# 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 SUMMARY

An analysis of 123 steam and hot water boilers has been conducted at the larger state operated facilities across North Carolina. The analysis included site visits to the facilities, interviews with boiler operators and maintenance personnel, and measurements of important variables for identifying energy saving opportunities and boiler efficiencies. The tests were conducted by NCSU as part of the Utility Savings Initiative (USI) Program administered by the State Energy Office (SEO). These tests are a necessary first step in the development of a comprehensive program to improve boiler operation/efficiency at state facilities and to reduce their overall energy costs. Of the 123 boilers tested to date, 78 are steam boilers installed in the 28 central heating plants located across the state. The remaining 45 smaller boilers (including 18 steam and 27 hot water boilers) are located in individual buildings.

The boiler test data has been categorized into two parts. Part I includes the 78 larger boilers located in the central heating plants and Part II covers the 45 boilers located in individual buildings. An analysis shows that the Part I boilers in the central heating plants have an annual fuel bill of $23,666,407 (see Table 1). For these plants, the USI Boiler Program identified potential energy savings of $1,338,000 (or 5.65 percent of the total fuel usage) (see Table 2). Fuel use data on the smaller boilers (located in individual buildings) are not yet available. When they become available, these data will be included in the subject report.

The major findings and resulting recommendations growing out of the USI Boiler Program are presented below:



# RECOMMENDATIONS RELATED TO STACK LOSS

Temperature gauges to measure the stack temperature are not in place on any of the 45 boilers located in individual buildings. This measurement is essential for the proper monitoring of boiler operation and efficiency.

RECOMMENDATION: Install flue gas temperature gauges after the last point of heat recovery on all boilers 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 surfaces and/or repair the baffles to reduce the exit flue gas temperature.

Sixty-two (62) percent of the 123 boilers have not had a burner tune-up in the last 12 months. Forty-two (42) percent of the boilers in individual buildings have never been

tuned . Burner tune-ups can typically provide efficiency gains in the 1 to 5 percent

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

tune-ups.

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# RECOMMENDATION RELATING BOILER SIZE TO LOAD

Many of the boilers in state facilities are oversized and have to operate at low firing rates (particularly in th e summer) where they are generally less efficient.

RECOMMENDATION: At these facilities, identify a boiler that can be tuned for low fire operation.

COMMENT: It should also be noted that radiation losses (as a percent) become quite large at lower firing rates.



# RECOMMENDATION 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 equivalent to a 6 percent energy loss.

RECOMMENDATION: Establish a program for the continuous evaluation and repair of condensate return systems.



# RECOMMENDATIONS RELATED TO FUEL USAGE

Fuel flow to individual boilers is not measured on seventy-three (73) percent of the boilers tested. For boilers in individual buildings, fuel flow is not measured on any of

the 45 smaller boilers.

RECOMMENDATION: Install fuel flowmeters on boilers larger than 50 HP. It is also recommended that plant personnel track their monthly energy use and report it to the SEO or NCSU.

Because of the recent increase in the price of natural gas, many state facilities have switched to oil firing. This switch has the potential to create maintenance problems in the future because of sulfur induced cold-end corrosion inherent in oil firing. As a result, state administrators should consider increasing their maintenance budgets to cover the higher maintenance costs (expected to show up in about two years).

RECOMMENDATION: Increase maintenance budgets to cover the higher

maintenance costs.

Facilities that only have the capability to fire natural gas are at risk to future price increases in natural gas. Most of the boilers located in individual buildings fall in this

category.

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 limited to reduce the potential for

corrosion.

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# RECOMMENDATIONS RELATED TO EQUIPMT. & MAINT.

The lack of parts has become a serious problem in maintaining boilers in an operational condition. This is particularly true for burner and control system parts – even for systems of recent vintage (less than 10 years old). This problem appears to be an outgrowth of the state’s current "low bid process." Other factors will have to be included in the bidding process to insure that the state equipment purchases will have replacement parts available for at least ten years.

RECOMMENDATION: Establish a new bid process that considers system quality and guarantees the availability of parts for at least ten

years.

The larger boilers in the central heating plants are better maintained than the smaller boilers located in the individual buildings. This can be attributed to the fact that the central plants typically have staff dedicated to their operation and maintenance.

RECOMMENDATION: For smaller facilities where boilers are likely to be located in individual buildings, the administration should be encouraged to establish a maintenance team dedicated to the maintenance of the boilers in the individual buildings.

