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High Voltage Jet (HVJ) Electrode Boilers
PRECISION Boilers
Producing Enough Steam for a Cruise Ship, Precision’s HVJ Electrode Boilers Rule the Electric Steam Boiler Industry.
With Installations on Multiple Continents, Precision Boilers is the Expert When it Comes to Producing
Steam Using High Voltage Jet Electrode Boilers
PH 423.587.9390 Fax 423.581.1440, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.2PRECISION Boilers, Inc.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
AnMed Health, the leading hospital complex in Anderson, SC. did not expect a 50-70% jump in the cost of natural gas during a single year. With three hospitals, including the 533-bed Anderson Area Medical Center and the AnMed ambulatory campus, it was impossible to stay within their energy budget.
Using a high-effi ciency electrode boiler operating during off-peak hours at off-peak electric rates, Precision Boilers was able to help AnMed dramatically reduce energy costs immediately. During peak electric rate hours (1pm to 9 pm), AnMed’s gas boilers operate, but during off-peak hours, the system uses the electrode boiler operating at just pennies per kilowatt hour. In AnMed’s case, off-peak rates constitute approximately 80% of the time. As natural gas prices continue to rise, so do the savings realized by AnMed.
With the total investment considered, the ROI was less than two years. Since the electrode boiler quietly pro-vides virtually instant steam, switching from natural gas to electrically produced steam reduces noise in the boiler room and eliminates the possibility of an interruption in steam service.
Precision Boilers provided all the controls and exper-tise to “marry” the two system together. Real time fuel switching allows Precision’s customers to negotiate better energy rates and automatically use the least expensive energy source.
As a world-class commercial printer of catalogs and large publications, R.R. Donnelley was facing ever increasing competition from overseas printers and paperless trans-actions over the internet. Energy costs had risen signifi -cantly with recent increases in natural gas pricing.
Since R.R. Donnelley could not signifi cantly reduce the amount of steam it uses, Peregrine Corporation, an energy solutions provider, was consulted. Peregrine, after an evaluation of R.R. Donnelley’s steam require-ments, provided all the design, procurement, construction services, start-up, and training in a turn-key lump sum contract for installation of an electrode boiler from Preci-sion Boilers.
Precision Boilers and Peregrine partnered together to provide a turn-key solution to R.R. Donnelley’s problem. The project saved enough in gas costs to pay for itself in less than 18 months. The scope of the work included a 46’ X 52’ X 30’ High building including the foundation. A 33,000 kW electrical feed stretching over 330’ buried and enclosed in a concrete duct bank was provided. Precision model HVJ-438 electrode boiler capable of producing more than 100,000 lb/hr of steam was installed with an Allen Bradley PLC controller and high voltage switchgear.
Reduce Energy Costs
Precision HVJ Boilers Save Money, Space, and Eliminate Unhealthy
Emissions Associated with Fossil Fueled Boilers.
With Installations Throughout The U.S., on Several Continents, and in the Toughest Applications Such as
Nuclear Power Plants, Precision is the Industry Expert on High Voltage
Electrode Boilers!
AnMed Reduces Energy Cost With Hybrid System
World Class Paper Company, R.R. Donnelley Receives Turn-Key Solution
HVJ Installed in R.R. Donnelley boiler Room
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
3 PRECISION Boilers, Inc.
HVJ Features and Benefi tsControls-- ► Water level control integrated with the boiler master programmable logic control (PLC) au-tomatically ensures adequate water level in the shell. Water conductivity is continuously monitored by a conductivity control allowing automatic adjustment of conductivity (chemical feed system optional), an automatic blowdown process, or sounding an alarm. The control system incorporates both a pressure and current load control in the primary control system.Valves ► --Two ASME safety valves with an aggregated capacity set at not less than 3.5 PPH of kW input are supplied. A back pressure regulating valve is sup-plied for fi eld installation on the steam outlet and is incorporated into the boiler’s master PLC.Other Standard Trim Features ► --Standby heater, steam pressure gauge, boiler water temperature gauge, feedwater stop valve, check valve and 3-valve bypass, one slow opening and one quick opening blowdown valve, auto and manual air re-lease valves, steam outlet non-return stop and check valves, steam outlet gate valve with 1” free-blow vent valve, sample cooler, bypass feeder (for electrolyte), and circulation pump cooling water fl ow switches.Insulation, Casing and Terminal Guards ► --The pressure vessel is surrounded by four inches of lagged foil-faced insulation. Boiler casing is con-structed of 16 gauge steel panels. A protective screen enclosure surrounds high voltage terminals with type D Kirk-Key interlocks on the access open-ings preventing entrance unless the boiler supply switchgear is locked open.Control Panel ► --A NEMA 12 control cabinet is wired with numbered/color coded 16 gauge stranded cop-per wire. Control of the boiler is facilitated via a PLC with a human machine interface (HMI) touch screen control. The control system typically includes a tele-phone jack, modem, and communication ports that have the capability to communicate with a central digital control system (DCS) and/or building automa-tion system (BAS).Field Erection of Boiler ► --HVJ boilers are fully as-sembled and hydrotested at the factory. Various sections of piping are removed for shipping purposes and require fi eld attachement. Precision can help fi nd a turn-key partner, such as Peregrine, for fi eld erection of HVJ boilers.
