Assessment Recommendations

Primary Primary Secondary Secondary Tertiary Tertiary Quaternary Quaternary Implementation

Number of BP Tool AR Primary Cost Secondary Tertiary Cost Quaternary Implementat
AR Number ARC Code APP Code AR Name AR Author Savings Savings Savings Savings Savings Savings Savings Savings Other Cost Incremental Cost After
Pages Used Description Savings Cost Savings Savings Cost Savings ion Cost
Source Quantity Source Quantity Source Quantity Source Quantity Incentives
# 10 2.1116Manufacturing Process None
Boiler Fan VFD with O2
al Controls
consumption. Insert Name
Electrical Consumption50,000 2,500 Natural Gas 500 2,500 0 0 0 0 0 0 5,617 N 5,567

Resource Streams
Source Name Source Code Units
Electrical
EC kWh (site)
Consumption
Electrical kW Months /
ED
Demand
Other yr
EF no units
Electrical Fees
Natural Gas E2 MMBtu
L.P.G. E3 MMBtu
#1 Fuel Oil E4 MMBtu
#2 Fuel Oil E5 MMBtu
#4 Fuel Oil E6 MMBtu
#6 Fuel Oil E7 MMBtu
Coal E8 MMBtu
Wood E9 MMBtu
Paper E10 MMBtu
Other Gas E11 MMBtu
Other Energy E12 MMBtu
Water
W1 Gallons
Disposal
Other Liquid
W2 Gallons
(non-haz)
Other Liquid
W3 Gallons
(haz)
Solid Waste
W4 Pounds
(non-haz)
Solid Waste
W5 Pounds
(haz)
Gaseous
W6 Pounds
Waste
Personnel
R1 no units
Changes
Administrative
R2 no units
CostsRaw
Primary
R3 no units
Material
Ancillary
R4 no units
Material
WaterCost
R5 no units
Consumption
One-time
R6 no units
Revenue
Primary
P1 no units
Product
By-product
P2 no units
Production
Increase in
P3 %
Production
Process Heat
Application Codes
Recovery,
Application APP Code Variable
Examples
Manufacturing Air
Speed Drives
1 Compressors,
Process
Process on Process
2 Steam,
Equipment,
Lights,
Supportand
Building
3 Nitrogen,
Solvent Burn
Taxes,
HVAC,
Grounds Cogeneration
Recovery
Inventory
Administrative 4 Waste for Heat Mikhail Jones
Control, Sale
of Wastes
Production Units
Display Units Rutgers Units
Not Available Not Available
Pieces Pieces
Pounds Pounds
Tons Tons
BBL BBL
Thousand
1000's Gallons Thousand
Gallons
1000's ft./sq. Feed or
ft. Thousand
Bushels Bushels
Square Feet

BP Tools
Tool
Tool Name
Desciption
None None
AM+ AirMaster+
Chilled Water
CWSAT System
Fan System
FSAT Analysis Tool
Assessment
MotorMaster+
Tool and
Nox (FSAT)
MM+
4.0
Energy
NxEAT Process
Assessment
Heating
PHAST Tool
Pump System
Assessment
PSAT Steam System
Assessment
Tool (PHAST)
ASDMaster:
Tool Suite
(PSAT)
SSTS Adjustable
(SSST/SSAT/
ASD Speed Drive
3E+)
Evaluation
Tool
AR No. # - Boiler Fan VFD with O2 Controls
Boiler Fan VFD w/Controls template style 2015

Recommendation

Install an oxygen (O2) sensor in the boiler stack and a variable frequency drive (VFD) on the forced draft fan to
control fan speed based on oxygen content. This will increase combustion efficiency by optimizing the air-fuel
ratio and reduce natural gas consumption by 2.0%. Additionally, it will reduce fan power causing a 50%
decrease in fan electrical consumption.

Annual Savings Summary

Source Quantity Units Cost Savings
Electrical Consumption 50,000 kWh (site) $2,500
Natural Gas 500 MMBtu $2,500
Total 671 MMBtu $5,000

Implementation Cost Summary

Description Cost Payback (yrs)
Before Incentives $5,617 1.1
After Incentives $5,567 1.1

Facility Background

The 10.0 MMBtu/hr boiler uses a 10 hp forced draft fan with an outlet damper to control air flow. A damper
controls air flow by increasing flow resistance. Partially closed dampers are inefficient because significant
power is required to overcome the added resistance.

During the site assessment, facility personnel informed us that ( describe process and when airflow into boiler
needs to be maximum, and when it is turned down using the damper or inlet vane.) Fan and Motor data were
collected using a power quality analyzer and HOBO dataloggers. The data was analyzed using the Motor
Analysis Tool (MAT) and the Fan Control Analysis Tool (FCAT). This data was used to create a boiler
operation profile. It was found that the boiler operates at an average capacity of (enter percent capacity from
CEAT)

Combustion data was collected using a combustion gas analyzer, and efficiency was analyzed in the
Combustion Efficiency Analysis Tool (CEAT). The excess oxygen was ( enter %O2 here ) and the combustion
efficiency was ( enter here from CEAT ).
AR No. # - Boiler Fan VFD with O2 Controls
Boiler Fan VFD w/Controls template style 2015

Technology Background

Variable Frequency Drives (VFDs) vary the fan impeller speed instead of restricting airflow like a damper or
inlet vane. When the boiler requires a smaller amount of air, the VFD reduces motor speed to produce the
required airflow while using the least amount of energy. Likewise, it will increase motor speed as more air is
demanded by the boiler. Savings are achieved by installing a VFD to reduce the electrical power required to
operate the fan at specified settings. The power savings available by switching to a VFD controlled system are
represented by general curves of percent loaded power versus percent loaded capacity which are found in the
FCAT.