Some boiler plants have experienced problems that have persisted for years without resolution (e.g., cavitation in boiler feed pumps, reduction in boiler capacity over time).

RECOMMENDATION: Establish a technical assistance organization (perhaps at a state land-grant university) with the capability to research these problems and provide unbiased expert

advice/assistance.



# POLITICAL AND CULTURAL FACTORS

At a more philosophical level, the poor condition of the boiler rooms across the state

can be attributed to three factors: 1. The lack of education and training among boiler staff in boiler operating and efficiency principles. 2. The lack of funds to properly maintain the boilers and steam/hot water distribution equipment. 3. And, perhaps most importantly, the lack of top-management support. In cases where top-management support exists, factors (1) and (2) are usually not an issue.

_______________________________________________________________________

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# IMPLEMENTING RECOMMENDATIONS – SOME SUGGESTIONS

In light of the above analysis, the issue before us is: “How should the State of North Carolina move forward in the development of a comprehensive program to improve boiler operation and efficiency and reduce boiler fuel usage/cost?” As a first step, we would offer the following suggestions:

1. Establish a policy requiring all boiler operators, maintenance personnel, and boiler plant supervisors to regularly attend “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 provide advice, guidance and technical assistance to boiler operators and supervisory personnel in the implementation of the above recommendations. Without the burden 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 testing related to guarantees.

3. Establish a technical assistance program for 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 plant 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 agencies in determining when it is to their advantage to switch fuels (e.g., from natural gas to oil and vice versa).

6. Distribute to all participating State Agencies copies of the three master summary tables (to be provided under separate cover) entitled:

A SUMMARY OF PLANT FEATURES

A SUMMARY OF BOILER FEATURES

A SUMMARY OF RECOMMENDATIONS FOR EACH BOILER

These tables provide detailed information on the characteristics and operation of each boiler and plant, as well as related recommendations. These tables will enable plant personnel to compare their operation with others, will encourage communication and sharing of information among plant operating personnel across the state, and will serve to motivate and spur them to action. This process

# could be further enhanced through boiler workshops (conducted by the above proposed Center) that highlight the successful implementation of ECOs and

demonstrates for others how it is done.

7. Introduce a program for educating our legislators on the financial and operational costs associated with continual postponement of much needed maintenance projects.

TABLE 1. ANNUAL FUEL COST FOR CENTRAL HEAT PLANTS

FACILITY ANNUAL FUEL COST ($/yr)

UNC-CH $5,920,000 Appalachian State Univ. $2,250,000 Eastern Carolina Univ. (main campus) $1,830,000 DOA - Central Heating Plant $1,714,035 NCSU – Yarbrough $1,306,711
UNC – Greensboro $1,200,000 Cherry Hospital $1,153,500
UNC – Charlotte $1,093,600 A&T University $1,083,000
NCSU – Cates $798,070 Umstead Hospital $670,000
Dorothea Dix $571,607 Broughton Hospital $510,000
McCain Corr. Inst. $500,000
Winston-Salem State Univ. $404,000
Central Prison $400,000
Caswell Center $400,000
Murdoch Center $286,114
Women's Prison $275,000 NC Central University $273,000
NCSU - Vet Sch $228,000
NC School of Math & Science $221,870
Western Carolina Sch. For the Deaf $171,000
Black Mt. Center $164,000
Western Youth Institute $134,000 NC Special Care $87,200
Gov. Morehead School for the Blind $21,700

Western Carolina Univ.
Eastern Carolina Univ. (med. school)

