HomeMy WebLinkAbout770733.tiff - Nelson,Haley, Patterson &Quirk,Inc. Tel. 303/356-4444
Combustion Engineering, Inc.
2021 Clubhouse Drive
Greeley, Colorado 80631
CA TEC
Architects • Engineers• Planners
•
February 15, 1977
Mr. Barton Buss
Chief Accounting Officer
Weld County Centennial Center
915 10th Street
Greeley, Colorado 80631
Dear Bart:
RE: WELD COUNTY PUBLIC HEALTH BUILDING
Attached please find:
1) Revised copy of a report on the boiler leakage at the subject
project
2) Three proposals for repair of the boiler
3) Three proposals for replacement of the boiler
After my preliminary presentation of the report, I requested Greeley Plumb-
ing and Heating, Inc. , Wyco, Inc. , Stone and Stone, and Natkin Service Co.
of Greeley to provide proposals for the subject project to:
1) Replace four boiler sections
2) Install a five module modular boiler with separate water heater
As a result of the article in the Greeley Tribune, Hoden Plumbing and Heating,
and Comfort Control asked for permission to submit proposals. In addition,
Mr. Bill Hawn asked to look at the installation since he was involved in the
initial boiler installation.
I met with each of these firms on an individual basis to review the specific
requirements for the proposal. Mr. Andy Petruzzi was also in attendance at
these meetings. Since Andy was out of town when I met with Comfort Systems,
Mr. Frank Roseck represented Mr. Petruzzi's office.
We have received positive responses from three of the firms contacted. The
other firms informed me, by telephone, that they were unable to provide a
proposal for the work. The tabulation of the results is:
770733
, ro 2 a y2.), Jo, -1/4/77
Mr. Barton Buss
Page 2
February 15, 1977
Greeley p&H Wyco Hoden P&H
1) Replace Sections $6,695 $6,500 $5,240
2) New Boiler $8,980 $8,650 $8,590
3) Estimated cost to Owner
for new Boiler $2,285 $2,150 $3,350
These proposals are relatively close and within the estimates noted in my
report.
As stated in the report, I recommend the County authorize the installation
of a new boiler with a separate water heater. The primary reasons for
selection of this option are:
1) The insurance company will pay for the cost to repair the boiler,
and will credit this cost towards a new boiler. Thus, the County
would need to contribute from $2,150.00 to $4,000.00 to obtain a
new boiler. The exact amount will depend on the number of faulty
sections. (The more faulty sections, the lower the cost to the
County. In fact, the cost can be reduced by up to $1,000. 00 more
depending upon the salvage value obtained from the existing boiler
and burner. )
2) The new boiler would be fully insured. It is possible the insurance
company will not provide full coverage on the repaired boiler.
3) A one year guarantee on the new boiler would be in effect. No
guarantee is offered for the repair of the existing boiler.
4) Operating savings can be obtained from the use of a modular. boiler.
5) The installation of the new boiler can be accomplished in a shorter
period of time than repair of the existing boiler can be made. The
major delay for the repair option is in obtaining the replacement
sections from the East Coast.
• 6) Future heating boiler failures would not jeopardize the building
operation, since a given module could be isolated and repaired
without disturbing the building function.
In reviewing the situation with Mr. Bill Hawn, boiler installer, I found he
was a concerned citizen who happened to work for the company which performed
the installation. After careful review of the installation, he concurred
with my recommendations.
I have met a second time with the Hartford Insurance agent. He is also the
State Boiler Inspector. He informed me it was imperative corrective action
be taken immediately. He advised he would file a report with the State on
Friday, Feburary 18, 1977, if a contract is not signed by then to proceed
with the work. If he does file a report with the State, there are two
possible consequences:
Mr. Barton Buss
Page 3
February 15, 1977
1) A cost for the report with a second fee required upon completion
of the work.
2) The possibility that the State may require the boiler to be shut
down, which could seriously affect the operation of the building.
If you desire further background into the boiler, I offer the report en-
closed as a means to acquaint the new commissioners with the history of
the project and the investigations made.
As a result of the investigations, proposals, and the potential lower cost
to the owner, I recommend the County retain the services of Wyco, Inc. to
install the new boiler and water heater.
