Boiler Sizing Calculator

Boiler Sizing Calculator – Heating Load & Cost Estimator

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Boiler Sizing Calculator – Heating Load, Flow, Cost & Report
Heating Systems Guide

Boiler Sizing Calculator — What It Is, How It Works, and How to Use It (with a Full Worked Example)

This calculator estimates boiler capacity for hot-water heating. It converts your zone areas, ventilation targets, and design allowances into a clear recommendation: peak kW/MBH, hot-water flow, boiler count & size (N or N+1) with a fast cost & fuel snapshot. SI/Imperial toggles, sector presets, and standards hints are baked in.

1) What this calculator does

  • Segments your building (open office, conference, lobby, wards, classrooms, etc.).
  • Applies heating densities (W/m²) or your direct overrides (kW/MBH).
  • Computes ventilation heating from ACH × volume with user-set indoor/outdoor design temperatures.
  • Rolls in diversity, distribution losses, and safety to find a robust peak kW.
  • Derives hot-water flow from ΔT; recommends boiler count & size (N or N+1).
  • Estimates budget cost (equipment → installed → with markup) and annual fuel usage.
  • Outputs a clean HTML report with KPIs, tables, and change log (print-ready).
Good to know: Presets (Residential, Commercial, Education, Healthcare, Hospitality, Retail/Warehouse, Public/Civic) auto-seed realistic W/m² and ACH guidance that you can fine-tune.

2) How the math works (short version)

  1. Segment loads Qi = Ai × qW/m² / 1000 kW, or enter overrides in kW/MBH. Sum: Qint = ΣQi.
  2. Ventilation heating (ACH) Qvent,i ≈ ρ × (A × H) × ACH / 3600 × cp × ΔTair kW, with ρ≈1.2 kg/m³, cp≈1.005 kJ/kg·K, and ΔTair=Tindoor−Toutdoor.
  3. Allowances Qbase = Qint + Qvent + Qproc → Diversity → Distribution losses → Safety → Qpeak.
  4. Hot-water flow SI: L/s = Q(kW) / (4.186 × ΔT[K]); IP: gpm = 2 × MBH / ΔT[°F].
  5. Selection If N+1: (n−1) × size ≥ Qpeak.
  6. Fuel & cost Fuel power at average: Qpeak/η × loadFactor → kWh/year → tariff; Cost = installed kW × unit rate × install factor × (1+markup).
Full methodology, symbols & unit math

The article uses the same detailed methodology as the calculator’s “Methodology” panel. Standards notes are shown as “Values derived from <Standard> (user must verify).”

3) How to use it (step-by-step)

Select a standard & region. Pick CIBSE/EN/ASHRAE/ISHRAE profile and India/US/UK for currency & seed unit rates.
Set strategy. Choose climate, operating hours, water temps (e.g., 80/60 °C), and boiler core (condensing/non-condensing, electric, biomass).
Load your segments. Use a preset (e.g., “Commercial → Open Office”) or “Add Empty Segment.” Enter area, W/m², overrides, height, and ACH for ventilation.
Allowances. Adjust diversity, distribution losses and safety to your practice.
Selection & costing. Choose N or N+1, optional preferred size, and refine unit rate / install factor / markup / η / hours / tariff.
Calculate & report. Click Calculate to see KPIs, table and chart. Use Generate Report for a print-ready HTML report.

Related tools: You might also like Cooling Load Calculator, Duct Sizing Calculator, Pipe Design Calculator, and Psychrometrics – Moist Air Guide.

4) Worked example — Office floor (full calculation)

Goal: Size a hot-water boiler plant for an office floor with open office, conference room and lobby. SI math shown with key IP equivalents.

Inputs & assumptions

  • Indoor/Outdoor: 21 °C inside, 0 °C outside (ΔTair = 21 K)
  • Hydronic temps: 80 → 60 °C (ΔT = 20 K)
  • Allowances: Diversity 0.90; Distribution losses 5%; Safety 10%
  • Process/DHW: 10 kW
  • Ventilation basis: ACH per segment; ρ=1.2 kg/m³, cp=1.005 kJ/kg·K; ceiling height 3.2 m
  • Costing (India): Unit rate ₹3,000/kW; install ×1.5; markup 10%
  • Fuel & use: Condensing gas η=0.95; 2,500 h/year; avg load factor 0.55; tariff ₹8/kWh
  • Selection: N+1 redundancy
SegmentArea (m²)Heating (W/m²)OverridesHeight (m)ACH
Open Office600603.21.0
Conference200903.21.5
Lobby1001203.22.0

