SPRING 2017

TRENDS | TECHNOLOGIES | INNOVATIONS

AHEAD OF THE
CURVE
Modern coupling provides a gateway
to installation and performance under
St. Louis’ famous Arch.

HRSG Works Around Steam Stars At Field Day

Emissions And Coal Of The Past PAGE 16
Costs PAGE 10
PRESIDENT’S MESSAGE

MOVING THE NEEDLE —

PROMOTING OUR INDUSTRY

L
ast year, ABMA
refreshed To-
day’s Boiler and
received rave
reviews on the
upgrades to the content
and layout. I am pleased
to announce this refresh
has extended to the over-
all ABMA brand, and this
issue launches the new
SCOTT LYNCH ABMA logo and tagline:
Leadership for the Boiler
Industry. This continues
our evolution of the asso-
ciation and our focus on
expanding our reach and
promoting our industry.
No one event highlights
our recent advances in
these areas better than our
Manufacturers Conference
which recently took place
April 3-5 in Houston, TX.
This conference is focused on developing the
next generation of boiler industry leaders.
Conference attendance increased by almost
70% over the 2015 offering, including more
than 30 first-time attendees along with nu-
merous companies exploring membership in
ABMA. This conference also included partic-
ipation from end-users, state inspection agen-
cies, and related national trade associations.
The engagement and excitement at this event
were fantastic.
The conference agenda was a perfect mix of
overall manufacturing insights, boiler industry
trends, and development of leadership skills.
Attendees learned about advances in Cou-
plings from Victaulic, Steel Industry Trends
from North Shore Steel and a special session
on Leading with Influence led by Tony Swart
from Webco.
However, a Manufacturers Conference
would not be complete without plant tours,
and our attendees had the unique opportunity
to tour the TECO Plant at the Texas Medical
Center along with ABMA members ValvTech-
nologies and Quest-Tec Solutions.
Much of this conference also centered
around ABMA’s strategic initiative to grow the
workforce pipeline of engineers and skilled
trades for the boiler
industry. Monica Pfarr
from the American
Welding Society
(AWS) presented
their initiatives and
potential partnership
opportunities with
ABMA members, while
Mark Colman from
Rentech shared their
company’s successes
with local education
partnerships.
Prior to the start
of the conference,
the ABMA Board of
Directors met with
key leaders from
Lone Star Community
College and discussed
the industry challeng-
es with skilled trade
recruitment. Lone
Star has agreed to partner with ABMA on skill
set profiles to facilitate educational institu-
tion engagement and alignment with course
curriculum and industry needs. In addition to
the meeting with Lone Star, the conference
was attended by students and education of-
ficials from numerous local engineering and
trade schools.
At our core, ABMA remains a trade associa-
tion providing products and services for boiler
manufacturers and suppliers. To achieve our
lofty goals as an industry, we need to engage
those beyond our membership, and we are
focused on continuing down that path. We
want to help end-users use our products more
efficiently, we want to make sure installers
understand are educated as technology chang-
es, we want to make sure students realize
the great career opportunities in the boiler
industry, and we want to make sure regulatory
agencies understand our needs and capabili-
ties. We see ourselves as the organization that
can bring everyone together to take innovation
to new heights while ensuring safe installation
and operation of our products. TB
Scott Lynch is President & CEO of ABMA and
can be reached at scott@abma.com.

SPRING 2017 WWW.ABMA.COM | TODAY’S BOILER 3

I N S I D E T O DAY ’ S B OI L E R

TODAY’S
BOILER
12 TRENDS | TECHNOLOGIES | INNOVATIONS

SCOTT LYNCH
President &
Chief Executive Officer
ABMA
scott@abma.com

MIKE MURPHY
Publisher
murphym@bnpmedia.com

ROBERT BEVERLY
Senior Editor
beverlyr@bnpmedia.com
DEPARTMENTS & INFO

16 3 President’s Message
By Scott Lynch
JAMES SIEGEL
Editor
siegelj@bnpmedia.com
6 ABMA News
CARRIE HALBROOK
22 ABMA Membership List Midwest Advertising Manager
halbrookc@bnpmedia.com
FEATURE ARTICLES
RUSSELL BARONE JR.
8 Modern Coupling West Coast Advertising Manager
Victaulic baroner@bnpmedia.com

10 Recipe For Success VIC BURRISS

Rentech Eastern Advertising Manager

18 12 Growth From Within

Victory Energy
burrisv@bnpmedia.com

MELANIE KUCHMA
Project Manager
kuchmam@bnpmedia.com
14 Two Weeks At The Distillery
WARE KELLY SOUTHARD-
MITCHELL
16 Steam Power: Roots in Production Manager
southardk@bnpmedia.com
American Industry
Power Mechanical PATRICIA CATINI
Art Director
18 Corrosion Combat catinip@bnpmedia.com
BHI / AMEC Foster Wheeler

20 Boiler Water Feeding: On/Off

vs Modulating
Cleaver-Brooks

www.bnpmedia.com
AD INDEX 2401 W. Big Beaver Rd.
Suite 700
Troy, MI 48084
AERCO International, Inc...................................................................Page 7
248/244-8264
Hurst Boilers & Welding Co. ..............................................Inside Front Cover

Penn Separator Corp.........................................................................Page 6 IN PARTNERSHIP WITH

RBI. ......................................................................................... Back Cover

Victaulic...........................................................................................Page 5

Supplements Engineering Systems

Magazine. ES is a member of ABMA

4 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

DESIGNED FOR USE ON COMMERCIAL AND INDUSTRIAL STEAM APPLICATIONS

Eliminate the need to

weld steam systems
• Available in 2 – 8" | DN50 – DN200 sizes

• Pressures up to 200 psi | 1379 kPa | 14 bar

• Designed in accordance with ASME

B31.1, B31.3 and B31.9 codes to ensure
technical confidence and reliability

PRODUCT LINE ALSO INCLUDES:

Gate valve for bi-directional

shut-off service; Meets API 598
and API 600 requirements

Flexible loop to accommodate

piping movement from thermal
changes, seismic activity, and
differential building settlement

For more information visit

victaulicsteam.com/boiler

© 2017 VICTAULIC COMPANY. ALL RIGHTS RESERVED.