Broad Voltage kW Input Range ► --Available in volt-ages of 4,160 through 14 kV and inputs of 800-50,000 kW. Listing and Code Compliance (ASME) ► --Construct-ed, National Board inspected, and stamped in accor-dance with ASME Code Section I, Part PEB. Pres-sure vessel constructed, National Board inspected, and stamped in accordance with ASME Code Section VIII. Pressure vessel shell is fabricated of ASTM SA515-70 or SA516-70 steel.Jet Nozzles with Variable Frequency Drive Circu- ►lating Pumps--Continuous duty, mixed-fl ow centrifu-gal pump(s) with variable frequency drives provide the correct fl ow rate through the boiler’s central column and jet nozzles based on input from pressure and load controls, maintaining uniform phase loading at all fl ow rates. Steel Electrodes with Replaceable Electrode ►Strike Plates--Field replaceable, reusable, high volt-age strike plates are easy to remove, reuse, and/or replace.High Grade Porcelain Insulators-- ► High voltage electrodes are insulated from the boiler by specially designed and shaped porcelain insulators. Porcelain insulators are gasketed to eliminate high pressure leaks.Operator Adjustable kW Output ► --Field adjusted by the boiler operator through a range of 0-100%. Safety Controls-- ► Limit controls shut down the boiler due to excess steam pressure, low internal water level, or excessively high internal water levels. High conductivity levels and loss of circulation pump cool-ing water are alerted by an audible alarmed.
Water Jets Inside The HVJ Boiler Strike High Voltage Plates Creating An Electrical Circuit That Produces Steam
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.4PRECISION Boilers, Inc.
3
2
1
4
5
6
(-) (+)1
2
3
4
5
HVJ models are high voltage jet-type boilers in which wa-ter from the lower part of the boiler’s vessel is pumped by either an internal or external circulating pump (1) to the nozzle header (2) and fl ows by gravity through individual nozzles (3) creating a jet of water (4) that is directed onto an electrifi ed strike plate (5). The water fl ows down the strike plate across a counter electrode (6) and returns to the lower portion of the vessel.
Electrical connections are made to the electrode assem-blies on the top of the HVJ. When in operation, electrical current passes through the electrodes (1), across the strike plates (2), through the water jets (3) into the nozzle header (4) and fi nally through the boiler vessel’s shell to the neutral line. As the water resists current fl ow, steam is produced. As the unevaporated portion of the water fl ows from the bottom of the electrode, a second electrical circuit is created as it strikes a counter electrode (5), resulting in the production of more steam. About 3% of the fl owing water turns to steam.
How Precision High Voltage Jet (HVJ) Boilers Work
Water Flow Pattern Inside HVJ Boilers Electrical Circuit Inside HVJ Boilers
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
5 PRECISION Boilers, Inc.
HVJ Arc Shielding
1
4
5
5
5
5
5
5
5 5
3
4
4
4
2
5
High voltage electrode boilers are subject to arcing in three locations: (1) through the unintentional creation of an electrical path by a stray water jet between the elec-trode and the nozzle header, (2) between the electrode and the vessel wall should foam build up on the top of the water at the bottom of the vessel, and/or (3) around the high voltage porcelain electrode insulators.
HVJ models are protected from arcing by three different methods. The fi rst method is component spacing (4). All components are precisely spaced to prevent arcing. The second method is by inclusion of an arc barrier (5). Precision is currently the only electrode boiler manu-facturer that incorporates arc barrier protection. Two barrier systems are used depending on the pressure and temperature of the boiler. The fi rst method is applica-tion of a layer of high temperature Tefl on. An alternative for application temperatures above 375°F is proprietary application of a specially formulated thermally applied multi-layer barrier. Both barriers serve as an electrical insulator between high voltage components and ground.
The third system that prevents arcing is a conductivity sensor that continuously monitors the conductivity of boiler water, automatically adjusting conductivity within acceptable levels, and providing a safety shutdown if conductivity readings exceed a preset level.
HVJ models utilize a barrier coating to protect against arcing. Although only three electrodes are shown in the illustration above, many models have 6, 9, 12, or 15 electrodes. In some cases the barrier completely surrounds the inside of the tank in the arc zone. Electrode shields are protected in areas prone to arcing.
White areas indicate protected zones subject to arcing
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.6PRECISION Boilers, Inc.
Advantages of HVJ Electrode Boilers
HVJ Electrode Electric Resistance Fossil FuelScaling Probability Low Medium High
Maintenance Low Low High
Installed Capital Cost Low/kW above 4MW Medium to High (varies with input) High
Effi ciency 99.5% (all inputs) 99+% (all inputs)40-80+ (varies dramatically
depending on cycle times and standby time)
Load Swing Response Time Very Rapid (< 5 seconds) Fast (several minutes) Slow
Steam Quality 99.95% Pure 95-99% Pure 95-99% Pure
Reliability High High Medium to High
Environmentally Friendly Yes Yes Combustion By-products Not Envi-ronmentally Friendly
Water Treatment Chemicals Required Low Low Moderately High
Damage From Low Water Condition None Possibly Replace Elements Heat Exchanger and other Melted
Components
Cold Water Shock None None Risky
Catastrophic Failure Pos-sibilities Few Few More Potential Possibilities (fuel,
burner, heat exchanger)
Insurance Cost Very Low Very Low Moderate
Footprint/MW (MMBTU) Small Small Large
Downtime AdvantagesRepairable by Maintenance
Department, Few Spare Parts Required
Repairable by Maintenance Department, Moderate Amount of
Spare Parts Required
Specialized Labor Required to Rebuild Burners, Test Combustion,
and Restart Boiler. More Spare Parts Required.
Environmental Waste Fees None None Varies By State and Local Authority
Carbon Emissions None None Yes
Escalation Rate of Fuel Price to Power Boiler
Moderate With Good Off-Peak Rates in Some Areas
Moderate With Good Off-Peak Rates in Some Areas High and Variable
Operating Noise Quiet Quiet Moderately Noisy
Roof Penetrations Required None None Vent Penetration
HVJ boilers are the perfect solution for real time fuel switching. From their low pressure standby idle state (50 psi typ.) to full output at operating pressure takes only minutes. As fossil fueled boilers are shut down, HVJ boilers immediately take over without the loss of steam capacity during the changeover.
