ECONOMIZER ECM Turnkey Price Installed: $115,295 PRICE INSTALLED PER INVESTMENT GRADE AUDIT. CALCULATED ANNUAL SAVINGS OF $29,027.51 WITH A SIMPLE PAYBACK OF 3.97 YEARS. (SEE ATTACHED SAVINGS CALCULATIONS) BASIS OF DESIGN: The basis of price and design for the project is unit model HEATSPONGE-BOSS-11-[BPD- 5(S316)C] HeatSponge model economizer as manufactured by Boilerroom Equipment Inc. The retrofit will occur for boiler #1, a Cleaver Brooks Model CB400.600.150 steam boiler. We can modify our quote to price to base project on a Cleaver Brooks Boiler Stack Economizer. SCOPE SUMMARY A feed water economizer reduces steam boiler fuel requirements by transferring heat from the flue gas to incoming feed water. Boiler flue gases are often rejected to the stack at temperatures more than 100 F to 150 F higher than the temperature of the generated steam. Generally, boiler efficiency can be increased by 2% for every 40 F reduction in flue gas temperature. By recovering waste heat, an economizer can often reduce fuel requirements by 5% to 10% and pay for itself in less than 4 years. GENERAL DESIGN The economizer shall be manufactured and tested in accordance with Section VIII Division I of the ASME Boiler and Pressure Vessel Code. The unit shall be code stamped to a minimum of 600 PSIG design pressure at 600 degrees F. The unit shall consist of a finned tube gas-to-liquid heat exchanger designed to transfer heat from the flue gas into a liquid inside of the tubes. The pressure vessel within the gas flow stream shall not contain any welded joints or tube-toheader fittings. The unit must feature tube elements that can be individually replaced without the need to perform any welding. The individual tubes shall be able to be easily removed and replaced. Method of tube connection shall be to each manufacturer s standard however a compression fitting-type connection is preferred. The tube bundle shall consist of a rectangular square pitch arrangement to provide for maximum clean ability and maintenance. Coiled, triangular or staggered pitch arrangements shall not be considered. The unit shall be designed so a bypass damper is not required for the normal operation of the unit. This is defined as any economizer configuration that requires a damper to act as a gas flow diverter to force the flue gas over the economizer tubes. Should a bypass damper be required it shall be completely external to the economizer to physically isolate and prevent flue gas from passing over the tube bank. 1 P age
The economizer must be designed to be 100% drainable in both horizontal and vertical configuration to avoid the potential of trapped liquid pockets that could be subject to failure from freezing. Unit to be designed to be either suspended by hanger rod or supported from support structure. The economizer shall be capable of supporting a 500 static load only. The economizer shall not require to accommodate stack or other dynamic loading. The unit shall be supplied with integral inlet and outlet flue gas connections to the stack. The entire assembly shall be a factory-insulated one-piece design to allow for easiest installation. Units that do not provide a fully factory-insulated assembly shall not be considered. Units that require separate flue gas transitions shall not be considered. For all vertical gas flow up installations the lower gas inlet transition must be fitted with a watercatch system to collect moisture from condensing, rain, or from a tube failure and provide a means to drain it from the economizer without it entering the boiler. The economizer shall include at least one (1) removable access panel to provide full access to the inside of the economizer for routine maintenance, inspection, and repair. The header manifolds shall be threaded at each end and shall be 2 1/2 inch NPT. The economizer supplier shall include a Safety Relief valve suitable for the application in their base scope of supply. The SRV shall be a Kunkle model 913 or equal. MATERIALS OF CONSTRUCTION: Tubes: The tube material shall 316 stainless steel. Fins: The fins shall be supplied out of stainless steel. Carbon steel or aluminum fins shall not be considered. A fin pitch of 5 per inch shall be supplied. Fin-to-tube attachment shall be by a metallurgical brazing procedure only. Welded fins shall not be permitted. The economizer casing shall be manufactured out of carbon steel. Insulation: The entire economizer shall