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With zero emissions, economical electric steam and hot water boilers deliver maximum heat and hot water in minimum spatial footprint

Due to the threat of global warming as well as international commitments to the Paris Accord on Climate Change, municipalities and regions using district heating in Europe and North America are tasked with significantly reducing their environmental footprint in record time.  With district heating, towns or large areas typically receive heat and hot water, distributed to commercial, residential, or public buildings at greater economies of scale than individual heating systems.

In response, last year the 27-nation European Union (EU) agreed to cut greenhouse gas carbon emissions by 55% by 2030 compared to 1990 levels.  According to a recent report that has tracked the EU’s power sector since 2015, renewables surpassed fossil fuels last year (38% to 37%), indicating that municipalities relying on district heating are already pivoting away from often inefficient, outdated equipment that produces excess carbon emissions.

Even the U.S., which recently rejoined the Paris Agreement, has targets for American businesses to achieve a carbon pollution-free power sector by 2035 and a net-zero economy by 2050.

While the interest of regions using district heating in electric boilers has waxed and waned in the last century, suddenly it is in vogue again.  Whether to honor Environmental Social and Governance (ESG) goals, meet regulatory commitments, or take advantage of government credits and incentives, a growing number of municipalities are installing new or retrofit high-voltage electrode boilers that are compact, economical, and produce no emissions.

This is, in part, due to technological advances in electric boiler design that increase the output to a level that rivals even large gas or oil-fired boilers.  When utilized for district heating, electric-powered alternatives are sure to be a critical piece of the puzzle to meet future emission reduction goals.

Transitioning from High-Emission Gas and Oil-Fired Boilers

With district heating, besides the notorious greenhouse gasses carbon dioxide (CO2) and methane (CH4), natural gas-fired boilers and furnaces emit dangerous nitrogen oxides (NOx), carbon monoxide (CO), and nitrous oxide (N2O), as well as volatile organic compounds (VOCs), sulfur dioxide (SO2), and particulate matter (PM).

However, many facility engineers familiar with gas-fired boilers mistakenly believe that electric boilers cannot match the output of the traditional, fossil fuel burning units.  Due to considerable advances in electric boiler technology, that is far from the case.  Today, such technology can match the capacity of large gas or oil-fired boilers in a much smaller footprint.

Electric boilers utilize the conductive and resistive properties of water to carry electric current and generate steam.  An A.C. current flows from an electrode of one phase to ground using the water as a conductor.  Since chemicals in the water provide conductivity, the current flow generates heat directly in the water itself.  The more current (amps) that flows, the more heat (BTUs) is generated, and the more steam produced.  Crucially, almost 100% of the electrical energy is converted into heat with no stack or heat transfer losses.

As an example, the electrodes of the CEJS High Voltage Electrode Steam Boiler by Acme, a Canada-based manufacturer of industrial and commercial boilers, are vertically mounted around the inside of the pressure vessel.  This enables the unit to produce maximum amounts of steam in a minimum amount of floor space, with boiler capacity from 6MW to 52MW.

The boiler operates at existing distribution voltages, 4.16 to 25 KV with up to 99.9% efficiency, and can produce up to 170,000 pounds of steam per hour.  With pressure ratings from 105 psig to 500 psig, the boilers are designed to ASME Section 1, and are certified, registered pressure vessels at the location of the boiler.

“There is an entire generation of district heating facility engineers that grew up with oil and gas-fired boilers almost exclusively,” says Robert Presser, Vice President of Acme Engineering, which, along with North American facilities, builds in Europe to European standards and has a network of CE-compliant fabricators for the pressure vessel, as well as partners in France and the UK for local equipment assembly.

“As a result of preconceived notions, most view electric boilers as small underpowered units, like a hot water heater,” adds Presser.  “So, we frequently have to educate engineers that there is electric boiler technology that can match the capacity of large gas or oil-fired boilers available.”

