# USI BOILER EFFICIENCY PROGRAM

A REPORT SUMMARIZING

THE FINDINGS AND RECOMMENDATIONS

OF AN EVALUATION OF BOILERS

IN STATE OPERATED FACILITIES

Prepared for

The State Energy Office

NC Department of Administration

1830A Tillery Place

Raleigh, NC 27604

B 

# y

Dr. Herbert M. Eckerlin

Eric W. Soderberg

Mechanical & Aerospace Engineering

Industrial Extension Service

P.O. Box 7910

North Carolina State University

Raleigh, NC 27695

Telephone: (919) 515-5227

September 15, 2003 (original)

(this revision - 2/25/04)

# EXECUTIVE S U M M ARY

An analysis of 123 steam and hot water boile rs has been conducted at the larger state

operated facilities across North Carolina. Th e an alysis inc l ud ed site vis its to the

facilities, interviews with boiler operators and m a intenance personnel, and m easurem e n ts

of i m portant variables for id entifying energy savi ng opportunities and boiler efficiencies.

The tests were conducted by NCSU as part of the Utility Savings Initiative (USI)

Program adm i nistered b y the State E n ergy Offi ce (SEO). These tes t s are a necessary first

step in the developm ent of a com p rehensive program to i m prove boiler

operation/ef ficiency at state facilities and to reduce their overall energy costs. Of the 123

boilers tested to date, 78 ar e steam boile rs ins t alled in the 28 central heating plants

located acro ss the s t ate. The rem a ining 45 sm aller boilers (including 18 steam and 27 hot

water boiler s ) are loca te d in individual buildings.

The boiler test data has been categorized into two parts. Part I includes the 78 larger

boile rs loc a ted in the cen tra l heating plants and Part II covers the 45 boilers located in

individual buildings. A n analysis shows that th e Part I bo ile r s in the central heating

plants have an annual fuel bill of $23,666,407 (s ee Table 1). For these plants, the USI

Boiler Prog r a m identif ied potential energy savings of $1,338,000 (or 5.65 percent of the

total fuel us age) (s ee Table 2). Fuel use data on the sm aller bo ilers (located in individual

buildings ) a r e not yet ava ilab l e. W h en they b eco m e available

, these da ta will be inclu d ed

in the sub j ec t repor t.

The m a jor fi ndings and resulting recomm e ndations growing out of the USI Boiler

Program are presented b e low:



# RECOM M ENDATIONS RELATED TO S T ACK LOSS

• Tem p erature gauges to m easure the s t ack tem p erature are not in place on any of the

45 boilers located in indivi dual buildings. This measur em ent is essentia l f o r the

proper m onitoring of boiler operation and efficiency.

RECOMMENDATION: Insta ll f l ue g a s tem p eratu r e gauges af ter the las t p o int of

heat recovery on all boiler s included in this study.

• In 37 percent of the boilers tested, energy savings in the 2 to 5% range can be

achieved by reducing the stack temperature.

RECOMMENDATION: Clean the heat transfer s u rfaces and/or repair the baffles to

reduce the exit flue gas tem p erature.

• Sixty-two (62) percent of the 123 boilers have not had a burner tune-up in the la st 12

months. Forty-two (42) percent of the boile rs in i ndividual buildings have never been

tuned . Burner tune-ups can typically provide ef ficiency gains in the 1 to 5 percen t

range.

RECOMMENDATION: Establish a state-wide program that requires annual burner

tune-ups.

2

# RECOM M ENDATION RELATING BOI L ER SIZE TO LO AD

• Many of the boilers in state facilities are oversized and ha ve to operate at low firing

rates (pa r tic u lar l y in th e summer) where th ey are generally les s efficient.

RECOMMENDATION: At these f acilities, identif y a boiler that can be tuned for

low fire operation.

COMMENT: It should also be noted that radiation losses (as a percent)

becom e quite larg e at lower firing rates.



