Energy Savings Calculator for boiler replacement projects

Cells to be completed by user Values in cells are automatically calculated

Step 1 - Provide Details of Existing Boiler

Manufacturer Model Rated Output (kW) Fuel Year of manufacture Buderus GE215 180 Mains Gas 1989 Process

Are the boilers primarily used for space or process heating?

Select one of the four methods in the drop down menu and where appropriate fill in the blue cells. Note: Method 1 must be chosen if the boiler(s) are used for process heating. For space heating systems methods 2 to 4 are to be used only if the existing boiler(s) are well maintained and are less than eight years old , otherwise it is recommended that a boiler combustion efficiency test is conducted and that the results of the test are utilised by a competent person e.g. boiler engineer to estimate the seasonal efficiency of the boiler(s).

If the boiler(s) is used for process heating then select Method 1 only Method 1 - Seasonal Efficiency of Existing Boiler(s) Method 1 - Seasonal Efficiency of Existing Boiler(s) Enter the gross seasonal efficiency of the existing boiler(s)

(Select from drop down menu)

65%

Method 2 - Manufactures Efficiency Data at Full & Part Load Efficiency at 100% of load 70% Efficiency at 30% of load 78% Are the manufactures efficiency details based on net calorific or gross calorific value? Method 3 - Boiler Input & Output What is the boiler input at full load (100%) in kW? What is the boiler output at full load (100%) in kW? What is the boiler input at part load (30%) in kW? What is the boiler output at part load (30%) in kW? Is the boiler input based on net calorific or gross calorific value of the fuel? Method 4 - Star Rating Label What is the Star label of the existing boilers? Estimated Seasonal Efficiency of Existing Boilers (Gross CV)

Gross CV

100 95 30 25 Gross CV

** 65.0%

Step 2 - Provide Details of Replacement Boiler

Manufacturer Model Rated Output Fuel Year of manufacture Buderus GC266 255 Mains Gas 2011

Select one of four methods in the drop down menu and where appropriate fill in the blue cells. Method 1 must be chosen if the boiler(s) are used for process heating.

Note:

Method 1 - Seasonal Efficiency of Replacement Boilers Method 1 - Seasonal Efficiency of Existing Boiler(s) Enter the gross seasonal efficiency of the replacement boiler(s) Method 2 - Manufactures Efficiency Data at Full & Part Load Efficiency at 100% of load 70% Efficiency at 30% of load 65% Is the efficiency based on net calorific or gross calorific value?

(Select from drop down menu)

91%

Net CV

Method 3 - Boiler Input & Output What is the boiler input at full load (100%) in kW? What is the boiler output at full load (100%) in kW? What is the boiler input at part load (30%) in kW? What is the boiler output at part load (30%) in kW? Is the boiler input based on net calorific or gross calorific value of the fuel? Method 4 - Star Rating Label What is the Star label of the existing boilers? Estimated Seasonal Efficiency of Existing Boiler (Gross CV)

100 95 30 25 Net CV

**** 91.4%

Step 3 - Provide Details of Past Energy Consumption Data

To complete step 3 fill in the requested energy consumption data for a recent 12 month period. The fuel consumption needs to be inputted in kWh. The measurement period must be between 335 & 395 days.

Enter fuel consumption over a recent 12 month period (kWh) Enter the total cost of the fuel over the 12 month period

660000 24,420

Measurement period must be between 01-Jan-2010 and 31-Oct-2011 and the number of days must be between 335 and 395 days Measurement Period Start Date 4/5/2010 Measurement Period End Date 5/1/2011 391 Days Select building type Hotel N/a for process heating Select closest weather station Dublin Airport N/a for process heating

Average Unit Price (/kWh)

0.037

Results - Estimated Annual Energy Savings

Estimated Annual Energy Savings (kWh) Estimated % Reduction in Annual Fuel Consumption Estimated Annual Energy Cost Savings 6,590 178102 -28.9%

Evaluating energy savings for boiler retrofit or upgrade solutions

1 What is this calculation tool for?

This calculation tool will enable the user to estimate the annual savings associated with replacing all the existing boilers with high efficiency boilers in a LTHW single or multi boiler system. The calculation tool can only be used for multi boiler systems in which all the existing boilers are identical types and all the replacement boilers are identical types. 2 How to use the calculation tool To be able to use the calculation tool the user will need to input: -

the seasonal efficiency of the existing boilers or where appropriate the manufactures efficiency data the seasonal efficiency of the replacement boilers or where appropriate the manufactures efficiency data the fuel consumption of the existing boilers over a recent 12 month period information on location and building type for degree day correction purposes (for space heating systems on

Once the data is inputted to the calculator the annual kWh and cost savings will be calculated. Seasonal Efficiency of Existing Boilers Boiler efficiency, in the simplest terms, represents the difference between energy input and energy output. Over the period of one year the seasonal efficiency of the boiler is equal to the energy output divided by the energy input over a one year period multiplied by 100.

