See What Led One Company To It’s Decision
Modine Manufacturing produces thermal management technology and solutions, such as heat exchangers and cooling systems, for a wide range of industries, from on highway vehicles to data centers engineering mission-critical thermal management solutions. It is based in Racine, WI, and has operations in North America, South America, Europe, and Asia.
Right: Modine’s AMP DAWG™ low-profile residential/light commercial electric unit heater with advanced safety features, provides an energy-efficient compact heating solution for a small space or powerful warmth for a large area.
Maintaining Steam Levels and Temperature Is Crucial For Product Testing, and he Aging Clayton Steam Generators Were Losing Efficiency.
Don Raines, Modine Maintenance / Sample Shop Supervisor, said steam is used in simulated environmental conditions as well as direct applications. “We simulate conditions in order to produce a superior product for our customers.”
Modine was running two Clayton steam generators, a SEG-204 and an EG-154, that were now 23 years old and losing efficiency. According to Ryan Johnson, Clayton’s Thermal Sales Engineer, in order for Modine to produce the steam needed for manufacturing, they had to run both generators at the same time, which meant more water and fuel costs and higher emissions. “Modine is firmly committed to reducing its carbon footprint, so we needed to take care of these issues,” said Raines. But that wasn’t the only problem.
The Old Generators Were Loud, but Complaints About Their Noise Were Growing Louder
“Boiler harmonics” weren’t a problem until Modine moved a department of design and application engineers to a newly created office on the second floor— next to the boiler room. That brought complaints about disruptive noise and vibrations from the steam generators coming through the cinder block wall, causing headaches and loss of concentration. With productivity at stake, finding a solution became a top priority.
Relocate and Recondition The Generators — Or Replace Them?
Two goals needed to be met: create a quieter working environment for the engineers and lower operating costs and emissions. Raines and Johnson began investigating whether the current equipment should be reconditioned and relocated or replaced.
Costing Out the Scenarios
Todd Slicker, Clayton Western Regional Sales Manager, said that in this type of scenario, a company needs to compare the short- and long-term costs of relocating the equipment vs. replacing it with newer models.
office next to the boiler room, the “boiler harmonics” of
the aging Clayton steam generators caused them to lose
concentration. The need to move the steam generators
became urgent.
Reconditioning and Relocating the Existing Equipment
- Renting other boiler equipment while the Clayton boilers were relocated to an outside wall or elsewhere could cost $20,000 – $40,000 per month.
- Cost to transport the rental units to and from the location would add $15,000.
- Purchasing parts to retrofit the older equipment would also be costly.
Replacing the Equipment
- Clayton could install two new Clayton SEG-304 steam generators and remove the older existing equipment over a weekend, which would be less disruptive to operations
- The existing equipment would stay in service until the new generators were online, saving thousands of dollars in boiler rental costs
- New Clayton equipment would mean 20 to 30 years of reliability and energy efficiency
Operating Costs Vs. Capital Expenditure: The Convincing Economics of Choosing High Efficiency Steam
- Boiler equipment is only about 6% of the total steam production cost.
- Energy costs/fuel costs make up about 94% of the operation costs. Purchasing less efficient equipment.
Purchasing less efficient equipment would mean paying higher fuel, energy, and operation costs for 20-30 years (the equipment’s life) compared to purchasing high-efficiency equipment and saving substantial amounts in fuel costs over that same number of years.
Adding On An Economizer Could Save Another 3.5% On The Gas Bill
Johnson noted that Clayton steam generators are already very efficient, but an economizer can be added to the boiler—not one of those massive separate economizers, but an integrated economizer designed specifically for Clayton steam generators. This could result in another 3.5% savings on the gas bill. Gas companies often offer cost-saving incentives for energy efficiency, based on $ per therm saved.
Purchasing New Clayton E-304s Was A Clear-Cut Decision, But There Was Still One Important Test To Pass
Modine wanted to continue with Clayton steam generators because of their proven efficiency and reliability. However, since Clayton Industries had employed Don Raines as a Service Supervisor in Chicago before going to Modine Manufacturing, he wanted to prove that choosing Clayton wasn’t due to personal bias.
“I looked at package boilers of several other companies. I looked at how they worked, longevity, capability, breakdowns, and repair, and I just wasn’t satisfied with their quality. Clayton has proven themselves.” He shared other reasons they continued with Clayton’s equipment:
- We could fine tune the combustion better and more easily with the new technology of Clayton’s E-304s.
- We’d have the option to return the exhaust to combustion and re-use it, which aligned with Modine’s focus on sustainability.
- While steam pressure would be about the same, the volume from Clayton equipment would be better, so would run steadily and with greater efficiency.
- Clayton’s equipment is better able to maintain steam levels and temperature during test procedures, which would help us build better products for our customers.
- Clayton has a monotube design, and others have a multitube design. The monotube design offers greater heat transfer with better water flow.
Decision Made: Replace AND Relocate The Steam Generators
Raines and Johnson evaluated all possible solutions and created a plan.
- The decision was to purchase two new Clayton E-304s. The improved combustion capabilities would mean quieter, smoother operation. The energy/cost savings projections for the equipment’s life, 20 to 30 years, were too big to ignore. Modine could get the steam it needed for manufacturing by running just one E-304 instead of two less efficient generators. That would drastically reduce energy consumption and harmful emissions, aligning with Modine’s mission and purpose of Engineering a Cleaner, Healthier World. Plus, having a second E-304 provides a backup if they ever need most steam.
- The boilers would be located to the first floor directly below the current boiler room. The new steam pipes and stack would stay in the current boiler room above but against the outside wall, which would be quieter for the engineers.
- Building a new boiler room would require taking space from one of the testing labs, but having the boiler room next door would be worth it. “Before, our test engineers had to continually go to the second floor to monitor and test the steam,” said Raines. “Now they can step into the next room, which greatly improves operating efficiency.”
good, but it still has an old interior. We were able to achieve all of our goals, not just by buying new
equipment but also by its placement.” — Don Raines
Upgrading To New Clayton E304s Promises a Greener and More Productive Future For Modine
Regarding the steam used to test their products, Raines confirmed a noticeable improvement right off the bat. The new technology and higher steam production capability of the E-304s meant Modine could operate with just one unit. “That makes it easy to maintain the heat we need for the test. It’s easy to adjust if a different temperature is required. Being able to run just one steam generator is easier to maintain steady heat and is better at maintaining the load,” he said.
The new generators had only been online for a couple of months when Modine noted savings in water and fuel and reduced emissions. “We’re happy with the way things
are going, looking at our Green Goals for improving efficiency and cost savings,” Raines said. “And the engineers are more than pleased, too, having the steam generators next to the testing labs. The Clayton E-304s are so smooth that they don’t even know they’re running.”
Todd Slicker weighed in on the results, saying, “The fact that Don stayed using Clayton steam generators is a testament to the equipment and its efficiency and reliability. After two months of being online, the new equipment was running very well and reliably, and the steam quality is even better.”
significantly improving operational efficiency
