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Metalworking Aerospace
Support Facility
Due to unit failure,
WBI was requested to remove and replace one of the customers
Boiler (Kewanee) Systems with a Bryan Steam Flextube
unit.
The Kewanee unit was removed and
replaced. Also, while replacing the boiler, WBI installed a new blow
down separator and condensate return
Flex Tube – Water Tube
Boiler versus the less efficient Fire Tube units
The old Kewanee had estimated
combustion performance efficiencies of less than 60% . The old unit
was replaced with a Bryan Steam Flextube 250 hp that operates at combustion
efficiency > 82%
Benefits realized by client: Lowered energy
bills, much more user friendly system.
 Combustion
systems are used to generate steam and heat for vital manufacturing
processes, to heat materials as diverse as metals and chemical
feed stocks to change the mechanical and chemical properties
of materials and products. New technologies can spell increasingly
efficient, clean, fuel-flexible, and reliable combustion
systems, capable of producing uniform, high-quality end
products at high production rates, while also meeting anticipated
environmental requirements.
This project occurred at a metalworking,
Aerospace support facility. The plant utilized a boiler
which is no longer
made and difficult to support. After reviewing the applications
on site, WBI recommended a Flex Tube – Water Tube
unit made by Bryan Steam. The Kewanee unit was removed
and replaced along with a new blow down separator and condensate
return.
The Kewanee had estimated combustion
performance efficiencies of less than 60% . The Bryan
Steam Flextube (250 hp) that
replaced the old unit operates at a combustion efficiency > 85%.
Because of the replacement project the facility lowered
energy bills, and is experiencing a much more user friendly
system.
Aerospace Facility
An old system with
outdated burners provided poor return in BTU per unit
of natural gas
Remove and replace burner system
with new Gordon-Piatt unit and the latest in control systems
The gains came primarily from
two areas, the much improved turn down ratio capability of the Gordon-Piatt
burner and the installation of Honeywell controllers
Operating
at a 3 to 1 turndown ratio is impractical given the alternatives which
are readily available.
The new system also provides much better monitoring and controlling
capabilities making it a safer unit
Benefits realized by client: Lowered energy
bills, safer process
 Like
most aerospace plants, this customer is always looking
for ways to improve operating performance in the plant.
When their old Iron Fireman burner system was posing increased
difficulties to keep the combustion process optimized,
customer came to WBI for improvement recommendations.
Considering the boiler these burners were firing, replacement
of the entire system was deemed unnecessary when the lack
of performance was almost exclusively related to the burner
and controls. This unit was a good prospect for retrofit
using the Gordon-Piatt burner system, and adding on new
Honeywell controllers.
After presenting the specifications and cost to benefit,
the decision was made for WBI to remove and replace the
burners on the process steam boiler and update the controls.
With the new installation the modulation was greatly Improved
at a Turndown Ratio from 3 to 1 to 7 to 1.
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Aerospace Manufacturing
Melting operations
for Lead and Kirksite were experiencing issues with burner
backfire and poor operating efficiencies
WBI was asked to install upgraded
burners and controls systems
Gordon Piatt burners and Honeywell
controllers
The
old Eclipse burners were operating at less than 60% efficiencies. These
furnaces run at high
temps and for long periods, yielding ample savings opportunities by
raising efficiency > 82%
Benefits realized by client: Lowered energy
bills, and much safer operations
 The
Aerospace industry frequently utilizes high temperature
furnaces to melt various media applied to metal treatment
processes. This project involved “Melting Pots” at
the Aircraft Tool & Die Shop.
These melting pots are used to melt down Lead and Kirksite
to cast dies. The old burners (Eclipse) were not efficient
and because of the design were also a safety concern. The
old eclipse burners were appended with gas mixing chambers
which can be subject to explosions.
By changing out the burners and control
systems, operator control over heating processes was improved
yielding lower energy consumption and improved safety
in operations as the new burners mixed gases at the flame output location.
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Aerospace Manufacturing
At this facility they
used Salt Baths and Quench Ovens which needed to be upgraded
to Meet Government Standards.
To bring the units into operational
compliance, WBI installed a new burner and burner control systems and
chart recorder, equipped with centralized monitoring.
Gordon Piatt burners and Honeywell
controllers and recorders.
Performing
this upgraded resulted in improved control over heating process yielding
more effective usage
and lower energy consumption as well as documenting performance metrics
tied to traceable standards.
Using a more efficient system, saves money and
the new controls recorder satisfied Government Officials.
 To
bring the units into and document operational compliance,
WBI installed a new burner and burner control systems and
chart recorder, equipped with centralized monitoring. This
upgrade not only improved efficiencies in the process but
also streamlined the monitoring and recording processes
required by Mil Specs. Performing this upgrade resulted
in improved control over heating process yielding more
effective usage and lower operating costs.
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