How to Reduce Costs and Increase Efficiency in the Boiler Room

Boilerroom Equipment Inc. (BEI) Provides a HeatSponge Economizer

As manufacturers’ representatives for “products that produce results,” Engineered Energy Equipment (EEE) specializes in selecting the best equipment to meet our clients’ needs.  Often, we are asked how to save energy; how to reduce costs; and how to reduce a company’s carbon footprint.  All of these objectives can be met with the addition of an economizer—specifically the new generation of boiler economizers:  the HeatSponge by Boilerroom Equipment, Inc. (BEI).

BEI is a division of Thermal Energy International that engineers and manufactures ASME pressure vessels for many different industries. They are best known as the innovators behind the HeatSponge brand of boiler economizers:  the most modern steam boiler economizer available to global industry today. www.heatsponge.com

When asked why EEE recommends the HeatSponge, EEE Director of Sales Kevin Warren explained that the newer generation economizer does not require ASME welds.  “Without requiring ASME welds, it means means repairs are easier, and usually, no code inspection is required—that saves time and money upfront.” 

The BEI HeatSponge product lines were designed to maximize heat transfer via a heat exchanger that is used to transfer energy from an air stream into a liquid stream.  Most economizers use the flue gas that exits the boiler to preheat boiler feedwater being delivered to the boiler. Most natural gas or fuel oil-fired boilers will utilize economizers, because water absorbs heat better than a flue gas can transfer it.

Kevin Warren said that the addition of a boiler economizer often arises when start-up plans are made, but he has recommended adding a BEI HeatSponge after a boiler is in place. “We are often asked how boiler rooms can be more efficient, and often the conversation starts with how can we use less fuel?” Warren explained, “Wasted heat means wasted money…by extracting/recovering heat, it means you use less fuel.”

Recovering heat in an economizer is based on the Law of Thermodynamics. The flue gas exiting boilers contains a great deal of energy that cannot be recovered inside of the boiler itself. The gases inside of the boiler cannot be lowered to a temperature less than the temperature of the saturated water inside of the boiler. The HeatSponge product lines were designed to maximize heat transfer.

Greater efficiency means enhanced return on investment (ROI) in the boiler room operation. Warren explained that the fuel efficiency is gained by capturing the heat where the flue gases exit the boiler, “The gas heat is going through the economizer via the stack before being expelled into the atmosphere.  Those gases would otherwise enter our atmosphere increasing the carbon footprint and decreasing the heat capture,” said Warren.

HeatSponge steam boiler economizers reflect the global state-of-the-art for heat recovery. These High-Value-Added economizers were engineered from the ground up to be highly efficient and easily maintainable providing for a very long and productive life. Among the latest innovation are the Two-Stage HeatSponges which allow for optimum heat recovery by integrating two separate heat exchangers into one casing and can increase the efficiency of steam boilers to over 90%. EEE is proud to represent BEI and distribute the most innovative economizers available: the  HeatSponge.  With over 100 years of combined experience in the boiler business, the EEE team helps clients choose products that produce results while producing steam for applications from hospitals to theme parks to factories to distilleries throughout the state of Florida.  For more information about the manufacturers represented and products provided by Engineered Energy Equipment, go to https://eeeinc.net/products/.

Peerless® PUREFIRE® Boilers Puts the “E” in Efficiency

Peerless® Manufactures High Efficiency Condensing Commercial Gas Boilers

Engineered Energy Equipment (EEE) proudly represents the Peerless^® PUREFIRE^® commercial product line that features gas-fired, stainless-steel condensing boilers with inputs of 399 to 1.5 M MBH and thermal efficiencies of up to 96.6%.  So, what does that mean for your company and your boiler room? And why is it important?

Let’s start with the bottom line.  An energy-efficient boiler WILL decrease your monthly heating bill. Condensing boilers are designed to conserve more gas (natural or LP). The efficiency difference between a conventional and condensing boiler is about 75% efficiency vs. 90-95% efficiency.  The newer the equipment, the greater the efficiency will be.

The Peerless^® PUREFIRE^® commercial product line provides a cascade-capable (up to 16 boilers) boiler that has a condensate system with built-in neutralizer and 120V convenience outlet (PF-399 – PFC-460). The larger sizes allow for common vent capability. The PFC-850 to PFC-1500 models are essentially two (2) boilers in one (1) cabinet: the perfect choice for jobs requiring cascading and redundancy.

