The future for gas boilers efficiency

How are manufacturers achieving such high levels of efficiency and will it ever be possible to create a gas boiler that's 100% efficient?.

All new and replacement gas-boiler installations (with limited exceptions) must now run at over 86% efficiency.

Some boiler manufacturers are now only building SEDBUK A-rated models, which are over 90%.

With ongoing dedication to improving the efficiency of new boilers, how are manufacturers achieving such high levels of efficiency and will it ever be possible to create a gas boiler that's 100% efficient?.

Martyn Bridges, Worcester's director of marketing and technical support, sheds some light: "Gas domestic heating became popular here in the seventies when North Sea gas became a viable option for the UK to pump.

Until relatively recently, gas boilers were built in cast iron with a simple ignition system, which was often open flue.

In many instances boilers sat in a fire behind a back boiler.

"Many of these back boilers (regular units) had a permanent pilot light, which means that efficiency was compromised quite significantly.

In fact with a permanent pilot light it isn't possible to reach a SEDBUK band D rating (78 -- 82% efficiency).

In the late nineties these permanent pilot lights were eliminated.

"Energy efficiency has been an increasingly important factor in Government environmental policy for a good number of years.

In 1984, the first energy-efficiency rules were introduced within the Building Regulations.

They were extensively tightened in 2002 with the introduction of the SEDBUK (seasonal efficiency of domestic boilers in the UK) rating system within Part L1.

"Further strengthening then occurred in the 2004 updated regulations and precipitated the market's rapid transference to condensing boilers.

In the spring of 2005, all new and replacement gas-fired boiler installations were required to be condensing boilers of at least 86% efficiency (SEDBUK Band A or B).

"Over the years, the development of boiler technology has seen efficiency levels grow massively and now that Part L of the Building Regulations is now firmly in place for gas-fired appliances, manufacturers are keen to prove their boilers are amongst the most efficient.

"A high efficiency condensing boiler works on the principle of recovering as much as possible of the waste heat which is normally rejected to the atmosphere from the flue of a standard efficiency (non-condensing) boiler.

The best high efficiency condensing boilers convert more than 90% of their fuel into heat, compared to 78% for conventional types.

"This is accomplished by using a larger heat exchanger or sometimes two heat exchangers within the boiler which maximize the heat transfer from the burner as well as recovering useful heat which would normally be lost with the flue gases.

When in condensing mode the flue gases give up their 'latent heat' which is then recovered by the heat exchanger within the boiler.

As a result the temperature of the gases exiting the flue of a condensing boiler is typically 50-60degC compared with 120-180degC in a current non-condensing boiler.

At the same time an amount of water or 'condensate' is produced.

"There has been some talk in recent months of the 100% efficiency boiler, however in actual terms this will never be physically possible using current technology.

The highest achievable efficiency for gas-fired boilers is currently 91.6% and I don't see us being able to go much beyond that in the future.

"The real opportunity in terms of increasing efficiency with home heating and hot water provision is to look at secondary efficiency which can be affected by factors such as electricity consumption, standby losses, advanced controls and power save functions.

"At Worcester we are currently appraising a number of options in terms of extra components which will potentially improve these secondary efficiency levels in our Greenstar boilers.

"Other key factors which will also help a boiler run more efficiently include the correct pipework sizing, siting the boiler in the most suitable location and regularly flushing the system, helping to prevent corrosion and make sure it's free from debris.

"Over time your heating system can become rusted from the inside producing iron oxides (black sludge).

This sludge plays havoc with the working parts of a heating system, blocking pipes, radiators, valves, pumps and heat exchangers.

If left to corrode for too long this can significantly reduce the efficiency and even cause premature failure of any of these components.

"The overall carbon savings can be huge if homeowners take a little time out to think about their central heating system operation and installers have a big part to play in encouraging their customers to do this.

They have the direct contact with end-users and this is the best opportunity to convince them they can make a big difference with their actions.

Not just for the environment either; the financial benefits are significant too.

Research from the Energy Saving Trust (EST) claims that potential savings on heating bills can work out around GBP200 a year by replacing an old standard efficiency boiler with an A rated appliance, and combining that with well suited controls.

"Controls can significantly improve the efficiency of the heating system, but selecting the right unit is paramount.

Weather-compensation, for instance, is widely specified in Europe yet infrequently at present in the UK - even though it improves efficiency by reacting to actual weather conditions rather than flow and return water temperatures.

"Controls also have a vital role to play in adjusting a boilers firing rate (input) to meet the heating demand (output) of the system.

By modulating input correctly, less fuel is burned and wasted and emissions are reduced in the process.

"Recent technological advances mean a wide range of intelligent options are now available for installers to choose from in order to meet the exact requirements of each individual household they visit.

Whether specifying basic controls, like mechanical timers, or opting for more advanced controls with room thermostats, such as radio frequency or weather and load compensation systems, it is important to specify the most compatible product in order to ensure best performance from a high-efficiency boiler.

"Combining a high efficiency condensing boiler with our Greenskies solar water heating package will also improve a home's efficiency with 50 -- 70% of a home's hot water provision being provided for free by the sun.

