Patterson-Kelley recently published a blog post on innovation in boiler controls that we thought would be of interest to you. They are one of our most trusted lines of heat transfer equipment like boilers and water heaters. As you will see in the blog post, Patterson-Kelley is definitely committed to making boiler control technology one of the most impressive features of your heating systems. Read on!

The Evolution of Boiler Controls

The technological innovation of boiler systems has drastically enhanced how users interact with their boilers. The industry continues to improve safety and efficiency standards to fit the game changing environment. Today, users seek features that influence the return on their investment. These notable features include increased energy efficiency, great zone controls and low operational costs; all of which can be achieved by selecting the right boiler control technology.

Boiler control systems have evolved through the years, reducing energy waste and providing the user with greater control over their equipment. Innovation helps to facilitate day to day processes, and allows boilers to better respond to the genuine requirements for comfort heat and hot water demand.

Prevent Boiler Short-Cycling

We all want our heating system to increase cost savings and reduce carbon emissions. However, the issue of boiler short-cycling is the primary reason for boiler inefficiency, generating high operational costs for building owners. Boiler short-cycling occurs when the system fires only to recover its standing heat losses, without genuine comfort heat or hot water demand.

In a previous era, “time delay” devices were introduced to attempt to prevent short-cycling. This device keeps the boiler from firing on fixed time delays. However, it does not take heat or hot water demand into consideration, limiting the end user’s ability to realize cost saving energy reductions.

The introduction of building management systems(BMS) and building optimization positively affected the heating industry by increasing efficiency and providing the end user with more control over their system. But once again these controls have resulted in the implementation of technology that can interfere with existing control strategies, compromising the comfort levels of a building.

Today, we use a modern and intelligent boiler load optimization control. The computer-based control allows for continuous monitoring of both flow and returning temperatures in real time. The control consists of both hardware and software, and engineers have even found a way to integrate the use of internet protocols.

The Patterson-Kelley Solution

The Patterson-Kelley NURO® control system constantly analyzes the boilers outlet temperature and compares it to the current comfort heat setpoint. This enables the control to identify and prevent the boiler from short-cycling. When the outlet temperature drops below the setpoint, the NURO® commands the boiler to increase its firing rate, and as it approaches the comfort heat set point, the control will command the boiler to decrease its firing rate. Both the Comfort Heat Wizard and the Domestic Hot Water Wizard in the NURO®, allow the end user to easily set up and tune the comfort parameter for optimal performance. The control also allows for remote monitoring through a desktop or mobile device, with the NURO® Connect App. Who better knows how to control the boilers than the boiler manufacturer themselves.

The success of this approach led Patterson-Kelley to engineer a NURO® Conversion Kit, which allows current MACH® boiler owners to convert their control to the latest technology.

We’d be happy to talk with you and answer any questions on the Patterson-Kelley Boiler Control options for your next project. Give us a call at 800-355-7061.

This post originally appeared here

Don’t wait for it to get cold! Mechanical Equipment is offering a limited time 20% discount on our Patterson-Kelley Boiler Annual Maintenance Kits (part #BP-0000-0345). This special offer will be applied to maintenance kits orders starting July 10, 2018 through September 30, 2018.

As we approach the fall maintenance season, the importance of annual maintenance will help ensure optimal performance of your Patterson-Kelley Boilers and frankly, all of your equipment. Annual maintenance work provides your company with additional service revenue, gives you an opportunity to get in front of your customers again, and keeps them happy with superior service.

Orders of 15 or less maintenance kits will usually ship within 5-7 days. For orders, greater than 15, please call us to get the estimated ship date.

To order or learn more about our Patterson-Kelley Annual Maintenance Kits, just contact our office at 800-355-7061.

Patterson-Kelley is one of our most trusted lines of heat transfer equipment like boilers and water heaters. They recently published this article on boiler turndown rates that we thought you would find it of interest.

 

Operate at Peak Efficiency

Thermal efficiency is simply the chemical energy added to the boiler divided by the energy added to the boiler water.  As more energy is transferred from the hot gas into the boiler water, the thermal efficiency increases and the temperature of the hot gas decreases.

Almost all boilers are tuned to add excess air, which ensures ideal combustion of the fuel for proper air-fuel mixing. The excess air can also prevent the burner from overheating by “pushing” the combustion flames off the burner.

When energy from the hot gasses is transferred to the boiler water, the gas temperature dips below the dew point, which causes vapor to become liquid. The energy released from the conversion is picked up by the boiler water and results in a significant boost in efficiency. Every pound of water converted into liquid adds approximately 1000 BTUs to the boiler water. However, dry flue losses and loss of vapor can result in energy loss.

