SPRING 2012

T R E N D S, T E C H N O L O G I E S & I N N O VAT I O N S

PIECES
Whether its better controls, smart use of analyzers, or new boiler offerings, several ways to boost performance and cut emissions today are worth discussing.
The Ofcial Magazine of Supplement to Engineered Systems Magazine. ES is a member of ABMA.

CONVERSATION

Analyzers p.5

Controls Upgrades p.9

Deaerators & Safety Valves p.14

TOLL FREE

877-99HURST
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INSIDE
5 Reducing NOx Production While Keeping Expenses And Emissions Down
Autoame Engineering Ltd. Sounds good, right? Catch up on what the latest analyzers can do, and visit a large company who expanded Its steam capacity by 50% in Californias tough regulatory environment.

9 Retrotting Controls Reduces Fuel Costs

Cleaver-Brooks Check these tips for battling boiler inefciency. Could you join this plant in simply using a controls upgrade to achieve emissions and performance goals?

12 ABMA Member Products 14 Safety Valve Requirements For Deaerator Installations: How Much Relief?
Crane Environmental Learn about the proper location for those valves, managing blowoff steam and turbine exhaust, and more.

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ad index
BURNHAM COMMERCIAL BOILERS . . . . . . . . . . . . . . . . . . . . . . 17 CLEAVER-BROOKS, INC. . . . . . . . . . . . . . . . . . . . . . . . .Back Cover EVOLV INDUSTRIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HARSCO INDUSTRIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 HURST BOILER & WELDING CO. . . . . . . . . . . . .Inside Front Cover PENN SEPARATOR CORPORATION . . . . . . . . . . . . . . . . . . . . . . 11 RENTECH BOILERS . . . . . . . . . . . . . . . . . . . . . . Inside Back Cover TOPOG-E GASKET COMPANY . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

18 Issues and Events 20 Products

Cover photo courtesy of Cleaver-Brooks

RANDY RAWSON
President / Chief Executive Ofcer, ABMA // randy@abma.com
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THE WAY I SEE IT

BY RANDY RAWSON

HOW FINAL WILL FINAL BE?

urt Vonnegut, Jr. once observed, nothing in this If youre indeed affected by the rules slated for unveiling in late world is ever nal no one ever ends we keep spring/early summer, compliance with EPAs nal-nal ICI-BMACT on bouncing back and forth in time, we go on and Rules can be achieved with existing, affordable, state-of-the-art, technoon ad innitum. Instead of an attempt to dene logically-advanced, and fuel-exible products, along with innovatively his theory of time, to which this 1970 New York designed and engineered application solutions, provided by members Times quote is usually credited, Vonneguts observation could of the ABMA companies with decades of combined experience and also be aptly directed towards the way things work in Washing- expertise in meeting tough, state, local, regional, and national air qualton, DC and a lot of state capitals across this nation. ity codes, standards, and regulations with innovative, and real-world As this issue of Todays Boiler hits your desk, we likely know with design solutions all ready and able right now to help you to coma little more certainty and nality what is in store for the ever- ply with any new rules in a timely and affordable manner. Labor and diminishing numbers likely to be affected by the EPAs National materials costs are currently stable and domestic boiler, combustion, Emission Standards for Hazardous Air Pollutants for Area and and emissions-controls equipment manufacturing capacity is available Major Sources: Industrial, Commercial, and Institutional Boilers, now to service the full range of compliance options available under otherwise known as EPAs ICI-BMACT rules. any new, more exible rules as are anticipated If you own a boiler or boiler system, and you through EPAs lings this spring. If youre indeed are not aware of the ICI-BMACT rules from One nal thought. As we careen headlong affected by the rules EPA, get in touch with the company that into the 2012 general elections, it is very slated for unveiling in made your boiler, installed your boiler, or easy to succumb to cynicism over choices, maintains/services or repairs your boiler. over the indolence of incumbency, over late spring/early They will know if and how you are affected candidates willingness and inability to deal summer, compliance by these rules. truthfully with facts, over partisan panderwith EPAs nal-nal And, if you want clarity and informed ing, and over the excessive role money plays ICI-BMACT Rules can judgment on what you need to do and how in the entire process. And, as the pundits be achieved with you can go about doing it and you dont remind us that the outcome of this tortuous existing, affordable, know where to turn, use the ABMA as your process we have to endure over the next few state-of-the-art, go-to resource. weeks is unlikely to provide any additional technologically Go to http://abma.com and download long-term clarity, certainty, or leadership advanced, and fuela pdf-searchable copy of ABMAs Directhan we already have, it is even easier to tory of Members Product and Services let ourselves tune out and turn off. For the exible products. or go to http://abma.com/membershipwell-being of the Republic, however, please directory.html where you can either search by company remember and take solace in this admonition by noted educator name or by product. Robert Hutchins: The death of democracy is not likely to be an asA member company of the American Boiler Manufacturers sassination from ambush. It will be a slow extinction from apathy, Association is not just another steam, hot water, or combustion indifference, and undernourishment. Do your part, thenfor the equipment company. It is part of a tradition of excellence and sake of what is still the greatest country on the globe. TB signals its exceptional commitment and obligation to the market, its customers, and to the public to provide safe, efcient, Randy Rawson is president and chief executive ofcer of the clean, and reliable hot water, comfort heating, process steam, American Boiler Manufacturers Association. Contact him at heat recovery, and electricity-generating steam systems. randy@abma.com.

