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Boiler Efficiency Guide
Boiler Efficiency Guide
Boiler Efficiency Guide
GUIDE
F A C T S
Forward
Todays process and heating applications
continue to be powered by steam and
hot water. The mainstay technology for
generating heating or process energy is the
packaged firetube boiler. The packaged
firetube boiler has proven to be highly efficient
and cost effective in generating energy
for process and heating applications.
F A C T S
Introduction
1. Maintenance Costs
Replace or Repair
The decision to purchase a new boiler is
typically driven by the needed replacement of
an old boiler, an expansion of an existing boiler
room, or construction of a new boiler room
facility.
2
Efficiency Feature
Comparisons
F A C T S
5. Vessel design
Pressure vessel design is regulated by strict
ASME code requirements, however there are
many variations that will still meet the codes.
Proper water circulation, low internal stresses,
and easy accessibility for inspection and
maintenance are key criteria when evaluating
the design of a pressure vessel.
Firetube boilers are available in 2 basic vessel
designs, dryback or wetback. The difference
lies in the flue gas turnaround area at the
rear of the boiler. Each design has its own
advantages and disadvantages as follows:
F A C T S
Defining boiler
efficiency
Combustion Efficiency
Combustion efficiency is an indication of the
burners ability to burn fuel. The amount of
unburned fuel and excess air in the exhaust
are used to assess a burners combustion
efficiency. Burners resulting in low levels of
unburned fuel while operating at low excess air
levels are considered efficient. Well designed
conventional burners firing gaseous and liquid
fuels operate at excess air levels of 15% and
result in negligible unburned fuel. Well designed
ultra low emissions burners operate at a higher
excess air level of 25% in order to reduce
emissions to very low levels. By operating at
the minimum excess air requirement, less heat
from the combustion process is being used to
heat excess combustion air, which increases
the energy available for the load. Combustion
efficiency is not the same for all fuels and,
generally, gaseous and liquid fuels burn more
efficiently than solid fuels.
Thermal Efficiency
Thermal efficiency is a measure of the
effectiveness of the heat exchanger of the
boiler. It measures the ability of the exchanger
to transfer heat from the combustion process
to the water or steam in the boiler. Because
thermal efficiency is solely a measurement
of the effectiveness of the heat exchanger of
the boiler, it does not account for radiation
and convection losses due to the boilers
shell, water column, or other components.
Since thermal efficiency does not account for
radiation and convection losses, it is not a true
indication of the boilers fuel usage and should
not be used in economic evaluations.
Boiler Efficiency
The term boiler efficiency is often substituted
for thermal efficiency or fuel-to-steam
efficiency. When the term boiler efficiency
is used, it is important to know which type of
efficiency is being represented. Why? Because
thermal efficiency, which does not account
6
Components of
efficiency (impact and
sensitivity)
Boiler efficiency, when calculated by the ASME
heat balance method, includes stack losses
and radiation and convection losses. But what
factors have the most effect or sensitivity on
boiler efficiency? As discussed earlier, the basic
boiler design is the major factor. However, there
is room for interpretation when calculating
efficiency. Indeed if desired, you can make
a boiler appear more efficient than it really
is by using a little creativity in the efficiency
calculation. The following are the key factors
to understanding efficiency calculations.
1.
2.
3.
4.
5.
Efficiency (%)
figure 1
Butane
Propane
Ethane
Typical
Natural
Gas
Methane
250
275
300
325
350
375
400
425
450
475
500
Butane
84
Efficiency (%)
F A C T S
Propane
83
Ethane
82
Typical
Natural
Gas
81
80
figure 2
Methane
0.21
0.22
0.25
0.31
Hydrogen/Carbon Ratio
0.33
3. Excess Air
Excess air is the extra air supplied to the
burner beyond the required air for complete
combustion of the fuel. Excess air is
supplied to the burner because a boiler
firing without sufficient air, or fuel rich,
is operating in a potentially dangerous
condition. Therefore, excess air is used
to provide a safety factor above the
theoretical air required for combustion.