Step-by-step math

  1. Segment heating (W/m² → kW)
    Open Office: 600×60/1000 = 36.00 kW
    Conference: 200×90/1000 = 18.00 kW
    Lobby: 100×120/1000 = 12.00 kW
    Internal sub-total = 66.00 kW
  2. Ventilation heating (ACH per segment) with ρ=1.2, cp=1.005, ΔTair=21 K, height 3.2 m.
    Formula: kW = ρ × (A×H) × ACH / 3600 × cp × ΔTair
    • Open Office: V=600×3.2=1,920 m³ → ṁ=1.2×1920×1/3600=0.64 kg/s → 0.64×1.005×21 = 13.51 kW
    • Conference: V=200×3.2=640 m³ → ṁ=1.2×640×1.5/3600=0.32 kg/s → 0.32×1.005×21 = 6.75 kW
    • Lobby: V=100×3.2=320 m³ → ṁ=1.2×320×2/3600≈0.213 kg/s → 0.213×1.005×21 ≈ 4.50 kW
    Ventilation total = 24.76 kW
  3. Allowances → Peak
    Qbase = 66.00 + 24.76 + 10.00 = 100.76 kW
    Diversity: Q′ = 100.76 × 0.90 = 90.684 kW
    Distribution: Q″ = 90.684 × 1.05 = 95.218 kW
    Safety: Qpeak = 95.218 × 1.10 = 104.74 kW
  4. Convert & flow
    MBH: 104.74 × 3.412 = 357.39 MBH
    Flow (SI): L/s = 104.74 / (4.186×20) = 1.251 L/s
    Flow (IP): ΔT=36 °F → gpm = 2 × 357.39 / 36 = 19.86 gpm
  5. Boiler selection (N+1)
    Choose 3 × 60 kW. Check: (3−1) × 60 = 120 kW ≥ 104.74 kW
    Installed nameplate = 180 kW.
  6. Budget cost
    Equipment = 180 × ₹3,000 = ₹540,000
    Installed = ×1.5 = ₹810,000
    With markup (10%) = ₹810,000 × 1.10 = ₹891,000
  7. Annual fuel (condensing η=0.95, 2,500 h/yr, load 0.55, tariff ₹8/kWh)
    Fuel kW at average = (104.74/0.95) × 0.55 = 60.64 kW
    Annual kWh = 60.64 × 2,500 = 151,597 kWh
    Fuel cost ≈ ₹1,212,779 / year

Peak Heating

104.74 kW (357.39 MBH)

HW Flow

1.251 L/s (19.86 gpm)

Recommended Plant

3 × 60 kW (N+1)

Budget Installed

₹891,000

Segment breakdown (kW)

Bars show segment heating (W/m² basis). Ventilation values are listed in the table below.

SegmentArea (m²)Heating (kW)ACH Vent (kW)
Open Office600.036.0013.51
Conference200.018.006.75
Lobby100.012.004.50
Totals66.0024.76

Use in the calculator: Enter the same segments, set ACH-based ventilation, allowances, 80/60 °C water, choose N+1 and India pricing. Click Calculate → the KPIs will match these numbers. Then Generate Report for a print-ready sheet.

5) Notes, tips & references

  • Validation: Always sanity-check W/m² seeds against envelope U-values, infiltration, occupancy and internal gains. Presets are starting points.
  • Ventilation: If your jurisdiction mandates L/s·person or L/s·m² (e.g., CIBSE/ASHRAE/ISHRAE), convert to ACH or compute heating kW directly and enter as a manual ventilation value.
  • Hydronic ΔT: 20 K is common for radiators/fan-coils; radiant floors often run lower supply temps—check emitter selection.
  • N+1 choices: Three smaller modular boilers often improve turndown and serviceability versus two larger units.
  • Budgeting: Unit rate and efficiency are planning values—verify against vendor submittals and seasonal performance.
Citations (highlighted):
  • CIBSE Guide A (Heating), EN 12831 (Heat Load Calculation)
  • ASHRAE Fundamentals (Heating), ISHRAE Handbook (India)
  • BS 6644 for gas-fired hot-water boilers; IBR / ASME BPVC for construction/compliance

Values derived from <Standard>, clause ranges vary; users must verify against current editions and local codes.

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