Boiler System Improvements to Enhance Efficiency


Boiler System Improvements to Enhance Efficiency


ENTRUST Solutions Group partnered with a major barge cleaning and marine repair facility to assess their steam system and recommend economic efficiency improvements.


The client had several package boilers that were used for heating water to wash barges and for boiler feedwater de-aeration. At times, only one boiler was operated in idle while two other boilers were not running. The client requested a detailed study of the boilers and steam system usage to determine if hot water heaters could economically be used to heat barge wash water instead of the steam from the package boilers.


ENTRUST Solutions Group conducted a front-end engineering design (FEED) study of the package steam boilers and steam distribution usage. The study included the boiler steam production, the tankage heat losses, the transfer pumps horsepower requirements, the steam-to-water plate heat exchanger analysis, the heat loss from the steam piping, the barge wash water flow and cleaning frequency, the cost and installation of any new equipment such as new hot water heaters, and the demolition and removal of existing equipment. A FEED cost analysis was completed and a discounted cash flow (DCF) rate of return on investment (ROI) was done to determine if the project met the client’s internal DCF-ROI hurtle rate to proceed with the project. A detailed interactive Excel program with graphics was developed to perform engineering and economic analyses.

For the cost analysis, ENTRUST provided the cost of the detailed design, including piping design, electrical design, PLC programming, equipment specifications, as well as procurement assistance and on-site construction support to meet the customer’s goal of improving the economical efficiency of the system. The ENTRUST team presented a detailed design and cost estimate to the client, and the analysis proved that the existing system was more economical to operate than investing capital for a different system. The DCF-ROI fell short of the client internal hurtle rate.

A detailed FEED study and cost analysis proved the existing system was more economical than investing in a new system.

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