CTV008

Technology Overview

Low temperature hot water boilers

Introducing energy saving opportunities for business

Contents
Introduction Energy consumption
01 02 03

Summary of key areas Technology overview

How does a boiler work? Identifying your boiler

Identifying your heating system

05

04 06

Improvements to existing boiler plant Boiler controls Maintenance

08 10 14 16

Replacing boilers

Energy monitoring and targeting Next steps Glossary

20 21 22

Front cover image (top right and bottom): courtesy of Future Energy Solutions, from AEA Technology

Low temperature hot water boilers

01

Reducing energy use makes perfect business sense; it saves money, enhances corporate reputation and helps everyone in the fight against climate change. The Carbon Trust provides simple, effective advice to help businesses take action to reduce carbon emissions, and the simplest way to do this is to use energy more efficiently.

This technical overview of low temperature hot water boilers introduces the main energy saving opportunities for businesses and demonstrates how simple actions save energy, cut costs and increase profit margins.

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Technology Overview

About a third of the UKs ener is used for heating or producin

Energy consumption
About a third of the UKs energy consumption is used for heating or producing hot water. A significant proportion of this is provided by commercial boiler plant, so it should be included in any energy reduction strategy. Typically, energy improvements of 10% or more can be made relatively easily through maintenance and low cost, straightforward improvements. The financial rewards of these are often immediate or have a very short payback. Longer-term measures are also well worth considering. Many buildings may still be using very old hot water boilers that had an operating efficiency of only about 70% when first installed and which will now be worse due to poor maintenance. New condensing boilers can achieve efficiencies of over 90% and consequently it can be worth considering replacement. This overview covers some of the simple steps to saving on boilers, as well as the best approach to choosing a new boiler.

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rgy consumption ing hot water.

Summary of key areas

Boilers offer many energy saving opportunities, ranging from replacement of the boiler itself to retrofitting of controls and other equipment. The most appropriate solution will depend on what type of boiler and heating system you have, your business needs and your budget. There are also significant opportunities to save by considering improved boiler controls (see page 10) and by monitoring your energy use (see page 20).

CASE STUDY

Savings in existing systems

These can range from the addition of boiler and pipework insulation to retrofitting of new controls or flue gas heat recovery systems. See page 8.

Maintenance and monitoring

Both new and existing boilers require an effective maintenance programme to ensure that they operate to peak efficiency. See page 14.

Selecting a new boiler

A knitwear manufacturer in Hawick, Scotland, replaced their old, inefficient oil-fired boiler with two new high-efficiency gas-fired boilers that were sized to match more accurately the actual heating demand of the site. In addition, the new boilers had improved burner controls linked to a Building Management System. The resulting savings were 13,200 and 276 tonnes CO2 per year, with an overall payback time of under five years. The company also reported improved productivity and staff working conditions following the retrofit.

Effective boiler replacement

Not just as simple as replacing like for like, going through a careful analysis of what you really need can save a fortune. See page 16.

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Technology Overview

Technology overview
Low temperature hot water boilers produce hot water for space heating, general hot water demand or, occasionally, industrial processes.
Low temperature hot water (LTHW) boilers produce hot water at around 90C and are the type most commonly found in houses and commercial premises. The hot water produced is distributed via pipework to wet heating systems and hot water storage tanks.

How does a low temperature hot water boiler work?

LTHW boilers are usually gas-fired, but can also be run on oil or LPG models particularly in areas with no natural gas supply. Oil and LPG are more expensive than gas and emit more carbon dioxide to the atmosphere. Biomass boilers which use wood, specially grown fuel crops or organic waste as the fuel, are becoming more popular. These create very little net carbon dioxide, but are more expensive and the availability and storage of fuel can be difficult. Only gas-fired boilers are discussed in this publication; however, most of the energy saving advice is applicable across all models.

The controls 1 on the boiler set the required temperature and pressure of the water. If the water in the feed 2 (the return water) is at a lower temperature than required, the boiler must fire to produce heat, i.e. it must burn fuel. The gas burners 3 ignite a mixture of gas (from the gas inlet 4 ) and air (from the boiler surroundings) to produce hot combustion gases. The precise mixture of gas and air is controlled by the gas valve and burner controls 5 (this is covered in further detail later). The hot combustion gases pass over the heat exchanger (a network of pipes) 6 to heat the circulating water within. This water is circulated by a pump 7 . The resultant hot water is distributed to the heating system via the hot water outlet 8 and the exhaust gases escape to the atmosphere via a flue or chimney 9 . Any condensate leaves the boiler via a drain 10 . To prevent heat loss from the boiler, the whole mechanism is contained within an insulated metal enclosure 11 .

The diagram below shows the major components of a gas-fired LTHW boiler.

