Boiler E

Inputs
Basic Data about your Boiler
Manufacturer
Location
Control Type
Maximum Firing Rate

MMBtu/hr

Minimum Firing Rate

20

Inlet Air Temperature

80

Purge Air Temperature

75

Air Humidity Ratio

0.01

Purge Cycle Time

30

lbv/lb-air
s

Firing Rate

High

Medium

Percent Capacity

100

70

Annual Operating Hours

1000

High

Medium

Stack Conditions
O2%
CO2%
CO ppm
Stack Temerature F

Outputs

Firing Rate
Current Stack O2%

High/Medium Proposed O2%

Firing Rate

High

Combustion Efficiency Before Adjustment %

Combustion Efficiency After Adjustment %
Boiler Efficiency Before Adjustment %
Boiler Efficiency After Adjustment %
Energy Savings, MMBtu
Cost Savings, $

References and Equations

References
Fuel properties data was taken from Research Bulletin 60, OSU Forest Research Lab, 9/87
Combustion efficiencies were calculated from the combustion gas conditions measured us
convection and cycling losses were included in the calculation of the boiler efficiencies.
Calculations in this tool are based on the ASME PTC 4 Indirect Methods for computing boile
Constants
Steam Gas Constant: 0.1103 btu/(lbm-R)
Select Equations
Current Annual Energy Use = Fuel Input Annual Operating Hours

Adjusted Annual Energy Use = Fuel Input Annual Operating Hours Current Boiler Efficiency/Adjusted
Annual Energy Savings = Current Annual Energy Use - Adjusted Annual Energy Use

Annual Cost Savings = (Annual Energy Savings Fuel Cost) - (Estimated Equipment Cost + Estimated L

Acknowledgements
This tool is based off a similar tool created by the Oregon State University Energy Effic

Energy Efficiency Center can be found on the OSU Energy Efficiency Reference (EEREF)

http://eeref.engr.oregonstate.edu/.
Similar tools to the Boiler Tune-up Tool can be found on the OSU OpportunityTemplates websit
http://eeref.engr.oregonstate.edu/Opportunities_with_Calculation_Sheets.

Boiler Excess Air Tune-up

Steam System
Steam System Pressure Range

10

Steam System Volume

Steam Pressure
Fuel
Fuel Type
Fuel Cost
Installation Cost
Estimated Equipment Cost
Estimated Labor Cost

Medium

Boiler Firing Rate

Low

Standby

70

40

10

Medium

Low

Standby

Low/Standby Proposed O2%

Medium

Low

Standby

Total
0
$0

est Research Lab, 9/87.

conditions measured using the ASME indirect method. Radiation,
he boiler efficiencies.
ods for computing boiler efficiency.

Boiler Efficiency/Adjusted Boiler Efficiency

ment Cost + Estimated Labor Cost)

niversity Energy Efficiency Center. More information about the Oregon State University

cy Reference (EEREF) website at

unityTemplates website at

psi
ft3
psig

$/MMBtu
$
$

Instructions for using the Boiler Excess Air Tune-up Tool

1
2

Select the "Tool" tab loacted in the bottom left corner of this window highlighted in red.
Enter the values in the input section .
A.
Some inputs use drop-down menus which are selected like the following:

These drop-down inputs are used in the fields:

Control Type and Fuel Type

Key
Maximum Firing Rate
(MMBtu/hr)

The nameplate rating for the boiler.

Minimum Firing Rate (%)

The lowest rate at which the boiler can operate is usually between 10 and 40%, th
for larger boilers. Minimum fire affects boiler cycling losses at loads below minimu
minimum firing rate is unknown, it is recommended to use a default value of 20%.
Inlet Air Temperature:

The temperature of the air entering the burner. If the inlet air temperature is unk
recommended to use a default value of 80F.
Purge Air Temperature:

The temperature of the air leaving the boiler through the vent or purge outlet du
cycle. If the purge cycle time is unknown, it is recommended to use a default val
seconds.
Air Humidity Ratio:

The absolute humidity, specific humidity, or humidity ratio is the ratio of the mas
in a volume of air to the mass of dry air. It is used to calculate the boiler efficienc
heating water vapor in combustion air.
Purge Cycle Time

The time during which air is blown through the boiler without fuel for the purge c
average time in seconds for both pre (before burner) and post-purges.
Steam System Volume

Many boiler manufacturers specify the "steam chest" or "steam volume" as the volu
water level in a boiler. System volume also includes piping. If the steam system vo
unknown, it is recommended to use 0.2 ft3/Boiler hp.
Percent Capacity

This is a firing rate expressed as a percent of the nameplate capacity.

