1. Westbrook Apartments BOILER REPLACEMENT ASSESSMENT AND PROPOSAL AUGUST 2007

2. Westbrook Boiler Rooms Very large breeching / square / very tall chimney (70’+) B-1B-2B-3 E-1 E-2 E-3 DHX DP-1 DP-2 CAD Large single wall breeching with tall Chimney. Atmospheric boilers. System Expansion Tanks (Bladder). Domestic Heat Exchanger System. Domestic Storage Tank. Combustion Air Damper.

3. Westbrook Boiler and Breeching Very large breeching / square / very tall chimney (70’+) B-1B-2B-3 Atmospheric efficiencies UNDER 65%. Chimney barely meets an ANSI category I rating. Room is tremendously hot indicating horrific losses. Vents are very large. Stand by losses are huge. Concern with hot floor. Maintenance intensive with 60+ tubes per boiler and state inspections due. BTU output isn’t nearly what it should be. Each boiler is 2100 MBH IN but nets less than 1365 MBH of heat value. Load matching is very poor. Boiler Type can’t be turned down effectively.

4. Westbrook Domestic System DHX DP-1 DP-2 Domestic Hot water System uses a plate and frame heat exchanger. Additional 4 HP in electrical losses from two pumps. Boilers are oversized to match this load and summer operation is expensive. Condition of the tank is unknown Entire system should be removed and water should be heated directly by water heaters.

5. Westbrook Expansion Tanks E-1 E-2 E-3 Expansion tanks are fairly new. Bladders should be checked. Size is sufficient for new boiler plant as volume will be lower. Note there is NO expansion on the domestic side. This violates current plumbing codes.

6. Westbrook Combustion Air CAD Opening in wall may be too small for 6000 MBH. Infiltration is expensive / lack of air hurts efficiency. Louvers are rated around 60% blocked by screen and louver. Atmospheric boiler intensify losses with constant flow. No consideration for a variable rate of fire. Sizing properly is a minimum requirement for new or old plant.

7. Simple Combustion Efficiency 1000 Fuel In Cooler Water Back 800 In Heat Out 20% of fuel Wasted 80% Efficient Boiler Fuel is the energy the boiler is provided. (What you pay for) Heat out is how much you get out of that fuel. (What you actually get) Wasted is the Fuel you couldn’t use. (What went up the stack and outside) Cooler water is what you get back AFTER your building used the heat you provided it. Obviously, it needs to be heated again.

8. Simple Combustion Efficiency 1000 Fuel In Cooler Water Back 800 In Heat Out 20% of fuel Wasted 80% Efficient Boiler 80% = $1.00 SPENT TO GET $ 0.80 IN HEAT You’ll have to spend $10,000.00 to get $8,000 in Heat!

9. Simple Combustion Efficiency 1000 Fuel In Cooler Water Back 800 In Heat Out 20% of fuel Wasted 80% Efficient Boiler Put $500 back in your pocket by making the boiler fire 85% or $1000 @ 90%.

10. Other Waste? Electrical Losses from Pumps or large blowers. Jacket losses amplified by larger volumes and steel designs. Temperature Control Limitations. Purge Losses. Vent Losses. Maintenance or Life Cycle costs. 80% Efficient Boiler

11. Atmospheric Type Atmospheric Boilers Atmospheric (Flame at the bottom) boilers are OPEN flame boilers with the largest in stand by losses. Room air continually passes through the boiler cooling it down and stealing conditioned air on the off cycles. No air control, typical O2 around 10% (4% optimum) Negative room dangerous as Flames roll out, combustion enters room. Great Heat loss at the bottom of the boiler, you can almost burn your feet!

12. Forced Draft Forced draft uses a fan to add air to the ignited gas in a controlled way. Combustion air as needed (Fan may require more than natural) Good air control, typical O2 around 4% about 3:1 TD. Usually a category III Appliance. May need to line chimney. Jacket losses exist but stand by losses become PURGE and electrical losses.

13. Fan Assisted Draft Fan Assisted Fan assisted uses a small fan to premix the gas and the air before ignition. Combustion air as needed (Typically less HP than FD) Good air control, typical O2 around 3% about 4:1 TD. Usually a category I Appliance. Depends on Efficiency. Jacket losses and purge losses practically eliminated with design and low volume.

14. CondensingCondensing Condensing Combustion system usually fan assisted (lowest losses). Combustion air as needed (Typically less HP than FD) Good air control, typical O2 around 3% about 5:1 TD. Usually a category II or IV Appliance. AL29. Jacket losses and purge losses practically eliminated with design and low volume. Low water temperature is a MUST to offer a return.