Major components in a typical gas hot water boiler

Exhaust gases

Draft hood 2 Water feed 8 Hot water outlet 1 Temperature and pressure controls Flue 9

Heat exchanger 6

7 Circulating pump

10 Drain 11 Insulated metal enclosure 3 Gas burners

Gas valve and burner controls 5 Gas inlet 4

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Refrigeration

05

Identifying your heating system

Convectors draw room air through a casing and push out air warmed by a covered hot water pipe. They have a low surface temperature making them popular in schools and hospitals, where otherwise there may be a burning risk to occupants. Compared with radiators, they have a greater heat output per unit size and a faster heat-up time; however, their maintenance costs are greater. The running costs are further increased when the convector has a fan within the casing.

Radiators are metal units which exude the heat from the systems hot water pipes. Effective temperature control and low maintenance make radiator systems a popular choice, and they are the most common type of system found in the UK.

There are a variety of heating systems that can be used with LTHW boilers, offering different opportunities for savings. Understanding your type of heating system will help in identifying what kind of boiler you have, and where the best chances of saving are.

Under floor heating consists of a network of hot water pipes that is embedded between the floor finish and the main concrete floor slab. These pipes heat the whole floor surface and cause heat to rise throughout the space. The main advantage of under floor heating over radiators and convectors is that it is invisible and can give greater flexibility in the use of a space (for example, positioning of furniture). However, these will not be found in buildings which require under floor electrical services or in older buildings with wooden floors. While all systems can work with any type of LTHW boiler, some applications are more efficient with certain types of boiler. The next section covers these in more detail. Medium/high temperature hot water boilers and steam boilers tend to be found on large multi-building sites or industrial premises. They produce water or steam at high temperature and are not suitable for smaller commercial premises (for example, in offices) due to safety risks. The Carbon Trust has further information about these boiler systems.

For more information on heating and heating systems, see the Carbon Trusts overview on Heating, ventilation and air conditioning (CTV003).

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Technology Overview

Identifying your boiler

There are three main types of boiler: conventional, high-efficiency and condensing. These can be used alone or combined together within systems. Conventional boilers If your boiler is more than 12-15 years old, it is likely to be a conventional type, sometimes called standard boilers. They are often cast iron and larger than other boilers. Most use atmospheric burners, where the air required for combustion is drawn from around the boiler through natural convection. Flues tend to be larger on standard boilers as they are sized according to the air flow at peak load.

Condensing boilers

Even in modern high-efficiency boilers, waste heat in the exhaust gases is lost to the atmosphere via the boiler flue. Water vapour makes up some of these exhaust gases. In condensing boilers, a second heat exchanger is used to extract much of the waste heat and return it to the system. The temperature of the exhaust gases is reduced causing the water vapour to condense, and this is drained away. Condensing boilers are the most efficient on the market and since April 2005, legislation states that they must be considered as the first choice for all new or replacement installations. Condensing boilers work best with low-temperature applications, such as under floor heating. However, efficiencies will still be increased when used with radiator or convector circuits. Combination boilers

Some conventional boilers and most other boiler types will use forced/induced draught burners. These use a fan to force/induce air into the boiler and up the flue. Whilst this can give greater flexibility to flue design and result in smaller flues, they are noisier in operation. Forced/induced draught boilers are easy to identify since the fans are fitted to the front of the boiler. Conventional boilers are no longer available to buy due to their lower efficiency. Businesses with one of these boilers should consider replacement with either a high-efficiency or a condensing model. High-efficiency boilers

In a combination (or combi) boiler, there is a secondary heat exchanger integrated within the boiler housing that is used to provide hot water instantaneously. There is no need for a hot water storage cylinder and associated cold water feed tank and pipework. They can be particularly attractive options in properties where space is limited and are used mainly in domestic buildings. Combination boilers are limited to smaller applications so will not be appropriate for most businesses. However, if your business is run from a very small building and hot water demand is limited to taps, they may be an option.

Since 1997, high-efficiency boilers have been the required standard for new and replacement models. So if your boiler was installed from 1997 onwards, it is likely to be this type. These boilers have a low water content, a large heat exchanger surface area and increased insulation to the boiler shell. They tend to be smaller than standard boilers. High-efficiency boilers work with all heating systems. They are particularly suited to applications where a higher water temperature is required, for example radiators at peak load (typical flow temperature of 80C). Businesses with a lowtemperature application, for example, under floor heating, will find that a condensing boiler is a better option.

like your You can find out things and settings boilers rating, age s plate. from the manufacturer the side This is usually found on of the boiler casing.

QUICK TIP

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Refrigeration

07

Modular boiler systems

A modular boiler system is where a series of boilers are linked together to meet a variety of heating demands. Modular boiler systems are best suited to businesses with a large heat demand that varies.

Boiler efficiency

No boiler is 100% efficient. Energy is lost via the flue gases and through the main body of the boiler itself. Poor maintenance will exacerbate these losses.

