Boiler System Overhaul and Steam / Condensate Optimization

Improved steam capacity, reduced rental exposure, corrected condensate failures, and strengthened BMS/control readiness; fuel-efficiency improvement remains a reported performance reference.

Coordinated 350 HP 2-pass dryback firetube boiler; economizer; LMV51 BMS; CM burner; natural gas piping; flue stack; roof penetration flashing; economizer piping; insulation strategy; 350-gal stainless feedwater tank skid; dual CR5-18K pumps rated 35 GPM at 445 ft TDH, 7.5 hp; Model 10SS deaerator; level-control system; steam injection heater; chemical quills; solenoid makeup valve with bypass; NEMA 12 enclosure; twin FRP 160,000 grain softeners; reused chemical pumps/tanks with flow-based chemical dosing; 150 ft condensate return pipe with 36 in drop; steam trap routing corrections; 3 in steam isolation valves for disused mains; 22 ft x 28 ft x 20 ft CMU boiler room; 10 ft x 10 ft x 20 ft equipment room; 8 in 4500 PSI slab; roll-up door; R29 roof; city permitting; electrical feeds; BMS commissioning; I/O checkout; instrumentation calibration; operator training; P&IDs, PFD, instrument list, control narrative, electrical power plan, 3D scan, 29-30 week APO schedule, and A207360 schedule.

Improved thermal utility reliability, measured by $1.45M total capital, $1.2M boiler-room/equipment layer, projected $15K/month rental boiler elimination, a reported 10-15% annual fuel-reduction reference, and 1.135 MMBtu/hrfuel-savings commitment, by coordinating boiler, economizer, feedwater, deaerator, condensate, controls, building, and commissioning scope.

boiler-room/equipment layer; projected $15K/month rental avoidance; reported 10-15% annual fuel-reduction reference; 1.135 MMBtu/hr fuel-savings commitment; 0.5 MMBtu/hr modeled fuel savings; reported flue-gas values of 398 F and 285 F; reported efficiency values of 79.8% and 82.8%; reported >$11K/year energy-savings reference.

Led boiler-replacement engineering and coordinated the economizer, BMS, feedwater/deaerator skid, water softening, condensate rebuild, steam diagnostics, boiler-room construction, permits, controls testing and commissioning.

• Project Ownership

  Full lifecycle project ownership

  Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Coordinated boiler-room equipment, electrical and controls interfaces with steam-manifold and pressure-reduction improvements. Condensate recovery, control checkout and operating readiness were part of the same system scope. The work increased available steam capacity by about 25 percent and stabilized jacket pressure.

• Analyze Schedule Uncertainty and RiskApplication relevance
  Why these connect

  Which uncertainty can change the decision and what evidence would reduce it? Schedule uncertainty is relevant to the cited schedules. A completed Monte Carlo or PERT analysis is not asserted.

• Coordinate Detailed Engineering Design PackagesApplication relevance
  Why these connect

  Can the design decision be traced from need and alternatives to a controlled execution basis? This connection identifies where the capability can support the recorded work; it does not add a completed test or result.

• Develop and Review Engineering DrawingsApplication relevance
  Why these connect

  Which tool function supports the engineering activity and how is its output checked? Drawing and design-package work provide application context; use of each CAD product is not implied.

• Plan Delivery Baselines and Acceptance StrategyApplication relevance
  Why these connect

  Can the design decision be traced from need and alternatives to a controlled execution basis? This connection identifies where the capability can support the recorded work; it does not add a completed test or result.

• Prepare Contractor-Ready Technical InstructionsApplication relevance
  Why these connect

  Does the communication enable a specific engineering decision or operating action? This connection identifies where the capability can support the recorded work; it does not add a completed test or result.

• Building Envelope, Roofing, and Facility Rehabilitation — Application ReviewCapability application review
• Civil, Structural, Concrete, and Site Engineering — Application ReviewCapability application review
• Commissioning, Qualification, Acceptance, and Turnover — Application ReviewCapability application review
• Control Panels, BOMs, Fabrication, and Shipment — Application ReviewCapability application review
• Electrical Distribution Design and Installation Packages — Application ReviewCapability application review
• Engineering, Automation, and Enterprise Toolchain — Application ReviewCapability application review
• Food Safety, Sanitary Quality, and Regulatory Interfaces — Application ReviewCapability application review
• Instrumentation, Measurement, and Standards — Application ReviewCapability application review
• Lifecycle Artifacts: Front-End and Design — Application ReviewCapability application review
• Mechanical, Piping, Pumps, and Process Interfaces — Application ReviewCapability application review
• Risk, Uncertainty, and Decision Support — Application ReviewCapability application review
• Scheduling, Shutdowns, and Execution Sequencing — Application ReviewCapability application review