100 hp boiler needs replacing

Supernaut

Hi-

I'm buying a 95,000 sq ft mill in Massachusettes. I believe it has 2 100 hp oil boilers. The building has been abandoned for a few years, but much of it still looks good, such as the steam pipes.

I can get gas to the building. I'm trying to figure if I should pull the dinosaurs and plug a new "high efficiency" boiler(s) into the existing distribution system, convert to hot water, or even ignore the existing and move to some sort of distributed heating.

I need to keep construction costs low, and I like the idea of using existing if it makes sense economically.

Thanks.

Steamhead

Is this steam system

used just for heating the building, or for processes used in the mill? What pressure are the boilers rated at? 

Supernaut

Steam heat for 95,000'

It's just for heat. The mill will be converted to work studios. I have no idea about the pressure. If it's a new boiler, can it be a new pressure as well? The farthest run is about 200 ft.

Charlie from wmass

I am in Massachusetts

Where are you located? And yes I do service that area.

ColinFarquhar

If you decide to remove them...

Hi There:

   Just a side note from a lurker-If you do end up not using these boilers, they and/or any associated machinery might be of use to any local museums.  I'm heavily involved with antique steam restoration on the West Coast, and could pass the info along to some East Coast friends if you end up deciding to remove them.



Thanks,

Colin

Charlie from wmass

I am going to guess but I think

the boilers are from the 1980's or so. They may be older I would not not say antiques. They may very well have a market on the used preprocessor boiler market if they are high pressure boilers. Then again with TRV's they may be fine to heat the space they are in, staged burners and boilers.

RDSTEAM

very

nice boilers!!! hate to see them go, but if you are using them just for heat and your looking for more efficiency, you should probably go hot water and get gas to that place. What about solar?? if its a mill, im sure there is PLENTY of room for alternative energy.

nicholas bonham-carter

high effiency boilers

those boilers, with a new gas gun may be surprisingly efficient, when compared to other light commercial boilers [80-84%]. with a modulating burner, only one boiler may be able to do the job, as you will have no need for process steam.

how many floors are there? don't plan on a conversion to hot water unless you are re-piping, and perhaps re-radiating the system.

i hope  you will keep us informed as to the progress on this project.--nbc

Brad White

I suspect a mix of

process and heating functions, given that array of smaller piping. The boilers are Kewaunee but I am not sure if they are fire tube or water tube. If water tube, those tend to be higher pressure designs (easier to hold high pressure water and steam in a pipe than in a larger shell you see).



If it is a mix of process "with heating on the side", this may be a good time to assess the heating needs from top to bottom. Many mill buildings had pipe radiators, fairly inexpensive but effective.



I would get Charlie in there if agreeable and take stock of your true needs. You may wind up with a smaller boiler. I would opt for modulating fire though, not just staged, if you can get it in the final size.



Sounds like it could be a fun project. Where in MA is it, did you say?

Supernaut

No process,

just heat. It's actually a school complex built as the Bradford Durfee Textile School, and then it evolved into Durfee Tech. It's in Fall River MA and is constructed in the same fashion as the area mills. It's basically a tiny city of adjacent connected buildings on 1.3 acres. I'll post more pics tomorrow.



I would love to just replace the oil with a gas gun. I spoke to ACME Boilers out of East Providence about that, but they want me to replace the boilers. I think I need to drag the rep out to the site. If I'm going to replace like for like, I might as well save my $ with a conversion. If I need to get new boiler(s), I'm going to look a all my options.



Where can I get info on a 100 hp gas gun conversion? I've been looking online, but not finding anything bigger than residential. I met with the gas co reps last week. They have high pressure in the street.



Like I said, I need to do this cheap, and so if I can, I want to use what already exists.

Steamhead

PowerFlame

can furnish a burner in that size. I think you'd be looking at a C3 series burner (their site is down at the moment, www.powerflame.com), which can be ordered as oil, gas or dual-fuel. You definitely want to get at least a lo-hi-lo (2-stage) or preferably a full-modulating control system. These cost a little more but since they can vary their firing rates, won't be shutting off on pressure so much during the burner's run cycle. Since the burner must go thru a 90-second or so pre-purge every time it starts up, avoiding shutdowns on pressure during the cycle will save a lot of heat from being blown up the chimney.



That boiler company has a point- you definitely want to get these units inspected before trying to upgrade them. Who knows what lurks inside?



And I'll second Charlie to look it over. He's one of the best.

RDSTEAM

power flame

is definately the way to go. went out to kansas for a couple days last year so I can attend their training course. It was very interesting and quite fun (for kansas). If you do keep those boilers and go gas, get yourself a lo high lo or full mod. this will give you a very efficient burner for a steam app.

Supernaut

more pics

Here's some more pics of the boilers. I didnt take pics of the steam distribution system yet. It's in an adjacent room, but looked pretty good.