Because LTHW boilers work best when operated at full load, it makes sense to have a series of boilers to match the varying heating demands which UK businesses experience. For example, consider a building with a peak winter heating demand of 100kW. If a single boiler were to be used, it would operate at full capacity, and peak efficiency, for only a few weeks of the year. If five modular boilers of 20kW each were used instead, lower heating demands experienced at other times of the year could be met by a reduced number of boilers operating at full capacity. The system can be a mix of condensing and conventional boilers, but the condensing boilers should always be the lead to maximise efficiency. Seasonal efficiencies Boiler type Standard, old, poor condition Standard, good condition High-efficiency

Take care when considering boiler efficiencies. Manufacturers often quote instantaneous efficiencies which do not take into account the actual operation of the boiler or its practical use. A more accurate measure is the seasonal efficiency. This takes into account all characteristics of a boiler and is averaged over a season or year of true operation. It will therefore account for its performance under part-load conditions.

The table below shows the seasonal efficiencies for the different boiler types discussed above and how this would affect the energy input required to meet a heating demand of 100kW. Note that the boiler efficiency is also affected by the heating system type.

Typical seasonal efficiency 70% 82% 85% 87% 45%

Power input required to meet 100kW* heating demand 222kW 143kW 118kW

Condensing (used with fixed temperature radiators) Condensing (used with under floor heating)

122kW

Condensing (used with variable temperature radiators)

90% or more

111kW or less

115kW

*As a general rule of thumb, most commercial buildings will require a heating demand of around 70-90W/m2. So, a 100kW boiler would be sufficient to heat a building of 1,100-1,400m2. Retail and educational buildings will have a bigger heat demand (100-110W/m2) and so a 100kW boiler would be sufficient to heat a space of 900-1000m2.

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Technology Overview

Improvements to existing boiler plant

It may not be cost-effective to replace boilers that are relatively new. However, there are still opportunities to make substantial savings through improvements to other items of the boiler plant. Many of these measures will need specialist help. If in doubt, always consult a qualified technician.
Insulate boilers, pipework and valves
Heat loss through the boiler, pipework and valves leads to poor efficiency. All businesses should check their systems insulation.

Fit flue dampers

Most modern boilers are well insulated to reduce heat losses from the body of the boiler and these can account for less than 1% of the total energy input. However, on older boilers, the insulation may be in poorer condition and can account for heat losses of as much as 10% of the energy input. The boiler insulation should be assessed and replaced where it is insufficient or showing signs of degradation. Similarly, the insulation on the associated boiler pipework and valves should be assessed and replaced if necessary. This can result in additional savings of up to 10% of the boiler energy input.

On larger boilers, the flue can cause a flow of air through the boiler, even when it is not firing. This cools the boiler and valuable heat is lost to the atmosphere known as standing losses. A flue damper can be used to close off the flue automatically when the boiler is not firing, thus preventing this energy loss. Since 1998, regulations have required boilers to have improved efficiencies at both full and part-loads, and this has led to lower standing losses in modern boilers. Retrofitting flue dampers is therefore applicable to older, conventional boilers with a large load (typically >100kW). The advice of a qualified technician is essential.

Particular attention should be paid to valves as these are often left uninsulated because of access concerns. Modern valve-wraps solve this problem by providing suitable levels of insulation but allow easy access to the valve through quick-release fastenings.

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Refrigeration

09

Install variable speed drives and pumps

On forced/induced-draught boilers, a variable speed drive can be installed on the fan. The enables the fan to operate at lower speeds when less air flow is required. A reduction in fan speed of just 10% can result in fan energy consumption savings of around 20%, and a reduction in fan speed of 20% will save up to 40%. This is particularly relevant for big boiler systems. Variable flow control works on a similar principle. Most heating systems use the same amount of energy for pumping, regardless of the load on the system, but they normally require maximum flow for only a limited time. This is usually during the boost period when trying to raise the temperature of the building to a comfortable level. Variable speed pumps can be fitted which decrease the flow in the system to match demand. This can save 25-50% of the annual pumping energy consumption.

Recover heat from exhaust gases

In conventional boilers, the heat contained within the exhaust gases is lost to the atmosphere. If replacement with a condensing boiler is not possible, this heat can be recovered through the use of a heat exchanger. The heat can be used to pre-heat the return water or the combustion air. Increasing the temperature of the combustion air by 20C can improve the overall efficiency of the boiler by 1%.

This technology is best suited to conventional and highefficiency boilers with flue gases of a sufficient temperature. It is important that the economics of retrofitting such a system are assessed as the potential savings are relatively small. They will be most economical when applied to a larger system. Always consult a qualified technician.

Retrofitting of variable speed drives and pumps is best suited to larger systems with variable loads. If the load on the fan/pump is constant, energy consumption may actually increase through the installation of a VSD. The advice of a qualified technician is essential to assess the economic feasibility of this option.

