### CHAPTER 2. MARKET ASSESSMENT

TABLE OF CONTENTS

**2. 1**  **Introduction............................................................................................................. 2­1** 

**2. 1.1**  **Definitions................................................................................................... 2­1** 

**2. 1.2**  **Equipment Classes...................................................................................... 2­2** 

**2. 1.2.1**  **Existing Equipment**  **Classes......................................................... 2­2**

**2. 1.2.2**  **Equipment Classes**  **Established by**  **ASHRAE Standard**  **90.1­2007..**

**...................................................................................................... 2­2**

**2. 2**  **Market Assessment** 

**................................................................................................. 2­3** 

**2. 2.1**  **Trade Association** 

**....................................................................................... 2­3** 

**2. 2.1.1**  **AHRI............................................................................................ 2­3**

**2. 2.1.2**  **ABMA.......................................................................................... 2­4**

**2. 2.1.3**  **Additional Manufacturers ............................................................ 2­5** 

**2. 2.2**  **Regulatory Programs** 

**.................................................................................. 2­5** 

**2. 2.2.1**  **Current Federal**  **Energy Conservation**  **Standards.........................2­5**

**2. 2.2.2**  **State Energy**  **Conservation Standards.......................................... 2­5** 

**2. 2.2.3**  **Canadian Energy**  **Conservation Standards................................... 2­6** 

**2. 2.3**  **Non­Regulatory Programs** 

**.......................................................................... 2­6** 

**2. 2.3.1**  **ENERGY STAR .......................................................................... 2­6** 

**2. 2.3.2**  **Federal Energy**  **Management Program**  **........................................ 2­6**

**2. 2.3.3**  **Rebate Programs .......................................................................... 2­7** 

**Minnesota Energy**  **Resources....................................................... 2­7**

**Pacific Gas**  **and Electric**  **Company. .............................................2­7** 

**San Diego**  **Gas and**  **Electric Company.........................................2­7** 

**Southern California**  **Gas Company. .............................................2­8** 

**2. 2.4**  **Shipments.................................................................................................... 2­8** 

**2. 2.5**  **Equipment Lifetime** 

**.................................................................................... 2­8** 

**2. 2.6**  **Market Performance**  **Data........................................................................... 2­9**

**2. 2.6.1**  **Small Gas­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers........2­9**

**2. 2.6.2**  **Small Gas­Fired**  **Steam All**  **Except Natural**  **Draft Commercial** 

**Packaged Boilers........................................................................ 2­12** 

**2. 2.6.3**  **Small Gas­Fired**  **Steam Natural**  **Draft Commercial**  **Packaged**

**Boilers........................................................................................ 2­14**

**2. 2.6.4**  **Small Oil­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers.......2­17**

**2. 2.6.5**  **Small Oil­Fired**  **Steam Commercial**  **Packaged Boilers..............2­19** 

**2. 2.6.6**  **Large Gas­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers......2­21**

**2. 2.6.7**  **Large Gas­Fired**  **Steam All**  **Except Natural**  **Draft Commercial** 

**Packaged Boilers........................................................................ 2­23** 

**2. 2.6.8**  **Large Gas­Fired**  **Steam Natural**  **Draft Commercial**  **Packaged**

**Boilers........................................................................................ 2­26**

**2. 2.6.9**  **Large Oil­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers.......2­28**

**2. 2.6.10**  **Large Oil­Fired**  **Steam Commercial**  **Packaged Boilers..............2­30** 

**2­i**LIST OF FIGURES

**Figure 2.1**  **Efficiency Ratings**  **for Small**  **Gas­Fired Hot**  **Water Commercial** 

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­10** 

**Figure 2.2.**  **Efficiency Ratings**  **for Small**  **Gas­Fired Steam**  **All Except**  **Natural**

**Draft Commercial**  **Packaged Boiler**  **Models in**  **DOE’s Database** 

**................ 2­13** 

**Figure 2.3**  **Efficiency Ratings**  **for Small**  **Gas­Fired Steam**  **Natural Draft** 

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­15** 

**Figure 2.4**  **Efficiency Ratings**  **for Small**  **Oil­Fired Hot**  **Water Commercial** 

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­18** 

**Figure 2.5**  **Efficiency Ratings**  **for Small**  **Oil­Fired Steam**  **Commercial Packaged** 

**Boiler Models**  **in DOE’s**  **Database............................................................... 2­20** 

**Figure 2.6**  **Combustion Efficiency**  **Ratings for**  **Large Gas­Fired**  **Hot Water** 

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­22** 

**Figure 2.7**  **Efficiency Ratings**  **for Large**  **Gas­Fired Steam**  **All Except**  **Natural Draft** 

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­24** 

**Figure 2.8**  **Efficiency Ratings**  **for Large**  **Gas­Fired Steam**  **Natural Draft** 

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­27** 

**Figure 2.9**  **Combustion Efficiency**  **Ratings for**  **Large Gas­Fired**  **Hot Water** 

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­29** 

**Figure 2.10**  **Efficiency Ratings**  **for Large**  **Oil­Fired Steam**  **Commercial Packaged** 

**Boiler Models**  **in DOE’s**  **Database............................................................... 2­31** 

**2­ii**LIST OF TABLES

**Table 2.1**  **Equipment Classes**  **for Commercial**  **Packaged Boilers....................................**  **2­2**

**Table 2.2**  **Commercial Packaged**  **Boiler Manufacturers**  **Represented in**  **AHRI’s**

**I=B=R Ratings**  **Directory as**  **of January**  **2008................................................ 2­4** 

**Table 2.3**  **Current Federal**  **Energy Conservation**  **Standards for**  **Commercial**

**Packaged Boilers............................................................................................**  **2­5**

**Table 2.4**  **FEMP Recommended**  **Thermal Efficiency**  **Levels for**  **Commercial**

**Packaged Boilers............................................................................................**  **2­7**

**Table 2.5**  **Percentage of**  **Models by**  **Equipment Class**  **in DOE’s**  **Commercial**

**Packaged Boiler**  **Database.............................................................................. 2­8** 

**Table 2.6**  **Distribution of**  **Efficiency Levels**  **for Small**  **Gas­Fired Hot**  **Water**

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­11** 

**Table 2.7**  **Analysis of**  **Small Gas­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers**

**in DOE’s**  **Database....................................................................................... 2­11** 

**Table 2.8**  **Analysis of**  **Minimally Compliant**  **Small Gas­Fired**  **Hot Water** 

**Commercial Packaged**  **Boilers in**  **DOE’s Database ..................................... 2­12** 

**Table 2.9**  **Distribution of**  **Efficiency for**  **Small Gas­Fired**  **Steam All**  **Except**

**Natural Draft**  **Commercial Packaged**  **Boiler Models**  **in DOE’s** 

**Database....................................................................................................... 2­13**

**Table 2.10**  **Analysis for**  **Small Gas­Fired**  **Steam All**  **Except Natural**  **Draft**

**Commercial Packaged**  **Boilers in**  **DOE’s Database ..................................... 2­14** 

**Table 2.11**  **Analysis for**  **Minimally Compliant**  **Small Gas­Fired**  **Steam All**  **Except**

**Natural Draft**  **Commercial Packaged**  **Boilers in**  **DOE’s Database...............**  **2­14**

**Table 2.12**  **Distribution of**  **Efficiency for**  **Small Gas­Fired**  **Steam Natural**  **Draft**

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­16** 

**Table 2.13**  **Analysis for**  **Small Gas­Fired**  **Steam Natural**  **Draft Commercial** 

**Packaged Boilers**  **in DOE’s**  **Database.......................................................... 2­16**

**Table 2.14**  **Analysis for**  **Minimally Compliant**  **Small Gas­Fired**  **Steam Natural** 

**Draft Commercial**  **Packaged Boilers**  **in DOE’s**  **Database............................ 2­17** 

**Table 2.15**  **Distribution of**  **Efficiency for**  **Small Oil­Fired**  **Hot Water**  **Commercial**

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­18** 

**Table 2.16**  **Analysis for**  **Small Oil­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers**

**in DOE’s**  **Database....................................................................................... 2­19** 

**2­iii Table**  **2.17 Analysis**  **of Minimally**  **Compliant Small**  **Oil­Fired Hot**  **Water**

**Commercial Packaged**  **Boilers in**  **DOE’s Database ..................................... 2­19** 

**Table 2.18**  **Distribution of**  **Efficiency for**  **Small Oil­Fired**  **Steam Commercial** 

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­20** 

**Table 2.19**  **Analysis for**  **Small Oil­Fired**  **Steam Commercial**  **Packaged Boilers**  **in**

**DOE’s Database........................................................................................... 2­21** 

**Table 2.20**  **Analysis for**  **Minimally Compliant**  **Small Oil­Fired**  **Steam Commercial** 

**Packaged Boilers**  **in DOE’s**  **Database.......................................................... 2­21**

**Table 2.21**  **Distribution of**  **Efficiency for**  **Large Gas­Fired**  **Hot Water**  **Commercial**

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­23** 

**Table 2.22**  **Analysis for**  **Large Gas­Fired**  **Hot Water**  **Commercial Packaged** 

**Boilers in**  **DOE’s Directory** 

**......................................................................... 2­23** 

**Table 2.23**  **Distribution of**  **Efficiency for**  **Large Gas­Fired**  **Steam All**  **Except**

**Natural Draft**  **Commercial Packaged**  **Boiler Models**  **in DOE’s** 

**Database....................................................................................................... 2­25**

**Table 2.24**  **Analysis for**  **Large Gas­Fired**  **Steam All**  **Except Natural**  **Draft**

**Commercial Packaged**  **Boilers in**  **DOE’s Database ..................................... 2­25** 

**Table 2.25**  **Analysis for**  **Minimally Compliant**  **Large Gas­Fired**  **Steam All**  **Except**

**Natural Draft**  **Commercial Packaged**  **Boilers in**  **DOE’s Database...............**  **2­26**

**Table 2.26**  **Distribution of**  **Efficiency for**  **Large Gas­Fired**  **Steam Natural**  **Draft**

**Commercial Packaged**  **Boiler Models**  **in DOE’s**  **Database.......................... 2­27** 

**Table 2.27**  **Analysis for**  **Large Gas­Fired**  **Steam Natural**  **Draft Commercial** 

**Packaged Boilers**  **in DOE’s**  **Database.......................................................... 2­28**

**Table 2.28**  **Analysis for**  **Minimally Compliant**  **Large Gas­Fired**  **Steam Natural** 

**Draft Commercial**  **Packaged Boilers**  **in DOE’s**  **Database............................ 2­28** 

**Table 2.29**  **Distribution of**  **Efficiency for**  **Large Gas­Fired**  **Hot Water**  **Commercial**

**Packaged Boiler**  **Models in**  **DOE’s Database** 

**.............................................. 2­30** 

**Table 2.30**  **Analysis for**  **Large Oil­Fired**  **Hot Water**  **Commercial Packaged**  **Boilers**

**in DOE’s**  **Database....................................................................................... 2­30** 

**Table 2.31**  **Thermal Efficiency**  **Distribution for**  **Large Oil­Fired**  **Steam**

**Commercial Packaged**  **Boilers in**  **DOE’s Database ..................................... 2­31** 

**Table 2.32**  **Analysis for**  **Large Oil­Fired**  **Steam Commercial**  **Packaged Boilers**  **in**

**DOE’s Database........................................................................................... 2­32** 

**2­iv Table**  **2.33 Analysis**  **for Minimally**  **Compliant Large**  **Oil­Fired Steam**  **Commercial**

**Packaged Boilers**  **in DOE’s**  **Database.......................................................... 2­32**

**2­v**

### CHAPTER 2. MARKET ASSESSMENT

2.1 INTRODUCTION

**This chapter**  **details the**  **market assessment**  **that the**  **U.S. Department**  **of Energy** 

**(DOE) has**  **conducted in**  **support of**  **the ongoing**  **energy conservation**  **standards**

**rulemaking for**  **commercial packaged**  **boilers.**

**The goal**  **of the**  **market assessment**  **is to**  **develop a**  **qualitative and**  **quantitative**

**characterization of**  **the commercial**  **packaged boiler**  **industry and**  **market structure,**  **based**

**on publicly**  **available information**  **and data**  **and information**  **submitted by**  **manufacturers**

**and other**  **interested parties.**  **Issues addressed**  **include trade**  **associations and**  **manufacturer**

**characteristics, existing**  **regulatory and**  **non­regulatory efficiency**  **improvement initiatives,** 

**equipment shipments**  **and lifetimes,**  **and trends**  **in the**  **equipment markets**  **and**

**characteristics.**

**Commercial packaged**  **boilers provide**  **heating for**  **commercial facilities**  **by heating** 

**water and**  **distributing it**  **in the**  **form of**  **steam or**  **hot water.**  **Commercial packaged**  **boilers**

**are differentiated**  **from residential**  **boilers by**  **their gross**  **output capacity.**  **Residential**

**boilers have**  **a capacity**  **up to**  **300 thousand**  **British thermal**  **units per**  **hour (kBtu/h),** 

**whereas commercial**  **boilers have**  **capacities of**  **300 kBtu/h**  **or greater.**  **Commercial**

**packaged boilers**  **can be**  **separated into**  **equipment classes**  **based on**  **several characteristics,** 

**including fuel**  **type, output,**  **size, and**  **draft type.** 

2. 1.1 Definitions

**The Energy**  **Policy and**  **Conservation Act**  **(EPCA) defines**  **a “packaged**  **boiler” as** 

**“a boiler**  **that is**  **shipped complete**  **with heating**  **equipment, mechanical**  **draft equipment,** 

**and automatic**  **controls; usually**  **shipped in**  **one or**  **more sections.”**  **(42 U.S.C.** 

**6311(11)(B)) In**  **its regulations**  **at 10**  **CFR 431.102,**  **DOE further**  **refined the**  **“packaged**

**boiler” definition**  **to exclude**  **a boiler**  **that is**  **custom designed**  **and field**  **constructed.**

**Additionally, 10**  **CFR 431.102**  **provides that**  **if the**  **boiler is**  **shipped in**  **more than**  **one**