Using metered data is the most accurate method of determining the seasonal efficiency of an existing boiler. However very few existing heating systems have sufficient metering to monitor both the fuel supply and the heat output and so in instances where metered data is unavailable the seasonal efficiency needs to be estimated from combustion efficiency test results or from the manufactures boiler efficiency test data. The manufacturers test data was determined for the boilers in their as new condition, over time the efficiency of a boiler will reduce due to wear and tear and therefore it is recommended that if the existing boilers are poorly maintained or are 8 years old or more that combustion efficiency tes data be used for estimating the seasonal efficiency of the boiler as, in these instances, using the manufactures data will likely result in an over estimate of the seasonal efficiency. It is the responsibility of the user to ensure that the seasonal efficiency estimate is calculated to a reasonable degree of accuracy and should be calculated by a competent person such as a boiler engineer.

It is not necessary for the user to estimate the seasonal efficiency of the boiler where the user intends on using the manufacturers test data for a space heating system. Instead the user can chose to input the manufactures test data int the calculator and the calculator will automatically calculate the seasonal efficiency of the boiler. The procedure utilised the calculator to calculate the seasonal efficiency of a boiler is based on the procedure described in the Non Domestic Building Services Compliance Guide issued by the Department of Communities and Local Government in the UK. The user can choose to input the manufactures data using three different methods and which method the user chooses depends on the data available to the user. The user can either input the full load and part load efficiency, the input and output of the boiler at full and part load or the user can input the star rating of the boiler. See section 3 for further information on inputting manufactures data.

If the boiler is used for process heating then the user must input the seasonal efficiency of the existing boiler whether its derived from metered data, combustion efficiency tests or the manufacturers data. Seasonal Efficiency of the Replacement Boilers

If the boilers are to be used for space heating purposes then the user can input the relevant manufactures data and the calculator will automatically calculate the seasonal efficiency. If the boilers are used for process heating then the user must separately calculate the seasonal efficiency of the replacement boilers and input the efficiency into the calculator.

3 Manufacturers test data The user can input the manufactures: full and part load efficiency data, or input and output data at full and part load, or star rating data

The manufactures data should only be inputted to the calculator where the boilers are used for space heating purposes only. Full and Part Load Efficiency The full and part load efficiency to be entered into the calculator depends on the type of boiler, the likely operating temperature of the boiler and the available manufacturers test data. All modern boilers sold in the EU are tested according to the following conditions: Type of Boiler Full Load Average boiler water temperature (in Part Load Average boiler water temperat ure (in C) 70 50

C) Standard boilers Low temperat ure boilers (*) Gas condensi ng boilers
(*) Including condensing boilers using liquid fuels. (**) Temperature of boiler water-supply.

70

40

70 30 (**)

Where: boiler -

average temperature of the boiler water: is the average of the water temperatures at the entry and exit of th full load: 100% of rated output Part Load: 30% of rated output

In most cases the manufacturer will also have test data for different flow and return temperatures as well as those in the above table. The data the user will use will depend on the likely flow and return temperatures during operation.

The user can enter the full and part load efficiency based on the gross or net calorific value of the fuel. The calculator w automatically convert the net efficiency to gross efficiency if the user inputs the net efficiency. Manufactures Input or Output Data The boiler input and output data to be entered into the calculator depends on the type of boiler, the likely operating temperature of the boiler and the available manufacturers test data. All modern boilers sold in the EU are tested according to the following conditions: Type of Boiler Full Load Average boiler water temperature (in Part Load Average boiler water temperat ure (in C) 70 50

C) Standard boilers Low temperat ure boilers (*) Gas condensi ng boilers

70

40

70 30 (**)

(*) Including condensing boilers using liquid fuels. (**) Temperature of boiler water-supply.

Where: boiler -

average temperature of the boiler water: is the average of the water temperatures at the entry and exit of th full load: 100% of rated output Part Load: 30% of rated output

In most cases the manufacturer will also have test data for different flow and return temperatures as well as those in the above table. The data the user will use will depend on the likely flow and return temperatures during operation.

The user can enter the boiler input and output data based on the gross or net calorific value of the fuel. The calculator w automatically convert the input data from net to gross if the net value is entered. Star Rating

Some boilers manufactured from 1998 or later have a star rating on the boiler name plate. If a boiler has a star rating th the calculation tool can be used to estimate the seasonal efficiency of a boiler based on the star rating however it is mor preferable to use the efficiency or input and output data at full and part load which will result in a more accurate estimate of the seasonal efficiency. The following table shows the efficiency of the various star labels:

Take for example a boiler that has an output of 235kW and according to the name plate the boiler is a 2 star boiler (indicated by the number of stars on the name plate). Therefore the efficiency of the boiler at full and part load is calculated as follows:

Efficiency at full load (100%) = 87 + 2log(235) = 91.7% (Net Calorific Value) Efficiency at part load (30%) = 83 + 3log(235) = 90.1% (Net Calorific Value) The user will simply select the star rating and enter the rated output of the boiler. The calculator will then automatically calculate the seasonal efficiency of the boiler(s). 4 Calculation methodology