With PLC controls, HVJ boilers can communicate with most building automation systems for remote control and monitoring of the boiler. Optional modules and program-ming may be required.
Depending on available vottage, high voltage capabilities of HVJ models can eliminate the need for costly high volt-age/high amperage transformers.
With high reliability, high effi ciency, and high steam qual-ity, HVJ boilers are the obvious solution when an electric boiler of 3-4 MW or more is required.
HVJ Boilers Versus Standard Electric and Fossil Fueled Boilers
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
7 PRECISION Boilers, Inc.
Energy Cost Comparison
The graph above can be used to fi nd the equivalent cost of electricity based on the burner tip cost of natural gas, #2 fuel oil, or propane. This comparison is relevant to energy cost only and does not take into account non-fuel costs such as maintenance, fuel handling, insurance, building requirements, testing and/or licensing/permitting.
Natural Gas Comparison Example
Determine your burner tip cost of natural gas per therm (100,000 1. BTUs) for your application and locate it on the left axis of the graph. Burner tip cost includes transport, broker fee, and adminis-trative costDetermine the approximate effi ciency of the natural gas boiler.*2. Follow the horizontal line that represents your natural gas burner 3. tip cost until it intersects the sloping effi ciency line that represents your gas boiler’s effi ciency.From the intersection of both lines, follow the vertical $/kWH line to 4. the bottom of the graph to determine the $/kWH cost that equals the burner tip cost of natural gas at your boiler’s effi ciency. When the available $/kWH from the power company are less than the breakeven $/kWH cost, the HVJ will save money.
Example: If the burner tip natural gas cost is $1.40/therm with an over-all effi ciency of 70%, using the graph and reading across from $1.40 on the left side of the graph to the 70% sloping effi ciency line, the cost of electricity, .068 $/kWH, can be found by following the vertical line to the bottom of the graph. If the utility can provide power for less than approximately $.067/kWH, the HVJ will save money on the cost of fuel. When the breakeven electricity cost/kWH is favorable, a more indepth energy savings study should be undertaken to determine the cost sav-ings potential of installing an electrode, HVJ, boiler.
If the horizontal line for the burner tip cost of natural gas, $1.40, is fol-lowed across the graph, the equivalent cost of #2 fuel oil can be found, $1.93/gallon, or propane, $1.52/gallon.
To use the cost of #2 fuel or propane as the starting point, the graph is entered from the right side based on the cost of fuel.
*Effi ciency of the boiler refers to the overall operating effi ciency, not the manufacturer’s claimed thermal effi ciency. The inset graph refl ects typical overall effi ciency ranges. Thermal effi ciency does not take into account the ineffi ciencies of cycling the boiler at various inputs for vary-ing cycle periods under real world temperature and humidity conditions or ineffi ciencies of radiation heat loss. The overall operating effi ciency of most boilers will be in the 40-70% range.
.40
.50
.60
.70
.80
.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.10
2.20
.55
.69
.83
.97
1.11
1.24
1.38
1.52
1.66
1.80
1.93
2.07
2.21
2.35
2.49
2.62
2.76
2.90
3.04
.03.02 .04 .05 .06 .07 .08 .09 .10 .11 .12 .13 .14 .15 .16 .17 .18 .19 .20 .21 .22 .23 .24
.44
.54
.65
.76
.87
.98
1.09
1.20
1.30
1.41
1.52
1.63
1.74
1.85
1.96
2.07
2.17
2.28
2.39
Nat
ural
Gas
- $/
Ther
m
#2 F
uel O
il - $
/Gal
lon
Pro
pane
- $/
Gal
lon
Electrical Cost - $/kWH
30%*
40%
*
50%
*
60%
*
70%
*
80%
*
90%
*
100%
*
10
0
20
30
40
50
60
70
80
90
100
100 20 30 40 50 60 70 80 90 100% Boiler Load
Ove
rall
Effi
cien
cy (%
)
Electric (New or Old)
Fossil Fired (New)
Fossi
l Fired (Typical Operation)
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.8PRECISION Boilers, Inc.