**section, the**  **sections may**  **be produced**  **by more**  **than one**  **manufacturer, and**  **may be** 

**originated or**  **shipped at**  **different times**  **and from**  **more than**  **one location.**  **In its** 

**regulations in**  **10 CFR**  **431.82, DOE**  **also defines**  **a “commercial**  **packaged boiler”**  **as a** 

**type of**  **packaged low**  **pressure boiler**  **that is**  **industrial equipment**  **with a**  **capacity, (rated** 

**maximum input)**  **of 300,000**  **BTU per**  **hour (Btu/h)**  **or more**  **which, to**  **any significant** 

**extent, is**  **distributed in**  **commerce: (1)**  **For heating**  **or space**  **conditioning applications**  **in**

**buildings; or**  **(2) For**  **service water**  **heating in**  **buildings but**  **does not**  **meet the**  **definition of** 

**‘hot water**  **supply boiler’**  **in [part**  **431]. 10**  **CFR 431.82.** 

**EPCA specifies**  **the energy**  **conservation standards**  **for commercial**  **packaged**

**boilers in**  **terms of**  **combustion efficiency.**  **DOE defines**  **combustion efficiency**  **for a** 

**commercial packaged**  **boiler in**  **the** Federal Register **as “the**  **efficiency descriptor**  **for**

**packaged boilers,**  **determined using**  **test procedures**  **prescribed under**  **§431.86 and**  **equal**

**2­1 to**  **100 percent**  **minus percent**  **flue loss**  **(percent flue**  **loss is**  **based on**  **input fuel**  **energy).”**

**10 CFR**  **part 431.82.**  **The American**  **Society of**  **Heating, Refrigerating,**  **and Air** 

**Conditioning Engineers**  **(ASHRAE) and**  **the Illuminating**  **Engineering Society**  **of North** 

**America (IESNA)**  **Standard 90.1­2007,**  **“** Energy Standard for Buildings Except Low­Rise

Residential Buildings,” **(ASHRAE Standard**  **90.1­2007) specifies**  **efficiency levels**  **for**

**commercial packaged**  **boiler equipment**  **classes in**  **terms of**  **thermal efficiency**  **for eight** 

**equipment classes**  **and in**  **terms of**  **combustion efficiency**  **for two**  **equipment classes.**  **The**

**test procedure**  **for commercial**  **packaged boilers**  **incorporated by**  **reference into**  **the Code** 

**of Federal**  **Regulations (CFR)**  **is the**  **Hydronics Institute**  **(HI) Boiler**  **Testing Standard** 

**(BTS) 2000**  **(HI BTS­2000).**  **1 The**  **HI BTS­2000**  **defines thermal**  **efficiency as**  **“the ratio** 

**of heat**  **absorbed by**  **the water**  **or the**  **water and**  **steam to**  **the higher**  **heating value**  **in the** 

**fuel burned.”** 

2. 1.2 Equipment Classes

2. 1.2.1 Existing Equipment Classes

**The Federal**  **energy conservation**  **standards specified**  **in EPCA**  **separate**

**commercial packaged**  **boilers into**  **equipment classes**  **based solely**  **on the**  **type of**  **fuel the** 

**equipment uses.**  **(42 U.S.C.**  **6313 (a)(4)(C)­(D));**  **10 CFR**  **part 431.87.**  **This creates**  **two**

**equipment classes:**  **gas­fired commercial**  **packaged boilers**  **and oil­fired**  **commercial**

**packaged boilers.** 

2. 1.2.2 Equipment Classes Established by ASHRAE Standard 90.1­2007

**ASHRAE Standard**  **90.1­2007 divides**  **commercial packaged**  **boilers into**  **10**

**equipment classes**  **using fuel**  **type (**  i.e., **oil or**  **gas), size**  **(** i.e., **small (300­2,500**  **kBtu/h) or**  **large (>2,500**  **kBtu/h)), output**  **(steam or**  **hot water),**  **and draft**  **type (natural**  **draft or**  **other).**

Error! Reference source not found. **shows the**  **ten equipment**  **classes defined**  **in**

**ASHRAE Standard**  **90.1­2007.**

Table 2.1 Equipment Classes for Commercial Packaged Boilers

Commercial Packaged Boiler Equipment

Class Description of Characteristics

**Small Gas­Fired**  **Hot Water**  **Fuel input**  **of 300** 

− **2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **hot water**  **output**

**Small Gas­Fired**  **Steam All**  **Except Natural** 

**Draft Fuel**  **input of**  **300**

− **2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **steam output;**  **draft**

**mechanism other**  **than natural**  **draft (**  e.g.,

**forced or**  **induced draft**  **mechanism)**

**Small Gas­Fired**  **Steam Natural**  **Draft Fuel**  **input of**  **300**

− **2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **steam output;** 

**natural draft**  **mechanism**

**Small Oil­Fired**  **Hot Water**  **Fuel input**  **of 300** 

− **2,500 kBtu/h;**  **fueled by** 

**oil; hot**  **water output** 

**Small Oil­Fired**  **Steam Fuel**  **input of**  **300**

− **2,500 kBtu/h;**  **fueled by** 

**oil; steam**  **output**

**2­2 Large**  **Gas­Fired Hot**  **Water Fuel**  **input of**  **>2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **hot water**  **output**

**Large Gas­Fired**  **Steam All**  **Except Natural** 

**Draft Fuel**  **input of**  **>2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **steam output;**  **draft**

**mechanism other**  **than natural**  **draft (**  e.g.,

**forced or**  **induced draft**  **mechanism)**

**Large Gas­Fired**  **Steam Natural**  **Draft Fuel**  **input of**  **>2,500 kBtu/h;**  **fueled by** 

**propane or**  **natural gas;**  **steam output;** 

**natural draft**  **mechanism**

**Large Oil­Fired**  **Hot Water**  **Fuel input**  **of >2,500**  **kBtu/h; fueled**  **by oil;** 

**hot water**  **output**

**Large Oil­Fired**  **Steam Fuel**  **input of**  **>2,500 kBtu/h;**  **fueled by**  **oil;**

**steam output** 

2. 2 MARKET ASSESSMENT

**The following**  **market assessment**  **identifies the**  **manufacturer trade**  **associations**

**and domestic**  **and international**  **manufacturers of**  **commercial packaged**  **boilers. The** 

**market assessment**  **also identifies**  **existing regulatory**  **and non­regulatory**  **programs for** 

**commercial boilers,**  **and summarizes**  **relevant characteristics**  **and market**  **performance**

**data for**  **each equipment**  **class.**

2. 2.1 Trade Association

**To gain**  **insight into**  **the commercial**  **packaged boiler**  **industries, DOE**  **researched**

**various associations**  **available to**  **manufacturers, suppliers,**  **and users**  **of such**  **equipment.**

**DOE identified**  **the Air­Conditioning,**  **Heating, and**  **Refrigeration Institute**  **(AHRI) and** 

**the American**  **Boiler Manufacturers**  **Association (ABMA)**  **as the**  **only trade**  **groups that** 

**support, or**  **have an**  **interest in,**  **the commercial**  **packaged boiler**  **industry. DOE**  **used the** 

**member lists**  **of these**  **groups, along**  **with searches**  **of the**  **Canadian Standards**  **Association**

**(CSA)­International and**  **South Coast**  **Air Quality**  **Management District**  **(SCAQMD)**

**boiler databases,**  **to construct**  **a list**  **of commercial**  **boiler manufacturers**  **as part**  **of the** 

**market assessment.** 

2. 2.1.1 AHRI

**AHRI is**  **a national**  **trade association**  **of manufacturers**  **of residential,**  **commercial,**

**and industrial**  **appliances and**  **equipment, components,**  **and related**  **products. AHRI**  **was**

**established in**  **January of**  **2008 when**  **the Air­Conditioning**  **and Refrigeration**  **Institute**

**(ARI) merged**  **with the**  **Gas Appliance**  **Manufacturers Association**  **(GAMA). AHRI's** 

**scope includes**  **gas­fired, oil­fired,**  **and electric**  **products and**  **equipment. “[AHRI]** 

**members are**  **responsible for**  **more than**  **90 percent**  **of space**  **and water**  **heating shipments** 

**in the**  **United States”**  **during 2007.**  **2 AHRI**  **develops and**  **publishes technical**  **standards for** 

**residential and**  **commercial equipment**  **using rating**  **criteria and**  **procedures for**  **measuring**

**and certifying**  **equipment performance.**  **AHRI also**  **participates in**  **developing**

**international standards**  **and has**  **established a**  **policy of**  **adopting international**  **standards**

**for use**  **in the**  **United States**  **when technologically**  **and economically**  **feasible.**

**2­3 AHRI**  **maintains the**  **GAMA Efficiency**  **Certification Program.**  **AHRI also** 

**maintains a**  **database of**  **products and**  **equipment tested**  **under its**  **certification program**  **on**

**GAMA’s website,**  **the Institute**  **of Boilers**  **and Radiation**  **Manufacturers’ (I=B=R)**  **Ratings**

**for Boilers,**  **Baseboard Radiation,**  **Finned Tube**  **(Commercial Radiation),**  **and Indirect** 

**Fired Water**  **Heaters (January**  **2008 Edition).**  **3 This**  **database includes**  **commercial**

**packaged boilers**  **currently manufactured**  **by both**  **AHRI­member manufacturers**  **and non** 

**member manufacturers.**  Error! Reference source not found. **shows manufacturers**  **of**

**products covered**  **by this**  **rulemaking that**  **are represented**  **in the**  **2008 I=B=R**  **Directory.**

Table 2.2 Commercial Packaged Boiler Manufacturers Represented in AHRI’s

I=B=R Ratings Directory a as of January 2008

**A. O.**  **Smith Water**  **Products Co.**  **New Yorker**  **Boiler Co.,**  **Inc. (Burnham** 

**Holdings, Inc.)** 

**AE RCO**  **International, Inc.**  **P B**  **Heat, LLC** 

**BIASI, S.p.A.**  **c/o QHT,**  **Inc. Pennco**  **(ECR International,**  **Inc.)**

**Bosch Thermotechnology**  **Corp. Raypak,**  **Inc.**

**Burnham Commercial**  **(Burnham Holdings,** 

**Inc.) RBI**  **Water Heaters**  **(Mestek, Inc.)** 

**Burnham Hydronics**  **(Burnham Holdings,** 

**Inc.) Slant/Fin**  **Corporation**

**Columbia Boiler**  **Company of**  **Pottstown Smith**  **Cast Iron**  **Boilers**

**Crown Boiler**  **Co. (Burnham**  **Holdings,**

**Inc.) Thermal**  **Solutions Products,**  **LLC**

**(Burnham Holdings,**  **Inc.)**

**De Dietrich**  **Thermo­Dynamics Boiler**  **Co.**

**Dunkirk Boilers**  **(ECR International,**  **Inc.) Triangle**  **Tube**

**Heat Transfer**  **Products Inc.**  **Utica Boilers**  **(ECR International,**  **Inc.)**

**LAARS Heating**  **Systems Company**  **Viessmann Manufacturing**  **Company, Inc.** 

**Lochinvar Corporation**  **Weil­McLain**

2. 2.1.2 ABMA

**ABMA represents**  **manufacturers serving**  **a number**  **of markets,**  **including boilers** 

**intended for**  **use in**  **commercial systems.**  **b ABMA’s**  **website describes**  **“light commercial”** 

**systems as**  **having Btu**  **input capacities**  **of 400,000**  **to 12.5**  **MMBH and**  **applications that** 

**include “hydronic**  **hot water**  **heating boilers,**  **low­pressure steam**  **boilers...for heating...** 

**applications.” 4** 

**DOE identified**  **the following**  **ABMA manufacturers**  **as manufacturers**  **of**

**commercial packaged**  **boiler equipment:**  **AESYS Technologies,**  **Inc.; Ajax**  **Boiler, Inc.;** 

**Burnham Commercial;**  **Cleaver­Brooks, Inc.;**  **Easco Boiler**  **Corporation; Johnston**  **Boiler**

**Company; Miura**  **Boiler; Sellers**  **Engineering Company;**  **Superior Boiler**  **Works, Inc.;**  **and**

**Vapor Power**  **International LLC.** 

**a The**  **I=B=R Directory**  **provides efficiency**  **ratings for**  **many of**  **the commercial**  **packaged boilers** 

**manufactured in**  **the United**  **States. Produced**  **by the**  **Hydronics Institute**  **(HI) Division**  **of AHRI,**  **the**

**directory includes**  **boilers, baseboard**  **radiation, and**  **finned tube**  **radiation products.** 

**b For**  **more information**  **about ABMA,**  **visit www.abma.com.** 

**2­4**2.2.1.3 Additional Manufacturers

**DOE also**  **reviewed the**  **CSA­International c**  **and SCAQMD**  **d boiler**  **databases to** 

**identify commercial**  **boiler manufacturers**  **that may**  **not be**  **members of**  **a trade**  **association**

