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

 EERE-2008-BT-STD-0013 COMMENT 22
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

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 EERE-2008-BT-STD-0013 COMMENT 22
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

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 EERE-2008-BT-STD-0013 COMMENT 22
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

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 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.33 Analysis for Minimally Compliant Large Oil­Fired Steam Commercial

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

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 EERE-2008-BT-STD-0013 COMMENT 22
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

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 EERE-2008-BT-STD-0013 COMMENT 22
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 AirConditioning 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

 EERE-2008-BT-STD-0013 COMMENT 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.

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 EERE-2008-BT-STD-0013 COMMENT 22
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 IndirectFired Water Heaters (January 2008 Edition).3 This database includes commercial

packaged boilers currently manufactured by both AHRI­member manufacturers and nonmember 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 Directorya as of January 2008

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

Holdings, Inc.)

AERCO 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.

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 EERE-2008-BT-STD-0013 COMMENT 22
2.2.1.3 Additional Manufacturers

DOE also reviewed the CSA­Internationalc and SCAQMDd 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, airconditioning, 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 EC=80%*

Oil­Fired Commercial Packaged Boilers EC=83%*

*EC 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

 EERE-2008-BT-STD-0013 COMMENT 22
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 Programg (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.

FEMP 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

 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.4 FEMP Recommended Thermal Efficiency Levels for Commercial

8 Packaged Boilers

Equipment Class Recommended Thermal Effic

(%)

iency (ET)

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

 EERE-2008-BT-STD-0013 COMMENT 22
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

 EERE-2008-BT-STD-0013 COMMENT 22
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

 EERE-2008-BT-STD-0013 COMMENT 22
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 (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 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 ET and EC and ET

≤ EC. For equipment classes with no efficiency metric change, DOE analyzed models with an EC value

listed. If an ET is listed, then ET ≤ EC.

2­10

 EERE-2008-BT-STD-0013 COMMENT 22
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 (ET) 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 ET and EC where ET ≤ EC) by examining the maximum, minimum, and

average values for EC and ET, as well as the difference between the two efficiencies (�E).

DOE calculated the average EC by averaging the combustion efficiencies for all boiler

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

the average ET by averaging the thermal efficiencies for these boiler models. DOE

calculated the average �E by first taking the difference between EC and ET (EC – ET) 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 EC ET �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 compliediwith 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 EC was between 80 and 81 percent,

and oil­fired commercial packaged boilers to be minimally compliant if EC was between 83 and 84

percent).

2­11

i

 EERE-2008-BT-STD-0013 COMMENT 22
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 EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
79

80

81

82

83

84

85

86

77 78 79 80 81 82 83 84 85 86

Thermal Efficiency (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 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 (ET) 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 ET and EC where ET ≤ EC) 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 EC by averaging the combustion efficiencies for all commercial packaged boiler

models in its database that met the analysis criteria. DOE also calculated the average ET

by averaging the thermal efficiencies for these boilers. DOE calculated the average �E by

taking the difference between EC and ET (EC – ET) for each boiler model, and then finding

2­13

 EERE-2008-BT-STD-0013 COMMENT 22
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 EC ET �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 EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
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 (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 Efficiency Level (2010)

ASHRAE90.1­2007 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).

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 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.12 Distribution of Efficiency for Small Gas­Fired Steam Natural Draft

Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (ET) 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 ET and EC, where ET ≤ EC) 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 EC by

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

criteria (i.e., models that had values for both ET and EC, where ET < EC). DOE also

calculated the average ET by averaging the thermal efficiencies for these boiler models.

DOE calculated the average �E by first taking the difference between EC and ET (EC –

ET), 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 EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.14 Analysis for Minimally Compliant Small Gas­Fired Steam Natural Draft

Commercial Packaged Boilers in DOE’s Database

Category EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
82

84

86

88

90

92

94

78 80 82 84 86 88 90 92 94

Thermal Efficiency (%)

C

o

m

b

u

stio

n

Efficie

n

c

y (%)

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 (ET) 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 ET and EC where ET ≤ EC) 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 EC by averaging the

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

DOE also calculated the average ET by averaging the thermal efficiencies for these boiler

models. DOE calculated the average �E by taking the difference between EC and ET (EC –

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

2­18

 EERE-2008-BT-STD-0013 COMMENT 22
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 EC ET �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 EC ET �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 oilfired 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.

