Product Showcase: Save with AutoFlame       The Role of Stack Economizers       Blowdown Heat Recovery      
 
                                        Service Showcase Save Money with Steam Traps       Steam Trap Survey       The Benefits of the Survey

 
 
In the winter of 2004, this country entered into its worst fuel energy crisis in decades with natural gas leading the charge—with an over 30% increase from some sources.
 
As prices continue to soar, these developments can become a budget crisis for many of you that we consider our valued customers.
 
We at CSI have chosen to address this problem head-on. We discuss four methods that can reduce your overall fuel expenses this upcoming winter by 10-30%. The four methods are AutoFlame, Stack Economizers, Steam Trap Testing and Blowdown Heat Recovery.
 
Steam trap testing is a new service that CSI is now offering. As discussed under this heading, malfunctioning steam traps can be a leading cause of poor boiler room efficiencies. Finding and replacing just 1 trap can more than pay for the cost of the steam trap test.
 
The second new service that CSI is offering is FREE. That’s right…we will come to your boiler room and perform a FREE fuel energy audit of your boiler system. Your only cost is 27 minutes of your time to answer some questions and allow us to take some combustion information from your boilers. We will then prepare a detailed report showing the actual fuel savings you can achieve and expected payback periods for the implementation of the equipment.
 
If you are worried about capital costs, CSI can further assist by providing a lease-to-own program where the monthly payments will be structured to be less than the fuel savings realized.
 
With these two new services: Steam Trap Testing and Our Free Energy Audits we look forward to helping you meet your heating budgets.
 

Burner Controls

AutoFlame Combustion Controls Top of page
 
In today’s climate, we find ourselves under increasing pressure to burn fossil fuels more efficiently, keeping within ever decreasing limits. With the majority of burners, the AutoFlame Burner Management System is able to achieve and maintain 82% combustion efficiency on Natural Gas and 86% when firing on 35 seconds/#2 oil.
 
To maximize the efficiency of any boiler, two factors are of paramount important: The fuel/air ration and the temperature for pressure of the boiler. The air to fuel ratio should be kept to a minimum that ensures complete combustion within the limitations of the combustion head design. Once these settings are achieved, they should be infinitely repeatable to a high degree of accuracy. The temperature or pressure of the boiler should be monitored by the combustion system so that the exact amount of fuel and air are fired to achieve the target value. This target should be met at all times, regardless of any load change.
 
The mechanical systems that have traditionally involved cams and linkages to characterize the fuel/air ratio cannot meet the criteria above. At most times, the inaccuracy of the fuel input response to the monitored temperature/pressure has meant that the target value has been significantly exceeded or fallen short of. The technology in AutoFlame’s Micro Modulation system removes these inaccuracies.
 
In summary, by eliminating the conventional cams and linkages on many burners and programming and setting the boiler up for optimal operating efficiency you will realize real fuel savings of 4-10%+ of your annual fuel bills. CSI can prepare a FREE detailed payback analysis based on your specific conditions and fuels.
 

The Role of Stack Economizers

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Anywhere there is a combustion process that is generating stack temperatures in excess of 300 degrees F holds the potential for a heat recovery stack economizer. In the combustion process much of overall efficiency is lost by BTU’s going straight up and out the stack. Using a heat recovery stack economizer allows boiler room owners and operators to recover 3-5% of these BTU’s by converting them into heating the water supply. This works well in any boiler room but also works especially well in industrial oven/generator applications. In a timewhen every energy dollar counts, CSI is prepared to make a detailed payback analysis based on adding this device to your system, dialing in the effects of your unique conditions and fuels. Call 717-767-6984 ext. 115 to book this FREE service.
 

Blowdown Heat Recovery

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Most boiler manufacturers and water treatment companies recommend boiler water TDS be maintained at certain levels. The purpose of continuous blowdown is to continuously take boiler water from 4”-6” under the surface where the TDS is at its highest concentration so that it can be replaced with fresh water.
 
While continuous blowdown is the best way in controlling these solids in the boiler the heat lost down the drain over time can be tremendous.
 
Continuous Blowdown Heat Recovery Systems can recover 90% or more of this heat normally lost.
 
Two stages provide the heat recovery. The first is the flash area where the high pressure condensate flashes to a low pressure steam for use in a feedwater heater or deaerator. In the second area is a heat exchanger that transfers the remaining heat to the make-up water.
 
During our FREE fuel energy audit we can collect the necessary information to properly size and predict payback periods which is often 3 months to 1 year.
 

Steam Traps

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Not knowing enough about how steam traps function can result in energy loss, environmental costs, productivity problems, and increased safety concerns.
 
Whether it is business, industry, education, or TV shows, systems are only as effective as the weakest link. Plumbing and mechanical professionals need to appreciate the significance of this axiom, especially when it involves a steam system. Just one weak link in a steam system can be embarrassing, costly and potentially dangerous.
 
The weakest link when it comes to steam systems may not be an individual component, but a fundamental lack of knowledge. For example, a steam trap, when properly installed, may be the most beneficial but least understood piece of equipment in the system. However, the lack of knowledge about steam traps and how they function can result in excessive energy loss, compounded environmental costs, productivity problems and yes, safety concerns for personnel and property. This article is intended to help designers and end users better understand and appreciate the complexities and energy implications of their steam trap selection and maintenance.
 
A steam trap is an automatic valve designed to remove condensate, air, and CO2 from the steam system. The trap opens automatically to discharge condensate and closes to prevent steam loss from the system. The following list represents the most frequently mentioned trap expectations:
 

 
These expectations can be met only with a properly specified, installed and maintained steam trap. A misapplied steam trap can lead to premature failure, and a steam trap that allows live steam to pass through an open orifice is extremely wasteful.
Consider this: a steam trap with a 5/16” orifice blowing steam will cost approximately $19,500 each year. If there are just five traps this size wasting steam, the loss is more than $97,000 a year.
 
In addition, with every pound of steam loss, there is a corresponding increase in pollution (carbon monoxide [CO], nitrogen oxides [NOx], particulate matter [PM], sulfur oxides [Sox], and other compounds) created when fossil fuel is burned to generate replacement steam.
 
CSI is launching a new program that will test and identify leaking steam traps. We also have the tools and training to work with your staff to save valuable steam dollars by putting together a comprehensive steam trap maintenance program. Call 717-767-6984 x 115 for information.
 

Steam Trap Survey

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When a steam trap fails in the open position, steam is allowed to blow directly into the condensate return system, and is ultimately vented. Not only does this adversely affect heat transfer, it also results in a tremendous waste of energy and money. The table below shows how much money can be wasted by a single failed steam trap.
 

 

The Benefits of the Survey: Top of page   Each trap will be assigned a designation and marked with a permanent tag. The make, model, and serial number of each trap will be documented. Each trap will be examined using an ultrasonic listening device, and its condition noted. A report will be provided describing each steam trap, its condition, and an evaluation of the money being wasted.