Energy loss can be readily calculated if the amount of CO2 and O2 in the flue gas and the stack temperature is known.

With the evolution of boiler technology, manufacturers have found a way to offer units with multiple firing rates, and units that can modulate seamlessly between fixed low fire rates and fixed high fire rates. The fixed fire rates are defined as the boiler turndown capacities, and modulation is accomplished by reducing the air and gas flow into the boiler.

The benefit of this modulation is threefold; it reduces cycle losses, it reduces the wear on the components, and it can potentially lead to higher thermal efficiencies.

Impact of Turndown

This begs the fundamental question – wouldn’t a boiler with extreme turndowns be much more efficient than one with 5:1 turndown?  The answer to that is NO!

To achieve high turndowns, the boilers are tuned to deliver greater amounts of excess air at low firing rates to keep the burner from overheating. The additional excess air will significantly reduce the dew point of the water in the flue gas and alter the losses in the dry gas. To illustrate this effect, the example used in Figure A is updated to reflect a 20:1 turn down where the O2 is set to 11% (corresponding to a CO2 of 5.6% and 97% excess air).  The results are highlighted in Figure B below.

Note that the dew point has been lowered from 130.6° F to 117° F  and the boiler is no longer in the condensing range.  This represents a 3.7% DECREASE in overall efficiency and this is just the beginning of the bad news! 

When excess air well above 50% is used in the boiler, it impacts the stability of the combustion flame which can lead to excessive flame failures, nuisance trips and cycle losses.

The Analysis

Realistic boiler modulation rates have helped improve the overall boiler system efficiency from reduced cycle losses and increased thermal effi­ciencies. Extreme turndown produces the opposite effect. Boil­er plant designs must factor in actual (not extrap­olated) boiler efficiencies through the firing range of the equipment and matching the expected plant loads with the right boiler size selections.

Interested in learning more about Patterson-Kelley boilers or how turndown rates affect efficiency? Give us a call at 800-355-7061 and we’d be happy to help.

At Mechanical Equipment, we make an effort to carry the products that our customers need while at the same time, the products that fit into our complete hydronic package. Since adding boilers to our product list, we felt that the accessory steam and hot water products used with boilers, would also benefit our customers, so we added the Sterling / Sterlco steam specialty product line.

Sterlco Steam Control Products

Sterling / Sterlco manufacturers a very high quality line of steam and hot water accessories such as:

  • High Pressure Thermostatic Traps
  • All sizes and types of F&T Traps
  • All sizes and types of boiler-feed pumps and systems
  • Steam Temperature Control valves
  • Inverted Bucket Traps
  • All sizes and types of condensate pumps and tanks

They are located just outside of Milwaukee, in New Berlin Wisconsin, with over 100 years in business. We’ve sold quite a bit of Sterlco product since we signed them on, and we haven’t had a single issue with any aspect of the product whatsoever!

Sterlco Steam Control Products
Most recently, we were contacted by United Airlines with a request for us to furnish two new Sterlco boiler feed systems at 1,000 gallons each, for better consistency and reliability. They were ecstatic with the results!

The biggest reason we chose to represent Sterlco, was their high quality line of boiler feed and condensate pumps. They are made with a 3450 RPM motor, to assure maximum efficiency while maintaining minimum motor horsepower. Available in a wide range of sizes, they are AMERICAN MADE with options that will meet or exceed your needs.

The new K Series 2’ low NPSH Pump is designed to pump hot condensate up to +212° F, on elevated tank units. If (or more likely “when”) a steam trap fails in the system, this unit continues to operate up to 12° higher than standard units. The added inducer increases vapor pressure and prevents the whole system failing due to pump cavitation. Stainless steel construction on the impeller and inducer, lengthens the life of the pump and offers supreme corrosion resistance. The K Series pump is energy efficient and will reduce total cost as well. It is engineered to fit / retro-fit current Sterlco boiler feed and condensate units, and is also a drop in replacement for other brands as well.

We stock most of these items year-round, so we can get them to you quickly. Give us a call today at 800-355-7061 to learn more about Sterlco’ s Steam Control Systems or any of our other great products.

Mechanical Equipment is offering a 15% discount on our Patterson-Kelley Annual Maintenance Kits (part #BP-0000-0345 ). This special offer will be applied to maintenance kits orders starting October 16th, 2017 through October 31st, 2017.

As we approach winter, the importance of annual maintenance will help ensure optimal performance of your Patterson-Kelley Boilers and frankly, all of your equipment. Annual maintenance work provides your company with additional service revenue, gives you an opportunity to get in front of your customers again, and keeps them happy with superior service.

To learn more about our Patterson-Kelley Annual Maintenance Kits, just contact Dean in our office at 800-355-7061.