CO2 ppm

Carbon monoxide concentration is quantifiable measure of unburned fuel. Most co

analyzers measure CO in parts per million (ppm). Levels over 400 ppm are conside
for people. Many combustion analyzers do not measure levels above 400 ppm.

High/Medium Fire Proposed The proposed stack oxygen content will be determined by the tool based on the se
O2%:
type.

Low/Standby Fire Proposed

The proposed stack oxygen content will be determined by the tool based on the se
O2%:
type.

r Tune-up Tool

ow highlighted in red.
like the following:

ate is usually between 10 and 40%, the smaller rate

r cycling losses at loads below minimum fire. If the
mended to use a default value of 20%.

ner. If the inlet air temperature is unknown, it is

r through the vent or purge outlet during the purge

is recommended to use a default value of 30

humidity ratio is the ratio of the mass of water vapor

used to calculate the boiler efficiency loss due to

he boiler without fuel for the purge cycle. Enter the

burner) and post-purges.

m chest" or "steam volume" as the volume above the

ncludes piping. If the steam system volume is
Boiler hp.
the nameplate capacity.

le measure of unburned fuel. Most combustion

pm). Levels over 400 ppm are considered dangerous
t measure levels above 400 ppm.

etermined by the tool based on the selected fuel

etermined by the tool based on the selected fuel

Boiler Tune-Up Energy Saving

Date Created:

8/10/2016

Boiler Information
Manufacturer
Location
Control Type

Fuel Type

Fuel Cost

0 $/MMBtu

Maximum Firing Rate

0 MMBtu/hr

Minimum Firing Rate

20 %

Energy Savings Recommendation

Energy Savings Summary
Potential Energy Savings
(MMBtu/yr)
-

Potential Cost Savings

$
*1 MMBtu = 1,000,000 Btu, 1kWh = 3,413 B

Implement a boiler tuning program to maintain an optimum air-fuel ratio, improving combustio
boiler(s) will reduce associated fuel consumption by 0% MMBtu per year. It is recommended to
your boiler water side heat exchanger surfaces to increase combustion efficiency .This should b
after.

Ideally, a boiler would use just enough combustion air to burn all of the fuel, with no excess ai
boiler efficiency. However, all burners require some excess air to ensure complete combustion

Efficiency can also be improved by cleaning scale from the waterside heat transfer surfaces. S
silica, form a layer of material on the boiler heat exchanger surfaces. By removing the scale,
temperatures.

*Note: Potential cost savings does not take into consideration implementation cost. Estimated first yea
implementation cost

Up Energy Savings Summary

8/10/2016

Inlet Air Purge Temperature

80 F

Purge Air Temperature

75 %

Steam System Pressure Range

10 psi

Steam System Volume

0 ft3

Steam Pressure

0 psig

Air Humidity Ratio

Purge Cycle Time

0.01 lbv/lb-air
30 s

gy Savings Summary

Estimated Implementation
Cost
$
000,000 Btu, 1kWh = 3,413 Btu

Estimated First Year

Cost Savings
$
-

ir-fuel ratio, improving combustion efficiency and lowering fuel use. Tuning your
tu per year. It is recommended to have a boiler specialist tune your boiler and clean
mbustion efficiency .This should be done immediately and then once every year

all of the fuel, with no excess air. Excess air carries heat up the stack and reduces
r to ensure complete combustion.

aterside heat transfer surfaces. Scale deposits occur when calcium, magnesium, and
urfaces. By removing the scale, heat transfer will improve, lowering stack

ementation cost. Estimated first year cost savings does take into consideration