 ABMA NEWS
ABMA MEMBERS CELEBRATE COMPANY MILESTONES
Robinson Fans continues to
innovate after 125 Years
In 1892, Samuel and J.R. Robinson
acquired a machine company in
Monongahela and formed the Robin-
son Machine Company. Their work in
the early years laid the foundation for
the future success of Robinson Fans
(www.robinsonfans.com).
This year, Robinson Fans celebrates
125 years of a company that contin-
ues to have high standards for qual-
ity products with facilities that are
equipped with the most modern fab-
ricating facilities available, operating
under the requirements of the ISO
9001 Certified Quality Management
System. Their Zelienople plant has
the technology to fabricate metals
ranging from mild steel to some of
the most exotic alloys known to man.
Superior Boiler Works hits the
century milestone
Superior Boiler Works (www.
superiorboiler.com) is celebrating
100 years as a continuously operat-
ing business. The century milestone
has only been achieved by 1% of all
companies.
The company traces its roots back
to Hugh Gass, who opened Superior
Welding Shop on Washington Street
in Hutchinson, Kansas, in 1917.
Over the years, the company was
always considered one of the pio-
neers in the scotch-marine firetube
boiler industry, whether it related
to engineering or size. The quality
and reliability produced by Superior
Boiler’s skilled workers is a tradition
that remains a common trait of the
company today.
BFS Industries celebrating 70
years as a proud family business
BFS Industries (www.bfs-ind.com) was
founded in 1946 by John Garbarino
and now run by third generation owner
Tom Garbarino. Their journey has tak-
en them from modest beginnings in a
small fabrication shop in Brooklyn, NY,
to expanded facilities on Long Island to
our modern, state-of-the-art office and
manufacturing plant in Butner, NC.
BFS Industries manufactures a
complete line of boiler room and die-
sel generator support products, in-
cluding deaerators in spray, tray, and
packed column type; boiler feed and
condensate systems; and oil pumping
systems and day tanks.
6 TODAY’S BOILER | WWW.ABMA.COM
Nationwide Boiler - 50 years in
the boiler business
Established in 1967 for the main pur-
pose of providing emergency rental
boilers and auxiliary equipment to
steam users, Nationwide Boiler (www.
nationwideboiler.com) pioneered the
concept of mounting large package
boilers on highway-legal trailers.
Today, Nationwide Boiler is now
involved in virtually every other
aspect of the boiler industry including
boiler system sales, leasing, turnkey
installations, operations, and repair.
Their commitment to supplying the
most technologically advanced equip-
ment has been demonstrated by
the conversion of our entire fleet of
rental boilers to meet low NOx emis-
sions and our ongoing development
of high-capacity mobile boiler rooms
and portable steam plants.
Warren Environment reaches 50
years of business
Since 1967, Warren Environment
(www.warrenenvironment.com) has
furnished industry throughout the
world with exhaust systems. During
that time, Warren has designed and
manufactured approximately 1,500
stack and duct systems.
They currently produce more
custom, heavy-duty stacks each year
than any other stack supplier in the
world. With various stack designs
include free standing, tower support-
ed, braced, and guyed, applications
range from ambient air discharge to
highly corrosive saturated gases, to
high-temperature process and com-
bustion turbine exhausts.
Powerhouse Equipment - family
owned & operated for 35 years
Powerhouse Equipment (www.pow-
erhouse.com), celebrating their 35th
anniversary, started as Steam-Rent,
a small division of Penn-Jersey Boiler
in 1980 when Paul A. Stohner took
this small division and incorporated
Powerhouse Equipment in 1982.
Paul and Powerhouse quickly real-
ized the customers could not afford
downtime, so Powerhouse started
providing temporary used boilers.
Powerhouse soon decided to take
this concept several steps further
and began using new boilers and new
components. Powerhouse moved to a
dedicated facility in 1997 and has not
looked back.
SPRING 2017
 Benchmark
has gone Platinum.

Introducing AERCO’s most advanced boiler –

the Benchmark® Platinum. We’ve raised our gold
standard to an even higher level with a powerful
bundle that optimizes your system for maximum
efficiencies. You‘ll see exactly how your system
is working, know when you need to perform
maintenance and rejoice in how much you’re saving.

The Benchmark® Platinum. Performance that’s

©2017 AERCO

music to your ears.

800.526.0288 | aerco.com
V I C TA U L I C

MODERN COUPLING
PREFERRED STEAM SOLUTION PROVIDES A GATEWAY
TO INSTALLATION AND HIGH PERFORMANCE AT ST. LOUIS’
FAMOUS ARCH.

F
or almost 100 years, Victaulic has demon-
strated its couplings are the preferred
alternative to welding when joining piping
systems in the HVAC industry. However, the
most challenging of markets — steam piping —
remained untapped due to temperature and code
performance requirements that exceeded what
any existing mechanical coupling could endure.
Through conversations with customers in-
volved with the design and installation of steam
systems, Victaulic learned more about the
inherent challenges associated with time-inten-
sive traditional joining methods, including the
difficulty of welding in confined spaces, the need
for hot works permits and fire watches, and the
schedule delays that often result. As steam is
often used in critical piping systems such as hos-
pitals to sterilize equipment, at universities and
colleges to provide heat to campus buildings, and
in large cities to supply power to high-rise build-
KJWW Engineering Consultants designed the retrofit serving the
ings and businesses, the engineers at Victaulic
Museum of Westward Expansion, which became the first national
realized there was a need to develop a new coupling that monument to use this new grooved solution for saturated steam
would overcome these challenges and thrive in high-tem- and condensate piping systems.
perature environments.
In October 2015, Victaulic released their System Solu- for saturated steam and condensate piping systems. This
tion for Saturated Steam, the world’s first grooved solution product line, which includes the Style 870 rigid coupling
and a full line of fittings, was designed for use on both
commercial and industrial steam applications to elimi-
nate the need to weld steam piping, resulting in easier
installation and maintenance, compressed construction
schedules, reduced downtime and a safer, more productive
worksite. Additionally, the Style 870 coupling was designed
in accordance with ASME B31.1, 31.3, and 31.9 to ensure
technical confidence and reliability.
“Engineers have long relied on the superior performance
and design flexibility of Victaulic systems, while contrac-
tors depend on the total installed cost and time savings.
We’re pleased to bring these benefits to steam systems for
the first time,” said Kurt Gobreski, Victaulic’s Vice Presi-
dent of Valves and Large Diameter Systems. “This tre-
mendous technological advance allows those who design,
install, and maintain steam systems to experience the
absolute confidence that comes with specifying Victaulic.”
The system was designed for use on both commercial and industrial The same year the Style 870 coupling was released,
steam applications to eliminate the need to weld steam piping. This the City of St. Louis began renovations on the Muse-
creates the opportunity for easier installation and maintenance, um of Westward Expansion as part of its $380 million
compressed construction schedules, and a safer worksite. CityArchRiver 2015 project. Located under the famous

