06/12/2026
Replacing major steam plant equipment can be challenging. Doing so within the footprint of a decades-old facility while maintaining critical utility infrastructure requires a strategically coordinated design and engineering approach.
At Buffalo State University, RMF helped replace decades-old steam plant equipment while working entirely within the constraints of the existing facility. To accommodate the installation of three new boilers, a substantial portion of the roof was removed and reconstructed, allowing large equipment components to be safely removed and lowered into the existing facility. The new equipment was installed within the original boiler room and a 1965 addition, maximizing the use of existing infrastructure while extending the plant's operational life.
The upgrade replaced two original boilers with new 62,500 PPH packaged watertube boilers and a summer boiler with a new 27,500 PPH firetube boiler, resulting in a total installed steam generating capacity of 152,500 PPH. Each boiler features 10:1 turndown capability on natural gas, low-NOx burners, feedwater economizers, and advanced controls designed to improve efficiency, operational flexibility, and emissions performance.
Completed through multiple phases, the modernization included not only the replacement of the boilers but nearly all the plant's ancillary balance-of-plant (BOP) infrastructure, including the deaerator, condensate tanks, pumps, and associated support systems essential to reliable steam generation and plant operation.
The project also included a comprehensive controls modernization, featuring an Allen-Bradley PLC-based combustion control system (CCS) and microprocessor-based burner management system (BMS) integrated with new SCADA and historian platforms, as well as a new PLC-based Balance of Plant (BOP) control system with redundant controllers to enhance system resiliency, monitoring, and long-term reliability.
RMF provided controls engineering, mechanical engineering, electrical engineering, and civil engineering.
Projects like this demonstrate how thoughtful engineering can transform aging utility infrastructure into modern, high-performing systems that support facility operations for decades to come.