Total $23,666,407

6TABLE 2. ENERGY AND COST SAVING RECOMMENDATIONS FOR BOILERS IN CENTRAL HEATING PLANTSAnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)UNC-CH $5,920,000 Reduce Operating Pressure on New Boiler No. 8 $6,000(5)Appalachian State Univ. $2,250,000 Continue to Replace Old Condensate Return Lines to Increase Return $160,000Reduce Boiler Operating Pressure $27,000Reduce Maintenance on John English Boilers $15,000Watch for Economizer Plugging on Oil Firing -------Eastern Carolina Univ. (main campus)$1,830,000 Continue Improving Condensate Return SystemDOA - Central Heating Plant $1,714,035 RepairCondensate Return System to Improve Return. $100,000(5)Burner Tuneup on 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 Stack Temperature (600 F) on Boiler No. 4. $14,000(2)Improve Steam Trap Maintenance Program (Plumbing Shop) $10,000 $10,000 1Open Side Damper on Air Inlet Duct at Roofto Draw In Warm Boiler Room Air forCombustion. $8,000 $1,200 0.15Reduce Bottom Blowdown to 3 – 5seconds Per Blow. $5,000 Negligible ImmediateRepair In-Situ O2Readouts and Controls(as part of tuneup). Improves safety. --------UNC - Greensboro $1,200,000 Repair O2Trim (3 boilers) $42,000 $4,000/boiler(3)0.3Modify One Boiler for Low Load Operation $5,200 $2,600 0.5Repair Soot Blowers on All Boilers – Particularly for Oil Firing $4,500 $45,000 10Repair Flooding Problem in Steam Tunnels $1,400(1)Cost is for initial setup. Thereafter, annual tuning would be approximately $1,000/boiler.(2)An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However, the exact cause of the problem mustfirst be identified.(3)Total cost to repair O2 Trim is $12,000 (for three boilers) plus travel expenses.(5)Problems with condensate return systems are common in state facilities. The cost of repair varies widely depending on the size of the campus and the nature of theproblems. An evaluation of the system is required before a cost estimate can be made.(3)7AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NCSU – Yarbrough $1,306,711Insulate Oil Storage Tanks –insulation removed because of tank rust problem.$24,000Repair Condensate Return System to Increase Return –now being corrected.$16,000Improve Steam Trap Maintenance Program –part of steam distribution/condensate return systemnow under repair.$16,000Repair Cold-End Corrosion on all Tubular Air Heaters –underway.$11,000(5)Burner Tuneup to Reduce O2. $11,000$3,000 to$7,000/boiler(1)Repair/Replace O2Trim 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 Reduce Cold-End Corrosion and ReduceFuture Maintenance Costs.Cherry Hospital $1,153,500Boilers are Oversized; Purchase Smaller Boiler for Low Load Operation(Existing 2 boilers arerated at 66,000 lb/hr each)$30,000$50,000 1.7Improve Hot Water Distribution System -must be evaluated.$5,000Reduce Bottom Blowdown Time $1,000Negligible ImmediateEvaluate “Cascades” Hot Water Circulation System(by NCSU)UNC - Charlotte $1,093,600Repair Condensate Return System to Increase Return –partially underway, very important)$100,000(5)Burner Tuneup on Boilers No. 3 & 4 $25,000$3,000 to$7,000/boiler(1)0.5NC A&T University $1,083,000Combined Effect of Burner Tuneup and Reducing FG Temp. on all Boilers $46,000$3,000 to$7,000/boiler(1)1Repair Condensate Return System to Increase Return – veryimportant.$20,000(5)Improve Steam Trap Maintenance Program $10,000$10,000 1Repair Flooding Problem in Steam Tunnels $1,000(4)(1)Cost is for initial setup. Thereafter, annual tuning would be approximately $1,000/boiler.(4)Cause and effect of problem must be evaluated before this recommendation can be considered for implementation.(5)Problems with condensate return systems are common in state facilities. The cost of repair varies widely depending on the size of the campus and the nature of theproblems. An evaluation of the system is required before a cost estimate can be made.8AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NCSU - Cates Ave. $798,070Repair CondensateReturn System to Increase Return –campus-wide problem now beingaddressed.$24,000(5)Consider Switching to Lower Sulfur No. 2 Fuel Oil to Reduce Cold-End Corrosion and ResultingMaintenance –important preventive maintenance step.$20,000 $20,000 1Tune Boiler for Lower Load Operation(If Boiler Continues to Be the Summer Boiler)$14,700 $1,000 0.1Improve Steam Trap Maintenance Program -part of steam distribution/condensate return systemnow under repair.