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AUTOFLAME ENGINEERING LTD. >

REDUCING NOx PRODUCTION

While Keeping Expenses And Emissions Down
SOUNDS GOOD, RIGHT? CATCH UP ON WHAT THE LATEST ANALYZERS CAN DO, AND VISIT A LARGE COMPANY WHO EXPANDED ITS STEAM CAPACITY BY 50% IN CALIFORNIAS TOUGH REGULATORY ENVIRONMENT.

s regulations regarding emissions become more and more stringent in the boiler industry, particularly those concerning NOx levels, it is also essential to maintain high combustion efciency levels in order to keep carbon emissions to a minimum and keep fuel costs as low as possible. Current regulations on emissions are focused around single-digit NOx levels, typically 9 ppm. This trend towards lower NOx requirements looks set to continue, and before long, sub-5 ppm NOx may become a reality in certain parts of the U.S. As is well documented, low-NOx combustion can be obtained from many different burner designs, whether through adapting the existing burner, fuel and/or air staging, ue gas recirculation (FGR), or a specialist burner head design, of which several are currently available on the market. On many applications, lower instantaneous NOx levels are achieved by increasing

LOW-EMISSIONS EXHAUST STACK

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INDUCED FGR FOR LOW NOX

the amount of excess air, typically from 10% to 50% (this is equivalent of an increase in the oxygen in the emissions from 2% to 7.5%). An existing EPA document, Guide to Industrial Assessments for Pollution Prevention and Energy Efciency, states that the optimal quantity of excess air to guarantee complete combustion for natural gas is 10% (2% O2). In reality, this amount of excess air is not maintained in the majority of applications. Increasing the excess air levels causes several issues. First, the combustion efciency levels are reduced dramatically by higher excess air due to high O2 levels and elevated stack temperatures (increasing the amount of excess air causes the combustion gases to be pushed through the boiler tubes at higher velocities, lead6
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Higher percentages of FGR can also lead to dangerous combustion characteristics such as boiler vibration, excess noise, and tube impingement.

ing to reduced heat transfer time and greater heat loss up the stack; this means that more fuel must be burnt in order to achieve the same output). Secondly, by

introducing excess air and lowering the chances of complete combustion in the primary mix, there is a tendency to produce CO. This, in turn, can lead to carbon build-up in the tubes leading to increased maintenance requirements, but also reducing the heat transfer to the medium. Again, this will reduce the overall efciency of the system. FGR is commonly used in order to achieve lower NOx levels. Typically 15% to 30% ue gases are re-introduced into the mixing process. The effect is to lower the production of thermal NOx by reducing the ame temperature and amount of O2 available for combustion. There are obvious limitations to how much FGR can be introduced based on the burner design. Higher percentages of FGR can lead to major stability issues with ame retention causing nuisance failures, but also dangerous combustion characteristics such as boiler vibration, excess noise, and tube impingement. While it is certainly important to examine ways of reducing NOx levels in the combustion process itself, particularly in light of regulatory requirements, it is crucial to ensure that this is not achieved at the expense of excessive carbon production, which is also regulated. As technology advances, low-NOx burner techniques will improve and higher efciency levels will be maintained (particularly at lower ring rates), with burners also offering reasonable turndown (minimum 5:1 on natural gas) and reliability. Rapid technological improvements are currently being made in this area. Another method of reducing NOx after the combustion process is to use a selective catalytic reduction (SCR) system; typical NOx emissions are reduced by over 70% and often over 90% for a gas-red boiler application. This methodology uses a single-reactor unit complete with a catalyst and reducing agent delivery system (typically anhydrous ammonia). The unit passes the combustion gases through a grid system in which the

reducing agent is added to the combustion gases and is absorbed by the catalyst to remove the NOx. The reaction of the NOx (NO or NO2) and NH3 (ammonia) produces a byproduct of nitrogen and water vapor. Typical performance of such units will see NOx levels reduced from 30 ppm to sub-5 ppm.

MONITORING AND AUDITING THE EMISSIONS

The majority of analyzers used in the package boiler market measure oxygen and stack temperature, offering a calculated CO2 value and corresponding efciency. Further to this, CO can be an additional option for safety and monitoring clean combustion. In order to measure the NOx emissions, an additional analyzer will typically be required. With low-NOx burner technology, it is essential that further parameters of combustion are measured. The latest Autoame analyzer the Mk.7 CEMS Ex-

haust Gas Analyser (E.G.A.) has been specically designed in light of current regulations on emissions monitoring. The E.G.A. offers all of the requirements for the boiler industry ring on both gaseous and liquid fuels. As standard, this analyzer measures O2, CO2, CO, and NOx, with the option to include nitrogen dioxide and sulphur dioxide. Three of these parameters (O2, CO2, and CO) are used for the patented trim process, enabling tight combustion control especially with high-performance burners. It is also possible to use limits of combustion on all measured parameters to inform the client when certain conditions exceed performance guidelines or state or federal regulations (e.g., NOx level). All measured parameters offer an instantaneous analysis of the combustion gases (%, ppm, ft 3 /hr and lb/hr); additionally, a 10.4-in. full color touch screen HMI allows the user to view a totalised analysis of all of the emissions updating

the data every second and logging up to two years of data. This data can be manipulated to review a monthly emissions total for all of the measured parameters, but particularly the NOx and carbon emissions (ft 3, lbs, or tons). Incorporated into the Mk.7 CEMS E.G.A. is the ability to input the fuel composition data, the fuel ow (via an input signal), and also the fuel cost per unit. This allows the E.G.A. to calculate not only the total fuel input and average combustion efciency over the designated period, but also the fuel costs for each fuel. All of this data is displayed in tabular and graphical format and can be exported for client analysis. All of the data recorded and analyzed by the Mk.7 CEMS E.G.A. can be monitored via the latest Autoame Mk.7 Data Transfer Interface (D.T.I.) unit. This allows up to 10 boilers to be monitored and logged through any single D.T.I. unit, and this information can then be accessed via any

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EtherNet connection. The capabilities of this technology will allow the client to bring individual boiler room control to a higher management level, allowing immediate access to all emissions and operational data from each boiler located globally.

The next stage was to review the SCR system. Again, One Source Engineering chose a supplier that had vast experience in this technology, including many installations and successful case studies, and was also a local manufacturer. The Nationwide Environmental Solutions CataStak system was chosen.

