figure><\/div>\n\n\n\n

      Consider that a fiber mesh burner may be used to meet 9 ppm NOx\nrequirements without FGR. But, the additional costs of fuel \u2013due to the very\nhigh excess air levels (typically 8-9% oxygen dry in flue gas) and the costs of\nreplacing filters and fiber mesh combustion heads \u2013need to be factored in when\npurchasing a burner system.<\/p>\n\n\n\n

      Commonly observed, a burner constructed with flimsy, low grade\nsheet metals may need frequent service and replacement parts, while a burner\nconstructed out of durable steel can provide years of service beyond the normal\nwarranty periods.<\/p>\n\n\n\n

      The \u201cfull system integration\u201d approach requires an integrator to\nhave in-depth understanding and strong product offerings in all the following\nareas:<\/p>\n\n\n\n

      1. Boiler controls. The boiler controls ensure safe and smooth operation (water level control, burner firing rate based on temperature or pressure, draft control if necessary). It should have the capability to manage the lead-lag control of multiple boilers to ensure the boilers are\u00a0operating at maximum efficiency.<\/li>
      2. Fuel oil handling systems (main tank, day tank, pump sets, filtration, leak detection, etc.)<\/li>
      3. Burners\u2013especially those designed for both high efficiency and low emissions at the same time. The end user should not be forced to choose between high efficiency and low NOx.\u00a0 High turndown (such as 10:1) helps avoid cycling of the boiler, and low excess air minimizes loss of heat to flue gas. Use of FGR is acceptable, but the incremental costs of running a larger motor due to FGR should be factored in. Advanced designs of burners can achieve mandated NOx emissions with less, little, or no FGR (depending on the NOx levels required).<\/li>
      4. Burner controls.\u00a0 The burner must be equipped with the latest Burner Management\/ Combustion Control Systems (BMS\/CCS) to assure that safety aspects are in accordance with the latest requirements of NFPA 85 and CSD-1. When high efficiency or tight emissions are required, an oxygen trim system should be included, and parallel positioning or fully metered control should be used instead of jackshaft. The combustion control and the servos should be designed to modulate the controlled fluids (air, fuel, FGR etc.) in a coordinated manner.\u00a0 For example, if the air servo cannot move fast enough to be in sync with the fuel servo, then the fuel servo needs to be slowed down in modulation, and vice versa.<\/li>
      5. Commissioning and maintenance.\u00a0The burner system is commissioned and maintained by qualified service technicians that are knowledgeable about all the subsystems.<\/li>
      6. Technical support and spare parts. These should be available from nearby locations.<\/li><\/ol>\n\n\n\n
        \"\"<\/figure><\/div>\n\n\n\n

        Preferred Utilities Manufacturing Corporation has earned a reputation for accepting single-source responsibility. We firmly believe in the advantages of full system integration. Compared to the piece-meal approach, the benefits of full system integration make the choice clear. If you believe the same way, please contact us about your next project. <\/p>\n","protected":false},"excerpt":{"rendered":"

        Danbury, CT \u2013 A boiler system functions as a critical component to the continuous operation of a facility.  It is important to maintain safe, reliable, and efficient operation while minimizing any downtime of the boiler system to prevent disruption of operation and significant loss. A boiler system consists of many sub-systems working in harmony \u2013 the boiler, the burner and its controls, boiler […]<\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"content-type":"","footnotes":""},"categories":[4,10,11,13,12,7],"tags":[],"_links":{"self":[{"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/posts\/1699"}],"collection":[{"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/users\/3"}],"replies":[{"embeddable":true,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/comments?post=1699"}],"version-history":[{"count":12,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/posts\/1699\/revisions"}],"predecessor-version":[{"id":1716,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/posts\/1699\/revisions\/1716"}],"wp:attachment":[{"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/media?parent=1699"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/categories?post=1699"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.thepyroscope.com\/blog\/wp-json\/wp\/v2\/tags?post=1699"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}