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Burner Upgrade Savings Calculator

Estimate the gas, dollars, and CO2 a new burner saves, from your combustion readings, turndown, and how the boiler runs through the year. From the engineers at McKenna Boiler Works, Inc., a boiler manufacturer in California.

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Call (323) 987-1816
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ASME S · H · M · U

Code-built boilers and vessels

National Board R

Code repairs and alterations

Autoflame
Autoflame

Factory-authorized Tech Center

Limpsfield
Limpsfield

Factory-authorized Burner Tech Center

McKenna flame
Since 1921

Fifth generation, family-owned

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McKenna Boiler Works, Inc.’s burner upgrade calculator estimates the fuel a new burner saves from two things: less excess air, and more turndown so the burner cycles less at low load. Combustion efficiency comes from the U.S. Department of Energy’s natural gas table, using your O2 and stack temperature. Every start costs a purge that blows hot air out of the boiler; a burner with more turndown keeps firing at low load instead. DOE notes efficiency rises about 1% for each 15% cut in excess air. McKenna does burner retrofits across California and is a factory-authorized Limpsfield Burner Tech Center. McKenna also installs, sets up, and tunes burners from other manufacturers. Call (323) 987-1816.

Calculator

Estimate the savings.

Four steps. Results update as you type. Use the numbers from your last combustion report and gas bills for the most accurate answer.

1The boiler and how it runs

HP
MMBtu/hr
Leave the input blank to use boiler HP × 33,475 ÷ 80%. Use the nameplate if you have it.
psig
°F
PeriodLoad, % of capacityHours per year
%
%
%
Most boilers spend most of their hours at mid and low fire, not high fire. The results show how many hours fall at each firing rate.
$/therm
therms
Optional but recommended. Enter this boiler's gas use from last year's bills and the loads above are adjusted until the model matches your bills.

2

High fire
%
Mid fire (50%)
%
Low fire
%
°F
°F

3

High fire
%
Mid fire (50%)
%
Low fire
%
High fire
%
Mid fire
%
Low fire
%
HP
$/kWh

4Project cost and payback

$
$
$/yr
%/yr
years
Simple payback uses today's prices. The lifetime figures apply the energy price change each year. Set it to 0 to stay with today's prices. Only enter maintenance savings you can document, like repairs on worn linkages or an old burner.

Results

$0saved per year
0therms of gas saved per year
0points of seasonal efficiency gained
0tons of CO2 avoided per year
Payback

Where the burner runs today
Efficiency across the load range

Estimates for planning, not a guarantee. Combustion efficiency comes from the U.S. DOE natural gas table (Steam Tip Sheet #4), interpolated on excess air, with O2 interpolated between your high, mid, and low fire readings. Purge loss per start uses a published pre-purge loss formula (Bosch Industrial). Shell loss follows DOE Steam Tip Sheet #16. Fan power uses the EnergyPlus inlet vane damper and variable speed curves. Stack temperatures are held the same before and after, which is conservative. CO2 uses EPA's 53.06 kg per MMBtu of natural gas. McKenna confirms savings from a site survey and a combustion analysis.