A RECENT SOLUTION AND CASE STUDY

SYSTEM PERFORMANCE

In 2005, a leading health care company in California decided to Installation of the specied equipment began in November expand their steam capacity by 50%. A new 1,000 hp, four-pass 2011. The Limpseld burner was commissioned in January steam boiler was specied and selected for the expansion, along 2012, achieving a 5:1 turndown, sub-30 ppm NOx, corrected to with a sub-9 ppm low NOx burner and control system. 3% O2, CO was zero throughout the ring range, and the O2 By the end of 2006, the new boiler was installed and the sub-9 level was 2% to 3% from low to high re. The split head design ppm low NOx target had been achieved. However, the residual manufactured by Limpseld mixes the fuel and air in the highoxygen levels were in the range of 8% to 8.5%. In addition, pressure zone in the burner head offering superb stability and maintaining this low NOx level was causing many problems, ame retention, which is essential for this type of application. such as excessive vibration from Boiler capacity was also achieved the 125-hp blower motor running for the rst time ever. at 3,600 rpm, ame failures, and In February 2012, the SCR was material and refractory failures. Recommissioned and the NOx was reliability was a serious issue with the duced from sub-30 ppm to 1 ppm existing system, and further to this throughout the ring range. The the boiler could not reach the rated contractual NOx emission guarsteam capacity. antee to the client was sub-5 ppm In 2010, a steam reliability and below the required air permit study was conducted on site and level of sub-9 ppm NOx. Over time, commissioned by the Auto ame the NOx will be adjusted to approxiTechnology Centre in this region, mately 4 to 5 ppm, corrected to 3% One Source Engineering, Inc. It O2, by reducing the ammonia ow. was decided at this time that reliThe installation has been a great ability was a priority given the exsuccess and since commissionisting conditions and, therefore, ing the new Limpseld LCN123 replacing the burner and offering burner and CataStak TM SCR sysan SCR system was the best longtem have been operating without term solution for the client. This issue, with no faults, lockouts, or would not only offer the client improblems that were inherent beAUTOFLAME EXHAUST GAS ANALYSER (EGA) proved functionality and reliabilfore the upgrade. ity, but would also provide a high ef ciency burner complete Most importantly, the system has retained its commiswith low NOx and low carbon production. sioned values operating at high efciency, low excess air levThere were several requirements that any potential new els, low carbon production and ultra-low NOx. TB burner had to meet, such as the selected burner had to be robust incorporating a standard low NOx design (sub-30 ppm), as Autoame Engineering Ltd. can be contacted through email at well as being able to perform with a reasonable turndown ratio skemp@autoame.com. Autoame manufactures combustion (5:1). The dampers and bearing assembly, combustion air sys- management systems and solutions for the boiler industry havtem, burner head, and igniter system all needed to demonstrate ing pioneered the rst Micro Modulation fuel/air ratio controlhigh quality engineering and craftsmanship. It was important ler. Autoame works with a worldwide distribution network of to the client that the entire burner package had the appearance technology centers. and design of a quality engineered product. After reviewing the For more information please visit the principals websites: available burners on the market today, One Source Engineer- One Source Engineering (http://www.onesourceengineering. ing chose Limpseld Combustion Engineering Ltd. to supply com/home.htm); Autoame Engineering Ltd. (www.autoame. the burner, as theirs was a package that met all of these cus- com); Limpseld Combustion Engineering Ltd. (www.limpstomer specic requirements and would guarantee the neces- eld.co.uk); Nationwide CataStakTM (http://www.catastak.com/ sary efciency levels. index.html). 8
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CLEAVER-BROOKS >

RETROFITTING CONTROLS

REDUCES FUEL COSTS

CHECK THESE TIPS FOR BATTLING BOILER INEFFICIENCY. COULD YOU JOIN THIS PLANT IN SIMPLY USING A CONTROLS UPGRADE TO ACHIEVE EMISSIONS AND PERFORMANCE GOALS?

BY RAKESH ZALA

he main cause of boiler inefciency is heat loss, and upgrading the controls is one of the most effective ways to recapture lost heat in an existing system. There are several control options available, depending upon a facilitys needs and goals. To increase boiler system efciency and reduce costs, consider the following: O2 trim. Add an oxygen sensor/transmitter in the exhaust gas. The sensor/transmitter continuously senses oxygen content and provides a signal to the controller that trims the air damper and/or fuel valve, maintaining a consistent oxygen concentration. This minimizes excess air while optimizing the air-to-fuel ratio. Parallel positioning. Many boiler burners are controlled

INTEGRATED BOILER ROOM CONTROLS, SUCH AS THE CLEAVERBROOKS HAWK, HELP A FACILITY INCREASE ITS OPERATING EFFICIENCY AND REDUCE FUEL COSTS.

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by a single modulating motor with a single jackshaft and corresponding linkages attached to the fuel valve and air damper. This arrangement, set during startup, xes the air-to-fuel ratio over the ring range. Over time, the linkages wear down, causing the air-to-fuel ratio to become erratic as the burner modulates from low to high re. Parallel positioning uses dedicated actuators for the fuel and air valves, so lower excess air levels can be set due to consistent repeatability.

load. Lead lag allows the boilers to operate at peak efciency, reduce cycling, and decrease maintenance and downtime.

FACILITY REAPS THE BENEFITS OF A CONTROLS RETROFIT

A wastewater treatment plant in West Hill, Ontario, relies on ve, 400-hp, Cleaver Brooks hot-water, retube boilers to treat wastewater for a half a million area residents. The plants boiler

THE UPGRADED BOILER CONTROLS IN THIS WASTEWATER TREATMENT PLANT WILL SAVE THE FACILITY BETWEEN 12% AND 15% ANNUALLY IN FUEL COSTS.

