The Art of Boiler Tuning
Presented by Steve Connor
February 26, 2014
Today We Will Cover
1. What tuning
really is.
6. Post Tune-up
Procedures
5. Proper
Procedures During
Tune-up
The Art of
Boiler Tuning
2. Why is tuning
important?
3. Why is tuning
considered an
art?
4. Pre-Tune-up
Procedures
1. What Is Boiler Tuning?
Simple Definition
Simple Definition
Boiler tuning is essentially
tuning the burner - adjusting
the fuel/air ratio to operate
the boiler more efficiently
while maintaining safety.
1. What Is Boiler Tuning?
Encompasses All Types of Boilers
2. Why Is Tuning Important?
Economics
RULE OF THUMB
The boiler will
consume in fuel on
average 4 times its
initial cost every
year.
2. Why Is Tuning Important?
Economics
Issue: Heavy Sooting
Results
Overheated Tubes
Energy Losses
Downtime
2. Why Is Tuning Important?
Economics, Safety & Emission Compliance
Oxidation Requires
Fuel
Oxygen
Ignition source
Result
Heat
CO2
H2O
CO
NOx, SOx
Heat
C
H2
S
N2
Fuel
Some
Fuels
Output
- Mixing
Turbulence
- Temperature
- Contact
Time
O2
N2
Air
Output
CO2
H2O
CO
Output
NO NO2 SO2
Emission
Gases
(sometimes)
2. Why Is Tuning Important?
Excess Air & Efficiency
RULE OF THUMB
For every 2%
increase in O2,
you lose 1% in
efficiency
Reference PDF Available:
http://cleaverbrooks.com/Products-and-Solutions/Boilers/Firetube/CBEX-Elite/Excess-Air-and-Boiler-Efficiency.aspx
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2. Why Is Tuning Important?
Excess Air & Efficiency
The Variables
Barometric Pressure
Relative Humidity
Ambient Temperature
RULE OF THUMB
Tune your boiler
in the Spring &
Fall to avoid
ambient air
swings.
Combustion settings will
change as weather and
ambient conditions vary.
2. Why Is Tuning Important?
EPA Compliance
Major
Source
PERIODIC
TUNE-UPS REQUIRED
Area
Source
www.
Reference Material Available:
http://cleaverbrooks.com/epa.aspx
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2. Why Is Tuning Important?
EPA Compliance Exclusion
Area Source gas fired
boilers are NOT
included unless they
burn fuel oil and the
burning of it exceeds 48
hours annually, and it is
not the result of a gas
curtailment.
www.
Reference Material Available:
http://cleaverbrooks.com/epa.aspx
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BURNER TUNING
3. Burner Tuning Is An Art
Qualifications
1. Knowledge
2. Electro/Mechanical
3. Hands on Experience
13
3. Burner Tuning Is An Art
Preparedness
1. Fully Equipped
Combustion Analyzer
2. Parts Access
3. Ready Back-up
Basic Tools
14
3. Burner Tuning Is An Art
Equipment Uniqueness
Integral Burner
Gun Burner
15
3. Burner Tuning Is An Art
Disaster Avoidance
Fuel rich and uncontrolled
ignition can cause loss of
people and property.
Fireside explosion
16
3. Burner Tuning Is An Art
Proper Balance of Fuel/Air
Combustion Curve
Minimize excess air
Control CO
Maintain minimum safety
margin (15% excess air)
RULE OF THUMB
Stay at 3% O2 or
15% excess air
for efficiency and
safety.
17
4. Proper Pre-Tune-up Procedures
Initial Boiler Room Review
1.
2.
Nameplate Inspection
Burner Management
System/Programmer
3. Fuel/Air Ratio Control
4. Gas Train/Gas Pressure
5. Water Level
6. Stack/Breeching
Arrangement
7. Air Ventilation
8. Feedwater Sources
9. Electrical Supply
10. Boiler Room Log
11. Benchmark Expectations
18
4. Proper Pre-Tune-up Procedures
Nameplate Inspection
Boiler Model
Design Pressure
Maximum Input
Proper burner setup means
achieving full input as
efficiently and safely as
possible
19
4. Proper Pre-Tune-up Procedures
Burner Management System/Programmer
Sequence is automatic
All safeties in place
Pre-ignition interlocks
powered
Running interlocks
powered
The technician needs to
know the BMSs
characteristics - regardless
of whether it is electromechanical or PLC based.
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4. Proper Pre-Tune-up Procedures
Fuel/Air Ratio Control
Parallel Positioning
Single Point Positioning
Actuators
Drive Motor
21
Cams
4. Proper Pre-Tune-up Procedures
Gas Train/Gas Pressure
CHECK GAS
PRESSURE
Is it within the
manufacturers
recommended range?