HVJ Model
External Circulation Pumps Internal Circulation Pumps
114 120 128 132 138 228 232 238 328 332 338 428 432 438 538 638
Nominal Rating
MW 3 4.2 6 6.8 8.2 12 13.6 16.4 18 20 25 24 27 33 42 50
PPH Steam 10,000 14,000 20,000 22,600 27,300 40,000 45,300 54,600 60,000 67,000 83,000 80,000 90,000 110,000 140,000 167,000
Confi guration No. of Electrodes 3 3 3 3 3 6 6 6 9 9 9 12 12 12 15 18
Qty @ HP 1 @ 10 1 @ 15 1 @ 20 1 @ 20 1 @ 20 1 @ 40 1 @ 50 1 @ 60 1 @ 60 1 @ 75 ## 2 @ 50 2 @ 40 2 @ 50 2 @ 60 2 @ 75 ## 3 @ 60
VFD HP 15 20 25 25 25 40 50 60 75 75 50 40 50 75 75 75
Feedwater Flow (gpm) 20 28 40 45 54 80 90 108 120 134 166 160 184 220 280 334
TankCapacity
Operating (gal) 475 550 575 600 650 900 1075 1150 1700 1800 1425 2100 2300 2900 3500 3800
Flooded (gal) 1475 1650 1725 1850 2000 2450 2575 2800 3800 4100 3800 5200 5600 6800 8000 8800
StandbyHeater
Rating (kW) 30 30 30 30 30 36 40 40 60 60 60 90 90 90 120 120
Time Req’d*(hrs) 9 10 8 9 10 8 9 10 15 15 13 12 13 16 15 16
ConnectionSizes
(Inches)
Steam Output 3F 4F 6F 6F 6F 6F 6F 8F 8F 8F 8F 8F 10F 10F 2 @ 8F 2 @ 10F
Feedwater 1 1-1/4 1-1/2 1-1/2 1-1/2 2 2 2 2-1/2F 2-1/2F 2-1/2F 2-1/2F 3F 3F 3F 4F
Bottom Blowdown 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2
Surface Blowoff 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2
Air Release 1 1 1 1 1 1 1 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2
Riser Pipe 6 6 8 8 10 10 12 12 12 14 12 10 12 12 14 12
Weight (Lbs)
Tank*** 7,000 8,000 9,000 10,500 12,000 16,000 17,000 18,000 21,000 22,000 25,000 28,000 29,000 30,000 34,000 42,000
Circ Pump N/A N/A N/A N/A N/A 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,500 1,500
Nozzle Header 175 250 350 400 475 750 800 850 1,500 1,600 1,900 2,200 2,400 2,600 3,000 3,600
Ratings and Dimensions
ModelNumber
Nominal Rating (kW)** Nominal Rating PPH** Dimensions (inches) @ 13.2 kV Weight (lbs)****4160V 6.9kV 13,2kV 4160V 6.9kV 13.2kV Dia. OAL H H1 H2 P Ship Operate
HVJ-114* 800 1680 3000 2700 5600 10000 60 136 166 6 6 30 10000 13800HVj-120* 1200 2400 4200 4000 8000 14000 60 146 176 6 12 30 10500 14900HVJ-128* 1700 3400 6000 5700 11300 20000 60 156 186 6 24 30 11000 15600HVK-132* 1900 3800 6800 6300 12700 22600 60 166 196 6 28 36 11800 16400HVJ-138* 2300 4600 8200 7700 15300 27300 60 176 206 6 36 36 13000 17800HVJ-228 3400 6700 12000 11300 22300 40000 72 182 211 5 24 32 16000 23200HVJ-232 3800 7600 13600 12700 25300 45300 72 192 221 5 28 32 16800 24500HVJ-238 4600 9200 16400 15300 30600 54600 72 207 236 5 36 32 18000 27100HVJ-328 5100 10100 18000 17000 33600 60000 84 200 233 6 21 32 23000 38000HVJ-332 5700 11200 20000 19000 37300 67000 84 210 243 6 25 32 24000 39500HVJ-338 7100 14000 25000 23600 46600 83000 84 210 243 6 33 32# 27000 40000HVJ-428 6800 13400 24000 22600 44600 80000 96 198 231 6 21 32# 30000 47000HVJ-432 7600 15100 27000 25300 50300 90000 96 209 242 6 25 32# 31000 49000HVJ-438 9300 18500 33000 31000 61600 110000 102 229 262 6 33 32# 34000 57000HVJ-538 11900 23500 42000 39600 78300 140000 108 234 267 6 33 32# 42000 70000HVJ-638 14200 28000 50000 47300 93200 167000 120 231 264 6 33 32## 52000 82000
*External ANSI pump used. **Ratings are for operation at 150 psi with 220F feedwater. ***Weights are for 175 psi design pressure. #Two internal pumps used. ##Three internal pumps used.
Check local codes for compliance with minimum clearances. Dimensions shown on drawings and in tables are for reference only. Precision Boiler reserves the right to change dimensions without notice due to product improvements and/or product/trim options ordered. Due to the nature of welded construction, Precision Boilers, Inc. is not responsible for rough-in work that does not allow for adjustments during fi nal installation of the product. Rough-in fi nal pipe runs to and from the boiler and fl ange connections should be made after the boiler is in place.
Technical Data
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
9 PRECISION Boilers, Inc.
HVJ-228 thru 638HVJ-114 thru 138
1812
19
3
TOP VIEW
SSS
26
H211
10
9
8
7
6
24"
5
4
3
2
1
DIA
H1
12
13
14
15
161718
19
25
23
24
22
21
20
P
DIA+6"
OAL
H
SSS
H211
9
6
DIA
H1
21
22
26
5
3
3
96"
H
OAL
1812
19
TOP VIEW
1 - Blowdown Valves2 - Pump Removal Clearance3 - Circulation Pump w/VFD4 - Check Valve (for multiple pumps only)5 - Conductivity Cell6 - Sheet Metal Enclosure7 - Insulation8 - Safety Valves (2)9 - Electrode Terminal Enclosure
10 - Conduit Entrance Panel11 - Header Removal Clearance12 - Conductor Rod13 - High Voltage Insulators14 - Back Pressure Regulator15 - Steam Outlet16 - Non-Return Valve17 - Insulator Shields18 - Electrode/Strike Plate Assembly
19 - Nozzle Header Assembly20 - Counter Electrode21 - Pressure Manifold & Gage22 - Water Column & Gage23 - Surface Blowoff24 - Standby Heater25 - Feedwater Valve w/Bypass26 - Manhole
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.10PRECISION Boilers, Inc.
Model Selection
6 MW*(5.4-6.6)128
132
114
120
138
228
232
238
328
332
338/428
432
438
2.5 5.0 7.5 10.0 12.5 15.0 17.5 22.520.0 25.0 27.5 30.0 32.5 35.0
8.3 16.5 24.8 33.0 41.5 49.5 57.8 74.366.0 82.5 90.8 99 107.3 115.5
6.8 MW*(6.1 - 7.5)
8.2 MW*(7.4 - 9)
12 MW*(10.8 - 13.2)
13.6 MW*(12.2 - 15)
16.4 MW*(14.5- 18)
18.0 MW*(16.2 - 19.8
20.0 MW*(18 - 22)
25 MW*(22.5 - 27.5)
27.0 MW*(24.3 - 29.7)
33 MW*(29.7 - 36.3)
4.2 MW*(3.8-4.6)
HVJ
MO
DEL
NU
MBE
R
MEGAWATT OUTPUT RANGE
PPH (X 1000)**
*Nominal Output-Performance May Vary ± 10%. For Example, the Black Line Inside Each Horizontal Bar Represents Nominal Output at 13.2 kV. Lightly Shaded Area Represents Anticipated Performance Range. For Models Above 33MW, Consult With Precision’s Factory.