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 EERE-2008-BT-STD-0013 COMMENT 22
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

Thermal Efficiency (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 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 (ET) 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

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 EERE-2008-BT-STD-0013 COMMENT 22
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 ET and EC, where ET ≤ EC) 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 EC by averaging the

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

criteria. DOE also calculated the average ET by averaging the thermal efficiencies for

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

and ET (EC – ET) 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 EC ET �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 EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
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 gasfired 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)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 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

 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.21 Distribution of Efficiency for Large Gas­Fired Hot Water Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (EC) 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 EC listed, and if ET is listed, ET

≤ EC). 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 EC 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 EC

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

 EERE-2008-BT-STD-0013 COMMENT 22
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

Thermal Efficiency (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 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.

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 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.23 Distribution of Efficiency for Large Gas­Fired Steam All Except Natural

Draft Commercial Packaged Boiler Models in DOE’s Database

Efficiency Range (ET) 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 ET and EC where ET ≤ EC) 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 EC by averaging the combustion efficiencies for all boiler models in its database

that met the analysis criteria. DOE also calculated the average ET by averaging the

thermal efficiencies for these boiler models. DOE calculated the average �E by taking the

difference between EC and ET (EC – ET) 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 EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.25 Analysis for Minimally Compliant Large Gas­Fired Steam All Except

Natural Draft Commercial Packaged Boilers in DOE’s Database

Category EC ET �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

 EERE-2008-BT-STD-0013 COMMENT 22
79

80

81

82

83

84

75 76 77 78 79 80 81 82

Thermal Efficiency (%)

Combustion Efficiency (%)

Current Federal Energy Conservation Standard ASHRAE90.1­2007 Efficiency Level (2010)

ASHRAE90.1­2007 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 (ET) 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 ET and EC

where ET ≤ EC 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 EC by averaging the combustion efficiencies for

all boilers in its database that met the analysis criteria. DOE also calculated the average

ET by averaging the thermal efficiencies for these boiler models. DOE calculated the

average �E by taking the difference between EC and ET (EC – ET) for each model, and

then finding the average of those differences. The minimum and maximum efficiencies

2­27

 EERE-2008-BT-STD-0013 COMMENT 22
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 EC ET �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 EC ET �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 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 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

 EERE-2008-BT-STD-0013 COMMENT 22
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

89

C

o

m

b

u

stio

n

Efficie

n

c

y (%)

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

 EERE-2008-BT-STD-0013 COMMENT 22
Table 2.29 Distribution of Efficiency for Large Gas­Fired Hot Water Commercial

Packaged Boiler Models in DOE’s Database

Efficiency Range (EC) 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 EC listed, and if ET is listed, ET

≤ EC). 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 EC

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

 EERE-2008-BT-STD-0013 COMMENT 22
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 (%)

C

o

m

bustion Efficiency (%)

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 (ET) 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 ET and EC, where ET ≤ EC) 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 EC by averaging the

combustion efficiencies for all boiler models in DOE’s database that met the analysis

2­31

 EERE-2008-BT-STD-0013 COMMENT 22
criteria. DOE also calculated the average ET by averaging the thermal efficiencies for

these boilers. DOE calculated the average �E by taking the difference between EC and ET

(EC – ET) 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 EC ET �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 EC ET �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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 EERE-2008-BT-STD-0013 COMMENT 22
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Determine Efficiency of Commercial Space Heating Boilers. 2007.

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3 Institute of Boilers and Radiation Manufacturers (I=B=R). 2008. I=B=R Ratings for

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<www.gamanet.org/gama/inforesources.nsf/vAttachmentLaunch/E9E5FC7199EBB1BE8

5256FA100838435/$FILE/01­08_CBR.pdf>

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<www.abma.com/commercialSystems.html>

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<www.pge.com/includes/docs/pdfs/mybusiness/energysavingsrebates/rebatesincentives/0

8boilerswaterheating.pdf>

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 EERE-2008-BT-STD-0013 COMMENT 22
11 San Diego Gas & Electric Company. 2008 San Diego Gas & Electric Express

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<www.sdge.com/esc/docs/ExpressEfficiency_RebateForm.pdf>

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