**or actively**  **participate in**  **an efficiency**  **certification program.**  **DOE identified**  **10**

**additional boiler**  **manufacturers from**  **the two**  **databases: Fulton**  **Boiler; Parker**  **Boiler;**

**Patterson­Kelley Company**  **(division of**  **Harsco); Triad**  **Boiler Systems;**  **CAMUS**

**Hydronics, Ltd.;**  **Gasmaster Industries;**  **General Boiler**  **Co., Inc.;**  **Hurst Boiler;**  **Lattner**

**Boiler; and**  **Unilux Boiler.**  **5,6**

2.2.2 Regulatory Programs

**The following**  **section details**  **current regulatory**  **programs mandating**  **energy**

**conservation standards**  **for commercial**  **packaged boilers.**  **Section 2.2.2.1**  **discusses**

**Federal energy**  **conservation standards**  **and section**  **2.2.2.2 provides**  **an overview**  **of**

**existing State**  **standards. Section**  **2.2.2.3 reviews**  **Canadian standards**  **programs that**  **may**

**affect the**  **companies servicing**  **the North**  **American market.** 

2. 2.2.1 Current Federal Energy Conservation Standards

**Part A­1**  **of Title**  **III of**  **EPCA addresses**  **the energy**  **efficiency of**  **certain types**  **of**

**commercial and**  **industrial equipment.**  **e (42**  **U.S.C. 6311­6317)**  **EPCA contains**  **specific**

**mandatory energy**  **conservation standards**  **for certain**  **types of**  **commercial heating,**  **air**

**conditioning, and**  **water heater**  **equipment. (42**  **U.S.C. 6313(a)(3))**  **These requirements** 

**generally correspond**  **to the**  **efficiency levels**  **set in**  **ASHRAE Standard**  **90.1. Table**  **2.3**

**presents the**  **Federal energy**  **conservation standards**  **for commercial**  **packaged boilers**  **as presented**  **in section**  **87 of**  **10 CFR**  **part 431.** 

Table 2.3 Current Federal Energy Conservation Standards for Commercial

Packaged Boilers

Equipment Class Existing Federal Minimum Standard

**Gas­Fired Commercial**  **Packaged Boilers**  **E C**  **=80%***

**Oil­Fired Commercial**  **Packaged Boilers**  **E C**  **=83%***

***E C**  **is combustion**  **efficiency as**  **defined in**  **10 CFR**  **part 431.82.** 

2.2.2.2 State Energy Conservation Standards

**Under EPCA,**  **states may**  **petition to**  **have more**  **stringent energy**  **conservation**

**standards than**  **those codified**  **into law**  **by DOE**  **(see 42**  **U.S.C. 6297(d)).**  **At this**  **time, no** 

**states have**  **been granted**  **a petition**  **from DOE**  **to establish**  **more stringent**  **energy**

**conservation standards**  **than the**  **levels EPCA**  **established for**  **commercial packaged** 

**boilers.**

**For more**  **information, visit**  **www.csa­international.org/Default.asp?language=english.**

**d For**  **more information,**  **visit www.aqmd.gov/.** 

**e This**  **part was**  **originally titled**  **Part C.**  **However, it**  **was redesignated**  **Part A­1**  **after Part**  **B of**  **Title III**  **of**

**EPCA was**  **repealed by**  **Pub. L.**  **109­58.**

**2­5 c** 2.2.2.3 Canadian Energy Conservation Standards

**The Natural**  **Resources Canada**  **(NRCan) Office**  **of Energy**  **Efficiency regulation** 

**mandates minimum**  **energy conservation**  **standards for**  **gas­ and oil­fired**  **packaged boilers** 

**with a**  **fuel input**  **of less**  **than 300,000**  **Btu/h. However,**  **NRCan does**  **not currently**  **regulate**

**the energy**  **efficiency of**  **commercial packaged**  **boilers (**  i.e., **boilers with**  **a fuel**  **input ≥** 

**300,000 Btu/h).**  **7**

2.2.3 Non­Regulatory Programs

2. 2.3.1 ENERGY STAR

**ENERGY STAR,**  **f a**  **voluntary labeling**  **program backed**  **by the**  **U.S.**

**Environmental Protection**  **Agency (EPA)**  **and DOE,**  **identifies energy**  **efficient products** 

**through a**  **qualification process.**  **To qualify,**  **a product**  **must exceed**  **federal minimum** 

**standards by**  **a specified**  **amount, or**  **if no**  **federal standard**  **exists, exhibit**  **selected energy** 

**saving features.**  **The ENERGY**  **STAR program**  **works to**  **recognize the**  **top quartile**  **of**

**products on**  **the market,**  **meaning that**  **approximately 25**  **percent of**  **products on**  **the market** 

**meet or**  **exceed the**  **ENERGY STAR**  **levels. Currently,**  **there is**  **an ENERGY**  **STAR**

**program for**  **residential packaged**  **boilers, but**  **there is**  **no ENERGY**  **STAR program**  **for**

**commercial packaged**  **boilers.**

2. 2.3.2 Federal Energy Management Program

**DOE ’s**  **Federal Energy**  **Management Program**  **g (FEMP)**  **works to**  **reduce the**  **cost**

**and environmental**  **impact of**  **the Federal**  **government by**  **advancing energy**  **efficiency and** 

**water conservation,**  **promoting the**  **use of**  **distributed and**  **renewable energy,**  **and**

**improving utility**  **management decisions**  **at Federal**  **sites. FEMP**  **helps Federal**  **buyers**

**identify and**  **purchase energy**  **efficient equipment.** 

**FE MP**  **designates standards**  **for commercial**  **packaged boilers**  **purchased by**  **the**

**Federal government.**  **FEMP specifies**  **different efficiency**  **levels for**  **commercial packaged** 

**boilers based**  **on their**  **fuel type,**  **size, and**  **output. Although**  **the current**  **Federal minimum** 

**standards are**  **specified using**  **the combustion**  **efficiency metric,**  **FEMP levels**  **are specified** 

**using the**  **thermal efficiency**  **metric. Table**  **2.4 presents**  **the designated**  **FEMP commercial** 

**packaged boiler**  **standards levels.** 

**f For**  **more information,**  **visit www.energystar.gov.** 

**g For**  **more information,**  **visit www.eere.energy.gov/femp.** 

**2­6**Table 2.4 FEMP Recommended Thermal Efficiency Levels for Commercial

8 Packaged Boilers

Equipment Class Recommended Thermal Effic

(%) iency (E T )

**Small Gas­Fired**  **Hot Water**  **80**

**Large Gas­Fired**  **Hot Water**  **80**

**Small Gas­Fired**  **Steam 79** 

**Large Gas­Fired**  **Steam 80** 

**Small Oil­Fired**  **Hot Water**  **83**

**Large Oil­Fired**  **Hot Water**  **83**

**Small Oil­Fired**  **Steam 83** 

**Large Oil­Fired**  **Steam 83** 

2. 2.3.3 Rebate Programs

**DOE has**  **identified and**  **reviewed various**  **local utility**  **rebate programs.** 

**Commercial boiler**  **rebate programs**  **include the**  **Minnesota Energy**  **Resources**

**Commercial Custom**  **Rebate Program,**  **Pacific Gas**  **and Electric**  **Company (PG&E)** 

**Energy Efficiency**  **Rebates, San**  **Diego Gas**  **and Electric**  **Express Efficiency**  **and Small** 

**Business Super**  **Savers Programs,**  **and the**  **Southern California**  **Gas Company**  **Express**

**Efficiency Rebate**  **Program.**

Minnesota Energy Resources. **The Minnesota**  **Energy Resources**  **Commercial**

**Custom Rebate**  **program offers**  **businesses cash**  **rebates as**  **an incentive**  **to install**  **energy**

**efficient commercial**  **equipment, including**  **boilers and**  **boiler retrofits.**  **Minnesota Energy** 

**Resources does**  **not have**  **a standard**  **rebate amount;**  **rather it**  **individually reviews**  **each**

**application it**  **receives. Rebate**  **amounts are**  **awarded based**  **on the**  **incremental cost** 

**between a**  **standard product**  **and a**  **high­efficiency unit,**  **as well**  **as the**  **peak demand** 

**reduction, annual**  **energy use**  **savings, and**  **annual energy**  **cost savings**  **that will**  **result from** 

**purchasing more**  **efficient equipment.**  **9**

Pacific Gas and Electric Company. **Pacific Gas**  **and Electric**  **Company (PG&E)** 

**offers energy**  **efficiency rebates**  **to commercial**  **customers who**  **use energy**  **efficient space** 

**heating boilers**  **in their**  **businesses or**  **commercial facilities.**  **For space**  **heating boilers**  **with**

**a capacity**  **of ≥300**  **MBtu/h and**  **<2,500 MBtu/h**  **(i.e., small**  **commercial boilers)**  **and a** 

**thermal efficiency**  **≥ 84**  **percent, PG&E**  **offers a**  **rebate of**  **$1 per**  **MBtu/h of**  **capacity. 10** 

San Diego Gas and Electric Company. **The San**  **Diego Gas**  **and Electric** 

**Company (SDG&E)**  **offers rebates**  **to commercial**  **customers through**  **both its**  **Express**

**Efficiency and**  **its Small**  **Business Super**  **Savers rebate**  **programs. Rebates**  **through the** 

**Express Efficiency**  **program are**  **only available**  **to medium­ and**  **large­sized business** 

**customers with**  **a valid**  **commercial, industrial,**  **or agricultural**  **rate and**  **a monthly**  **electric**

**demand of**  **100 kW**  **or above**  **and/or an**  **average monthly**  **therm usage**  **of 4,166**  **therms or** 

**above. Rebates**  **through the**  **Small Business**  **Super Savers**  **program are**  **only available**  **to**

**small­sized business**  **customers with**  **a valid**  **commercial, industrial,**  **or agricultural**  **rate**

**and a**  **monthly electric**  **demand under**  **100 kW**  **and/or an**  **average monthly**  **therm usage** 

**below 4,166**  **therms. Both**  **programs provide**  **rebates for**  **gas­fired, space**  **heating, boilers** 

**2­7 with**  **a capacity**  **of ≥300**  **MBtu/h and**  **<2,500 MBtu/h**  **(i.e., small**  **gas­fired commercial** 

**boilers). Both**  **programs offer**  **identical rebates**  **of $0.25**  **per MBtu/h**  **of capacity**  **for small** 

**gas commercial**  **boilers with**  **a thermal**  **efficiency ≥**  **84 percent.**  **11, 12** 

Southern California Gas Company. **The Southern**  **California Gas**  **Company**

**offers cash**  **rebates through**  **its Express**  **Efficiency program**  **as an**  **incentive for**  **businesses**

**to replace**  **old, standard**  **equipment with**  **newer, high­efficiency**  **equipment. Businesses** 

**eligible for**  **Express Efficiency**  **are commercial,**  **industrial, and**  **agricultural customers.** 

**Eligible customers**  **can receive**  **a rebate**  **of $0.25**  **per MBtu/h**  **of capacity**  **for space** 

**heating, gas,**  **commercial boilers**  **with a**  **capacity ≥300**  **MBtu/h and**  **<2000 MBtu/h,**  **and**

**with a**  **thermal efficiency**  **≥ 84**  **percent. 13** 

2.2.4 Shipments

**Information about**  **annual equipment**  **shipment trends**  **allows DOE**  **to estimate**  **the**

**impacts of**  **energy conservation**  **standards on**  **the commercial**  **packaged boiler**  **industry.**

**Using AHRI**  **estimates, DOE**  **has examined**  **the number**  **of unit**  **shipments of**  **commercial**

**packaged boilers.** 

**DOE obtained**  **annual shipments**  **for commercial**  **packaged boilers**  **in 2007**  **from**

**AHRI, which**  **totaled approximately**  **36,000 units.**  **DOE used**  **its commercial**  **boiler**

**database, which**  **includes data**  **from the**  **2008 I=B=R**  **Directory and**  **manufacturer**

**datasheets, to**  **determine the**  **percentage of**  **models within**  **each equipment**  **class. Table**  **2.5**

**shows the**  **breakdown of**  **the percentage**  **of models**  **in each**  **equipment class.** 

Table 2.5 Percentage of Models by Equipment Class in DOE’s Commercial

Packaged Boiler Database

Equipment Class Percentage of

Models (%)

**Small Gas­Fired**  **Hot Water**  **24**

**Small Gas­Fired**  **Steam All**  **Except Natural**  **Draft 8** 

**Small Gas­Fired**  **Steam Natural**  **Draft 13** 

**Small Oil­Fired**  **Hot Water**  **7**

**Small Oil­Fired**  **Steam 11** 

**Large Gas­Fired**  **Hot Water**  **4**

**Large Gas­Fired**  **Steam All**  **Except Natural**  **Draft 7** 

**Large Gas­Fired**  **Steam Natural**  **Draft 9** 

**Large Oil­Fired**  **Hot Water**  **2**

**Large Oil­Fired**  **Steam 15** 

2. 2.5 Equipment Lifetime

**DOE reviewed**  **available literature**  **to establish**  **typical equipment**  **lifetimes. The** 

2000 Screening Analysis for EPACT­Covered Commercial Heating, Ventilating and AirConditioning (HVAC) and Water­Heating Equipment **report assumed**  **a 30­year**  **lifetime**

**2­8 for**  **commercial packaged**  **boilers based**  **on data**  **from ASHRAE’s**  **1995** Handbook of

HVAC Applications

**. 14**  **Therefore, DOE**  **used a**  **30­year lifetime**  **for commercial**  **packaged**

**boilers in**  **its analyses.**  **More information**  **about commercial**  **packaged boiler**  **equipment**

**lifetime can**  **be found**  **in the**  **life­cycle cost**  **and payback**  **period analyses**  **section in**  **chapter**

