techstuff 3.09

Compile January 14, 1997 Contents

Data Printout 5/22/2014

Data Compiled by

David C. Farthing

Voice 405-728-6709

WELCOME TO TECHSTUFF!! Month Year Date of Rev.

© 1997 David C. Farthing Revision 3.09 9 03.31.09

A Compilation of technical formula, solutions, and manufacturer's application notes.

Compiled by David C. Farthing as a service to those who need to know.

Use Mouse to Click on Button to GO TO desired formulas.

Instructions Fill in new data in yellow boxes.

General Calculations

Fluid Volumes in Cylindrical and Square Sided Tanks

Water Content in an Air Stream

Temperature Conversions

Pressure Conversions

Energy Conversions BTU/KW KW/BTU

Financial Analysis of a Project

Heating Loads

Calculating BTU Load of liquid in Square & Cylindrical tanks

Steam Load Across Fan Coils

Flowing Fluid Heating Loads

Building + Equipment Heating Load Combination

Solid Materials & Equipment Heating Loads

Refrigeration Loads

Refrigeration loads of flowing liquids

Boiler Calculations

Boiler Horsepower from BTU and/or Pound Per Hour Steam Flow

Fan Laws for Boiler Burner Applications and Fuel BTU Content Conversions

Rite Boiler Index for Stack & Boiler, Atmospheric & Power Burner

Combustion Efficiency Savings with O2 Trim & CO influence

Condensate & Feedwater Tank Sizing

Economizer Calculations

Excess Air & Oxygen Analysis & Combustion Air Requirements

The effect of Feedwater Temperature on Boiler Horsepower

The effect of Boiler Operating Pressure on System Design - Firetube Boilers

The effect of Boiler Operating Pressure on System Design - Watertube Boilers

The effect of Scale & Soot Build-up on Heat Transfer in Boilers

Dr. Mac Brockway's Boiler Water Chemistry Class (With Conductivity Conversions)

CSD-1 Fire & Water Side Control Requirements

Benchmarking a Boiler

Boiler Blowdown Calculations

Amount of Dissolved Oxygen in Make-up Feedwater vs. Temp.

ValveProving Sequencing Test Calculation

POWERHOUSE EFFICIENCY CALCULATIONS

Valve Sizing CV Calculations

Gas Flow Control Valve Sizing

Liquid Flow Control Valve Sizing

Steam Flow Control Valve Sizing

Pumps and Hydronics

Centrifugal Pump Affinity Laws

Pump NPSH Calculator

Expansion Tank Sizing Calculations

Hydronic Zone Flow Calculations

Pump VFD Affinity Laws & Curves

Electrical, Control and Instrumentation Stuff

Controller Out Put Voltage v. Impedance and Transmitter Troubleshooter

OHMS Laws

Instrument Application Selection Guide

Variable Frequency Drive Calculations

Steam Stuff

Condensate Loads & Steam Main Trap Sizing

Cost of Leaking Steam Traps in Lost Steam and Revenue

Steam Tables

Calculating Superheat in Pressure Reducing Stations

Blowdown Heat Recovery

Relief Valves

Cost to Produce Steam in $/Kpph

Flash Steam Calculator

Spirax Sarco Steam Cost Calculator

Flow Measurement & Piping Calculations

Gas/Steam Flow & Steam Velocity

Single Pipe Friction Loss Calculations

Thermal Expansion of Pipe

Water Hammer Calculations

Piping Insulation Losses

Halliburton Gas/Liquid Turbine Meter Calculations (Convert BTU to GPM #2 Diesel)

Product Selection Guide

ASCO Solenoid Valves TOMSPAVE

Boiler Application Guide

Flame Safety Control Selection Guide

Steam Trap Selection Guide

Pump Applications

Measurement, Control & Recorders

UDC3000 Cross Reference (DC300#)

UDC3000 Cross Reference (DC300X)

Volume

BTU

Refrig.

Chimney

BHP

FHL

AIR

Gas Valve

Liquid Val

Steam Val

Fan Coil

Pumps

Voltage

Pipe T.

Mains

Leaks

Flow Calcs

OHMS

TEMP

Tables

Friction

Hammer

ASCO

Boilers

FSG

Traps

Pumps

M&C

DC300#

Tank Size

O2/CO Trim

Back To Contents

Back To Contents

General Calculations

Heating Loads Refrigeration

Loads

Boiler Burner

Calculations Valve Sizing

Pumps and

Hydronics

Controls -Transmitters &

VFD

Steam Stuff

Flow & Piping Data

Revision Notes

Electric Motor Data

Product Selection

Guide

Back To Contents

Financial

IASG

Econo

B&E

Equip Ht

Comb Air

Expansion

Hallibutron

Hydronics

Superheat

Heat

FW Temp

SCALE

MKUP O2

PRESSURE

DC300X

BENCHMK

Systems

Warranty Accuracy

Contact Info

Back To Contents

Back To Contents

CSD1

ENERGY

BLDOWN

VFD

Relief Val

FAN &

DR.MAC

Pump

PUMP VFD

Systems-W

Steam $$

VPS

EFFICEINC

Insulation

SARCO $$

FLASH

Revision Notes

Rev # Date Notes

1.102 1/31/2002 Correct nomenclature in 02 trim calcs and add Revision Notes page.

2.103 2/12/2003 Add VFD Drive Calcs and Motor Data.

6.103 6/30/2003 Add Fan Laws for Burners data.

8.0603 8/6/2003 Enhanced Steam Flow Calculations with updated AGA material.

12.1.03 12/1/2003 Add Dr. Mac Brochway's Boiler Water Charts

02.7.04 2/7/2004 Enhanced Fan Laws for Burner data based on infor from Oneok evaluations.

04.30.04 4/30/2004 Added Pitot Tube Flow Calculator

09.14.04 9/14/2004 Added Effect of Co on OxyTrim Efficiency Calculations.

11.09.04 11/09/04 Cleaned up Motor Torque data in VFD calculations.

12.16.04 12/16/04 Added ABMA Boiler Water Chemcal Guidelines and Dr. Mac's pH Correction Table for TDS

6.5.5 6/5/2005 National Standards Institue Heat Loss Due to Scale Deposits

6.21.06 6/21/2005 BTU to #2 Diesel Conversion for Halliburton Turbine Meters

3.12.07 3.12.07 Add Oxygen Trim Calculator to O2 Trim Worksheet

4.10.07 4.10.07 Add VPS Volume & Time Calculator

7.8.7 7.8.7 Add Density Calculator to Gas Flow Meassurement calcs.

8.7 8.22.07 Unlock Pump VFD Cells and Add Pump Process Data Inputs.

8.7 8.28.07 Add Powerhouse Efficeincy Calculations

10.7 10.15.07 Add Conductivity Conversions to Dr. Mac's page.

10.7 11.28.07 Correct Expansion tank factor.

12.07 12.13.07 Changed Therms to Dekatherms on Economizer Calcs to ease reading of data.

4.08 4.30.08 Add Pipe Insulation Losses

8.08 8.19.08 Add Flash Steam Calculator

3.09 3.11.09 Finish Flash Steam Calculator

3.09 3.18.09 Add Exhaust Stack Velocitiy Calculations

3.09 3.31.09 Correct Piping Insulation Losses Calculator.

Added ABMA Boiler Water Chemcal Guidelines and Dr. Mac's pH Correction Table for TDS

Warranty of Accuracy Statement

© 1997 David C. FarthingTECHSTUFF© 1997

TechStuff© is provided as a free service by the compilers. While the compilers have exercised great care

in compiling this data there is NO warranty of any kind on the accuracy of the calculations.

The user is warned that to use this service is at their own risk.

When in doubt it is always advisable to seek the services of a Professional Engineer.

The compilers assume no responsibility of liability for the use of this service.

Should you find an error in this application you are encouraged to notify the compilers at the following address.

David Farthing

Voice 800-239-7301

Fax 405-232-5438

[email protected]

[email protected]

TECHSTUFF© is a Microsoft Excel 5.0 application and may be ran on Windows 95 or newer versions.

It is recommended that the application be saved as a 95/5.0 application so that the user may readily

transfer the free upgrades from www.federalcorp.com. The application is saved as a 95 version to

allow the greatest number of users to use the service.

Compiled January 14, 1997 Tank Fluid Volumes


Data Compiled by

David C. Farthing

Voice 405-239-7301

CAPACITY OF LIQUID IN CYLINDRICAL TANKS IN U.S. GALLONS

CAPACITY of CYLINDRICAL TANKS = D^2 * L * .0043

WHERE D = DIAMETER IN INCHES

L = LENGTH IN INCHES

.0043 = CONSTANT

INPUT DATA MAY BE IN EITHER INCHES OR FEET. NOTE APPROPRIATE DATA TABLE

Dimensions INCHES FEET

D = 12 1

L = 12 1

VOLUME = 5.88 5.88 Gallons U.S.

CAPACITY OF LIQUID IN SQUARE SIDED TANKS IN U.S. GALLONS

CAPACITY of SQUARE TANKS = (D-FB) * W * L * 7.5

Dimensions Depth Width Length Freeboard, inches Fluid Volume

INCHES 12 12 12 0 7.43 Gallons U.S.

FEET 1 1 1 0 7.43 Gallons U.S.

Customer Johns Manville NOTE: CUSTOMERS TANKS MUST BE INSULATED

Contact Greg MINIMUM 2.0" FIBERGLASS BAT RECOMMENDED.

Tank Name: Mixer In Open Top Tank application. 0.5 F/Sec Air Velocity over top of tank.

Load Calculations

No. of Tanks Tank Configuration Type Letter S or C in box Tank Designations

12 Square/Cylinder C Mixer, 60% Powdered Lime 40% Asphalt 50 Degree Lime Temp

IS TANK OPEN or CLOSED TOP?(O/C) C Enclosed Mixer, Maintenance and Re-heat load.

Square Sided Tank Data

Depth Width Length Freeboard, inches Fluid Volume Total Fluid Volume

1 1 1 0 7.482 89.784

Total Tank Surface Area Surface Square Feet 1.00

Cylindrical Tank Data

Dimensions FEET

D = 6 Total Fluid Volume

L = 9 All Cylindrical Tanks Open Top Area Sq./Ft.

FLUID VOLUME = 1903.58 22842.94 0

Fluid Data: Product: Water

Final Temperature Sp./Gr. Sp./Ht

216 1 1 NOTE: PAGE DOWN FOR COMMON LIQUID DATA

Q=W X Sp./Ht. X (T2-T1) Based on 80% Efficient Boiler Cost to Operate Rise 8Hr. Cost to Maintain/Hr

Where Q= Quantity of Heat in BTU Energy Cost Gas/MMBTU 12.00$ 72.17$ 9.97$

W= Weight of Product to Be Heated Energy Cost Electric/KW 0.0780$ 109.96$ 15.18$

Sp./Ht = Specific Heat of Product

T2= Ending Temperature T2 216 Caution Above Boiling Point!

Ambient Losses T1= Beginning Temperature T1 212.5 Calculated Base Maintenance Loss.

Ambient Shop Temperature TA 70

Solution for boiler loading

Per Tank Load 55,366 Maintenance Load ONLY 218 55,366

Open Top Loss - Tank radiance and surface losses. 6200 Open Top Radiant Loss Factor

Total Tankage Load 664,387 Total Maintenance Load Btu per hour for all tanks combined.

Cold Start 30,793,799 Cold Heat-up Btu Required for all tanks from Cold Start of: (TA) w/ 10% Loss. 121,035 ########

Note: 10% tank and process loss included.