According to Presser, the electric boiler technology is used for residential and commercial district heating, which is increasing in demand, particularly within urban centers.  With district heating, distributed heat is generated in a central location through an insulated pipe system, and utilized for high-efficiency, low-pollution, space and water heating.  For central heating applications, electric boiler technology quietly supplies ample power for its compact size.  This approach is currently being considered to install several 50MW steam boilers in the center of Manhattan, replacing gas-fired boilers to provide centralized steam to a number of buildings.

Typically, district heating upgrades are initiated due to high heating costs that customers find unaffordable, often due to expensive fossil fuels or an aging system that needs to be replaced.  Increasingly, such upgrades are pursued to minimize environmental impact.

The upgrades often entail retrofitting or replacing boilers (the heat source) with cleaner, more efficient electric alternatives, along with the heat distribution network (pipes/ heat exchanger stations).

In addition, electric boilers have several advantages compared to oil or gas-fired boilers, including superior safety, ease of installation, faster start-up and shut down time, and quiet operation. Electric boilers do not have a high minimum operating level to make them immediately available.

“Electric boilers do not need an operator because if anything goes wrong, the breaker trips, preventing further escalation of the issue,” says Presser. “With gas burning boilers, however, any gas leak can increase the risk of an explosion.  So, gas units must usually be continually monitored or periodically inspected.”  He notes that state and municipal safety guidelines vary depending on boiler type and the expected frequency of inspection.

With electric boilers, the energy input as well as adjustment is also precise and virtually immediate.  In contrast, increasing or decreasing the temperature in a gas fired boiler is a slower process because it takes time for the heat in the boiler to rise or dissipate before reaching the targeted output.

The electric units are also exceptionally quiet compared to fuel fired boilers.  “Unlike gas-powered burners that throttle like turbine engines almost continually, electric boilers keep operational noise levels down,” says Presser.  “Because the loudest boiler component is a circulating pump motor, it is easy to have a conversation next to one without having to raise your voice.”

As the EU and U.S. resolve to dramatically cut their greenhouse gases to combat climate change, the urgency for areas using district heating to similarly reduce their carbon emissions will only grow. In this battle to protect the environment before the global climate hits an irreversible tipping point, municipalities along with state and federal government, and the commercial sector must do their part.  Fortunately, advanced, zero-emission electric boiler technology can be a readily implementable part of the solution.

For more info, contact Robert Presser at Acme Engineering rpresser@acmeprod.com; phone: 888 880-5323; or visit our website.

All closet augers are created equal. Right?

“Wrong” says Alan Trout of Trout Plumbing LLC in Pittsburgh, PA.

“Most off-the-shelf closet augers lack the durability, spring action, and special features professionals need,” he argues. “You can’t just waltz into Wal-Mart for one.”

That’s why Trout counts on a pair of popular, innovative Teletube^® Flexicore^® closet augers from General Pipe Cleaners.

Versatility And Reliability Count

The heavy-duty Teletube Flexicore closet auger remains the industry’s most durable auger – and excels at clearing stoppages just beyond the bowl.

That’s because General’s rugged tool carries three extra feet of Flexicore^® cable telescoped inside the guide tube.

“I just push the button for extra cable length when I need it,” Trout says. “And with a total reach of six feet, there’s usually no need to pull the bowl!”

General’s Flexicore closet augers are the ideal for quickly clearing clogged toilets. The strength and durability of Flexicore cable make the difference.

Flexicore comprises two layers of tempered spring steel coiled tightly over a core of 49-strand wire rope – for remarkable resistance to kinking.

The design is so tough, it’s guaranteed against breakage for a full year – including damage to the cable, as well as to the closet auger’s other components.

Performance – Inside And Out

On one recent job, a homeowner unsuccessfully tried unclogging a three-inch cast-iron stack – after feeding 25 feet of cable into the line.

“The customer must’ve missed the stoppage – or his cable was too small,” Trout recalls, “because I extended Teletube to six feet upon arrival – and quickly cleared the clog!”

