Boiler Blog | Nationwide Boiler Inc.

Are you looking for a boiler that offers the latest boiler technology in emissions and efficiency? Does your boiler need to meet an upcoming compliance deadline date and you are not sure what to do? If so, you have come to the right place.

Nationwide Boiler continually seeks technology that offers the maximum emission reductions and the highest thermal efficiency that may provide valuable emission credits and energy rebates. Our Best Performance Standards Boiler keeps this tradition alive and is equipped with the latest technology to ensure you are operating with the greatest efficiency possible.

The BPS boiler is designed with the latest efficiency upgrades (high turndown controls, O2 trim, VFDs, and extended surface economizers) and includes the CataStak SCR System for 2.5 ppm NOx.  Nationwide's patent pending NOx reduction control system is also included for precise ammonia flow control.

The yearly efficiency savings and emission reductions that are quickly achieved with a BPS boiler provide a greater return on investment and most importantly, peace of mind with compliance assurance for years to come.

Call us today to obtain a free product bulletin and to learn more about our BPS solution.

Even with the best pretreatment programs, boiler feedwater often contains some degree of impurities, such as suspended and dissolved solids. The impurities can remain and accumulate inside the boiler as the boiler operation continue, leading to carryover of boiler water into the steam, causing damage to piping, steam traps and even process equipment. The increasing concentration of suspended solids can form sludge, which impairs boiler efficiency and heat transfer capability.

One way to improve efficiency is to review your blowdown practices. This includes the use of an automatic blowdown control system by regulating water volume discharged in relation to the amount of dissolved solids present.  This system maintains proper water chemistry within acceptable limits, while minimizing blowdown and reducing energy losses. Cost savings come from the significant reduction in the consumption, disposal, treatment, and heating of water.

The U.S. Department of Energy's Industrial Technologies Program calculated annual cost savings associated with the installation of an automatic blowdown control system that reduced blowdown rate from 8% to 6%. The example below assumes a continuously operating natural gas-fired, 150 psig, and 100,000 lb/hr steam boiler. Makeup water temperature of 60 degrees, with boiler efficiency of 83%, with fuel valued at $3.00 MMBTU was used, and the total water, sewage and treatment costs are $0.004 per gallon.

The annual cost savings in the example above equals:

Boiler Feedwater:

Initial = 100,000 / (1-0.08) = 108,695 lbs/hr

Final = 100,000 / (1-0.060 = 106,383 lbs/hr

Makeup Water Savings = Initial - Final, or 108,695 lbs/hr - 106,383 lbs/hr = 2,312 lbs/hr

Enthalpy of boiler water = 338.5 Btu/lb; for makeup water at 60 degrees = 28 Btu/lb

Thermal Energy Savings = 338.5 - 28= 310.0 Btu/lb

Annual Fuel Savings = 2,312 lbs/hr x 8760 hrs/yr x 310.5 Btu/lb x $3.00/MMBtu / 0.82 x 106 = $23,007

Annual Water and Chemical Savings = 2,312 lbs/hr x 8760 hrs/yr x $0.004/gal / 8.34 lbs/gal = $9,714

Annual Cost Savings = $23,007 + $9,714 = $32,721
If you need additional information about feedwater systems or other ways you can decrease costs, contact Nationwide Boiler today and we are happy to discuss ways to improve your bottom line: 1-800-227-1966.

In order for your boiler to operate at peak efficiency, it is important that the correct balance of fuel and combustion air is achieved. Air and fuel ratios are controlled through linkages, fans, dampers and the increase or decrease of gas pressure. Gas pressure is controlled through a pressure regulator and a fan controls the volume of combustion air.
If there are any problems with the fan, more energy may be introduced into the system, causing decreased efficiency. To help ensure that your equipment is running at its peak performance, please review the common fan problems below.

Fan Capacity/Pressure is Below Rating:

1. Dampers or variable inlet vanes are not adjusted properly


2. Fan inlet or outlet conditions are impaired


3. Multiple air leaks within the system


4. Damage sustained to the blower wheel


5. Direction of rotation is incorrect

Fan Vibration:

1. Worn bearings


2. Unstable foundation


3. Foreign material in the fan causing an imbalance


4. Misalignment of bearings, couplings, wheel or v-belt drive


5. Damaged wheel or motor


6. Bent shaft


7. Worn coupling


8. Loose dampers or variable inlet vanes


9. Speed too high or incorrect fan rotation


10. Vibration to fan transmitted from another source


11. Uneven blade wear


12. Loose or broken bolts or set screws

Overheated Bearings:

1. Improper lubrication


2. Poor alignment


3. Damaged wheel or driver


4. Bent shaft


5. Abnormal end thrust


6. Dirt in bearings


7. Improper belt tension

Overload on Driver:

1. Speed too high


2. Direction of rotation is incorrect


3. Bent shaft


4. Poor alignment


5. Improper lubrication


6. Wheel wedging or binding on fan housing

Are you interested in learning how to improve your facility's energy efficiency? We hope that most, if not all of you are.

The U.S. Department of Energy (DOE) Industrial Technologies Program (ITP) offers no-cost webcasts to help industrial companies improve energy efficiency. This is achieved through an understanding of current and future technologies, ITP tools, energy assessments and utilizing industry wide best practices.  Past subjects include the following: Energy Assessments: What are the Benefits to Small and Medium Sized Facilities, State and Utility Partnerships, Super Boiler Technologies and Using Wireless Technology to Reduce Facility Energy Usage.

Webcasts are offered on Thursdays from 1:00 to 2:00 pm (Eastern Time) and they are a convenient and cost-effective way to learn how you can improve your operations and energy use.

Nationwide Boiler has helped many of our customers realize positive gains through energy efficiency upgrades with a quick return on investment. Give us a call today so we can better understand your needs and can present a solution that's right for you 800-227-1966.

Upcoming webcast sessions:

• March 12, 2009 — Steam System Tool Suite
  Find out how to use DOE's suite of tools for evaluating and identifying steam system improvements in your facility.


• March 19, 2009 — MotorMaster+ Tool
  See how this energy-efficient motor selection and management tool can help you analyze, identify, and report on energy savings.


• March 26, 2009 — ITP Nanotechnology Research and Development
  Learn about ITP R&D nanotechnology activities and the direction of future research and application of this technology in a variety of industries.


• April 2, 2009 — ITP's Top Low- or No-Cost Improvements
  Get tips for identifying and implementing energy efficiency improvements based on frequent recommendations from DOE Energy Experts.


• April 9, 2009 — Project Financing — From Identification to Implementation
  Ensure that improvement measures identified during energy assessments become reality by exploring effective funding mechanisms in this Webcast.


• April 16, 2009 — Energy Assessment Results - Most Commonly Identified Recommendations
  Hear from DOE Energy Experts about the most common recommendations for cost and energy savings identified during an assessment.


• April 23, 2009 — Data Center Assessment Case Studies — Verizon and Lucasfilm
  Discover energy efficiency recommendations and best practices identified during DOE data center energy assessments at Verizon and Lucasfilm.