Boiler BTU Required 1 Hr Rise 4Hr Rise 6 Hr Rise 8 Hr Rise 12 Hr. Rise

Assumed 80% Eff. 38,492,249 9,623,062 6,415,375 4,811,531 3,207,687

Boiler Horsepower 80% Eff. 1150 288 192 144 96

Common Specific Gravity's & Specific Heats for Various Liquids. First Number Sp.Gr. Second Number Sp.Ht.

Water 1/1 Castor Oil 1.2/.43 Kerosene .86/.48

Acetone .79/.51 Citron Oil 1.2/.44 Naphthalene 1.14/.41

Alcohol's .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47

Ammonia .62/1.16 Ethyl Ether 1.16/.53 Propane .50/.59

Aniline 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54

Benzol 1.02/.42 Fuel Oils 2-6 .90/.45 Seawater 1.02/.94

Calcium Chloride 1.2/.43 Gasoline .81/.53 Soybean Oil .93/.47

Paraffin Wax 1.12/.69 Gypsum 1.21/.26 Sandstone .93/.22

Asphalt/Tar 1.2/.35

Plating Applications Diluted Solutions

Nickel 1.23/1

Acid 1.23/1

Chrome/Fluorides 1.23/1

Electro-Klean 1.12/1

Soak Clean 1.12/1

Data Compiled January 14, 1997 Refrigeration Loads


Data Compiled by

David C. Farthing

Voice 405-728-6709

Refrigeration of Liquids

Customer Name

Contact

Phone Number

Refrigeration Load = Mass expressed as G/Hr.;((Flow in Gallons / Hr. *8.31)*Specific Gravity* Specific Heat * (T1-T2))/12000

Flow = 1119 GPM

Flow = 67140 Gallons / Hour

Sp. Gr. 1

Sp. Ht. 1

T1 = 95

T2 = 85

Tons Refrigeration Required = 466.06




Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47


Aniline 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54



Data Compiled January 14, 1997 Rite Boiler Chimney Effect


Data Compiled by

David C. Farthing

Voice 405-728-6709

Exhaust Gas Volumes for Typical Boiler Operating ConditionsResult is Approximate Actual Cubic Feet/Minute Per 100 Hp.

NOTES: Gas fuel based on 9% CO2, #2 Oil fuel based on 13% CO2 emissions. 80% Thermal Efficient Boiler

85+% Efficient Combustion Excess Air Volume=15%

Fuel Gas=1/Oil=0 1 Enter 1 or 0

Flue Gas Temperature 60

Boiler Horsepower 239

Exhaust Volume 16,748.66 Actual Cubic Feet/Min. At Stack Temperature

Emissions Make-Up Percent of FG

Excess Air = 15% Mol Wt. by Volume SCF/10^6 BTU Lbs./10^6 BTU PPM

CO2 = 44 10.10 1095.44 126.84

O2 = 32 3.00 306.12 25.78

CO = 28 0.0020 0.2 0.015 20

N2 = 28 86.900 8876.40 654.05

Nox=NO2 46 0.0025 0.25 0.03 25

Hydrocarbons 16 0.001 0.100 0.004 10

Sox=SO2 64 0.000 0 0.00

H2O = 18 2237 105.96

Particulates 0.00

Total 100 12515.52 912.68

Total Emissions this application = 12,512.60 912.47

Exhaust Stack Velocitiy for Typical Boiler Operating ConditionsV = (2.4Q x Vs)/A Where ...

V = Velocity in Feet per Minute

Q = Flow in Lbs/Hr.

Vs = Spicific Volume of Gas at the Flowing Pressure

A = Internal Area of the Stack

Note: Q and Vs are calculated from the above "Exhaust Gas Volumes" Calculations and automatically placed in the following equation.

Stack Internal Diameter (Inches) = 60.00

Calculated Internal Area of the Stack (Sq In)= 2,826.90

Stack Velosity Ft/Min = 10.62

NOTE: Always consult a Professional Engineer when Life Safety or Federal Standards are involved. These equations are for representitive values only.

Compiled January 14, 1997 Boiler Horsepower


Data Compiled by

David C. Farthing

Voice 405-728-6709

Boiler Horsepower

When Pounds Per Hour Steam Flow are known.

BHP = #/Hr Steam Flow / 34.5

Steam Flow = 60000

Boiler Hp = 1739 At and From 212 deg. "F"

When BTU of Burner is Known. Boiler HP from BTU Output

Useful BHP = Fuel BTU Input/ 33,465 * Rated Efficiency BTU Output= 12500000

Fuel Input = 14,500,000 Boiler HP = 374

Boiler Hp = 351 at 81% Eff. At and From 212 deg. "F"

Boiler Hp = 325 at 75% Eff. At and From 212 deg. "F" KW/Hr. 6000

BTU/Hr. 20,491,200

When Boiler Rated Horsepower is Known. Boiler Hp 612

Steam Flow #/Hr = Boiler Rated Hp * 34.7 Meg.W 6

Boiler Hp = 250 Notes

Steam Flow = 8626 At and From 212 deg. "F" 1KW = 1,000 Watts

1 MW = 1,000,000 Watts

When BTU Required by the Process is Known. 1 MW = 1,000 KW

Process Input = 60,000,000

Boiler Hp = 2213 Fire Tube at 81% Eff. At and From 212 deg. "F" Eletric Motor Hp 16000

Boiler Hp = 2391 Water Tube at 75% Eff. At and From 212 deg. "F" KW/Hr. 11931.2

Boiler Input = 74,074,074 Fire Tube at 81% Eff. At and From 212 deg. "F" MegW/Hr 11.9312

Boiler Input = 80,000,000 Water Tube at 75% Eff. At and From 212 deg. "F" Boiler Hp 1216.352

When Heating Surface area is Known.

Heating Surface = 10,750 5.28

Fire Tube BHP = 2150 Fire Tube at 81% Eff. At and From 212 deg. "F" 5.33

Fire Box BHP = 2087 Fire Box at 80% Eff. At and From 212 deg. "F" 5.35

Water Tube BHP = 2028 Water Tube at 75% Eff. At and From 212 deg. "F" 5.38

Boiler BTU Output = 71,949,750 Fire Tube at 81% Eff. At and From 212 deg. "F" 5.51

Boiler BTU Output = 67,877,123 Water Tube at 75% Eff. At and From 212 deg. "F" 5.32

5.17

4.92

TURBINE to BOILER Horsepower Requirements

KW/Hr. 2200

Meg.W 2.2

BTU/Hr. 7,513,440

Efficiency 22.18%

Boiler Hp 1012.25

Steam Flow PPH 34,923

UNDER CONSTRUCTION DO NOT USE THIS CALCULATION

5/22/2014 THEORETICAL THERMAL EFFICIENCY OF A STEAM PLANT Data Compiled by

David Farthing

From Manufacturer's Data

POWERHOUSE EFFICIENCY CALCULATIONS

SITE LiDestri Foods, Fresno CA Plant at optimum performance. (NOT AS FOUND)

BOILER TYPE (F/W) F

STEAM RATE PPH 16000

BTU INPUT @212 "f" 19,950,000 (As rated by manufacturer.)

BOILER HORSEPOWER 463.7681159

RATED EFFICIENCY 80.20%

STEAM OPERATING PRESSURE 110

STEAM TEMP AT OP PSIG 344 (From Steam Tables in TechStuff.)

BTU CONTENT OF STEAM 1191 (From Steam Tables in TechStuff.)

BLOWDOWN RATE % 1% (See BLDOWN Tab in Techstuff for calculating this number.)

PPH WATER FLOW @ BD% 160 (Not to Exceed Rated PPH of Manufacture)

MAKE-UP WATER TEMP 68

BTU AVAILABLE FOR HEAT RECOVERY 21,179 Based on MADDEN BDHR Data for Recoverable Btu in Water Side)

HEAT RECOVERY MAKE-UP FLOW RATE 1600

EXIT WATER TEMP 80 (Based on 10 Degree Approach.)

BTU RECOVERED WATER SIDE 19,061

PERCENT MAKE-UP REQUIRED 15%

MAKE-UP FLOW REQUIRED 2400

TOTAL FLOW REQUIRED 2560 Includes Blowdown

MAKE-UP WATER TEMP TO SECONDARY RECOVERY 69

ECONOMIZER INLET TEMP 227

ECONOMIZER BTU RECOVERY 238000 (See ECONO Tab in Techstuff for calculating this number.)

ECONOMIZER EXITING TEMP 320

NUMBER OF ECONOMIZERS IN SYSTEM 1

DEAERATOR INLET TEMP 109

DEAERATOR OUTLET TEMP 227

BTU REQUIRED FOR DEAERATOR 302,080

BTU RECOVERED AS FLASH FROM BDHR UNIT 26,981 Based on MADDEN BDHR Data for Recoverable Btu in Flash Steam Side)

ADDITIONAL BTU REQUIRED FROM BOILER 275,099

TOTAL PLANT HEAT OUTPUT 16,000,000

GROSS PLANT HEAT INPUT 19,950,000

TOTAL HEAT RECOVERED (284,042)

NET PLANT HEAT INPUT 19,665,958

TOTAL PLANT EFFICIENCY 81.36%

Data Source Sterling Radiator

5/22/2014 4:05 PMBuilding Machinery Heating/Cooling Loads Data Compiled by

David Farthing

Voice 405-728-6709

BUILDING HEAT LOSS CALCULATION Changeable data WALLS

CONSTRUCTION INSULATION THICKNESS - INCHES

CLIENT St. Greg Unv. METAL 0 1 2 3 4 5 6 WALL INS PER IN.

LOCATION Shawnee DATE 29:Sep:04 ROCK, GLASS BATT 1.2 0.23 0.13 0.088 0.067 0.054 0.046 0.00 3.50

BUILDING NAME MaBee Buldg EXPED STYROFOAM 1.2 0.21 0.11 0.078 0.059 0.048 0.04 0 4

WOOD OR PLYWOOD

1" 0.56 0.19 0.11 0.081 0.063 0.052 0.044 0.040 3.500

2" 0.38 0.16 0.1 0.076 0.060 0.050 0.042 1.880 3.500

BUILDING LENGTH 250 SLAB U FACTOR 0.81

BUILDING WIDTH 276 WALL U FACTOR 0.38 CONCRETE BLOCK (NO INSULATION) "U" VALUES

BUILDING HEIGHT EVE 16 PERCENT GLASS 10% SAND / GRAVEL AGGREGATE OPEN CORE FILLED CORE

BUILDING HEIGHT RIDGE 18 GLASS U FACTOR 0.69 4" THICK (R=0.71) 0.64 0.36

ROOF U FACTOR 0.067 8" THICK (R=1.11) 0.51 0.38

DOOR AREA (FT SQ.) 75 DOOR U FACTOR 1.22 12" THICK (R=1.28) 0.47 0.38

CINDER AGGREGATE

OUTSIDE AIR TEMPERATURE 15 BUILDING VOLUME 1173000 4" THICK (R=1.11) 0.51

INSIDE AIR TEMPERATURE 73 DELTA TEMP 58 8" THICK (R=1.72) 0.39 0.18

12" THICK (R=1.89) 0.37 0.16

AIR CHANGES PER HR 4

BRICK - COMMON NO INSULATION

VOLUME REQUIREMENT 4,898,448.00 BTU 4" THICK (R=0.8) 0.61

WALL HEAT LOSS 413,407.30 BTU 8" THICK (R=1.60) 0.48

ROOF HEAT LOSS 268,162.16 BTU 12" THICK (R=2.40) 0.31

DOOR HEAT LOSSES 5,307.00 BTU

SLAB LOSS 49,422.96 BTU

TOTAL BUILDING LOAD 5,634,747 BTU METAL AND TRANSITE NO INSULATION

CORRUGATED METAL 1.5BOILER HORSE POWER 168.2014153 HP COATED METAL 0.9

3/8" TRANSITE - FLAT 1.1

3/8" TRANSITE - CORRUG 1.3

HEATER CALC.S ROOFS

CONSTRUCTION INSULATION THICKNESS - INCHES

BTU CAP @ 20 DEG DROP 250000 HEATERS REQ 37.56498276 METAL W/O BUILDUP 0 1 2 3 4 5 6 WALL INS PER IN.