Teletube’s extra reach even lets Alan Trout clear outside stoppages.

On another job, the powder room toilet in a two-room home office suite suddenly backed up.

After unsuccessfully snaking the drop head Teletube through the bowl, Trout went in through the outside fresh-air vent – and immediately got things flowing.

“That extra three feet made all the difference,” he smiles.

Special Features Enhance Appeal

He likes General’s down head option, too.

The optional down head follows bowl contours – and springs through sharply angled passages while protecting inner walls from chipping or breaking.

Alan Trout also has an optional Closet Auger Bag. General’s convenient carrying case puts an end to dragging dripping closet augers though homes, hospitals, and offices.

It keeps a closet auger contained and out-of-sight between jobs. Three vent holes let the auger dry between tasks. And thick shoulder strap keeps hands free to carry other tools.

“Until I got the bag, I’d carry a bucket with the Teletube,” Trout chuckles. “General’s Closet Auger Bag enhances ‘professional’ appearance – and keeps customer property clean.”

Building Trust – Job After Job

From installations and repairs to leaks and stoppages, Trout Plumbing handles a wide range of problems for Pittsburgh-area customers – both commercial and residential.

“On every job, we aim to build a level of professional trust that turns new customers into lifetime customers,” Trout says.

Proper equipment operation helps makes the difference, he quickly adds. But he isn’t afraid to push his Teletube closet augers to the limit – inside and out.

Part Of The Drain Cleaning Arsenal

For most inside drain cleaning jobs, Trout favors General’s classic Super-Vee^® hand-held machine.

“I use it at least once a week – if not more – on 1-1/4” to 2” lines,” he notes.

In fact, Super-Vee easily unclogs sink, tub, and laundry drain lines up to 3” in diameter. With a dependable motor, durable aluminum drum, and tough Flexicore cable, Super-Vee withstands the most demanding small line tasks, and keeps working.

Convenient, quick-change cable cartridges also make Flexicore cable switching clean and easy.

“With 3/8” cable, my Super-Vee was actually able to snag – and remove – a broken cable in one customer’s slow-draining line,” Trout recalls. “And that solved the problem!”

The Bottom Line

Like Teletube closet augers, Super-Vee carries an almost legendary reputation for rugged reliability – and longevity.

“I actually bought my Super-Vee from a plumber with excess equipment when I first went into business,” he continues. “So I’d say it’s nearly 15 years old – and still works great!”

His Teletube closet augers work great, too.

“As a plumbing service contractor, I use Teletube toilet augers from General,” Trout concludes. “The Teletube can almost do it all!”

For more information, contact the Drain Brains at 800-245-6200, or visit https://drainbrain.com/en/products/closet-augers-2/

When Dana Spears assumed full ownership of Cornerstone Pros in 2009, it was a very different company than it is today. She credits much of her Tampa Bay, FL business’ increased success to her relationship with KickCharge Creative, a New Jersey-based marketing agency that serves small businesses across the country.

The partnership began in 2013 when Cornerstone sought KickCharge’s expertise to rebrand the heating and cooling company. As the company expanded its services to include plumbing and electrical, its name changed from Cornerstone Air to Cornerstone Pros. The team at KickCharge created a dapper, friendly retro technician mascot to communicate Cornerstone’s differentiator—old-fashioned quality service in today’s fast-paced world. KickCharge Creative wove the retro brand into all of Cornerstone’s marketing efforts, including its service vehicles, initial brand announcement, brochures, blogs, print ads, billboards and stationery.

Cornerstone Pros had five service vehicles when its rebranded fleet first hit the streets in 2014. But Spears said the visibility and power of the new brand made customers feel like there were many more vehicles out there. Today, Cornerstone has roughly 56 vehicles in its fleet. Spears said the increased visibility has helped with employee recruitment efforts, too.

