Energy savings: A compelling case for boiler upgrades
In this example, the author’s company performed the repair work at a large facility with a heating requirement of 48 million BTUh, and their staff manages the maintenance.
Earlier in the year, one of the existing heat exchangers at this facility experienced a failure. After evaluating the loads, the company replaced it with a unit of lower capacity. Post-replacement testing revealed the new unit, although 250,000 BTUh smaller in capacity, heated water more effectively. This improvement can be attributed to the degradation and deposits present in the original unit.
When replacing a heat exchanger, it is critical to select the unit with serviceability in mind. Units that are easier to service tend to receive more regular maintenance, an insight rooted in the company’s strong service background. Ensuring the service-friendliness of heat exchangers involves the use of isolation valves, the installation of easily disassembled joints, and providing ample clearance for tube bundle removal.
Upon completing calculations and creating a piping diagram, the replacement of a heat exchanger should generally be accomplished in less than a day, allowing the continued use of the pool. The exact duration depends on factors such as the amount of piping required and the mechanical room layout.
Through enhancements to heat exchangers in pool facilities, achieving a conservative expectation of 15 per cent efficiency improvement is feasible. If this improvement falls short of expectations, facility owners should contemplate upgrading their boilers. By replacing standard efficiency boilers with high-efficiency models, and ensuring proper sizing, design, and installation, a minimum energy savings of 35 per cent can be anticipated.
Author
Tom Soukup is the principal of Patriot Water Works Co. with more than 20 years as a hydronic designer and installer. He specializes in high-efficiency and green technology and brings his expertise to custom hydronic work, pool heating, and agricultural projects. He can be reached via email at twsoukup@patriotwaterworks.com.
