Boiler Replacement

But why – and when – would you replace your old boilers?

While there are various motivating factors for boiler replacement, a good rule of thumb is to replace any boiler if it is more than 15 years old. The fact is that if boilers are any older than this, the likelihood is that they will be operating at no more than 70% efficiency, often not more than 50%. This is because older models were considerably less efficient than contemporary devices, coupled with the fact that they inevitably suffer from wear and tear. Additionally, older boilers tend to be unreliable, and if they are faulty they might be dangerous.

New boilers not only operate more efficiently because they are new, but they are also designed for increased efficiency and safety. While boiler replacement will involve an initial investment, from day one it will save you money in operating costs.

Remember, too, that while old boilers and boiler systems may be replaced, others may be upgraded to improve energy efficiency.

Efficiency Rating of Boilers

Generally, products that meet Federal Energy Management Program (FEMP) efficiency requirements and/or those that qualify in terms of ENERGY STAR standards have an input rating of no more than 300,000 Btu/h (which is the measure of British thermal units – the amount of heat energy it takes to raise the temperature of a pound of water by 1 deg. F – in an hour) are acceptable for residential use. Commercial and industrial boilers have input ratings that are higher than this and are excluded from these consumer-orientated guidelines for obvious reasons. Instead, a mechanical, electrical, and plumbing (MEP) engineer will have the knowledge and expertise to make the choice. 

Nevertheless, it’s useful to understand the way efficiency ratings of boilers work. The U.S. Environmental Protection Agency (EPA) provides efficiency levels that relate to products and their specifications on its ENERGY STAR website. Federal buyers also use ENERGY STAR data to identify and verify compliant models.

What is important is that the efficiency of boilers is measured by annual fuel utilization efficiency (AFUE). This reveals how efficiently appliances convert the energy from the fuel used to power them over a period of a year. So, for example, if a boiler has an AFUE of 90% (which is considered to be highly efficient), that is the percentage of fuel that is converted into heat while 10% is lost, usually up chimneys that may or may not be ducted.

While heat can be lost in the piping that is incorporated in boiler plants and systems, these heat losses are not included in the AFUE, even though they can be substantial. This is why it is so important for pipework to be designed to maximize efficiency.

The Federal Trade Commission (FTC) requires the AFUE percentage to be displayed on all boilers so that engineers and consumers know what they are buying and can compare the heating efficiencies of different models.

The U.S. Department of Energy (DOE) compares the efficiency of different heating systems:

• Old systems are not energy efficient and their AFUE rating is between 56% and 70%. Generally heavy heat exchangers, old boilers incorporate a continuous pilot light and a natural draft that results in a constant flow of combustion gases.
• Mid-efficiency systems have an AFUE of around 80% to 83% largely because they are smaller in size and lighter in weight, which reduces cycling losses. The flue pipe also has a much smaller diameter and there is no pilot light, instead, ignition is electronic. Exhaust fans in mid-efficiency heating systems control the flow of combustion gases and air more accurately.
• A 90% to 98.5% AFUE indicates that the heating system is highly efficient. This rating usually applies to new designs that feature sealed combustion and a secondary heat exchanger where flue gases are condensed to maximize energy efficiency.

Additionally, the DOE recommends that sealed-combustion units are specified because they avoid the risk of gases back-drafting and escaping into the inside airof buildings, big or small. Boilers that are not sealed-combustion units are also known to waste energy because they tend to draw the heated air into the unit and this air escapes up the chimney.

The DOE recommends ENERGY STAR natural gas boilers that have an AFUE of 90%, or better still, the best available gas boilers that have an AFUE of 97% which have a lifetime cost saving of nearly double the ENERGY STAR models.

However, the DOE also advises in general terms that “efficient products” are only cost-effective when the energy savings of the boiler during its entire lifetime are greater than the up-front costs when compared to the same equation of an option that is less efficient.

While it is safe to assume that ENERGY STAR-qualified products and those that meet FEMP requirements are cost-effective for their lifecycle, Nearby Engineers New York Engineers negates the need for guesswork and rule-of-thumb assessments. Instead, we will analyze every client’s needs and ascertain in individual situations what the best options are in terms of efficiency and cost.

For example, while it makes perfect sense to invest in high-efficiency boilers if you live in a cold climate area, where there are milder climatic conditions, the additional investment may not be justifiable.