• If you need any additional information or work performed, please contact
me. I really appreciate the opportunity to be of service to you in this
matter.
Respectfully yours,
NELSON, HALEY, PATTERSON and QUIRK, INC.
Jere' C. Hamilton, P.E.
JCH/csd
•
Enclosure: Report
MTN CIYN(rgissais
J '
1 FEB 16 1977
GREL•-L'7.• COLO.
REPORT ON BOILER LEAKAGE AT
WELD COUNTY PUBLIC HEALTH BUILDING
T
FOR
PRESENTATION TO WELD COUNTY COMMISSIONERS
a
..
1 BY
JERE' C. HAMILTON
NELSON, HALEY, PATTERSON and QUIRK, INC.
2021 Clubhouse Drive
Greeley, Colorado 80631
p
p.
DATE
..
February 4, 1977
r
REPORT ON BOILER LEAKAGE AT
WELD COUNTY PUBLIC HEALTH BUILDING
•
FOR
PRESENTATION TO WELD COUNTY COMMISSIONERS
BY
JERE' C. HAMILTON
NELSON, HALEY, PATTERSON and QUIRK, INC.
2021 Clubhouse Drive
Greeley, Colorado 80631
— DATE
February 4, 1977
INDEX
Page
Number
I. SUMMARY 1
II. PROJECT HISTORY 2
III. INVESTIGATIONS AND EVALUATION 3 - 6
IV. DISCUSSION ON NATURAL GAS AVAILABILITY 7 - 8
V. CONCLUSIONS AND RECOMMENDATIONS 9
I. SUMMARY
In 1973, the design was completed and construction started for the new
Weld County Public Health Building. Construction was completed in the summer
of 1974. In January 1977, the heating system boiler developed a water leak.
Without complete disassembly of the boiler, it is impossible to ascertain
the full extent of the problem. An external inspection of the boiler indicates
as many as four (4) of the thirteen (13) cast iron boiler sections may be leaking.
It appears the leak is from cracks or holes in the cast iron sections and not
from installation deficiencies . Both internal and external leaks have occurred.
Immediate action must be taken, by the Owner, to repair or replace this
boiler so the building may be kept in continual operation. The problem could
quickly advance to total boiler failure at any time. This would cause up to
five weeks of building down time.
I recommend the Owner replace the present boiler with a modular type
boiler and separate water heater. This system would have gravity fired natural
gas burners. I estimate the cost to replace the boiler at $9,000.00. This
is approximately $2,000.00 more than it would cost to repair the present boiler.
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II. PROJECT HISTORY
The original design of the mechanical system for this project incorporated
the use of a cast iron boiler (normal life expectancy of forty years) and a
separate domestic hot water heater. Both the boiler and water heater had
gravity-fired burners utilizing natural gas.
At the start of project construction, the "energy crisis" arose. There
were serious concerns in the minds of the nation's engineers and other experts
in the field, as to the future availability of natural gas. Because of this
"energy crisis" and the information available at the time, the design team
advised the Owner of possible energy source alternatives. This included changing
the design to incorporate a system which would allow simple conversion to a
secondary fuel. In light of the information available at the time, the Owner
instructed the design team to incorporate secondary fuel provisions in the design.
A cast iron boiler capable of burning either natural gas (the primary fuel)
or No. 2 oil (the secondary fuel) was specified. The boiler also contained an
integral water heater. This solution kept the original concept of a heating
boiler with an expected forty year life. To keep initial capital costs to a
minimum, the oil storage tank and other secondary fuel appurtances were not
installed.
The design team based the specifications around products manufactured by
American Standard, a long-standing boiler manufacturer. The Contractor wished
to install a boiler and burner unit manufactured by the Crane Company. Since
the boiler was of comparable size and capacity, and was manufactured by another
reliable company, approval was given to use the Crane system. The system
operated satifactorily until January, 1977, when a water leak was observed.
.. -2-
III. INVESTIGATION AND EVALUATION
I have inspected the boiler. Without complete disassembly of the boiler,
it is impossible to ascertain the full extent of the problem. Disassembly of
the boiler at this time of year without repair or replacement parts available
would mean up to six weeks of "down time" to the Owner.