VSDs. VSDs enable a motor to operate only at the speed needed at a given moment, rather than a constant rpm, regardless of ring or delivery rate. This speed variance results in the elimination of unnecessary electrical energy consumption. A VSD can be used on any motor but is most common on boiler feed pumps and combustion air motors greater than 5 hp. These drives also reduce maintenance costs by decreasing the stress on the impeller and bearings. Lead lag (boiler sequencing control). Lead lag sequences the operation of multiple boilers, matching system 10
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controls were outdated and compromised the systems efciency. In addition, the two newest models (1998) had 30 ppm NOx reduction capabilities, but the plants three older boilers did not. The plant wanted to bring all of its boilers into compliance with CCME (Canadian Council of Ministers and the Environment) guidelines. After analyzing their options, plant management determined that upgrading the controls would meet both their efciency and emissions goals. Plant management contacted Kevin Kingston, sales and project manager for Johnson Paterson Inc., in Aurora, Ontar-

io. Based upon the treatment plants needs and goals, Kingston recommended the following: Add digester gas ring capabilities to the three older boilers, including new stainless steel gas trains and associated fuel components. Convert each burner to high (10:1) turndown ring capabilities. Add an advanced Cleaver-Brooks Hawk PLC control system to each boiler. Add parallel positioning (linkage-less controls) to each boiler. Add a new Siemens HE blower motor and VSD control system to each boiler. Install O2 trim on each boiler. Convert the three older boilers to 30 ppm NOx ring. Install a Hawk master boiler lead lag sequencing control. The conversion took place in three phases, beginning in June 2010. It was completed in January 2012. The wastewater treatment plant expects annual fuel savings of 12% to 15%. There are several reasons for the anticipated double-digit fuel savings. First, the new boiler controls enable the plant to operate on digester gas more continuously, which also decreases the rate of natural gas consumption. The plant only uses natural gas as a backup fuel. Prior to the conversion, the older

The two newest models (1998) had 30 ppm NOx reduction capabilities, but the plants three older boilers did not. Plant management determined that upgrading the controls would meet both their efciency and emissions goals.

boiler control system was not able to provide proper boiler sequencing and controlled re rates, so natural gas was tapped frequently. In addition, the new Hawk master boiler lead lag sequencing control was interfaced with the boiler building SCADA system, providing operator interface with the individual boiler control panels and the master boiler lead lag sequencing control. The design engineer for the project wrote a strategy to control the main heating systems circulating pumps based on the plant's heating loads. Summer heating loads require lower ow rates than the winter heating loads. The Cleaver-Brooks Hawk control systems are programmed to transmit a signal to the main remote processing unit (RPU). Depending on the number of boilers operating and the rate of ring, ow rates will increase or decrease to the main heating pumps, controlled by new VSDs, to match the heating loads. Lastly, with 10:1 burner turndown, there is less cycling, and repeatability in the management of the fuel mixtures through the new parallel positioning controls. TB Zala is director of product engineering for packaged boiler systems at Cleaver-Brooks. To learn more about how a controls retrot can help your facility increase efciency and reduce costs, contact an authorized Cleaver-Brooks representative at (800) 250-5883, or visit www.cleaverbrooks.com. 11
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ABMA PRODUCTS >

B
A. STEAM GENERATOR
The latest design of the companys Circulatic Steam Generator incorporates linkageless controls and communications capabilities. The linkageless controls offer improved combustion, fuel savings through improved efciencies, and more reliability with the elimination of mechanical linkages. The new design still offers all of the advantages of the original Circulatic, such as 5 minute startup, compact design, and full modulation with 10 to 1 turndown ratios. Vapor Power offers boilers up to 600 BHP and 3200 psi as well as thermal uid heaters up to 20,000,000 btu/hr. VAPOR POWER, WWW.VAPORPOWER.COM

B. SHUT-OFF VALVES
Maxons Series 8000 safety shut-off valves have new features designed to keep them your rst choice for safety, reliability, and maximized system up-time. Searing heat or bitter cold gives sure closing at temps to -50C (-58F) while meeting API 6FA Fire Safe standards. The larger open/closed indicator clearly announces valve position in high-contrast colors. Series 8000 meets tough Class VI leakage standards, carries multiple global endorsements, and are SIL-3 capable. Unique metal-to-metal seats wear in, not out, with each cycle, and numerous body and trim options provide excellent application exibility. MAXON, WWW.MAXONCORP.COM

C. RETROFIT PACKAGE
Alzeta Corporation delivers its system solution for Bay Area atmospheric boilers. It features FireStar, ALZETAs latest ceramic-metallic surface, modular system design, simple operation, quick and easy installation. Other details include premixed surface-stabilized combustion; less than 15 ppm NOx @ 3% O2; and low pressure drop. It comes in capacities from 1 million to 10 million Btu/hr and features a durable cast-iron body. The unit is also complete with combustion air blower, gas train boiler, and burner controls and instrumentation. It is applicable to all atmospheric systems, and installation typically takes one or two days, once the existing burner system is removed. ALZETA CORPORATION

D. STEAM GENERATOR
The FC-OSSG forced-circulation large-capacity steam generator offers up to 250 T/H of steam. With less than 2% blowdown with evaporator water, and 99.5% steam purity, the unit also tolerates substantial upsets in water quality, heat ux, and ow. The FC-OSSG features modern, water-cooled walls and optimized, heat-transfer surfaces, reducing its footprint and weight by 50%. It is specically designed with signicant margins to avoid metal temperature excursions and tube failures. A two-layer defense addresses uctuations in water quality, increasing reliability compared to traditional OTSGs. CLEAVER-BROOKS, INC.

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NEWS
MAXITROL NAMES VP OF SALES
David Holcomb is the new vice presidentof sales, Maxitrol Company. He joined Maxitrol Company in July 2006 as national sales manager. Before joining Maxitrol Company, Mr. Holcomb held a variety of sales and sales management positions, primarily in the automobile industry. Holcomb has a B.A. from Michigan State University and a Juris Doctor from the Detroit College of Law at Michigan State University.

INDUSTRY

E
E. BURNER MANAGEMENT
The company has introduced two new Simatic Burner Management Systems (BMS), designed to give endusers greater exibility to cost-effectively comply with revised 2011 burner standards. Designed with TUV certied hardware and customizable software, the compact BMS300F and BMS 151F systems comply with NFPA, IEC, and ANSI/ISA standards for single or dual fuel applications with single or multiple burners. The models are also capable of meeting up to SIL 3 with appropriate eld devices. SIEMENS

For more information about Maxitrol and its afliate, Mertik Maxitrol, visit www.maxitrol.com and www.mertikmaxitrol.com.