CONVERSION FACTORS (1=Steam)(.6=Water) 0.6 GPM REQ ROCK, GLASS BATT 1.3 0.23 0.13 0.088 0.067 0.054 0.046 0.00 3.50

HEATER GPM REQ 40 HEAD REQ 12 EXPED STYROFOAM 1.3 0.21 0.11 0.078 0.06 0.048 0.04 0 4

PRESSURE PROP FT. WATER 2 METAL W/ PREFORMED INSULATION

HEATER PIPE LENGTH 600 1.30 0.26 0.15 0.110 0.081 0.067 0.056 0.000 2.780

PIPE SIZE 4

FRICTION /100FT 2 WOOD W/ PREFORMED INSULATION

1" 0.49 0.21 0.13 0.096 0.076 0.063 0.053 0.940 2.780

2" 0.34 0.17 0.12 0.088 0.071 0.059 0.051 1.880 2.780

MISC. "U"

INTERIOR WALLS GLASS - HORZ AIR LOSS= CFHX0.018XTD

SHEET METAL 0.74 SINGLE PANE 1.22

1/2" PLYWOOD 0.05 DOUBLE PANE 0.75 DILUTION AIR - PER 1,000 BTUH

8" CONCRETE BLOCK 0.32 NATURAL GAS - 4 CFM

3/8" GYP BOARD 0.6 EXTERIOR DOORS PROPANE GAS - 5 CFM

FLAT METAL 1.2

GLASS - VERTICAL 1" WOOD 0.64

SINGLE PANE 1.13 2" WOOD 0.43

DOUBLE PANE 0.69

TRIPLE PANE 0.47 FLOOR SLABS (BTUH/LN.FT. / DEG. F)

STORM WINDOW 0.56 UNINSULATED 0.81

INSULATED 0.55

TechStuf 'C' 1997 David Farthing Tech Stuff

Heating Solid Materials

5/22/2014 4:05 PM

Data Compiled by

David Farthing

Voice 405-728-6709

Heating Solid Materials and Equipment

Formula = Lbs/Hr = W*Cp*Delta T/(L*t)

Where W= Weight of Material

Cp= Specific Heat of Material

L= Latent Heat of Steam (Btu/Lb)

t= Time in Hours

Material = Steel Part in Platen Heater

W= 1300 Lbs.

Cp= 0.109 From Charts

L= 344 From Steam Charts

Start Temp 80

Final Temp 190

Delta T= 110

t= 1

Lbs/hr= 45.31105 BTU/Hr = 15,587.00

Boiler Hp 0.47

Common Specific Heats of Solid Materials Water Cp = 1.0

Steel 0.12 Carbon-Coke 0.203 Glass, normal 0.2 Nickel Steel 0.109

Iron 0.12 Chalk 0.215 Gneiss 0.18 Paraffin Wax 0.69

Aluminum 0.22 Charcoal 0.2 Granite 0.2 Porcelain 0.22

Alumina 0.35 Cinders 0.18 Graphite 0.2 Quartz 0.23

Asbestos 0.2 Coal 0.3 Gypsum 0.26 Quicklime 0.217

Ashes 0.2 Concrete, Dry 0.156 Hornblend 0.2 Rose Metal 0.05

Bakelite 0.35 Constantine 0.098 Humus soil 0.44 Salt, rock 0.21

Basalt 0.2 Cork 0.485 India Rubber 0.37 Sand 0.195

Bell Metal 0.086 Corundum 0.198 Kaolin 0.224 Sandstone 0.22

Bismuth-tin 0.043 D'Arcet metal 0.05 Lead Oxide 0.055 Serpentine 0.25

Borax 0.229 Dolomite 0.222 Limestone 0.217 Silica 0.191

Brass, Y 0.088 Ebonite 0.33 Lipowitz Metal 0.04 Soda 0.231

Brass, R 0.09 German Silver 0.095 Magnesia 0.222 Sulfur 0.18

Bronze 0.104 Glass, Crown 0.16 Magnesite 0.168 Talc 0.209

Brick 0.22 Glass, flint 0.12 Marble 0.21 Tufa 0.33

Vulcanite 0.331 Wood (AVG) 0.63 Wood's metal 0.04 Type metal 0.039

TechStuf 'C' 1997 David Farthing Tech Stuff

Heating Solid Materials

5/22/2014 4:05 PM

Data Compiled by

David Farthing

Voice 405-728-6709

Compiled January 15, 1997 Flowing Fluid Heating


Data Compiled by

David C. Farthing

Voice 405-728-6709

Flowing Fluid Heating Loads

You may use either GPH or GPM for your problem. Be sure to use the correct data box.

Heating Load = Flow #/hr * Sp.Gr.*Sp.Ht. * Delta "T" in deg. "F"

INPUT DATA INPUT DATA

Gal/Hour Gal/Minute

Flow = 175000 GPH 1600 GPM

Sp. Gr. 1 1

Sp.Ht. 1 1

T1 = 97.5 88

T2 = 120 Boiler Hp Steam Flow 95 Boiler Hp Steam Flow

Load BTU/Hr. = 32,799,375.00 980.11 33,813.79 5,597,760.00 167.27 5,770.89




Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47


Anilin 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54



Water Content In Air Stream

Water Content in Air Streams

1# of Air at 62 "F"=13.65 CF

Datum 1CFt of Air holds .0225# Water at 65"F" and 40% RH

CFM = 2500

Total Water / Min. = 56.25 in Lbs.

Lb./Hr Water = 3375

Gallons/Hr. Water = 406.1372

David Farthing's

TechStuff ValvesGas Valve Thanks to Honeywell for the basic CV calculator

Courtesy of HONEYWELL, INC. - Modified by David Farthing GAS

ChemTrade SSOV-1 SSOV-2 Regulator 25%

CONDITIONS CONDITIONS CONDITIONS CONDITIONS

BASE FLOW SCFH 12,000.00 12,000.00 12,000.00 8,088.00

SAFETY FACTOR X 1.00 1.00 1.00 1.00

FLOW SCFH 12,000.00 12,000.00 12,000.00 8,088.00

INLET PRESS PSIG 1.25 1.00 40.00 14.00

OUTLET PRESSURE PSIG 1.03 0.78 1.25 0.50

PRESS DROP PSI 0.22 0.22 38.75 13.50

TEMPERATURE DG.F 68 68 68 68

SPEC GRAV 0.63 0.63 0.63 0.63

REQUIRED Cv 85.745 86.430 4.773 6.267

V-Cut Degrees Open Degrees Open Degrees Open Degrees Open

V-Bal 900Rotation 60 85.74 86.43 4.77 6.27

Percent Open Percent Open Percent Open Percent Open

CV of Installed Val 90 95.272% 96.033% 5.303% 6.964%

David Farthing's

TechStuff ValvesLiquid Valve Thanks to Honeywell for the basic CV Calculator

Courtesy of HONEYWELL, INC. - Modified by David Farthing LIQUID

Producers COOP 100% 75% 50% 25%


BASE FLOW GPM 28.00 21.00 14.00 7.00

SAFETY FACTOR X 1.15 1.00 1.00 1.00

ACTUAL FLOW GPM 32.20 21.00 14.00 7.00

INLET PRESS PSIG 205.00 180.00 180.00 180.00


PRESS DROP PSID 42.00 30.00 30.00 30.00

SPECIFIC GRAV 0.98 0.98 0.98 0.98

VISCOSITY CS 0.96 0.96 0.96 0.96

TEMP(WATER) DG.F 227 366 366 366

MAX ALLOW

¸P (WATER) PSI 158.964 37.162 37.162 37.162

REQUIRED Cv 4.919 3.796 2.530 1.265

Linear V-Ball V-Cut Degrees Open Degrees Open Degrees Open Degrees Open

V-Bal Rotation 60 19.67 15.18 10.12 5.06



Actuator Type N/A ELECTRIC Body Materials Cast Steel(or SS)

N/A VOLTAGE End Connections THREADED

4/20mASIGNAL Steem & Seat Per factory

N/A MANUAL OVERRIDE POSITIONER Per factory

Yes PNEUMATIC

40 AIR SUPPLY PSIG

No DOUBLE ACTING

Yes SPRING RETURN

David Farthing's

TechStuff ValvesSteam Valve Thanks to Honeywell for the basic CV Calculator

Courtesy HONEYWELL, INC. - Modified by David Farthing STEAM

TAG # Original Design Reduction #1 Reduction #2 (ENTER TAG #)


BASE FLOW #/HR 7,300.00 5,800.00 16,000.00 12,000.00

SAFETY FACTOR X 1.00 1.00 1.00 1.00

DESIGN FLOW #/HR 7,300.00 5,800.00 16,000.00 12,000.00

INLET PRESS PSIG 125.00 100.00 75.00 75.00


PRESS DROP PSI 100.00 75.00 25.00 25.00

TEMPERATURE DG.F 266 266 250 240

REQUIRED Cv 26.670 26.097 115.864 86.260

V-Cut Degrees Open Degrees Open Degrees Open Degrees Open

V-Bal 900Rotation 60 0.00 0.00 0.00 0.00



VPS Calculations

5/22/2014Complied by David Farthing

VALVE PROVING SEQUENCING TEST CALCULATIONS

V1= Upstream Valve Volume

V2= Downstream Valve Volume

D= Pipe Diameter (Inches Nominal-Schd. 40)

L= Pipe Length Between V1 & V2 (Feet)

P= Inlet Gas Pressure to V1

C= Burner Maximum Firing Capacity (CFH)

X= Calculated Test Valve Train Volume

T= Minimum Test Time in Seconds

Calculation of Valve Train Volume

X= V1+V2+((A x L)/144)

Calculation of Valve Proving Test Time

Test Time (Sec) = 187,000 X (P x X)/C

Is Inlet Gas Pressure in InWc or PSI (I or P) p

Inlet Gas Pressure 10

P= 10

D= 4

Area Sq/In = 12.9940945

L= 2

V1= 0.08

V2= 0.08

Total Volume Cft (X)= 0.34047353

C= 52000

Min.Test Time Seconds (T) = 12.24

GAS V2

V1

vps

L

Fan Coils

Steam Demand in a Fan Coil

Formula used for calculations Q=( CFM X 1.08 X TD ) / 1000

Where Q = Air flow across fan coil in cfm

TD = Temperature Differential across fan coil

1000 = Latent heat of 15 PSI Steam

1.08 = Correction factor for fouling of coils

INPUT DATA

CFM = 6,000

Inlet Air Temp = 60

Exhaust Air Temp = 180

Lbs/ Hr. Steam Load 777.6

BTU Load 777,600

Calculating NPSHa (Available) for Centrifugal Pump ApplicationsENTER "X" to Select Formula

Suction Lift Open Tank NPSHa = Pb - (Vp + Ls + Hf)

Suction Lift Closed Tank NPSHa = p - (Ls + Vp + Hf)

Suction Head Open Tank NPSHa = Pb + Lh - (Vp + Hf)

X Suction Head Closed Tank NPSHa = p + Lh - (Vp + Hf)

Suction Head and Lift are meassured from the liquid surface to the pump centerline.