**4 of**  **the TSD.** 

2. 2.6 Market Performance Data

**DOE reviewed**  **the performance**  **data for**  **commercial packaged**  **boilers currently** 

**on the**  **market by**  **examining the**  **I=B=R ratings**  **directories for**  **2008, along**  **with**

**manufacturer datasheets**  **for commercial**  **boiler models**  **not listed**  **in the**  **directory. DOE** 

**made efforts**  **to include**  **equipment not**  **listed in**  **the directory**  **in the**  **commercial boiler** 

**market analysis**  **whenever performance**  **data was**  **available.**

**DOE reviewed**  **the market**  **for all**  **ten equipment**  **classes, but**  **specifically reviewed** 

**the relationship**  **between thermal**  **and combustion**  **efficiencies for**  **boilers that**  **fell into** 

**each of**  **the eight**  **equipment classes**  **for which**  **a metric**  **change occurred.**  **DOE determined** 

**the average**  **combustion efficiency**  **for all**  **equipment classes**  **and the**  **average thermal** 

**efficiency for**  **each equipment**  **class when**  **a metric**  **change occurred.**  **DOE also**  **identified**

**the average**  **thermal efficiency**  **for those**  **boilers DOE**  **considers minimally**  **compliant (**  i.e.

**, those**  **boilers with**  **a combustion**  **efficiency equal**  **to or**  **within one**  **percentage point**  **of the** 

**Federal energy**  **conservation standards).**  **DOE’s database**  **lists 2,033**  **commercial**

**packaged boiler**  **models from**  **31 manufacturers.**  **ASHRAE Standard**  **90.1­2007 changed** 

**the efficiency**  **metric for**  **1,932 of**  **the boilers**  **listed. Of**  **these, 83.6**  **percent had**  **a thermal** 

**and combustion**  **efficiency listed**  **in the**  **2008 I=B=R**  **Directory. However,**  **the ratings**  **for**

**21 percent**  **of these**  **boilers appear**  **to be**  **erroneous because**  **the directory**  **lists a**  **thermal**

**efficiency rating**  **that is**  **greater than**  **the combustion**  **efficiency rating,**  **which is**  **physically**

**impossible. Because**  **thermal efficiency**  **includes the**  **effects of**  **jacket losses,**  **but**

**combustion efficiency**  **does not,**  **it is**  **impossible for**  **a boiler’s**  **thermal efficiency**  **to be** 

**greater than**  **its combustion**  **efficiency. Excluding**  **these boilers,**  **DOE reviewed**  **the**

**thermal and**  **combustion efficiency**  **ratings for**  **the remaining**  **65.9 percent**  **of the**  **boilers**

**when both**  **types of**  **efficiency ratings**  **were available.** 

2. 2.6.1 Small Gas­Fired Hot Water Commercial Packaged Boilers

**Small gas­fired**  **hot water**  **boilers have**  **a fuel**  **input between**  **300 kBtu/h**  **and 2,500** 

**kBtu/h, are**  **fueled by**  **either natural**  **gas or**  **propane, and**  **supply hot**  **water for**  **space**

**heating. Small**  **gas­fired hot**  **water commercial**  **packaged boilers**  **fall under**  **the gas­fired** 

**commercial packaged**  **boilers equipment**  **class, whose**  **Federal energy**  **conservation**

**standards require**  **a combustion**  **efficiency of**  **no less**  **than 80**  **percent. (42**  **U.S.C.**

**6313(a)(4)(C); 10**  **CFR 431.87(a))**  **ASHRAE Standard**  **90.1­2007 changes**  **the efficiency** 

**metric for**  **these boilers**  **and requires**  **a thermal**  **efficiency of**  **at least**  **80 percent.** 

Manufacturers. **Small gas­fired**  **hot water**  **commercial packaged**  **boilers are**  **the**

**largest commercial**  **packaged boiler**  **equipment class,**  **accounting for**  **24.2 percent**  **of all** 

**2­9 the**  **boiler models**  **DOE analyzed.**  **h Major**  **manufacturers of**  **small gas­fired**  **hot water** 

**commercial packaged**  **boilers include**  **A.O. Smith**  **Water Products**  **Co., Bosch** 

**Thermotechnology Corp.**  **(a division**  **of Bosch**  **USA, which**  **is a**  **branch of**  **The Bosch** 

**Group), Lochinvar**  **Corp., Raypak**  **Inc., RBI**  **Water Heaters**  **(a division**  **of Mestek**  **Inc.),**

**and Slant/Fin**  **Corp.**

Market Data. **Of the**  **617 small**  **gas­fired hot**  **water commercial**  **packaged boiler** 

**models listed**  **in DOE’s**  **commercial boiler**  **database, 326**  **(52.8 percent)**  **had values**  **listed**

**for both**  **thermal and**  **combustion efficiency**  **and a**  **combustion efficiency**  **greater than**  **or**

**equal to**  **thermal efficiency.**  **To examine**  **the relationship**  **between thermal**  **and combustion** 

**efficiency and**  **to show**  **the current**  **efficiencies of**  **products on**  **the market,**  **DOE plotted** 

**the thermal**  **versus combustion**  **efficiency for**  **the small**  **gas­fired hot**  **water boiler**  **models**

**it considered**  **in the**  **analysis (Figure**  **2.1).**

75 80 85 90 95 100

75 80 85 90 95 100

Thermal Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.1 Efficiency Ratings for Small Gas­Fired Hot Water Commercial Packaged

Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies**

**for small**  **gas­fired hot**  **water commercial**  **packaged boiler**  **models in**  **its commercial**  **boiler**

**database across**  **several thermal**  **efficiency ranges,**  **shown in**  **Table 2.6.**  **To determine**  **the**

**percentage of**  **models in**  **each efficiency**  **range, DOE**  **considered models**  **with an** 

**efficiency rating**  **greater than**  **or equal**  **to the**  **lower bound**  **of the**  **efficiency range**  **and**

**models with**  **efficiencies less**  **than the**  **upper bound**  **of the**  **efficiency range.**  **For example,** 

**for the**  **efficiency range**  **of 79**  **to 80**  **percent thermal**  **efficiency, DOE**  **considered models** 

**with efficiency**  **levels from**  **79.0 to**  **79.9 to**  **be within**  **this range.**  **For the**  **last efficiency** 

**range identified**  **for each**  **equipment class,**  **DOE included**  **those models**  **with efficiency** 

**h DOE**  **analyzed 1,349**  **commercial packaged**  **boilers listed**  **in its**  **database. For**  **those equipment**  **classes for** 

**which ASHRAE**  **Standard 90.1­2007**  **specified a**  **different efficiency**  **metric from**  **the current**  **Federal**

**standard, DOE**  **only analyzed**  **commercial packaged**  **boilers that**  **had values**  **listed for**  **both E**  **T and**  **E C**  **and E**  **T**

**≤ E**  **C**

**. For**  **equipment classes**  **with no**  **efficiency metric**  **change, DOE**  **analyzed models**  **with an**  **E C**  **value**

**listed. If**  **an E**  **T is**  **listed, then**  **E T**  **≤ E**  **C**

**.**

**2­10 levels**  **equal to**  **the higher**  **bound. The**  **shaded box**  **in Table**  **2.6 represents**  **the minimum** 

**thermal efficiency**  **level set**  **by ASHRAE**  **Standard 90.1­2007.** 

Table 2.6 Distribution of Efficiency Levels for Small Gas­Fired Hot Water

Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(< 80%)**  **8. 9** 

**Baseline (80%)** 

**– EL**  **1 (82%)**  **14. 3** 

**EL 1**  **(82%)**

**– EL**  **2 (84%)**  **29. 3** 

**EL 2**  **(84%)**

**– EL**  **3 (86%)**  **22. 3** 

**EL 3**  **(86%)**

**– EL**  **4 (92%)**  **7. 7** 

**Above EL**  **4 (>**  **92%) 17.**  **5**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **small gas­fired**  **hot**

**water commercial**  **packaged boiler**  **models considered**  **in the**  **analysis (**  i.e.

**, boilers**  **that had** 

**values for**  **both E**  **T and**  **E C**  **where E**  **T ≤**  **E C**  **) by**  **examining the**  **maximum, minimum,**  **and**

**average values**  **for E**  **C and**  **E T**  **, as**  **well as**  **the difference**  **between the**  **two efficiencies**  **(�E).**

**DOE calculated**  **the average**  **E C**  **by averaging**  **the combustion**  **efficiencies for**  **all boiler** 

**models in**  **its commercial**  **boiler database**  **that met**  **the analysis**  **criteria. DOE**  **calculated**

**the average**  **E T**  **by averaging**  **the thermal**  **efficiencies for**  **these boiler**  **models. DOE** 

**calculated the**  **average �E**  **by first**  **taking the**  **difference between**  **E C**  **and E**  **T (E**  **C**

**– E**  **T )**  **for**

**each boiler**  **model, and**  **then finding**  **the average**  **of those**  **differences. The**  **minimum and** 

**maximum efficiencies**  **correspond to**  **the lowest**  **and highest**  **efficiencies listed**  **for the** 

**models DOE**  **considered. The**  **maximum and**  **minimum �Es**  **correspond to**  **the largest**  **and**

**smallest differences**  **between combustion**  **and thermal**  **efficiency. Table**  **2.7 shows**  **the**

**results of**  **this analysis**  **for small**  **gas­fired hot**  **water commercial**  **packaged boilers.** 

Table 2.7 Analysis of Small Gas­Fired Hot Water Commercial Packaged Boilers in

DOE’s Database

Category E

C E

T �E

**Average (%)**  **85. 72**  **84. 87**  **0. 88** 

**Maximum (%)**  **98. 30**  **98. 10**  **5. 10** 

**Minimum (%)**  **80. 00**  **76. 80**  **0**

**Standard Deviation**  **(%) 5.**  **12 5.**  **44 1.**  **23**

**Count (Number**  **of Models)**  **326 326**  **326**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied i**  **with the**  **Federal**

**energy conservation**  **standard of**  **80­percent combustion**  **efficiency (**  i.e., **equipment with**  **a**

**DOE considered**  **“minimally compliant”**  **equipment to**  **be equipment**  **with efficiency**  **levels at**  **the Federal** 

**minimum standard**  **level through**  **1 percent**  **higher than**  **the Federal**  **standard level**  **(** i.e., **DOE considered** 

**gas­fired commercial**  **packaged boilers**  **to be**  **minimally compliant**  **if E**  **C was**  **between 80**  **and 81**  **percent,**

**and oil­fired**  **commercial packaged**  **boilers to**  **be minimally**  **compliant if**  **E C**  **was between**  **83 and**  **84**

**percent).**

**2­11 i** **combustion efficiency**  **between 80**  **and 81**  **percent). Of**  **the 326**  **models analyzed,**  **16**

**models (4.9**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the**

**paragraph above.**  **Table 2.8**  **shows the**  **results of**  **this analysis**  **for minimally**  **compliant**

**small gas­fired**  **hot water**  **commercial packaged**  **boilers.**

Table 2.8 Analysis of Minimally Compliant Small Gas­Fired Hot Water

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 00**  **78. 33**  **1. 67** 

**Maximum (%)**  **80. 00**  **80. 00**  **3. 00** 

**Minimum (%)**  **80. 00**  **77. 00**  **0**

**Standard Deviation**  **(%) 0**  **1. 58**  **1. 58** 

**Count (Number**  **of Models)**  **16 16**  **16**

2. 2.6.2 Small Gas­Fired Steam All Except Natural Draft Commercial

Packaged Boilers

**Small gas­fired**  **steam all**  **except natural**  **draft boilers**  **have a**  **fuel input**  **between**

**300 and**  **2,500 kBtu/h,**  **are fueled**  **by either**  **natural gas**  **or propane,**  **supply steam**  **for space** 

**heating, and**  **use a**  **draft mechanism**  **other than**  **natural draft**  **(** e.g.

**, forced**  **or induced**  **draft**

**systems). Small**  **gas­fired steam**  **all except**  **natural draft**  **commercial packaged**  **boilers fall** 

**under the**  **gas­fired commercial**  **packaged boilers**  **equipment class,**  **whose Federal**  **energy**

**conservation standards,**  **require a**  **combustion efficiency**  **no less**  **than 80**  **percent. (42** 

**U. S.C.**  **6313(a)(4)(C); 10**  **CFR 431.87(a))**  **ASHRAE Standard**  **90.1­2007 changed**  **the**

**efficiency metric**  **for these**  **boilers and**  **requires a**  **thermal efficiency**  **of at**  **least 79**  **percent.**

Manufacturers. **Small gas­fired**  **steam all**  **except natural**  **draft boilers**  **comprise**

**8. 2**  **percent of**  **the boiler**  **models DOE**  **analyzed. Major**  **manufacturers of**  **these boilers**  **are**

**Burnham Commercial**  **(a subsidiary**  **of Burnham**  **Holdings Inc.),**  **Crown Boiler**  **Company,**

**Peerless Boilers**  **(a subsidiary**  **of Aegis**  **International), Smith**  **Cast Iron**  **Boilers (a**  **division**

**of Mestek**  **Inc.), and**  **Weil­McLain.**

Market Data. **Of the**  **111 small**  **gas­fired steam**  **all except**  **natural draft** 

**commercial packaged**  **boiler models**  **listed in**  **DOE’s commercial**  **boiler database,**  **four**

**(3. 6**  **percent) had**  **values listed**  **for both**  **thermal and**  **combustion efficiency**  **with a** 

**combustion efficiency**  **that was**  **greater than**  **or equal**  **to thermal**  **efficiency. To**  **examine**

**the relationship**  **between thermal**  **and combustion**  **efficiency, and**  **to show**  **the current** 

**efficiencies of**  **products on**  **the market,**  **DOE plotted**  **the thermal**  **versus combustion** 

**efficiency for**  **the small**  **gas­fired steam**  **all except**  **natural draft**  **boilers considered**  **in the** 