BFS INDUSTRIES ESTABLISHES NEW PRODUCT DIVISION

The fuel oil market in North America has evolved over the last decade. These changes have created a new mission critical market requiring a different approach to fuel system design and equipment selection. In recognition of the market needs, BFS has invested in building a new product division. This Division is called Critical Fuel Systems and is dedicated to serving the needs of the mission critical fuel market. In addition to pump sets, Critical Fuel Systems will also offer a full line of UL listed day tanks and accessories, fuel ltration and maintenance systems, fuel oil specialties, and custom control systems.

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CRANE >

RELIEF?
HOW MUCH
LEARN ABOUT THE PROPER LOCATION FOR THOSE VALVES, MANAGING BLOWOFF STEAM AND TURBINE EXHAUST, AND MORE.

Safety Valve Requirements For Deaerator Installations:

High-pressure (HP) condensate is condensate that is produced at a temperature greater than the operating temperature of STEAM PRESSURE the deaerator. The usual sourcREDUCING VALVES es of this condensate are proA deaerator requires a source of cess equipment (cookers, driers, heat in the form of steam to heat SAFETY RELIEF VALVE SHOWN MOUNTED ON THE STEAM LINE etc.) and heat exchangers. the feedwater to saturation and AFTER THE STEAM PRESSURE REDUCING VALVE. In some plants, this HP conto remove dissolved gases. For many deaerators, this source of steam is high-pressure steam densate is drained to a receiver where its pressure and temperareduced to the desired deaerator operating pressure by a steam ture is reduced to atmospheric conditions (0 gauge pressure, 212F or less). Pumps are then used to transfer the 'ashed" pressure control valve. In the event of a steam pressure control valve failure, an ex- condensate to the deaerator. Under these conditions, the HP cess ow of steam will be provided to the deaerator, causing the condensate does not present a risk of overpressurizing the dedeaerator pressure to rise. In the worst conceivable case, the aerator. However, in many situations where it is desired to con14
T O DAY S B O I L E R SPR I N G 2 012

ery few deaerators utilize vessels that are not constructed and stamped in accordance with ASME VIII Pressure Vessel rules. The ASME Code requires that all pressure vessels be protected against overpressure from any source, if not by positive control of the pressure source then by the use of properly sized relieving devices. What are the sources that could result in loss of deaerator pressure control? The most likely sources are discussed below. In all cases, the worst-case scenario would occur if the deaerator load is zero due to high water level and/or temporary diversion of low-temperature condensate returns away from the deaerator.

maximum excess steam ow may be considered to be the steam ow which the pressure reducing valve can pass with the usual supply pressure on its upstream side and deaerator design pressure on its downstream side. This assumes that the valve has failed in the wide open position and that the deaerator load is zero (i.e., the deaerator has a zero steam demand). The wide open capacity of pressure control valves can be obtained with the valve manufacturer's assistance or can be calculated from data in the form of maximum ow coefcients for the valve(s) installed in the system.

HIGH-PRESSURE CONDENSATE RETURNS

serve heat, HP process condensates may be returned directly to the deaerator. In these cases, the excess heat in the condensate must be absorbed by colder streams (e.g., makeup water and cool condensates) entering the deaerator if the deaerator pressure is to be controlled at a steady level. Heat not absorbed goes into elevating the operating temperature and pressure within the deaerator. If the condensate can produce a positive amount of ash steam when reduced to the deaerator design pressure, that amount of ash steam should be included in the safety valve capacity requirement.

to the steam sources described above. Usually, the safety valves required for liquid relief alone would be considerably smaller in size than those required for steam relief.

SAFETY VALVES PROVIDED BY THE MANUFACTURER

Usually, the deaerator manufacturer will not provide full capacity safety valves with his equipment. When specied to be within this scope of supply, the deaerator manufacturer can size and supply the required safety valves only when the user or plant designer has supplied all needed details related to sources of overpressure in his system. In the absence of complete information, the deaerator supplier may furnish relief valves in accordance with the HEI Standards For Deaerators. The safety valve number and sizes recommended by the HEI standards are determined on an arbitrary basis and are intended to protect the deaerator against overpressure due to minor sources

CONTINUOUS BLOWOFF / RECOVERED STEAM

In plants using a continuous blowoff heat recovery system, the ash steam produced by the blowdown is usually directed to the deaerator so that its heat content can be recovered. As with HP condensate returns, if the deaerator is operated at loads capable of utilizing the heat in this steam, the deaerator pressure can be controlled at a desired level. If the deaerator load is such that there is insufcient demand for the blowoff steam, the pressure in the deaerator will rise above the control point unless the excess steam is relieved. Safety valve capacity required to protect against overpressure due to excessive continuous blowoff may be determined by calculating the amount of ash steam produced when the maximum blowoff ow is ashed to a pressure equal to the design pressure of the deaerator and that amount of ash steam should be included in the safety valve capacity requirement. The maximum blowoff ow to be considered is a function of boiler pressure, the number, size, and setting of the blowoff valves as well as the blowoff line size.

TURBINE EXHAUST
In some installations, the steam supply to the deaerator may consist of steam turbine exhaust, augmented with reduced high-pressure steam (described above). If the maximum turbine exhaust pressure exceeds the deaerator design pressure, safety valves must be provided to protect the deaerator; otherwise, relief or safety valves will be needed to protect the turbine. Since the worst case for excessive turbine exhaust ow would occur at zero deaerator load, the safety valve capacity needed to protect against overpressure due to a turbine exhaust is equal to the throttle ow of all turbine(s) connected to the deaerator steam line. Maximum throttle ow information can be obtained from the turbine manufacturer.

MINIMUM SENTINEL RELIEF VALVE SIZE PER HEI STANDARDS SHOWN MOUNTED ON DEAERATOR VESSEL. A FULL-SIZE SAFETY RELIEF VALVE IS ALSO PROVIDED ELSEWHERE ON THE SYSTEM.

of overpressure, such as the introduction of excess amounts of HP condensate. However, the HEI-recommended safety valve sizes should be considered as minimums and to ensure a compliant installation, their adequacy for any application should be veried.