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Technology Overview

Boiler controls
The most effective way to improve boiler performance is through controls.
The first step is to assess what controls already exist, find out if they are calibrated accurately, and check that their settings match the businesss requirements. If they do not, adjust them either by asking for help from a qualified professional, or referring to the operating manual (usually downloadable from manufacturers websites if they have been lost). The next step is to decide whether additional controls would be beneficial. Again, installation of new controls should be carried out by a professional. Types of burner control The simplest form of burner control is single-stage or on-off control and is the type of control found on most older, standard boilers. With this type of control, the burner fires at full capacity when heat is required and is off otherwise. Air purges immediately before the burner is switched on and after the burner is switched off to ensure that no residual fuel or combustion vapour remains in the boiler, but this also causes heat to escape via the flue. An improvement to the above is two-stage or high-low control. With this type of control, rather than being completely switched off, the burner has the option of going to a low firing rate, typically 40% of full capacity. This reduces the number of times the burner switches off and the number of air purges, and improves boiler efficiency under part-load conditions.

A brief description of a number of different control options is given below, with details on the optimum settings for these controls. Manufacturers will be able to give more advice on the best control options for particular boilers. Please refer to the Carbon Trusts technology guide Heating control (CTG002) for more in-depth information.

Burner controls

As part of routine servicing, a qualified technician will measure the fuel-to-air ratio of a boiler. This can then be compared with the manufacturers recommendations and, where necessary, the appropriate remedial actions taken. In some cases, the boiler technician will simply adjust the burner as part of the service but for more complex systems, particularly those operating at part load for much of the year, it may well be cost-effective to consider a replacement burner control that will improve efficiency and result in energy savings.

Burner controls manage the fuel-to-air ratio which is critical to the efficient operation of the boiler: too little air and there will not be enough oxygen for complete combustion to occur resulting in a build-up of potentially dangerous carbon monoxide in the flue; too much air and energy will be wasted in trying to heat the excess. The fuel-to-air ratio is normally set on the burner controls and will be based on the boiler manufacturers recommendations. Proper control of this ratio will ensure that the boiler is as efficient as possible.

A further improvement is modulating control. With this type of control, the fuel and air supplies are regulated to exactly match the required heat demand. This ensures good efficiency across the whole heat output range of boilers. Modern burners use micro-processors fitted to fuel valves and air dampers to monitor flue gases continually and control fuel-to-air ratios accurately. Retrofitting of burner controls is best suited for older, conventional boilers with large, variable heat loads.

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Refrigeration

Boiler interlock

Linking the boiler controls with the heating system controls (such as room thermostats) via a boiler interlock will ensure that the boiler does not operate when there is no heat demand and will prevent dry-cycling. This can be done using standard wiring between the boiler control and the main heating control, or can be achieved through the installation of a specialised integrated controller. The best option will be determined by the size of the system and location of the boiler and controls. A qualified technician should be consulted for advice. Interlock control is appropriate for all types of boiler.

Boilers can continue to fire even when there is no demand for heat (called dry-cycling) and so all the heat energy is lost to the flue. Find out whether this is happening by turning off the heat distribution system and then observing the boilers themselves. If they continue to fire when no load is required, dry-cycling is occurring. Clearly this should be avoided.

Sequence control

If there are two or more boilers, it is a good idea to consider sequence control if it is not already installed. Find out whether or not sequence control is operating by observing the boilers during part-load conditions, such as in spring or autumn. If all boilers are firing under mild conditions, it is likely that they are operating only at part-load and do not have sequence control.

Good sequence control ensures that only the minimum number of boilers required to meet the heat demand actually fire and that these boilers are used to full capacity rather than part-load. Also, sequence controllers ensure that the order in which the boilers fire can be rotated to minimise maintenance costs. Note that where there are both condensing and standard boilers installed, the condensing boiler should always take the lead. Good sequence control could save 5-10% of the overall energy consumption of the boiler plant. Where not already installed, sequence control should be retrofitted to multiple boiler applications with a variable load pattern.

External temp C

iler can use A poorly maintained bo one that is 10% more energy than well-maintained.

DID YOU KNOW ?

16
ON OFF OFF

Mild weather Cold weather

12 8 4 0 Boilers firing
ON ON OFF

ON

ON

ON

Deep winter

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Technology Overview

Optimised start/stop control

Most heating systems will be controlled via a timeswitch. This will be set to switch the heating system (and hence the boiler) on and off at pre-set times in the morning and evening, corresponding to building occupancy patterns. An optimiser is a sophisticated timeswitch linked to the internal and external thermostats that switches the boiler on at exactly the right time to ensure that the building reaches the required internal temperature in time for occupation. Similarly, the boiler is switched off early so that the internal temperature is maintained only when required. Savings of 5-10% of the overall energy consumption of the boiler plant could be achieved. Most buildings with standard operating hours would benefit from installing optimised start/stop control.
24 20
Internal temp C

To achieve more savings, the temperature of the water can be regulated according to outside temperature. In milder weather, the flow temperature is reduced, thus saving energy. This is done through the use of a compensator linked to internal and external thermostats. This form of control is particularly useful in condensing boilers as lower return water temperatures can be achieved, thus ensuring that maximum condensation occurs within the boiler and increasing efficiency.
20
External temp C