The calculator estimates savings by subtracting the annual fuel consumption for the heating system from the estimated annual fuel consumption post the installation of the replacement boilers. The tool requires the user to enter the fuel consumption for the heating system over a recent 12 month period (365 days 30 days) and also requires that the user inputs the start and end date of the measurement period. For a process heating system the annual fuel consumption is then calculated as follows:

Annual fuel consumption = (fuel consumption during measurement period / number of days in the measurement period) 365

If the heating system is used for space heating the user must identify the nearest weather station and the building type. The calculator then assumes that a percentage of the fuel is used for heating hot water based on the building type while the remainder is assumed to be used for space heating. Annual fuel consumption is then calculated as follows:

Annual fuel consumption = {(fuel consumption during measurement period * % space heating / number of degree days during measurement period) X 2021*} + {(fuel consumption during measurement period X % hot water heating / numbe of days in the measurement period) x 365}
* The weather year is standardised at 2021 degree days per year, to the base 15.5C

To calculate the annual fuel consumption post the installation of the replacement boilers the calculator estimates the existing heat demand by simply multiplying the existing annual fuel consumption by the existing boiler seasonal efficienc The annual fuel consumption post the installation of the replacement boilers is then estimated by dividing the heat demand by the seasonal efficiency of the replacement boilers. As an example, if the annual fuel consumption is 100,000kWh, the existing seasonal efficiency is 75% and the seasonal efficiency post the installation of the replacemen boilers is estimated to be 91% then the annual savings is calculated by the calculator as follows:

Savings = 100,000 - (100,000*0.75)/0.91 = 15,582kWh. Net & Gross Calorific Value The net calorific value of a fuel excludes the latent heat of water vapour in the exhaust and so is lower that the gross calorific value. Efficiency test results and European standards normally use net calorific values. If the user inputs data based on the net calorific value of the fuel the calculator converts to gross values using the following net to gross conversion factors: Fuel LPG Oil Natural Gas Conversion Factor 0.921 0.937 0.901

% Fuel Utilised for Space Heating The % of fuel assumed to be used for space heating purposes is based on the building type. The following table shows the percentage fuel assumed to be used for space heating purposes for each building type:
Percent of fuel proBuilding Type rated to degree days General office 55% High street agency 0% General retail 0% Large non-food shop 55% Small food store 0% Large food store 55% Restaurant 30% Bar, pub or licensed club 40% Hotel 45% Cultural activities 55% Entertainment halls 55% Swimming pool centre 55% Fitness and health centre 40% Dry sports & leisure facility 55%

Covered car park 0% Public buildings with light usage 55% Schools & seasonal public 55% bld University campus 55% Clinic 55% Hospital -clinical & research 5% 5 Long term residential 55% General accommodation 55% Emergency services 55% Laboratory / operating theatre 55% Station 55% Terminal 55% Workshop 55% Storage facility 70% Cold storage 55%

As an example, a clinic that consumes 100,000KWh over the measurement period is assumed to consume 55,000kWh for space heating purposes whilst the remaining 45,000kWh is assumed to be consumed for hot water heating.

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priate the manufactures efficiency data ppropriate the manufactures efficiency data month period ection purposes (for space heating systems only)

gs will be calculated.

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onal efficiency of the existing boiler whether its ers data.

input the relevant manufactures data and the s are used for process heating then the user ers and input the efficiency into the calculator.

e boilers are used for space heating purposes

on the type of boiler, the likely operating odern boilers sold in the EU are tested

e water temperatures at the entry and exit of the

and return temperatures as well as those in the return temperatures during operation.

net calorific value of the fuel. The calculator will ts the net efficiency.

on the type of boiler, the likely operating odern boilers sold in the EU are tested

e water temperatures at the entry and exit of the

and return temperatures as well as those in the return temperatures during operation.

net calorific value of the fuel. The calculator will ntered.

oiler name plate. If a boiler has a star rating then oiler based on the star rating however it is more ad which will result in a more accurate estimate various star labels:

he name plate the boiler is a 2 star boiler ency of the boiler at full and part load is

boiler. The calculator will then automatically

ion for the heating system from the estimated The tool requires the user to enter the fuel ays 30 days) and also requires that the user eating system the annual fuel consumption is

d / number of days in the measurement period) x

nearest weather station and the building type. ting hot water based on the building type while umption is then calculated as follows:

d * % space heating / number of degree days rement period X % hot water heating / number

cement boilers the calculator estimates the mption by the existing boiler seasonal efficiency. ers is then estimated by dividing the heat mple, if the annual fuel consumption is ficiency post the installation of the replacement e calculator as follows:

n the exhaust and so is lower that the gross se net calorific values. If the user inputs data s values using the following net to gross

n the building type. The following table shows ach building type:

ent period is assumed to consume 55,000kWh o be consumed for hot water heating.