During the eight years since this partnership began, the new brand continues to pay dividends, including a 300% boost in revenue. Spears said annual revenue was $3 million before the rebrand and it jumped quickly to $5 million within the first year after introducing the retro brand and new services.

Since 2016, KickCharge has been managing Cornerstone’s highly successful digital marketing campaigns, which include search engine optimization, email marketing and pay-per-click advertising. KickCharge also launched a retro-themed, custom-designed website for this brand.

THE STATS:

• 300% growth in annual revenue since rebrand\
• Increase from 5 to 35 service vehicles

Spears’ goal is slow-based growth. As of 2020, the company had more than $12 million in annual revenue and roughly 78 employees. Cornerstone has nearly 2,000 reviews on Google with a 4.8/5 average rating. Its closing ratio is 87 percent even when the team has too much work to tackle same-day appointments.

For Cornerstone, newspaper ads were once a primary driver of leads and Spears relied heavily on print, billboards and home-based advertising as well as some radio spots. These days, digital marketing is the dominant force. Google is the leading source of call volume (80 percent of leads), followed by repeat and referral customers.

“I am now dominating online so I don’t need to spend as much in other marketing areas,” she said.

Digital marketing campaigns offer more control over lead volume because they can be targeted specifically and adjusted instantly based on demand and seasonality. Those are factors Spears likes. It’s also easier to track these campaigns and to evaluate results.

“Although I was reluctant to turn my marketing over to an agency,” Spears said. “I’m glad that I did.”

The National Science Foundation’s Daniel K. Inouye Solar Telescope in Maui, Hawaii, uses the largest mirror of any solar telescope in the world. Thanks to its 13-foot-wide mirror, it collects seven times more sunlight than any other solar telescope, producing the clearest, highest-resolution images ever taken of the sun.

Not surprisingly, a solar telescope of this size produces a lot of heat. With a working lifespan of about 50 years – after more than two decades of planning by the National Solar Observatory and its partners – there is a lot that goes into keeping the telescope cooled so it can provide groundbreaking scientific insights.

And that’s where Viega comes to the table.

An enormous, unique project

Eventually, there will be more than seven miles of thermal piping within the telescope and support buildings, explained Lou Szabo, Facility Thermal Systems Site Coordinator for the National Solar Observatory. He spends his days helping to finish construction and commissioning the equipment that recently began collecting images of the sun.

Much of the piping was prefabricated years ago, as various parts of the facility and telescope were being built (construction has taken about 10 years). Traditional methods, mainly welding, were used. But then the project came to a crossroads.

“As the various science instruments are installed and other devices added to the telescope, the final piping needs to be completed or modified, and oftentimes in close proximity to optics or one-of-a-kind electronics that are worth millions of dollars – things that would take many years to reproduce if damaged,” Szabo said. “We can’t have any joining methods that use heat or fumes. It has to be a very clean process.

“The only way to install these remaining piping runs is with a joining system that meets the ‘no heat, no fumes, no dust’ requirements – and Viega hit that mark. We can go into these critical areas with very little equipment and complete press joints within inches of sensitive equipment, and the crews don’t have to worry about damaging it.”

As the need for a press-fitting solution surfaced, Szabo was already aware of Viega. He’s been in the piping trades for more than three decades and had previously used Viega.

He also knew that Viega had a large variety of fitting choices and, more importantly, offered plenty of technical support.

“When I presented the press system to the lead engineers and the decision-makers, I had to bring the best system I knew of,” he said. “Viega had been around the longest and had the best technical support if we had a question or got into a bind. We knew we had the reliability of the system behind us. It was really the only choice. I wouldn’t have been comfortable with others.”

Another factor to account for is the ozone conditions. The telescope is located at Haleakalā Observatories, at 10,000 feet in elevation, on the island of Maui. This location allows for great conditions for observing the sun but brings with it other unique elements, too.