Where Pb = Barometric pressure in feet absolute (Fa)

Vp = Vapor Pressure of the liquid at maximum pumping temperature, in feet absolute (Fa)

p = Pressure on surface of liquid in closed suction tank in feet absolute (Fa)

Ls = Maximum stactic suction lift in feet.

Lh = Maximum stactic suction head in feet

Hf = Friction loss in feet in suction pipe at required capacity. (Go to Calculator)

Feet Absolute Calculator - Enter Data in Guage Readings to get Feet Absolute

Guage Reading Fa

Pb = 29 32.79

Vp = 10 57.03

p = 10 57.03

Input Data

Pb = 32.79

Vp = 57.03

p = 57.03

Ls = 0.00

Lh = 5.50

Hf = 1.39

NPSHa = 4.11 Pump must require an NPSHr less than or equal to this value.

Friction

Producers COOP

Peerless F21250AM

11.0" Impeller

5/22/2014 Pump Affinity Laws

Pump Horsepower Requirements

Q= 1840

H = 60

PSIG = 25.97

Sp.Gr.= 1

Pump Eff. 65.00%

Minimum Motor Hp BHP= 42.89044289

Cost to Operate Pump

$/KW/Hr = 0.044

Hours/Day = 24

Days/Month = 15

Cost Per Month = 506.82$

Burner Fan Laws

by David Farthing5/22/2014 David Farthing's

TechStuffFan Laws for ESTIMATING Boiler Burner Fan Performance

CFM Estimates based on 950 But/ft^3 fuel, 9.67 ft^

3 Air per 1 ft^

3 Fuel at Sea Level and 100 deg "F" Combustion Air.

Q = Fan Volume Flow Rate CFM or ft^3/Min Assumed Data

D = Fan Diameter in Inches Air Density = 0.0584

N = Fan Shaft RPM Air Temp = 100

H = Static Pressure of Fan at Design Point, Inch/WC Elevation = <1700 Ft/ASL

Enter known data in Yellow Boxes Bhp = Fan Horsepower = Q X H / (6356* Eff)

BuzziUnicem Diff P = Differential Pressure Across Windbox at Firing Rate

Todd Heater -1 Eff = (ft^3/min X H) / (5263 X Motor Hp)

Pryor OK Plant Burner Input 12,000,000.00 BTU/Hr from Burner Data Plate

21MM Btu Input Max Gas Flow 12,000.00 Ft^3/Hr

Min Gas Flow 1,200.00 Ft^3/Hr

Max Air Flow @15% EA. 2,275.29 CFM base on 9.67 Ft^3 Air/1Ft^3 Gas at Sea Level & 80 deg "F". 15% Excess Air.

Min Air Flow 227.53 CFM at LOW (10%) FIRE.

Fan Motor HP 60.00 Taken from Fan Motor Data Plate

Fan Static Pressure H 18.00 *At Stall 0 Flow Fan Damper CLOSED taken at fan discharge ahead of dampers.

Calculated Fan Eff. 12.970% As a check this number should be above 72-75% w/80% Average)

Calculated Fan HP 49.68 Check against actual Fan Motor Data Plate

Expected Fan Eff Performance? Within expected performance

Original Fan Speed 1770 RPM at Shaft FAN LAWS FUEL CONVERSIONS & ENERGY CONTENT

New Fan Speed 1150 RPM at Shaft Q1/Q2 = N1/N2 (N) NATURAL GAS (C/Ft) Averaged

New Fan Flow 1478 CFM H1/H2 = (N1/N2)^2 (2) #2 DIESEL (RED) (1-Gallon) API Spec.

New Fan Max SP 7.60 Inch WC Bhp1/Bhp2 = (N1/N2)^3 (1) #1 DIESEL(AUTO) (1-Gallon) API Spec.

New Fan Bhp 2.67 Bhp at the shaft. Q1/Q2 = D1/D2 (BV) BIO-GAS VEGATABLE (C/Ft) Averaged

Original Boiler Output PPH 9,896.91 Saturated H1/H2 = (D1/D2)^2 (BL) BIO-GAS LANDFILL (C/Ft) Averaged

Original Boiler Output PPH 8,313.40 Superheated <700 Deg F Bhp1/Bhp2 = (D1/D2)^3 BTU Input of Burner =

New Boiler Output PPH 6,430.12 Saturated

New Boiler Output PPH 5,401.30 Superheated <700 Deg F EQUEVELENT Fuel Flow Units/Hour

EQUEVELENT Fuel Flow Units/Minute

Note1 Data marked with an asterisk * may also be taken from manufacturer's data sheets. NOTE: 1 D/Therm = 1,000,000 Btu

TechStuff C1997 Combustion Efficiency Calculations

Printout 5/22/2014 4:05 PM

Data Compiled by

David Farthing

Combustion Efficiency Calculations

Boiler Type & Data LiDestri Foods Fresno CA CB500 (475)

Minimum O2 Allowed This Fuel Type

Fuel (Gas =1, Oil =2) 1 2.00%

Rated Boiler Hp 475 Steaming Rate PPH

Name Plate Efficiency 80.00% 13110

Current O2 % as found 9.82%

Current Co2 % as found 6.25%

Air Diluted CO ppm as found 90.00

CO in Flue Gas ppm Corrected 169.77

Approximate Fuel Loss out stack 0.05% Cu/Ft Gas/Hr.@NFR@ As Found Eff.

Normal Firing Rate NFR (0-100) 80% 15,870

Recommended O2% @ NFR 2.75% Data from Ideal O2 Table

Average Hours/Day Run Time 24

Average Days/Month Run Time 22

Fuel Cost/Dk-Therm from billings 6.36$ Equivalent Cost / 1000 Cu/Ft = 6.36$

Average Combustion Air Temp 80

Stack Temp at Firing Rate 376

Net Flue Gas Temp Rise 296 Performance Data

Net Efficiency Loss to Wasted Fuel as Co 0.1698% 46% Present Excess Air Mass.

As Found Combustion Efficiency 80.1% 13% New Excess Air Mass.

New Calculated Combustion Efficiency 83.5% $7.70 OLD Fuel Cost per 1,000 Lb/Steam.

New Stack Temp 364 $7.39 NEW Fuel Cost Per 1,000 Lb/Steam.

New Net Flue Gas Temp Rise 284 4.51% Percent Fuel Cost Savings.

Net Combustion Efficiency Gain 4.04%

Current Cost to Operate Per Month 53,292.86$

New Cost to Operate Per Month 51,142.15$

Current Fuel Dollars Wasted as Excess CO 252.42$

Savings Per Month 2,403.13$ Controller Output= 45

Savings Per Year 28,837.57$ Raw Air Flow= 100

NOTES O2 Reading= 3

O2 Corrected Air Flow= 102.5

Voltage

#DIV/0!

CONTROLLER IMPEDANCE VS. VOLTAGE

Impedance of Device Controller is Controlling 250 OHMS

Ma output of controlling Device 4

Out Put Voltage You Should Read at Controller Output 1

When Controller Out Put = Ma in Cell 'F6'.

Common Control Device Impedance and their associated Voltage

Impedance Control Voltage

250 Ohms 5 VDC

120 Ohms 2.4 VDC

100 Ohms 2.0 VDC

TRANSMITTER TROUBLESHOOTER

HIGH SIDE 0.00

LOWSIDE -22.00

4/20 MA READING 12.00 (NOTE: Max Value = 19.99 otherwise DIV/0 Error)

RATIO 1.00 This is any RATIO applied by the display device.

BIAS 20.00 This is any BIAS applied by the display device.

DISPLAY READS 9.00

NOTES:

1] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING HIGH AND PROCESS IS LOW THEN CHECK LOW (REFERENCE) SIDE FOR PLUGGED LEG.

2] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING LOW AND PROCESS IS HIGH THEN CHECK HIGH SIDE FOR PLUGGED LEG.

3] ATTACH A 'Ma' METER IN SERIES TO THE TRANSMIITER NEGITIVE SIGNAL LEG AND READ Ma. INCERT IN 4/20 MA CELL IN FORMULA

Voltage

CONTROLLER IMPEDANCE VS. VOLTAGE

1] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING HIGH AND PROCESS IS LOW THEN CHECK LOW (REFERENCE) SIDE FOR PLUGGED LEG.

2] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING LOW AND PROCESS IS HIGH THEN CHECK HIGH SIDE FOR PLUGGED LEG.

3] ATTACH A 'Ma' METER IN SERIES TO THE TRANSMIITER NEGITIVE SIGNAL LEG AND READ Ma. INCERT IN 4/20 MA CELL IN FORMULA

Pipe Expansion

PIPE THERMAL EXPANSION CALCULATIONSCalculations good for Carbon Steel and Carbon Molybdeum Steel Pipe.

Pipe Size

Pipe Run Length 361

Operating Temperature = 347 Expansion Coefficients

Thermal Expansion per 100 ft = 9.99 Coeff. 212-250 251-359 360+ Temp.

TOTAL Thermal Expansion = 36.08 2.88 1.61 2.02 2.88 Coeff. Factor

This calculation gives good practical results. It is not intended to provide exact data.If exact data is required contact a registered professional engineer.

Compiled October 10, 1997

Source: Skidmore/ASME

Condensate Tank Sizing


Data Compiled by

David C. Farthing

Voice 405-728-6709

Condensate & Feedwater Tank Sizing

Boiler Hp. 1740

Evaporation Rate from and at 212 deg. F. 7223.827 Gallons Per Hour

GPM Flow Rate Start/Stop Feedwater System 300.9928 Gallons Per Minute 2.5 Safety Factor

GPM Flow Rate Modulated Feedwater System 180.5957 Gallons Per Minute 1.5 Safety Factor

Storage Holding Time Desired, Minutes 7 Minutes Holding Time

Tank Size for Start/Stop Feedwater System 3009.928

Tank Size for Modulated Feedwater System 1805.957

Compiler November 3, 1997

Source: Spirax Sarco

Steam Mains Trap Sizing


Data Compiled by

David C. Farthing

James W. Carr

Voice 405-728-6709

Steam Mains Trap Sizing

Steam Main Data Assumes 2.0" of Fiberglass Insulation

Pipe Diameter 6

Steam Header Pressure(PSIG) 150

Ambient Air Temperature 70

Warm-up Load / #Steam(Condensate) per 100 Ft. of Pipe 75 From Spirax Sarco Look-up Tables below.

