Boilers 101

Asit Patel
ANP Energy Consulting Services

Learning objectives

• Define what is a boiler?

• What are different classification of
boilers?
• Define combustion efficiency, thermal
efficiency, and fuel to fluid efficiency.
• Identify different type of boilers
• Criteria for boiler selection

1
Lets look at what the Merriam-Webster
dictionary says the BOILER IS…

What is a boiler?

• A boiler is a closed metal container

(pressure vessel) in which water is
heated to produce steam and heated
water

2
Boiler Classifications

• Low Pressure:
• Section IV of ASME Code (Heating Boiler)
• Steam: Up to 15 PSIG
• Water: Up to 160 PSIG and or 250°F

• High Pressure:
• Section I (Power Boiler) of ASME Code
• Steam: Above 15 PSIG
• Water: Above 160 PSIG and or 250°F
5

Boiler Efficiency Classification

• Standard Efficiency (80-84%)
• Most Steel and Cast Iron Boilers

Non-
• Mid Efficiency (85-90%) Condensing

• Copper Fintube Boilers

• High Efficiency (90%+)

• Condensing Boilers
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Defining Boiler Efficiency

• Combustion Efficiency - indicates a burners

ability to burn fuel measured by unburned fuel
and excess air in the exhaust.

• Thermal Efficiency - indicates the heat

exchangers effectiveness to transfer heat from
the combustion process to the water or steam in
the boiler, exclusive radiation and convection
losses .

• Fuel to Fluid Efficiency - indicates the

overall efficiency of the boiler inclusive thermal
efficiency of the heat exchanger, radiation and
convection losses - output divided by input.
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Where do we get input and output

information for a boiler?
Boiler Brochure

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Boiler Capacity
Units of Measurement

• Input (Firing rate)

• GPH – Gallons per hour
• MBH (M = 1,000 btu)
• Output
• BHP = Boiler Horse Power = 33,475 btu

• Sqft of steam = 240 btu

• lbs/hr (34.5 lbs of steam = 1 BHP)

What is a BTU?

• British Thermal Unit (btu) = Unit of

measurement of heat energy.
• Amount of heat energy required to raise
one pound of water by one degree
Fahrenheit.
• one gallon of water = 8.33 lbs
• Approximate amount of heat released
by one kitchen match.
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5
Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin tube type
• Condensing boilers
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Types of Boilers

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Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
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Boiler Types
Cast Iron Sectional

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 Boiler Types
Cast Iron Boilers
• Advantages • Disadvantages
• Modular Design • Low Pressure Only

• High Number of Options • Limited to 200 horsepower

• Low Initial Cost • Not Recommended For

Process Applications
• Durable Construction
• Medium to High Level of
Maintenance

• Low Efficiency in Field

15

Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
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Boiler Type
Steel Firetube Scotch
Two Pass – Dryback

Three Pass – Wetback

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Boiler Type
Steel Firetube Scotch - Four Pass - Wetback

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Boiler Type
Steel Firetube Scotch - Wetback
• Design Principles
• Rear turnaround is totally surrounded by
water

• No expensive refractory to maintain

• Rear doors are either lightweight lift off

type or split-hinged
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Boiler Type
Steel Firetube Scotch - Dryback
• Design Principles
• Rear turnaround is a refractory wall

• Door refractory is a maintenance item

• Rear door is vessel-sized in diameter,

extremely heavy, and hinged or davited

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Boiler Type –
Steel Firetube Scotch - Dryback

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Boiler Type
Steel Firetube Scotch
• Advantages • Disadvantages
• Wide range of sizes • Operating weight
• Both high and low • Requires more floor
pressure space
• Higher Efficiency • Space required for
• Easy to clean tube removal &
• No mud legs cleaning
• Longevity • Refractory
Maintenance (dryback
• No refractory floor design only)
• No rear door refractory
(3-Pass & 4-Pass
Wetback Only)
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Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
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Boiler Type
Steel - Firebox

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Boiler Type
Steel - Firebox
• Advantages • Disadvantages
• Wide range of sizes • Low Pressure ONLY
• Compact (for places • Operating weight
where Scotch will not • Refractory
fit) maintenance costs
• Easy to clean • Space required for
• Longevity tube removal &
cleaning (but not as
much as Scotch)

25

Boiler Type
Modified Firebox (fits through 36” door)

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Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
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Boiler Type
Flexible Watertube

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Boiler Type
Flexible Watertube
• Advantages • Disadvantages
• Lower Cost • Low Pressure
• Lower operating Application ONLY
weight • Water treatment more
• Long life expectancy critical (difficult to
(40 Years) clean)
• Wide range of sizes
• Knockdown capability
• Minimum space
required for tube
removal & cleaning
• Tubes easily replaced 29