8 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

Gateway Arch, the museum project
was deemed high-profile due to its
association with the national monu-
ment. Time and safety were of the
essence, and it was vitally important
the products used on the project
were dependable, quick to install,
and cost-effective.
SystemAire, Inc., a Missouri-based
full-service mechanical contractor
and long-time partner of Victaulic
on heating and chilled water appli-
cations, was contracted to overhaul
the HVAC and saturated steam piping
systems for the museum.
Having heard of the new Style 870
coupling and corresponding fittings
from their Victaulic contacts, Syste-
mAire and the project’s engineer of
record, KJWW Engineering Consul-
tants, specified the coupling due to
their confidence in Victaulic prod-
ucts and the success of its previous
projects. As a result, the museum’s
steam piping system was installed
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SPRING 2017
using Style 870 rigid couplings and
fittings, making it the first national
monument to use Victaulic’s new
steam solution.
SystemAire knew that if they
decided to weld, they would need to
procure hot work permits and factor
in an extended fire watch, prolong-
ing the project schedule and incur-
ring additional costs. These concerns
led them to conclude that Victau-
lic’s System Solution for Saturated
Steam was the best fit for the job.
The product line’s inherent increased
safety, paired with an installation
time up to five times faster than
welding, let the team avoid unneces-
sary steps, minimize costs, and keep
the project on schedule.
“We reduced our installation time
dramatically and eliminated a three-
hour fire watch,” said Brad Stearns,
SystemAire’s project manager. “The
museum’s piping system is suspend-
ed 15 feet in the air, and it would
esmagazine.com/connect
It’s now easier than ever to stay up to date
with the latest news and information.
TM
have been extremely difficult and
hazardous for a welder to access with
heavy equipment.”
In addition to these benefits, the
reliability of the Style 870 coupling
and visually-verified installation pro-
vided assurance to the installers, the
general contractor, and the engineer
on this high-profile project.
“The innovation of Victaulic’s
Style 870 coupling brought im-
proved safety to our project, and
that was a key priority,” said Neil
Hadigan, the lead foreman for Sys-
temAire and a member of UA Local
562. “I am pleased to say the line
was commissioned with absolutely
no issues, and we consider the in-
stallation a complete success.” TB
For more information on the Style
870 coupling and Victaulic’s System
Solution for Saturated Steam, visit
www.victaulicsteam.com.
WWW.ABMA.COM | TODAY’S BOILER 9
RENTECH

Recipe For Success

HRSG UNITS PROVED TO BE TATE & LYLE’S KEY INGREDIENT
FOR WORKING AROUND EMISSIONS COMPLEXITIES AND COAL
COSTS.

A
major U.S. Tate & Lyle plant faced some
tough decisions. The processing facility’s
two coal boilers and one package boiler
had been burning low-sulfur coal mined
nearby. However, the price of local coal
grew steadily more expensive as it became more
difficult to find.
One way to improve the economics was to utilize
cheaper coal from areas such as the Powder River
Basin in the Western United States. However, that
coal had a higher sulfur content that made it diffi-
cult and potentially expensive to meet ever stricter
emissions limits.
“Future coal costs were skyrocketing,” said Jim
Lang, Senior Process Engineer at the Loudon Plant
near Knoxville, TN, part of Tate & Lyle Global Op-
erations. “Bringing in cheaper coal meant putting
in expensive pollution control equipment, and the
payback from that was much too long to make
economic sense.”
He’s talking about the addition of flue-gas desul-
furization (FGD) to remove SO2 from the exhaust flue A new boiler being installed at the Tate & Lyle plant in Loud-
gases of power plants, using methods such as the use of on, TN. The company built a new natural gas-fired generat-
ing plant in tandem with waste heat boiler technology.
alkaline sorbent or seawater to scrub the flue gas, a wet
sulfuric acid process to turn sulfur into sulfuric acid, and
dry sorbent injection systems. Another possible option was Heat Recovery Steam Generators (HRSGs) with supple-
the use of Selective Catalytic Reduction (SCR) technology; mental duct firing from Rentech Boiler Systems (Abilene,
SCR treats the flue gas with a reactant, which oxidizes it TX). Commissioning was successfully completed and the
so it can be absorbed into a catalyst. Both approaches, natural gas-fired combined heat and power (CHP) plant is
though, would be expensive. now online.
“With new regulations setting far more stringent emis- The new natural gas-fired CHP system represented a
sions limits, and our coal and electricity costs rising sharply, $60 million investment by Tate & Lyle. The result has been
it was not looking good for our future,” said Lang. significantly improved energy and operational efficiency,
as well as a reduction in greenhouse gas emissions by
ONSITE SUCCESS nearly 50%. Tate & Lyle’s global CO2 emissions will also be
Instead of adding these technologies to stay within Boiler reduced by around 10%.
MACT limits and threatening the viability of the facility, “The new facility will reduce emissions by over 2,000
management looked for a way to improve the overall eco- tons per year, satisfy our steam needs, and enable us
nomics of the plant while reducing emissions. According- to realize big saving by switching from grid power to
ly, they decided to spend a little more than it would have generating its own electricity,” said Lang. “As boiler
taken to add FGD or SCR to existing boiler production by efficiency will rise sharply, fuel costs will also be con-
revamping its steam and electricity production capabili- siderably lower.”
ties. Tate & Lyle built a new natural gas-fired generating Tate & Lyle produces all its own steam and power
plant in tandem with waste heat boiler technology to onsite instead of having to buy electricity from the grid.
boost efficiency, lower emissions, and satisfy its steam The power output of the Siemens SGT-700 matched what
requirements. the plant required. Management was drawn to the idea
The facility consists of two SGT-700 gas turbines and of CHP as the same electrical and thermal outputs could
two SGen-100A generators from Siemens Power & Gas and be achieved at much lower costs, while emissions are

10 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

minimized. In addition, it enabled the company to lower
its carbon footprint.
“The trend toward distributed energy systems gives
our customers an opportunity to implement innovative
solutions to address their power generation needs,” said
John Gibson, Head of Sales North America, Siemens Power
& Gas. “By generating electricity on-site and recovering
heat that would typically be wasted, Tate & Lyle not only
increases energy efficiency, but also substantially reduces
energy costs and carbon emissions.”
The Rentech HRSG recovers energy from the exhaust
stream of a turbine. As supplemental duct burners are in-
cluded, Tate & Lyle intends to run them regularly to double
steam production. Land added that he himself and others
in the plant had dealt with the company before on other
jobs. Tate and Lyle had purchased a packaged boiler from
Rentech several years before for another plant and had a
good experience with that installation.
The old boilers, however, are not being scrapped. The The HRSG unit recovers energy from the turbine’s exhaust
production demands of the Loudon facility mean that stream, and supplemental duct burners can double steam
they are being retained. As well as increasing overall production when deployed.
steam output, they can act as backup during HRSG
maintenance periods. up,” said Lang. “The coal boilers will sit cold unless we
“The HRSGs and duct firing will supply the primary have an outage, in which case they will be fired up for
steam with our package boiler being used as a hot back- steam production.” TB

What are you watching?

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SPRING 2017 WWW.ABMA.COM | TODAY’S BOILER 11
V IC TORY ENERGY

Growth From Within

LISTENING WELL AND MAXIMIZING THE FRUITS OF
ENGINEERED-TO-ORDER SOLUTIONS ARE TWO COMPONENTS
OF A SUCCESSFUL, ORGANIC BUSINESS PHILOSOPHY.