Do you know your current boiler’s energy factor? Our EEE technicians can check your present boiler and provide a relevant comparison with the Peerless^® PUREFIRE^® Boiler when you are ready to increase efficiency and lower your costs with a condensing boiler.

Producing the same amount of heat for less money, a condensing boiler has a more complex design, so you want to work with highly trained technicians who have experience with adding necessary parts (i.e. condensate drain) during installation.  Also, changes to the piping system are frequently required.

Installation and maintenance are important considerations with the added efficiency and complexity of a condensing boiler. With over 100 combined years of experience, EEE represents the top manufacturers in the industry like Peerless Boilers, and we proudly provide state-of-the-art installation and maintenance of your boilers, burners and auxiliary boiler room equipment.  

Peerless® PUREFIRE^® commercial boilers include a one-year parts and labor warranty and a 10-year limited warranty on the heat exchanger (product MUST be registered for warranty coverage).

Added efficiency also means a condensing boiler is better for our environment. By significantly reducing carbon emissions, a condensing boiler reduces your carbon footprint.  Instead of releasing its flue products outside, a Peerless® PUREFIRE® Boiler repurposes much of the heated carbon dioxide and condensation.

In addition to helping to save the environment, the Peerless® PUREFIRE® Boiler saves space, as it provides a compact design with easy access to controls. Its unique design allows common venting of multiple boilers. It features outdoor reset capability and a combination temperature/pressure gauge.

To learn more about condensing boilers and specifically, the Peerless® PUREFIRE® Boilers, call our pros at EEE at (863) 682-3333, or e-mail us at info@eeeinc.net

Weathering the Storm, Part 4: Have a Fuel Back-up Plan

Webster Combustion Provides Combination Burners with Increased Efficiency, Cost Savings, and Reduced Emissions

Every boiler needs a burner, and Engineered Energy Equipment (EEE) proudly represents Webster Combustion Technology LLC: a Kansas-based manufacturer that provides the highly efficient JBE Series Burners.

According to EEE Director of Sales Kevin Warren, “Webster’s JB and JBE Series Burners are some of the most competitively priced and reliable burners in our industry.” Warren added that in addition to the reliability of the JBE, he prefers the multi-fuel boiler-burners, “Webster offers burners that can work with a variety of fuel sources to include natural gas (the most common), #2, #4, #6 fuel oil, propane, and some bio-fuels.”

Florida boiler rooms are prone to power outages and power surges, so having a fuel back-up plan is essential, according to Webster’s National Sales Manager Eric Graham. He added that EEE is a long-time trusted representative of Webster.

Because Webster offers burners that can fire multiple fuels, Warren explained that this should be a part of a boiler room back-up plan that can solve problems in hours as opposed to experiencing down-time for days. “A cut or disabled fuel line can lead to an unexpected interruption of your primary fuel source, so you need a burner that accommodate a variety of fuels,” said Warren

EEE works with a number of Florida-based schools, universities and hospitals that appreciate the reliability and affordability of Webster’s high efficiency burners due to the superior mixing of fuel and air that results in lower motor horsepower requirement, which results in significant total energy savings.

How does the JBE Series Provide the Best Possible Return on Your Burner Investment?

Webster has combined their unique high swirl firing head technology with a highly efficient in-line combustion air fan to provide improved mixing of the fuel and air, and lower motor horsepower requirements. This combination allows the JBE series burners to operate with low excess air across a large operating range. Less excess air means high fuel efficiency, and high efficiency combined with high turndown means very low heat loss in your boiler that can result from cycling when a burner is stopping and starting. (webster-engineering.com)

Warren added that “The Webster JBE is more efficient, because it combines the in-line motor and high swirl firing head to create an overall mix that minimizes O2
levels for low to no CO burn.

To evaluate the potential cost savings, Webster has provided an Efficiency Comparison Calculator on their website at https://www.webster-engineering.com/product.php?id=18

Contact EEE, your Webster Combustion representative, to determine your potential cost savings and to help you secure a back-up plan for your boiler room at info@eeeinc.net; call us at 863-682-3333, or visit our Webster Combustion Features Page at https://eeeinc.net/webster/ #TheBetterBoilerBurner

Weathering the Storm, Part 3: When Gale Force Winds Can Blow Your Stack

Engineered Energy Equipment Provides Boilers, Burners and Auxiliary Equipment in Florida

Engineered Energy Equipment (EEE) is a Florida-based manufacturers’ representative that sells and services the highest quality boilers, burners, and auxiliary boiler room equipment. They are proud to be a part of the Van-Packer family whose stack line is among the best for the Florida climate where chimneys, vents and exhaust systems are subject to lightning, high winds, earth movement (sink holes), and excessive and sustained sunlight and heat.

