Boiler Combustion Tuning & Burner Tuning
A burner that is out of tune wastes fuel, stresses equipment and can push emissions higher than they need to be. Complete Controls Services, LLC (CCS) performs burner efficiency tuning of combustion systems for optimum performance, maximum efficiency and lowest emissions. We have the know-how to make your furnace, industrial burner or combustion system work to its original specifications. CCS provides combustion tuning for boilers, dryers, HRSGs and heaters of any size or fuel, for customers across the Midwest and nationwide.
Our Combustion Tuning Services
Burner Efficiency Tuning
We set fuel and air across the firing range so the burner runs efficiently and stably from low fire to high fire. The goal is the right balance between efficiency, flame stability and emissions for your equipment and operation.
Analyzer-Based Tuning
Tuning is done with a combustion analyzer, not by eye. Measuring flue gas lets us adjust each point of the firing curve based on real data and document the results.
Diagnosing Combustion Problems
Tuning your boiler and burner equipment can help you identify and address:
Elevated NOx and CO levels
Steam and stack temperature variance
Boiler control issues
Tube failure
Don't wait for your industrial boiler and burner to cause an emergency shutdown.
Controls Review During Tuning
Because CCS is a controls company, we look beyond the burner. Linkages, actuators, parallel positioning, O2 trim, firing rate control loops and instrumentation all affect combustion. When we find a controls problem, we can fix it on the spot or recommend a boiler controls upgrade.
Calibration Alongside Tuning
For burner applications, calibrations are recommended to be performed in conjunction with efficiency tuning. Accurate transmitters and analyzers keep a tuned system tuned. See instrument calibration & loop tuning.
Equipment We Tune
Industrial and commercial boilers (steam and hot water)
Dryers and dryer burners
HRSGs and duct burners
Process and thermal fluid heaters
Furnaces and other industrial combustion systems
CCS has experience with burners of many designs, of any size or fuel, and has performed initial commissioning, retrofits and controls upgrades of many different systems.
Controls Platforms
Modern combustion controls are often integrated with a PLC or plant control system. We work with Allen Bradley (Rockwell Automation), Siemens, Schneider, Fanuc, Keyence, Pro-face, C-more and other platforms, and can integrate combustion data into SCADA, including Ignition. We are a Certified Ignition integrator.
What Happens During a Tuning Visit
We start by reviewing how the equipment has been running and checking the condition of linkages, actuators and key instruments. Next, we take as-found analyzer readings across the firing range. We then adjust fuel and air point by point, verifying flame stability, oxygen and CO at each step, and confirm the burner responds smoothly to load changes. Before we leave, we review the results with your team and note any controls or mechanical issues that should be addressed.
Why CCS for Combustion Tuning
Founded by technicians in 2017, with hands-on boiler and burner experience.
Controls and tuning in one visit. We can address the burner, the combustion controls and the instruments together.
Any size, any fuel. Boilers, dryers, HRSGs and heaters.
Efficiency and emissions focus. We tune for performance and lower emissions, not just to get the burner to light. For emissions-specific work, see emissions tuning.
Cost-effective, Midwest-based service from Blair, NE, with travel to sites across the US.
Related CCS Services
Emissions Tuning: NOx and CO focused burner tuning and combustion testing with documented before-and-after readings.
Boiler Service: Troubleshooting and repair of boiler controls, burners and instruments on steam and hot water boilers.
Boiler Controls Upgrades: Retrofits for obsolete combustion, drum level and feedwater controls, including O2 trim and parallel positioning.
Calibration & Loop Tuning: On-site calibration and PID loop tuning, scheduled or as needed.
Combustion Tuning FAQ
How often should a boiler be tuned?
It depends on operating hours, fuel, load changes and permit requirements. Many facilities tune at least annually, and again after any burner or controls work. We can help you set a schedule that fits your equipment.
Can tuning lower fuel costs?
A properly tuned burner runs closer to its optimum fuel-air ratio, which can improve efficiency. Results vary with the condition and design of each system, so we evaluate your equipment before making recommendations.
Do you tune equipment other than boilers?
Yes. We provide combustion tuning for boilers, dryers, HRSGs and heaters of any size or fuel.
Should calibration be done at the same time?
For burner applications, we recommend performing calibrations in conjunction with efficiency tuning so the controls are working from accurate measurements.
Schedule Combustion Tuning
Get your combustion equipment running the way it was designed to. Call Complete Controls Services at (833) CCS-AUTOMATION ((833) 227-2886), Monday–Friday, 7:30 AM–4:30 PM, or reach us through our contact page.