# RECOM M ENDATION RELATED TO CONDENSATE RETURN

• In 39 percent (11 out of 28) of the central heating plants, condensate return is 50% or

less. A 50% loss in condensate is eq uivalent to a 6 percent energy loss.

RECOMMENDATION: Establish a program for the continuous evaluation and

repair of condensate return system s.



# RECOMMENDATIONS RELATED TO FUEL USAGE

• Fuel flow to individual boile rs is not m easured on sevent y-three (73) percent of the

boile rs te ste d. For boile rs in in dividual buildings, fuel flow is not measured on any of

the 45 sm aller boilers.

RECOMMENDATION: Insta ll f u el f l owm e ters o n boile rs larger than 50 HP. It is

also recomm ended that plant personnel track their m onthly

energy use and report it to the SEO or NCSU.

• Because of the recen t increase in the price of natu ral gas, m a ny state facilities h a ve

switched to oil firing. This switch has the po tential to create m a intenance problem s in

the future because of sulfur induced cold-e nd corrosion inherent in oil firing. As a

result, state adm i nistrators should consid er increasing their m a intenance budgets to

cover the higher m a intenance costs (expect ed to show up in about two years).

RECOMMENDATION: Increase m a intenance budgets to cover the higher

m a intenance costs.

• Facilities th at only hav e the capab ility to fi re natural gas are at risk to future price

incre a ses in natura l gas. Most of the boile rs loc a ted in ind i vid u al building s f a ll in this

catego r y.

RECOMMENDATION: Establish dual fuel capability for these boilers (e.g., low

sulfur oil or propane). If oil is selected as the second fuel,

its use should be lim ited to reduce the potential f o r

corrosion.

3

# RECOM M ENDATIONS RELATED TO EQUIPMT. & MAINT.

• The lack of parts has becom e a serious problem in m a intain in g boile rs in an

operational condition. This is particularly true for burner and control system parts –

even for system s of recent vintage (less than 10 y ears old ) . T h is problem appears to

be an outgrowth of the state’s current "low bid process." Other factors will have to be

included in the bidding p r ocess to ins u re th a t the state equipm ent purch ase s will hav e

replacem ent parts av ailable f o r at lea s t ten y ears.

RECOMMENDATION: Establish a new bid process th at considers system quality

and guaran t ees the availability of parts for at least ten

years.

• The large rb o ile rs in the centr al hea t ing pl ants are bette r m a intained th an the sm aller

boilers located in the individual buildings. Th is c a n be attribu t ed to the f act tha t the

central plants typically have staff dedi cated to their operation and m a intenance.

RECOMMENDATION: For sm aller f acilities wh ere boiler s a r e likely to b e loca ted

in individual buildings, the adm i nistration should be

encouraged to establish a m a intenance team dedicated to

the m a intenance of the boile rs in th e indiv i dual buildings.

• Som e boiler plants have experienced problem s that have persisted for years without

resolution (e.g., cavita tion in boiler feed pum ps, re duction in boiler capacity over

tim e).

RECOMMENDATION: Establish a technical ass i stance o r gan i zation (perh a ps at a

state land-grant university) with th e c a pability to r e sear ch

these problem s and provide unbiased expert

advice/ass istance.



# POLITICAL AND CULTURAL FACTORS

• At a m o re philosophical level, the poor c ondition of the boiler room s across the state

can be attrib uted to three factors:

1. The lack of education and training am ong boiler staff in boiler operating and

efficiency princip l es.

2. The lack of funds to properly m a inta in the boilers and steam /hot water

distribution equipm ent.

3. And, perhaps m o st i m portantly, the lack of top-managem e nt support. In cases

where top-m a nagem e nt support exists, factors (1) and (2) are usually not an issue.

