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1961 KEWANEE BOILER CONTROL UPGRADE
Ideas are welcome for updating controls on school house heating system.
The owners need a budget plan for improving efficiency of this hot water system:
1961 Kewanee 3R6FO, output rated at 792 MBH (23.6 HP) converted from oil to
Adams Speedflame NG power burner--HP 800 (800,000 to 300,000 BTUH)
NG meter clocked @ 514,285 BTUH input. Combustion test shows 313.2 temp. stack--6% oxygen--2 ppm CO--3ppm CO air free--85.2 % Eff.gross-35.8% excess air --8.35% CO2--86.7* amb temp. (Testo 320 is a new toy for me, so does this sound to be possibly correct)
Boiler stays hot for entire heating season (manual shut-off). Honeywell reset control installed. (quite old).
Pump pushes thru boiler; is B&G PDI 121 1/2 HP 6.5 amps 120VAC.
Pumping control is outdoor T-stat-- off at approx 60* . There are 2 pumps with flow switch to start back up pump in case of # 1 failure. (pumps do not alternate)
There is a B&G FAS 2" flow control installed for each pump.
Emitters consists of commercial baseboard running nearly the entire length of the building (north/south sides) with a Nesbitt Syncretizer (fan coil) installed in each classroom. There are 10 convector units for hall & RR etc. use.
There is a pneumatic control system consisting of 6 Powers day/night T-stats.(Most work fairly well) . Also is a manual master "day/night" switch in the boiler room.
Building is 137' X 70' = 9,590 sq feet on slab, no bsmt or attic. 1961 insulation is minimal. Masonry walls thru out. Only 1 classroom is in use daily M-F. The entire building is in use only on Wednesday. The master night/day control is set to night except for Wed. The M-F classroom sets its T-stat to "day" as needed.
1. Need boiler temp control that will maintain return water temp to avoid condensation. (A 1 1/4" manual by-pass was installed to maintain return temp and avoid high head on the pump, some automatic control would be good. )
2. Most balancing valves are throttled down to slow flow. On "day" mode the fan coil valves open and there is more flow needed for Wednesday.----Is this a place for ECM pumping? Pump must maintain some water flow thru out all emitters to avoid freezing.
3. Power burner orifice can be down sized as I have not noticed constant operation on coldest days. (checked daily).
Thanks for any direction provided !!