**analysis (Figure**  **2.2).**

**2­12**79 80 81 82 83 84 85 86

77 78 79 80 81 82 83 84 85 86

Therm al Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.2. Efficiency Ratings for Small Gas­Fired Steam All Except Natural Draft

Commercial Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**small gas­fired**  **steam all**  **except natural**  **draft commercial**  **packaged boiler**  **models in**  **its**

**database across**  **several thermal**  **efficiency ranges**  **(Table 2.9).**  **To determine**  **the**

**percentage of**  **models in**  **each efficiency**  **range, DOE**  **used the**  **method described**  **in section** 

**2. 2.6.1.**  **The shaded**  **box in**  **Table 2.9**  **represents the**  **minimum thermal**  **efficiency level**  **set**

**by ASHRAE**  **Standard 90.1­2007.** 

Table 2.9 Distribution of Efficiency for Small Gas­Fired Steam All Except Natural

Draft Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(< 79%)**  **10**

**Baseline (79%)** 

**– EL**  **1 (80%)**  **26**

**EL 1**  **(80%) –EL**  **2 (81%)**  **45**

**EL 2**  **(81%)**

**– EL**  **3 (82%)**  **9**

**EL 3**  **(82%)**

**– EL**  **4 (83%)**  **3**

**Above EL**  **4 (83%)**  **7**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **small gas­fired**  **steam**

**all except**  **natural draft**  **commercial packaged**  **boiler models**  **considered in**  **the analysis** 

**(** i.e.

**, models**  **that had**  **values for**  **both E**  **T and**  **E C**  **where E**  **T ≤**  **E C**  **) by**  **examining the** 

**maximum, minimum,**  **and average**  **values for**  **combustion efficiency**  **and thermal** 

**efficiency, as**  **well as**  **the difference**  **between the**  **two efficiencies.**  **DOE calculated**  **the**

**average E**  **C by**  **averaging the**  **combustion efficiencies**  **for all**  **commercial packaged**  **boiler**

**models in**  **its database**  **that met**  **the analysis**  **criteria. DOE**  **also calculated**  **the average**  **E T**  **by averaging**  **the thermal**  **efficiencies for**  **these boilers.**  **DOE calculated**  **the average**  **�E by** 

**taking the**  **difference between**  **E C**  **and E**  **T (E**  **C**

**– E**  **T )**  **for each**  **boiler model,**  **and then**  **finding**

**2­13 the**  **average of**  **those differences.**  **The minimum**  **and maximum**  **efficiencies correspond**  **to**

**the lowest**  **and highest**  **efficiencies listed**  **for the**  **models considered.**  **The maximum**  **and**

**minimum �Es**  **were the**  **largest and**  **smallest differences**  **between combustion**  **and thermal** 

**efficiency. Table**  **2.10 shows**  **the results**  **of this**  **analysis for**  **small gas­fired**  **steam all** 

**except natural**  **draft commercial**  **packaged boilers.** 

Table 2.10 Analysis for Small Gas­Fired Steam All Except Natural Draft

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **82. 25**  **80. 47**  **1. 81** 

**Maximum (%)**  **86. 00**  **83. 30**  **3. 30** 

**Minimum (%)**  **80. 50**  **78. 00**  **0**

**Standard Deviation**  **(%) 1.**  **09 1.**  **32 0.**  **79**

**Count (Number**  **of Models)**  **111 111**  **111**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 80­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 80**  **and 81**  **percent). Of**  **the 111**  **models analyzed,**  **four**

**models (3.6**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the previous** 

**paragraph. Table**  **2.11 shows**  **the results**  **of this**  **analysis for**  **minimally compliant**  **small**

**gas­fired steam**  **all except**  **natural draft**  **commercial packaged**  **boilers.**

Table 2.11 Analysis for Minimally Compliant Small Gas­Fired Steam All Except

Natural Draft Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 73**  **79. 63**  **1. 10** 

**Maximum (%)**  **80. 90**  **79. 90**  **1. 50** 

**Minimum (%)**  **80. 50**  **79. 30**  **0. 90** 

**Standard Deviation**  **(%) 0.**  **17 0.**  **25 0.**  **27**

**Count (Number**  **of Models)**  **4 4**  **4**

2. 2.6.3 Small Gas­Fired Steam Natural Draft Commercial Packaged Boilers

**Small gas­fired**  **steam natural**  **draft commercial**  **packaged boilers**  **have a**  **fuel input** 

**at or**  **above 300**  **and less**  **than or**  **equal to**  **2,500 kBtu/h.**  **They are**  **fueled by**  **either natural** 

**gas or**  **propane, supply**  **steam for**  **space heating,**  **and use**  **a natural**  **draft. Small**  **gas­fired**

**steam natural**  **draft commercial**  **packaged boilers**  **fall under**  **the gas­fired**  **commercial**

**packaged boilers**  **equipment class,**  **whose Federal**  **energy conservation**  **standards require**  **a**

**combustion efficiency**  **of no**  **less than**  **80 percent.**  **(42 U.S.C.**  **6313(a)(4)(C); 10**  **CFR**

**431.87(a))**

**ASHRAE Standard**  **90.1­2007 set**  **two different**  **thermal efficiency**  **levels for**  **this**

**equipment, as**  **well as**  **two effective**  **dates. The**  **first efficiency**  **level specified**  **in ASHRAE** 

**Standard 90.1­2007**  **includes a**  **77­percent thermal**  **efficiency effective**  **March 2,**  **2010.**

**2­14 The**  **second efficiency**  **level includes**  **a 79­percent**  **thermal efficiency**  **effective March**  **2,**

**2020.**

Manufacturers. **Small gas­fired**  **steam natural**  **draft commercial**  **packaged boilers** 

**account for**  **12.6 percent**  **of the**  **boiler models**  **DOE analyzed.**  **Major manufacturers**  **of**

**these boilers**  **are Burnham**  **Commercial, Dunkirk**  **Boilers and**  **Pennco (both**  **of ECR** 

**International Inc.),**  **Peerless Boilers,**  **Smith Cast**  **Iron Boilers,**  **Slant/Fin Corp,**  **and Weil** 

**McLain.**

Market Data. **Of the**  **331 small**  **gas­fired steam**  **natural draft**  **boiler models**  **listed**

**in DOE’s**  **database, 170**  **(51.3 percent)**  **had values**  **listed for**  **both thermal**  **and combustion** 

**efficiency, with**  **a combustion**  **efficiency greater**  **than or**  **equal to**  **thermal efficiency.**  **To**

**examine the**  **relationship between**  **thermal and**  **combustion efficiency,**  **and to**  **show the** 

**current efficiencies**  **of products**  **on the**  **market, DOE**  **plotted the**  **thermal versus** 

**combustion efficiency**  **for the**  **small gas­fired**  **steam natural**  **draft boiler**  **models**

**considered in**  **the analysis**  **(Figure 2.3).**  **The data**  **points in**  **Figure 2.3**  **show that**  **multiple**

**models have**  **a thermal**  **efficiency level**  **below that**  **specified in**  **ASHRAE Standard**  **90.1­**

**2007 for**  **both the**  **2010 and**  **2020 effective**  **date.**

79 80 81 82 83 84

75 76 77 78 79 80 81

Thermal Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level (2010)

ASHRAE 90.1­2007 Efficiency Level (2020)

Figure 2.3 Efficiency Ratings for Small Gas­Fired Steam Natural Draft Commercial

Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies**

**for small**  **gas­fired steam**  **natural draft**  **commercial packaged**  **boiler models**  **across several** 

**thermal efficiency**  **ranges (Table**  **2.12). To**  **determine the**  **percentage of**  **models in**  **each**

**efficiency range,**  **DOE used**  **the method**  **described in**  **section 2.2.6.1.**  **The shaded**  **box in** 

**Table 2.12**  **represents the**  **minimum thermal**  **efficiency level**  **set by**  **ASHRAE Standard** 

**90.1­2007 (effective**  **March 2,**  **2020).**

**2­15**Table 2.12 Distribution of Efficiency for Small Gas­Fired Steam Natural Draft

Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(< 77%)**  **26. 5** 

**Baseline (77%)** 

**– EL**  **1 (78%)**  **41. 8** 

**EL 1**  **(78%)**

**– EL**  **2 (79%)**  **9. 4** 

**EL 2**  **(79%)**

**– EL**  **3 (80%)**  **19. 4** 

**Above EL**  **3 (>**  **80%) 2.**  **9**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **small gas­fired**  **steam**

**natural draft**  **commercial packaged**  **boiler models**  **considered in**  **the analysis**  **(** i.e.

**, models** 

**that had**  **values for**  **both E**  **T and**  **E C,**  **where E**  **T ≤**  **E C**  **) by**  **examining the**  **maximum,**

**minimum, and**  **average values**  **for combustion**  **efficiency and**  **thermal efficiency,**  **as well** 

**as the**  **difference between**  **the two**  **efficiencies. DOE**  **calculated the**  **average E**  **C by** 

**averaging the**  **combustion efficiencies**  **for all**  **models in**  **its database**  **that met**  **the analysis** 

**criteria (**  i.e.

**, models**  **that had**  **values for**  **both E**  **T and**  **E C,**  **where E**  **T <**  **E C**  **). DOE**  **also**

**calculated the**  **average E**  **T by**  **averaging the**  **thermal efficiencies**  **for these**  **boiler models.** 

**DOE calculated**  **the average**  **�E by**  **first taking**  **the difference**  **between E**  **C and**  **E T**  **(E C** 

**–**

**E T**  **), and**  **then finding**  **the average**  **of those**  **differences. The**  **minimum and**  **maximum**

**efficiencies correspond**  **to the**  **lowest and**  **highest efficiencies**  **listed for**  **the models** 

**considered. The**  **maximum and**  **minimum �Es**  **were the**  **largest and**  **smallest difference** 

**between combustion**  **and thermal**  **efficiency. Table**  **2.13 shows**  **the results**  **for this**  **analysis**

**for small**  **gas­fired steam**  **natural draft**  **commercial packaged**  **boilers.**

Table 2.13 Analysis for Small Gas­Fired Steam Natural Draft Commercial

Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 64**  **77. 43**  **3. 21** 

**Maximum (%)**  **83. 30**  **80. 40**  **5. 10** 

**Minimum (%)**  **80. 00**  **75. 40**  **1. 00** 

**Standard Deviation**  **(%) 0.**  **95 1.**  **44 1.**  **46**

**Count (Number**  **of Models**  **170 170**  **170**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 80­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 80**  **and 81**  **percent). Of**  **the 170**  **models analyzed,**  **111**

**models (65.2**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the**

**paragraph above.**  **Table 2.14**  **shows the**  **results of**  **this analysis**  **for minimally**  **compliant**

**small gas­fired**  **steam natural**  **draft commercial**  **packaged boilers.** 

**2­16**Table 2.14 Analysis for Minimally Compliant Small Gas­Fired Steam Natural Draft

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 12**  **76. 68**  **3. 44** 

**Maximum (%)**  **80. 90**  **78. 60**  **5. 10** 

**Minimum (%)**  **80. 00**  **75. 40**  **1. 80** 

**Standard Deviation**  **(%) 0.**  **23 0.**  **93 1.**  **05**

**Count (Number**  **of Models)**  **118 118**  **118**

2. 2.6.4 Small Oil­Fired Hot Water Commercial Packaged Boilers

**Small oil­fired**  **hot water**  **boilers have**  **an input**  **between 300**  **and 2,500**  **kBtu/h, are** 

**fueled by**  **oil, and**  **supply hot**  **water for**  **space heating.**  **Small oil­fired**  **hot water** 

**commercial packaged**  **boilers fall**  **under the**  **oil­fired commercial**  **packaged boilers** 

**equipment class,**  **whose Federal**  **energy conservation**  **standards, require**  **a combustion** 

**efficiency of**  **no less**  **than 83**  **percent. (42**  **U.S.C. 6313(a)(4)(D);**  **10 CFR**  **431.87(b))**

**ASHRAE Standard**  **90.1­2007 changes**  **the efficiency**  **metric for**  **these boilers**  **and requires** 

**a thermal**  **efficiency of**  **at least**  **82 percent.** 

Manufacturers. **Small oil­fired**  **hot water**  **commercial packaged**  **boilers comprise** 

**6. 8**  **percent of**  **the boiler**  **models DOE**  **analyzed. Major**  **manufacturers of**  **these boilers**  **are**

**Bosch Thermotechnology**  **Corp., Burnham**  **Commercial, Slant/Fin**  **Corp., and**  **Viessmann**

**Manufacturing Co.** 

Market Data. **Of the**  **110 small**  **oil­fired hot**  **water commercial**  **packaged boiler** 

**models listed**  **in DOE’s**  **database, 92**  **(83.6 percent)**  **had values**  **listed for**  **both thermal**  **and**

**combustion efficiency**  **with a**  **combustion efficiency**  **that was**  **greater than**  **or equal**  **to**

**thermal efficiency.**  **To examine**  **the relationship**  **between thermal**  **and combustion** 

**efficiency, and**  **to show**  **the current**  **efficiencies of**  **equipment on**  **the market,**  **DOE plotted** 

**the thermal**  **versus combustion**  **efficiency for**  **the small**  **oil­fired hot**  **water boilers** 

**considered in**  **the analysis**  **(Figure 2.4).** 

**2­17**82 84 86 88 90 92 94

78 80 82 84 86 88 90 92 94

Thermal Efficiency (%)CombustionEfficiency(%)

