Repair, Modify or Replace?? What is the right answer?? By : Joe Mozeika

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1 Repair, Modify or Replace?? What is the right answer?? By : Joe Mozeika

2 First you have to determine what s really wrong with what you have? Analyze how old your unit is? What are really trying to achieve with your decision? What makes the most sense financially?

3 Repair!! This should be your first line of defense when trying to save your budget. There are several circumstances when performing a detailed tune up with minor repairs can save you thousands

4 Fouled tubes can appear as a major problem. Reality is, you a good cleaning and burner tune up!! Linkages are a major culprit of a fouled boiler Tube cleaning removes all the fuel Impurities that buildup over the Course of a heating season More than a dozen set screws and pivot points

5 Inches The effects of a fouled boiler that is needing repair 34.3% 31.4% 28.2% 24.8% 20.7% 16.4% 11.6% 6% 7/32 3/16 5/32 1/8 3/32 1/16 1/32 efficiency loss per inch of scale 1/4 60.8% 16.2% 27.9% efficiency loss per inch of soot 57.6% 53.8% 49.2% 43.7% 36.8%

6 Modify!! Your boiler is still in good structural condition, but some of the mechanical attributes are starting to tire and are beyond a cost efficient repair. Out with the old. In the with the new.

7 Opting to upgrade or modify your boiler Changing out the current burner for a new, linkage less burners Higher turndown rates with constant O2 levels Separate your gas turndown from your oil turndown Add controls to your modifications. O2 trim kits Turbulators

8 Linkageless Burners 1.Easily adapts to existing burner mountings. 2.Allows for finer tuning over entire combustion range. Can be anywhere from 7 to 18 points throughout modulation that can be tuned in vs. 3 points on a linkage burner. 3. Can adapt more technologically advanced controls to burner control. 4. Tighter tolerances yield better combustion process over entire heating season and reduce annual maintenance costs.

9 Linkageless Burner Add-ons 1.BMS integration 2. O2 trim allowing the highest level of combustion efficiency 3. Independent curves for dual fuel burners 4. Variable Frequency Outputs

10 Turbulators 1.Increases flue gas turbulation, reducing laminar flow in tubes. 2.Easy to install, but does require burner to be re-tuned 3. Increases overall boiler efficiency.

11 Outdoor Reset Controls!! Allows for the water temperature to be turned down when there is a light demand. Determines demand based on outdoor design temperature vs design day temperature.

12 Adding just a few of these features could have a rather dramatic effect on fuel savings. Just changing out the burner could easily save 3-5% in energy consumption. Reset controls, turbulators, trim kits and other accessories just add to the savings

13 Replace!! When this decision is made, that is the time to design and implement the replacement system to give the greatest return on investment.

14 How does your current system operate? Does your current boiler plant ever run at full fire? Has there been any other building envelope upgrades since the old boiler was put in? Can you utilize an outdoor reset control to lower water temperatures based on outside air? Do you really need to replace the whole boiler plant?

15 Spending money where it counts Utilize what still works. Only replace what absolutely must be replaced and what financially makes sense. Work with your utility to review your gas volume history or help provide a natural gas energy analysis. Find out what you real load is. If your system can t be lowered to temperatures below 140 degrees F, look at replacing only one boiler with a smaller condensing boiler rather than entire boiler plant.

16 Upgrading to high efficiency! In todays world, efficiency is all the hype! We want the most efficient anything because it will pay for itself and save us in the long run. That may be true for some things, but with boilers, that is a big variable. Physics tells us how well our boiler will operate based on the conditions we run it at. The key thing to remember about high efficiency boilers is that if we can t run them cold, they are not high efficiency! There are ways to utilize both the condensing and non condensing technologies if your system needs to have the warmer water in the dead of winter to keep the building warm

17 Condensing High Efficiency Boiler Upgrade This is a very popular type of new or upgraded mechanical room. But if you can t run low water temperatures the boiler is only going to run at a typical efficiency of about 85%. That certainly is not the efficiency you hoped for when you bought the equipment. So while this system has the potential to be the most efficient it is only going to be the most efficient if it is applied correctly, and that can be difficult.

18 N O N - C O N D E N S I N g S u p p l y W a t e r T e m p Retrofit Building Equipment Design 180 deg. F supply temperature Shows boiler able to condense only 64% of the time at best Shows boiler able to condense only 74% of the time at best Shows boiler able to condense only 97% of the time at best 36% 64% Outside Air Temperature Typical reset curve shows that boiler only condenses 64% of the time. 80 Represents the time spent in each range of outside temperatures

19 Potential savings using a new high efficiency boiler with average seasonal efficiency of 92%.

20 Hybrid System A mix of condensing and non-condensing boilers. The condensing boiler controls are smart enough to protect the non condensing boilers and only run them when it is safe to do so. This saves you up front cost, can sometimes yield a higher overall efficiency and reduced maintenance costs.