T
he “build it or buy it” debate rages on unabat-
ed about which is the best method of business
growth to employ — organic or inorganic. It’s
been discussed and dissected for decades.
Each approach has staunch advocates and keen
detractors. Despite not always being on the same page
about the best approach to realizing business growth,
there is overwhelming consensus among business leaders
about the necessity of achieving growth through new
products and services in order for companies to remain
vibrant. It’s a case of being distinct or becoming extinct,
with new products and services being the determining
factor on your ultimate business fate.
Industry best practices indicate that close to 30% of
sales must be derived from new products that have been
launched over the past three years. This puts tremendous
pressure on developing products that are market validat-
ed and meet user application requirements — both those
spoken and unspoken. It comes down to how much actual
customer value is being created through new product
development. Innovative companies such as 3M, long re-
nowned for being zealots in product innovation, map their
efforts through a Product Development Vitality Index.
Inorganic growth, usually realized through mergers or
acquisitions, offers immediate return with product and
services in place that complement a company’s current
offering. Organic growth takes longer, is harder, and
comes in three forms: increased output, customer base
expansion, or the Holy Grail: new product development.
That route is time-consuming, stretches resources, and
requires tremendous nurturing. High-performance, organic
growth companies realize at least 10% of sales being de-
rived from organic growth year over year.
THE BIG PICTURE
Since the inception of the business, Victory Energy has
been all in with product development that comes from
within the walls of the company. The overriding goal for
product development at Victory Energy is focused entirely
on creating value through products that are right for the
market, customer, and application. The new product or
service must pass a stringent test. Does it create more
value for the customer? It often means tackling tough
challenges or entering new market adjacencies and going
far beyond and breaking down “niche” perceptions. It
involves bold decisions that require significant amounts of
capital.
PAYING OFF VERTICAL INTEGRATION
Vertical integration is an integral element in delivering on
the Victory Energy concept-to-completion positioning. It is
the essence of organic growth being manifested in action.
The company is migrating increasingly closer to achieving
a position of total vertical integration on the company’s
boilers, combustion, and heat recovery products. The
drive to manufacture and produce under one roof every-
thing that goes into and on our products is a relentless
pursuit at Victory Energy.
After many years of product development initiatives and
voice of the customer research that revealed considerable
market reception, the company embarked upon a major
program to develop a comprehensive line of burners. The
burner line made strategic sense for the business and
further reinforced the vertical integration promise. The
Vision® line of burners, with over 13 different product
configurations, was introduced in 2014. Today, several
Vision burners are operating on boilers around the globe.
The Vision burner is an integral part of the overall
Victory Energy Combustion Controls business that offers
combustion controls and fuel train product competen-
cies. Investments in engineering talent and resources are
providing validation that Victory Energy is all in on the
combustion side of the business.
PRODUCT LINE EXTENSION — THE RIGHT
REASONS
Although primarily identified as a strong and valued indus-
trial boiler manufacturer, Victory Energy was perceived
as a credible player across a specific niche of wetback

12 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

firetube boiler applications.
Missing was a complete line of
dryback firetube products to
both enhance and complete
the company’s firetube prod-
uct offering. A distribution
sales network to call on the
extensive firetube business
base wasn’t in place.
At the same time, the mar-
ket was asking Victory Energy
to enter the firetube business
in a big way. Many customers
and distributors felt there was
a significant need for another
player. This market valida-
tion provided the impetus for
Victory Energy to go all in to
achieve organic growth with
firetube boilers. Product line
extension was the right busi-
ness decision.
Rather than employ an
inorganic acquisition strategy,
A specific set of circumstances and challenges described by
the company made the conscious decision to build a com-
university and hospital customers prompted work that even-
plete firetube product portfolio by converting the existing
tually led to a full commercial line of high-temperature hot
Cushing operation to be dedicated to manufacturing only water fluid generators like this one.
firetube products. The product line was expanded to meet
any and all user applications. A nationwide distribution
network was put in place, with regional managers charged upon the findings uncovered. Commercialization of “one
with sales management and training. Internal engineering off” product concepts is an efficient way to capitalize on all
and sales resources were recruited to quote products and of the engineering and manufacturing time invested. The
help manage projects through the plant. All of this was result is organic growth opportunities.
accomplished within a one-year window. One such product that evolved out of the End Market
This year, the expansion of the firetube business con- work is the GENESIS HTHW — High Temperature Hot Wa-
tinues unrestricted with the further penetration of Victory ter Fluid Generator. Increasingly, educational institutions
Energy into Latin America. Plans are to have 20 distribu- — (especially colleges and universities), hospitals, and mu-
tion relationships in place throughout the region by the nicipalities — are migrating to using high-temperature, hot
end of 2017. water fluid generators to provide campus-wide heat. It’s
a trend that continues in all sections of the country. The
MARKET NEED — THE VOICE OF THE CUSTOMER insights gained about what customers required in these
Product development ideas are everywhere and are voiced products informed the product development of GENESIS.
by customers in many different ways. Opportunities exist
to seize on them if you’re acutely listening to customers MISSION: ORGANIC GROWTH
and salespeople alike. That is one of the fundamental core Organic growth comes in many different forms. There is
competencies of the Victory Energy End Market — working no set formula for how to implement a methodology that
hand in hand with endusers. Being in front of them and works for the company and culture. There are always the
listening to their frustrations and challenges is invaluable. inevitable cultural and integration challenges that occur
It is essentially organic product growth practiced on the fly along the way. Resources are stretched and focus can be
in real life applications. diverted from the core mission. Capital is often strained.
The group actively employs an ETO (Engineered to New product development programs require discipline and
Order) product way of thinking and working. In many in- accountability
stances, it helps tailor a product around a particular set of What can’t be overlooked is the vast importance of
application requirements where standard product config- uncovering ways to grow a business organically. It’s the
urations won’t or don’t work. There is intensive engage- responsibility of everyone who has a customer-facing role
ment with the customer with rigorous engineering and in the business. Ideas for growth are valued at Victory
thermal analysis effort required to solve their challenges. Energy. The next product innovation, evolution, or exten-
Many times these “one off” Engineered to Order products sion is always close by. These are all best-practice growth
become a standard Victory Energy product offering based strategies that Victory Energy lives by. TB

