Boiler Room Modernization Project
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Key Container was in dire need of an upgrade - they were relying on two Cleaver-Brooks boilers dating from 1966 to meet the process steam needs of their plant. These boilers had outlived their useful life and repairs - and corresponding downtime - became increasingly frequent and expensive.
The goals for this project were to increase efficiency and reliability while reducing maintenance, fuel, and electrical costs. In addition, this project made Key Container’s everyday operation more ‘green’ by utilizing natural gas with the best available technology in combustion equipment and control systems. |
This boiler room modernization project included:
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Eclipse Gas Booster
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The Eclipse gas booster increases the incoming street pressure of 6" w.c. to the required 20" w.c. The gas lines in this boiler room are identified with bright yellow paint.
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Installation - Piping
Examples of our pipefitters' work is displayed in the pictures below.
All piping is insulated to conserve energy while giving a clean, crisp finished look.
All piping is insulated to conserve energy while giving a clean, crisp finished look.
350 HP Series 500 Boiler
Replacing a 200 HP boiler with a 4-Pass, 350 HP boiler utilizing a high turndown burner means that only one boiler will be required to carry the fluctuating plant load. The wetback construction of the Hurst boiler is better able to match heavy load swings. The S.T. Johnson burner is equipped with a combustion control system featuring parallel positioning with O2 trim and VFD for blower motor.
Deaerator and Stack Economizer
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The installation of a deaerator in conjuction with a stack economizer is used to produce feedwater temperatures almost equal to the temperature of the boiler water. Steam pressure variations are reduced, leading to fuel and energy savings. |
Custom Combustion Controls
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Featuring an easy to read 15" color touch screen, panel lights for pump and burner operation, and an emergency stop button, this NEMA1 double-door floor mounted panel monitors the entire plant. |
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Blowdown Separator with Aftercooler
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To meet code requirements, for safety, and for protection of other equipment in the boiler room, a Hurst 14X34A blowdown separator with aftercooler was also installed.
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The blowdown lines, painted in green, are tied to both the new and existing boilers.
Now the steam travels through a vent on the separator and through piping leading out to the roof, versus escaping into the boiler room where it damaged equipment. The water travels through the automatic aftercooler, where it is cooled to a safe temperature before being discharged. |
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