_______________________________________________________________________

4

# IMPLEMENTING RECOMMENDATI ONS – SOME SUGGESTIONS

In light of the above analysis , the issue before us is: “How should the State of North

Carolina move forward in the developmen t of a comprehensive program to improve

boiler operation and efficiency an d reduce boiler fuel usage/cost?” As a first step, we

would offer the following suggestions:

1. Establish a policy requiri ng all boiler operators, ma intenance personnel, and

boiler plant supervisors to regularly atte nd “Boiler Efficiency Workshops” offered

by NCSU under sponsorship of the State Energy Office. State personnel would

be able to attend at no charge.

2. Establish a Technical Resource Center for Plant Operations at one of the state

supported land-grant universities to pr ovide advice, guidance and technical

assistance to boiler operators and superv isory personnel in the implementation of

the above recommendations. Without the bu rden of having to sell a particular

service or product, this Center would be able to provide unbiased advice on a

wide variety of boiler issues, as well as assisting on bid evaluation, project

oversight, and performance tes ting related to guarantees.

3. Establish a technical assistance program fo r the resolution of irritating problems

that have tended to persist for years. Examples of these types of problems are

"feedwater pump cavitation" and "boilers unable to attain full load operation."

These types of problems may be caused by a variety of factors and often cannot

be resolved in a telephone call or a single pl ant visit. Allowing these problems to

continue unattended is a disservice to the state and its citizens.

4. Develop guidelines for assisting state agencies in establishing realistic

maintenance budgets for their boilers and other mechanical equipment.

5. Develop guidelines for assisting state agenci es in determining when it is to their

advantage to switch fuels (e.g., from na tural gas to oil and vice versa).

6. Distribute to all participating State Agen cies copies of the three master summary

tables (to be provided unde r separate cover) entitled:

• A SUMMARY OF PLANT FEATURES

• A SUMMARY OF BOILER FEATURES

• A SUMMARY OF RECOMMENDAT IONS FOR EACH BOILER

These tables provide detailed informati on on the characteristics and operation of

each boiler and plant, as well as relate d recommendations. These tables will

enable plant personnel to compare their operation with others, will encourage

communication and sharing of informa tion among plant operating personnel

across the state, and will serve to motivat e and spur them to action. This process

# could be further enhanced through boiler workshops (conducted by the above

proposed Center) that highlight the su ccessful im plem entatio n of ECOs and

dem onstrates for others how it is done.

7. Introduce a program for educating our legi slators on the financ ial and operational

costs associated with co ntinual postponem e nt of m u ch needed m a intenance

projects.

TAB L E 1. ANN U A L FUE L COST FO R CENT RA L H E AT PLA N T S

FACILITY ANNUAL FUEL COST

($/y r)

U N C

- C H $ 5

, 9 2 0

, 0 0 0

Appala c hia n State Univ. $2,250,0 00

Eastern Ca rol i na Univ. (mai n camp us) $1,830,0 00

DOA - Centra l Heating Pla n t $1,714,0 35

NCS U – Yarb roug h $1,306,7 11

UNC – G r een sbo r o $1,200,0 00

Che rry Hospital $1,153,5 00

UNC – Charl o tte $1,093,6 00

A&T University $1,083,0 00

NCS U – Cate s $798,0 70

Umste ad Hospital $670,0 00

Dorothea Dix $571,6 07

Broug hton Hospital $510,0 00

McCain Corr. Inst. $500,0 00

Win s ton-S a le m State Univ. $404,0 00

Central Priso n $400,0 00

Ca swell Cent er $400,0 00

Murd och Ce n t er $286,1 14

Wome n' s Prison $275,0 00

NC Central University $273,0 00

NCS U - Vet Sch $228,0 00

NC School of Math & Science $221,8 70

We stern Ca rolina Sch. Fo r the Deaf $171,0 00

Black Mt. Ce nter $164,0 00

We stern Youth In s t i t u t e $ 1 3 4

, 0 0 0

NC Spe c ial Care $87,20 0

Gov. Moreh e ad Scho ol for the Blind $21,70 0

We stern Ca rolina Univ.