Stack, by its very nature, reaches the highest elevation in a given area. Chimneys also are prone to extraordinary corrosion and combustion processes that need to be regularly inspected for deteriorated linings, excessive soot, temperatures and other conditions. “It is good practice with all chimneys, vents and exhaust systems to inspect them annually to ensure that no unusual conditions exist.” (Van-Packer)

Kevin Warren, Director of Sales for EEE, said that the company chose to represent Van-Packer for many reasons—not the least of which is the ability for the stack to sustain 100mph winds. The EEE team has proudly installed Van-Packer stack in their clients’ facilities to include Tampa General Hospital, AdventHealth System, and Disney.

Warren said, “Van-Packer also manufactures venting systems for condensing boilers equal to the infamous AL294C material referred to as the VP 1738A.  This material is made and used especially for high moisture applications such as condensing boilers. “

He added, “Van Packer has been with EEE since our beginning in 2005, and they remain one of our core manufactures…every petroleum-fired boiler needs a stack, and we incorporate that into our product presentations and proposals.”

According to their website, Van-Packer Company has continuously produced Underwriters Laboratories (UL) listed chimneys since 1944 at the same location in Buda, Illinois. During that time, the company has increased its manufacturing floor space under roof to 81,136 sq. ft. (Van-Packer)

In addition to their history and quality, Warren was asked why EEE selected to represent Van-Packer instead of other brands. “They meet the highest approvals and industry standards, and they are at an affordable price point for our clients,” said Warren.

“Van-Packer gives a 1-year warranty and offers an extended 15-year warranty. For a long lasting, competitive price and easily installed chimney let Van-Packer assist you with System Design, Corrosion Analysis and Thermal Analysis.” Together, EEE and Van-Packer help clients weather the storm. For more information about the manufacturers represented and products provided by Engineered Energy Equipment, go to https://eeeinc.net/products/.

Weathering the Storm, Part 2: Water Water Everywhere, and Why Feedwater Treatment is Essential in Florida

Engineered Energy Equipment Provides Boilers, Burners and Auxiliary Equipment in Florida

In the last Boilerman Blog, we outlined the effects that water quality has on efficiency, longevity, and safety of a boiler. Florida, in particular, is known for hard water which is hard on pipes, tubes, and boilers. Other environmental factors like heat, humidity, salt, and water intrusion make the purchase of a boiler in Florida and the selection of your boiler room technicians muis importanté!

“Water chemistry is one of the most important elements in maintaining a boiler,” said Kevin Warren, EEE Director of Sales.  “You need a water softener no matter where you’re operating a boiler,” he added.

According to one of EEE’s water treatment providers, Sci Chem LLC, “…hard water is formed when water flows through the lime rock in our Karst topography and dissolves calcium and magnesium carrying it into our [facilities]. These minerals bind with metal, reducing the efficiency of [boilers] causing excessive wear to our water using [systems]. http://www.sci-chemllc.com/index.php/central-florida-water.html

Florida is not alone in its water quality problems. All fresh and natural water contains some amount of impurities, and these impurities become critical factors when the water is used for generating steam. Higher-pressure boilers require pre-treated water in order for them to function smoothly (with good thermal conductivity). For optimal efficiency, the water supplied to the boiler (feed water) must be pre-treated for removal of impurities to prevent scaling and corrosion.

The feed water must be pretreated by filtration and processes that include softening, ion exchange, evaporation, etc. The boiler system also has to be conditioned for impurities through internal treatment to prevent corrosion, and regular inspections should be a part of standard boiler room operation. Annual maintenance should always include checking for signs of scaling and corrosion.

So, how does scaling and corrosion happen? Insoluble carbonates are formed from the carbon dioxide released when magnesium and calcium salts are heated and dissolved in water. These form deposits on the surface of the boiler. The accumulation of these deposits leads to failure of tube functioning due to overheating. Efficient transfer of heat from the tubes to water fails to take place due to the excessive deposit formations. They act as total or partial obstructions in boiler tubes eventually leading to overheating and reduced efficiency.

Corrosion: Low pH levels of water as well as the occurrence of dissolved carbon dioxide and oxygen in the feed water system can cause corrosion. The form of corrosion known as deep pitting can lead to leakage in the tubes of the boiler system. Corrosion that occurs below the boiler deposits leads to tube failure due to the weakening of metal. Essentially, corrosion leads to reduced efficiency by weakening of tubes which can lead to water leakage: a worst case scenario.