Running Load / #Steam (Condensate) per 100 ft. of Pipe. 31

Feet Between Trap Points 100

Total Trap Warm-up Load Per Trap Point 75 #/Hr Condensate Load

Total Trap Running Load Per Trap Point 30.75 #/Hr Condensate Load

Pressure vs. Pipe Size Look-up Table

Steam Pressure (psi) 2.00 2.50 3.00 4.00 5.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 24.00 0F Correction Factor *

0.00 6.2 9.7 12.8 18.2 24.6 31.9 48 68 90 107 140 176 207 208 1.5

5.00 6.9 11 14.4 20.4 27.7 35.9 48 77 101 120 157 198 233 324 1.44

10.00 7.5 11.8 15.5 22 29.9 38.8 58 83 109 130 169 213 251 350 1.41

20.00 8.4 13.4 17.5 24.9 33.8 44 66 93 124 146 191 241 284 396 1.37

40.00 9.9 15.8 20.6 29.3 39.7 52 78 110 145 172 225 284 334 465 1.32

60.00 11 17.5 22.9 32.6 44 57 86 122 162 192 250 316 372 518 1.29

80.00 12 19 24.9 35.3 48 62 93 132 175 208 271 342 403 561 1.27

100.00 12.8 20.3 26.6 37.8 51 67 100 142 188 222 290 366 431 600 1.26

125.00 13.7 21.7 28.4 40 55 71 107 152 200 238 310 391 461 642 1.25

150.00 14.5 23 30 43 58 75 113 160 212 251 328 414 487 679 1.24

175.00 15.3 24.2 31.7 45 61 79 119 169 224 265 347 437 514 716 1.23

200.00 16 25.3 33.1 47 64 83 125 177 234 277 362 456 537 748 1.22

250.00 17.2 27.3 35.8 51 69 89 134 191 252 299 390 492 579 807 1.21

300.00 25 38.3 51 75 104 143 217 322 443 531 682 854 1045 1182 1.2

400.00 27.8 43 57 83 116 159 241 358 493 590 759 971 1163 1650 1.18

500.00 30.2 46 62 91 126 173 262 389 535 642 825 1033 1263 1793 1.17

600.00 32.7 50 67 98 136 187 284 421 579 694 893 1118 1367 1939 1.16

800.00 38 58 77 113 203 274 455 670 943 1132 1445 1835 2227 3227 1.156

1000.00 45 64 86 126 227 305 508 748 1052 1263 1612 2047 2485 3601 1.147

1200.00 52 72 96 140 253 340 566 833 1172 1407 1796 2280 2767 4010 1.14

1400.00 62 79 106 155 280 376 626 922 1297 1558 1988 2524 3064 4440 1.135

1600.00 71 87 117 171 309 415 692 1018 1432 1720 2194 2786 3382 4901 1.13

1750.00 78 94 126 184 333 448 746 1098 1544 1855 2367 3006 3648 5285 1.128

1800.00 80 97 129 189 341 459 764 1125 1584 1902 2427 3082 3741 5420 1.127

Compiled by David Farthing 5/22/2014 4:05 PM Sources Marks 7th Ed.

GPSA 9th Ed.

Mid-West Instruments Delta-Tube Flow Calculatordp= (Lb/H/(359.12*Cf*(D^2)*(wf^.5)))^2

Lb/h = (dp^.5)*(((359.12*Cf*(D^2)*(wf^.5))^2)^.5)

Cf = 0.672 from Manufacturer's Model 301

Cf' = 241.32864 Cf' = (359.12 * cf)

D = 3.826 Inside Pipe Diameter

Fp = 100 Flowing Pressure in PSIG used to look up "wf" from Steam Tables

wf = 0.3635 Specific Weight at Flowing Conditions from Steam Tables

Lb/h 13339 Flow Rate Expected

dp= 39.22333672 Calculated dp from formula

Lb/H = 13339.96294 Proofing #

error = 0.007%

dp = 39.229

HC900 Math Block Assignments

Typical 'wf' @ 150 PSI a = dp 39.22334

Flow = 5000 9000 12000 25000 40000 b = Cf' 241.3286

wf = 0.310 0.364 0.3635 0.364 0.384 c = D^2 14.63828

d = wf^.5 0.3635

Dp Flow Dp Flow Dp Flow e = 2

1 32982 11 109389 21 151142 f = 0.5

2 46643 12 114253 22 154699 g = off

3 57126 13 118918 23 158176 h = off

4 65964 14 123407 24 161578 (a^f)*((b*c*(d^f))^e)^f

5 73750 15 127739 25 n/a Math Block Function Proof = 13339.00 PPH

6 80789 16 131928 26 n/a

7 87262 17 135988 27 n/a

8 93287 18 139931 27.5 n/a

9 98946 19 143765

10 104298 20 147500

Fan Laws for ESTIMATING Boiler Burner Fan Pressures/Flows

Q = Volume Flow Rate

D = Fan Diameter

N = RPM

P = Pressure

Diff P = Differential Pressure Across Fan at Firing Rate

H = Fan Horsepower

Eff = ft^3/min X P (in H20)/(6356 X Motor Hp)

Burner Input 29,400,000.00 MMBTU

Max Gas Flow 29,400.00 Ft^3/Hr

Min Gas Flow 2,940.00 Ft^3/Hr

Max Air Flow 4,738.30 CFM base on 9.67 Ft^3 Air/1Ft^3 Gas.

Min Air Flow 473.83 CFM at LOW (10%) FIRE.

Fan Motor HP 30.00 Taken from Fan Motor Data Plate

Fan Stall Pressure 29.00 At Stall 0 Flow Fan Damper CLOSED

Calculated Fan Eff. 72.064% As a check this number should be 72-75% w/72% Average)

Calculated Fan HP 30.03 Check against actual Fan Motor Data Plate

Fan Performance OK

Q = C' * (P^.5) Air Flow at varying pressures measured down stream of damper vanes

C' = 2940 Arbitrary C' to reach necessary air flow shown in Max Air Flow in above cell.

Diff P = 100 Differential Inches H20 Across Fan At Maximum Flow High Fire Position of Fan Damper

Q = 29400.000 Must Equal MAX AIR FLOW!! Adjust C' as needed to correct.

% Flow 100%

DP = 99 88 77 66 55

Q = 29252.631 27579.645 25798.395 23884.673 21803.624

% Flow 99.499% 93.808% 87.750% 81.240% 74.162%

DP = 98 87 76 65 54

Q = 29104.515 27422.494 25630.326 23703.038 21604.500

% Flow 98.995% 93.274% 87.178% 80.623% 73.485%

DP = 97 86 75 64 53

Q = 28955.642 27264.438 25461.147 23520.000 21403.523

% Flow 98.489% 92.736% 86.603% 80.000% 72.801%

DP = 96 85 74 63 52

Q = 28805.999 27105.461 25290.836 23335.527 21200.641

% Flow 97.980% 92.195% 86.023% 79.373% 72.111%

DP = 95 84 73 62 51

Q = 28655.575 26945.545 25119.371 23149.583 20995.800

% Flow 97.468% 91.652% 85.440% 78.740% 71.414%

DP = 94 83 72 61 49

Q = 28504.358 26784.675 24946.727 22962.134 20580.000

% Flow 96.954% 91.104% 84.853% 78.102% 70.000%

DP = 93 82 71 60 12.5

Q = 28352.333 26622.832 24772.880 22773.142 10394.470

% Flow 96.437% 90.554% 84.261% 77.460% 35.355%

DP = 92 81 70 59 5

Q = 28199.489 26460.000 24597.805 22582.568 6574.040

% Flow 95.917% 90.000% 83.666% 76.811% 22.361%

DP = 91 80 69 58 2 0.137

Q = 28045.813 26296.159 24421.474 22390.373 4157.788

% Flow 95.394% 89.443% 83.066% 76.158% 14.142% 1.49

DP = 90 79 68 57 1

Q = 27891.289 26131.292 24243.861 22196.513 2940.000

% Flow 94.868% 88.882% 82.462% 75.498% 10.000%

DP = 89 78 67 56 0.025

Q = 27735.905 25965.377 24064.937 22000.945 464.855

% Flow 94.340% 88.318% 81.854% 74.833% 1.581%

CFM base on 9.67 Ft^3 Air/1Ft^3 Gas.

Taken from Fan Motor Data Plate

At Stall 0 Flow Fan Damper CLOSED

As a check this number should be 72-75% w/72% Average)

Check against actual Fan Motor Data Plate

Differential Inches H20 Across Fan At Maximum Flow High Fire Position of Fan Damper

Compiled November 4, 1997

Source: Simple Math Context

Revenue Loss


Compiled by

David Farthing

Voice 405-728-6709

Cost of Leaking Steam Traps in Lost Steam and RevenueCustomer

Site

INPUT DATA

Total Number of Traps Surveyed 60

Number of Traps Leaking 24

Number of Traps Plugged 0 Trap Type Surveyed

Capacity of Traps in #/Hr. 550 1/2" TD

Steam Line Pressure 100

Condensate Return Line PSI 12

Temperature of Condensate at Traps 245

Temperature of Condensate in Tank 190

Hours per Day of Production 24

Days per Year of Production 340

Rated Boiler Horsepower 700

Cost of Fuel/Therm 6.36$

Cost of Steam Production / 1,000# 7.62$

Results of Survey

Percent Traps Leaking 40.00%

Percent Traps Plugged 0.00%

Percent of Traps Operational 60.00%

# Lost Steam To Leaking Traps 7,417,440 Annually

BTU Lost to Flash Steam Venting 407,959,200 Annually

Lost Revenue to Wasted Steam 59,088.04$ Annually

Steam Trap Survey Form

Customer Name

Location

Plant Contact

Contacts Phone

Contacts e-mail

Location Trap # Trap Style Temp IN Temp OUT Status Test Means Comments and Notes

Back to Cost of

Compiled January 16, 1998 Ohms Law


Data Compiled by

David C. Farthing

Voice 405-728-6709

OHMS Laws of Electricity

Fill in any TWO (2) known pieces of data under the factor you are looking for.

E = Voltage I = Current/Amps R = Ohms Resistance W = Watts

Input the known data from your application.

To Find AMPS = 0.0417 To Find WATTS = 11.560 Kw=

Voltage 24 Voltage 110

OHMS 330 OHMS 100

Watts 1 Amps 0.34

To Find VOLTS = 1.000 To Find OHMS = 1.000

Watts 1 Voltage 1

OHMS 1 Amps 1

Amps 1 Watts 1

To Find KVA = 0.001

# of Phases 1

Amps 1

Voltage 1

Compiled January 16, 1998 Ohms Law


Data Compiled by

David C. Farthing

Voice 405-728-6709

Fill in any TWO (2) known pieces of data under the factor you are looking for.

0.01156

Temperature Conversions

Enter Known Temperature in 'F' or 'C' for results.

Degree F Degree C

INPUT DATA 60 15.56

Degrees C = 15.56

Degrees K = 288.71

Degrees R = 519.69

Degrees F= 60.01

Calculating Flash Steam for Secondary UseFormula = ((SH1 - SH2)/LH2) X 100 = % Flash Steam

SH1 = Temperature of High Pressure Steam from Steam Tables

SH2 = Temperature of Steam at Flash Pressure from Steam Tables

LH2 = Latent Heat of Flash Steam at Flash Pressure From Steam Tables

SH1 = 338

SH2 = 227

LH2 = 960

Flash % 11.56%

Boiler Blowdown going to Flash Tank in PPH = 828

Total PPH Flash Available for Work = 95.74

Btu/Hr Available for Work = 91,908

Example: A 800 Bhp (27,600 PPH) operating at 100 PSIG has a surface blowdown rate of 3%. Calculate the Flash Steam available to the DA at 5 PSIG.

SH1 = 338

SH2 = 227

LH2 = 960

Blow Down = 27,600 * 3% = 828 PPH

SH2 = Temperature of Steam at Flash Pressure from Steam Tables

LH2 = Latent Heat of Flash Steam at Flash Pressure From Steam Tables

Example: A 800 Bhp (27,600 PPH) operating at 100 PSIG has a surface blowdown rate of 3%. Calculate the Flash Steam available to the DA at 5 PSIG.