Series1 Current Federal Energy Conservation Standard Series3

Figure 2.4 Efficiency Ratings for Small Oil­Fired Hot Water Commercial Packaged

Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**small oil­fired**  **hot water**  **commercial packaged**  **boiler models**  **across several**  **thermal**

**efficiency ranges**  **(Table 2.15).**  **To determine**  **the percentage**  **of models**  **in each**  **efficiency**

**range, DOE**  **used the**  **method described**  **in section**  **2.2.6.1. The**  **shaded box**  **in Table**  **2.15**

**represents the**  **minimum thermal**  **efficiency level**  **specified in**  **ASHRAE Standard**  **90.1­**

**2007.**

Table 2.15 Distribution of Efficiency for Small Oil­Fired Hot Water Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(< 82%)**  **29. 3** 

**Baseline (82%)** 

**– EL**  **1 (84%)**  **31. 5** 

**EL 1**  **(84%)**

**– EL**  **2 (86%)**  **12. 0** 

**EL 2**  **(86%)**

**– EL**  **3 (88%)**  **20. 7** 

**Above EL**  **3 (>**  **88%) 6.**  **5**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **small oil­fired**  **hot**

**water commercial**  **packaged boiler**  **models considered**  **in the**  **analysis (**  i.e.

**, models**  **that**

**had values**  **for both**  **E T**  **and E**  **C where**  **E T**  **≤ E**  **C )**  **by examining**  **the maximum,**  **minimum,**

**and average**  **values for**  **combustion efficiency**  **and thermal**  **efficiency as**  **well as**  **the**

**difference between**  **the two**  **efficiencies. DOE**  **calculated the**  **average E**  **C by**  **averaging the** 

**combustion efficiencies**  **for all**  **boiler models**  **in its**  **database that**  **met the**  **analysis criteria.** 

**DOE also**  **calculated the**  **average E**  **T by**  **averaging the**  **thermal efficiencies**  **for these**  **boiler**

**models. DOE**  **calculated the**  **average �E**  **by taking**  **the difference**  **between E**  **C and**  **E T**  **(E C** 

**–**

**E T**  **) for**  **each model,**  **and then**  **finding the**  **average of**  **those differences.**  **The minimum**  **and**

**2­18 maximum**  **efficiencies correspond**  **to the**  **lowest and**  **highest efficiencies**  **listed for**  **the**

**models considered.**  **The maximum**  **and minimum**  **�Es correspond**  **to the**  **largest and** 

**smallest differences**  **between combustion**  **and thermal**  **efficiency. Table**  **2.16 shows**  **the**

**results for**  **this analysis**  **for small**  **oil­fired hot**  **water commercial**  **packaged boilers.** 

Table 2.16 Analysis for Small Oil­Fired Hot Water Commercial Packaged Boilers in

DOE’s Database

Category E

C E

T �E

**Average (%)**  **86. 07**  **83. 79**  **2. 28** 

**Maximum (%)**  **93. 30**  **92. 90**  **5. 30** 

**Minimum (%)**  **83. 20**  **79. 20**  **0**

**Standard Deviation**  **(%) 1.**  **83 2.**  **58 1.**  **24**

**Count (Number**  **of Models)**  **92 92**  **92**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 83­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 83**  **and 84**  **percent). Of**  **the 92**  **models analyzed,**  **seven**

**models (7.6**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the same**  **method described**  **in the** 

**paragraph above.**  **Table 2.17**  **shows the**  **results of**  **this analysis**  **of minimally**  **compliant**

**small oil­fired**  **hot water**  **commercial packaged**  **boilers.**

Table 2.17 Analysis of Minimally Compliant Small Oil­Fired Hot Water

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **83. 44**  **80. 69**  **2. 76** 

**Maximum (%)**  **83. 80**  **81. 80**  **4. 00** 

**Minimum (%)**  **83. 20**  **79. 20**  **2. 00** 

**Standard Deviation**  **(%) 0.**  **20 0.**  **77 0.**  **63**

**Count (Number**  **of Models)**  **7 7**  **7**

2. 2.6.5 Small Oil­Fired Steam Commercial Packaged Boilers

**Small oil­fired**  **steam boilers**  **have a**  **fuel input**  **at or**  **above 300**  **and less**  **than or** 

**equal to**  **2,500 kBtu/h,**  **are fueled**  **by oil,**  **and supply**  **steam for**  **space heating.**  **Small oil** 

**fired steam**  **commercial packaged**  **boilers fall**  **under the**  **oil­fired commercial**  **packaged**

**boilers equipment**  **class, whose**  **Federal energy**  **conservation standards,**  **a combustion** 

**efficiency of**  **no less**  **than 83**  **percent. (42**  **U.S.C. 6313(a)(4)(D);**  **10 CFR**  **431.87(b))**

**ASHRAE Standard**  **90.1­2007 changes**  **the efficiency**  **metric for**  **these boilers**  **and requires** 

**a thermal**  **efficiency of**  **at least**  **81 percent.** 

Manufacturers. **Small oil­fired**  **steam commercial**  **packaged boilers**  **comprise**

**11. 4**  **percent of**  **the boiler**  **models DOE**  **analyzed. Major**  **manufacturers of**  **these boilers** 

**are Burnham**  **Commercial, Peerless**  **Boilers, Slant/Fin**  **Corp., Smith**  **Cast Iron**  **Boilers, and** 

**Weil­McLain.**

**2­19**Market Data. **Of the**  **169 small**  **oil­fired steam**  **commercial packaged**  **boiler**

**models listed**  **in DOE’s**  **database, 154**  **(91.1 percent)**  **had values**  **listed for**  **both thermal** 

**and combustion**  **efficiency and**  **also had**  **a combustion**  **efficiency that**  **was greater**  **than or** 

**equal to**  **thermal efficiency.**  **To examine**  **the relationship**  **between thermal**  **and combustion** 

**efficiency and**  **to show**  **the current**  **efficiencies of**  **equipment on**  **the market,**  **DOE plotted** 

**the thermal**  **versus combustion**  **efficiency for**  **the small**  **oil­fired steam**  **boilers considered** 

**in the**  **analysis (Figure**  **2.5).**

82 83 84 85 86 87 88

79 80 81 82 83 84 85 86

Therm al Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.5 Efficiency Ratings for Small Oil­Fired Steam Commercial Packaged

Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**small oil­fired**  **steam commercial**  **packaged boiler**  **models across**  **several thermal** 

**efficiency ranges**  **(Table 2.18).**  **To determine**  **the percentage**  **of models**  **in each**  **efficiency**

**range, DOE**  **used the**  **method described**  **in section**  **2.2.6.1. The**  **shaded box**  **in Table**  **2.18**

**represents the**  **minimum thermal**  **efficiency level**  **specified in**  **ASHRAE Standard**  **90.1­**

**2007.**

Table 2.18 Distribution of Efficiency for Small Oil­Fired Steam Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(< 81%)**  **17. 5** 

**Baseline (81%)** 

**– EL**  **1 (82%)**  **24. 0** 

**EL 1**  **(82%)**

**– EL**  **2 (83%)**  **34. 4** 

**EL 2**  **(83%)**

**– EL**  **3 (85%)**  **18. 2** 

**Above EL**  **3 (>**  **85%) 5.**  **8**

**2­20**Efficiency Metric Comparison. **DOE further**  **analyzed the**  **small oil­fired**  **steam**

**commercial packaged**  **boiler models**  **considered in**  **the analysis**  **(** i.e.

**, models**  **that had** 

**values for**  **both E**  **T and**  **E C,**  **where E**  **T ≤**  **E C**  **) by**  **examining the**  **maximum, minimum,**  **and**

**average values**  **for combustion**  **efficiency and**  **thermal efficiency**  **as well**  **as the**  **difference**

**between the**  **two efficiencies.**  **DOE calculated**  **the average**  **E C**  **by averaging**  **the**

**combustion efficiencies**  **for all**  **boilers in**  **the I=B=R**  **directory that**  **met the**  **analysis**

**criteria. DOE**  **also calculated**  **the average**  **E T**  **by averaging**  **the thermal**  **efficiencies for** 

**these boiler**  **models. DOE**  **calculated the**  **average �E**  **by taking**  **the difference**  **between E**  **C**

**and E**  **T (E**  **C**

**– E**  **T )**  **for each**  **model and**  **then finding**  **the average**  **of those**  **differences. The** 

**minimum and**  **maximum efficiencies**  **correspond to**  **the lowest**  **and highest**  **efficiencies**

**listed for**  **the models**  **DOE considered.**  **The maximum**  **and minimum**  **�Es correspond**  **to**

**the largest**  **and smallest**  **differences between**  **combustion and**  **thermal efficiency.**  **Table**

**2. 19**  **shows the**  **results of**  **this analysis**  **for small**  **oil­fired, steam,**  **commercial packaged** 

**boilers.**

Table 2.19 Analysis for Small Oil­Fired Steam Commercial Packaged Boilers in

DOE’s Database

Category E

C E

T �E

**Average (%)**  **84. 71**  **82. 23**  **2. 48** 

**Maximum (%)**  **87. 50**  **85. 60**  **5. 30** 

**Minimum (%)**  **83. 00**  **79. 70**  **0. 00** 

**Standard Deviation**  **(%) 0.**  **98 1.**  **33 1.**  **17**

**Count (Number**  **of Models)**  **154 154**  **154**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 83­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 83**  **and 84**  **percent). Of**  **the 154**  **models analyzed,**  **48**

**models (31.2**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the**

**paragraph above.**  **Table 2.20**  **shows the**  **results of**  **this analysis**  **for minimally**  **compliant**

**small oil­fired**  **steam commercial**  **packaged boilers.** 

Table 2.20 Analysis for Minimally Compliant Small Oil­Fired Steam Commercial

Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **83. 53**  **81. 55**  **1. 97** 

**Maximum (%)**  **83. 90**  **83. 60**  **3. 60** 

**Minimum (%)**  **83. 00**  **79. 70**  **0**

**Standard Deviation**  **(%) 0.**  **18 1.**  **03 0.**  **95**

**Count (Number**  **of Models)**  **48 48**  **48**

2. 2.6.6 Large Gas­Fired Hot Water Commercial Packaged Boilers

**Large gas­fired**  **hot water**  **commercial packaged**  **boilers have**  **a fuel**  **input at**  **or**

**above 2,500**  **kBtu per**  **hour, are**  **fueled by**  **either natural**  **gas or**  **propane, and**  **supply hot** 

**2­21 water**  **for space**  **heating. Large**  **gas­fired hot**  **water commercial**  **packaged boilers**  **fall**

**under the**  **gas­fired commercial**  **packaged boilers**  **equipment class,**  **whose Federal**  **energy**

**conservation standards**  **require a**  **combustion efficiency**  **of no**  **less than**  **80.0 percent.**  **(42**

**U. S.C.**  **6313(a)(4)(C); 10**  **CFR 431.87(a))**  **ASHRAE Standard**  **90.1­2007 specifies**  **a more** 

**stringent combustion**  **efficiency of**  **no less**  **than 82**  **percent.**

Manufacturers. **Large gas­fired**  **hot water**  **commercial packaged**  **boilers comprise** 

**3. 9**  **percent of**  **the boiler**  **models analyzed**  **by DOE.**  **Major manufacturers**  **of large**  **gas**

**fired hot**  **water boilers**  **are Bosch**  **Thermotechnology Corp.,**  **DE Dietrich**  **(part of**  **the DE** 

**Dietrich Thermique**  **Group), Laars**  **Heating Systems**  **Company (a**  **subsidiary of**  **Bradford**

**White Corp.),**  **Slant/Fin Corp.,**  **and Viessmann**  **Manufacturing Co.** 

Market Data. **Because ASHRAE**  **Standard 90.1­2007**  **does not**  **change the** 

**efficiency metric**  **for large**  **gas­fired hot**  **water boilers,**  **DOE only**  **examined combustion** 

**efficiency when**  **analyzing the**  **market. Figure**  **2.6 shows**  **combustion efficiencies**  **and**

**input fuel**  **capacity for**  **these boiler**  **models.**

79 83 87 91 95 99

2000 2500 3000 3500 4000 4500 5000 5500 6000 6500

Fuel Input (kBtu/h)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.6 Combustion Efficiency Ratings for Large Gas­Fired Hot Water

Commercial Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **examined the**  **distribution of**  **efficiencies**

**of the**  **large gas­fired**  **hot water**  **boiler market**  **across various**  **combustion efficiency**  **ranges**

**(Table 2.21).**  **To determine**  **the percentage**  **of models**  **in each**  **efficiency range,**  **DOE used** 

**the method**  **described in**  **section 2.2.6.1.**  **The shaded**  **box in**  **Table 2.21**  **represents the** 

**minimum combustion**  **efficiency level**  **specified in**  **ASHRAE Standard**  **90.1­2007.**

**2­22**Table 2.21 Distribution of Efficiency for Large Gas­Fired Hot Water Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (E C ) Percentage of

Models (%)

**Below Baseline**  **(82%) 17.**  **0**

**Baseline (82%)** 

**– EL**  **1 (83%)**  **32. 1** 

**EL 1**  **(83%)**

**– EL**  **2 (84%)**  **28. 3** 

**EL 2**  **(84%)**

**– EL**  **3 (85%)**  **5. 7** 

**EL 3**  **(85%)**

**– EL**  **4 (95%)**  **11. 3** 

**Above EL**  **4 (95%)**  **5. 7** 

Combustion Efficiency Data. **DOE calculated**  **the average,**  **maximum, and** 