Not only will this represent a further cost saving on bills, it will further reduce the CO2 emissions from the household as the majority of the time you turn on the hot water during the year the boiler will not need to burn any fuel, the heat will be provided by the solar panels.

"According to the EST if everyone in the UK with gas central heating installed a high efficiency condensing boiler, we would save enough energy to heat 3.7 million homes for a year.

So we don't need 100% efficiency boilers, we just need more people to re-think their current heating system.".
http://www.buildingtalk.com/news/woc/woc135.html

Power gear cos may get separate orders for boilers & turbines

NEW DELHI: The government plans to tweak the tendering process for very large power equipment to allow companies to bid separately for boilers
and turbines, a power ministry official said.
The move to withdraw the earlier policy of seeking turnkey contracts, where the winning bidder hands over the completed project, for the proposed supercritical power plants will enable larger participation from global equipment manufacturers, the official said on condition of anonymity.

Supercritical power plants are very large with a minimum capacity of 660 mw for every unit and are more efficient.

Public sector NTPC and Damodar Valley Corp (DVC) will soon come out with tenders inviting bids for 11 units of 660 mw power equipment for five of their upcoming projects.

A turnkey contract criteria limits the race to select few like BHEL and Larsen & Toubro (L&T), the official said. "Our aim is to invite a larger participation and enhance competition so that the country is able to absorb the best technology," he said.

So far, five companies - BHEL, L&T-Mitsubishi Heavy Industries (MHI) combine, Alstom-Bharat Forge, Toshiba-JSW and Italian company Ansaldo Caldie - have expressed interest in participating in the bulk tendering for supercritical equipment.

While L&T and BHEL will participate in entire plant package, Alstom and Toshiba want to bid only for turbine-generator package, and Ansaldo only for boilers. "The changes in the tendering process have been approved by a high-level committee on infrastructure on power sector issues," the official said.

The committee has representation from the prime minister's office (PMO), finance ministry, power ministry, heavy industries ministry and Planning Commission, among others.

It has been decided that the tender for boiler package will be split between two bidders and that for the turbine-generator package between three bidders. While the lowest bidder (R1) in the boiler package will get three projects, the second-lowest bidder (R2) will get two projects after matching price quoted by R1. The number of units for each bidder would be either seven and four, or six and five. The turbine-generator package is proposed to be split amongst three bidders, with the last bidder getting only one project.

Public sector BHEL will be given preference in the tendering process and would be necessarily ranked R2, if it is not R1 and R2 already. This would ensure that BHEL does not lose out in the tendering process to get projects for its supercritical foray.

An inter-ministerial group is finalising the details, the official said. The power companies will start the tendering process after that, he added.

The move will also lead to winning bidders setting up manufacturing for large equipment facilities. At present, only BHEL has large-scale power equipment manufacturing capability in the country while L&T is expected to start manufacturing of main power equipment soon. Having more equipment manufacturing companies in the country will ensure the shortage of equipment does not derail capacity-addition programmes, the official said.
http://economictimes.indiatimes.com/News/News-By-Industry/Indl-Goods--Svs/Engineering/
Power-gear-cos-may-get-separate-orders-for-boilers--turbines/articleshow/4371667.cms

High Efficiency Boilers

Start with the news release ABB for cost-effective wiring solutions from ABB, which we summarised at the time by saying "ABB has launched its Concept BS range of switches and switch accessories, ideal for achieving a high specification look in new builds, at a lower cost.". Several months prior to that, we featured the news release RIDBA members sign up to a health and safety from RIDBA: "Corporate contractor members of the Rural and Industrial Design and Building Association (RIDBA) erect more than 5,000 buildings per year.".

In April 2009, we covered the news from Hexis S.A. - take a look at Hexis launch new cast vinyl films at FESPA Digital which says: "Hexis will be at FESPA Digital Printing 2008 to show an all-new cast film combined with Hex'Press adhesive technology specially designed for full vehicle wraps. ".

Take a look also at the news release from Jet Environmental, Jet Environmental control for Pharma Warehouse, as well as More Part 3 passes with Super Spacer from Edgetech from Edgetech, and Interbuild constructs dedicated specifier show from Interbuild - The Building Show.
http://www.buildingtalk.com/guides/high-efficiency-boilers.html

Reno boilers highlighted at CIH Show

Johnson and Starley has introduced five new models to the RENO range and applications now cover small dwellings as well as larger houses.

Best Value and life time costs remain the key criteria for most publicly accountable organisations when specifying long-term purchases.

Boiler systems are no exception and the RENO range from Johnson and Starley continually demonstrates that it is ahead of other makes when it comes to energy efficiency, quality, life costs and service.

These qualities will be highlighted in the RENO range on show at the Chartered Institute of Housing Exhibition (Stand 196-Hall C), 20-23 June 2006, Harrogate.

This year, Johnson and Starley has introduced five new models to the RENO range and applications now cover small dwellings as well as larger houses.

All RENO boilers are very efficient, complying with SEDBUK Band A as well as the new Energy Savings Trust endorsement scheme.