SPIRAX SARCO STEAM COST CALCULATOR

STEAM COST CALCULATOR

COST OF NATURAL GAS 12.65 $/MMBTU

BOILER OPERATING PRESSURE 150 psig

STEAM TOTAL ENTHALPY 1196 Hg (BTU/LB)

BOILER BLOWDOWN ENTHALPY 339 Hf (BTU/LB)

STEAM LATENT ENTHALPY 857 Hfg (BTU/LB)

BOILER EFFICIENCY (GAS) 82.0% %

BOILER BLOWDOWN RATE 2% %

CONDENSATE RETURN 80% %

CONDENSATE RETURN TEMPERATURE 165 °F

MAKE UP WATER TEMPERATURE 60 °F

BOILER FEED WATER TEMPERATURE 144 °F

BOILER FEED WATER ENTHALPY 112 BTU/LB

MAKE UP WATER COST 3.00 $/1000 GALLS

MAKE UP WATER TREATMENT COST 1.25 $/1000 GALLS

ENERGY REQUIRED PER LB OF STEAM 1088.6 BTU/LB

STEAM ENERGY COST 16.79 $/1000 LBS

STEAM WATER & CHEMICALS COST 0.52 $/1000 LBS

TOTAL STEAM COST 17.31 $/1000 LBS

SPIRAX SARCO INC · 203 GEORGIA AVE. · DEER PARK, TX 77536 · TEL:(281) 478 4002 · FAX:(281) 478 4615

SPIRAX SARCO STEAM COST CALCULATOR

$/1000 GALLS

$/1000 GALLS

SPIRAX SARCO INC · 203 GEORGIA AVE. · DEER PARK, TX 77536 · TEL:(281) 478 4002 · FAX:(281) 478 4615

Calculated Total Cost to Produce Steam-Natural Gas Fired Plant w/ Possible Secondary Waste Fuel Stream

Rated Boiler Output in Kpph 18

Thermal Efficiency of Boiler 82

MMBTU/Hr Input 21.95 at Stated Boiler Thermal Efficiency

Total Operating Electric Horsepower 45 Fan and Feedwater Pumps

Hours Per Year Operation 8000

Cost of Fuel per MMBTU 12.00$

Fuel Cost per Kpph 14.63$

Contribution of Secondary Waste Fuel Stream 30%

Fuel Cost per Kpph w/ Contributed Waste Fuel $10.24

Cost of Electricity per KWH 0.14$

Electrical Cost per Kpph 0.26$

Cost of Water per 10,000 Gal 2.33$

Percent Make-up to Boiler 3%

Calculated Water Treatment Cost per 1000 Pounds 0.01$

Operators Annual Salary 40,000.00$

Overhead and Benefits of Operator 14,400.00$

Percentage of Operator Cost to Operation of Boiler 6%

Annual Maintenance & Inspection 1,165.00$

Cost to Produce 1Kpph 11.07$

Depreciation on Equipment as % 5.00%

Cost to Produce 1Kpph w/ Depreciation 11.62$

Cost of Purchased Steam from Outside source 9.56$

Saving(+)/Cost(-) to Operate Owners On-Site Plant ($296,481.36)

Calculated Total Cost to Produce Steam-Natural Gas Fired Plant w/ Possible Secondary Waste Fuel Stream

at Stated Boiler Thermal Efficiency

Fan and Feedwater Pumps

PROPERTIES OF SATURATED STEAM

Specific

Temp- Volume Gauge Temp-

erature Cu. ft. Pressure erature

Deg F Sensible Latent Total per lb. PSIG Deg F Sensible Latent Total

25 134 102 1017 1119 142 185 382 355 843 1198

20 162 129 1001 1130 73.90 190 384 358 841 1199

15 179 147 990 1137 51.30 195 386 360 839 1199

10 192 160 982 1142 39.40 200 388 362 837 1199

5 203 171 976 1147 31.80 205 390 364 836 1200

0 212 180 970 1150 26.80 210 392 366 834 1200

1 215 183 968 1151 25.20 215 394 368 832 1200

2 219 187 966 1153 23.50 220 396 370 830 1200

3 222 190 964 1154 22.30 225 397 372 828 1200

4 224 192 962 1154 21.40 230 399 374 827 1201

5 227 195 960 1155 20.10 235 401 376 825 1201

6 230 198 959 1157 19.40 240 403 378 823 1201

7 232 200 957 1157 18.70 245 404 380 822 1202

8 233 201 956 1157 18.40 250 406 382 820 1202

9 237 205 954 1159 17.10 255 408 383 819 1202

10 239 207 953 1160 16.50 260 409 385 817 1202

12 244 212 949 1161 15.30 265 411 387 815 1202

14 248 216 947 1163 14.30 270 413 389 814 1203

16 252 220 944 1164 13.40 275 414 391 812 1203

18 256 224 941 1165 12.60 280 416 392 811 1203

20 259 227 939 1166 11.90 285 417 394 809 1203

22 262 230 937 1167 11.30 290 418 395 808 1203

24 265 233 934 1167 10.80 295 420 397 806 1203

26 268 236 933 1169 10.30 300 421 398 805 1203

PSIG

IN V

AC

Gauge

Pressure Heat in Btu/lb. Heat in Btu/lb.

Specific



Deg F Sensible Latent Total per lb. PSIG Deg F Sensible Latent TotalPSIG

IN V

AC

Gauge


28 271 239 930 1169 9.85 305 423 400 803 1203

30 274 243 929 1172 9.46 310 425 402 802 1204

32 277 246 927 1173 9.10 315 426 404 800 1204

34 279 248 925 1173 8.75 320 427 405 799 1204

36 282 251 923 1174 8.42 325 429 407 797 1204

38 284 253 922 1175 8.08 330 430 408 796 1204

40 286 256 920 1176 7.82 335 432 410 794 1204

42 289 258 918 1176 7.57 340 433 411 793 1204

44 291 260 917 1177 7.31 345 434 413 791 1204

46 293 262 915 1177 7.14 350 435 414 790 1204

48 295 264 914 1178 6.94 355 437 416 789 1205

50 298 267 912 1179 6.68 360 438 417 788 1205

55 300 271 909 1180 6.27 365 440 419 786 1205

60 307 277 906 1183 5.84 370 441 420 785 1205

65 312 282 901 1183 5.49 375 442 421 784 1205

70 316 286 898 1184 5.18 380 443 422 783 1205

75 320 290 895 1185 4.91 385 445 424 781 1205

80 324 294 891 1185 4.67 390 446 425 780 1205

85 328 298 889 1187 4.44 395 447 427 778 1205

90 331 302 886 1188 4.24 400 448 428 777 1205

95 335 305 883 1188 4.05 450 460 439 766 1205

100 338 309 880 1189 3.89 500 470 453 751 1204

105 341 312 878 1190 3.74 550 479 464 740 1204

110 344 316 875 1191 3.59 600 489 473 730 1203

115 347 319 873 1192 3.46 650 497 483 719 1202

120 350 322 871 1193 3.34 700 505 491 710 1201

Specific



Deg F Sensible Latent Total per lb. PSIG Deg F Sensible Latent TotalPSIG

IN V

AC

Gauge


125 353 325 868 1193 3.23 750 513 504 696 1200

130 356 328 866 1194 3.12 800 520 512 686 1198

135 358 330 864 1194 3.02 900 534 529 666 1195

140 361 333 861 1194 2.92 1000 546 544 647 1191

145 363 336 859 1195 2.84 1250 574 580 600 1180

150 366 339 857 1196 2.74 1500 597 610 557 1167

155 368 341 855 1196 2.68 1750 618 642 509 1151

160 371 344 853 1197 2.60 2000 636 672 462 1134

165 373 346 851 1197 2.54 2250 654 701 413 1114

170 375 348 849 1197 2.47 2500 669 733 358 1091

175 377 351 847 1198 2.41 2750 683 764 295 1059

180 380 353 845 1198 2.34 3000 696 804 213 1017

Total per lb.

Calculating Superheat in Pressure Reducing Stations

High Pressure Point 250

Reduced Pressure 14

High Pressure Volume/CuFt 1.75 From Tabels above

Reduced Pressure Volume/CuFt 14.3 From Tabels above

High Pressure Temperature 406 From Tabels above

Reduce Pressure Normal Temperature 248 From Tabels above

Resultant Superheat 19.3357

Temperature of Reduced Pressure Steam 267.336

Specific

Volume

Cu. ft.

per lb.

2.29

2.24

2.19

2.14

2.09

2.05

2.00

1.96

1.92

1.89

1.85

1.81

1.78

1.75

1.72

1.69

1.66

1.63

1.60

1.57

1.55

1.53

1.49

1.47

Specific

Volume

Cu. ft.

per lb.

1.45

1.43

1.41

1.38

1.36

1.34

1.33

1.31

1.29

1.28

1.26

1.24

1.22

1.20

1.19

1.18

1.16

1.14

1.13

1.12

1.00

0.89

0.82

0.75

0.69

0.64

Specific

Volume

Cu. ft.

per lb.

0.60

0.56

0.49

0.44

0.34

0.23

0.22

0.19

0.16

0.13

0.11

0.08

Technical Source

National Hydraulic Inst.Piping Friction Loss Analysis Compiled by:

David C. Farthing

Voice 405-728-6709

68 Degree Water Data!! Piping Friction Loss and Velocity Analysis

Single pipe system. For multiple pipe sizes in a single run calculate each section and add

all section total losses together to get Total Head Loss for system.

Lookup Tables are available from most any pump/pipe manufacturer.

IS this calculation for Suction or Discharge Pipe S or D ? SSystem Size 2.064 It is helpful to input actual pipe ID.

Linear Feet Pipe 6.00

Number of 90 Ells 1.00


Number of Valves 1.00

Flow Rate Required 35.00 GPM

Pipe Schd 40.00

Lookup Table > Friction Loss/100 Ft 1.00 Head Friction Loss/100 Feet of Pipe

Federal Catalog Velocity 3.33 Feet Per Second

Pages 265-266 Effective Reynolds Number 53027.89 Flow is no longer laminar!

K Factor 90 Ells Short 0.98 Averaged for pipe size range


K Factor Valves Globe 6.75 Averaged for pipe size range

Head Velocity V2/2G 0.17

Total Loss Line Pipe 0.06 Feet Head Formula

Total Loss from 90 Ells 0.17 Feet Head h=K*(V2/2G)


Total Loss from Valves 1.16 Feet Head h=K*(V2/2G)

Back Pressure Valve Setting 0 0.00 Feet Head

Total Head Loss 1.39 Feet of Head Loss

Pump

Financial Analysis

5/22/2014

Compiled by

David C. Farthing

Voice 405-728-6709

Financial Analysis of a Project

Project Name ABC Processors

OXYGEN TRIM TO CROSS LIMITED F/A

Initial Cost of Investment Materials 5,000.00$

Initial Cost of Investment Installation 3,850.00$

Annual Pay Back Expected from this investment 19,429.00$

Base Line Years to Payout 0.46

Fixed Cost of Money in percent to be used for this exercise 6.85%

How many Years will the Project be Amortized over? 0

First Year Cost of Money -$

Second Year Cost of Money -$

Third Year Cost of Money -$

Fourth Year Cost of Money -$

Fifth Year Cost of Money -$

Estimated Cost of Perishables during first five years of ownership -$

NET Years to Payout 0.46

Expected Life Span of Investment 15.00

*Total Dollars Returned Over Life of Investment 282,585.00$

*Note: Return on investment includes paying off original equipment investment.

Original Investment 8,850.00$ Interest Rate 6.85% Interest Paid -$

Hydronic Load Calculations

Process Recovery v Tank Size

Heater Size Selected 1825 Tank Size 3000

Usage Recovery Percent

Time Load In-Temp Out-Temp Time Rate Heat Heater Recovery of Tank Vol.

