Replace or Repair The decision to purchase a new boiler is typically driven by the needed replacement of an old boiler, an expansion of an existing boiler room, or construction of a new boiler room facility. When considering the replacement of an old boiler, review the following points to make sure you are performing a comprehensive evaluation of your situation.
Maintenance Costs Review your maintenance costs carefully. The old unit is costing you money in various ways, including emergency maintenance, downtime, major maintenance requirements (past and pending), difficult-to-find and expensive parts requirements, operator time in keeping the unit on-line, and overall vessel, burner, and refractory problems. Many of these costs can be hidden within your overall maintenance budget. You are paying the price for having outdated boiler room equipment. But the costs need to be investigated and totaled.
Boiler performance New Gas-Fired boilers have much higher performance standards than older design units. Turndown, excess air, automatic operation, accurate-repeatable air/fuel ratio burner designs, computer linked combustion controls, low emission technology, and high guaranteed efficiency all are now available on premium designed packaged firetube boilers. The result is low operating costs and automatic power generation for your facility. All cost saving reasons to consider a new packaged firetube boiler.
The Importance of Modulation In general, modulation refers to the ability to adjust a boiler or water heater's firing rate (input) to meet the heating demand (output) of the system. A fully-modulating design which precisely matches firing rate to actual building demand.
The Importance of Modulation Where Conventional Equipment Falls Short The oldest boiler designs had only one level of power - 100%. They were either on or off. This creates cycling losses each time the unit shuts down; the heat exchanger cools off and must be fully "re-heated" before heat transfer can begin. Once the unit re-starts, the 100% firing rate may be far more than what is required to meet the building's load.
The Importance of Modulation New Technology Can Not Match the Competion While newer burners and boiler designs incorporate 5:1 or 3:1 turndown ratios, limited firing rates still result in some wasteful overshooting or cycling losses.
The Importance of Modulation Competition provides superior efficiency A 2.0 million BTU/hr. capacity boiler can run with as little as 100,000 BTU/hr., or 5% input. A 1.0 million BTU/hr. capacity heater maintains steady combustion with only 70,000 BTU/hr. input. Drawing only enough fuel to meet actual load changes, each unit will gradually increase its capacity - in precise 1% increments - up to 100% full capacity.
The Importance of Modulation Part Load means Superior Seasonal Efficiency Not only is less fuel burned as a result of modulating input, but heat transfer is also enhanced when the units operate at "part-load." Constant operation maintains temperatures within the heat exchanger, yet the reduced input increases the time these combustion gases are in contact with the heat exchanger surface to promote greater energy transfer and cooler exhaust gases.
Since the majority of a boiler's operating hours will be under "part load conditions," modulating units promise greater seasonal efficiency. The Importance of Modulation