In ultra low emission burners, excess air
is also used to eliminate CO production
and particulate, and reduce the formation
of oxides of nitrogen (NOx) to very low
levels by controlling the temperature of
the flame. Because excess air is heated
by the flame, it takes energy away from
combustion, thus taking away potential
energy for transfer to the water in the
boiler. In this way, excess air reduces boiler
efficiency. A quality design will allow firing
at minimum excess air levels of 15% (3%
as 02) for a conventional burner and 25%
(5% as 02) for ultra low emissions burner.*
Seasonal changes in temperature and
barometric pressure can cause the excess
air in a boiler to fluctuate 5% - 10%.
Furthermore, firing at low excess air levels
can result in high CO and boiler sooting,
specifically if the burner has complex linkage
and lacks proper fan design. The fact is even
burners theoretically capable of running at
less than 15% excess air levels rarely are
left at these settings in actual practice. A
realistic excess air level for a boiler in operation
is 15% if an appropriate safety factor is to be
* O2 represents percent oxygen in the flue gas. Excess air is
measured by sampling the O2 in the flue gas. If 15% excess air
exists, the oxygen analyzer would measure the O2 in the excess
air and show a 3% measurement.
Efficiency (%)
85
80
75
70
0
figure 3
10
O2 Concentration (%)
EFFICIENCY VS. AMBIENT TEMPERATURE
Efficiency (%)
84
83
82
81
80
0
figure 4
20
40
60
Ambient Temperature (deg F)
maintained.
80
100
F A C T S
Firing Rate
Load)
(% of
25%
100-350 BHp
Op. Pressure
= 10 PSIG
400-800 BHp
Op. Pressure
= 125 PSIG
Op. Pressure
= 10 PSIG
Op. Pressure
= 125 PSIG
1.6%
1.9%
1.0%
1.2%
50%
.7%
1.0%
.5%
.6%
75%
.5%
.7%
.3%
.4%
100%
.4%
.5%
.2%
.3%
table 1
vessel. Boilers are insulated to minimize
these losses. However, every boiler has
radiation and convection losses. Efficiency
is sometimes represented without any
radiation or convection losses. This is not
a true reflection of the efficiency of the
boiler. Cool surface temperatures on the
boiler are an indication of low radiation and
convection losses. In this way, the boiler
construction and design can have an impact
on these losses. Dryback boilers, due to the
refractory in the rear door, tend to have cooler
rear surface temperatures and therefore less
overall losses than a similar wetback design.
Likewise, a boiler with an insulated shell
will have lower surface temperatures, and
therefore lower losses, when compared to a
similar uninsulated boiler. Boilers operating
with high surface temperatures are wasting
energy every time the unit is fired.
Radiation and convection losses also are a
function of air velocity across the boiler. A
typical boiler room does not have high wind
velocities. Boilers operating outside, however,
will have higher radiation and convection
losses.
Table 1 shows expected radiation and
convection losses for 4-pass firetube boilers
designed and insulated for
high efficiency.
Summary
Selection of a boiler with designed-in low
maintenance costs and high efficiency can
really pay off by providing ongoing savings and
maximizing your boiler investment. Remember,
first cost is a relatively small portion of your
boiler investment.
High boiler efficiency is the result of specific
design criteria, including:
- Heating surface
EXAMPLE
Assume 15 lb. design, 100 HP CB Boiler, fired on gas at 100% of Rating.
Stack temperature is 320 F. and room temperature is 80 F.
(320 - 80 = 240)
You measure CO2 of 10% with no CO.
From Hays chart, at 240 and 10% CO2, you get stack loss of 15.2% going up the stack.
(See table 2)
Add .4% for Radiation and Convection Losses. (For a CB Boiler, see table 1)
15.2% plus .4% = 15.6%
100 - 15.6 = 84.4% Fuel-to-Steam Efficiency.
11
F A C T S
= 13,390,000 Btu/hr
= $2.08/gallon
= 16,329,268 @ 82%
= 15,660,819 @ 85.5%
Payback
Payback
Payback
0.22 years
(2.7 months)
0.3 years
(3.6 months)
0.45 years
(5.4 months)
0.7 years
(8.4 months)
Conclusion: First cost can be deceiving! Buy the most efficient boiler.
12
NOTE: The percent increase in fuel costs is greater than the nominal percent decrease
in fuel-to-steam efficiency!
e.g. A 3% drop in efficiency increases fuel costs 3.8% (85% vs 82%)
e.g. A 5% drop in efficiency increases fuel costs 6.3% (85% vs 80%)
e.g. A 7.5% drop in efficiency increases fuel costs 9.7% (85% vs 77.5%)
e.g. A 10% drop in efficiency increases fuel costs 13.5% (85% vs 75%)
How is this proven?