SPRING 2017 WWW.ABMA.COM | TODAY’S BOILER 13

WA R E
TWO WEEKS AT THE DISTILLERY
IT’S IMPOSSIBLE TO COORDINATE AND COMPLETE A MASSIVE
DEMOLITION AND INSTALLATION PROJECT IN 14 DAYS … OR IS IT?
M
ost people think of a trip to a distillery as a “day
off,” but not the team at WARE.
In early 2014, Heaven Hill Brands contacted
WARE to replace an old boiler at its distillery in
downtown Louisville, KY. The complexity of the project
ensured that it would be anything but a “day off” for the
team at WARE.
Heaven Hill didn’t just need a new boiler installed — they
also needed an old boiler to be demolished and replaced.
The new boiler would need new valves, pipes, pumps, and
a new de-aerator (DA) system.
The project totaled 50 weeks, and while it wasn’t rocket
science, it was pretty close.
SELECTION & TRANSPORT
Early-stage meetings between WARE, Heaven Hill, and the
engineering firm used for the project, Vitok Engineers,
Inc., determined the need for an 82,500 pounds per hour
(PPH) Victory Energy boiler. The boiler’s design not only
had to account for the current needs of Heaven Hill, but
also the specifications of the boiler being replaced.
During the planning stages, Mitch Kennedy, engineer-
ing consultant at WARE, realized that the distillery would
benefit from a different burner as well. He recommended a
high-efficiency Limpsfield burner to save on fuel costs. The
burner would allow the new boiler to use 15% less fuel.
After seeing the potential savings, Heaven Hill opted to
install the Limpsfield burner, which ended up saving the
distillery about $140,000 per year.
“We’re able to do the same thing we’ve been doing a lot
cheaper,” said Roy Nall, Maintenance and Distillery Super-
visor at Heaven Hill.
The size and specifications of the new Victory boiler
required that it be custom-made, which necessitated a 34-
week lead time. The 35-ft boiler was too large to travel by
more traditional means, so it had to be transported by rail.
WARE had to partner with the rail company to make
sure that the boiler didn’t get held up in any railyards.
Each day, the rail company would communicate the boiler’s
status to WARE, who would then pass that information to
Heaven Hill.
If that doesn’t make things interesting enough, consider
the fact that Heaven Hill is an operating distillery. Accord-
ing to Nall, the process is a “one-time shot.”
“We have to have perfect steam going into the still
exactly the way that it was done since prohibition. So we
don’t have the ability to go back and do it again,” he said.
ONE SHOT (AND ONE SURPRISE)
There was a two-week production window in which the old
boiler had to be demolished and the new boiler, burner,
14 TODAY’S BOILER | WWW.ABMA.COM
pumps, piping, valves, and DA had to be installed.
Installing the 100,000 PPH BFS Industries DA and con-
trols required pulling a section of roof off the facility and
using a crane to drop it in.
As if things weren’t already complicated, the old DA and
feedwater were running differently than what was required of
the new system. So, the WARE team had to call an audible in
the middle of the project to accommodate the new equipment.
The days during that two-week window were long.
“Some days longer than others,” says Kennedy between
laughs. “We did a lot of pre-planning to try to make that
transition as smooth as possible.”
“To do the amount of work in a two-week period … was
phenomenal, and especially the ability that WARE had to
support that,” said Nall.
According to Nall, Heaven Hill didn’t just want a boiler or a
burner. They wanted the whole package: boiler, DA, pumps,
engineering support, and the trusted relationship with WARE.
Kennedy understands the value of that partnership.
“We’re not there to just sell you something and leave.
We’re there to be a partner with you and make sure that
you stay in business.”
The value of that relationship was not lost on Heaven
Hill, who turned around a few months after completion and
ordered the installation of another 50,000 PPH boiler and a
DA system to go with it for an expansion project elsewhere
at the distillery.
According to Kennedy, “That’s a testament to how well
the first project went.”
Nall seems to agree, “It was a great decision to use WARE.”
Kennedy has been at WARE for 15 years and has been
partnered with Heaven Hill for nearly as long. “I think the
partnership that WARE tries to form with our customers
and be a resource for them — not just a parts company —
goes a long way,” he said.
The success of this project and the promise of a future
one indicate just that. TB
SPRING 2017
 Since our founding in 1888, the boiler industry and our member
base has relied on the American Boiler Manufacturers Association
(ABMA) to lead the industry as it tackles challenges and embraces
opportunities in our constantly evolving sector. Through participation
with ABMA, our members are better informed, connected, and
positioned to thrive in today’s global boiler industry.

ADVOCATE CONNECT ADVANCE

ABMA is the regulatory ABMA brings together ABMA raises awareness of
voice in Washington for industry leaders to foster the boiler industry for all
the boiler industry. innovation in today’s stakeholders: member
boiler community. companies, workers,
and end-users.