SAFETY VALVE REQUIREMENTS

The ASME Code requires that sufcient relief valve capacity be provided to prevent the pressure inside the deaerator and storage tank from rising more than 10% or 3 psi, whichever is greater, above the maximum allowable working pressure of the vessels when a single safety valve or relieving device is utilized. When multiple safety valves are utilized, the set pressures of the individual devices may be staggered as permitted in paragraph UG-134 of the code. Safety valves on deaerators are normally set to relieve at maximum allowable working pressure of the vessels. 15
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LIQUID STREAMS
If the pressure of any feedstream to the deaerator exceeds, or may exceed, deaerator design pressure, adequate relieving capacity must be provided to protect the unit against overpressure from that source. Consideration should be given to the shutoff heads of feedpumps and water supply pressures as well as

Safety valves for use on ASME Code vessels must meet the manufacturing and certication requirements set by the Code and outlined in Paragraphs UG-125 through UG-136 of ASME Section VIII, Division 1.

LOCATION OF SAFETY VALVES

The ASME Code requires that safety valves intended for relieving steam be connected to the steam space of the pressure vessel when the source of overpressure is internal to the vessel. For this reason, it is common to connect the safety valves to protect against overpressure due to excessive ashing returns directly on the deaerator. If the source of overpressure is external to the pressure vessel, the ASME Code does not require the safety valves to be installed directly on the vessel. It is for this reason that the full capacity safety valves, whether provided by the purchaser or the deaerator manufacturer, are not normally located on the deaerator but on the piping connecting the deaerator to the source. In this way, the deaerator is protected and the risk of internal damage due to steam ows in excess of design is minimized.

OPERATION
The reaction-type safety valves normally used are characterized by 'pop' action where the valve is rapidly pushed to the wide open position shortly after set pressure is exceeded. The safety

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valve remains open until such a time that vessel pressure has been reduced to a value approximately 5% below the set pressure of the safety valve. This difference between set pressure and reseating (closing) pressure is termed blowdown. Due to these operating characteristics, it is important to consider the potential effects of safety valve operation on the deaerator. Consider a deaerator operating at a controlled pressure of 10 psig but designed for 50 psi maximum allowable working pressure with a safety valve set at 50 psi. If for some reason, the deaerator is supplied with more heat input than can be absorbed at 10 psig by the incoming water, the deaerator pressure will begin to rise. The deaerator will heat the incoming water to the saturation temperature corresponding to each new (higher) operating pressure and this water will be held in the storage vessel. If the excess steam condition persists, the pressure in the deaerator will continue to rise toward the safety valve setpoint. Just prior to actuation of the safety valve, 50 psi in this example, the deaerator will be delivering water at 298 to the storage tank. At the set pressure, the safety valve opens and soon reaches full open position; the deaerator is delivering water heated to 298 to 302 to the storage vessel all while the safety valve is blowing. As the source of overpressure begins to diminish, the safety valve remains open until the pressure in the deaerator decreases to approximately 45 psig. During the time period when the deaerator pressure is decreasing toward the control point (10 psi), the hot stored water is cooling to saturation temperature by ashing and steam is owing from the storage tank to the deaerator through the equalizers. If possible, water ow rates should be controlled for slow rates of change during a safety valve blowing operation; at rapid rates of change, the deaerator may be subject to damage as a result of rapid depressurization. Installation of relief valves in parallel with the safety valves on deaerator installations can prevent unnecessary activation and chattering of the safeties from minor upsets in pressure control, e.g., situations where a discharge of steam considerably less than the combined safety valve capacity would sufce to prevent overpressurization. In contrast to safety valves (pop action to full capacity), relief valves open only in proportion to the amount of overpressure present, preventing excessively high discharges from slight disturbances. Many older boiler plants were equipped with relief valves in this manner but the practice has waned in the recent past. However, the prevention of frequent safety valve discharges remains a worthwhile goal to reduce noise emissions and maintenance requirements.

CONCLUSION
The information provided above is intended to illustrate typical procedures for determining the maximum ows to a deaerator which might overpressure the unit and provide a basis for sizing of relief valves. Since the design of each installation varies, the user is responsible for identication of all potential sources of overpressure and provision of sufcient relief valve capacity to ensure safe operation of the deaerator. TB

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ISSUES&EVENTS
ICI-BMACT STATUS U.S. EPA, POLICY ADVOCATES SHOULD IMPROVE JOB IMPACT ANALYSES, SAYS REPORT
The ICI-BMACT rules were under fire by opponents as job-killers; the major CIBO/IHS jobs analysis of the impact of the ICI-BMACT rules was termed flawed by the Congressional Research Service (CRS), and readers were warned not to put much stock in the job-killer analysis. Now the Institute for Policy Integrity weighs in with a new report, Regulatory Red Herring: The Role of Job Impact Analyses in Environmental Policy Debates, telling both USEPA and policy advocates that they need to do more to incorporate job impact analyses into their assessments of environmental regulations. The report can be downloaded at http://policyintegrity.org/files/ publications/Regulatory_Red_Herring.pdf. Applying proper analytical tools and disclosing assumptions and modeling limitations will provide policymakers with the necessary data to develop regulations, Michael Livermore, executive director of the institute, says. Some analyses of USEPA regulations produce flawed jobs impact predictions because they apply these models in ways they were never intended to be used, said Livermore, who was lead author of the report. Nearly every controversial environmental policy proposed during the last several years has featured a debate over the possible employment effects, the report said. Unfortunately, few of the studies used to support either side in these debates meet the criteria for well-executed models, and even less frequently do the political debates mention the potential limitations of the results, Livermore noted. Manufacturing Partnership (AMP) to the Better Buildings, Better Plants (BBBP) initiative launched in 2011. The BBBP initiative calls for commercial and industrial buildings to increase energy efficiency 20% by 2020. A higher-tier challenge program requires firms to provide data to verify efficiency gains, and to make a commitment to showcase energy-saving projects. The USDOE estimates that the energy to operate commercial buildings, shopping centers and malls, and schools costs the U.S. about $200 billion a year, of which about 30% is wasted. Energy consumed by the U.S. manufacturing sector costs an additional $180 billion annually, and a reduction of just 20% in energy consumption could cut that amount by $45 billion a year, according to the department. The USDOE also recognizes manufacturers efforts to increase energy efficiency under the broader Better Buildings, Better Plants Program. While participating manufacturers do not face the more stringent requirements of the challenge program they do not have to commit to showcase projects or publicly disclose energy efficiency data they do pledge to cut their energy intensity (or use per unit of production) 25% over a 10yr. period, de Fontaine says. A showcase project is an investment in energy efficiency costing the company at least $1 million. Companies participating in the BBBP program include Briggs and Stratton, Cummins Inc., GE, Nissan North America, Schneider Electric, and the SaintGobain Corp. More information on USDOE's Better Buildings, Better Plants program is available at www4. eere.energy.gov/challenge/.