**minimum combustion**  **efficiencies of**  **the large**  **gas­fired hot**  **water commercial**  **packaged**

**boiler models**  **considered in**  **the analysis**  **(** i.e.

**, models**  **with E**  **C listed,**  **and if**  **E T**  **is listed,**  **E T** 

**≤ E**  **C ).**  **Table 2.22**  **shows the**  **average, maximum,**  **and minimum**  **combustion efficiencies** 

**for large**  **gas­fired hot**  **water commercial**  **packaged boilers**  **listed in**  **DOE’s database.**  **The**

**average E**  **C is**  **the average**  **combustion efficiency**  **for all**  **boilers considered**  **in the**  **analysis.**

**The maximum**  **and minimum**  **combustion efficiencies**  **are the**  **highest and**  **lowest**

**combustion efficiencies**  **listed for**  **the large**  **gas­fired hot**  **water commercial**  **packaged**

**boiler models**  **that DOE**  **analyzed.**

Table 2.22 Analysis for Large Gas­Fired Hot Water Commercial Packaged Boilers

in DOE’s Directory

Category E

C

**Average (%)**  **83. 57** 

**Maximum (%)**  **96. 80** 

**Minimum (%)**  **81. 00** 

**Standard Deviation**  **(%) 3.**  **44**

**Count (Number**  **of Models)**  **53**

2. 2.6.7 Large Gas­Fired Steam All Except Natural Draft Commercial

Packaged Boilers

**Large gas­fired**  **steam all**  **except natural**  **draft commercial**  **packaged boilers**  **have a** 

**fuel input**  **at or**  **above 2,500**  **kBtu/h, are**  **fueled by**  **either natural**  **gas or**  **propane, supply** 

**steam for**  **space heating,**  **and use**  **a draft**  **mechanism other**  **than natural**  **draft (**  e.g.

**, forced** 

**or induced**  **draft systems).**  **Large gas­fired**  **steam all**  **except natural**  **draft commercial** 

**packaged boilers**  **fall under**  **the gas­fired**  **commercial packaged**  **boilers equipment**  **class,**

**whose Federal**  **energy conservation**  **standards require**  **a combustion**  **efficiency of**  **no less** 

**than 80**  **percent. (42**  **U.S.C. 6313(a)(4)(C);**  **10 CFR**  **431.87(a)) ASHRAE**  **Standard 90.1­** 

**2007 changes**  **the efficiency**  **metric for**  **these boilers**  **and requires**  **a thermal**  **efficiency of** 

**at least**  **79 percent.** 

Manufacturers. **Large gas­fired**  **steam all**  **except natural**  **draft commercial** 

**packaged boilers**  **account for**  **7.1 percent**  **of the**  **boiler models**  **DOE analyzed.**  **Major**

**2­23 manufacturers**  **of these**  **boilers are**  **Burnham Commercial,**  **Peerless Boilers,**  **Smith Cast** 

**Iron Boilers,**  **and Weil­McLain.** 

Market Data. **Of the**  **158 small**  **gas­fired steam**  **all except**  **natural draft** 

**commercial packaged**  **boiler models**  **listed in**  **DOE’s database,**  **96 models**  **(60.8 percent)** 

**had values**  **listed for**  **both thermal**  **and combustion**  **efficiency and**  **also had**  **a combustion** 

**efficiency greater**  **than or**  **equal to**  **thermal efficiency.**  **To examine**  **the relationship** 

**between thermal**  **and combustion**  **efficiency and**  **to show**  **the current**  **efficiencies of** 

**products on**  **the market,**  **DOE plotted**  **the thermal**  **versus combustion**  **efficiency for**  **the**

**large gas­fired**  **steam all**  **except natural**  **draft commercial**  **packaged boiler**  **models**

**considered in**  **the analysis**  **(Figure 2.7).** 

79 80 81 82 83 84

78 79 80 81 82 83 84

Therm al Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.7 Efficiency Ratings for Large Gas­Fired Steam All Except Natural Draft

Commercial Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**large gas­fired**  **steam all**  **except natural**  **draft commercial**  **packaged boiler**  **models across** 

**several thermal**  **efficiency ranges**  **(Table 2.23).**  **To determine**  **the percentage**  **of models**  **in**

**each efficiency**  **range, DOE**  **used the**  **method described**  **in section**  **2.2.6.1. The**  **shaded box** 

**in Table**  **2.23 represents**  **the minimum**  **thermal efficiency**  **level specified**  **by ASHRAE** 

**Standard 90.1­2007.** 

**2­24**Table 2.23 Distribution of Efficiency for Large Gas­Fired Steam All Except Natural

Draft Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(79%) 17.**  **7**

**Baseline (79%)** 

**– EL**  **1 (80%)**  **20. 8** 

**EL 1**  **(80%)**

**– EL**  **2 (81%)**  **35. 4** 

**EL 2**  **(81%)**

**– EL**  **3 (82%)**  **3. 1** 

**EL 3**  **(82%)**

**– EL**  **4 (83%)**  **3. 1** 

**Above EL**  **4 (>**  **83%) 19.**  **8**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **large gas­fired**  **steam**

**all except**  **natural draft**  **commercial packaged**  **boiler models**  **considered in**  **the analysis** 

**(** i.e.

**, models**  **that had**  **values for**  **both E**  **T and**  **E C**  **where E**  **T ≤**  **E C**  **) by**  **examining the** 

**maximum, minimum,**  **and average**  **values for**  **combustion efficiency**  **and thermal** 

**efficiency, as**  **well as**  **the difference**  **between the**  **two efficiencies.**  **DOE calculated**  **the**

**average E**  **C by**  **averaging the**  **combustion efficiencies**  **for all**  **boiler models**  **in its**  **database**

**that met**  **the analysis**  **criteria. DOE**  **also calculated**  **the average**  **E T**  **by averaging**  **the**

**thermal efficiencies**  **for these**  **boiler models.**  **DOE calculated**  **the average**  **�E by**  **taking the** 

**difference between**  **E C**  **and E**  **T (E**  **C**

**– E**  **T )**  **for each**  **model, and**  **then finding**  **the average**  **of**

**those differences.**  **The minimum**  **and maximum**  **efficiencies correspond**  **to the**  **lowest and** 

**highest efficiencies**  **listed for**  **the models**  **considered. The**  **maximum and**  **minimum �Es** 

**correspond to**  **the largest**  **and smallest**  **differences between**  **combustion efficiency**  **and**

**thermal efficiency.**  **Table 2.24**  **shows the**  **results of**  **this analysis**  **for large**  **gas­fired steam** 

**all except**  **natural draft**  **commercial packaged**  **boilers.**

Table 2.24 Analysis for Large Gas­Fired Steam All Except Natural Draft

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **81. 73**  **80. 60**  **1. 13** 

**Maximum (%)**  **83. 70**  **83. 20**  **2. 30** 

**Minimum (%)**  **80. 70**  **78. 70**  **0. 20** 

**Standard Deviation**  **(%) 0.**  **98 1.**  **50 0.**  **67**

**Count (Number**  **of Models)**  **96 96**  **96**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 80­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 80**  **and 81**  **percent). Of**  **the 96**  **models analyzed,**  **four**

**models (4.2**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the**

**paragraph above.**  **Table 2.25**  **shows the**  **results of**  **this analysis**  **for minimally**  **compliant**

**large gas­fired**  **steam all**  **except natural**  **draft commercial**  **packaged boilers.** 

**2­25**Table 2.25 Analysis for Minimally Compliant Large Gas­Fired Steam All Except

Natural Draft Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 83**  **79. 43**  **1. 40** 

**Maximum (%)**  **80. 90**  **79. 90**  **1. 90** 

**Minimum (%)**  **80. 70**  **78. 80**  **1. 00** 

**Standard Deviation**  **(%) 0.**  **10 0.**  **56 0.**  **47**

**Count (Number**  **of Models)**  **4 4**  **4**

2. 2.6.8 Large Gas­Fired Steam Natural Draft Commercial Packaged Boilers

**Large gas­fired**  **steam natural**  **draft commercial**  **packaged boilers**  **have a**  **fuel input** 

**at or**  **above 2,500**  **kBtu/h, are**  **fueled by**  **either natural**  **gas or**  **propane, supply**  **steam for** 

**space heating,**  **and use**  **a natural**  **draft. Large**  **gas­fired steam**  **natural draft**  **commercial**

**packaged boilers**  **fall under**  **the gas­fired**  **commercial packaged**  **boilers equipment**  **class,**

**whose Federal**  **energy conservation**  **standards require**  **a combustion**  **efficiency of**  **no less** 

**than 80**  **percent. (42**  **U.S.C. 6313(a)(4)(C);**  **10 CFR**  **431.87(a))**

**ASHRAE Standard**  **90.1­2007 set**  **two different**  **thermal efficiency**  **levels for**  **this**

**equipment and**  **two effective**  **dates. The**  **first efficiency**  **level specified**  **in ASHRAE** 

**Standard 90.1­2007**  **for this**  **equipment class**  **includes a**  **77­percent thermal**  **efficiency**

**effective March**  **2, 2010.**  **The second**  **efficiency level**  **includes a**  **79­percent thermal** 

**efficiency effective**  **March 2,**  **2020.**

Manufacturers. **Large gas­fired**  **steam natural**  **draft commercial**  **packaged boilers** 

**account for**  **9.1 percent**  **of the**  **boiler models**  **DOE analyzed.**  **The major**  **manufacturers of** 

**these boilers**  **are Crown**  **Boiler, Peerless**  **Boiler, Dunkirk**  **Boilers, Pennco,**  **Utica Boilers,** 

**and Smith**  **Cast Iron**  **Boilers.**

Market Data. **Of the**  **157 models**  **of large**  **gas­fired steam**  **natural draft** 

**commercial packaged**  **boilers listed**  **in DOE’s**  **database, 123**  **(78.3 percent)**  **had values**  **for**

**both thermal**  **and combustion**  **efficiency, with**  **a combustion**  **efficiency greater**  **than or** 

**equal to**  **thermal efficiency.**  **To examine**  **the relationship**  **between thermal**  **and combustion** 

**efficiency, and**  **to show**  **the efficiencies**  **of products**  **on the**  **market, DOE**  **plotted the** 

**thermal versus**  **combustion efficiency**  **for the**  **large gas­fired**  **steam natural**  **draft**

**commercial packaged**  **boilers considered**  **in the**  **analysis. The**  **data points**  **in Figure**  **2.8**

**show that**  **few models**  **have a**  **thermal efficiency**  **below the**  **efficiency level**  **specified in** 

**ASHRAE Standard**  **90.1­2007, effective**  **March 2,**  **2010. However,**  **multiple models**  **have**

**an efficiency**  **level below**  **that specified**  **in ASHRAE**  **Standard 90.1­2007,**  **effective March** 

**2, 2020.** 

**2­26**79 80 81 82 83 84

75 76 77 78 79 80 81 82

Therm al Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level (2010)

ASHRAE 90.1­2007 Efficiency Level (2020)

Figure 2.8 Efficiency Ratings for Large Gas­Fired Steam Natural Draft Commercial

Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**large gas­fired**  **steam natural**  **draft commercial**  **packaged boiler**  **models across**  **several**

**thermal efficiency**  **ranges (Table**  **2.26). To**  **determine the**  **percentage of**  **models in**  **each**

**efficiency range,**  **DOE used**  **the method**  **described in**  **section 2.2.6.1.**  **The shaded**  **box in** 

**the table**  **represents the**  **minimum thermal**  **efficiency level**  **specified in**  **ASHRAE**

**Standard 90.1­2007,**  **effective March**  **2, 2020.** 

Table 2.26 Distribution of Efficiency for Large Gas­Fired Steam Natural Draft

Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(77%) 3.**  **3**

**Baseline (77%)** 

**– EL**  **1 (78%)**  **8. 9** 

**EL 1**  **(78%)**

**– EL**  **2 (79%)**  **45. 5** 

**EL 2**  **(79%)**

**– EL**  **3 (80%)**  **18. 7** 

**EL 3**  **(80%)**

**– EL**  **4 (81%)**  **16. 3** 

**Above EL**  **4 (>**  **81%) 7.**  **3**

Efficiency Metric Comparison. **DOE further**  **analyzed the**  **large gas­fired**  **steam**

**natural draft**  **commercial packaged**  **boiler models**  **that had**  **values for**  **both E**  **T and**  **E C** 

**where E**  **T ≤**  **E C**  **by examining**  **the maximum,**  **minimum, and**  **average values**  **for**

**combustion efficiency**  **and thermal**  **efficiency, as**  **well as**  **the difference**  **between the**  **two**

**efficiencies. DOE**  **calculated the**  **average E**  **C by**  **averaging the**  **combustion efficiencies**  **for**

**all boilers**  **in its**  **database that**  **met the**  **analysis criteria.**  **DOE also**  **calculated the**  **average**

**E T**  **by averaging**  **the thermal**  **efficiencies for**  **these boiler**  **models. DOE**  **calculated the** 

**average �E**  **by taking**  **the difference**  **between E**  **C and**  **E T**  **(E C** 

**– E**  **T )**  **for each**  **model, and** 

**then finding**  **the average**  **of those**  **differences. The**  **minimum and**  **maximum efficiencies** 

**2­27 correspond**  **to the**  **lowest and**  **highest efficiencies**  **listed for**  **the models**  **DOE considered.** 

**The maximum**  **and minimum**  **�Es correspond**  **to the**  **largest and**  **smallest differences** 

**between combustion**  **efficiency and**  **thermal efficiency.**  **Table 2.27**  **shows the**  **results for** 

**this analysis**  **for large**  **gas­fired steam**  **natural draft**  **boilers.**

Table 2.27 Analysis for Large Gas­Fired Steam Natural Draft Commercial

Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 85**  **78. 91**  **1. 94** 