Learn more about ABMA programs, membership,

events and resources, visit ABMA.com.
POWER MEC HANIC AL , INC .
Steam Power: Roots in
American Industry
I
n today’s fast-paced and constantly evolving society,
trends in technology, software, and even equipment
can sometimes become nearly obsolete in only a short
time after being adopted. With global research in nu-
merous industries, it’s an ever changing and competitive
marketplace to say the least. Developments in engineering
methods and practices today would likely have raised an
eyebrow or two 30 years ago, or possibly would’ve been
smiled at as genius. Regardless of the industry, the bar
is constantly being raised. Inarguably, most of today’s
engineering practices and techniques are still built off of
some of the earliest methods. Now to bring it to a relative
level, there is a common denominator in most industrial
processes that we all know quite well: Steam.
For decades, steam has served an integral role in our
way of life. Countless products, processes, and industries
rely on a continued alliance from the product many of us
play a role in providing. As it sits, steam certainly does
not look to be a factor that will be leaving these equa-
tions, although (like all other engineering) it has and will
change with continual improvement. Facilities now can use
a single boiler in place of plants once operating off multiple
units with much larger footprints and lower efficiencies.
Packaged boilers for light commercial applications are now
rolling off the factory floors, not much larger than the
average refrigerator in our homes.
Rick Reuter, President of Power Mechanical Inc. (Newport
News, VA) has through the years seen many changes in the
boiler industry. Take 1985, when the four-man mechanical
outfit found its way onto the rental scene, the rental fleet
and customer plants didn’t always offer a lot in terms of
16 TODAY’S BOILER | WWW.ABMA.COM
BY EDWARD MCKELLAR
newness. The technicians generally had a diverse array of
equipment, from modern to not so much, that they needed
to be familiar with. The troubleshooting and maintaining
of the various manufactures, designs, and ages certainly
gave Power Mechanical Inc. a chance to “pay their dues.”
The hearty design of most boilers offers a lot in terms of
longevity. Power Mechanical takes great pride in being loyal
to the equipment and keeping it maintained properly.
A 150 HP Corliss Steam Engine (left), with a 12-foot
flywheel, powers this fully functioning saw mill just
as it would have been used nearly a hundred years
ago. Today, vintage equipment also stamps out ice
cream spoons for onlookers at Field Day Of The
Past.
There are a handful of those rental boilers from
the earliest days of Power Mechanical that are still
pumping out steam. As this article is being written, Power
Mechanical’s very first mobile boiler is on rental at a local
college with zero service calls since its connection and
startup. With proper operation and maintenance, these well
engineered systems can last many decades. Power Mechan-
ical Inc. has grown from those early days of a small shared
office space to multiple facilities comprising 25 acres and
over 100 employees. The team is now shipping rental and
reconditioned boilers, chillers, and other facility equipment
around the world. With a much larger and newer rental fleet
these days, the company can meet near any steam or hot
water demand a plant may require.
It’s common within most businesses to find that many
of the owners and founders generally started out with or
developed a fondness for the historical relics and aspects
of their enterprises. As with Rick growing up, it started with
trains and then on into the intrigue of that which powered
SPRING 2017
them. That very same desire propelled a group of enthu-
siast to start what was expected to be a small exhibition
of steam powered engines nearly 25 years ago. The event
proved to be a success, and it grew from there. Much like a
county fair type venue, Field Day of the Past is packed with
historical themes and industrial and agricultural relics.
Every September, this show kicks off and visitors flock
in to enjoy the offerings of the event. Making your way
past the main gate, amidst the ambient sounds of crowds,
carnival rides, distant tractor pull, and rattles from an
antique farming machine, a recurring hum can be heard as
you near the aft section of the grounds. With every step a
faint and familiar hissing, mixed with that buzzing sound,
becomes clearer. As the sound of steam and the now
evident buzzing of a saw blade drowns out the surrounding
show, you’ve arrived at the center stage of the event. The
Earl Liesfeld’s Steam Powered Sawmill, constructed and
operating in a nearly exact fashion of a mill dating back to
the early 1900s.
Spectators can get an up close look at just how those
logs were milled down into usable pieces of lumber. The
150 Horse Power Corliss Steam Engine affixed with a 12-ft
diameter flywheel and turning at approximately 100 RPM
disperses the needed power to various other belt driven
implements for the plant’s production. The 48-in saw blade,
which likely earns the most attention, spins at over 550
RPM and onlookers can witness the ease of its cutting these
logs to nearly exacting standards. Logs are milled into piec-
es that will be shipped on for further processing as railroad
ties. Drops from each log will be planed down for pallets.
Around the back of the mill, a retired steam condenser
from the historical Brown’s Island in Richmond, VA can
be seen resting quietly among the collection of relics.
Brown’s Island is cited to have been powering surround-
ing areas with coal and hydro-electricity from two plants
by 1899. Many spectators will pass through without much
thought on the matter. Simply just another old machine.
However, the condenser and the potential role it played
The 48-in saw blade slices easily through the green lumber as
the cross ties quickly cut with a near modern day precision.
SPRING 2017
Back in the 21st century, this type of portable boiler
equipment arrives each year to support assorted activities
at the event.
for numerous businesses and families during its career will
give visitors a deeper appreciation of all the industrial and
agricultural contraptions on display.
Around another corner, you’ll notice a gathered crowd
watching intently as something is being crafted. The curious
can watch wood being milled into sheets of veneer, then
forwarded on over to a die cutter, stamping out little ice
cream spoons. Just to the side of this operation, blocks of
wood are placed into the vice of a rotary cutting machine
that spins furiously as stacks of another carved style wood-
en spoon are created. Visitors are welcomed and encour-
aged to take advantage and stock up on their woodenware.
Just down the hill from the sawmill, you can use one of
your fresh off-the-mill spoons to sample some of the sor-
ghum molasses made fresh right there like it would have
been decades ago. The entire show offers much more
in terms of family entertainment and educational fun.
Though getting to see some of these early methods of
industry can be quite the spectacle, it’s only the tip of the
iceberg in terms of things to see. Many of the machines
are there just going through the motions for the show,
while some like The Sawmill are in full production mode.
These century-old steam driven machines affirm the
necessity and longevity of steam in all industries. As a
provider of this invaluable commodity, it’s important to
keep its origins and traditions as alive as possible. Power
Mechanical Inc. is proud to annually sponsor the event,
donating the rental of a mobile boiler room with high-pres-
sure steam to run the sawmill and other exhibits. You
can see a video with more information on the event and
the sawmill at Power Mechanical Inc.’s You Tube Channel
(https://www.youtube.com/watch?v=Oucup2svgB0). Rest
assured, there’s nothing like the real thing. If you ever
have the chance to visit Field Day of the Past in Rockville,
VA, you won’t leave disappointed.
As with the sawing of logs, making molasses, electric-
ity, and even ice cream spoons, many other industries,
products, and processes are changing daily. With boilers,
while a lot has remained fairly consistent over the past
three decades, a lot has certainly changed as well. Power
Mechanical Inc. is excited to see what the next 30 years
brings to our thriving industry. It’s without a doubt that
the best is yet to come. TB
WWW.ABMA.COM | TODAY’S BOILER 17
BHI /
AMEC FOSTER WHEELER

CORROSION COMBAT
A CERTAIN DEVELOPMENT IN PLANT DESIGN AND ASSOCIATED LOW
FEEDWATER TEMPERATURE CAN SPELL TROUBLE FOR HRSG UNITS. LEARN
THE SCIENCE OF HOW A PARTICULAR ENAMEL IS ENGAGING THE
PROBLEM, INCLUDING A SUCCESS AT A SOUTH KOREAN POWER PLANT.

A
mec Foster Wheeler is a world-leading
expert in combustion and environ-
mental control technology. Through
the Industrial Products Division of its
Global Power Group, Amec Foster Wheeler has
successfully licensed numerous technologies to
our South Korean licensee BHI. Established in
1998, BHI is a privately held company that has
successfully supplied power plant equipment
with world class quality and efficient designs.
Now being ranked in the top five HRSG suppli-
ers globally, and having been an Amec Foster
Wheeler licensee since 2005, BHI has used
their expanding experience base to develop and
implement a novel concept in cold-end HRSG
corrosion that it can now offer to the market. Enameled fin tubes after three years of actual operation.
Combined cycle power plants are gaining
wider acceptance due to increasing availability of natural
gas and distillate oil, higher overall thermal efficiencies,
short duration of construction, and fast start-up capa-
bilities. One of the key advantages of these combined
cycle power plants is that unlike other conventional fuel
power plants, the plant can run with daily start-and-stop
(DSS) operation mode, providing flexibility to the owners
in terms of electricity generation. However, such a mode
Visual inspection of the fin tube specimens after four years
of operation.
also has a side effect: the heat recovery steam genera-
tor (HRSG) has to suffer due to corrosion of the fin tubes
located at the low temperature zone of the HRSG. These
HRSG use relatively cold feedwater from sources like
the condenser hotwell storage tank. A risk introduced by
this design is that if the feedwater temperature is below
the water-vapor dew point temperature of the turbine
exhaust gas, then corrosive condensation will form on
HRSG fin tubes. The section most affected by this dew
point corrosion is the LP (Low Pressure) economizer, the
tube rows prior to the stack. As soon as the feedwater
temperature falls below the dew point, a series of acid
reactions take place that create an aggressive corrosion
process capable of attacking carbon steel. To avoid such a
corrosion process, most of the HRSGs operating today are
designed for base load where feedwater inlet temperature
is maintained above the dew point or else the unit utilizes
high-cost material with adequate corrosion resistance.
However, the number of startup and shutdown sequences
that HRSGs actually are experiencing is large (for exam-
ple, over 100 daily starts-stops in a year), as market con-
ditions have forced most combined cycle plants from base
load operation to cycling operation. As a result, HRSGs are
experiencing too many instances of idle time when it was
designed for continuous operation, so the equipment is
open to much risk of gas side corrosion from the humidity
in ambient air. Such frequent idleness increases exposure
to wet weather, boosting the potential for damage un-
less preventative action is taken. Rainwater and humid-
ity entering through an open stack also help drive the