Ideally, a boiler would use just enough combustion air to burn all of the fuel, with no excess air. Excess air
carries heat up the stack and reduces boiler efficiency. However, all burners require some excess air to ensure
complete combustion. Practically, natural gas boilers should be able to achieve 4.0% excess oxygen.

An oxygen sensor placed in the boiler stack can be used to control the VFD. The sensor detects the excess
oxygen in the stack, and if it exceeds a set percentage, the VFD will switch the boiler fan to a lower setting to
decrease the airflow. This will optimize boiler combustion efficiency.

Proposal

Install an oxygen sensor in the boiler stack to measure excess oxygen from combustion. Set the damper in the
boiler forced draft fan to wide open and install a VFD to control fan impeller speed based on excess oxygen.
This will reduce excess oxygen in the combustion process and improve efficiency. Also install a VFD bypassso
the process can continue uninterrupted if the VFD fails, needs maintenance, or needs reprogramming. If
implemented, natural gas costs will be reduced by $2,500 annually and fan electrical costs will be reduced by
$2,500 annually, totaling to $5,000 annual cost savings. The estimated implementation cost is $5,617 resulting
in a 1.1 year payback.

Notes

Fan electrical savings were calculated based on the change in control strategy assuming the airflow will remain
the same. However, the current airflow is more than what is required for combustion so additional savings will
occur with airflow reductions. Associated savings are expected to be small and are not calculated in this
recommendation.

The proposed excess oxygen set point was determined based on industry standards for combustion systems.
However, achieving this set point may be difficult depending on the specific system. Savings will be less if the
excess oxygen cannot be fully lowered to the desired set point.

Based on Data Collection Author Orange Team Review Black Team Review
AR No. # - Boiler Fan VFD with O2 Controls
Boiler Fan VFD w/Controls template style 2015
Unmodified Template Insert Name Insert Name Insert Name Insert Name
Date last Modified Insert Name
 AR No. # - Analysis
Boiler Fan VFD w/Controls template style 2015

Data Collected Equations

Boiler Data Eq. 1) Electrical Cost Savings (CSE)
Boiler Fan Type Forced Draft ES E  ICE
Current Fan Control Type Outlet Damper
Operating Hours 8,760 hrs/yr (N. 1) Eq. 2) Natural Gas Cost Savings (CSG)
Maximum Firing Rate 10.00 MMBtu/hr (N. 2)
ES G  ICG
Fan Motor Horsepower 10 hp (N. 2)
Utility Data Eq. 3) Total Material Cost (CM)
Incremental Electricity Cost (ICE) $0.0500 /kWh (Rf. 1)
CVFD  CEC  CS  CC
Incremental Natural Gas Cost (ICG) $5.00 /MMBtu (Rf. 1)
Eq. 4) Total Labor Cost (CL)
Savings Analysis CLVFD  CLC
Electrical Savings
Current Fan Electrical Consumption (ECE) 100,000 kWh (Rf. 2) Eq. 5) Annual Cost Savings (S)
Fan Electrical Energy Savings (ESE) 50,000 kWh (Rf. 2)
S E  SG
Electrical Cost Savings (SE) $2,500 /yr (Eq. 1)
Natural Gas Savings Eq. 6) Implementation Cost (CI)
Current Boiler Natural Gas Consumption (ECG) 25,000 MMBtu/yr (Rf. 3)
CM  C L
Boiler Natural Gas Energy Savings (ESG) 500 MMBtu/yr (Rf. 3)
Natural Gas Cost Savings (SG) $2,500 /yr (Eq. 2) Eq. 7) Simple Payback (tPB)
CI
Implementation Cost Analysis S
Material Costs
Boiler Fan VFD (CVFD) $1,289 (N. 3) References
Electrical Circuitry/Bypass (CEC) $1,630 (N. 3) Rf. 1) Developed in the Utility Analysis located
O2 Sensor (CS) $785 (Rf. 4)
in the Site Data section.
Controller (CC) $800 (Rf. 4) Rf. 2) Developed in the following Fan Control
Total Material Cost (CM) $4,504 (Eq. 3)
Analysis Tool (FCAT).

Labor Costs Rf. 3) Developed in the following Combustion

VFD Installation (CLVFD) $1,000 (N. 3)
Efficiency Analysis Tool (CEAT).
Controller Installation (CLC) $113 (Rf. 4) Rf. 4) RSMeans Mechanical Cost Data 2012. Pg.
Total Labor Cost (CL) $1,113 (Eq. 4)
269. O2 Sensor cost estimated using carbon
monoxide detector cost.

