Commercial Boiler Room Re-design/Retrofit Installation November 2007 Chicago
 
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The images show the before and after shots of a boiler room upgrade to the system piping and combustion air intake that we designed and installed. The first few images show the effects of the poor original design of the room. The uncontrolled combustion air intake was a few inches from the #4 boiler and a couple feet away from the building water mains causing freezing of the pipes and damage to the boilers.

The original piping was installed without consideration to low boiler return water temperatures from radiant floor heat and outdoor snow melting nor system efficiency. The images also show the effects of low water return temperatures typical of radiant and many other types of hot water heating systems without proper primary/secondary piping on non condensing type boilers. The rust beneath the boilers is accumulation of just one year of operating with return temperatures below manufacturers' recommended levels.

Another problem with the original piping was that all the return water from the building was circulated through all four boilers continuously, regardless of whether the boiler was fired or not. Coupled with the uncontrolled outdoor combustion air, the off-line boilers acted like heat emitters giving up heat from the return water up the chimney. Basically, like having four very large radiators outside.

The solution was to retrofit the piping to provide for both off-line boiler isolation and individual pumps and 3 way valves to maintain minimum return temperature requirements and prevent condensation and further corrosion of the cast iron boiler sections. The other aspect of the job was installing individual combustion air intakes and blowers interlocked with respective boilers, including the domestic hot water boiler, only supplying the required amount of combustion air to each boiler as it is brought online by the new Tekmar 268 boiler control.