**PPH Based on 150PSI, With 220˚F Feedwater
Note: Output and performance will vary based on conductivity and kV source. Conductivity of 2000 Micro Seimens used for the above calculations.
3 MW*(2.7-3.3)
3-4 MW* Typical Transition Zone That Separates Electrode Boilers From Standard Resistance Boilers
Nominal Rating (MW) 4160V 6.9kV 13,2kVHVJ-114* .8 1.7 3.0HVj-120* 1.2 2.4 4.2HVJ-128* 1.7 3.4 6.0HVK-132* 1.9 3.8 6.8HVJ-138* 2.3 4.6 8.2HVJ-228 3.4 6.7 12.0HVJ-232 3.8 7.6 13.6HVJ-238 4.6 9.2 16.4HVJ-328 5.1 10.1 18.0HVJ-332 5.7 11.2 20.0HVJ-338 7.1 14.0 25.0HVJ-428 6.8 13.4 24.0HVJ-432 7.6 15.1 27.0HVJ-438 9.3 18.5 33.0
Output at 6.9 kV
Output at 4160V
Performance Safety Margin1. - Performance varies due to many factors. Such factors include, but are not limited to: conductivity of the water, voltage fl uctuations, hystereses of the controls, and system pressure fl uctuation. Precision recommends that 10% be added to the maximum PPH requirement when selecting the boiler, as demonstrated in step 2 above.MW Requirement2. - As shown on the chart above, the economical transition between standard electric resistance boilers to electrode boilers is between 3-4 MW.Ramp Up Period3. - Electrode boilers perform more rapidly than gas boilers or electric resistance boilers. With a ramp up of virtually seconds, HVJ boilers respond immediately to steam demand.Transformer and Voltage4. - For some voltages, one of the benefi ts of electrode boilers is their ability to use line voltage without a transformer. Control Logic5. - HVJ boilers can be integrated with most building automation systems giving system monitoring personnel visibility and control of the boiler.
*Maximum output based on 13.2 kV.
To select an HVJ electrode steam boiler, follow these steps:
Determine the maximum anticipated steam demand.1. Multiply the demand by 1.1.2. Determine the voltage available at your facility3. Using the graph on the preceding page, look up the 4. maximum PPH determined in step 1 on the top of the graph.Follow the maximum PPH vertically down the graph 5. until the it is as close to the left of the triangle, star, or vertical black line (according to voltage) as pos-sible. If the available voltage is different than in the chart, use the closest voltage shown in the chart.Follow the bar to the left to determine the HVJ model 6. number required for your facility.
Example: Maximum steam load is 40,000 PPH and the voltage available is 13.2 kV. The top of the chart includes a line labeled 41.5. Follow the line vertically down the chart to the bar that reads 13.6 MW. The line intersects the bar in the yellow region just to the left of the black bar. Reading across to the left, the model number is an HVJ-232.
Example: Using the example above with voltage of 6.9 kV, the same vertical line is followed down the chart until it is left of the star that indicates 6.9 kV. Following the bar to the left indicates that model HVJ-338 or HVJ-428 is correct for your facility.
Example: Using the example above with voltage of 4160 volts, the same vertical line does not intersect a bar to the left of the triangle indicating 4160 volts. Therefore, a suitable HVJ model is not available unless multiple units are used. If the load is split in half, 20,000 PPH/unit, the chart indicates that two HVJ-338 or HVJ-428 models would be required.
Switchgear6. - HVJ boilers require a switchgear for connecting to high voltage power. The cost of a switchgear can be included with the boiler or it can be purchased locally.Fuel Switching7. - The ability to choose the least expensive fuel in real time becomes critical to minimizing the cost of energy for boiler applications. HVJ models work seamlessly with gas and/or oil boilers to allow real time fuel switching. External input signals may be required.Space8. - HVJ boilers require about half the space of conventional gas boiler of equal output.Turn-Key Solutions9. - With turn-key providers such as Peregrine, Precision can help facilitate providing a total steam solution with the least possible pain on our customer’s part. Everything from fi nancing and building construction to startup and maintenance can be rolled into a single easy turn-key solution.
Selection of the right HVJ boiler requires an overall evaluation and consideration of many factors. Listed below are some of the factors that should be considered when selecting an electrode boiler.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
11 PRECISION Boilers, Inc.
Existing Boiler System EvaluationTo help evaluate your steam requirements and potential savings associated with fuel switching and HVJ boilers, com-plete the following form and fax it to Precision Boilers, 423-587-9394.
Site InformationLocation
Contact NameContact Phone Number
Contact Email
Electrical Power InformationAvailable Voltages (Volts
or kV) 13.2kV 6.9kV 4160VOther:
List Voltages, and Phase, Already on Site
VPH
VPH
VPH
VPH
Power Availability (Megawatts, MW)
Power Connection(D=Delta or W=Wye)
Electricity Supplier
Current $/kWH Rate Specifi c Tariff:
Steam Generation InformationEstimated Pounds/Hour (PPH) Steam
Requirements
Peak: Average:
System Design Pressure (PSI)
Steam Operating Pressure (PSI)
Current Fuel Usage InformationSpecify Gas /Oil or Propane Usage per Month (Deca-therms for Natural Gas or Gallons for Oil or Propane
Delivery Rate /Month/Decatherm (or Gallon)% of Gas/Oil/Propane Used by Your Boiler
What Do You Pay Your Local Distribution Company to Transport Your Gas/Oil/Propane?