U.S. DOE SAYS 100 COMPANIES, GROUPS PLAN TO DROP ENERGY USE 20% BY 2020
According to Andre de Fontaine of USDOEs advanced manufacturing office, the DOE now has 110 U.S. companies and other organizations committed to a 20% cut in energy use by 2020. The pledges equal about 5% of the total energy footprint of the U.S. manufacturing sector. To bolster U.S. energy efficiency through voluntary means, agency efforts range from its Advanced

U.S. DOD PURSUING EFFICIENCY TO REDUCE $4 BILLION ENERGY BILL

The U.S. Defense Department is pursuing energy efficiency and other measures to lower its energy bill and increase its energy security, officials told the U.S. House Armed Services Committee in late March. The department spends $4 billion a year on energy, Dorothy Robyn, deputy undersecretary of defense for installations and environment, testified at the hearing on planned energy investments. DOD operates more than 300,000 buildings, which have an environmental

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footprint six times greater than the General Services Administration and three times larger than Walmart, Robyn said. To reduce its energy demand and costs, the DOD seeks $1.1 billion in funding in fiscal year 2013 for energy efficiency retrofits of buildings, Robyn said. It also made a commitment outside of the budget to enter into more than $1 billion worth of energy savings contracts, she said. The USDOD is ramping up its partnerships with the private sector to pursue energy efficiency and energy reduction projects, according to officials. Katherine Hammack, assistant secretary of the Army for installations, energy, and environment, said the Army is quadrupling the number of its energy savings performance contracts in fiscal year 2012. Through the contracts, the Army partners with the private sector to build energy efficiency projects. In fiscal year 2011, the Army executed approximately $73 million in energy savings performance contracts. The Army has already executed $93 million in contracts in the first quarter of fiscal 2012 and plans to have at least $400 million by the end of the fiscal year. Terry Yonkers, assistant secretary of the Air Force for installations, environment, and logistics, said the Air Force is also aggressively pursuing these types of contracts. The Air Force has invested $143 million over the past five years in energy savings performance contracts, with returns of $27 million per year in energy savings, he said. Robyn also said the department is applying energyefficiency technologies from the private sector and the Energy Department to aid in the commercialization of these technologies. The first user of a new technology assumes significant costs and risks but does not benefit any more than a later user, Robyn said. As the owner of 300,000 buildings, we look at risk differently, she said. She said the department looks at military installations as a distributed test bed for demonstrating and validating new technologies. For example, the department is linking its bases around the San Diego area onto the same smart grid system, Jackalyne Pfannenstiel, assistant secretary of the Navy for energy, installations, and environment, said at the hearing.

The regional smart grid system features local control of energy supply and demand combined with onsite distribution and storage technologies, which will reduce energy costs, she said. According to Sharon Burke, assistant secretary of defense for operational energy at USDOD, 90 percent of the department's fiscal 2013 budget request for energy used in military operations is for initiatives that reduce the military's demand for energy. Burke said the department's goal is to increase energy security by reducing demand for energy and by diversifying and securing new energy supplies. Our supply line has been vulnerable, she said, and the cost in lives, injuries, and resources to resupply fuel has been much too high. Burke said the military will continue to rely heavily on conventional fuels for the foreseeable future but is looking at alternative fuels and will purchase them on a larger scale when they become price competitive. USDOD requested $16.3 billion for fiscal year 2013 for petroleum-based fuels.

INDIA SETS EFFICIENCY TARGETS FOR 478 LARGE POLLUTING BUSINESSES

Nearly 500 of India's largest industrial energy consumers have been assigned energy efficiency targets; the Bureau of Energy Efficiency set the targets in late March for 478 industrial units, spanning eight heavily polluting sectors. The units account for one third of the 500 million tons of oil equivalent (MTOE) of commercial energy consumed in the country. Long in the works, the Energy Conservation Rules, 2012, took effect immediately (they do include boiler efficiency criteria). Sectors covered are thermal power, iron and steel, cement, chlor alkali, paper and pulp, aluminum, textiles, and fertilizers. Most energy sources are affected, including coal, furnace oil, and fuel oil, but biomass and renewable energy were excluded. Full text of the Energy Conservation Rules, 2012, is available at http://220.156.189.23/schemes/documents/ nmeee/pat/PAT_Rules_English.PDF. The notification assigning specific energy use standards for each industrial unit is available at http://220.156.189.23/schemes/documents/nmeee/ pat/PAT_Notification_English.pdf. TB

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PRODUCTS >
A D

B
A. INTEGRATED CONTROLS

The company has introduced its comprehensive line of high efciency integrated boiler control systems featuring graphical visualization and information collection to facilitate easier and better operational management of boilers and supporting peripherals. Each integrated control system provides PLC control, VFDs, and HMI interfaces devices. To facilitate centralized control and data collection, the BOILERMaster brings all the aforementioned components to a central point of control and collection of all the information about the companys connected equipment. HURST BOILER & WELDING CO.

