Project Highlight: Turnkey Boiler System Installation for Manufacturing Facility
Industry: Manufacturing
Location: Newcomerstown, OH
Equipment: 225 HP Ohio Special • Integrated Hawk Controls • Economizer • Deaerator
Engineering Support: Piping Schematics
Background
When a Newcomerstown manufacturing company moved operations into a new building, they needed a reliable, high-efficiency steam system to support production. Having operated Cleaver-Brooks boilers for years, the facility was familiar with the equipment’s performance, dependability, and long service life. Their positive experience made it an easy decision to keep Cleaver-Brooks as their preferred boiler partner for the new facility.
To ensure a seamless transition, the customer selected Energy Control to provide a complete turnkey boiler room solution—from system design through installation, commissioning, and ongoing service support.
Solution: Fully Integrated Boiler System
Energy Control delivered a 225 HP Ohio Special boiler package, equipped with advanced Cleaver-Brooks technologies to maximize performance and simplify operation.
Key System Features
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Hawk PLC Controls for intuitive operation and advanced diagnostics
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Parallel Positioning to optimize fuel/air ratios across the firing range
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O₂ Trim System to maintain ideal combustion under changing conditions
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VSD Combustion Air Blower reducing electrical usage and improving efficiency
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Integrated Economizer to recover waste heat and lower fuel consumption
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Spray-Type Deaerator to protect the boiler against oxygen-related corrosion
These upgrades represent a significant improvement over the customer’s previous system, which utilized older FSG-style controls with no digital communication or advanced combustion management.
Results: Improved Efficiency, Reliability & Visibility
The new boiler system increases operational efficiency by at least 3% through precise combustion control and O₂ trimming—translating to meaningful energy savings over the boiler’s lifecycle.
Remote communication and modern PLC capabilities now give the plant better system visibility, trending data, and easier troubleshooting.
Turnkey Installation & Ongoing Support
Energy Control provided:
- Complete installation
- Piping schematics
- Commissioning
- Operator support
- Preventative maintenance programs
- Emergency service coverage
The customer values that Energy Control not only supplied the equipment but also continues to provide dependable service, ensuring their new boiler system operates safely and efficiently.
Summary
This project demonstrates how replacing outdated boiler controls and equipment with an integrated Cleaver-Brooks system can dramatically enhance performance, reliability, and long-term cost savings. With full turnkey service and advanced combustion technology, Energy Control helped this manufacturer start up their new facility with confidence.