Current Boiler InformationMake Boiler Model #
Model BHPWater Treatment System
(Softners/RO/Demineralizer)Current Feedwater Operation
(Batch on/off or continuous running)
How Fuel Switching Works
The HVJ is installed in parallel with existing gas/oil/propane-fi red boiler(s) to produce steam with whichever boiler provides the lowest fuel cost. In cooperation with the power company, an energy price signal is sent to the HVJ when electric rates are favorable, such as during off-peak hours or when the fossil fuel fi red boiler is operat-ing in the lower effi ciency range. The HVJ is set to run at 5 psig higher than the fossil fuel fi red boiler(s). The HVJ boiler produces steam at the higher pressure which causes the gas boilers to automatically shut down.
10
0
20
30
40
50
60
70
80
90
100
100 20 30 40 50 60 70 80 90 100% Boiler Load
Ove
rall
Effi
cien
cy (%
)
Electric (New or Old)
Fossil Fired (New)
Fossi
l Fired (Typical Operation)
As demonstrated in the graph below, fossil fueled boilers do not operate at or near their optimum effi ciency when the steam load drops below 50%. The overall effi ciency of most fossil fueled boilers is usually in the 50-70% range, making constant low rate off-peak electric power very attractive. When the fossil fueled gas boiler is op-erating at 50% effi ciency, the actual cost of fuel is twice the provider’s unit rate, whereas HVJ boilers operate at a constant 99.5% effi ciency keeping fuel cost low and predictable.
Fossil Fueled Boilers @ 80 psigHVJ Boiler @ 85 psig
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.12PRECISION Boilers, Inc.
3800
3900
4000
3700
3600
3500
3400
3000
3100
3200
3300
2900
2800
0 50 100 150 200 250 300 350 400 450 500
Operating Pressure (PSIG)
Stea
m G
ener
atio
n (L
BS/
mW
H)
Feed
wat
er T
empe
ratu
re (°
F)
40
70
140
100
160
180
200190
220212
230240
260250
280
300
320
120
Shaded Area Represents Most Commonly Used Feedwater Temperature Design Ranges
Selection Using Steam Output Table (99% Effi ciency Rating)
How To Read Steam Output Table
Determine the temperature 1. (°F) of the boiler’s feedwater.Determine the system’s 2. operating pressure.Locate the feedwater tem-3. perature on the right axis of the graph and follow the feedwater temperature curve to the left until it intersects with the operating pressure curve.From the intersection point 4. of the two curves, follow the graph horizontally to the left axis to determine the Lbs/MWH of steam produced us-ing the feedwater tempera-ture and pressure selected.
For example: If the feedwater temperature is 190°F, and the operating pressure is 150 psi, the steam output is approximately 3,400 pounds/MWH.
To select the correct MW HVJ based on feedwater tem-perature, operating pressure, and PPH:
Determine the feedwater temperature of your system.1. Determine the operating pressure of your system2. Determine the total amount of steam required for 3. your application in pounds/hour (PPH)Use the chart above to determine the LBS/MWH that 4. can be produced for your feedwater temperature and operating pressure.Multiply your required PPH by 1.1 and divide the 5. product by the amount found in step 4 above to de-termine the MW input requirement of the boiler.
Example: If your feedwater temperature is 190°F, the operating pressure is 150 psi, and you require 34,000 PPH of steam, the pounds of steam per hour that can be produced per MWH is approximately 3,300 from the chart above. The total PPH requirement is 34,000 X 1.1 or 37,400 PPH. The boiler must be at least 11.3 MW in order to do the job, 37,400/3300=11.33.
The chart and example above utilize an effi ciency of 99% whereas HVJ models are closer to 99.5% effi cient. Multiplying the required PPH by 1.1 adds a safety factor of 10% to the required PPH output. The 10% factor may be ignored if the requirement calculation originally included a similar safety factor.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
13 PRECISION Boilers, Inc.
Typical Boiler Room Layouts
CP - Control Panel MV SG- Main Voltage Switchgear
The boiler room for an HVJ is not complicated. The fl oor should be constructed according to local building codes. Every HVJ boiler is provided with tiedown locations for anchoring the unit to the fl oor.
If the HVJ is an addition to an existing boiler system, the system’s existing feedwater system including the deaera-tor, water softener, blowdown tank, and chemical feed may be used by connecting them to the HVJ. Deionized or demineralized water may be used in lieu of softened water.
The JIB crane shown in the illustration is suffi cient for hanging the electrodes on any HVJ boiler. However, siz-es larger than 2 (Models 328-638) require an additional overhead hoist. Precision can provide a suggested boiler room layout drawing as part of the quotation process.
A maintenance platform (1) and JIB crane (4) can be pro-vided by Precision with any HVJ model (8). The access ladder (7) is protected by a ladder cage (6) when the maintenance platform installation exceeds 144” in height.
During maintenance, removing and inspecting the nozzle header is simply a matter of removing the hinged top of the protective cage (5), the top cover, unbolting the noz-zle header, and lifting it out through the top using the JIB crane on model sizes 114-238. Larger models require a larger overhead crane.
Guard rails (3) protect workers from falling during main-tenance procedures. A 36” removeable section of guard rail (2) allows tools and maintenance parts to be lifted to the maintenance platform using a forklift or JIB crane.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
Hgt.
Overhead Crane*
*Required with all models larger than Model HVJ-238.