Eastern Ca rol i na Univ. (me d . sch ool)

T o t a l $ 2 3

, 6 6 6

, 4 0 7

6TABLE 2. ENERGYAND COST SAVINGRECOMMENDATIONS FOR BOILERS IN CENTRAL HEATING PLANTSAnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)UNC-CH$5,920,000Reduce Operating Pressure onNewBoiler No. 8$6,000(5)Appalachian State Univ.$2,250,000Continue to Replace Old Condensate ReturnLines to Increase Return$160,000Reduce BoilerOperating Pressure$27,000Reduce Maintenance on JohnEnglish Boilers$15,000Watch for Economizer Plugging on Oil Firing-------Eastern Carolina Univ. (maincampus)$1,830,000Continue Improving Condensate Return SystemDOA - CentralHeating Plant$1,714,035Repair Condensate Return System toImprove Return.$100,000(5)Burner Tuneupon Boilers No.2, 3, & 4 to Adjust O2and Reduce CO.(O2onBoiler No. 4 is Dangerously Low).$40,000$3,000 to$7,000/boiler(1)0.5 to 0.7Correct High StackTemperature (600F)on Boiler No. 4.$14,000(2)Improve SteamTrap Maintenance Program (Plumbing Shop)$10,000$10,0001Open SideDamper on Air Inlet Duct atRoof to DrawIn Warm Boiler RoomAir forCombustion.$8,000$1,2000.15Reduce Bottom Blowdownto3 – 5 seconds Per Blow.$5,000NegligibleImmediateRepair In-SituO2Readouts and Controls(aspart of tuneup). Improves safety.--------UNC - Greensboro$1,200,000Repair O2Trim (3 boilers)$42,000$4,000/boiler(3)0.3ModifyOne Boiler for LowLoad Operation$5,200$2,6000.5Repair Soot Blowers onAll Boilers– Particularlyfor Oil Firing$4,500$45,00010Repair FloodingProblem in Steam Tunnels$1,400(1)Cost is forinitial setup.Thereafter,annual tuning would be approximately$1,000/boiler.(2)An analysis ofthe problem must first beconducted.The solution mayberelativelyinexpensive,yieldinga goodpayback. However,the exact cause of the problem mustfirst beidentified.(3)Total cost torepairO2 Trim is $12,000(forthree boilers)plus travel expenses.(5)Problems with condensate return systems arecommon in state facilities.The cost ofrepairvaries widelydepending onthe sizeof the campus and the nature oftheproblems. Anevaluation ofthesystem isrequired before a costestimatecanbemade.(3)7AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NCSU – Yarbrough$1,306,711Insulate Oil Storage Tanks –insulation removed because of tank rust problem.$24,000Repair Condensate ReturnSystem to Increase Return –nowbeing corrected.$16,000Improve SteamTrap Maintenance Program –part of steamdistribution/condensate returnsystemnowunder repair.$16,000Repair Cold-End Corrosion onall Tubular Air Heaters –underway.$11,000(5)Burner Tuneupto Reduce O2.$11,000$3,000 to$7,000/boiler(1)Repair/ReplaceO2Trim System –required for tuneup to work effectively.$11,000$4,000/boiler1 year(bothtuneup andO2 trimrepair)Consider Switching to Lower Sulfur No. 2 Fuel Oil to ReduceCold-End Corrosionand ReduceFuture Maintenance Costs.CherryHospital$1,153,500Boilers are Oversized; Purchase Smaller Boiler for LowLoad Operation(Existing 2 boilers arerated at 66,000lb/hr each)$30,000$50,0001.7Improve Hot Water Distribution System -must beevaluated.$5,000Reduce Bottom BlowdownTime$1,000NegligibleImmediateEvaluate “Cascades” Hot Water CirculationSystem(by NCSU)UNC - Charlotte$1,093,600Repair CondensateReturn System to Increase Return –partially underway, very important)$100,000(5)Burner Tuneupon Boilers No.3 & 4$25,000$3,000 to$7,000/boiler(1)0.5NC A&TUniversity$1,083,000CombinedEffect of Burner Tuneup and ReducingFGTemp. on all Boilers$46,000$3,000 to$7,000/boiler(1)1Repair Condensate ReturnSystem to Increase Return – veryimportant.