A 200 Hp Unit has an output of 6,700,000 BTU/Hr.
Assume No. 6 oil @ 150,000 BTU/Gal.
Boiler X
Boiler CB
Fuel-to-Steam Efficiency
80%
85%
8,375,000 BTU/Hr.
7,882,000 BTU/Hr.
Input gal/Hr.
55.8
52.5
55.8/52.5
13
F A C T S
BOILER INFORMATION:
(1) Size:______________BHp; Op. Pressure_________________ PSIG; Fuel: No._______________ Oil
:__________________ Gas
(2) Operating Hours/Year:_________________________Hours at_____________________ % of Rating
(3) Fuel Cost: Oil______________________________$/Gal; Gas________________________ $/Therm
FUEL-TO-STEAM EFFICIENCY:
(4) Cleaver-Brooks, Guaranteed
No. 2 Oil
No. 6 Oil
Gas
COMPARISON:
(7) Other Boiler
No. 2 Oil
No. 6 Oil
Gas
14
17
16
15
14
CO
CO
#
6F
ue
#
lO
2F
il
ue
lO
il
13
12
10
9
8
7
atu
N
G
ral
as
lO
EN
ue
G
F
Y
N
OX
E
YG
X
O
ils
5
4
3
2
1
0
10
20
30
40
figure 5
15
50
11
F A C T S
EXAMPLE
Consider the same 400BHP, 150 lb. design boiler firing on natural gas. The boiler operates for 5500 hours per year with the following profile:
1000 hours per year = 20% load
1500 hours per year = 40% load
1500 hours per year = 60% load
1000 hours per year = 80% load
500 hours per year = 100% load
Natural gas cost is $0.83/Therm while electricity cost $0.09/KWh
Under these conditions, the estimated annual fuel cost is $600,585/yr and the estimated
annual electricity cost is $3,898/yr.
With the addition of O2 trim, the estimated fuel cost drops to $593,641/yr, for a projected
savings of $6944/yr, or 1% of the annual fuel bill.
With the addition of a variable speed drive on the blower motor, the electricity cost drops
to $1,365/yr, for a projected savings of $2,533/yr, or a 65% reduction. The majority of the
savings occur during part load operation.
16
17
table 3
560 580 600 620 640 660 680 700 750 800 850 900 950 1000
56.0 57.9 59.6 61.5 63.5 65.0 66.8 68.8
49.4 50.9 52.2 53.9 55.7 57.0 58.3 60.0 63.8 67.8
44.1 45.5 46.9 48.1 49.8 50.9 52.1 53.8 57.0 60.2 63.9 67.1
40.1 41.2 42.5 43.8 45.0 46.3 47.4 48.8 51.8 54.6 57.8 60.9 63.9 66.9
36.8 38.0 39.2 40.1 41.7 42.4 43.7 44.7 47.4 50.1 52.9 55.8 58.3 61.2
34.5 35.3 36.4 37.4 38.4 39.6 40.3 41.7 44.0 46.5 49.0 51.8 54.1 56.5
32.3 33.1 34.2 35.0 36.0 36.9 37.9 38.9 41.0 43.5 45.8 48.0 50.3 52.8
30.6 31.3 32.3 33.0 34.1 34.8 35.7 36.5 38.7 40.8 42.9 45.1 47.5 49.7