4
6
7
8
HV
J
Overhead Door
Doo
r
CP
MV SG
1
35
2
Model Minimum* Preferred*
HVJ-114 189 214
HVJ-120 205 231
HVJ-128 229 254
HVJ-132 243 269
HVJ-138 261 286
HVJ-228 255 281
HVJ-232 269 296
Top View
Bottom View
Model Minimum* Preferred*
HVJ-238 292 318
HVJ-328 270 297
HVJ-332 295 322
HVJ-338 292 339
HVJ-428 261 307
HVJ-432 286 332
HVJ-438 314 360
Orientation of the boiler and system components may change according to the installation’s layout, the size of HVJ required and other boiler room equipment. Local code may require that the high voltage switchgear be located outside the boiler room. Since models 114-238 can be fully serviced using the JIB crane, the inside clearance height of the building is slightly less than installations requiring an auxillary crane.
Unobstructed Installation Height Requirements
The preferred installation height requirement is based on extracting the nozzle header without removal of the safety cage located on top of the HVJ. Only the safety cage’s top cover is removed while the nozzle header is lifted over the side of the protective cage. The minimum installation height requirement is based on removing the entire cage assembly before removing the nozzle header.
*All dimensions given in inches.
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.14PRECISION Boilers, Inc.
Typical Connection Diagram
HVJ Boiler
J-BOX
Three-Phase High Voltage Wires (Multiple Required)
Low VoltageControl Box
Wiring
BoilerCirculating
Pump
Chemical FeedLow Voltage Wiring
Boiler Control Panel
Pre-Heater Wiring(Usually 480 Volt/3-PH)
(+ 100% Neutral) BoilerPre-Heater
Ground Wire
High Volt-age Circuit
Breaker and Disconnect
Switch
Low Voltage Auxillary Lighting Circuit and Electric Receptacle
Pump Wiring(Usually 480 Volt/3-PH)
120 VoltPanel
MotorControlCircuit
(Typically 480V-3PH)
Typically 480 Volt-3PH
HVJ boilers require a 3-phase, 4-wire supply circuit from a wye-connected transformer with the transformer neutral solidly grounded at the transformer and extended by means of a full size insulated conductor to the boiler neutral lug. Wire size is dependent on the boiler’s rated output. The boiler enclosure and control cabinet must be grounded to the building’s ground sys-tem via properly sized grounding equipment.
The typical pump motor circuit is 480-volt/3-phase/60-Hertz. Other voltages as well as 50-Hertz can be accommodated. The boiler control circuit is low voltage, typically 120-volt/60-Hertz.
A high voltage switchgear is required for HVJ boilers and can be supplied by others unless specifi ed otherwise. The switchgear must be a stored energy type rated for the boiler voltage and amp load, and must be equipped to protect both the branch and feeder circuits. The switchgear should also include remote tripping so it can be opened by the boiler limit controls for safety shutdown and remote closing by the boiler operator and service personnel. Control circuit power, current transformers, and monitoring relays are provided as part of the switchgear control circuit.
Typical Boiler Water CharacteristicsFEEDWATER
TYPE OF BOILER
Hard-ness(ppm) pH
Alkalinity(ppm-total)
Fe + Cu*(ppm)
Oxy-gen(cc/l)
Conductivity(pmho)
RESISTANCE
Hot Water 0-10 7.5-9.5 25-400 0-5 4 0-600
Steam 0-5 7.5-9.5 1-50 0-1 0.03 0-500
ELECTRODE STEAM
High Voltage @ 4.16kV 0-2 7.5-9 1-50 0-1 0.005 0-350
High Voltage @ 6.9kV 0-2 7.5-9 1-50 0-1 0.005 0-300
High Voltage @ 13.2 kV 0-2 7.5-9 1-50 0-1 0.005 0-250
*Total Iron (i.e. FE+FE2O3+FE3)4) plus total copper (i.e. Cu+CuO). #This limit should be reduced by 9 1/2 max if copper elements are used. ##If hydrazine is used to scavenge oxygen, the maximum hydrazine residual recommended is .2 ppm unless boiler is “bronze free.”
HVJ boiler water treatment is primarily concerned with control of boiler water pH, iron, conductivity, and, like oth-er boilers, pre-boiler and internal boiler water treatment. Typically, standard boiler water treatment can be used. The program selected should be based on feedwater analysis and the recommendation of an experienced chemical treatment company. Boiler water conductivity is vital to the boiler’s output and must be controlled within acceptable limits. Allowing the conductivity to escalate unchecked may half facilitate arcing inside the boiler. Allowing the conductivity to fall too low will result in lower steam output.
BOILER WATER
TYPE OF BOILER
Hard-ness(ppm) pH
Alkalinity(ppm-total)
Fe + Cu*(ppm)
Oxy-gen(cc/l)
Conductivity(pmho)
RESISTANCE
Hot Water 0-10 7.5-9.5# 25-600 0-50 0 0-6000
Steam 0 7.5-9.5# 25-600 0-5 0 ## 0-4500
ELECTRODE STEAM
High Voltage @ 4.16kV 0 7.5-10.5 100-350 0-3 0 ## 500-2500
High Voltage @ 6.9kV 0 7.5-10.5 100-350 0-3 0 ## 500-2500
High Voltage @ 13.2 kV 0 7.5-10.5 100-350 0-2 0 ## 500-2100
HVJ boilers do not have high temperature fl ux between components inside the boiler. Therefore, hard scale buildup is much less of a problem than in fossil fueled boilers. However, soft scale buildup should not be al-lowed to interfere with the fl ow of water through nozzles inside the boiler. Standard HVJ boiler water treatment should not include, anti-foaming agents, chelants, and fi lming amines. For more information concerning boiler water treatment, contact Precision Boilers.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
PH 423.587.9390 Fax 423.587.9394, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