Direct weather compensation control

16 12 8 4 0 0 20 40

Normally two settings Minimum flow temperature Ratio or slope of graph

Potential energy savings Timeswitch set for 6am Typical settings Maximum heat-up period e.g. 6am to 9am Normal occupancy period e.g. 9am to 5pm Optimised start 4 5 6 7 8 9 10 11 12

60

80

100

16 12 8 0

Flow temp C

Time (hours)

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Refrigeration

Controls work best when their operation is integrated and linked to the actual requirements of the building. A Building Energy Management System (BEMS) is a computer-based control system which automatically monitors and controls a range of building services. Installing a BEMS means that control options such as sequencing, optimisation and compensation can be carried out by one system. It allows various environmental parameters to be taken into account and provides logs of useful data that can be used in maintenance, energy monitoring and assessing further improvements to the system. 10-20% of heating energy can be saved by installing a BEMS in place of several independent control options. However, they are expensive and may only be cost-effective for larger boiler plant. They will also be effective only if operated by trained staff and maintained and calibrated regularly. Manufacturers can advise on the most suitable BEMS for their boiler plant.

Building Energy Management Systems

Summary of control options Boiler size What are the minimum controls you should have? Boiler interlock Want to save even more energy?

For boilers up to 50kW

Minimum standard

Minimum standard PLUS Optimisation Direct weather compensation

Good standard

For boilers over 50kW

Boiler interlock

Sequence control

Minimum standard PLUS Optimisation Direct weather compensation

Check controls

The benefits of improved controls will be realised only if frequent checks are carried out on control settings and their operation. This is particularly important if business needs have affected the controls. For example, controls are set to cover a period when staff work out of hours, but are not returned to their original settings. A regular check will spot where energy is being wasted in this way.

Building Energy Management System (BEMS)

Simple control settings (such as timeclocks) can be adjusted by non-professional building staff as circumstances require, provided they have had appropriate training and take care. More sophisticated controls should be adjusted by a qualified technician. Similarly, control operation and calibration should be checked annually by a qualified technician. A simple way of assessing the effectiveness of boiler controls is to plot heating energy consumption on a graph and compare with periods of building operation and outside weather conditions. Does the building show a high energy use out-of-hours? Is there a high heating load when the weather is mild? These are indications that control settings are inaccurate or that additional controls are required.

Sequence controls, optimised start/stop controls and direct weather compensation controls can be purchased as a unit or can be programmed as part of a Building Energy Management System (BEMS).

For more advice and publications on energy monitoring, contact the Carbon Trust.

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Technology Overview

Maintenance
Effective maintenance is essential in getting the best performance from your LTHW boilers. Without it, boiler efficiency can drop significantly and equipment life expectancy is reduced. Effective maintenance can also highlight potential problems quickly and enable remedial action to be taken before there is a major impact on performance.
Perform regular servicing
A full boiler service should be carried out by a qualified technician on an annual basis, ideally before the start of the heating season. This service should include a flue gas analysis (to check fuel-to-air ratio), an operational check, controls calibration, burner cleaning and limescale treatment.

Remove soot

If combustion conditions are not correct, particularly if too little air is used, unburnt fuel particles soot will build up on the fire side of the boilers heat exchanger. This soot creates an insulating layer, inhibiting heat transfer to the water. More heat input is required to meet the heat demand and more heat energy will be lost to the flue. All hydrocarbon fuels gas, oil, coal will create soot. Gas boilers create less soot and will require cleaning every six months. Oil and coal boilers should be cleaned more regularly. Cleaning should be carried out by a qualified technician.

Boiler maintenance should be carried out by CORGI or OFTEC registered contractors ONLY.
Analyse flue gas
As mentioned in the previous section, the fuel-to-air ratio is critical in ensuring efficient boiler operation. Analysis of the boilers flue gases for levels of carbon dioxide (CO2), oxygen (O2) and carbon monoxide (CO) will determine whether this ratio is correct and what adjustments need to be made. Different ratios will be required for different boilers and your boiler manufacturer or maintenance technician can give the appropriate advice. Flue gas analysis should be carried out every three months by a suitably qualified technician. Ask for a report on the combustion efficiency which includes measures for improving it.

For very large boilers, typically used in industrial application, integrated soot-blowers are often installed in boilers to provide continual cleaning; however, these will need to be checked regularly to ensure good working.

in energy l cause a 10% increase A 1mm layer of soot wil demand. meet the same heat input to the boiler to

DID YOU KNOW ?

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Refrigeration

Minimise limescale build-up

In hard water areas, limescale can build up on the water side of the boilers heat exchanger. This creates an insulating layer, inhibiting heat transfer to the water in the same way as the soot deposits above. The most effective method of limescale removal is through chemical treatment of the water. This should be done annually by a qualified technician to minimise limescale build-up and keep your boiler running at its most efficient.

To ensure effective maintenance is carried out, a maintenance plan should be put in place. This will detail what maintenance tasks are to be carried out, the frequency of these tasks and who is responsible.

