​Boiler Tune Up: (including Burner Inspection)

Implementation: Tune-up Requirements Q25: What is a tune-up?A. A tune-up consists of the actions defined in section 63.11223(b)
Inspect the burner, as applicable, and clean/replace any components of the burner as necessary.
  Inspect the flame pattern, as applicable, and adjust the burner to optimize the flame pattern, consistent with the manufacturer’s specifications, if available.
  Inspect the system controlling the air-to-fuel ratio, as applicable, and ensure that it is correctly calibrated and functioning properly.
  Optimize total emissions of CO, consistent with the manufacturer’s specifications, if available, and any applicable nitrogen oxide requirements.
​  Measure the concentrations in the effluent stream of CO in parts per million, by volume, and oxygen in volume percent, before and after the adjustments are made (measurements may be either on a dry or wet basis, as long as it is the same basis before and after the adjustments are made).
  Maintain an onsite report with the concentrations of CO in the exhaust gas in parts per million, by volume, and oxygen in volume percent, measured at high fire or typical operating load, measured before and after the tune-up of the boiler, a description of any corrective actions taken as a part of the tune-up of the boilerand the type and amount of fuel used over the 12 months prior to the tune-up of the boiler if the unit was capable of using more than one fuel during that period.[See 40 CFR § 63.11223(b)]

Energy assessments:

Existing oil, biomass, and coal-fired boilers with a design heat input capacity of 10 MMBtu/hr or greater must conduct a one-time energy assessment performed by a qualified energy assessor by March 21, 2014. An energy assessment completed on or after January 1, 2008, that meets or is amended to meet the energy assessment requirements of the rule, satisfies the energy assessment requirement. Energy assessor approval and qualification requirements are waived in instances where past or amended energy assessments are used to meet the energy assessment requirements. A facility operating under an energy management program compatible with ISO 50001 that includes affected units also satisfies the energy assessment requirement.

The energy assessment must include the following 7 items. The on-site technical hours required, as specified in Table 1 below, are appropriate for the extent of the evaluation for items 1) through 4).

1. A visual inspection of the boiler system (e.g. cracks, corrosion, leaks, insulation);

2. An evaluation of operating characteristics of the affected boiler systems, specifications of energy use systems, operating and maintenance procedures, and unusual operating constraints;

3. An inventory of major systems consuming energy (i.e., energy use systems) from affected boiler(s) and which are under the control of the boiler owner or operator;

4. A review of available architectural and engineering plans, facility operation and maintenance procedures and logs, and fuel usage;

5. A list of major energy conservation measures that are within the facility’s control;
6. A list of the energy savings potential of the energy conservation measures identified; and

7. A comprehensive report detailing the ways to improve efficiency, the cost of specific improvements, benefits, and the time frame for recouping those investments.

Energy Use Systems: The energy assessment applies to the boilers and their associated components (i.e., the boiler system), and their energy use systems that meet certain energy production thresholds as identified in Table 1 below.

  •   Boiler system means the boiler and associated components, such as, the feedwater systems, combustion air systems, fuel systems (including burners), blowdown systems, combustion control systems, steam systems, and condensate return systems, directly connected to and serving the energy use systems.

  •   Energy use system includes the following systems located on the site of the affected boiler: 1) process heating; compressed air systems; machine drive (motors, pumps, fans); process cooling; facility heating, ventilation, and air conditioning systems; hot heater systems; building envelope, and lighting; or 2) other systems that use steam, hot water, process heat, or electricity, provided by the affected boiler. Energy use systems are only those systems using energy clearly produced by affected boilers.

  •   The on-site energy use system(s), serving as the basis for the percent of affected boiler(s) energy production required to be evaluated, as identified in Table 1 below, may be segmented by production area or energy use area as most logical and applicable to the specific facility being assessed (e.g, product x manufacturing area, product y drying area, building z).