$10,000Umstead Hospital $670,000Burner Tuneup to Reduce O2(3 boilers)$11,000$3,000 to$7,000/boiler(1)1.4Clean Heat Transfer Surfaces to Reduce Stack Temp. $5,000 $5,000 1Institute Steam Trap Maintenance Program $7,000 $10,000 1.5Reduce Bottom Blowdown Time $1,000 Negligible ImmediateRepair Blowdown Heat Recovery $2,500 $2,500 1Dorothea Dix $571,607Repair Condensate Return System to Increase Return $14,000(5)Burner Tuneup - Reduce O2(4 Boilers)$7,500 $1,000/boiler 0.6Reduce Soot Deposits on Boiler No. 3(some analysis is requiredto identify cause of problem).$6,000 $18,000 3Reduce Bottom Blowdown Time $2,000 Negligible ImmediateRepair Economizer on BoilerNo. 1: Also Repair Soot Blowers(some analysis is required to identifycause of problem).$2,000(2)Broughton Hospital $510,000Correct High Stack Temperature $32,000(2)Repair Condensate ReturnSystem and Increase Return- very important$19,000(5)Burner Tuneup on Boiler No. 2 & 4 – Reduce O2 and CO $12,000 $3,000 0.25Reduce Bottom Blowdown Time $1,500 Negligible Immediate(1)Cost is for initial setup. Thereafter, annualtuning would be about $1,000/boiler.(2)An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However, the exact cause ofthe problem must first be identified.(5)Problems with condensate return systems are common in state facilities.The cost of repair varies widely depending on the size ofthe campus and thenature of the problems. An evaluation of the system is required before a cost estimate can be given.9AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)McCain Corr. Inst. $500,000RepairCondensate Return Systemand Increase Return $37,000(5)Reduce Stack Temperature(the two boilers are over 50 years old and may not be worth fixing).$25,000(2)Burner Tuneups to Reduce O2and CO -(because of boiler age, this may not be practical).$19,000(6)Initiate Steam Trap Maintenance Program $5,000 $5,000 1Purchase Smaller Boiler for Summer Operation $2,500Refurbish Continuous Blowdown System $1,000 $1,000 1Reduce Duration of Bottom Blowdown $500 Negligible ImmediateReplace BoilersWinston-SalemState Univ.$404,000Repair Condensate Return System to Improve Return $24,000(5)Improve Steam Trap Maintenance Program $5,000 $5,000 1Add Soot Blowers to Boilers No. 1 and 3 if use of No. 2 Fuel Oil Increases $3,600 $10,000 3Burner Tuneup on Boiler No. 2 – Adjust O2and Reduce CO $2,400 $1,200 0.5Burner Tuneup on Boiler No. 3 to Reduce O2and Stabilize Combustion $1,800 $1,200 0.7Correct High Stack Temp. on Boiler No. 3 $1,200 $2,400(2)2Central Prison $400,000Burner Tuneup – Reduce O2$12,000 $3,000 0.25Reduce Stack Temp.$12,500 $15,000(2)1.2Repair Condensate Return System and Increase Return $4,000(5)Initiate Steam Trap Maintenance Program $5,000 $5,000 1Reduce Bottom Blowdown Time $1,200 Negligible ImmediateDesignate one boiler for low-load operation $2,000 $1,000 0.5(2) An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However,the exact cause ofthe problem must first be identified.(5)Problems with condensate return systems are common in state facilities.The cost of repair varies widely depending on the size ofthe campus and thenature of the problems. An evaluation of the system is required before a cost estimate can be given.(6)These burners are quite old and may have to be replaced.10AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)Murdoch Center $286,114Burner Tuneup for All 3 Units(3 boilers)$10,600 $3,000 0.3Reduce Stack Temp. on Boiler No. 2 & 3 $10,000 $15,000(2)1.5Tune One Boiler for Low Load Summer Operation $5,000 $2,000 0.4Re-establish a Good Water Treatment Program $1,000 $1,000 1Women's Prison $275,000Correct High Stack Temp.(3 boilers)$8,600 $13,000(2)1.5Burner Tuneup – Reduce O2(3 boilers)$6,900 $3,000 0.5Increase Condensate Return$3,000(5)Designate and Tune One Boiler for Summer Operation $1,900 $2,000 1Initiate Steam Trap Maintenance Program $1,600 $2,000 1.2Reduce Bottom Blowdown Time $1,000 Negligible ImmediateNC CentralUniversity$273,000Reduce Exit Flue Gas Temperature On Boiler No. 1. $1,000 $2,000(2)1.8Conduct Burner Tuneup on Boiler No. 2 $13,200 $1,000 <0.1OrDiscontinue Alternating Boilers No. 1 & 2 in Winter.Or$13,200 $500 <0.1Conduct Burner Tuneup on Boiler No. 3 $1,000 $800 0.8Repair Campus Condensate Return System $33,000(5)Reduce Bottom Blowdown Time$500 Negligible ImmediateInstall Makeup Water Flowmeter $1,000 $1,000 1Institute Steam Trap Maintenance Program $5,000 $5,000 1NCSU - Vet Sch $228,000Burner Tuneup - Reduce O2(on existing boiler)$3,000 $1,000 0.3Measure and Increase Condensate Return $3,000(5)Establish a Steam Trap Maintenance Program $3,000 $5,000 1.7Designate and Tune One Boiler for Low-Load Summer Operation(perhaps new boiler)$2,000 $2,000 1(2)An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However, the exact cause ofthe problem must first be identified.