Produce a maintenance plan, manual and logbook

A maintenance manual should be produced that is updated regularly. This manual should include: The maintenance plan Block diagram of the boiler plant showing the location of key components and controls Operating instructions and control settings Emergency shutdown procedures

A 1mm layer of limescale will cause a 7% increase in energy input to the boiler to meet the same heat demand.

Schematic diagrams of the heating system and the controls

A maintenance logbook should be kept giving detailed records of maintenance tasks, including which actions were taken, the person responsible, and when they were completed. This logbook will ensure that tasks are carried out at the correct frequency and will highlight ongoing problems. Summary of maintenance requirements Maintenance task Frequency Responsibility

Particular attention should be paid to specific instructions from manufacturers as these will ensure the optimum performance of the boiler plant. Also, failure to follow them may invalidate warranties.

Contact details of installation/maintenance technicians and boiler manufacturers.

Review boiler maintenance policy Full service Flue gas analysis (combustion check) Remove soot deposits Limescale treatment

Yearly Yearly

Energy/facilities manager with the advice of qualified technician Qualified technician Qualified technician

Quarterly Yearly

Six-monthly (more frequent for oil/coal boilers) Quarterly, or as changes to building operation demand Yearly, or as changes to building operation demand Yearly Yearly

Qualified technician Building staff

Check/adjust simple control settings Adjust/re-programme complex controls Check control operation Calibration of controls

Qualified technician Qualified technician Qualified technician Qualified technician

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Technology Overview

Replacing boilers
If a boiler is more than 15 years old, or if it is showing signs of inefficient operation, it should be replaced. This is not as simple as noting the old boilers rating and purchasing a new, condensing model. To find the best solution, thoroughly review the buildings heating demand and your business needs, and check these against your technical, financial and policy requirements.
When considering a boiler replacement, advice should be sought from a qualified building services engineer or boiler technician. To help them, consider the following information. Start by reviewing the buildings internal environment and general operation. What is the current internal temperature of the building? Are employees happy with the internal environment? Are there any hot or cold spots within the building? Are there any areas of the building where temperature is critical? When is the building occupied?

The buildings heating requirements

The most important aspect in selecting a new boiler is getting the size right. It was once common practice to oversize boiler plant with the mistaken notion that this would provide greater flexibility in the future. However, it is now realised that this is unnecessary as the heating demand for many commercial buildings has fallen. This is due to improvements in building fabric and an increase in internal heat gains, such as from IT equipment, lighting and occupants. If a boiler has not been replaced for many years, the heating load of the building may have changed significantly.

Next, review your annual energy bills. What fuel do you currently use for heating? How much energy has the building used over the last year and how much did it cost? How does this compare with other similar building types? To do this, divide the annual heating energy used by the area of the building to gain a benchmark in kWh/m2. The Carbon Trust and other organisations publish typical benchmarks for different types of building for comparison. Call the Carbon Trust to see if relevant benchmarks exist for your building type. Smaller boilers cost less, so look for ways of reducing the heating demand. Can the insulation of the building be improved? Could draught-proofing be improved?

Find out the buildings heating requirements Information Source How is this information used?

Floor area of building Occupied hours Internal environmental data, such as temperature Annual energy use/cost for heating Details of planned energy saving measures

Property documents Direct measurement Staff records Direct measurement Control settings Staff comments

Energy benchmarks

Utility bills Energy monitoring and targeting system

Calculating heating demand Assessing effectiveness of existing heating system Energy benchmarks

Calculating heating demand Selecting boiler controls

Company energy policy

Calculating heating demand

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Refrigeration

Technical considerations

The choice of boiler will be dependent on a number of technical issues. A building services engineer or boiler technician can give advice, but you can provide some basic information to help. Fuels Ultimately, the choice of fuel will be based on cost and availability of supply. Ask which fuels are available on-site. Is there a natural gas supply? If not, are there issues relating to the supply or storage of fuels such as LPG. Unless biofuels are a realistic option, natural gas is the best choice where a supply is available as it is the most versatile and has the lowest carbon emissions. Boilers are designed to operate with particular fuels and are rarely interchangeable. Location Where you have more than one boiler, find out if the existing boiler plant is centralised or de-centralised.

Flue outlet

De-centralised plant (where a number of smaller boilers are located around the building) will reduce pipework losses, but you will not have the option of integrating control operation and maintenance may be more problematic and expensive. This is because it costs more to carry out maintenance checks on several smaller boilers than one large boiler.

Where is the boiler flue outlet? Condensing boilers generate lower temperature flue gases and visible plumes of steam. This may cause problems if the flue outlet is close to other building surfaces. Heating system What type of heating system is currently used in the building? Unless a major refurbishment is planned, it may not be cost-effective to replace the whole heating system so the new boiler must be compatible with what is there already. Condensing boilers work best with lowtemperature applications such as under floor heating, but will still provide a higher level of efficiency when applied to a radiator circuit. It may be necessary to upgrade the heating controls of the system to get the best from the new boiler. Do not forget to account for these costs when considering the purchase price.

