Cleaver-Brooks - Complete Boiler Room Solutions
Enews signup

The Importance of Boiler System Integration

Tip Sheet: October 2012

Key Facts

  • The performance of a boiler is based on the ability of the burner, boiler and controls to work together
  • Every boiler assembly has its own resonant frequency, so a burner’s combustion characteristics must integrate harmonically
  • Adding the right control system to manage a boiler system minimizes cycling and increases efficiency

Because its boiler components are engineered to work together, Cleaver- Brooks products are more efficient and more reliable than systems assembled with universal parts from different manufacturers.

     

Ultimately, the performance of a boiler is based on the ability of the burner, boiler and controls to work together. Boilers that incorporate equipment from a variety of manufacturers following different protocols typically cannot achieve industry-best results.  

     

The significance of matching a burner to a boiler cannot be underestimated. Flame characteristics are an important factor to consider. A burner’s flame shape and length, or flame envelope, must be matched to the furnace or combustion chamber to transfer the most heat, yet not impinge on the furnace walls in a manner that could be detrimental, such as degrading the boiler tubes and/or causing incomplete combustion rumble and sooting because of flame quenching.  

     

Another key aspect to matching the burner to the boiler or heat exchanger involves a phenomenon known as combustion noise or combustion vibration, often referred to as “combustion rumble.” Every boiler assembly has its own resonant frequency, so a burner’s combustion characteristics must integrate well harmonically. Otherwise, at certain loads, the whole package may vibrate excessively, thereby causing undue wear and tear on the system’s components.  

     

Adding the right control to manage the boiler system is also paramount. Often in a multiple boiler system, a facility will try to save money by selecting the lowest-cost control system, either installing an inadequate control or no sequencing control at all. It is limiting to have a simple boiler sequencing control operate a multiple-boiler system. It is even worse to have multiple boilers cycle and modulate on their own without any coherent strategy. Both scenarios lead to excessive wear, inefficient operation and higher-than-necessary fuel costs.  

     

Cleaver-Brooks is committed to integrated engineering, and its boiler systems are designed and tested extensively at its research and development facility. Because its boiler components are engineered to work together, Cleaver-Brooks products are more efficient and more reliable than systems assembled with universal parts from different manufacturers.  

     

As noted, Cleaver-Brooks operates a dedicated research and development center where engineers use the latest technology, including mathematical modeling, finite element analysis and advanced computational fluid dynamics (CFD), to optimize the total boiler/burner/control system, maximizing energy efficiency and reliability while minimizing emissions.  


In addition to developing energy-efficient, low-emissions products, Cleaver-Brooks engineers also offer state-of-the-art retrofit solutions for commercial, institutional and industrial markets.