be insulated with a minimum of 2 inches of mineral wool insulation. This includes inlet and outlet gas adapter areas. PERFORMANCE: The design parameters of the unit shall be as follows and calculated at 100% load Boiler Maximum Capacity: 600 HP Primary Fuel Fired: Natural Gas Standby Fuel Fired (if applicable): #2 Fuel Oil - Standby Only Boiler FGR Rate (if applicable): 0% Boiler Excess Air Rate: 15% Design Water Flow Rate: 20700 PPH Water Inlet Temperature: 227 deg F Water Outlet temperature: 247.5 deg F Maximum Water Side Pressure Drop: 8.9 psi Design Gas Flow Rate: 22156 PPH Flue Gas Inlet Temperature: 364 deg F Flue Gas Outlet Temperature: 292 deg F Maximum Gas Side Pressure Drop: 0.24 inches water column Flue Gas Dewpoint: 135 deg F Unit BTU Duty: 424826 btu/hr 2 P age
APPROCAH Steam management will perform all design engineering and provided stamped mechanical, electrical and P&ID drawings. Arrow Time Consultants, LLC will provide project management and commissioning services. Royal Steam Heater will provide licensed pipefitters and electricians for the installation of new equipment, mechanical, electrical, structural to install the measure per final design specifications. Prior to the actual installation of the economizer, we will construct a structural steel catwalk around the existing stack. The purpose of the catwalk is to provide a safe working platform for both the installation of the economizer and for its service and maintenance requirements. For the purpose of this bid, we have included a catwalk built and installed to the specific drawing prepared under DCAM guidance by SEBESTA, dated 12-10-2015 and labeled STRUCTUAL DETAILS S-DT-052. We take issue with this design, however, because the floor mounted supports and access ladder will interfere with the servicing of the CB boiler. We would suggest a different style catwalk supported from the roof structure and the adjacent roof support upright beams. Our concept would also have guard rails, but it would be accessed by a step up from the existing catwalk on top of the boiler which already has a ladder from the floor. Our concept will not cost any additional money than the specified drawing design. We will connect a new 3 welded steel feed-water line to the existing 3 steel boiler feed line and run up to the supply connection on the new economizer. From the return connection on the economizer, we will drop back down reconnect to the existing boiler feed. We will provide a 3 valve by pass line to allow for the isolation of the new economizer and the continued operation of the boiler as it is currently supplied. This new piping will be properly insulated. We are assuming that the new economizer is a factory insulated product. We have carried the price of the electrical work, as we understand the scope. We are assuming that there will be a control panel which will require power wiring and control wiring from new sensors, valves, etc. provided with the economizer and installed by our pipefitters. We assume that the existing sensors will be disconnected and reconnected electrically once they have been relocated by our pipefitters. We assume that there will be connecting wiring between the new equipment control panel and the existing FSU building energy management system, with the interconnection module provided to our electrician by the existing energy management control company. 3 P age
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BOILER ECONOMIZER HEAT RECOVERY: Performance Heat Sponge Boss-11: Boiler Maximum Capacity: 600 HP Primary Fuel Fired: Natural Gas Standby Fuel Fired: #2 Fuel Oil - Standby Only Boiler FGR Rate: 0% Boiler Excess Air Rate: 15% Design Water Flow Rate: 20700 PPH Water Inlet Temperature: 227 deg F Water Outlet Temperature: 247.5 deg F Maximum Water Side Pressure Drop: 8.9 psi Design Gas Flow Rate: 22156 PPH Flue Gas Inlet Temperature: 364 deg F Flue Gas Outlet Temperature: 292 deg F Maximum Gas Side Presssure Drop: 0.24 inches water column Flue Gas Dewpoint: 135 deg F Unit BTU Duty: 424826 BTU/HR Fuel Cost: $0.78 per Therm Annual Operating Hours: 8760 Annual Load Factor LF: 0.65 Steam Plant Efficiency: 65% FuelCost$ LF 0.65 0.78 100000 TotalCostSavings TotalCostSavings = 29027.51 LF 424826 8760 Economizer System Installed Cost $: FuelCost$ 0.65 InstalledCost 115295.00 SimplePayback InstalledCost TotalCostSavings SimplePayback = 3.97 Years Page 1 of 1 Non-Commercial Use Only