Centralised plant (where all boilers are in one plantroom) may be easier to maintain and control, but heat losses through long pipework runs will be higher. Combine the replacement of boilers with upgrades to the pipework insulation. Also take advantage of the central location to install upgraded controls or re-programme existing ones. Find out the technical requirements Information Source

Fuel supply available Centralised or de-centralised plant Location of flue outlet Type of heating system

Utility companies Local authority Observation

How is this information used? Specification of boiler type

Observation Observation

Specification of boiler type Assessing effectiveness of existing heating system Specification of boiler type Heating controls

Specification of boiler type Selecting boiler controls Pipework insulation required

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Technology Overview

Financial considerations

Consider the costs of the new boiler, including capital expense, fuel and maintenance. This is called life costing, that is, how much will the boiler cost over its actual lifespan. It is important to capture all the activities associated with the ownership of a boiler if it is to last its normal life expectancy. Capital expense How quickly will the investment pay for itself through reduced running costs? Will this influence the purchasing budget? Condensing boilers are more expensive than standard high-efficiency boilers, but they are more efficient and cost less to run. So the extra cost is often paid back within two years or less.

Maintenance

As stated previously, maintenance of boilers is important. Will the maintenance costs of the new boiler be higher? Will extra staff training be required to ensure efficient operation? Can maintenance be done in-house or will it be contracted out? Make sure that all staff involved in the operation and maintenance of the boiler plant have a say in the choice of the new boiler.

The business may be able to take advantage of Energy Efficiency Loans or the Enhanced Capital Allowance Scheme (see next page for information on the Carbon Trusts financial products). Fuel Fuels vary in price. Consider your current and projected energy use and calculate the cost of running the boiler. Find out financial considerations Information Source

Replacing a conventio nal boiler with a conde nsing model can save 10-20 % of annual energy cos ts more if the original boiler is in a particularly poor condition. Example: A building wit h a heating demand of 100kW has an annual gas bill of 7,150.1 A new con densing boiler is installed at a cost of 2,000 with a seasonal efficiency of 90%. The new annual gas bill is 5,550 a saving of 22% or 1 ,600/year. Maintenance costs are increased by 200 per year. Therefore, the cost of the new boiler is pa id back within 18 month s.
Based on a 70% efficie nt boiler, 2,500 operati ng hours/year and 2p/kWh gas pric e.

DID YOU KNOW ?

Purchase budget

Availability of loans/tax incentives Running costs of new boiler

Carbon Trust HM Revenue and Customs

Finance/Company director

Specification of boiler

How is this information used?

Changes to purchase budget

Maintenance costs of new boiler

Building services engineer Boiler technician Manufacturers Utility bills Building services engineer Boiler technician Manufacturers Finance dept.

Calculating payback periods Predicting future energy expenditure Life costing Calculating payback periods Predicting future energy expenditure Assessing staff training needs Developing a maintenance plan Life costing

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Environmental considerations

As well as reducing running costs, condensing and high-efficiency boilers will have reduced emissions of carbon dioxide (CO2) and harmful pollutants such as sulphur dioxide (SO2) and nitrogen dioxide (NO2). Does your company have an environmental policy? Will this influence the choice of a new boiler? Find out environmental considerations Information Environmental policy Source Company director How is this information used? Specification of boiler to ensure reduced emissions

The Carbon Trust can provide an energy efficiency loan to SMEs in England and Wales of up to 100,000* and for all businesses in Northern Ireland of up to 200,000 for investment in energy saving projects such as the upgrading or replacement of lighting, boilers or insulation. The loans are interest-free, unsecured, repayable over a term of up to four years and with no arrangement fees. In Scotland, the Scottish Executive offers a similar scheme called Loan Action Scotland.
*Subject to terms and conditions and local funding.

Energy Efficiency Loans

Preparing a detailed brief

Once this information has been gathered, use it to prepare a detailed brief for a building services engineer or boiler technician. They will use this information to select the best boiler to achieve your needs within the proposed budget. A detailed brief will save time and money and ensure that your new boiler is both efficient and effective.

Enhanced Capital Allowances (ECAs) enable businesses to buy energy efficient equipment using a 100% rate of tax allowance in the year of purchase. Businesses can claim this allowance on the investment value of energy efficient equipment, if it is on the Energy Technology List. The procedure for claiming an ECA is the same as for any capital allowance. For further information please visit www.eca.gov.uk or call the Carbon Trust on 0800 085 2005.

Tax incentives

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Technology Overview

Energy monitoring and targeting

If energy use is not monitored, it cannot be controlled. An energy efficiency strategy will be most effective when accompanied by appropriate energy monitoring and targeting. By monitoring the energy used by the boiler plant, the effect of improvements can be assessed in both financial and environmental terms. In addition, unusually high energy consumption can be spotted quickly, problems identified and remedial action taken.
The first step is to take regular meter readings at least monthly, although weekly would be better for larger buildings. If a BEMS is installed, it may be possible to automate this process. This will be dependent on the type of meter installed and advice should be sought from the BEMS manufacturer and/or the utility company. Depending on the size of the building, utility companies may be able to provide half-hourly energy data.