Economic Results
Annual Cost Savings (S) $5,000 /yr (Eq. 5)
Implementation Cost (CI) $5,617 (Eq. 6)
Simple Payback (tPB) 1.1 years (Eq. 7)

Notes
N. 1) Data provided by facility personnel.
N. 2) Data found on boiler name plates.
N. 3) VFD Equipment Cost estimated based on AC Drive VFD prices found at
http://www.grainger.com/ Prices will vary with brand and input/output phase,
amperage, and voltage.
 3 - AR No. 1 - Incentives
Boiler Fan VFD w/Controls template style 2015

Recommendation Details
Implementation Cost $5,617
Annual Cost Savings $5,000 /year
Simple Payback 1.1 years

Incentive Analysis Summary

Description Incentive After Incentive Payback Notes
(yrs)
$50

Totals $50 $5,567 1.1

No Incentives
This measure does not include the purchase of capital assets and is ineligible for incentives.
The implementation cost associated with this measure is so small that it does not warrant the time and overhead
associated with applying for incentives. Analysts believe this measure already has an attractive simple payback period.
Analysts were unable to identify any published incentives for this measure. This does not necessarily mean incentives are
unavailable; custom incentives with utility providers can sometimes be arranged.

REAP
You may be eligible for a Rural Energy for America Program grant. These grants are available to agricultural producers
who gain 50% or more of their gross income from agricultural operations and small businesses who are located in a rural
area as defined by the SBA (Small Business Association). Eligible projects include but are not limited to energy
efficiency improvements and renewable energy systems (wind, solar, biomass, geothermal, hydro power and hydrogen-
based sources). These grants are awarded on a competitive basis and can be up to 25% of the proposed project's cost, and
are limited to $500,000 for renewable energy systems and $250,000 for energy efficiency improvements while the loan
guarantee may not exceed $25 million. The combined amount of a grant and loan guarantee may not exceed 75% of the
project’s cost.

ETO
Energy Trust cash incentives are available to help pay for implementation of energy saving measures deemed cost
effective if customers are paying a public purpose charge. Incentives can be anticipated to equal the minimum of 50% of
total project cost, $0.25 per kWh saved, or $1 per therm saved.

ESI
Bonneville Power Administration's Energy Smart Industrial reimbursement incentive is available to help pay for
implementation of energy saving measures that are deemed cost effective and have a minimum 10-year life span.
Incentives can be anticipated to equal minimum of 70% of total project cost or $0.25 per kWh saved.
 3 - AR No. 1 - Incentives
Boiler Fan VFD w/Controls template style 2015

ITC
You may also be eligible for a Federal Business Investment Tax Credit. These grants are available to industrial
producers and the credit is equal to 27.4% (as of March 1 st, 2013 the incentive was reduced from 30% to its current value)
of expenditures for solar, fuel cells, small wind turbines, and 10% of expenditures for geothermal systems, microturbines
and combined heat and power with no maximum credit. The credits are for eligible systems placed in service on or
before December 31, 2016.
 VFD Cost Estimate
Motor HP VFD Manual bypass Labor Total
Equipment w/circuit breaker Cost Implementation
Cost & 3% line reactor Cost
0 $0 $0 $0 $0
0.25 $231 $1,360 $500 $2,091
0.5 $240 $1,370 $500 $2,110
0.75 $257 $1,380 $500 $2,137
1 $280 $1,400 $500 $2,180
2 $363 $1,430 $500 $2,293
3 $436 $1,470 $500 $2,406
5 $794 $1,500 $500 $2,794
7.5 $1,071 $1,540 $500 $3,111
10 $1,289 $1,630 $1,000 $3,919
15 $1,559 $1,710 $1,000 $4,269
20 $2,086 $1,900 $1,000 $4,986
25 $2,285 $1,940 $1,200 $5,425
30 $2,361 $1,960 $1,200 $5,521
40 $3,585 $2,130 $1,500 $7,215
50 $4,257 $2,580 $1,800 $8,637
60 $4,550 $2,890 $1,900 $9,340
75 $4,938 $3,600 $2,000 $10,538
100 $5,526 $4,480 $2,000 $12,006
125 $9,293 $5,100 $2,000 $16,393
150 $9,300 $6,350 $3,000 $18,650
200 $10,677 $7,600 $3,000 $21,277
250 $12,063 $8,850 $3,000 $23,913
300 $13,238 $10,100 $3,000 $26,338
350 $14,413 $11,350 $3,500 $29,263
400 $16,970 $12,600 $3,500 $33,070
500 $24,447 $13,850 $3,500 $41,797
600 $32,737 $16,350 $3,500 $52,587
700 $45,463 $18,000 $4,000 $67,463
800 $63,482 $20,000 $4,000 $87,482
900 $76,492 $22,000 $4,000 $102,492
1,000 $86,474 $24,000 $4,000 $114,474
Linear Interpolation Formulas
Horsepower VSD Bypass Labor
10 $1,289 $1,630 $1,000