B. CONDENSING BOILERS
The Creek high-efciency condensing boiler line is the companys rst foray into the condensing market. The boilers are available in standard sizes from 4,000,000 Btuh to 12,000,000 Btuh at 160 psig design pressure and operating efciencies to 98% and higher in some cases. The Creek boiler also is available to support applications and installations where low NOx emissions are required. SUPERIOR BOILER WORKS

C. BOILERS
The companys NeoTherm LC condensing boiler is a fully packaged, 1 million BTU, space-saving hydronic solution that offers 94% thermal efciency. NeoTherm LC is a direct vent, sealed combustion boiler that modulates with a 10 to 1 turndown. The unit features zero clearance to combustibles with all piping and wiring from the back, which is suitable for tight installations. LAARS

BOILER CONTROLS
The inSite for ModSync tool provides a private portal for remote web-based access to a facilitys boiler room controls. Used in conjunction with the companys ModSync sequencing system, the inSite for ModSync interface provides real-time boiler system status using any traditional web browser, including a web-enabled cell phone. SYNEX CONTROLS

D. CONTROL SYSTEMS
The companys control system, ACS, is a exible controller designed to maximize energy savings in modular boiler plants. The ACS can stage and coordinate the operations of up to 32 boilers and is uniquely designed to maximize the operating efciency of condensing equipment capable of unmatched modulation. With individual unit turndown as high as 20:1, a ve-boiler plant delivers 100:1 system turndown when staged to operate sequentially. AERCO

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The New MACH C4000. Knocking down size, not walls.

At Harsco, were cutting down the footprint and the fuel bill. Our new MACH C4000 is efcient to the core, and it allows you to get 4 million BTUs right through the door. With these advantages, its the right t. For more information, contact T 570.476.7261 E pkmarketing@harsco.com or www.harscopk.com

PRODUCTS >
G F E
E. HYDRONIC BOILERS
The companys NH150-DV and NH199-DV tankless hydronic boilers are suited for constant room temperature comfort for various heating choices, such as panel radiators, baseboard ooring, and radiant oor heating. Featuring a gas-consumption range of 55,500 Btuh to 150,000 Btuh for the NH150-DV and up to 199,900 BTUh for the NH199-DV, the units offer nine temperature settings (140180F) for hydronic heating applications. Each unit has a high-ow capacity of 14 gpm with a three-speed Grundfos Pumps circulator, providing multiple pump curves, rather than the one-pump curve of a typical single-speed pump. NORITZ

F. FLUE GAS ANALYZERS

The Rosemount Analytical 6888 in situ O2 analyzer is designed to provide accurate measurement of the oxygen remaining in the ue gases coming from combustion processes such as boilers and industrial heating furnaces. By maintaining the ideal level of oxygen in the ue gases, optimal efciency is achieved and the lowest levels of NOX, CO, and CO2 are produced. Probe lengths are available from 18 in. to 12 ft, and a slip mounting option provides the ability to mount a long probe at any insertion depth. Signal conditioning electronics reside in the head of each probe, eliminating the need for expensive signal cable. EMERSON

G. INDUCERS
The companys line of Auto-Draft RT Series rooftop inducers with a constant operating pressure control (COP) are designed for noncondensing modulating gas and oil red heaters and multiple heaters tied into a common vent. The inducers deliver precise draft or exhaust by modulating fan speed to deliver a constant negative pressure within a chimney or chase as draft requirements or exhaust loads change. The result is common vented boilers and water heaters operate more efciently, rooftop chase exhaust fans modulate to actual demand saving make-up air and motor power consumption. TJERNLUND PRODUCTS, INC.

H. BOILER CONTROL
The SMART SYSTEM Multi Temperature Loop Control (MTLC) is designed to simplify the integration of the companys KNIGHT heating boilers into multiple temperature hydronic heating systems, by accurately controlling up to three separate space heating loop temperatures, while maximizing the efciency of the heating boiler as a primary function. The new MTLC works in conjunction with the on-board SMART SYSTEM control on all second generation KNIGHT XL commercial heating boilers. LOCHINVAR

I. HYDRONIC BOILERS
The company has added a renewable fuel options for its Vantage condensing hydronic boiler. The boiler can now use B100 biodiesel and ultra-low sulfur (under 15 ppm) heating oils for full condensing operation. The B100 biodiesel Vantage boiler is commercially available up to 4,000,000 Btuh, and is capable of congurations for liquid fuel, natural gas, or dual-fuel operation. For boiler installations that do not yet have biodiesel or ultra-low sulfur heating oil available, boiler controls can allow the boiler to be red short-term with conventional #2 heating oil in non-condensing mode. FULTON

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Unlike a phony cowboy who is all hat with no cattle, a boiler from RENTECH will pass muster.
Each boiler is designed and built to meet its demanding specications and operate in its unique conditions in a variety of industries, including rening, petro-chemical and power generation. Our quality control system assures you that RENTECH boilers are safe, reliable and efcient. For a real, genuine, original boiler, you can depend on RENTECH. Honestly.

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THE MOST RADICAL FIRETUBE BOILER IN THE WORLD DESERVES A LITTLE PIZZAZZ.
Introducing the new CBEX
When we decided to revolutionize the firetube, we challenged ourselves to build a completely new system from the ground up. Our new EX technology is at the heart of a whole new way to experience efficiency. We optimized the tubes for better heat transfer. We optimized the geometry of the furnace for near-perfect combustion. Then we integrated the burner and the controls. Every core component has been designed and built to work together, resulting in the most fuel-efficient and lowest-emissions firetube system ever.

Visit cleaverbrooks.com/EX or call 1.800.250.5883.

WHAT MAKES THE CBEX DIFFERENT FROM ANY OTHER BOILER IN THE WORLD?
Lighter Weight and Smaller Footprint achieved through less heating surface for the same BTU output as traditional firetubes. On average, has a 15% smaller footprint and weighs 20% less than traditional boilers. Extended Pressure Vessel Life resulting from uniform furnace temperature and reduced turnaround gas temperature. Industryleading 15-year pressure vessel limited warranty. Highest Fuel Efficiency Maintains 3% 02 across a 10:1 turndown range, achieving the highest operating efficiency of any firetube. Lowest Possible NOx can attain sub-5 ppm without Selective Catalytic Reduction (SCR) on select models. Quick Steam Up is 20% faster than traditional firetubes, due to smaller footprint and lower water volume.

2012 Cleaver-Brooks, Inc.