28.9 29.8 30.5 31.4 32.3 33.0 33.8 34.6 36.5 38.6 40.5 42.7 44.7 46.6
27.5 28.2 29.0 29.8 30.6 31.3 32.2 32.9 34.8 36.5 38.5 40.3 42.3 44.2
26.3 27.0 27.8 28.5 29.2 30.0 30.8 31.5 33.2 35.0 36.8 38.5 40.2 42.1
25.3 25.9 26.7 27.3 28.0 28.8 29.4 30.1 31.8 33.5 35.2 36.9 38.7 40.2
24.4 25.0 25.7 26.3 27.0 27.7 28.3 28.9 30.5 32.1 33.8 35.3 37.0 38.5
23.5 24.1 24.8 25.4 26.0 26.7 27.2 27.9 29.4 31.0 32.5 34.0 35.5 37.2
22.8 23.4 24.0 24.6 25.1 25.8 26.3 27.0 28.3 29.9 31.4 32.9 34.4 35.7
21.5 22.0 22.6 23.1 23.7 24.2 24.8 25.3 26.7 28.0 29.4 31.8 32.1 33.5
20.5 20.9 21.4 22.9 22.4 22.9 23.5 24.0 25.2 26.5 27.8 29.0 30.2 31.7
19.6 20.1 20.5 21.1 21.3 21.8 22.3 22.8 24.0 25.2 26.3 27.5 28.8 30.0
18.7 19.2 19.7 20.2 20.6 21.0 21.4 21.8 22.9 24.1 25.2 26.2 27.4 28.6
18.1 18.4 18.9 19.4 19.8 20.3 20.6 21.0 22.0 23.1 24.2 25.2 26.2 27.3
CO2 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540
3.0 24.1 25.8 27.7 29.3 31.3 33.9 34.8 36.4 38.2 40.0 42.9 44.8 45.5 47.0 49.0 50.8 52.4 54.3
3.5 21.7 23.1 24.8 26.2 27.8 29.2 31.7 32.5 33.9 35.3 36.9 38.5 40.0 41.7 43.1 44.8 46.1 47.8
4.0 19.9 21.2 22.5 24.9 25.2 26.5 27.9 29.2 31.7 32.0 33.3 35.8 36.0 37.3 38.7 40.0 41.4 42.9
4.5 18.4 19.7 20.8 22.0 23.2 24.4 25.6 26.9 28.0 29.3 30.4 31.8 32.9 34.2 35.6 36.7 37.8 39.0
5.0 17.2 18.5 19.5 20.7 21.7 22.7 23.8 24.9 26.0 27.1 28.2 29.4 30.3 31.5 32.7 33.8 34.9 35.9
5.5 16.3 17.4 18.4 19.4 20.4 21.3 22.3 23.3 24.3 25.4 26.3 27.3 28.4 29.4 30.6 31.4 32.4 33.6
6.0 15.6 16.5 17.4 18.3 19.3 20.4 21.2 22.0 23.0 23.9 24.9 25.8 26.8 27.7 28.6 29.5 30.4 31.4
6.5 14.9 15.7 16.7 17.5 18.4 19.3 20.1 20.9 21.8 22.7 23.6 24.5 25.3 26.1 27.0 27.8 28.8 29.6
7.0 14.4 15.3 16.0 16.8 17.8 18.4 19.3 20.1 20.9 21.7 22.4 23.2 24.1 24.9 25.7 26.5 27.3 28.1
7.5 13.9 14.6 15.4 16.2 16.9 17.7 18.5 19.2 20.1 20.7 21.3 22.2 23.0 23.8 24.5 25.2 26.0 26.8
8.0 13.5 14.3 14.9 15.7 16.3 17.1 17.7 18.5 19.3 20.0 20.7 21.4 22.1 22.8 23.5 24.2 25.0 25.7
8.5 13.2 13.8 14.5 15.2 15.8 16.5 17.3 17.8 18.6 19.3 20.0 20.6 21.3 21.9 22.6 23.3 23.9 24.6
9.0 12.8 13.4 14.1 14.7 15.4 16.0 16.7 17.3 17.9 18.6 19.3 20.0 20.6 21.2 21.8 22.4 23.1 23.8
9.5 12.5 13.2 13.7 14.3 14.9 15.7 16.3 16.8 17.4 18.1 18.6 19.3 19.9 20.5 21.1 21.7 22.4 22.9
10 12.3 12.8 13.4 14.0 14.6 15.2 15.7 16.3 16.9 17.5 18.1 18.7 19.3 20.0 20.5 21.0 21.6 22.2
