Boiler Blog | Nationwide Boiler Inc.

At Nationwide Boiler we are continually increasing our stock inventory to ensure that we have as much equipment available to customers as possible. The newest addition to our rental fleet is two (2) new 70,000 lb/hr trailer-mounted saturated, package watertube boilers with design pressures of 400 psig. Built by Cleaver-Brooks Nebraska Boiler, these units are completely pre-piped and pre-wired and can be fired with natural gas or no. 2 oil. Both boilers are equipped with low NOx burners and have the option of adding EconoStak economizers for added fuel efficiency. These boilers are available and are ready for immediate shipment worldwide!

Visit our website at www.nationwideboiler.com to see more boilers and equipment available for rental or purchase.

Companies utilizing steam in their everyday processes should know their correct cost of steam for many reasons, all linking to improvement of the bottom line. This knowledge will allow companies to optimize operations and minimize costs, but many companies are unaware of and don’t account for all factors associated with the cost of steam. Some of these factors include the cost of fuel, steam operating pressure, percentage of makeup water/condensate return, and boiler efficiency. Lower fuel costs and a lower operating pressure will lead to a lower cost, and a higher boiler efficiency will minimize costs as well. Boiler efficiency can be calculated using the ASME boiler performance test code.

There are two methods used to calculate the cost of steam. The true cost of steam is calculated by using the loaded steam cost method. The loaded method provides a more accurate steam cost because it takes into account all aspects and expenses of steam production, rather than just the costs associated with boiler operation (as seen with the unloaded method). The unloaded steam cost method can actually be as low as half the cost found by the loaded cost method. Additional factors included in the loaded method include electrical power, chemicals, water and sewer, emissions payments, labor, management, operations, maintenance, waste disposal, and new projects.

For a more detailed explanation about steam cost calculation, check out the article in Process Heating Magazine.

Nationwide Boiler Inc. recently facilitated the expedited delivery of a new boiler system in less than six months to a major crude oil refinery in El Paso, Texas. The boiler supplied is a new, in-stock Babcock & Wilcox D type watertube package boiler, model FM120-124, capable of producing 200,000 lb/hr of superheated steam and designed at 750 psig / 750°F superheat. The system includes a low NOx burner, an EconoStak economizer, a Nationwide CataStak™ SCR NOx Reduction System (using 19% aqueous ammonia and vaporizer), SIL Level 2 Burner Management System, desuperheater, stack, and FD fan.

The plant currently processes approximately 128,000 bpd of crude oil and with this replacement boiler, plant capacity is expected to increase to 150,000 bpd. “As refineries seek to quickly increase capacity and comply with strict emission regulations, Nationwide Boiler is uniquely qualified to provide in-stock boiler solutions that incorporate the highest standards in safety, efficiency and emission reducing capabilities," said Larry Day, Nationwide Boiler Vice President, Sales & Marketing. “Our long-lasting relationship with Babcock & Wilcox and other OEM suppliers has enabled Nationwide Boiler to provide the highest quality boiler systems to customers located throughout the world. This project is another example of how we can meet the needs of those customers seeking immediate boiler solutions.”

Improper water treatment is one of the leading causes of poor boiler performance and can cause boiler tube damage that is irreversible. This is because hard water, or mineral rich water, can result in scale on boiler watersides. This scale is undesirable in water systems because it acts as an insulator and prevents proper heat transfer. Scale deposits of just 1/16” thick can decrease boiler efficiency by 20% and can lead to premature boiler failure and costly downtime.

To avoid this scenario, water softening is a widely-used and economical type of pre-treatment for boiler system. A water softener is an ion exchanger designed to remove the positively charged ions and replace them with sodium or potassium exchanger ions. Hard water contains the positively charged ions magnesium, calcium and iron. The water softening process nearly frees the water from these minerals and decreases the risk of tube scaling and irreversible boiler damage. Water softening, when combined with a reliable water treatment chemical program and blowdown schedule, can lead to many years of reliable boiler system performance.

We’ve installed duplex water softening systems in all of our mobile boiler rooms and mobile steam plants to ensure optimal boiler performance. We also have larger skid-mounted duplex water softeners available for rent or purchase. For more information on products and services available, visit our website at www.nationwideboiler.com.