**Maximum (%)**  **83. 70**  **81. 10**  **5. 10** 

**Minimum (%)**  **80. 00**  **75. 40**  **1. 00** 

**Standard Deviation**  **(%) 1.**  **01 1.**  **29 0.**  **69**

**Count (Number**  **of Models)**  **123 123**  **123**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 80­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 80**  **and 81**  **percent). Of**  **the 123**  **models analyzed,**  **73**

**models (59.3**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **the previous** 

**paragraph. Table**  **2.28 shows**  **the results**  **of this**  **analysis for**  **minimally compliant**  **large**

**gas­fired steam**  **natural draft**  **commercial packaged**  **boilers.**

Table 2.28 Analysis for Minimally Compliant Large Gas­Fired Steam Natural Draft

Commercial Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **80. 15**  **78. 10**  **2. 05** 

**Maximum (%)**  **80. 90**  **79. 40**  **5. 10** 

**Minimum (%)**  **80. 00**  **75. 40**  **1. 30** 

**Standard Deviation**  **(%) 0.**  **30 0.**  **78 0.**  **76**

**Count (Number**  **of Models)**  **73 73**  **73**

2. 2.6.9 Large Oil­Fired Hot Water Commercial Packaged Boilers

**Large oil­fired**  **hot water**  **commercial packaged**  **boilers have**  **a fuel**  **input at**  **or**

**above 2,500**  **kBtu/h, are**  **fueled by**  **oil, and**  **supply hot**  **water for**  **space heating.**  **Large oil** 

**fired hot**  **water commercial**  **packaged boilers**  **fall under**  **the oil­fired**  **commercial packaged** 

**boilers equipment**  **class, whose**  **Federal energy**  **conservation standards**  **require a** 

**combustion efficiency**  **of no**  **less than**  **83 percent.**  **(42 U.S.C.**  **6313(a)(4)(D); 10**  **CFR**

**431.87(b)) ASHRAE**  **Standard 90.1­2007**  **adopted a**  **more stringent**  **combustion efficiency** 

**of 84**  **percent.**

Manufacturers. **Large oil­fired**  **hot water**  **commercial packaged**  **boilers comprise** 

**1. 9**  **percent of**  **the boiler**  **models DOE**  **analyzed. Major**  **manufacturers are**  **Bosch**

**Thermotechnology Corp.,**  **Burnham Commercial,**  **DE Dietrich,**  **Slant/Fin Corp.,**  **and**

**Viessmann Manufacturing**  **Co.**

**2­28**Market Data. **Because ASHRAE**  **Standard 90.1­2007**  **does not**  **change the** 

**efficiency metric**  **for large**  **oil­fired hot**  **water commercial**  **packaged boilers,**  **DOE only** 

**examined combustion**  **efficiency when**  **analyzing the**  **market. Figure**  **2.9 shows**  **the**

**distribution of**  **combustion efficiencies**  **for commercial**  **boiler models**  **listed in**  **DOE’s**

**database.**

82 83 84 85 86 87 88 89CombustionEfficiency(%)

3000 3500 4000 4500

Fuel Input (kBtu/h) 2000 2500 5000 5500 6000 6500

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.9 Combustion Efficiency Ratings for Large Gas­Fired Hot Water

Commercial Packaged Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **examined the**  **distribution of**  **efficiencies**

**of the**  **large gas­fired**  **hot water**  **commercial packaged**  **boiler market**  **across various** 

**combustion efficiency**  **ranges (Table**  **2.29). To**  **determine the**  **percentage of**  **models in** 

**each efficiency**  **range, DOE**  **used the**  **method described**  **in section**  **2.2.6.1. There**  **is no** 

**shaded box**  **in the**  **table to**  **represent the**  **minimum efficiency**  **level specified**  **in ASHRAE** 

**Standard 90.1­2007,**  **because the**  **ASHRAE Standard**  **90.1­2007 level**  **is lower**  **than the** 

**combustion efficiency**  **of any**  **large oil­fired**  **hot water**  **boilers found**  **in DOE’s**  **database.**

**DOE was**  **not able**  **to identify**  **any large**  **gas­fired hot**  **water commercial**  **boilers currently** 

**available on**  **the market**  **that are**  **less efficient**  **than the**  **ASHRAE Standard**  **90.1­2007**

**level.**

**2­29**Table 2.29 Distribution of Efficiency for Large Gas­Fired Hot Water Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (E C ) Percentage of

Models (%)

**Below Baseline**  **(< 84%)**  **0**

**Baseline (84%)** 

**– EL**  **1 (86%)**  **48**

**EL 1**  **(86%)**

**– EL**  **2 (87%)**  **28**

**EL 2**  **(87%)**

**– EL**  **3 (88%)**  **0**

**Above EL**  **3 (>**  **88%) 24** 

Combustion Efficiency Data. **DOE calculated**  **the average,**  **maximum, and** 

**minimum combustion**  **efficiencies of**  **the large**  **oil­fired hot**  **water commercial**  **packaged**

**boiler models**  **considered in**  **the analysis**  **(** i.e.

**, models**  **with E**  **C listed,**  **and if**  **E T**  **is listed,**  **E T** 

**≤ E**  **C ).**  **Table 2.30**  **shows the**  **average, maximum,**  **and minimum**  **combustion efficiencies** 

**for large**  **oil­fired hot**  **water boilers**  **in DOE’s**  **database. The**  **average combustion** 

**efficiency is**  **the average**  **combustion efficiency**  **for all**  **boiler models**  **considered in**  **the**

**analysis. The**  **maximum and**  **minimum combustion**  **efficiencies are**  **the highest**  **and lowest** 

**combustion efficiencies**  **listed for**  **the large**  **oil­fired hot**  **water commercial**  **packaged**

**boilers that**  **DOE analyzed.** 

Table 2.30 Analysis for Large Oil­Fired Hot Water Commercial Packaged Boilers in

DOE’s Database

Category E

C

**Average (%)**  **86. 52** 

**Maximum (%)**  **88. 50** 

**Minimum (%)**  **85. 50** 

**Standard Deviation**  **(%) 1.**  **18**

**Count (Number**  **of Models)**  **25**

2. 2.6.10 Large Oil­Fired Steam Commercial Packaged Boilers

**Large oil­fired**  **steam commercial**  **packaged boilers**  **have a**  **fuel input**  **at or**  **above**

**2,500 kBtu/h,**  **are fueled**  **by oil,**  **and supply**  **steam for**  **space heating.**  **Large oil­fired**  **steam**

**commercial packaged**  **boilers fall**  **under the**  **oil­fired commercial**  **packaged boilers** 

**equipment class,**  **whose Federal**  **energy conservation**  **standards require**  **a combustion** 

**efficiency of**  **no less**  **than 83**  **percent. (42**  **U.S.C. 6313(a)(4)(D);**  **10 CFR**  **431.87(b))**

**ASHRAE Standard**  **90.1­2007 changes**  **the efficiency**  **metric of**  **these boilers**  **and requires** 

**them to**  **have a**  **thermal efficiency**  **of at**  **least 81**  **percent.**

Manufacturers. **Large oil­fired**  **steam commercial**  **packaged boilers**  **comprise 15** 

**percent of**  **the boilers**  **that DOE**  **analyzed. Major**  **manufacturers of**  **these boilers**  **are**

**Burnham Commercial,**  **Peerless Boilers,**  **Smith Cast**  **Iron Boilers,**  **and Weil­McLain.** 

Market Data. **Of the**  **242 large**  **oil­fired steam**  **commercial packaged**  **boilers listed** 

**in DOE’s**  **database, 202**  **(83.5 percent)**  **had values**  **for both**  **thermal and**  **combustion**

**efficiency, with**  **a combustion**  **efficiency greater**  **than or**  **equal to**  **the thermal**  **efficiency.**

**To examine**  **the relationship**  **between thermal**  **and combustion**  **efficiency, and**  **to show**  **the**

**2­30 current**  **efficiencies of**  **models on**  **the market,**  **DOE plotted**  **the thermal**  **versus combustion** 

**efficiency for**  **the large**  **oil­fired steam**  **boilers considered**  **in the**  **analysis (Figure**  **2.10).**

82 83 84 85 86 87

80 81 82 83 84 85 86 87

Thermal Efficiency (%)CombustionEfficiency(%)

Current Federal Energy Conservation Standard ASHRAE 90.1­2007 Efficiency Level

Figure 2.10 Efficiency Ratings for Large Oil­Fired Steam Commercial Packaged

Boiler Models in DOE’s Database

Distribution of Efficiencies. **DOE also**  **analyzed the**  **distribution of**  **efficiencies of** 

**large oil­fired**  **steam commercial**  **packaged boilers**  **across several**  **thermal efficiency** 

**ranges (Table**  **2.31). To**  **determine the**  **percentage of**  **models in**  **each efficiency**  **range,**

**DOE used**  **the method**  **described in**  **section 2.2.6.1.**  **There is**  **no shaded**  **box in**  **Table 2.31** 

**to represent**  **the thermal**  **efficiency level**  **specified in**  **ASHRAE Standard**  **90.1­2007,**

**because the**  **minimum thermal**  **efficiency level**  **set in**  **ASHRAE Standard**  **90.1­2007 is** 

**lower than**  **the thermal**  **efficiency of**  **any models**  **currently on**  **the market.** 

Table 2.31 Thermal Efficiency Distribution for Large Oil­Fired Steam Commercial

Packaged Boilers in DOE’s Database

Efficiency Range (E T ) Percentage of

Models (%)

**Below Baseline**  **(81%) 0.**  **0**

**Baseline (81%)** 

**– EL**  **1 (82%)**  **34. 2** 

**EL 1**  **(82%)**

**– EL**  **2 (83%)**  **25. 3** 

**EL 2**  **(83%)**

**– EL**  **3 (84%)**  **24. 8** 

**EL 3**  **(84%)**

**– EL**  **4 (86%)**  **15. 8** 

**Above EL**  **4 (>**  **86%) 0** 

Efficiency Metric Comparison. **DOE further**  **analyzed large**  **oil­fired steam** 

**commercial packaged**  **boiler models**  **considered in**  **the analysis**  **(** i.e.

**, models**  **that had** 

**values for**  **both E**  **T and**  **E C,**  **where E**  **T ≤**  **E C**  **) by**  **examining the**  **maximum, minimum,**  **and**

**average values**  **for combustion**  **efficiency and**  **thermal efficiency,**  **as well**  **as the**  **difference**

**between the**  **two efficiencies.**  **DOE calculated**  **the average**  **E C**  **by averaging**  **the**

**combustion efficiencies**  **for all**  **boiler models**  **in DOE’s**  **database that**  **met the**  **analysis**

**2­31 criteria.**  **DOE also**  **calculated the**  **average E**  **T by**  **averaging the**  **thermal efficiencies**  **for**

**these boilers.**  **DOE calculated**  **the average**  **�E by**  **taking the**  **difference between**  **E C**  **and E**  **T (E**  **C**

**– E**  **T )**  **for each**  **model, and**  **then finding**  **the average**  **of those**  **differences. The** 

**minimum and**  **maximum efficiencies**  **correspond to**  **the lowest**  **and highest**  **efficiencies**

**listed for**  **the models**  **considered. The**  **maximum and**  **minimum �Es**  **correspond to**  **the**

**largest and**  **smallest differences**  **between combustion**  **efficiency and**  **thermal efficiency.** 

**Table 2.32**  **shows the**  **results for**  **this analysis**  **for large**  **oil­fired steam**  **commercial**

**packaged boilers.** 

Table 2.32 Analysis for Large Oil­Fired Steam Commercial Packaged Boilers in

DOE’s Database

Category E

C E

T �E

**Average (%)**  **84. 30**  **82. 79**  **1. 52** 

**Maximum (%)**  **86. 30**  **85. 80**  **3. 60** 

**Minimum (%)**  **83. 20**  **81. 00**  **0. 20** 

**Standard Deviation**  **(%) 0.**  **96 1.**  **33 0.**  **69**

**Count (Number**  **of Models)**  **202 202**  **202**

**DOE also**  **examined the**  **thermal efficiency**  **values and**  **the difference**  **between**

**thermal and**  **combustion efficiency**  **for models**  **that minimally**  **complied with**  **the 83­** 

**percent combustion**  **efficiency Federal**  **energy conservation**  **standard (**  i.e., **equipment with** 

**combustion efficiency**  **between 83**  **and 84**  **percent). Of**  **the 202**  **models analyzed,**  **100**

**models (49.5**  **percent) were**  **classified as**  **minimally compliant.**  **DOE calculated**  **the**

**average, maximum,**  **and minimum**  **combustion efficiency**  **and thermal**  **efficiency as**  **well**

**as the**  **difference between**  **the two**  **efficiencies using**  **the method**  **described in**  **section**

**2. 2.1.**  **Table 2.33**  **shows the**  **results of**  **this analysis**  **for minimally**  **compliant large**  **oil­fired**

**steam commercial**  **packaged boilers.** 

Table 2.33 Analysis for Minimally Compliant Large Oil­Fired Steam Commercial

Packaged Boilers in DOE’s Database

Category E

C E

T �E

**Average (%)**  **83. 55**  **81. 89**  **1. 66** 

**Maximum (%)**  **83. 90**  **83. 50**  **2. 50** 

**Minimum (%)**  **83. 20**  **81. 10**  **0. 20** 

**Standard Deviation**  **(%) 0.**  **16 0.**  **63 0.**  **60**

**Count (Number**  **of Models)**  **100 100**  **100**

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