Boiler Emissions Tuning & Combustion Testing (NOx/CO)

Elevated NOx and CO levels are often a sign that a burner or its controls are not performing the way they should. Complete Controls Services, LLC (CCS) provides burner emissions tuning and combustion testing for boilers, heaters, dryers and HRSGs. Our goal is to tune your combustion equipment for optimum performance, maximum efficiency and lowest emissions, and to help you correct the controls issues that drive emissions up. CCS is based in Blair, Nebraska, emphasizes the Midwest and serves customers across the United States.

What Our Emissions Tuning Includes

NOx and CO Tuning

We adjust fuel and air across the firing range with a combustion analyzer, working to reduce NOx and CO while keeping the flame stable and the burner efficient. Emissions tuning is a balance: pushing one value down can drive another up, so we tune each point of the firing curve with the whole picture in mind.

Combustion Emissions Testing

Analyzer readings before and after tuning show where the burner started and where it ended up. We document what we measured and what we adjusted so you have a clear record of the work. Formal compliance stack testing required by a permit is typically performed by a qualified testing firm; our tuning helps prepare your equipment for that testing.

Finding the Root Cause

High emissions are not always a tuning problem. Worn linkages, failing actuators, drifting transmitters, poor O2 trim performance or outdated combustion controls can all cause emissions to creep up. Because CCS is a controls company, we can troubleshoot and correct those issues, or recommend a controls upgrade when equipment is obsolete.

Calibration for Consistent Results

For burner applications, calibrations are recommended to be performed in conjunction with efficiency tuning. Accurate instruments help a tuned burner stay in tune. See calibration & loop tuning.

Signs You May Need Emissions Tuning

• Elevated NOx or CO readings

• Steam and stack temperature variance

• Unstable flame or rumbling at certain firing rates

• Boiler control issues or frequent trips

• Recent burner, fuel or controls changes

• Signs of tube damage or failure

Equipment We Tune for Emissions

• Industrial and commercial boilers

• Process and thermal fluid heaters

• HRSGs and duct burners

• Dryers and other industrial burners

We work with burners of many designs and fuels, and have performed initial commissioning, retrofits and controls upgrades on many different systems.

Controls and Data Integration

Emissions-related signals such as O2, firing rate and analyzer outputs can be brought into your PLC, HMI or SCADA system for trending and reporting. We program Allen Bradley (Rockwell Automation), Siemens, Schneider, Fanuc, Keyence, Pro-face, C-more and other platforms, and we are a Certified Ignition integrator.

Our Approach

We begin with as-found readings across the firing range to see where NOx, CO and oxygen stand. We inspect the parts that affect combustion, including actuators, linkages, dampers and fuel valves, and verify critical instruments. Tuning then proceeds point by point. If we find a controls or instrument problem that limits what tuning can achieve, we tell you what it is and what it would take to correct it.

Why CCS for Emissions Tuning

• Technician-founded in 2017, with real boiler and burner operating experience.

• Tuning plus controls. We fix the controls and instrument problems that tuning alone can't.

• Boilers, heaters, dryers and HRSGs of any size or fuel.

• Cost-effective service focused on safety, efficiency and reliability.

• Midwest emphasis, nationwide service from Blair, NE.

Related CCS Services

• Combustion Tuning: Analyzer-based burner tuning for efficiency and performance on boilers, dryers, HRSGs and heaters.

• Boiler Controls Upgrades: Retrofits for obsolete combustion, drum level and feedwater controls, including O2 trim and parallel positioning.

• Instrumentation: Installation, repair, configuration and troubleshooting of process and boiler instruments.

• SCADA & Ignition: SCADA design, data collection and migration from a Certified Ignition integrator.

Emissions Tuning FAQ

Can tuning reduce NOx and CO?

Tuning can help identify and address elevated NOx and CO levels. How much improvement is possible depends on the burner design, fuel and condition of the equipment, so we evaluate your system first.

Do you perform permit compliance stack testing?

CCS focuses on tuning, combustion testing with analyzers and controls work. Official compliance testing is usually performed by a qualified stack testing firm; we can tune your equipment ahead of that test.

What's the difference between combustion tuning and emissions tuning?

They overlap. Combustion tuning focuses on efficiency and performance; emissions tuning puts extra emphasis on NOx and CO targets.

Do you work outside the Midwest?

Yes. We are based in Blair, Nebraska, and serve customers in all US states.

Talk to CCS About Emissions Tuning

If your emissions are trending up, don't wait for a problem. Call Complete Controls Services at (833) CCS-AUTOMATION ((833) 227-2886), Monday–Friday, 7:30 AM–4:30 PM, or contact us through our contact page.