Summarizing: With 100+ years of combined experience, the technicians at Engineered Energy Equipment have specific experience in some of the most challenging of all feed water situations:  the high seas where ballast water is used. Kevin Warren, Director of Sales at EEE, became a Boiler Technician in the US Navy, where he became a Chief Petty Officer overseeing the boiler operations of many Navy ships that depended on efficient boilers to transport patriots to wherever our US military was called upon. With over 100 years of combined experience in the boiler business, the EEE team helps their clients choose the equipment that can weather the storm while producing steam for applications from hospitals to theme parks to factories to distilleries throughout the state of Florida For more information about the manufacturers represented and products provided by Engineered Energy Equipment, go to https://eeeinc.net/products/.

Weathering the Storm, Part 1: The Importance of Water Treatment in Boilers

Engineered Energy Equipment Provides Boilers, Burners and Auxiliary Equipment in Florida

Maintaining and optimizing your boiler in the state of Florida presents a number of challenges when your boiler room is operating in the Sunshine State.  Namely, it’s hot! It’s humid! And our water quality (or lack thereof) is known for impurities that create scale in boilers.

With Tampa’s elevation less than 50 feet above sea level, many boiler rooms are located in basements (where molds and mildew thrive).  Most are below sea level and prone to flooding.  Add to that our annual storm season and some might say Florida boiler rooms present some of the most challenging environments in the United States.  And unlike the boiler rooms in Las Vegas casinos, most are not air conditioned.

The Engineered Energy Equipment (EEE) team was born and raised in Florida, and their offices are located in Lakeland where they have faced all the heat, humidity, and all that Mother Nature brings to the Sunshine State.

During Florida’s Hurricane Season (June 1 – November 30), EEE works closely with clients to make sure their stack can withstand up to 100 mph winds and that they have back-up fuel in the case of power outages.  Working with a number of hospitals from Homestead to Winter Park, EEE recognizes the vital need to maintain the ability for medical facilities to produce steam that sterilizes instruments for everything from surgery to general cleaning.  A boiler can literally be the “life blood” of a hospital.

Regardless of the time of year or where your boiler room is, the water that runs through a boiler must be “soft.” Florida, in particular, is known to have hard water characterized by a high calcium and magnesium content, and it requires comprehensive water treatment services.

“Water chemistry is one of the most important elements in maintaining a boiler,” said Kevin Warren, EEE Director of Sales.  “You need a water softener no matter where you’re operating a boiler,” he added.

According to R2J Water Treatment in Tampa, “Boilers are water-containing vessels that transfer energy from a fuel source, such as oil, to heat the water and create steam. The steam is then piped to equipment, where it can be used in [commercial or] industrial processes…Because the entire process is reliant on water, poor water quality can have myriad negative effects not only on the boiler itself, but also equipment throughout a facility. Proper boiler water treatment for Tampa Bay area businesses is essential in preventing corrosion due to water impurities as well as ensuring continuous heat exchange and the production of high-quality steam.” https://www.r2j.com/boiler-water-treatment/

In addition to lowering the efficiency of the boiler itself, Warren explained that failure to treat and maintain water quality in the boiler can become dangerous not only  for the workers in the boiler room but to everyone in and around the building.

“One day we got a call that there was a boiler out in the middle of the highway in Lakeland. We couldn’t believe it.  The boiler had become so scaled from poor water quality that it blew up and went through the wall and out onto the road,” said Warren.

When asked how the scale (from water sediment) could create an explosion of that magnitude, Warren explained that the scale prevented the boiler from releasing the energy so that the heat couldn’t be absorbed.  “If you’re buying a boiler, you need to buy a water softener in addition to a chemical formulation and any required treatment accessories,” said Warren

EEE performs annual inspections and provides ongoing service and support for their clients who purchase boilers, burners, and auxiliary equipment for their boiler rooms.   As part of an EEE annual service, technicians check the fire side and water side of the boiler (where signs of scale and corrosion can be seen).   Most insurance companies require regular boiler inspections.

With over 100 years of combined experience in the boiler business, the EEE team helps their clients choose the equipment that can weather the storm while producing steam for applications from hospitals to theme parks to factories to distilleries throughout the state of Florida For more information about the manufacturers represented and products provided by Engineered Energy Equipment, go to https://eeeinc.net/products/.