15. Water Temperature and Efficiency 18040 130 inlet water temperature boiler efficiency, % 80 80100 86 86 94 94 condensing boiler condensing boiler non-condensing boiler dew point natural gas = 1050 Btu/ft 3 80

16. Solving Waste by Boiler Type Boiler TypeCondensingCopperSteel Firetube Steel Water Tube Cast Iron Typ. Efficiency 85% - 98%85% - 88%78% - 82%80% - 85%80% - 84% Minimum Return Temp 60F or below 120F140F130F135F – 140F 2000 MBH Typ. Price $25,000$15,000V: $16,000 H: $20,000 $16,000$13,500 (Must assemble)

17. Which is best for you? Boiler TypeCondensingCopperSteel Firetube Steel Water Tube Cast Iron Typ. Efficiency85% - 98%85% - 88%78% - 82%80% - 85%80% - 84% Minimum Return Temp 60F or below120F140F130F135F – 140F 2000 MBH Typ. Price$25,000$15,000V: $16,000 H: $20,000 $16,000$13,500 (Must assemble) Low Temperature System – Use Condensing (Return at 80F or below) Mid Temperature System – Use Copper (Return at least part of the season at 120F or above) High Temp System – Use Steel Fire or Water Tube/Cast Iron. (Return at 140F – 160F – Usually 180F – 200F supply)

18. Thermal Efficiency Life Cycle Cost Decrease in Thermal Efficiency Decrease in Thermal Efficiency 5% 10% 7.5% 6% 9.3% 12.8% Increase in Fuel Cost for Life of Product

19. Load Matching SOLID SIZING DONE BY EXPERIENCED AND ACCREDITED ENGINEERING BOILER TURNDOWN MODULAR BOILER PLANT. CONTROL WITH INTER- BOILER COMMUNICATION TAKE FULL ADVANTAGE OF SEASONAL OR WATER TEMPERATURE OPPORTUNITIES.

20. Load Matching When loads vary, the boilers need to match the load. Proper sizing of the boilers and sufficient turndown (not excessive) adds to efficiency. Offset first cost quickly with proper evaluation of system demands. Eliminate short cycling while firing boilers at the most efficient rate (low fire) most of the season. based on Windsor Locks, CT 5656 degree days months 10 jan degree days 20 30 40 50 dec

21. Identify Your System HOT WATER HEATING LOOP (Basic main loop, radiation, air handlers, etc.. May be cut into or flow off of this loop.) STEP ONE: Determine the water temperature required for the system and roughly how many degrees the system will remove from the water (system delta tee) 140F-180F 120F-160F

22. Identify Your System HOT WATER HEATING LOOP (Basic main loop, radiation, air handlers, etc.. May be cut into or flow off of this loop.) STEP TWO: Begin to weigh first cost vs. long term savings. Look closely at the cost of maintaining and operating your plant. Proper boiler selection OR system piping becomes CRITICAL!

23. SYSTEM REQUIREMENTS MID TEMPERATURE HEATING LOOP. STANDARD EFFICIENCY BOILERS (STEEL or CAST): Return Temperatures will be limited to 140F to prevent fireside and refractory damage. Limitations will prevent top efficiency reset ratios. Load matching is much more difficult as standard ratios are 3:1 Maintenance cost will be higher as turndowns require expert settings and consistent adjustment. Efficiency limited to around 83%.

24. SYSTEM REQUIREMENTS MID TEMPERATURE HEATING LOOP. HIGH EFFICIENCY BOILERS (CONDENSING): Must have a very low return temperature to achieve over standard efficiency (60F-100F). High return temperatures will net no more than 88% efficiency. Cost is 25% greater but when conditions are met, payback can be quick. Special venting is required, but typically smaller. Masonry chimneys will need an AL29 liner. If tall chimneys 40’ or above are required, first cost may take too long to be recouped.

25. SYSTEM REQUIREMENTS MID TEMPERATURE HEATING LOOP. MID EFFICIENCY MODULAR BOILERS (COPPER FIN): Can handle 120F temperatures. Primary / Secondary piping gives great control. Depending on model, Category I (85%) can be used in existing chimneys. Modular design offers staged firing which works well for load matching. System changes are unnecessary. System flow is unchanged. Small footprint gives back valuable space. Sealed combustion offers maximum boiler plant efficiency and is used ILO refrigeration detection systems.