11 11.8 12.4 12.8 13.4 13.9 14.5 15.0 15.5 16.2 16.7 17.2 17.8 18.3 18.7 19.4 20.0 20.5 20.9
12 11.4 11.8 12.5 12.9 13.4 13.9 14.4 14.9 15.4 15.9 16.4 16.9 17.4 17.9 18.4 18.9 19.5 20.0
13 11.2 11.6 12.1 12.5 12.9 13.4 13.9 14.3 14.7 15.3 15.8 16.3 16.7 17.2 17.7 18.1 18.6 19.1
14
11.3 11.8 12.2 12.6 13.0 13.4 13.8 14.3 14.8 15.3 15.6 16.2 16.5 16.9 17.4 17.8 18.3
15
11.4 11.7 12.4 12.6 13.1 13.5 13.8 14.3 14.8 15.3 15.6 15.9 16.4 16.7 17.3 17.7
table 2
560 580 600 620 640 660 680 700 750 800 850 900 950 1000
47.8 49.0 50.0
42.8 43.8 45.0 46.2 47.7 48.3 49.8
38.8 39.9 40.9 42.1 43.0 44.1 45.2 46.2 48.8
35.9 36.8 37.8 38.6 39.8 40.4 41.5 42.6 44.8 47.2 49.8
33.6 34.3 35.7 36.2 36.9 37.8 38.8 39.7 41.8 43.8 46.0 48.2
31.8 32.3 33.2 34.1 34.9 35.8 36.3 37.3 39.2 41.0 43.0 45.3 47.2 49.0
30.0 30.8 31.5 32.2 32.9 33.8 34.3 35.2 36.8 38.8 40.4 42.5 44.3 46.2
28.7 29.2 30.0 30.9 31.4 32.1 32.8 33.5 34.6 36.8 38.4 40.3 42.0 43.8
27.4 28.0 28.8 29.4 30.0 30.8 31.2 32.0 33.8 35.3 36.8 38.3 40.0 41.8
26.4 26.9 27.7 28.2 28.8 29.4 30.1 30.8 32.2 33.8 35.2 36.8 38.3 39.9
25.5 26.0 26.7 27.2 27.8 28.4 29.0 29.5 31.0 32.4 33.8 35.4 36.8 38.2
24.8 25.3 25.8 26.4 26.9 27.4 28.1 28.6 29.9 31.3 32.8 34.2 35.4 36.8
24.1 24.5 25.2 25.8 26.2 26.7 27.2 27.8 29.0 30.3 31.8 33.0 34.3 35.7
23.4 23.8 24.4 24.9 25.4 25.9 26.4 26.9 28.2 29.4 30.8 32.0 33.3 34.5
22.8 23.3 23.8 24.2 24.8 25.2 25.8 26.2 27.4 28.6 29.8 31.2 32.2 33.4
21.9 22.3 22.8 23.2 23.7 24.2 24.6 25.0 26.2 27.2 28.3 29.5 30.8 31.8
21.1 21.4 21.9 22.3 22.8 23.2 23.6 24.0 25.1 26.1 27.2 28.3 29.2 30.3
CO2 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540
3.0 23.1 24.4 25.9 27.2 28.6 30.0 31.3 32.8 34.1 35.8 36.9 38.2 39.8 41.0 42.2 43.8 45.0 46.3
3.5 21.2 22.5 23.8 24.9 26.1 27.2 28.4 29.6 30.9 32.0 33.2 34.4 35.8 36.8 37.9 39.2 40.3 41.6
4.0 19.9 20.9 22.0 23.1 24.1 25.1 26.2 27.2 28.3 29.4 30.4 31.8 32.5 33.8 34.8 35.8 36.8 37.8
4.5 18.9 19.9 20.9 21.8 22.7 23.6 24.5 25.5 26.4 27.3 28.3 29.2 30.2 31.2 32.2 33.0 34.0 34.9
5.0 18.0 18.9 19.8 20.6 21.4 22.2 23.1 24.0 24.9 25.8 26.8 27.5 28.3 29.1 30.1 30.9 31.8 32.5
5.5 17.4 18.1 18.9 19.8 20.5 21.2 22.1 22.9 23.8 24.5 25.2 26.2 26.9 27.8 28.5 29.2 30.0 30.8
6.0 16.8 17.4 18.2 18.9 19.6 20.4 21.1 21.8 22.7 23.3 24.1 24.9 25.5 26.2 27.0 27.8 28.4 29.2
