How to optimize Boiler Load management and rightsizing? (Energy Efficiency Tip of the Day)

Tip summary
o An oversized boiler will turn on and off more often than a boiler that has been properly matched to the demand* which may result in short-cycling losses.
o If the boiler is instead left on standby* short-cycling losses will be avoided but energy will be wasted in keeping the boiler on standby.
o The main reason for energy losses at standby mode for the boiler is the lost amount of heat required to heat the boiler casing at this mode.
o Rather than sizing a boiler to meet the highest possible load* fuel savings can be achieved by adding a smaller boiler sized to meet the plant’s average loads* or by using multiple small boilers.
o Multiple small boilers offer reliability and flexibility to operators to follow load swings without over-firing and short cycling.
o Load management also helps to reduce load variation. As this measure is normally an end-of-life option there should be no incremental costs to right size a boiler but a benefit exists by purchasing a smaller boiler.

Proposed actions
o Evaluate your current boiler load management strategy.
o For multi boilers systems* try to adjust steam demand to keep and boilers loads to keep the selected boiler running with acceptable load for long time (without steam venting).
o The load management could be done manually by changing the current operating procedures or automatically by modifying boilers load control.
o Consider/evaluate installing a small boiler to cover small load periods instead of operating large boiler at low load.

Economics
o System tuning will have low cost.
o New small boiler addition will have medium cost but quick ROI.

Savings
o Estimated energy savings range: 10-50% of boiler energy use.
o Decrease equivalent amount of boiler load and decrease CO2 emissions accordingly to save the environment.

Conclusion
o Boilers Load Management Assessment could save up to 50% of boiler energy use.
o The load management is easy to implement with low cost for proper control modifications.
o Please share this tip with others to share knowledge and increase energy efficiency awareness.
o Please contact me for any advice or support about this issue or other energy management issues.

Tip video

[link Point to another website Only the registered members can access]
Link to download tip slides

[link Point to another website Only the registered members can access]
Tip video Arabic version

[link Point to another website Only the registered members can access]
My blog

[link Point to another website Only the registered members can access]
#Energy #energyefficiency #energymanagement #steam #steamsystem #sustainable #sustainability #engineering #engineer #chemicalengineering #boiler #360practiveengineer #loadmanagement #steamboiler # EnergyEfficiencyTipoftheDay