$20,000(5)Improve SteamTrap Maintenance Program$10,000$10,0001Repair FloodingProblem in Steam Tunnels$1,000(4)(1)Cost is forinitial setup.Thereafter,annual tuning would be approximately$1,000/boiler.(4)Causeandeffect of problemmust be evaluated beforethis recommendation can beconsidered forimplementation.(5)Problems with condensate return systems arecommon in state facilities.The cost ofrepairvaries widelydepending onthe sizeof the campus and the nature oftheproblems. Anevaluation ofthesystem isrequired before a costestimatecanbemade.8AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NCSU - CatesAve.$798,070Repair Condensate Return System to Increase Return –campus-wide problem nowbeingaddressed.$24,000(5)Consider Switching to Lower Sulfur No. 2 Fuel Oil to ReduceCold-End Corrosionand ResultingMaintenance –important preventive maintenancestep.$20,000$20,0001Tune Boiler forLower LoadOperation(If Boiler Continues toBe the Summer Boiler)$14,700$1,0000.1Improve SteamTrap Maintenance Program -part of steam distribution/condensate returnsystemnowunder repair.$10,000Umstead Hospital$670,000Burner Tuneupto Reduce O2(3 boilers)$11,000$3,000 to$7,000/boiler(1)1.4CleanHeat Transfer Surfacesto Reduce StackTemp.$5,000$5,0001Institute SteamTrap Maintenance Program$7,000$10,0001.5Reduce Bottom BlowdownTime$1,000NegligibleImmediateRepair BlowdownHeat Recovery$2,500$2,5001Dorothea Dix$571,607Repair Condensate Return System to Increase Return$14,000(5)Burner Tuneup- Reduce O2(4 Boilers)$7,500$1,000/boiler0.6Reduce Soot Deposits on Boiler No. 3(someanalysis is requiredto identify cause of problem).$6,000$18,0003Reduce Bottom BlowdownTime$2,000NegligibleImmediateRepair Economizer on BoilerNo. 1: Also Repair Soot Blowers(some analysis is requiredto identifycause of problem).$2,000(2)Broughton Hospital$510,000CorrectHigh StackTemperature$32,000(2)Repair Condensate Return System and Increase Return- very important$19,000(5)Burner Tuneupon Boiler No. 2 & 4 – ReduceO2 and CO$12,000$3,0000.25Reduce Bottom BlowdownTime$1,500NegligibleImmediate(1)Cost isfor initial setup.Thereafter, annual tuningwouldbeabout$1,000/boiler.(2)Ananalysis ofthe problem must first beconducted. The solution mayberelatively inexpensive, yieldingagoodpayback.However, the exact causeofthe problemmust first beidentified.(5)Problemswithcondensatereturnsystems are commoninstate facilities. The cost ofrepairvaries widely dependingonthesize of the campus and thenatureof theproblems. Anevaluationofthesystemisrequiredbefore acostestimatecan begiven.9AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)McCain Corr. Inst.$500,000Repair CondensateReturn System and Increase Return$37,000(5)Reduce Stack Temperature(the two boilers are over 50years old andmay not be worth fixing).$25,000(2)Burner Tuneupsto Reduce O2and CO -(because of boiler age, thismay not be practical).$19,000(6)Initiate SteamTrap Maintenance Program$5,000$5,0001Purchase Smaller Boiler for Summer Operation$2,500Refurbish Continuous BlowdownSystem$1,000$1,0001Reduce Duration of Bottom Blowdown$500NegligibleImmediateReplace BoilersWinston-SalemState Univ.