“There is a high ozone content in the atmosphere here. Ozone was attacking a lot of rubbers and things, so we use HNBR sealing elements in all of our fittings,” Szabo said. “Some of the coolants we use are more exotic, and the HNBR holds up.”

The bulk of the coolant used is Dynalene HC20. The manufacturer lists both HNBR and EPDM as compatible materials, but the EPDM seal isn’t as resilient with the ozone presence, so Viega’s HNBR sealing elements are the right fit.

Inner workings of the telescope site

A series of primary loops come from the main mechanical/utility building, where all the chillers are located. The loops run to heat exchangers, followed by secondary and tertiary loops. There are dozens of pumps and tanks involved in the complex setup.

Piping in the system includes everything from 6” carbon steel piping to ½” copper tubing. Stainless steel is also used. The miles of piping run coolants and air to keep the telescope project at an appropriate temperature and to keep everything working smoothly. Viega ProPress fittings up to 3” in diameter and MegaPress fittings as large as 2” are used throughout the site.

The mirrors and transfer optics are cooled in a variety of ways, including cooled liquid and air. For example, air a few degrees below ambient temperature is typically blown on the back of the mirror cells.

The Dynalene coolant runs at a very low temp, some as low as –2 degrees F, some around 45 degrees. The coolant is also environmentally friendly, which was important for the culturally sensitive site that carried with it many environmental guidelines. Propylene glycol mixtures are also used in some of the scientific chillers.

“A challenge we have in the middle of the Pacific is having fittings available, and that’s why we try to keep our setup as simple as we can,” Szabo said. “It’s also why we went with MegaPress and ProPress. Much of it is available on the islands, whereas other systems are more difficult to get.

“We try to keep a stock of certain fittings and materials on hand and stay ahead of the game. Oftentimes we’re looking at a two- to four-week lead time to get less-common fittings to the island. Thankfully our supplier, PACE Supply, can often get us common fittings within a couple of days.”

Szabo said they strive to keep the piping runs as simple as possible to both limit flow restriction and allow the use of standard elbows, adapters, tees and couplings, which are more readily available on the island.

One-of-a-kind solar research

Plans for the Inouye Solar Telescope (named for the late Daniel Inouye, the U.S. Senator from Hawaii who played a crucial role in getting finances approved for the project and was a big advocate of STEM and science) started 25 years ago. Dr. Claire Raftery, Head of Education, Outreach and Communication for the National Solar Observatory, said innovating how to build something so complicated – and then get it funded – was a massive undertaking.

There was an extensive survey done to determine the location of the telescope. A few hundred sites worldwide were reduced to a short list of 72, which was whittled down to a six. From there, only three met the specific requirements that scientists were looking for, and the location in Maui was chosen.

The Inouye Solar Telescope’s unique location combines clear and vivid blue skies needed to observe the faint corona of the sun with a high elevation and low air turbulence of the atmosphere above the telescope. Thanks to all these things, the telescope can produce the best images of the sun ever taken so that scientists can learn more about the dynamic star.

“We’re studying an object that there’s still a lot of mystery around. Many questions remain unanswered because we don’t yet have the capability to answer them,” Raftery said. “We need more detail, higher resolution – and these are things this telescope will bring to the table. It’s really a fortuitous time to be working in the solar physics industry.”

The telescope is expected to be operational for at least 44 years – four solar cycles – which is one of the benefits of ground-based astronomy, Raftery explained.

“We can expand the abilities of this project much longer than we could from space,” she said. “It’ll never really stop being finished. We can adapt and improve. The team will continue to bring new science experiments online through the life of the telescope.”

Part of the federal requirements from the National Science Foundation include returning the site back to the way it was found, so in 50 years they won’t simply turn off the lights and walk away, but instead the project will eventually be removed from the site after it has run its course.

But with that prospect decades into the future, for now everyone involved with the project is exhilarated as the telescope begins recording images of the sun.

“I remind the crews that they are the only ones in the entire world working on this unique system,” Szabo said. “This is truly a one-of-a-kind project.”