We have found that
improvements can be achieved in boiler efficiency by better controlling
how the boiler operates in response to the changing conditions of a
facility, as well as managing limescale within the piping system.
Combining technologies provides significant improvements in boiler power
Boiler Power Plant Efficiency
The following Boiler Efficiency Graphs
show run-time comparisons utilizing Savastat LC in a day-on, day-off
test cycle over a period of seven days:
You can readily see the difference in the cycle patterns
during the days Savastat LC is managing the boiler, by the varying mean
temperatures. Savastat LC closely manages the boiler based on
actual demand. The days LC is not controlling the boiler, the
firing pattern is very regimented between the boiler set point, and
When we take a closer look to compare an on-day to an
Here we can better see that the mean temperature is
"modulating" to accordance to system demand (load), whereas the off-day
maintains a consistent internal boiler temperature regardless of the
The mean temperature reduction
of only a few degrees results in significant efficiency improvements, as
the heat is transferred more effectively into the system at a wider
differential. Holding off the boiler when heat is not needed also
significantly adds to the efficiency improvements achieved.
Typically a reduction in run-times of 20% or more are achieved.
Facility managers can conduct similar boiler
efficiency analysis by tracking boiler run-times and day degree
Boiler Power Plant Efficiency
The following graph shows how
limescale effects water tube boiler efficiency:
Similar losses are true in
regard to fire tube boiler efficiency as well, only the scale forms
on the outer surface of the tubing rather than inside the tubing.
ECMI and our Associates help our clients improve boiler
operating efficiency in three ways:
By implementing the Savastat LC on
compatible boiler systems to better manage boiler operation.
By implementing HydroFLOW
to improve heat exchange efficiency loss due to limescale build-up in
the boiler system and heat exchangers throughout the facility.
By implementing the Stack Draft Regulator on
appliances to manage system flu draft losses.
By improving Boiler operating efficiency, boiler heat
efficiency, and stack drafting, significant energy savings can be achieved. The
combination of the systems can easily achieve savings in excess of 40% during a typical
heating season. Savastat LC implements "load compensation control"
which enables the boiler to function more efficiently in real time based
on the current ever-changing weather conditions and facility
environment, HydroFLOW keeps the system free of limescale and
operating at peak heat exchange efficiency, and the Stack Draft
System optimizes appliance performance.
How Does ECMI Helps Clients Improve Boiler Power Plant
Is compatible with low pressure hot water heat loop system
Will eliminate boiler short cycling
Will extend the boiler and equipment's lifecycle
Is easily installed with little down-time
Will provide a guaranteed 15%
savings or a 24 month or less ROI.
Will remove limescale from inside the boiler and piping
Continues to keep limescale from forming within the system.
Keeps the boiler operating at peek efficiency.
Eliminates the need for frequently scheduled boiler cleaning,
as well as the need and associated costs for expensive and environmentally
Brings appliance efficiency back near
to the manufacturer's specifications
Eliminates heat losses due to negative
drafting sucking the heat right out of the system
Provides a better flame pattern across
the heat exchanger and eliminates "rope flame"
Cleaner burns means less soot and lower
O2 readings in the stack
More efficient burns also means less
fuel going up the stack
Keeps more heat in the system thus
reducing burn cycles and burn frequency
Works with most any appliance with a
flame and a stack!
VERY Significant savings when
multiple appliances feed into a common stack!
Contact us so we can work with your
organization to help improve boiler power plant efficiency in your
Improving Boiler efficiency