$404,000Repair Condensate Return System to Improve Return$24,000(5)Improve SteamTrap Maintenance Program$5,000$5,0001Add Soot Blowers to BoilersNo. 1 and3 if useof No. 2 Fuel Oil Increases$3,600$10,0003Burner Tuneupon Boiler No. 2 – Adjust O2and Reduce CO$2,400$1,2000.5Burner Tuneupon Boiler No. 3 to Reduce O2and Stabilize Combustion$1,800$1,2000.7Correct High StackTemp. on Boiler No. 3$1,200$2,400(2)2Central Prison$400,000Burner Tuneup– Reduce O2$12,000$3,0000.25Reduce Stack Temp.$12,500$15,000(2)1.2Repair Condensate Return System and Increase Return$4,000(5)Initiate SteamTrap Maintenance Program$5,000$5,0001Reduce Bottom BlowdownTime$1,200NegligibleImmediateDesignateoneboiler for low-load operation$2,000$1,0000.5(2)Ananalysis ofthe problem must first beconducted. The solution mayberelatively inexpensive, yieldingagoodpayback.However, the exact causeofthe problemmust first beidentified.(5)Problemswithcondensatereturnsystems are commoninstate facilities. The cost ofrepairvaries widely dependingonthesize of the campus and thenatureof theproblems. Anevaluationofthesystemisrequiredbefore acostestimatecan begiven.(6)Theseburners arequiteold andmayhave tobereplaced.10AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)Murdoch Center$286,114Burner Tuneupfor All 3 Units(3 boilers)$10,600$3,0000.3Reduce Stack Temp. on Boiler No. 2 & 3$10,000$15,000(2)1.5Tune One Boiler for LowLoadSummer Operation$5,000$2,0000.4Re-establish a Good WaterTreatment Program$1,000$1,0001Women's Prison$275,000Correct High StackTemp.(3 boilers)$8,600$13,000(2)1.5Burner Tuneup– Reduce O2(3 boilers)$6,900$3,0000.5Increase Condensate Return$3,000(5)DesignateandTune One Boilerfor Summer Operation$1,900$2,0001Initiate SteamTrap Maintenance Program$1,600$2,0001.2Reduce Bottom BlowdownTime$1,000NegligibleImmediateNC CentralUniversity$273,000Reduce Exit Flue Gas Temperature On BoilerNo. 1.$1,000$2,000(2)1.8Conduct BurnerTuneup onBoiler No. 2$13,200$1,000<0.1OrDiscontinueAlternating Boilers No. 1 & 2 inWinter.Or$13,200$500<0.1Conduct BurnerTuneup onBoiler No. 3$1,000$8000.8Repair CampusCondensate Return System$33,000(5)Reduce Bottom BlowdownTime$500NegligibleImmediateInstall MakeupWater Flowmeter$1,000$1,0001Institute SteamTrap Maintenance Program$5,000$5,0001NCSU - Vet Sch$228,000Burner Tuneup- Reduce O2(on existing boiler)$3,000$1,0000.3Measure and Increase Condensate Return$3,000(5)Establish a Steam Trap Maintenance Program$3,000$5,0001.7DesignateandTune One Boiler for Low-LoadSummer Operation(perhapsnewboiler)$2,000$2,0001(2)Ananalysis ofthe problem must first beconducted. The solution mayberelatively inexpensive, yieldingagoodpayback.However, the exact causeofthe problemmust first beidentified.(5)Problemswithcondensatereturnsystems are commoninstate facilities. The cost ofrepairvaries widely dependingonthesize of the campus and thenatureof theproblems. Anevaluationofthesystemisrequiredbefore acostestimatecan begiven.11AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NC School of Math& Science$221,870Repair Condensate Return System to Improve Return$13,000(5)Burner Tuneupto Reduce O2and CO(Newburner controls were installedinsummer of2002).$5,000(7)Establish SteamTrap Maintenance Program$2,500$2,5001Check Effectiveness of Oxygen Removal fromFeedwater –Minimize Oxygen Pitting--------Caswell Center$400,000Correct 800 FStackTemp. on Boilers No. 2& 3and Repair Economizer Problem on Boiler No. 2.