When a burner consumes more natural gas than expected, the cause is not always the burner itself. Combustion efficiency, actual load, boiler losses, and measurement accuracy must be examined.
Actual load check
Compare the consumption with the thermal load actually being served. Increased steam or hot water production may explain high consumption without any fault.
Flue gas analysis
High O₂, high flue gas temperature, or incomplete combustion can reduce efficiency. Measuring CO, O₂, and temperature is essential for a proper assessment.
Air-gas ratio setting
An incorrect combustion curve or improperly positioned servomotors can lead to excess air or incomplete combustion.
Boiler losses
Surface fouling, poor insulation, or deposits can increase consumption without changing the burner setting.
Measurement check
Before drawing conclusions, verify that the meter and pressure/temperature correction are working correctly.