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Good Plumbing Performs High-Efficiency Boiler Replacement for Catholic Church

Good Plumbing, Heating and Air Conditioning, a company with over 75 years of experience in Southeast Pennsylvania, has developed a specialized expertise in hydronic systems for religious institutions. This case study details their recent high-efficiency boiler replacement project at Our Lady of Guadalupe, a 25,000-square-foot Catholic church in Doylestown, PA, built in 2011. The church’s original heating system, which used four 399 MBH atmospheric cast iron boilers, experienced a significant failure in February 2024, with two boilers leaking. The project manager, Bob Weikel, sought multiple options for repair or replacement, ultimately receiving ten estimates. Good Plumbing, along with manufacturer’s rep firm ROI Marketing, presented a solution focused on energy efficiency and system longevity. Roger Prevost, general manager and hydronic system designer at ROI Marketing, noted that the original boilers were not piped in a primary-secondary configuration, which may have contributed to their failure due to thermal shock from low return water temperatures, although this could not be definitively confirmed. The proposed solution involved replacing the four existing boilers with two 650 MBH Citadel condensing boilers from U.S. Boiler Company. This upgrade maintained system redundancy and significantly improved energy efficiency. The new dual-Citadel system offers a wide modulation range, from 65,000 to 1.3 million BTUH, which is a major advantage for a facility like a church that experiences drastic fluctuations in heating demand. Condensing boilers are also impervious to the low return water temperatures that potentially damaged the old cast iron units. To meet the church’s request for remote monitoring, a tekmar 294 Boiler Control was integrated into the new system, allowing the maintenance team to remotely monitor individual zone temperatures. The installation process, led by Good’s Lead Mechanic Tom Grasse and Mechanic Wade Loughridge, involved removing the old boilers and modifying the boiler room for primary-secondary piping. New closely-spaced tees were welded into the existing supply and return lines, along with fittings for air elimination and sensors. The two Citadel boilers were placed on the existing pad, with careful attention to clearance for easier venting using six-inch Centrotherm polypropylene for both venting and combustion air through sidewall penetrations. A challenging aspect was core drilling through the concrete wall. The team opted to draw combustion air from outside, despite the Citadel boilers being approved for boiler room air, for optimal performance. The system was completed before Independence Day, with Prevost, Landis, Grasse, and Loughridge later programming and starting up the tekmar 294 Boiler Control in September. The tekmar control utilizes an outdoor reset function, sending a 4-20v signal to the boiler to adjust the firing rate based on outdoor temperature. The system was designed for a 20°F outdoor design temperature to ensure fast recovery, providing 180°F supply water at 20°F ambient and 120°F water at 70°F ambient. This setup is expected to result in a 40 percent natural gas savings for the church, thanks to higher efficiency, greater turndown, and the elimination of standby loss. The church maintenance team's practice of heating the sanctuary one hour before mass ensures the heat exchangers condense for extended periods, maximizing energy efficiency. #HydronicSystems #BoilerReplacement #HighEfficiencyBoilers #CatholicChurch #EnergyEfficiency #HVACRetrofit #CondensingBoilers #RemoteMonitoring #ThermalShockPrevention #HydronicSystems #BoilerReplacement #HighEfficiencyBoilers #CatholicChurch #EnergyEfficiency #HVACRetrofit #CondensingBoilers #RemoteMonitoring #ThermalShockPrevention
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