21 Hybrid System Using Your Existing Boiler Still a mix of condensing and non-condensing boilers. In this scenario we use your existing boiler/boilers with the addition of a new condensing boiler sized for the appropriate boiler load for the time periods in which it would be in a low water temperature zone( below 140 ) Condensing boiler controls existing boiler and only runs it when needed and safe to do so. Existing non condensing condensing

22 Potential savings using a new Hybrid boiler plant with average seasonal efficiency of 92%.

23 Lets sum it up to see what really makes the most sense!!

24 Repair! Repair A detailed boiler tune up should consist of 1-2 days of labor and approximately $300 - $500 in parts. Estimated cost of $2,500. Take into consideration your Boiler Tune Up Rebate from CenterPoint Energy ( in this case $ every other year ) and your looking at $2, Based on potential savings from getting your boiler repaired and back to its intended efficiency your still on track to save almost $9,000 the next heating season. Do keep in mind though that your boiler is now running at peak efficiency of 80-82% efficiency. That s the best its ever going to get. ( based on the 3 million BTU example from earlier slide. )

25 Modify! Modify An upgraded linkageless burner with outdoor reset is going to be approximately $25,000. Take into consideration your Boiler System Upgrade Rebate from CenterPoint Energy (in this case $3,150 ) and your out of pocket is now $21,850!!! Based on potential savings from getting your boiler modified your on track to save several thousands each year have a return on investment of less than 5 years. Do keep in mind though that your boiler is now running at peak efficiency of 83-85% efficiency. That s the best its ever going to get and that your boiler is already 20 plus years old. It can t be more efficient and it certainly isn t getting any younger. ( based on the 3 million BTU example from earlier slide. )

26 Replace! Replace An upgraded condensing boiler will cost somewhere in the range of $75,000 for equipment and installation Take into consideration your Boiler System Upgrade Rebate from CenterPoint Energy (in this case $10,500 based on 92% eff.) and your out of pocket is now $64,500!!! Based on potential savings from replacing your boiler your on track to save several thousands each year have a return on investment of less than 8-10 years. Do keep in mind though that you have now purchased a very efficient product. Efficiency has its own costs aside from just initial install price. Newer boilers are well built machines, but they are not intended to last as long as your old boilers did. These are year boilers at best. ( based on the 3 million BTU example from earlier slide. )

27 Replace with Hybrid! Replace An upgraded condensing/non condensing boiler plant will cost somewhere in the range of $60,000 for equipment and installation Take into consideration your Boiler System Upgrade Rebate from CenterPoint Energy (in this case $10,200 ) and your out of pocket is now $49,800!! Gained redundancy of a 2 boiler system instead of just one. Based on potential savings from replacing your boiler your on track to save several thousands each year have a return on investment of less than 6-8 years. Do keep in mind though that you have now purchased a very efficient product. Efficiency has its own costs aside from just initial install price. Newer boilers are well built machines, but they are not intended to last as long as your old boilers did. These are year boilers at best. ( based on the 3 million BTU example from earlier slide. )

28 Replace Partial with Condensing! Replace An upgraded condensing boiler for partial load would cost somewhere in the range of $ 40,000. Take into consideration your Boiler System Upgrade Rebate from CenterPoint Energy (in this case $6,150 ) and your out of pocket is now $33,850!! Gained redundancy of a 2 boiler system instead of just one. Based on potential savings from replacing your boiler your on track to save several thousands each year have a return on investment of less than 6-8 years. Do keep in mind though that you have now purchased a very efficient product. Efficiency has its own costs aside from just initial install price. Newer boilers are well built machines, but they are not intended to last as long as your old boilers did. These are year boilers at best. ( based on the 3 million BTU example from earlier slide. )

29 Breakdown of Repair Calculator.. Repair - $ rebate from CenterPoint Energy. CenterPoint Energy pays 25% of the cost or $ which ever is greater. ( based on the 3 million BTU example from earlier slide. )

30 Breakdown of Modify Calculator.. Modify - $3, rebate from CenterPoint Energy. CenterPoint Energy pays $1,350 for modulating burner, $900 for linkageless controls, $750 for turbulators and $150 for outdoor reset control. ( based on the 3 million BTU example from earlier slide. )

31 Breakdown of Replace Calculator.. Replace - $10,500 rebate from CenterPoint Energy based on 92% efficiency. CenterPoint Energy pays $8,100 for equipment 88% and greater, $2,400 for difference in efficiency between 88 and average efficiency of new boiler, in this case 92%. ( based on the 3 million BTU example from earlier slide. )

32 Breakdown of Replace with Hybrid System Calculator Replace - $10,200 rebate from CenterPoint Energy based on 95% efficiency and 88% efficiency. CenterPoint Energy pays $4,050 for equipment 88% and greater, $2,100 for difference in efficiency between 88 and average efficiency of new boiler, in this case 95%. ( condensing boiler, but higher claimed efficiency because I will only run in condensing mode and in seasons with partial load which increases boiler efficiency. ) CenterPoint Energy pays $4,050 for equipment 88% and greater for non-condensing boiler. ( based on the 3 million BTU example from earlier slide. )

33 Breakdown of Replace Partial with Condensing Calculator. Replace - $6,450 rebate from CenterPoint Energy based on 95% efficiency. CenterPoint Energy pays $4,050 for equipment 88% and greater, $2,100 for difference in efficiency between 88 and average efficiency of new boiler, in this case 95%. ( condensing boiler, but higher claimed efficiency because I will only run in condensing mode and in seasons with partial load which increases boiler efficiency. ) ( based on the 1.5 million BTU example from earlier slide. )

34 Like everything in life, there are several ways to accomplish what you are trying to do. Today s intent was to potentially open new thought processes and show you examples of how thinking outside of the box may provide a better net result

35

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