6.5 16.3 16.9 17.6 18.4 19.0 19.8 20.4 21.1 21.8 22.4 23.2 23.8 24.5 25.2 25.9 26.5 27.2 27.9
7.0 15.8 16.5 17.1 17.8 18.4 19.1 19.8 20.4 21.0 21.8 22.3 22.9 23.6 24.2 24.9 25.5 26.2 26.8
7.5 15.5 16.1 16.7 17.2 17.9 18.5 19.1 19.8 20.3 20.9 21.5 22.2 22.8 23.3 24.0 24.6 25.2 25.8
8.0 15.2 15.7 16.3 16.9 17.4 18.0 18.6 19.2 19.8 20.3 20.9 21.5 22.1 22.8 23.2 23.8 24.4 25.0
8.5 14.9 15.4 15.9 16.5 17.1 17.6 18.2 18.7 19.3 19.8 20.4 20.9 21.4 22.0 22.5 23.1 23.7 24.2
9.0 14.6 15.2 15.7 16.2 16.6 17.2 17.8 18.3 18.8 19.3 19.9 20.4 20.9 21.4 21.9 22.5 23.0 23.5
9.5 14.4 14.9 15.4 15.9 16.4 16.9 17.4 17.9 18.4 18.9 19.5 19.9 20.5 20.9 21.4 21.9 22.4 22.9
10 14.2 14.6 15.2 15.6 16.1 16.6 17.1 17.5 18.1 18.5 19.0 19.5 20.0 20.4 20.8 21.4 21.8 22.4
11
14.4 14.7 15.2 15.6 16.1 16.5 16.9 17.4 17.8 18.4 18.8 19.3 19.6 20.2 20.5 20.9 21.4
12
14.4 14.8 15.2 15.6 16.1 16.5 16.9 17.3 17.8 18.2 18.6 19.0 19.4 19.8 20.2 20.6
table 4
560 580 600 620 640 660 680 700 750 800 850 900 950 1000
60.3 62.0 64.1 66.2 68.1 70.1
49.4 50.9 52.2 53.9 55.7 57.0 58.3 60.0 63.8 67.8
46.9 48.2 49.8 51.2 52.9 54.2 56.0 57.8 61.1 65.0 68.9
42.2 43.5 45.0 46.3 47.9 49.0 50.1 51.9 55.0 58.2 61.8 65.1 68.5
38.8 39.8 41.0 42.3 43.8 44.9 46.1 47.5 50.1 53.6 56.3 59.8 62.3 65.8
35.8 37.0 37.9 39.2 40.1 41.3 42.3 43.8 46.1 49.1 52.0 54.7 57.8 60.1
33.5 34.3 35.3 36.5 37.5 38.3 39.7 40.5 43.0 45.8 48.2 50.9 53.5 56.0
31.4 32.3 33.4 34.3 35.1 36.1 37.1 38.0 40.2 42.8 45.1 47.6 49.9 52.1
29.0 30.2 31.2 32.2 33.0 33.9 34.9 35.8 37.9 40.1 42.1 44.4 46.8 49.0
27.9 28.8 29.6 30.5 31.2 32.1 33.0 34.9 35.9 37.9 40.0 42.0 44.1 46.1
26.6 27.4 28.2 29.0 29.9 30.6 31.5 32.1 34.1 36.0 38.0 40.0 41.9 43.9
25.5 26.2 26.8 27.6 28.2 29.1 29.9 30.8 32.6 34.2 36.2 38.0 39.9 41.8
24.4 25.0 25.7 26.5 27.1 27.9 28.7 29.4 31.1 32.9 34.6 36.3 38.0 39.9
23.5 24.0 24.7 25.4 26.1 26.8 27.5 28.1 29.8 31.2 33.2 34.9 36.4 38.1
22.6 23.2 23.8 24.5 25.1 25.8 26.4 27.0 28.7 30.1 31.8 33.5 35.0 36.7
21.2 21.7 22.3 22.9 23.5 24.1 24.8 25.2 26.8 28.1 29.8 31.2 32.5 34.1
19.9 20.4 21.0 21.6 22.1 22.7 23.1 23.8 25.0 26.4 27.9 29.1 30.5 31.9
18.9 19.3 19.8 20.4 20.9 21.4 21.9 22.4 23.8 24.9 26.2 27.5 28.9 30.0
18.0 18.5 18.8 19.4 19.9 20.4 20.9 21.2 22.5 23.7 24.9 26.1 27.2 28.5
17.3 17.7 18.2 18.6 19.0 19.5 19.9 20.3 21.5 22.6 23.8 24.9 25.9 27.1