(5)Problems with condensate return systems are common in state facilities.The cost of repair varies widely depending on the size ofthe campus and thenature of the problems. An evaluation of the system is required before a cost estimate can be given.11AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)NC School of Math& Science $221,870Repair Condensate Return System to Improve Return $13,000(5)Burner Tuneup to Reduce O2and CO(New burner controls were installed in summer of 2002).$5,000(7)Establish Steam Trap Maintenance Program $2,500 $2,500 1Check Effectiveness of Oxygen Removal from Feedwater – Minimize Oxygen Pitting --------Caswell Center $400,000Correct 800 F Stack Temp. 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 Blowdown Time$1,000 Negligible ImmediateBurner Tuneup on Boiler No. 1 to Reduce O2$500 $800 1.6Black Mt. Center $164,000Burner Tuneup – Improve O2and Reduce CO $4,000 $2,000 0.5Replace Burner on Boiler 3.Work completed in 2003. Cost= $95k. Savings projected at $143k.? ?Initiate Steam Trap Maintenance Program $2,000 $2,000 1Boilers are Oversized; Designate One Boiler for Low-Load Operation $2,000 $2,000 1Repair Flooding Problem in Steam Tunnels $1,000(4)Correct Boiler Feed Pump Cavitation Problem; Allow Deaerator to Operate Above 212F. $1,000 $1,000(2)1Install makeup water flowmeter to get a more accurate Measure of Condensate Return -------(5)Clarify Rationale for Low Nox Burner on Boiler No. 3. -------Western CarolinaSch. For the Deaf$171,000Establish a Steam Trap Maintenance Program $2,200 $2,500 1Burner Tuneup to Reduce O2on Boiler No. 3 $2,100 $1,000 0.5Boiler No.1 (800hp) is greatly oversized. Reduce Radiation Loss by not operating 800 hp Boiler.Consider selling it to larger facility and use the proceeds to purchase a smaller boiler.$1,500 Negligible ImmediateAvoid Low-Load Operation on Boiler No. 3 $1,000 Negligible Immediate(2)An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However, the exact cause ofthe problem must first be identified.(4)Cause and effect of problem must be evaluated before this recommendation can be considered for implementation.(5)Problems with condensate return systems are common in state facilities.The cost of repair varies widely depending on the size ofthe campus and thenature of the problems. An evaluation of the system is required before a cost estimate can be given.(7)The new controls were installed one year before the survey was conducted. Project cost was $108,497, with a projected savings of $64,300/yr. (56% ofannual fuel bill. After one year of operation, fuel usage actually increased by 13.2%. Further study is recommended.12AnnualImpementationPaybackFuel CostSavingsCostPeriodFacility($/yr)Recommendations($/yr)($)(yrs.)Western Youth Institute $134,000Convert Webster Burner to Dual-Fuel Firing(having dual-fuel capability is important)$23,400 $25,000(8)1Repair Boiler Feed Pump Controls to Stop Continuous Pump Operation $1,600 $3,200 2Repair Water Level Float in Deaerator and Reduce the use of Sodium Sulfite $1,000 $1,500 1.5Solve Feedwater Pump Cavitation Problem –Reduce Maintenance$1,000(2) (9)Repair Multiport Relief Valve on DeaeratorNC Special Care $87,200Repair Feedwater Pump Cavitation Problem and Operate Deaerator Properly(Above 212 

# F) $2,100(10)Install Makeup Water Meter to determine Condensate Return $1,600 $500 0.3Burner Tuneup on Boiler No. 2 to Reduce O2$500 $800 1.6Boiler Tuneup on Boiler No. 1 to Reduce O2at High Fire $500 $800 1.6Gov. Morehead School for the Blind $21,700Burner Tuneup - Reduce CO & O2$800 $1,000 1.25Initiate Steam Trap Maintenance Program $600 $2,000 3Designate 1 Boiler for Low Load Operation $300 $1,000 3Reduce Boiler Operating Pressure $200Western Carolina Univ.Eastern Carolina Univ. (med. school)Total $23,666,407$1,338,000(2)An analysis of the problem must first be conducted. The solution may be relatively inexpensive, yielding a good payback. However, the exact cause ofthe problem must first be identified.(8)Final cost will depend on if a new fuel trainis required. Total cost estimateis $20,000 to $25,000.(9)A new bypass orifice may solve the problem.(10)Problem has been solved with a new bypass orifice.13