Energy Conservation Opportunities 251

Figure 15-3. Water Level Controls and Pressure Relief Valve

High Fuel-to-air Ratios and High Air-to-fuel Ratios

A high fuel-to-air ratio causes sooting and lowers boiler ef-
ficiency. In certain conditions, it may also be dangerous if there’s
not enough air for complete combustion and dilution of the fuel.
A high fuel-to-air condition can be caused by an improperly ad-
justed burner, a blocked exhaust stack, the blower or dampers set
incorrectly or any condition which results in a negative pressure
in the boiler room. A negative pressure in the boiler room can be
the result of one or a combination of conditions such as an ex-
haust fan pulling a negative pressure in the boiler room, a re-
stricted combustion air louver into the room, or even adverse
wind conditions. High air-to-fuel ratios also reduce boiler effi-
ciency. If too much air is brought in, the hot gases are diluted too
much and rapidly swept out of the tubes before proper heat trans-
fer can occur. High air volumes are caused by improper blower or
damper settings.
252 HVAC Fundamentals

ECOs:
• Ensure the proper amount of air for combustion is available.
Check that primary and secondary air can enter the boiler’s
combustion chamber only in regulated quantities and at the
correct place.

• Inspect boiler gaskets, refractory, brickwork and castings for

hot spots and air leaks.

• Defective gaskets, cracked brickwork and broken casings

allow uncontrolled and varying amounts of air to enter the
boiler and prevent accurate fuel-air ratio adjustment.

• Perform a flue-gas analysis. Take stack temperatures and

oxygen readings routinely, and inspect the boiler for leaks.

• Repair all defects before resetting the fuel-air ratio. Consider

installing an oxygen analyzer with automatic trim for larger
boilers. This device continuously analyzes the fuel-air ratio
and automatically adjusts it to meet the changing stack draft
and load conditions.

• Check that controls are turning off boilers and pumps as

outlined in the sequence of operations. Observe the fire
when the boiler shuts down. If it does not cut off immedi-
ately, check for a faulty solenoid valve, and repair or replace
it as needed.

• Adjust controls on multiple systems so a second boiler will

not fire until the first boiler can no longer satisfy the de-
mand. Make sure that reset controls work properly to sched-
ule heating water temperature according to the outside air
temperature.

• Install automatic blowdown controls. Pipe the blowdown

water through a heat exchanger to recover and reuse waste
heat.