16.6 16.9 17.4 17.9 18.2 18.8 19.1 19.5 20.6 21.6 22.7 23.8 24.8 25.9
CO2 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540
3.0 24.5 26.5 28.5 30.2 32.2 34.5 36.5 38.2 40.4 42.2 44.4 46.4 48.2 50.0 52.3 54.3 56.3 58.2
3.5 21.8 23.4 25.2 26.8 28.6 30.4 32.1 33.8 35.5 37.4 39.0 40.6 42.2 44.0 45.6 47.5 49.2 51.0
4.0 19.8 21.2 22.8 24.2 25.7 27.3 28.8 30.2 31.6 32.5 34.8 36.3 37.8 39.4 40.8 42.2 43.8 45.1
4.5 18.2 19.4 20.8 22.2 23.5 24.8 26.2 27.4 28.8 30.4 31.5 33.0 34.2 35.4 37.0 38.1 39.4 41.0
5.0 16.8 18.0 19.3 20.4 21.7 22.8 23.2 25.3 26.6 27.8 29.0 30.3 31.4 32.6 33.8 35.3 36.2 37.5
5.5 15.8 16.8 18.0 19.2 20.3 21.3 22.5 23.5 24.6 25.8 26.9 28.0 29.2 30.2 31.4 32.5 33.5 34.7
6.0 14.8 15.8 16.9 18.0 19.0 20.0 21.1 22.0 23.1 24.2 25.2 26.3 27.3 28.2 29.3 30.3 31.3 32.3
6.5 14.3 15.2 16.1 17.1 18.0 18.9 19.9 20.8 21.8 22.8 23.7 24.6 25.5 26.5 27.5 28.5 29.4 30.4
7.0 13.5 14.4 15.3 16.2 17.1 17.9 18.8 19.7 20.6 21.5 22.4 23.3 24.2 25.0 25.8 26.8 27.7 28.6
7.5 13.0 13.8 14.6 15.5 16.3 17.3 18.0 18.8 19.7 20.5 21.4 22.2 22.9 23.7 24.6 25.4 26.3 27.2
8.0 12.5 13.3 14.1 14.8 15.7 16.4 17.3 18.0 18.8 19.6 20.4 21.2 21.9 22.7 23.5 24.2 25.0 25.8
8.5 12.2 12.8 13.6 14.4 15.1 15.7 16.6 17.3 18.0 18.7 19.6 20.3 21.0 21.6 22.5 23.3 23.9 24.7
9.0 11.7 12.4 13.2 13.8 14.6 15.3 15.9 16.6 17.4 18.1 18.8 19.5 20.2 20.8 21.6 22.3 22.9 23.7
9.5 11.4 12.1 12.7 13.4 14.1 14.7 15.4 16.0 16.7 17.5 18.1 18.7 19.4 20.0 20.7 21.4 22.1 22.8
10 11.2 11.7 12.3 13.0 13.7 14.4 14.8 15.5 16.2 16.8 17.5 18.2 18.7 19.4 20.0 20.6 21.3 21.9
11 10.6 11.3 11.8 12.4 12.9 13.5 14.2 14.7 15.3 15.8 16.5 17.0 17.6 18.2 18.8 19.4 20.0 20.6
12 10.2 10.7 11.3 11.7 12.3 12.8 13.4 13.8 14.5 15.1 15.6 16.2 16.7 17.2 17.8 18.3 18.8 19.4
13
10.3 10.8 11.3 11.8 12.3 12.8 13.3 13.8 14.4 14.8 15.4 15.8 16.3 16.8 17.3 17.9 18.4
14
9.8 10.4 10.8 11.4 11.8 12.3 12.8 13.3 13.7 14.3 14.7 15.2 15.6 16.2 16.6 17.1 17.5
15
10.2 10.6 11.0 11.4 11.8 12.4 12.7 13.3 13.7 14.2 14.6 15.0 15.4 15.8 16.4 16.8
16
10.3 10.7 11.1 11.5 11.8 12.3 12.8 13.3 13.7 14.0 14.4 14.8 15.3 15.7 16.2
F A C T S
18
Boiler
Size
B Hp
Output (BTU/Hr)
FTSE
= Input (BTU/Hr)
Input (BTU/Hr)
= Therms/Hr
100,000 BTU/Therm
table 5
NO. 2 OIL FUEL BURNING RATES (GPH) AT VARIOUS EFFICIENCIES
Boiler
Size
B Hp
Output (BTU/Hr)
FTSE
= Input (BTU/Hr)
Input (BTU/Hr)
140,000 BTU/Gal.
