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Linkageless Burner Retrofits for Steam Boilers

Going Beyond Carburetor Technology in the NYS Market

Fun Fact #1: Space heating and domestic hot water generation represent two of the greatest energy end uses in New York State.

Fun Fact #2: More than 70 percent of all New York City buildings utilize steam for space heating.

Background

The clear majority of the distribution systems in these NYC buildings are supplied by high mass steam boiler plants. Digging down a bit further, it is important to note that the most common air:fuel control for these boilers is a mechanical linkage that connects a single servo motor to both the combustion air damper and the fuel control valve(s). We know that adjusting one part of the linkage’s movement affects fuel and air rates elsewhere in the range, making accurate adjustment difficult. We also know that modern linkageless controls use separate servo motors to operate the fuel control valves, combustion air damper, and (in some cases) the flue damper, allowing for finer control.

mechanical linkage system and linkageless system

In fact, SWA recently completed a demonstration study (partially funded through NYSERDA’s Advanced Building Program) to evaluate linkageless burner retrofits on two buildings with respect to energy savings and carbon reductions, as well as qualitative or non-energy benefits. The retrofit materials were funded by Preferred Utilities Manufacturing Corp. of Danbury, CT, who also provided manufacturer’s technical support. The study also focused on quantifying the seasonal efficiency of intermediate-sized, high mass steam boiler plants, which had not previously been studied. The demonstration addresses this gap in the industry’s knowledge.

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Over Pressure (Part Two)

Welcome back! In Part One we talked about how steam pressure gets too much attention. Controlling pressure for its own sake should never be the end goal—steam pressure is just a means to an end. In this post we’ll discuss one way that controlling steam pressure can be useful—where it can help you balance the system, control the temperature, and yes, save energy.

Two-pipe Steam

The biggest issue plaguing two-pipe steam heating systems are steam traps. Steam traps are supposed to do just that—trap steam—keeping the pressurized steam on the supply side of the system and allowing air and water (i.e., condensate) to pass through into the returns. Keeping the supplies and returns separate is critical, but steam traps are too failure prone to accomplish this reliably.

Radiator steam “trap” failed open

Radiator steam “trap” failed open

At the start of any heating cycle, the system is full of air, which must be removed for steam to enter the heaters. In most two-pipe systems, the steam pushes the air out of the heaters, through the traps, and into the return piping where it eventually exits the system through a vent in a vacuum or condensate tank. That’s what happens when the traps are working. But a failed open trap is no trap at all. It lets the steam flow into the return piping and, with pressure on both the supply and return sides, air is trapped in the system. This affects those farthest from the boiler—the heaters near the ends of the mains and on the top floors—the most.  (And with air trapped inside keeping the metal cold, are they even heaters?)

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Oh, the Weather Inside is Frightful!

Winter in the City

Wintertime in New York City: cold wind whips down the avenue and seems to follow you as you leave the frozen street and enter your building. The cold gust pulls the heat out of the lobby and even seems to follow you as you make your way up the building, whistling through the elevator shaft as it goes. The colder it gets outside, the worse it gets inside. Can’t somebody please make it stop? Is it too much to ask to be comfortable in your own lobby?

No, it is not too much to ask, and yes, we can help. It is 2016 and we have the technologies and expertise to better manage this all-too-common problem, but first we must examine what forces lay at the heart of the issue.

multifamily_ventilation_winter

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