22
4. Proper Pre-Tune-up Procedures
Water Level
Hot Water Boiler
Steam Boiler
Expansion Tank
Low Water Cut Off
& Gauge Glass
23
4. Proper Pre-Tune-up Procedures
Stack/Breeching Arrangement
Looking for:
Leakage/condensation
Excessive restrictions
or bends
Exceeding manufacturers
recommended draft pressure
(+/-) in stack/breeching will
cause combustion problems
24
4. Proper Pre-Tune-up Procedures
Combustion Air
RULE OF THUMB
1 in2/2000 BTU
Input of open
area
1 in2/4000 BTU
Input for fan
25
4. Proper Pre-Tune-up Procedures
Feedwater Sources
Vented Receiver
Deaerator
26
4. Proper Pre-Tune-up Procedures
Feedwater Sources
Modulating
Feedwater Valve
Must be working properly;
supplying adequate
feedwater matched to
evaporation rate
27
4. Proper Pre-Tune-up Procedures
Electrical Supply
Electrical Cabinet
CHECK FOR
LOCK OUT/
TAG OUT
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4. Proper Pre-Tune-up Procedures
Boiler Room Log
Cleaver-Brooks Boiler Room Log: Steam
Date
Time
Boiler #
Operator
Gas pressure, flue gas
temperature, and ambient
air temperature impact the
proper tuning of the burner.
Water visible in gauge glass
Combustion check (visual)
Steam pressure
Feedwater pressure
Feedwater temperature
Flue gas temperature
Burner
Gas pressure
Gas meter reading
Oil pressure (regulated)
Oil temperature
Oil meter reading
Atomizing air pressure
Ambient air temperature
Make-up water
Blowdown water column
Blowdown boiler
Chemical analysis
Comments/Observations
29
4. Proper Pre-Tune-up Procedures
Benchmark Expectations
What are the customers
expectations regarding:
Excess Air
Carbon Monoxide
NOx
30
5. Proper Procedures During Tune-up
Scenario Assumptions
Assuming:
Natural Gas
Load
Hot Boiler
Near Operating Pressure
31
5. Proper Procedures During Tune-ups
Flue Gas Analysis
Insert probe into the stack:
Stack Temperature
O2
CO
32
5. Proper Procedures During Tune-ups
Pre-Purge
Power the burner switch
and place in manual mode
BMS will go through
pre-purge before pilot
and main flame
ignition
Burner Switch
33
Manual/Auto Switch
5. Proper Procedures During Tune-ups
Pilot Adjustments
Pilot problem?
Burner switch off
Trial for ignition
Pilot test switch on
Make pilot adjustments
Adjustments are made through
the gas pilot regulator and
manual cock in the pilot line.
Pilot Test Switch
34
5. Proper Procedures During Tune-ups
Low Fire Adjustment
Check Analyzer for O2 &
CO readings
Check Manifold Pressure
Manifold Pressure
Low Fire
RULE OF THUMB
A good excess
air at low fire is
between 5 8 %
O2.
35
5. Proper Procedures During Tune-ups
Cam Adjustments
Single Point
Positioning System
Cam
36
5. Proper Procedures During Tune-ups
Increasing the Firing Rate
Low Fire
Increased Input
Check for signs of
sooting or instability.
37
5. Proper Procedures During Tune-ups
Fuel/Air Ratio Adjustments
Analyzer
Cam Adjusting
RULE OF THUMB
Assure the
combustion is set at
the maximum
efficiency at the rate
your boiler fires
most of the time,
while maintaining
15% excess air, and
as close to a linear,
but safe curve from
low to high fire as
possible.
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5. Proper Procedures During Tune-ups
High Fire Check
Manifold Pressure
Do you have the full input to
the burner as defined by the
manufacturer?
39
5. Proper Procedures During Tune-ups
High Fire Check
Manual/Auto Switch
High Fire
Low Fire
Single Point Positioning: Do
you have any hitches or
slippage in the linkage?
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5. Proper Procedures During Tune-ups
Boiler Pressure & Temperature Relationship
Pressure Gauge
Stack Temperature
Gauge
RULE OF THUMB
A stack temperature
between 50-100
degrees above the
saturation or water
temperature = well
tuned boiler/burner.
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6. Post Tune-up Procedures
Safety Checks
1. Check Low Water Cut-Off
(Evap. Test)
2. Check ALWCO
3. Check Additional
Safeties:
a) Scanner
b) CAPS
c) HGPS
d) LGPS
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Todays Take-A-Ways
Tuning is an art requiring knowledge &
experience
There are many benefits
Important to review the boiler room before
starting
Need the proper tools and back-up
The boiler needs to be hot to properly tune it
Fuel pressures and combustion air are critical
Proper tuning is a compromise between
efficiency & safety
The correlation between stack temperature &
efficiency
Post tuning safety checks
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Contact Us
Ron Churchill
Senior Application Engineer
rchurchill@cleaverbrooks.com
414-577-3149
cleaverbrooks.com
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