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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).
2) How the math works (short version)
- Segment loads
Qi = Ai × qW/m² / 1000
kW, or enter overrides in kW/MBH. Sum:Qint = ΣQi
. - 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. - Allowances
Qbase = Qint + Qvent + Qproc
→ Diversity → Distribution losses → Safety →Qpeak
. - Hot-water flow
SI:
L/s = Q(kW) / (4.186 × ΔT[K])
; IP:gpm = 2 × MBH / ΔT[°F]
. - Selection
If N+1:
(n−1) × size ≥ Qpeak
. - 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)
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
Segment | Area (m²) | Heating (W/m²) | Overrides | Height (m) | ACH |
---|---|---|---|---|---|
Open Office | 600 | 60 | — | 3.2 | 1.0 |
Conference | 200 | 90 | — | 3.2 | 1.5 |
Lobby | 100 | 120 | — | 3.2 | 2.0 |
Step-by-step math
- 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 - 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
- Open Office: V=600×3.2=1,920 m³ → ṁ=1.2×1920×1/3600=0.64 kg/s →
- 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
- 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
- Boiler selection (N+1)
Choose 3 × 60 kW. Check:(3−1) × 60 = 120 kW ≥ 104.74 kW
✓
Installed nameplate = 180 kW. - Budget cost
Equipment =180 × ₹3,000 = ₹540,000
Installed =×1.5 = ₹810,000
With markup (10%) =₹810,000 × 1.10 = ₹891,000
- 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
HW Flow
Recommended Plant
Budget Installed
Segment breakdown (kW)
Bars show segment heating (W/m² basis). Ventilation values are listed in the table below.
Segment | Area (m²) | Heating (kW) | ACH Vent (kW) |
---|---|---|---|
Open Office | 600.0 | 36.00 | 13.51 |
Conference | 200.0 | 18.00 | 6.75 |
Lobby | 100.0 | 12.00 | 4.50 |
Totals | 66.00 | 24.76 |
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.
- 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.