26. CURRENT PLANT CONFIGURATION BOILER PLANT SYSTEM PIPING

27. NEW PLANT CONFIGURATION REMOVE 2 BOILERS AND SYSTEM PIPING LEAVE DOMESTIC RUNNING SYSTEM PIPING

28. NEW PLANT CONFIGURATION CONNECT SYSTEM PIPING AS SHOWN – SYSTEM FLOW IS UNCHANGED. SYSTEM PIPING

29. NEW PLANT CONFIGURATION INSTALL TWO PRIMARY LOOP TEES MAXIMUM 12” APART IN THE SYSTEM. THIS WILL BE THE NEW INLET/OUTLET SYSTEM PIPING

30. NEW PLANT CONFIGURATION PLACE NEW MODULAR 85% COPPER FIN BOILERS IN PLACE. CONNECT EXPANSION TO SYSTEM. SYSTEM PIPING

31. NEW PLANT CONFIGURATION CREATE AND PIPE YOUR PRIMARY LOOP TO THE NEW BOILERS. SYSTEM PIPING

32. NEW PLANT CONFIGURATION REMOVE HEAT EXCHANGER AND PIPING ASSOCIATED WITH OLD BOILER. PLACE AND PIPE NEW DIRECT WATER HEATERS. SYSTEM PIPING

33. NEW PLANT CONFIGURATION REMOVE LAST OLD BOILER. ENJOY A COOLER ROOM, LOWER BILLS AND COMPLETE REDUNDANCY. SYSTEM PIPING

34. NEW PLANT CONFIGURATION OPTION ONE: REMOVE OLD TANK INSTALL MULTIPLE SMALL TANKS. SYSTEM PIPING

35. NEW PLANT CONFIGURATION OPTION 2: REMOVE LARGE AND WASTEFUL LOUVER, ADD MATCHING COMBUSTION SYSTEM. SYSTEM PIPING

36. NEW PLANT CONFIGURATION OPTION 2B: AS PART OF THE COMBUSTION AIR SYSTEM INSTALL A MODS SYSTEM TO CONTROL DRAFT. SYSTEM PIPING

37. NEW PLANT CONFIGURATION OPTION 3: USE AT LEAST AN ECONOMICAL STAGING CONTROL TO RESET AND MAXIMIZE EFFICIENCY. months 10 jan degree days 20 30 40 50 dec

38. ABOUT RBI FUTERA II 85% EFFICIENT CATEGORY I APPLIANCE VERTICAL TRUE FLAME SAFEGUARD DESIGN NON PROPRIETARY CONTROLS UV FLAME MONITORING SPARK IGNITION ALL BRONZE HEADERS FULLY DIAGNOSTIC PANEL EASY ACCESS / SERVICEABILITY STAINLESS STEEL JACKET OPTIONAL

39. HEAT EXCHANGER

40. DIAGNOSTIC PANEL

41. Terminal Strips Jumo 2-Stage High Limit Honeywell RM7895C ELECTRICAL PANEL

42. SIMPLE 2 STAGE CONTROL

43. WHO OWNS RBI? Manufacturer of HVAC & Metal Forming Equipment Became a private company once again in 2006. Headquartered in Westfield, Massachusetts 25+ Locations Throughout US and Canada Approx. 3000 Employees Approx. $375 million in Sales HVAC Metal Forming

44. WHERE MESTEK STARTED Founded in Westfield, MA in 1946 as Sterling Radiator by John E. Reed 4 employees in a rented garage Produced only hydronic finned-tube heating element

45. WHO OWNS RBI? MESTEK KNOWS THE HVAC INDUSTRY – THEY OWN ALL THESE GUYS!

46. MESTEK NATIONAL ACCOUNTS THESE GUYS TRUST US – SO SHOULD YOU!

47. LOCAL SUPPORT? ROBERTS MECHANICAL EQUIPMENT COMPANY IS THE DIRECT FACTORY REPRESENTATIVE FOR RBI LOCATED IN GARFIELD HEIGHTS OHIO. WE ARE DEDICATED TO THE FULL SUPPORT OF MCPHILLIPS ON THIS PROJECT. MCPHILLIPS WILL BE FULLY FACTORY AUTHORIZED TO SERVICE AND MAINTAIN THIS EQUIPMENT. WE ARE OFFERING FULL FACTORY START UP AND COMMISSIONING. FACTORY TRAINING WILL BE OFFERED TO K & D ON SITE OR AT THE FACGTORY. WE ARE THE AREA’S LARGEST REPRESENTATIVE FIRM DEDICATED TO THE APPLICATION AND CARE OF BOILERS AND BOILER RELATED EQUIPMENT. OVER 100 YEARS OF COMBINED EXPERIENCE INCLUDING SALES, PARTS, WARRANTY SERVICE AND ENGINEERING SUPPORT FOR OUR CONTRACTORS. THANK YOU FOR YOUR TIME AND FOR YOUR CONSIDERATION!