FAQ about The Program

What must I have to run this BOP program?

This program is designed to provide the maximum results with a minimum of requirements. However, there are some absolute minimum needs! First, you must be able to measure excess oxygen or CO2 at the stack along with temperatures. If you do not now have this capability you should consider buying or borrowing or renting a portable gas analyser . Quite simply, if you are not prepared to invest in this capability you have to accept that you are not really interested in improving your results!

We have an Efficiency Analyser, why do we need boilerOptimizer?

The efficiency calculated by most analysers does not adjust for humidity or radiation losses nor do they provide for actual fuel analyses. They only provide a spot reading and do not create economic values or statistical analysis and projections. They are a great starting point but BOP will take you to the next level of optimization.

Why is the program running as a text only DOS version?

The program is currently a DOS text program because this is extremely efficient. It looks old fashioned and by current standards, not very pretty but the same computations running under a fancy graphic interface could be about 30-50 MB. This would not be viable to download a DEMO version and we would be faced with snail mailing CDs all over the world. A fancy interface would not only be slower but will not improve the INFORMATION and RESULTS one iota! Lets keep our priorities straight!

How accurate are the computed Steam Tables?

The steam table equations are of professional main frame quality and are quite complex and sufficiently accurate but if you compare them with the published tables, you may find they don't agree to 5 or 6 significant figures. However, since your instruments are unlikely to be more accurate than 3 significant figures, we are totally comfortable with our tables! These are the only steam tables we have found online that covers all superheated conditions as well as saturated.

Why do we need to measure the Input/Output Efficiency?

The Loss method is incredibly simple, you just need the fuel chemistry, the stack CO2 and temperature. It's quick and useful. That's why everyone uses it, BUT bottom line budgets depend on the actual gallons of fuel purchased and the real number of pounds of steam generated! Because of normal instrumentation discrepancies, the Loss method is almost always optimistic about the boiler performance. The Input/Output method is complex and difficult to calculate but it does relate real pounds of fuel with real pounds of steam. Our concept is that you need an accurate measurement tool before you can reliably improve the performance. Optimizer is unique in using the two methods to confirm the validity and accuracy of your data.

How do we compensate for rain on an exposed boiler?

If your boiler is outside, exposed to to the elements, we can compensate for cold air, even strong winds but if it's raining, all bets are off!! We can't measure or estimate the radiation and convection losses in rain. This could add up to an error of several % points which is significant. Wait for a better day!

The radiation and convection loss uses the standard ABMA (American Boiler Manufacturers Association) estimate for average boilers. It is based on the current load and the design values and makes a number of assumptions about insulation, exposed surfaces etc. but experience has shown this computed value is adequate for our purposes and cannot be improved on with any reasonable amount of additional measurements or calculations. We do provide for estimating the correction for outside exposure but again you need to make some reasonable guesses as to average skin temperature etc.

We can't measure or estimate the steam used to atomize the fuel oil!

We've never seen a plant that actually measures this. However, experience says, "lets just ignore it". In the grand scheme of things the overall affect on efficiency is negligible. Since there is no change of state through the boiler, there is no significant heat change.

We have a Hot Water "Boiler", will Optimizer work?

We now have a new Hot Water specific version. Because the variables on a HW system are somewhat limited, the program will not provide as many possible solutions but it is designed to meet the needs of the less sophisticated user who may not have as much system information as available in a higher rated Steam plant.

We are burning Coke Oven Gas,

The current version allows using Coke Oven Gas but because of the potentially complicated fuel composition we do not yet have really good correlation data. If you wish, the program will compute a theoretical BTU content of the gas assuming all the other values are correct. Unless you have on-line gas composition metering, this may be the best available data.

Do you recommend the ORSAT analyzer?

The ASME recommended instrumentation for efficiency testing includes an ORSAT gas analyzer. In the real world, we believe this finicky, glass device is best relegated to the laboratory. Newer, digital, solid state or rugged industrial gas measurement devices can provide comparable data much easier and with suitable accuracy. Of course, if you have one, it's clean and functioning with fresh chemicals, by all means use it until you can justify easier to use equipment. Bararach the primary company in this field still has it's liquid Fryrite devices for O2 and CO2 . They are inexpensive and reliable.

Will the Optimizer recommend HOW to increase efficiency?

The current version is not intended to provide specific recommendations on YOUR ACTION PLAN from the efficiency data generated. This program is intended as a powerful Diagnostic Measurement TOOL that will give you the information to reliably quantify your options. By comparing the performaance curves of all of your boilers it will be clearly indicated how to maximise overall performance and minimize costs and GHG production. If you are unable to consistantly achieve the improved conditions you desire, the program will provide potential budget savings available to finance new instrumentation, burners and/or control systems.

You may consider reducing excess air, recovering radiation losses by pulling combustion air from the ceiling, reducing radiation losses with additional insulation, you may consider reducing operating pressure or changing which boiler is best on Base load etc The program will show you the gains that are potentially available but other reference material or a local professional consultant should be consulted to develop a plan.

Who created boilerOptimizer?

The primary creator of the boilerOptimizer is John Souvage. With a mechanical engineering background, John's career includes over 20 years as a staff consultant in fuel treatments and energy systems with one of the world's primary water treatment companies. Experience varied from the smallest firetube heating boilers to being the water treatment specialist on site for the commissioning of both of the Tar Sands boiler plants to providing computed assisted energy audits at several different provincially owned 100+MW power generation plants. John was an NACE qualified corrosion expert and was a world recognized specialist in oil refinery crude unit problems. He has taught and lectured on both corrosion engineering and energy computation at several universities and colleges. His energy audit computer programs were adopted and used by many divisions and countries within the water treatment company. John now owns and runs a computer based communication company in Burlington Ontario Canada.