From the external inspection it appears as many as four (4) of the
thirteen (13) cast iron boiler sections may be leaking. It appears the leak
is from cracks (or holes) in the cast iron sections. There is both internal
and external leakage. There is increased leakage when the boiler is hot and
no leakage when the boiler cools down. As a result, I do not feel the leak
is from installation deficiencies, but from a failure within the boiler.
It appears the leak is flowing more water as time goes by. For this
reason, it is imperative corrective action be taken immediately. This is
necessary to avoid a major building "down time". I have investigated several
possible alternatives available to correct the situation with minimum "down
time". Of these, the feasible alternatives are:
A. Repair the boiler
B. Replace the boiler with a new boiler and separate domestic water
heater, each with gravity type natural gas burners
A. Repair the Boiler
Since the time of the installation, both American Standard and the Crane
Company have gone out of the boiler manufacturing business. There have been
several other manufacturers who have also quit producing cast iron boilers.
Even so, some companies are still manufacturing cast iron boilers. Now, as it
was in 1973, cast iron boilers are one of the most reliable type of boilers
manufactured.
-3-
Because this particular boiler is no longer being manufactured, I have
three major concerns; 1) Possible future failures - It is possible a defective
batch of castings occurred during the construction of this boiler. If this is
the case it is probable that future failures will occur. Without an expensive
test, it is impossible to ever determine if this is really the case. 2) Re-
placement part availability - There are still replacement sections available,
which can be obtained, for this specific boiler. They are, however, available
at a premium cost. It is unknown as to how long there will be a supply available
for this boiler. 3) Insurability - The insurance company may increase rates
or decide not to insure the boiler if they question its worth.
It is, therefore, questionable as to the worthiness of repairing this
boiler, since parts may not be available in the future and continual failures
may occur. This is a major concern of mine with the facts available at this
time.
I have estimated the time and costs required for replacement of the sections.
It will take a minimum of three weeks from "authorization to proceed" to
obtain the four replacement sections. It will then take one week to replace the
sections. A minimum of three days of building "down time" will be required. I
suggest the repairs take place over a three day weekend to keep the building
"down time" to a minimum. The cost to accomplish this work should not exceed
$7,000.00.
Since it is unknown as to the exact number of faulty sections, the Owner
will need to purchase a minimum of four sections. This is required even if
only one need be replaced.
B. Replace Boiler - Separate Domestic Heater
There are several different types of boilers available on the market today.
Because of the limited space available for the boiler, and the limited access
space, the most practical solution is to install a modular type of cast iron
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boiler. There are three major advantages obtained from a modular boiler:
1) Able to be installed in spaces with limited access;
2) Operating savings
3) A failure of one module will enable continued operation of the building
while the module is being repaired.
This type of cast iron boiler is still being manufactured and stays with
the original design concept of a long life boiler. One cannot predict if they
will still be manufactured tomorrow. To the best of my knowledge, these manu-
-
facturers intend to stay in business. Because of the limited access, a cast
iron boiler is the only type which can be economically installed in the present
boiler room. Installation of a different type of boiler would result in re-
moving a portion of the exterior wall, installing the boiler, and then replacing
the wall. This is not economically feasible.
Operating savings are obtained, since the boiler consists of several modules.
Mechanical equipment operates most efficiently at full load. With the modular
boiler concept, the modules operate in steps with each module at full capacity.
Thus, if only one third of the boiler capacity is required, then only two modules
(of a six module boiler) would operate. Since they operate at high efficiency
and only as needed, operating savings are obtained, which results in lower fuel
consumption.
With the modular concept, a failure as presently experienced by the Owner,
would not result in building "down time". The specific module with the failure
could be isolated from the remainder of the modules. The building could then
remain in continual operation while the module was repaired during normal
-- working hours.
A separate domestic water heater would be installed adjacent to the boiler.
This unit would operate independent of the boiler. Therefore, the boiler could
be shut down whenever outside temperatures rose above 75°F (subject to the need
for the reheat coils in the lab area).