18 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

corrosion process. Another driver is the change in ambient
temperature between daytime and night time, where the
tube metal temperatures lag behind the daily high ambient
temperatures. The corrosion process can also contribute
to a decrease in thermal efficiency and an increase in draft
losses on the long term; fin tube corrosion and the scat-
tered rust powder by dropout fins may also cause environ-
mental pollution. To prevent or limit the effect of corrosion
during cycling operation, power plant owners are recom-
mended to conduct regular inspections and cleaning of the
fin tube surfaces. The ultimate solution to such corrosion
is to use corrosion-resistant materials (for example, stain-
less steel) — the only reliable and lasting but expensive
solution. Here is where BHI’s patent technology comes
in. (The patent is registered in Korea and the U.S.) BHI’s
enamel-coated carbon steel fin tube is a development of a
technical solution as an alternative for expensive stainless
steel tubes to help HRSGs against corrosion problems.
Enamel is a type of glass specifically produced for the
corrosion protection of metals with a particular chemical
composition and physical features that — partly enriched
with additives — can be molten onto steel plates. Enamel
is thus absolutely non-pollutive and a unique compound
material made of glass and metal. The major characteristic
of the enamel is that it has a good coverage of the sur-
face while excluding the risk of thickening. Furthermore,
we have developed an optimum chemical and mechan-
ical enamel coating method for corrosive conditions of
HRSGs. Using a proper coating will considerably extend
the lifetime of equipment in the aforementioned scenario
of a corrosive environment below the acid dew point. The
use of the low-priced enameled fin tubes will improve the
availability and reduce maintenance costs. Because of the
low temperature, the high moisture, and the additional
carry-over of droplets, fin-tubes in the HRSGs are always
fitted with an enameled coating surface. In order to qual-
ify for the use as a corrosion protection agent in HRSGs,
the enamel must meet the following criteria:
- High chemical resistance against the aggressive flue
gas constituents (acid, water vapor) - High mechanical
resistance against flue gas and sufficient resistance during
Ten observation points were selected and were installed with
different types of fin tubes.
SPRING 2017
Different types of fin tubes were welded at the existing fin
tubes and were field tested for four years.
soot-blowing and water washing of the fin-tube packages -
Homogeneous coating thicknesses in respect to the profile
geometry.
Compared to carbon steel fin tubes, the enamel qual-
ities available today are able to increase the service life
quite considerably, thus drastically reducing the number of
fin-tubes required. An actual field test was conducted to
HRSGs operating at Shin Incheon Combined Cycle Power
Plant, South Korea, owned and operated by Korea South
Power Company (KOSPO). The power plant has operated
for 18 years and was designed to operate with continuous
operation mode. However, the market situation forced the
plant to run with DSS mode, and then the plant experi-
enced a significant corrosion problem. Also, environmental
issues may occur when the corrosion particles leave the
HRSG through the main stack. In 2008, the plant decided
to study with BHI regarding the application of the enam-
eled fin tubes. BHI installed different specimens in the ex-
isting HRSGs within the plant and observed the conditions
of the fin tubes for four years. Comparing results from the
corrosion-affected enamel-coated specimen with those
of the normal metallic substrate shows very clearly the
fact that enamel coating has a good corrosion resistance.
Satisfied with the field test, KOSPO decided to replace all
evaporator and economizer sections of its eight units of
HRSGs with enameled fin tubes in 2012. Since installation
in 2013, the eight units have operated with DSS and have
not experienced further corrosion problems. HRSGs are
susceptible to corrosion at the flue gas exit points. Fouling
and corrosion are the most serious problems in the recov-
ery of heat, decreasing thermal efficiency and scattering
the rust powder through the stack. In conclusion, the use
of this advanced enamel coating process can help signifi-
cantly delay the cold-zone corrosion problems currently
experienced by most of today’s operating HRSGs, with sig-
nificant economic advantages in cost difference as well as
material availability as compared to stainless steel tubes.
This enamel coating process is not only used for HRSGs
but can also be applied in other types of power plants that
require the presence of fin tube type heat exchangers. TB
WWW.ABMA.COM | TODAY’S BOILER 19
C L E AV E R - B R O O K S
BOILER WATER FEEDING:
ON/OFF VS. MODULATING
Long-term benefits may make the case for making the investment.
T
he question facing many consulting engineers to-
day is whether to specify on/off operation or mod-
ulating continuous feed when boiler size is between
250 and 1,200 hp. To answer this question, it is
important to understand the difference between the two.
Figure 1 shows a typical on/off piping arrangement for
a single- or multiple-boiler application. With this piping
scheme, a single- or multiple-pump arrangement (one is
standby with manual switching) is dedicated to a single
boiler, and its operation is triggered by the low-water-cut-
off and pump control on the boiler, which is electrically
tied into the pump circuit and actuated when a specific
level is reached in the boiler.
Compare this piping scheme to one using the modulat-
ing continuous feed control (Figure 2), and feeding based
FIGURE 1
FIGURE 2
20 TODAY’S BOILER | WWW.ABMA.COM
BY STEVE CONNOR
on the water level in the boiler as it gradually reduces due
to the evaporation of water to steam leaving the unit.
In this case, the pumps are pumping into a common
(pressurized) manifold serving all the boilers connected to
it and drawing from a single-feed tank (vented receiver or
deaerator) as was the case with the on/off arrangement
noted above.
With the modulating continuous feedwater piping
scheme, the pumps are all running constantly at full rating
with individual modulating feedwater valves controlling
the amount of flow to the boiler based on its evaporation
rate. In this case, as the feedwater valve throttles toward
closed, the piping includes a bypass (or recirculation line)
between the pump and the feed tank to keep the pump
from dead heading.
Let’s look at the advantages and disadvantages of both
approaches.
ON/OFF OPERATION
Due to its relative simplicity, it is less expensive to buy
and install an on/off piping system compared to a mod-
ulating one. Material and labor costs are lower because
there is no modulating feed valve or bypass line, and it
involves smaller pump horsepower.
However, there are considerable disadvantages with the
on/off piping system, beginning with stress on the boiler
itself.
Many of these boilers are fed from vented receivers
that can vary greatly in the feedwater temperature based
on the amount of hot condensate returning, and/or if the
tank includes a pre-heating steam diffuser, which could
increase the temperature to 180–200ºF maximum. This
being the case, the boiler is instantly fed with a large
slug of relatively cold water (boiler operating at 100 psig
= 338ºF). This causes the metal in the feed connection
area to suddenly contract, putting inordinate stress on the
welded connection. Cracks will ultimately occur, causing
leakage and eventually a boiler repair with commensurate
downtime.
A second disadvantage is starting and stopping during
many hours of operation that puts considerable stress on
the pump motor, shaft, and bearings, which leads to costly
repairs and possible downtime.
Lastly, the on/off feedwater operation often causes
problems with the boiler’s water level as it demonstrates
dramatic swings (sink & swell) and consequential boiler
trips on low water or carryover of water into the steam
SPRING 2017
 FIGURE 4