15 PRECISION Boilers, Inc.
BDN - Blowdown
CFB - Chemical Feed BoilerCWS - Cooling Water Supply
M 1/2"
CFB
1/2"
BDN
CWS
FWS
HPS - High Pressure Steam
Field Analog Control WiringField Wiring
1/2"FS ~2 GPM
1 1/2"1 1/2"
1/2"
LC
1/2"
1/2"
VFD
CE
1/2"
LS
1-1/2"1" 3/4"
1"
3/4"T
P
S
3/4"
1/2"
PS PT
LGLS
PS PI
1"
1"
CIRCUITBREAKER
15 KV
HPS PROCESS STEAM125 PSI
1/2"
Field Piping (Not Supplied by PPC)
LT
VP
Globe ValveCondensing Pot
Ball ValveGate ValveStrainerNeedle or Metering ValveCheck ValvePneumatic Solenoid ValvePressure Relief ValveLow Select
LC - Level Control
TI - Temperature Indication
LG - Level GaugeLS - Level Switch
VP - Valve Positioner
CE - Conductivity Element
PC - Pressure Control
JC - Power Control
PI - Pressure Indication
JT - Power TransmitterIT - Current Transmitter
ET - Voltage Transmitter
IS - Current Switch
M - Mixer
FWS - Feedwater Supply
3/4"
PS - Pressure Switch
PT - Pressure Transmitter
LT - Level Transmitter
VFD - Variable Frequency Drive
FS - Flow Switch
VP
2"
Cv=
1/2"
Concentric Reducer
6"Cv=
PC
IS HI
ET
PC
JC<
<
Pneumatic Operator
JTIT
BLOWDOWN
3 GPM @ 40-60 PSICOOLING WATER SUPPLY
FEEDWATER SUPPLY75 GPM @ 150 PSI
MAKEUP WATER SUPPLY5 GPM @ 40-60 PSI
2-1/2"
2-1/2xLx4@ 150/155 PSI
1/2"
2"
1-1/2"
SAMPLE
VENT
1"
Chemical Feed
HVJ Boiler
CirculatingPump
PS
P
S
Typical Piping and Instrumentation Diagram
The example above of a standard Piping and Instrumen-tation Diagram (P & ID) is for a model HVJ-228 with a 150 psi design pressure. This system also includes a chemical feed system to the HVJ. Piping, controls, and electrical components vary by HVJ model and job site requirements.
Every job includes a P & ID. While the above example is a basic system, Precision can provide multiple boilers op-erating together, deaerator for the FWS, blowdown tank, blowdown heat recovery, and other major system com-ponents. When other major components are supplied, Precision includes them on the fi nal P & ID for approval as part of the submittal process.
As can be seen from the P & ID above, Precision pro-vides a boiler water sampling location, water level controls, relief valves, a conductivity circuit, pressure regulation monitoring, and power monitoring functions with every HVJ boiler.
All valves shown on the P & ID are included with the boil-er. Valves can be steel, threaded or welded, or threaded bronze construction.
HIGH VOLTAGE JET (HVJ) ELECTRODE STEAM BOILERSHigh Capacity, Compact, Vertical Design, With 800-50,000 kW
Sample List of HVJ Electrode Boiler Installations
3MAnMed MedicalAugusta TissueCapsugel/Pfi zerDelta TOCGold-KistHoi Mor Industrial
IBMKerr-McGeeLinpac PaperMetrolina GreenhousesMar-Jac PoultryNestlePrincess Cruises
QuantegyRock-TennR.R. DonnellySlay Bulk Terminal TysonWrigleyPower Plant Projects
Precision Boilers Can Provide A Turn-Key Solution
Energy Audit Services
Contractor Referral ServiceUtility Company Communications
Product Availability
Financing Referral Services
Startup and Commissioning Services
Every project starts with an energy audit. Precision and Peregrine can assist in auditing the energy requirements of the boilers or provide a referral to a full service energy auditing fi rm that can perform an overall comprehensive energy audit.
Installation of the boiler may require construction of a building, pouring a concrete boiler pad, rerouting piping, and/or installing a new electrical service. Precision can locate a contractor such as Peregrine to design and coor-dinate the entire job with various trades and code authori-ties, or you can use internal personnel to do most of the work. Peregrine, an energy solutions provider, specializ-es as a general contractor on many turn-key jobs, taking the worry out of a HVJ installation project.
Precision’s complete line of high voltage jet (HVJ) boil-ers is well known in the industry for their dependability and performance. Precision can provide the boiler, switchgear, and all the controls required for the job. With deliveries as quick as 8-14 weeks, installations all over the world, and proprietary technology, Precision is the industry’s leading authority on the application and instal-lation of electrode boilers.
Precision can help you communicate and coordinate with the utility company to verify rate information and assist with coordinating the implementation of upgraded service requirements. In some applications, Precision’s technol-ogy will even allow the boiler to communicate in real time with the utility company’s rating system. This allows the utility company to control switching the boiler on and off according to prevailing real time energy rates.
Precision can help fi nd fi nancing for the installation of an electrode boiler if the payback is within reasonable limits. Precision and Peregine’s contacts within the fi nancial industry can locate Energy Savings Companies that can fi nance your project, allowing them to participate in part of the generated savings for a limited period of time.
Service and Maintenance
Precision can provide engineers and fi eld service techni-cians to participate in and supervise the startup and com-missioning of HVJ boilers.
Precision’s fi eld service team is available for trouble-shooting and diagnosing all issues with HVJ boilers. Precision can refer you to a service contractor that can handle standard periodic maintenance needs on HVJ boilers.
Precision Boilers5727 Superior Drive
Morristown, TN 37814www.precisionboilers.com
Fax: 423-581-7749Phone: 423-587-9390 #228Don Woody - HVJ Projects
Email: [email protected] 423.587.9390 Fax 423.581.1440, WWW.PRECISIONBOILERS.COM Copyright © 2008, All rights reserved. Specifi cations subject to change without notice.
HVJ-1-82008