They now include models that modulate down to 4kW, providing heating in the efficient condensing mode in most circumstances RENO represents a package of sophisticated, well engineered features that enable it to deliver high efficiency for the maximum proportion of the time it is operating.

With high quality components, including a stainless steel heat exchanger, RENO boilers have excellent life expectancy.

Johnson and Starley manufactures and installs comfort solutions for domestic and commercial markets including heating, hot water, ventilation and cooling.

These include Europe's largest range of domestic Gas fired Warm Air Heating products, ventilation units with heat recovery and vented, unvented and direct fired water heating systems.

Products comply with Part L and other regulations.

Johnson and Starley also offers comprehensive training for installation, systems replacement and maintenance as part of its support to installers and specifiers.
http://www.buildingtalk.com/news/joh/joh144.html

Worcester boilers of the highest quality

Leading boiler manufacturer, Worcester, has won the new Bosch Thermotechnology Quality Award for for the Greenstar i Junior, i System and Si boilers.

The accolade was judged by an expert panel against the other 19 manufacturing sites across the international Bosch Thermotechnology Group and Worcester came out the clear winner.

Worcester Greenstar i Junior

The prize was won for the Greenstar i Junior, i System and Si boilers which are all high efficiency condensing gas-fired models.

Worcester has recently developed and enhanced these boliers to raise the standard even higher, which contributed towards the win.

New features for Winter 2008 include the ability to pre-plumb the condensate pipework to the wall mounting jig and a universal fitting for the condensate trap, which is capable of accommodating various different pipe manufacturers' products meaning no additional work has to be carried out on site.

Other benefit-driven additions to the Greenstar i, and Si boilers include an optional vertical pre-piping assembly of pre-fabricated pipework together with an earth bonding strip.

This relieves installers from having to pre-bend pipework behind the boiler should a vertical pipework be necessary.

Martyn ,Bridges director of marketing and technical support at Worcester, said: "The Bosch name is synonymous with quality so for us to have produced products here at Worcester which have been commended as being the highest quality amongst the other Bosch heating and hot water brands throughout the world is an incredible result.".

http://www.buildingtalk.com/news/woc/woc149.html

Bracket guess has Boilers heading West

ANN ARBOR, Mich. -- For Purdue men's basketball fans, the primary focus is on tonight's game at Michigan.
But anyone who enjoys the college game is watching ESPN's Bracketology, compiled by Joe Lunardi.

Certainly, all of this will change by the time you refresh your computer browser, but Lunardi has six Big Ten teams in the NCAA tournament.

He has Matt Painter and the Boilermakers in Portland, Ore. for first- and second-round action, then staying in the West Regional (Phoenix) if they advance to the Sweet Sixteen.

Lunardi has Purdue as the West's No. 4 seed facing No. 13 seed Nevada in the first round, opposite No. 5 seed Washington and No. 12 seed Maryland.

He has Minnesota as the No. 11 seed in the West.

The South (Memphis) would include 3 seed Michigan State and 9 seed Ohio State. The East (Boston) would have Wisconsin as the 11 seed.

Lunardi seems to like Bruce Weber and Illinois. Bracketology has the Fighting Illini as the Midwest Regional's 7 seed, traveling to Kansas City for first- and second-round action.

If Illinois would reach the Sweet Sixteen, it's off to Lucas Oil Stadium in Indianapolis.

Bracketology in no way reflects what the NCAA tournament selection committee will do on March 15. But it's still fun.
http://www.jconline.com/article/20090226/SPORTS06/902260323

Valero boiler malfunctions, bringing release of gases

A boiler shut down at the Valero Refinery near Delaware City this morning, resulting in a huge cloud of smoke and flame that emitted gases into the atmosphere.

The incident occurred about 8:30 a.m. at the plant at 4550 Wrangle Hill Road.

Sulfur dioxide, nitrous oxide and hydrogen sulfide were released to the atmosphere, according to a filing with the state Department of Natural Resources and Environmental Control.

Valero spokesman Pat Covert said the plant lost one of the boilers in the steam producing unit that runs the refinery process.

That was following by a the shutdown of a second boiler.

The yellowish-green cloud lasted about 45 minutes as the process unit cooled down.

Along with the cloud, a sulfur odor was detected, he said.

“We monitored around the community and we weren’t taking any negative readings in the community,” he said.

Capt. William P. McDaniel II, operations supervisor for air and waste management enforcement in the Department of Natural Resources and Environmental Control, said there had been few citizens’ odor complaints.

“They were taking numerous calls about the smoke,” he said.

Covert said that things were stable as of about 1 p.m.

“As soon as we’re able to get the steam production on line we will be starting the boilers,” he said.

According to the U.S. Energy Department, Valero Energy Corp., the largest U.S. refinery, can produce 190,200 barrels of crude oil a day. The refinery mostly handles heavy, high-sulfur, harder-to-process crude oils sold at a discount compared with the lighter crudes handled at Conoco-Philips' Trainer, Pa., refinery and at Sunoco's Marcus Hook, Philadelphia and Eagle Point, N.J., complexes.3
http://www.delawareonline.com/article/20090216/NEWS/90216029