high-level or low-water conditions as well as advises

the operator when the column should be blown down
and whether it was blown down successfully.
Another key option one might consider is adding
variable-frequency drives (VFD) to the feed pump
system. The carryover can add to the possibility of water motors. A VFD dramatically reduces the electrical draw on
hammer within the steam system, which can be both de- the motor because the draw is reduced by the cube of the
structive and dangerous. speed reduction. The VFD is mounted on or near the motor
and can be retrofitted or added to new feed systems,
MODULATING OPERATION WITH mounted, and wired as a package.
CONTINUOUS FEED In addition to the VFD drive, a pressure transducer has
When comparing the on/off with the modulating continu- to be added between the pump and the feed valve(s). This
ous system, we find the modulating system offsets all the transducer will send a signal to the VFD to increase or
disadvantages of the on/off system. slow down based on the feed valve(s) opening or closing,
With the modulating continuous system, the feeding of thereby increasing or decreasing flow and pressure in the
the boiler water is closely matched to the steaming rate common manifold piping.
of the boiler thereby mitigating the stress problem. This The last value-added option to consider with the mod-
metered feeding of ulating continuous system is a PLC-based control system
boiler water also pro- (Figure 4).
vides a more stable With a PLC-based control system, all the burner-man-
water line and fewer, agement and combustion-control systems can be tied into
if any, trips and a single platform, including the level control and the VFD
certainly drier steam drive(s). Not only does this make the wiring complexity
because carryover is less arduous, but it also enables excellent system control
better controlled if and information to be gathered and trended, including
not fully eliminated. troubleshooting. This saves fuel, electricity, service costs,
The other im- and costly downtime.
portant advantage The disadvantage of a modulating continuous system is
with the modulating its cost.
continuous piping Using a modulating system requires more piping and
arrangement is the controls, which increases capital spend and includes the
possibility of employ- bypass line(s), modulating feed water valve(s), and larger
ing key value-added horsepower motor(s) because of additional piping and the
options to the boiler feedwater valve pressure drops. Adding the recommended
system to make it options, including the VFD, Level Master and C-B Hawk
more efficient and control, increases capital costs as well. However, when
reliable. looking at these additions from an internal rate of return
FIGURE 3
It starts with con- (IRR) perspective, the savings often offsets the cost in an
sidering a different low-water cutoff and pump control us- acceptable period of time. TB
ing magnetostrictive technology (Figure 3). This system
employs a red brass rod with imbedded wire and titanium
float that monitors and displays the float’s movement, Steve Connor is an industry expert in steam and hot
sending an analog (4-20 ma) signal to the modulating water generation with more than 50 years of experience.
feedwater valve to move toward open or close relative to He retired from Cleaver-Brooks as Director of Technical
the steaming rate of the boiler. and Marketing Services. Steve can be reached at
The control also signals the operator in the event of sconnor@cleaverbrooks.com.

SPRING 2017 WWW.ABMA.COM | TODAY’S BOILER 21

S PR ING 2017 ME MBE R S HIP L IS T

Victory Energy Operations, LLC Nationwide Boiler, Inc.

BOILER AND BURNER
MANUFACTURER MEMBERS VPI Precision Holdings, LLC NIULPE, Inc.
Webster Combustion Technology, LLC North Shore Steel
Alzeta Corporation
Weishaupt Corporation PanGlobal Training Systems LTD
AMEC Foster Wheeler
Williams & Davis Boilers
Applied Heat Recovery, LLC Parish Transport, LLC
Zeeco, Inc.
Babcock & Wilcox Company Peerless Aarding
Burnham Commercial Boilers SUPPLIER MEMBERS PennWell
C-B Sales & Services, Inc. Pentair Valves & Controls
Applied Water Systems, Xylem
Chanute Manufacturing Company Plibrico Company LLC
Autoflame Engineering LTD
Clayton Manufacturing Company
Bekaert Power Mechanical, Inc.
Cleaver-Brooks Powerhouse Equipment & Engineering
Benteler Steel & Tube Corporation
Cochrane by Newterra Co., Inc.
BFS Industries Quest-Tec Solutions, Inc.
Detroit Stoker Company
BNP Media / Engineered Systems
English Boiler LLC Magazine Robinson Fans

E-Tech, Inc. BNSF Logistics R-S Matco, Inc.

Express Integrated Technologies, LLC Chicago Blower Corporation SCC, Inc.

Fintube, LLC Clarage Spirax Sarco, Inc.

Forney Corporation Clark-Reliance Corporation Strategic Contract Resources, LLC
Groupe Simoneau ClearSign Combustion Corporation Synergy Catalyst
Industrial Combustion, LLC Coalition for Sustainable Rail The National Board of Boiler and PVI
Industrial Steam Cormetech, Inc. Thermogenics Inc.
John Zink Hamworthy Cust-O-Bend, Inc.
Tioga Pipe Supply Company
Johnston Boiler Company Everlasting Valve Company
Toyota Tsusho America, Inc.
Limpsfield Combustion LTD Fireye, Inc.
Tulsa Fin Tube
NATCOM Fox Equipment
ValvTechnologies, Inc.
Nooter/Eriksen GE Oil & Gas
Vector Systems, Inc.
NTFB Combustion Equipment USA, Inc. Haldor Topsoe
Victaulic
Power Flame, Inc. Halgo Power, Inc.
Wabash Power Equipment Co.
Powermaster Boiler Hays Cleveland
Ware
Preferred Utilities Mfg. Corp. Honeywell
Warren Environment, Inc.
Rentech Boiler Systems, Inc. Hooper Welding
WEBCO Industries
Riello Burners HPAC/Penton Media

Sellers Manufacturing Company HSB Global Standards PROFESSIONAL MEMBERS

Sterling Deaerator Company, Inc. Karl Dungs, Inc. JMA Consulting, Inc.

Stork Thermeg B.V. Laars Heating Ouestime

Superior Boiler Works, Inc. Maxitrol Company Senterprise Company

Trenergy, Inc Maxon, A Honeywell Company

Vapor Power International Michigan Seamless Tube, LLC

22 TODAY’S BOILER | WWW.ABMA.COM SPRING 2017

 3.0

RELIABLE. BOLD. INNOVATIVE.