$20,000$30,000(2)1.5Increase Condensate Return$7,000(5)Reduce Bottom BlowdownTime$1,000NegligibleImmediateBurner Tuneupon Boiler No. 1 to Reduce O2$500$8001.6Black Mt. Center$164,000Burner Tuneup– Improve O2and Reduce CO$4,000$2,0000.5Replace Burneron Boiler 3.Work completedin2003. Cost =$95k. Savingsprojectedat $143k.??Initiate SteamTrap Maintenance Program$2,000$2,0001Boilers are Oversized; Designate One Boiler for Low-LoadOperation$2,000$2,0001Repair FloodingProblem in Steam Tunnels$1,000(4)Correct BoilerFeed Pump Cavitation Problem; AllowDeaerator to OperateAbove 212°F.$1,000$1,000(2)1Install makeupwater flowmeter to get amore accurate Measureof Condensate Return-------(5)ClarifyRationale for LowNoxBurner on Boiler No. 3.-------Western CarolinaSch. For the Deaf$171,000Establish a Steam Trap Maintenance Program$2,200$2,5001Burner Tuneupto Reduce O2on Boiler No. 3$2,100$1,0000.5Boiler No.1 (800hp) is greatlyoversized. Reduce RadiationLoss bynot operating800 hpBoiler.Consider sellingit to larger facilityand use the proceeds to purchase a smaller boiler.$1,500NegligibleImmediateAvoid Low-Load Operation onBoiler No.3$1,000NegligibleImmediate(2)Ananalysis ofthe problem must first beconducted. The solution mayberelatively inexpensive, yieldingagoodpayback.However, the exact causeofthe problemmust first beidentified.(4)Causeandeffectofproblemmustbe evaluatedbeforethisrecommendationcanbeconsideredfor implementation.(5)Problemswithcondensatereturnsystems are commoninstate facilities. The cost ofrepairvaries widely dependingonthesize of the campus and thenatureof theproblems. Anevaluationofthesystemisrequiredbefore acostestimatecan begiven.(7)Thenew controlswere installed one yearbeforethesurveywas conducted.Projectcostwas$108,497,withaprojected savings of$64,300/yr.(56%ofannual fuel bill.Afteroneyear ofoperation,fuelusageactually increased by13.2%.Further study isrecommended.12AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)Western YouthInstitute$134,000Convert Webster Burner to Dual-Fuel Firing(having dual-fuel capability is important)$23,400$25,000(8)1Repair Boiler Feed PumpControlsto Stop Continuous PumpOperation$1,600$3,2002Repair Water Level Float in Deaeratorand Reduce the useof Sodium Sulfite$1,000$1,5001.5Solve Feedwater Pump Cavitation Problem –Reduce Maintenance$1,000(2) (9)Repair Multiport Relief Valve onDeaeratorNC Special Care$87,200Repair Feedwater Pump Cavitation Problem and Operate Deaerator Properly(Above 212 

# °F)$2,100(10)Install MakeupWater Meter to determineCondensate Return$1,600$5000.3Burner Tuneupon Boiler No. 2 to Reduce O2$500$8001.6Boiler Tuneupon Boiler No. 1to Reduce O2at High Fire$500$8001.6Gov. Morehead School for the Blind$21,700Burner Tuneup- Reduce CO& O2$800$1,0001.25Initiate SteamTrap Maintenance Program$600$2,0003Designate1 Boiler for LowLoad Operation$300$1,0003Reduce BoilerOperating Pressure$200Western Carolina Univ.Eastern Carolina Univ. (med. school)Total$23,666,407$1,338,000(2)Ananalysis ofthe problem must first beconducted. The solution mayberelatively inexpensive, yieldingagoodpayback.However, the exact causeofthe problemmust first beidentified.(8)Final costwill dependonif anew fuel trainisrequired. Total cost estimate is $20,000to $25,000.(9)Anew bypass orifice maysolve theproblem.(10)Problemhas beensolvedwithanewbypass orifice.13