0.00 300 50 165 0.083 3,454,157 1,460,000 10%

0.25 255 50 165 243,691 1,460,000 9%

0.50 365 50 165 348,812 1,460,000 12%

0.75 255 50 165 243,691 1,460,000 9%

1.00 365 50 165 348,812 1,460,000 12%

Recovery Time

Minutes

874,518.37

10.01

14.33

10.01

14.33

874,567.07

Instrument Application Selection GuideA guide to help you select the equipment needed to

accomplish an instrumentation application.

What is the Application? 1 Under Construction Do Not Use This Page.Heating = 1

Level = 2

Pressure = 3

Flow = 4

Vaccum = 5

Cooling = 6

Equipment Needed Controller Reverse Action - Thermal element RTD or Thermocouple - Control Valve and thermal extionsion wire

Controller Reverse Action

Transmitter Use a Thermocouple or RTD for Temperature Measurement

Control Valve

Special Equipment

Under Construction Do Not Use This Page.

Controller Reverse Action - Thermal element RTD or Thermocouple - Control Valve and thermal extionsion wire

Water Flow Through an Orifice

Qh=C' X (Hw*Pf)^.5

Qh= Lbs/Hr Mass Flow UNDER CONSTRUCTION

C' = Flow Constant DO NOT USE FOR DEFINITIVE DATA!!

Hw = Differential in Inches Water

Pf = Static Gauge Pressure in PSIA

Assumed Factors for Water

Fb Orifice Factor

Fr Reynolds Number

Y Expansion Factor

CV = GPM / DP^.5 x SG.

Inlet Pressure, PSIG 60 74.65 Calculated Pf GPM

Discharge Pressure 10 24.65 Corrected to PSIA Pressure Drop

Calculated HW 1386 Inches Water Differential Specific Gravity

ID of Orifice 1.55 CV=

ID of Pipe 4 Orifice Size

GPM= 299.82

Average Orifice Size 1.80

These Values are ONLY Approximate and are not to be used for custody transfer calculations.

DO NOT USE FOR DEFINITIVE DATA!!

CV = GPM / DP^.5 x SG.

300

Pressure Drop 50

Specific Gravity 1

42.43

Orifice Size 2.05

These Values are ONLY Approximate and are not to be used for custody transfer calculations.

David Farthing's TechStuff 5/22/2014 Helpful Boiler Burner Calculations

Combustion Air Requirements in Sq./Ft for Atmospheric and Power Burners

IN PUT DATA


Boiler Eff. 80%

Boiler Input BTUH 33,476,923

Combustion Air Area Requirements 27.9 Square Feet Free Air Flow Area

Authority Oklahoma Boiler and Pressure Vessel Safety Act 1982, Edition 1993

Table 380:25-7-18(b)

Combustion Analysis This section under construction DO NOT USE THIS FUNCTION!

Stack Temperature 525

Ambient Temperature 90

Net Temperature Rise 435

Excess O2 Reading 4%

Calculated Efficiency 79.1 Examples Only!

Calculated Excess Air 21.1 Examples Only!

Gas Analysis for Natural Gas

%O2 0.0 0.5 1.0 1.5 2.0 2.5 3.0

% Excess Air 0.0 2.1 4.5 7.1 9.8 12.2 15.1

% Co2 11.9 11.6 11.3 11.0 10.7 10.5 10.2

%O2 3.5 4.0 4.5 5.0 5.5 6.0 6.5

% Excess Air 18.1 21.2 24.5 28.2 32.0 36.1 40.4

% Co2 9.9 9.6 9.3 9.0 8.7 8.5 8.2

%O2 7.0 7.5 8.0 8.5 9.0 9.5 10.0

% Excess Air 45.0 50.2 55.5 61.2 67.8 74.6 82.0

% Co2 7.9 7.6 7.3 7.0 6.8 6.5 6.2

%O2 10.5 11.0 11.5 12.0 12.5 13.0 13.5

% Excess Air 90.4 100.4 109.2 120.6 133.0 146.8 163.1

% Co2 5.9 5.6 5.3 5.1 4.8 4.5 4.2

General Notes

High "C" Carbon (soot) need more air.

High "CO" Carbon Monoxide, need more air.

High "CO2" Carbon Dioxide, need LESS air.

Typical Safe Oxygen Standards

High Fire 2.0-4.5% Excess O2

Mid Fire 3.5-5.0% Excess O2

Low Fire 6.0-8.0% Excess O2

Ideal Excess Oxygen Curve for Natural Gas

Ideal O2 Firing Rate

6 20

5.75 30

4.75 40

3.6 50

3.3 60

3.05 70

2.8 80

2.5 90

2.3 100

Fuel Oil 2

Molectular Make-up Ideal Air = 144*(8.01*Carbon+23.86*(Hydrogen-(Ox/8)+3*Sulfur)/HV/Lb

Carbon % 87.30 Ideal Air for this fuel oil per 10,000 Btu = 7.572031

Hydrogen % 12.50 Ideal Combustion Air Ft^3/Gallon = 1355.562

Oxygen % 0.00 Gallon/Min @ High Fire = 4.074046

Sulfur % 0.20 Combustion Air for this Oil CFM = 6497.201 at 15% EA

Specific Gravity 0.865 Combustion Air for Gas CFM = 6249.026 at 15% EA

Heating Val/Gal 136952 Controller Ratio Factor Oil/Gas Bias = 1.039714

Heating Val/Lb 18981.6583

Air Density @ 70F Lb/Ft^3 0.0765

01234567

20 30 40 50 60 70 80 90 100

Ex

ce

ss

Ox

yg

en

%

Firing Rate

Ideal Excess Oxygen Natural Gas

Condensing Economizer for Deaerators Energy CalculationsCustomer Cargill Feed Mills

Firetube Dryback

Boiler Type Watertube/Firetube F

Fuel Type Gas or Oil G

Boiler Rated Horsepower 700

Boiler Rated Efficiency 82.00%

Normal Firing Rate (NFR) 50.0%

Boiler Operating Pressure PSIG 110

Combustion Make-up Air Temperature 70

Entering Feedwater Temperature 240 Equivalent Fuel Cost/1000 CF

Fuel Cost per D/Therm 9.500$ 9.50$ Per 1000 CF

Hours/Day Operation 22

Days/Month Operation 28 Acid Dewpoint Tables

Operating Steam Temperature (Saturated) 344.00 Fuel Dewpoint Minimum Minimum

Firing Boiler Horsepower @ NFR 350 Stack Temp Feedwater

Boiler Fuel Input @ NFR 14,283,841.46 Inlet Temp.

BTU Output @ NFR 11,712,750 Natural Gas 150 250 210

Net Operating Efficiencies as found 84.37%

Theoretical Entering Stack Temperature 399.00 Default #2 Diesel Fuel 180 275 210

Actual Observed Stack Temperature 341.00 Low Sulfur Oil 200 300 220

Entering Make-Up Water Temperature 68.00

Temperature Rise Across Econ. 273.00

Water Flow #/Hr 12,075.00

Gross BTU to Feedwater/Hr 921,315.96

Exiting Make-Up Water Temperature "F" 144.30

Exiting Stack Temperature 182.83 Caution Stack Temp Below Dew Point!

Gain in Efficiency 3.23% Condensing Economizer Required

New Net Calculated Thermal Efficiency 87.59%

Fuel Savings/Hr 4.38$

Annual Current Cost of Operation 1,003,068.48$

Total Annual Savings w/ Economizer 32,349.25$ Based on Gain in Efficiency

Annual Cost of Operation w/ Economizer 970,719.24$

Economizer Equipment Cost 23,000.00$

Economizer Estimated Installation 11,500.00$

Actual Economizer Installation Quote 13,785.00$

Simple Pay-Back in Years 1.14

Economizer Heat Recovery Calculations 5/22/2014 4:05 PM Data Compiled by

David Farthing

Federal Corporation

Economizer Energy CalculationsCustomer LiDestri Foods, Fresno

CB500 @ 467Bhp

Boiler Type Watertube/Firetube F

Fuel Type Gas or Oil G

Boiler Rated Horsepower 467

Boiler Rated Efficiency 79.00%

Normal Firing Rate (NFR) 80.0%

Boiler Operating Pressure PSIG 120

Combustion Make-up Air Temperature 80

Entering Feedwater Temperature 227 Equivalent Fuel Cost/1000 CF

Fuel Cost per D/Therm 6.300$ 6.30$ Per 1000 CF

Hours/Day Operation 22

Days/Month Operation 28 Acid Dewpoint Tables

Operating Steam Temperature (Saturated) 350.00 Fuel Dewpoint Minimum Minimum

Firing Boiler Horsepower @ NFR 373.6 Stack Temp Feedwater

Boiler Fuel Input @ NFR 15,825,980 Inlet Temp.

BTU Output @ NFR 12,502,524 Natural Gas 150 250 210

Net Operating Efficiencies as found 80.22%

Actual BTU Input 15,584,975

Theoretical Entering Stack Temperature 438.00 Default #2 Diesel Fuel 180 275 210

Actual Observed Stack Temperature 405.00 Low Sulfur Oil 200 300 220

Temperature Rise Across Econ. 178.00

Water Flow #/Hr 12,889.20

Gross BTU to Feedwater/Hr 489,387.22

Exiting Feedwater Temperature "F" 264.97

Exiting Stack Temperature 329.17 Application OK, Stack Temp Above Dew Point.

Gain in Efficiency 2.47% .

New Net Calculated Thermal Efficiency 82.70%

Fuel Savings/Hr 2.47$

Annual Current Cost of Operation 737,009.55$

Total Annual Savings w/ Economizer 18,232.45$ Based on Gain in Efficiency

Annual Cost of Operation w/ Economizer 718,777.09$

Economizer Equipment Cost 13,850.00$

Economizer Estimated Installation 11,080.00$

Actual Economizer Installation Quote 13,785.00$

Simple Pay-Back in Years 1.52

Condensing Vertical

Efficiency Firetube Firing Rate

85% 77% 20

85% 75% 40

80% 68% 50

75% 60% 60

65% 55% 75

60% 50% 90

57% 45% 100

85% 85% 80%

75%

65% 60%

57%

77% 75%

68%

60% 55%

50% 45%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

20 40 50 60 75 90 100

No

n-C

on

den

sin

g E

co

no

miz

ers

Co

nd

en

sin

g E

co

no

miz

ers

Firing Rate

Economizer Efficiencies

Conventional

Condensing

David Farthing's TechStuff

Worksheet by Stephen Youngblood, P.E.Piping Insulation Losses Data Compiled by David Farthing

PIPING INSULATION LOSSESNOTE-1: Emistivity based on Steel Pipe between 130 and 530 Deg 'C' = .78

See Mark's Engineering Handbook 9th Edition McGraw-Hill

Emistivity Loss Calculates as (((T1+460)-(T2+460))/.78)/ Ins. Eff% X Surface Area

NOTE-2 This Calculator returns a relatively LOW result in order to not over state the loss in the pipe work.

One should always contact a Professional Engineer expert in Thermodynamics when considering insulated piping losses.