Set targets and monitor progress

Simply monitoring energy use will not result in savings. Targets for reduction should be set and measures put in place to achieve those targets. A 10% reduction in heating energy can often be achieved through simple adjustments to existing boiler plant. Greater reductions can be achieved through the replacement of equipment, components or controls. Keep a check on progress towards meeting targets. If progress is slow, carry out another review of the heating system and look for additional measures that can be taken. Report progress to all building occupants this will increase energy awareness and get everyone involved in reducing the buildings energy use.

Effective energy monitoring and targeting can highlight potential problem areas and lead to swift, remedial actions.
The meter readings should be recorded on a table and the energy consumption for the period calculated. Graphs can then be produced to show the energy consumption over time and comparisons can be made to assess performance.

If the individual performance of a boiler is required, spot meters should be installed on the individual fuel intakes. This may not be cost-effective for smaller boilers so should be considered carefully.

It is important to assess heating energy use in the context of weather conditions and building operation. For example, heating energy will increase when the weather is colder and heating energy should be minimal when the building is unoccupied. If your heating energy use profile does not match weather conditions or building operation, it may be an indication of poor control.

For more information on energy monitoring, contact the Carbon Trust.

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Refrigeration

Next steps
The checklist below will help you to carry out an initial review of the boiler plant and assess what actions can be taken. Many such actions can be taken in-house; however, you may need specialist support from your contractor or consultant for others.
Review Make, model, size, type and age of boiler Fuel consumption of boiler plant Check physical condition Assess controls Check control settings Review maintenance history Is the boiler more than 15 years old? Is the boiler oversized? How efficient is the plant? Questions Replacement Actions to be considered Different improvement options will apply depending on boiler type Assess through meter readings. Estimate efficiency based on consumption and rated output Comments

Replacement

Is there any corrosion? Is insulation adequate/ in good condition?

What type? Are sequencers, optimisers or compensators used? Are they appropriate? Do they match building operation patterns?

Get service done Replace/upgrade insulation Replacement Install additional controls Adjust settings Establish a proper maintenance plan Order service/maintenance check

Poor physical condition will cause poor performance; consider replacement

Improved control will reduce energy consumption Improved control will reduce energy consumption

When was the last maintenance carried out? Is a proper maintenance plan in place?

Poor maintenance can reduce boiler performance by up to 10%

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Technology Overview

Glossary
Atmospheric burner Boiler Boiler efficiency Boiler interlock Building Energy Management System (BEMS) Burner Combustion A burner where the air required for combustion is drawn in via natural convection. A comparison of the energy output versus the energy input of the boiler. A vessel for converting heat produced by combustion of fuel into hot water or steam. Where the boiler and system controls are linked to ensure the boiler does not fire when there is no heating demand. A computer-based system that operates all building controls and enables automatic adjustment and monitoring of settings. The device producing the flame for combustion in the boiler. A device, or feature within a device, that adjusts the temperature of the water circulating through the heating system according to the temperature measured outside the building. A boiler that reclaims heat from the exhaust gases to improve overall efficiency. A heat emitter that heats a room through either natural or forced convection. The boilers chimney used to transport exhaust gases to the atmosphere. The process of turning fuel into useful heat.

Compensator Condensing boiler Convector Flue Energy benchmark Flue damper

A measure of a buildings energy use that can be compared to other buildings of a similar type. Expressed in kWh/m2. A device that shuts off the flue, avoiding cold air penetrating the boiler when it is not firing. A burner where the air required for combustion is drawn in via a mechanical fan. A network of pipes within a boiler whereby the heat from the burner is transferred to the circulating water. Where the fuel and air intake are controlled over the whole range of boiler output. A sophisticated timeswitch linked to the internal and external thermostats that switches the boiler on at exactly the right time to ensure that the building reaches the required internal temperature in time for occupation. A heat emitter, made of metal, that heats a room through a combination of radiation and convection. Where the burner is either on or off and fuel/air intakes are the same regardless of heating demand. Where the burner can revert to a low-firing range under part-load conditions. A controller for multiple boiler systems that ensures the minimum number of boilers is used to meet the required heating demand.

Forced/induced draught burner

Heat exchanger Modulating burner control Optimiser Radiator Sequencer Single-stage burner control Two-stage burner control Under floor heating Variable flow control Variable speed drive

A network of low temperature hot water pipes installed under the floor finish which heat a room from beneath. Where the pump flow is regulated to match demand and flowrate. A device fitted to electric motors that regulates speed to match demand.

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Notes

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Technology Overview

Notes

For further information

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The Carbon Trust works with business and the public sector to cut carbon emissions and capture the commercial potential of low carbon technologies. An independent company set up by the Government to help the UK meet its climate change obligations through business-focused solutions to carbon emission reduction, the Carbon Trust is grant funded by the Department for Environment, Food and Rural Affairs, the Scottish Executive, the Welsh Assembly Government and Invest Northern Ireland.

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