= GPH
table 6
NO. 6 OIL FUEL BURNING RATES (GPH) AT VARIOUS EFFICIENCIES
Boiler
Fuel To Steam Efficiency
Size
B Hp
60.0 62.5 65.0 67.5 70.0 72.5
75 76 77 78 79 80 81 82 83 84 85 86 87 88
37.0 35.5 34.5 33.0 32.0 31.0 30.0
29.5 29.0 28.5 28.5 28.0 27.5 27.0 27.0 26.5 26.0 26.0 25.5 25.5
100
46.5 44.5
43.0 41.5 40.0 38.5 37.0 36.5 36.0 36.0 35.5 35.0 34.5 34.0 33.5 33.2 33.0 32.5 32.0 31.5
125
56.0 53.5 51.5 49.5 48.0 46.0 44.5
44.0 43.5 43.0 42.5 42.0 41.5 41.0 40.5 40.0 39.5 39.0 38.5 38.0
150
200
74.5 71.5 68.5 66.0 64.0 61.5 59.5 58.5 58.0 57.0 56.5 56.0 55.0 54.5 54.0 53.0 52.5 52.0 51.5 50.5
93.0 89.5 86.0 82.5 79.5
77.0 74.5 73.5 72.5 71.5 70.5 69.5 69.0 68.0 67.0 66.5 65.5 65.0 64.0 63.5
250
300 111.5 107.0 103.0 99.0 953.5 92.5 89.5 88.0 87.0 86.0 85.0 83.5 82.5 81.5 80.5 79.5 79.0 78.0 77.0 76.0
350 130.0 125.0 120.0 115.5 111.5 107.5 104.0 103.0 101.5 100.0 99.0 97.5 96.5 95.5 94.0 93.0 92.0 91.0 90.0 89.0
400 149.0 143.0 137.5 132.5 127.5 123.0 119.0 117.5 116.0 114.5 113.0 111.5 110.0 109.0 107.5 106.5 105.0 104.0 102.5 101.5
500 186.0 178.5 171.5 165.5 159.5 154.0 149.0 147.0 145.0 143.0 141.0 139.5 138.0 136.0 134.5 133.0 131.5 130.0 128.5 127.0
600 223.0 214.0 206.0 198.5 191.5 184.5 178.5 176.0 174.0 171.5 169.5 167.5 165.5 163.5 161.5 159.5 157.5 155.5 154.0 152.0
700 260.5 250.0 240.5 231.5 223.0 215.5 208.5 205.5 203.0 200.5 198.0 195.5 193.0 190.5 188.0 186.0 184.0 181.5 179.5 177.5
800 297.5 285.0 274.5 264.5 255.0 246.5 238.0 235.0 232.0 229.0 226.0 223.0 220.5 217.5 215.0 212.5 210.0 207.5 205.0 203.0
No. 6 Oil = 150,000 BTU/Gal.
Output (BTU/Hr)
FTSE
= Input (BTU/Hr)
table 7
19
Input (BTU/Hr)
150,000 BTU/Gal.
= GPH
table 8
GUARANTEED FUEL-TO-STEAM EFFICIENCIES
NO. 2 OIL
BOILER
SIZE
table 9
GUARANTEED FUEL-TO-STEAM EFFICIENCIES
NO. 6 OIL
BOILER
SIZE
100
125
150
200
250
300
350
400
500
600
700
800
100%
88.0
87.0
88.1
88.7
87.1
87.7
88.4
88.1
89.2
89.4
89.6
89.5
100%
85.8
84.8
85.8
86.5
85.0
85.6
86.2
85.9
86.9
87.2
87.4
87.3
* See notes.
table 10
20
Notes:
1. Efficiencies Based on the Following
Fuel Analysis
Natural Gas:
No. 2 Oil:
No. 6 Oil:
21
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