Maximizing the System Performance with CondensingNon Condensing Waters Boilers

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• Maximizing the System Performance with
  Condensing/Non Condensing Waters Boilers

Alan Wedal Commercial Boiler Product
Manager awedal_at_cleaver-brooks.com www.cbboilers.co
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• Flow Intelligence The ability to operate
  boilers based on the real-time building load.
• Intelligent Load Sharing The ability to
  optimally use boilers of different sizes.
• Hybrid Capability The ability to use
  condensing and non-condensing boilers together.

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How it works . . .
System ?T Flow Real-time Building Load Flow
Intelligence takes the guesswork out of boiler
control theory. PID looks at limited system
information and makes assumptions, Flow
Intelligence gathers appropriate system
information to handle every heat problem.
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An Overview of . . .Intelligent Load Sharing
Maximum and minimum outputs of each boiler in
the system are entered into the system. The
system will use the load information to always
choose the appropriate boiler for the current
load. The system can then choose if splitting
the load between two boilers is
appropriate. The system should also balance run
time across boilers when there are
overlapping turndowns.
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An Overview of . . .Intelligent Load Sharing
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Why it works!

• Knowing the Real Time load means the end of
  needless over firing.

• With Flow Intelligence micro-loads get a
  micro-response.

• Flow Intelligence means the end of excessive
  cycling. NOTHING is more important to energy
  savings than reducing cycles.

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Columbus, OH
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Spokane, WA
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Designing to handle micro-loads
Always choose smallest boilers first.
Design for 30 minutes on run time under zero
load conditions.
The Formula for proper system sizing Min MBH
2(SV x 8.33 x ?T)? Where Min MBH Minimum
desired input SV System volume in
gallons 8.33 The weight of water in
lbs./gal. ?T The maximum allowable
deviation from the
set-point (above and
below).
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Practice System Volume 1,000 gallons Maximum
allowable temp from set-point is 5/-5
1,000 x 8.33 8,330 8,330 x 10
83,300 83,300 x 2 166,600
BTU/Hr Smallest Boiler must have the ability to
turndown to 166,600 BTU/Hr or there will be
cycling during low load times.
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Where does the System Volume come from?

• New designs
• Details from the piping layout
• Existing buildings
• Chemical provider
• Hand over hand the system
• Expansion tank volume (with caution!)
• Original drawings (if exists)

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An Overview of . . . Hybrid Systems
With two independent reset loops of control,
boilers of different types (condensing,
non-condensing) can be used to maximize the
ability to condense 100 of the condensible load
in conventionally designed systems. These
systems have the added benefit of being
installed for about 2/3 of the cost.
Best option for legacy buildings and for those
designed for non-condensing.
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• Sizing the Hybrid System Size the Condensing
  boilers so they can handle the building down to
  32-35F outdoor air.
• For most buildings you should size the
  condensing boilers for 1/3 of design loads.

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What are the effects of these breakthroughs?

• Significant reduced fuel usage!
• Elimination of short-cycling!
• Increased life-expectancy of equipment!
• Dramatically reduced stack emissions!

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What else can be done?

• Many owners and engineers have been sold (on) the
  high efficiency concept
• Some have concerns because they expect high
  efficiency all the time but need 180F
• Without redesigning the entire building for low
  temperature, there are options to reach these
  expectations

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Indirect fired
Boiler
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Conventional supply temperature and no low
temperature return.
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10 flow colder temperature to the lower return
can raise efficiency by 3-6, driving unit into
condensing mode.
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A New Concept and Conversation
Questions ?