Boiler Type
Steel - Watertube
• D Type
• S Type
• A Type
• O Type

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Boiler Type
Steel Watertube

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Boiler Type
Steel - Watertube
• Advantages • Disadvantages
• High Pressure up to • Steam Only
900 psig • Process Only
• Fast Steaming
• Low Water Content
• Quick Response to
Load Demands

32

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Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
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Boiler Type
Copper Fin Tube – Horizontal Lay-out

Source: Hydronic Institute

Installation Guide: Residential hydronic
heating – Guide 2000

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Boiler Type
Copper Fin Tube – Vertical Lay-out

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Boiler Type
Copper Fin Tube

• Advantages • Disadvantages
• Medium efficiency • Gas only
• Low initial cost • Water only
• Low Mass • Special vent
• Low operating weight requirements
• Small footprint
• Lower stand-by losses

36

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Types of Boilers

• Cast Iron Sectional

• Scotch Marine Steel
• Firetube
• Firebox
• Watertube
• Low water content copper fin
• Condensing boilers
37

Boiler Type
High Efficiency – Condensing Boilers

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True Operating Efficiency of
Condensing Boiler

Condensing boilers actually operate at higher

part-load efficiency while in condensing mode.
39

Boiler Type
High Efficiency – Condensing Boilers
• Advantages • Disadvantages
• Highest Efficiency • Water only
• Can be used in low • Gas only
RWT systems
• Special venting
• Various types
• Costly???
• Condensate will not
harm properly
designed boiler
• Standard features &
Controls
• Smaller Venting

40

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 TYPES OF BOILERS
Atmospheric - Gas

Increased standby losses

– Air from building free to move through units and up
through stack at all times
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Types of Boilers

• Knockdown
• Boiler (vessel) only
• Packaged
• Boiler and burner
• May be the same manufacturer or may be two
different manufacturers
• Mostly two different manufacturers
• Integral unit
• Boiler and burner is one unit
• Most condensing boilers 42

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Criteria for boiler selection

• Application
• Heating/Process
• Steam/Hot Water
• High Pressure/Low Pressure
• Fuel availability and venting options
• Space availability
• Budget
• Efficiency
43

What makes one boiler more

efficient than other?
• Capability to transfer more BTU’s from
combustion process to make hot water or steam.
• Heat exchanger design and construction

• Lower jacket and stand-by losses

• Better insulation and heat exchanger isolation
during off cycles.

• Capability to match the boiler’s output to actual

load
• Better modulation capability (higher turn-down
ratio) 44

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From operating perspective..

• The best boiler for your application is

the one that is properly sized to match
your load.
• A boiler that runs non-stop.

45

How do we achieve that…

• Multiple smaller capacity boilers…

• Larger boiler(s) with modulation burner
• Turn down ratio
• Typical – 4:1 (100% – 25%) 5:1 (100% - 20%)
• Highest - 20:1 (100% - 5%)

• But then, what about part load

efficiency?
46

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Part-Load Efficiency Curves of
Non-condensing High Mass boiler

Typical high
mass boilers
have low part-
load efficiency.

Another concern
is flue gas
condensation.

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Part Load Efficiency of

Condensing Boiler

Condensing boilers actually operate at higher

part-load efficiency while in condensing mode.
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 So What Makes Condensing Boiler
Efficient?
• Condensation of water vapor.
• Extraction of latent heat that is otherwise
going up the chimney in form of water
vapor.

49

Fuels and Combustion

• Fuels are “Hydro-Carbons” Flame

• Oxygen is 21% of air (78% is Nitrogen) Quality

• HC + O2 Carbon
• Good, “complete” combustion Monoxide
• CO2 + H20(vapor) + heat hazard

• Incomplete combustion of gas

• CO2 + CO + H2O + heat Soot = $
lost
• Incomplete combustion of oil
• CO2 + CO + C + H2O + heat 50

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Energy Improvement Opportunities
Associated with Boilers/burners
• Maximize combustion efficiency
• Minimize excess air

• Maximize heat exchange

• Clean up fireside and waterside fouling

• Minimize stand-by losses

• Jacket losses and cyclical losses
51

How much excess air should we

strive for?

FEMP
O&M
Manual
Ver. 3

P. 9.17

52

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Opportunity in field

Lowering of excess
air results in lower
exhaust gas
temperature and
higher efficiency

53

Heating System Efficiency

Soot on Heat Exchanger

• Acts as an insulator
• Increases amount of heat lost through
chimney

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Heating System Efficiency

Scale on Water Side of

Heat Exchanger
• Acts as an insulator
• More heat lost through chimney

55

Just so that you know that I am not making

these things up.

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Optimization Opportunity
(Minimize stand-by losses)

If this damper is left in open position, it

can significantly impact the stand-by
losses and if not adjusted properly can
have significant impact on combustion
process.

57

Thank You

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Q&A

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