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Boiler Sizing

The boiler output is based on the total heat losses for the building
plus hot water boiler power.
Other additional items that can be considered are; heater battery
outputs and other equipment that require heat.

For details of Boiler Power for Hot Water cylinder see Hot and Cold
water section Hot water generation & storage page 2.

Boiler Output (kW) = Heat Loss (kW) + Boiler


Power for HW cylinder (kW)

Boiler Margin.

It is useful to add a margin to the previous figure for;

1. In case of future extension.


2. Quick heat up when the system is cold.
3. In case of mistakes in heat loss calculations.
4. Loss of efficiency later in boiler life.

We could add between 15% and 33% as a boiler margin.


A large margin means the boiler is less efficient since it is firing
for less time.
The more time a boiler sits idle with a full capacity of hot water,
the more heat is lost up the flue and to a lesser extent from the
casing.
A suitable margin for most projects is 20% margin.

Total Boiler Output (kW) = Heat Loss (kW) + Boiler


Power for HW cylinder (kW) + 20% margin.

Note:
In most cases a margin has already been added to the heat loss to size
heat emitters.
It should be remembered that if this margin is 10% and a further 20%
margin is added for boiler sizing then the net resultant margin is 32%.
In continuously operated heating systems such as hospitals, a smaller
margin is acceptable since the system is not heated from cold each
morning.

Multiple Boiler Installations

In the past if two boilers were to be installed, each one was sized
at 2/3rds of the total capacity.
This overall margin of 33% is on the high side so a lower margin is
more acceptable.
A multiple boiler installation is a more efficient method of
providing heating since the more boilers that are installed the
more they will operate at full load when switched on.

Recommendations

CIBSE guide F (2002) section 10.1.2.2 and BSRIA Guidance Note


12/97 Oversized Heating Plant gives details of plant sizing.

As a guide to boiler capacity (heating load) the following yard


sticks can be used; 90 W/m2 for offices and industrial
buildings, 110 W/m2 for retail, health care and education
establishments.

Also for Hot Water calorifier sizing the following yard sticks can be
used; 4 l/person for offices, retail, education and restaurant
establishments, 23 l/person for hotels, 33 l/person for health care.

Other considerations for oversizing are;

1. Oversizing boilers is a greater capital cost.


2. Seasonal efficiency will be less is boilers are oversized.
3. Oversizing of control valves means that they dont
control the flow of water effectively.
4. Oversizing pumps means that they consume
more electricity than is necessary.
5. Also oversizing pumps means that it is more difficult to
control the water flow.
6. Pumps that are too large will not be operating at the
most efficient part of the characteristic curve.
7. Pipe heat losses are increased.
8. Oversizing heat emitters mean that the system is more
difficult to control with temperature sensors since the
room temperature will drift easily beyond the set point.
9. The heat gains from; lights, people and machinery will
offset the heat loss in a building.
This is not usually considered when calculating boiler
outputs but helps to reduce the amount of heat required
in winter time.

Plant Size Ratio

CIBSE guide B1 (2002) section 4.7 gives details of Plant Size Ratio
(PSR).

This is defined as; PSR = installed heat emission / design


heat loss

Factors for PSR of between 1.2 and 2.0 are common.

A building with low thermal inertia heats up more quickly than


one with high thermal inertia and therefore a lower plant size ratio
may be used.

The optimum plant size ratio is a compromise between the


following factors;
1. occupancy pattern.
2. pre-heat time.
3. thermal response of the building.
4. greater capital cost and maintenance cost.
5. stability of controls..
6. seasonal efficiency.
Blog
HVAC Maintenance Checklist: Air-Cooled Chiller
Inspection
Comments Closed
In HVAC,chillers are an important component in the cooling systems . The chiller removes
warmth from the air, and can also be used for the purposes of cooling down equipment or
machines inindustrial buildings or medical facilities.
We previously posted an article on how to keep your water-cooled chiller running efficiently, but
what about air-cooled chillers? If you have a packaged air-cooled chiller then the maintenance
tasks will differ from a water-cooled unit.
Were offering a detailed list of the maintenance tasks we complete for each part when we
perform routine maintenance work for air-cooled chillers.
Air-Cooled Chiller Inspection and Maintenance Checklist(HVAC);
1) Water inlet and outlet
Inspect and check for leaks

2) Sump
Clean and inspect for corrosion

3) Cooling Coil
Inspect and clean surfaces
Comb bent fins
Check for leaks and corrosion

4) Zone Control Actuators


Inspect operation
Clean surfaces
Make adjustments as needed

5) Compressor
Check refrigerant charge
Check crankcase heater
Check for oil and refrigerant leaks
Check oil levels and change oil as needed
Check for vibration
Observe the operating temperatures

6) Condenser Coil
Clean fin surfaces and comb bent fins
Check for leaks or corrosion

7) Condenser Fan
Clean any dirt accumulation
Lubricate bearings and check for wear
Check drive couplings and belts; adjust tightness of belts if necessary

8) Electrical Disconnect
Inspect and clean contacts
Check for proper operation

9) Exhaust Air Damper


Check for proper operation
Adjust and calibrate
Lubricate bearing

10) Return Air Damper


Check for proper operation
Adjust and calibrate
Lubricate bearings

11) Fresh Air Damper (Economizer)


Check for proper operation
Adjust and calibrate
Lubricate bearings

12) Filter Dryer


Replace filters as needed
How often should you perform a full maintenance inspection on a
chiller?
Using the checklist above, we recommend a complete checkup 4 times per year for chillers that
are in use all year long, or 2 times per year for chillers that are in use during the cooling season
only.
A check-up on your chiller can save on operating costs

Chillers are expensive to purchase so its a good idea to perform preventative maintenance on a
regular basis to prevent equipment breakdowns and extend the lifespan of the equipment.
Chillers often require more energy use than other pieces of heating and cooling equipment. By
keeping up on routine inspections and adjustments you can improve the efficiency of your
chiller and help keep your energy costs under control.

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