-5-
With this scheme, the burners would be of the gravity type and would not
use No. 2 oil for secondary fuel provisions. The Owner must, therefore, make
the decision as to the need for the secondary fuel provisions. It is possible
to install a second set of burners in the future, or change the burner orifices
in the future. One could then use propane as the secondary fuel source.
This system, with a five module boiler and a separate water heater, is
available and in Denver stock. The system could be installed within two weeks
of "authorization to proceed". As with the previous scheme, three days of
building "down time" is needed to accomplish the majority of the work. This
' could also be accomplished over a three day weekend. The cost for the scheme
should not exceed $9,000.00.
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IV. DISCUSSION ON NATURAL GAS AVAILABILITY
r I have discussed the current gas situation with the Greeley Gas Company.
Greeley Gas Company feels there is no immediate problem with the local gas
supply. There is ample gas available for their customers. Since there has
been a load established on the Weld County Health Building, Greeley Gas is
committed to providing natural gas while the supply is available.
If for some undiscernable reason, problems did start to occur, action would
be taken with a priority something like this:
1) Greeley Gas would eliminate the installation of new taps
2) Greeley Gas would have their interruptable customers use less
natural gas
3) Greeley Gas would request industrial customers to reduce their gas
consumption
4) Greeley Gas would have other critical installations reduce their gas
usage
5) Greeley Gas would have residential customers reduce their gas
consumption
Greeley Gas Company has never established a waiting list for new taps. At
this time, priority numbers are assigned (as they were at the construction of
Weld County Public Health Building) and new taps are given out as required on a
day-to-day basis. Greeley Gas does have a limitation, however. They cannot
provide new gas taps to a customer which would use over 25,000 MCF annually.
It is interesting to note, at this time, (three years after the start of the
"energy crisis" in which individuals have had a chance to sit back and fully
analyze the natural gas situation) that the problems do not seem to be as serious
as they were in 1973. A part of this change has come about from increased fuel
costs which have allowed for additional exploration and new gas sources. At
this time, there appears to be ample natural gas reserves for current Greeley
Gas Company customers.
The "energy crisis" presently occuring in the East is from extremely harsh
weather. In addition, it is occurring in an area which does not have a plenti
—
ful natural gas supply. The majority of the East uses No. 2 oil for its energy
source.
-7
Of course, no one can predict the weather in any given winter, nor can
anyone predict the _full natural gas availibility. Even so, since I have spoken
with the Greeley Gas Company, I feel confident the Owner would not be jeopari-
dized by replacing his present boiler installation with a new gravity fired
boiler. If a shortage does ever come about, other fuel options will be available
at that time, i.e. , propane, coal, electricity, solar, or maybe even a new
source, unknown at this time.
_g_
V. CONCLUSIONS AND RECOMMENDATIONS
It is not possible to determine the full extent nor the reasons for the
leak in the boiler without disassembly of the boiler thereby closing the
building for a period of time. Investigations indicate a failure of up to
four cast iron sections.
To keep the building closure to a minimum, a decision must be made by the
Owner to either repair the boiler sections or replace the entire boiler. The
cost to repair the boiler will be the same whether one or four sections failed.
Because of the proximity of the boiler installation and the closing of business
by the boiler manufacturer, consideration must be given as to the possibility
of future failures.
The availability of natural gas appears to be better today than it was
three years ago. The need for a secondary fuel burner does not seem to be as
important today as it was then. The choice of a secondary fuel burner in 1973
still seems appropriate considering the information available then. It does
not appear justified today, since the oil tanks and appurtenances were not in-
-
stalled, the availibility of No. 2 oil is questionable, better fuel sources are
being developed, and natural gas is still plentiful.
I have conferred with the local Hartford Insurance agent. The Owner's
insurance will cover the cost required to replace the number of defective
cast iron sections. This contribution from the insurance company can be
applied to the cost for replacement with a new boiler.
Based on the above facts, I recommend the Owner install a five module
boiler with separate water heater. I feel the additional capital investment
(estimated at $9,000.00 - $7,000.00 = $2,000.00) is justified to do this since
operating costs can be obtained to offset this investment, and future building
^ down periods from the boiler should be eliminated.
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