Pipe Run Data Main Condensate Line Outside of Building

Diameter Inches 84

Length Feet 12

Total Surface Area Sq Ft 461.8152

Insulation Eff % 54%

Ambient Temp 'F' 72

Fluid Temp 'F' 160

Emisitivity 208.93 Btu/Sq Ft

Pipe Loss = 96,485.61 Btu/Hr

Annual Operating Hours 8,760

Annualized BTU Loss 845,213,916

Total DkTherms 845

Cost/DkTherm 6.36$

Cost of Inadequate Insulation 5,375.56$

Water Flow Characteristics - Water Hammer

PVC and CPVC Pipe CalculationPressure Surge = aV/ 2.31g = Shock Pressure pipe is exposed to.

a= 4660/ (((1+ (Kdi/Et))^.5)

Where a= wave velocity, ft/Sec Calculated factor see results below.

p= pressure surge caused by the sudden change in velocity

V= maximum velocity change, ft/Sec (V= Q/A) Pipe Area =0.785398 * d^2

g= acceleration of gravity, 32.2 ft/Sec ^2

k= fluid bulk modulus, 300,000 psi for water

di= inside pipe diameter in inches

E= modulus of elasticity of the pipe,

420,000 psi PVC, 360,000 psi CPVC,

t= pipe wall thickness, inches

Q= Flow Through Pipe, GPM

INPUT DATA

Q= 450

di= 4.025 Results for "a" a= 1021.10

V= 11.26 Results for Pressure Surge 155 PSIG

K= 300000 NOTE: Maximum safe Pressure Surge for PVC pipe = 98 PSIG.

E= 420000

t= 0.145

Steel Pipe Water Hammer Calculations Source Tube-Turn

Pressure Surge = P + (60V)

Where P= Flowing Pressure in PSIG

V= Flowing Velocity in ft/Sec.

INPUT DATA

Q= 450

P= 100 Results for Pressure Surge 775.4471 PSIG

di= 4.025

V= 11.26

ASCO Solenoid Valve Application GuideTOMSPAVE

Application 25 degree f chiller service

T Type of Valve 2

2-Way, 3-Way, 4-Way

O Operation of Valve NC

Universal, NC, NO

M Media L

Liquid. Gas, Steam Go to Liquid Valve Sizing Guide

S Size of Flowing Pipe 1 CV From Valve Sizing Guide 4.92

P Pressure Minimum Maximum Drop Across Valve

10 15 5

A Atmosphere Valve will Operate In. Clean

V Voltage Requirements 115

24 VDC, 115 VAC

E Extras for this application.

Fluid Temperature 25 http://www.ascovalve.com/products/html/valve_selector.htm

Ambient Temperature 90

http://www.ascovalve.com/products/html/valve_selector.htm

STEAM TRAP SELECTION GUIDE

The chart below lists various steam trapping applications and enables the correct choice of trap to be made.

A = First choice

B = Alternate choice Spirax Sarco Spirax Sarco

F & T Range FT/TV/SLR

(Float/ (Float/Thermo-

Thermostatic) static with

Steam Lock

Application Release)

CANTEEN EQUIPMENT F & T Range FT/TV/SLR

Boiling Pans-Fixed A B

Boiling Pens-Tilting A

Boiling Pans-Pedestal B B

Steaming Ovens

Hot Plates B B

FUEL OIL HEATING

Bulk Oil Storage Tanks

Line Heaters A

Outtlom Heaters A

Tracer Lines & Jacketed Pipes

HOSPITAL EQUIPMENT F & T Range FT/TV/SLR

Autoclaves and Sterilizers B B

INDUSTRIAL DRYERS F & T Range FT/TV/SLR

Drying Coils (continuous) A

Drying Coils (grid)

Drying Cylinders B A

Multi Bank Pipe Dryers A

Multi Cylinder Sizing Machines B A

LAUNDRY EQUIPMENT F & T Range FT/TV/SLR

Garment Presses B

Ironers and Calendars B A

Solvent Recovery Units A

Tumbler Dryers A B

PRESSES F & T Range FT/TV/SLR

Multi Platan Presses

(parallel connections) B

Multi Platen Presses

(series connections)

Tire Molds B

PROCESS EQUIPMENT F & T Range FT/TV/SLR

Boiling Pans-Fixed A B

Boiling Pan-Tilted A

Brewing Coppers A B

Digesters A

Evaporators A B

Hot Tables

Retorts A

Bulk Storage Tanks

Vulcanizers B

SPACE HEATING EQUIPMENT F & T Range FT/TV/SLR

Shell & tube Heat Exchangers A B

Heating Coils & Unit Heaters A B

Radiant Panels & Strips A B

Radiators & Convection Cabinet Heaters B

Overhead Pipe Coils B

STEAM MAINS F & T Range FT/TV/SLR

Horizontal Runs B

Separators A

Terminal Ends B

Shut Down Drain

(Frost Protection)

TANKS AND VATS F & T Range FT/TV/SLR

Process Vats

(Rising Discharge Pipe) B

Process Vats

(Discharge Pipe at Base) A

Small Coil Heated Tanks

(quick boiling) A

Small Coil Heated Tanks

(slow boiling)

1. With air vent in parallel 2. At end cooling leg Minimum length 3 ft (1m)

3. Use special traps which offer fixed temperature discharge option.

The chart below lists various steam trapping applications and enables the correct choice of trap to be made.

Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco

FT/SLR TD Range BPT SM Thermoton

(Float/Steam (Thermo- (Balanced (Bimetallic) (Liquid

Lock Release) dynamic) Pressure Expansion)

Thermostatic)


B1 B1 B

B B

B1 A2

A2

B1 A2

A

B A3 B B


B1 A


B B

B A

B1

B

B1


A

B1 B1 B

B

B1


A

A1

A B


B1 B1 B

B

B1

B1

B1

B A

A1

A


B1

B1

B1 B1

A B

A


A B2

B B2

A1 B2

B3 A


A B

B B

B

A

Spirax Sarco

lB Range

(Inverted

Bucket)

lB Range

B1

B1

B1

lB Range

B

lB Range

B

B1

B1

B1

B1

lB Range

B

B1

B

B1

lB Range

B

B1

B

lB Range

B1

B1

B1

B1

B1

B1

lB Range

B1

B1

B1

B1

lB Range

B

B

B1

lB Range

B

B

B

Courtesy of Spirax-Sarco

Boiler Application GuideThis application helps you select the vender and type of boiler you might use.

Do you need Steam = S or Water = W s Steam Boiler Application 0

Operating Pressure 12 Low Pressure System 1 0

Is the load Continuous or Cyclic? Cont./ Cyc. Cont.

How Much Steam or Hot Water is needed?

Water Applications BTU 0 NO ENTRY REQUIRED Water applications only

Operating Temperature (Water) 210 0 0

Steam Flow #/Hr. 10,000 Please enter Steam Load 1 1

Burner Type Power or Atmospheric p Power Burner Selected 1 1

Fuel Oil/Gas or Oil & Gas g Gas 2

What pressure is the Primary fuel 1 I Inches/PSI 2 0

Feed Water System desired? m Start/Stop or Modulating 1 1

Boiler Hp Required 6

Steam 289.86

Water 0.00

Net BTU Output 9,700,000

Special Note 1 None

Boiler Types To Look At Steam Boilers Kewanee Rite or Peerless

Application Note 1 Steam Application

Application Note 2 Low Pressure Steam Application

Application Note 3 none

Application Note 4 Modulating Feedwater System Selected, Price Boiler Accordingly

Application Note 5 IRI Fuel Train Required

Application Note 6 Gas Fired Burner

Application Note 7 Low Pressure Gas Train Required, Check Pressure Drops in Gas Train

Select a boiler shell with a minimum working pressure of 15 PSIG

Flame Safety Selection GuideThis application helps you answer the questions that need to be answered to select FSG.

Application B

Boiler, Oven, Furnace

BTU Input 3,465,000 IRI Codes Required

Operation A You have selected Automatic Operation

Automatic, Semi-Automatic, Manual

Pre-Purge Required Y

Yes / No

Purge Time Specified By Manufacturer This Application guide uses gas flow to determine purge time.

Purge Time Recommended if not specified. 2.31 Minutes

Pilot Style I

Interrupted, InTermittent, Standing

Results of your questions.Use Programming Controller such as a RM7800 or RM7840

Use RM 7800 or 7840 series Programmers on Automatic Boiler Applications

Purging Relay required, RM7800 / 7840 on automatcis, and RM7895 on Semi-Automatics

Use Interupted Amplifier & Relay Combinations

This application helps you answer the questions that need to be answered to select FSG.

1

This Application guide uses gas flow to determine purge time.

Suction Piping Calculations68 Degree Water Data!! Piping Friction Loss and Velocity Analysis




System Size 3.068 It is helpful to input actual pipe ID.

Specific Gravity for other than 68 deg Water 1.000 1.0 is default for 68 degree water.

Linear Feet Suction Pipe 6.00




Flow Rate Required GPM 330.00 From Pump work sheet

Pipe Schd 40.00

Lookup Table Friction Loss/100 Ft from look-up tables 26.30 Head Friction Loss/100 Feet of Pipe












Total Head loss corrected for Specific Gravity 4.13

Discharge Piping Calculations68 Degree Water Data!! Piping Friction Loss and Velocity Analysis




System Size 3.068 It is helpful to input actual pipe ID.

Linear Feet Discharge Pipe 100.00




Flow Rate Required 330.00 GPM

Pipe Schd 40.00

Lookup Table Friction Loss/100 Ft 26.30 Head Friction Loss/100 Feet of Pipe











Back Pressure Valve Setting 0 0.00 Feet Head


Total Head loss corrected for Specific Gravity 53.24

Halliburton Turbin Gas Flow Meter Calculations

Flowing Pressure 15

Flowing Temperature 60

Observed Flow Rate 19250 Actual Cubic Feet

Corrected SCF Flow 38852.851 Standard Cubic Feet

Totalizer Divisor

Factory Calibration Factor 123.42 Actual

Set Totalizer Read Out Divisor to = 61.147 Registers in Standard Cubic Feet

Set Totalizer Read Out Divisor to = 611.472128 Registers in TENTHS of a Standard Cubic Foot

Flow Rate Indicator Full Sacle Frequency Factor

Full Scale Flow Rate 38800 SCF/ Time Base

Factory Calibration Factor 123.42

Time Base Conversion Factor 3600 Seconds Per Time Base (86400/day, 3600/Hr, 60/Min)

Full Scale Frequency = 659.056

K-Factor

Factory Calibration Factor 123.42

K-Factor = 61.147

Temperature Effects

Plus or Minus Temperature Change 22 Degree F

Calculation for Plus 37274.838

Percent Effect 4.062

Calculation for Minus 40570.380

Percent Effect -4.421

Presure Effects

Plus or Minus Presure Change 5 PSIG

Calculation for Plus 45387.135

Percent Effect 16.818

Calculation for Minus 32318.568

Percent Effect -16.818

Halliburton Oil Meter Calculator for known Btu Input

#2 Diesel Oil

BTU Input 72000000

Btu/Gal/Oil 139000

Total Gal/Oil 517.9856

Total Lbs./Oil 74.02967

GPM FLOW 8.633094

ASME formula

Ref: Marks9th, p12-69/12.4.25/22/2014 4:05 PM

Hot Water Boiler Expansion Tank Sizing Non-Bladder Air Charged Steel Tank

International Mechanical Code 1009.2 and ASME

All Calculations based on 14.73 PSIA Sea Level 40 degree make-up water.

Vt=((0.00041T-0.0466) X Vs) / (Pa/Pf)-(Pa/Po)

Vt= Minimum volume of expansion tank, gallons

Vs= Volume of water in system less expansion tank, gallons

T= Maximum Average Operating Temperature of system, degrees 'F'

Pa= Atmospheric pressure fixed at 14.73 in this calculation.

Pf= Filling pressure (psig).

Po= Maximum operating pressure (psig).

NOTE Calculations correct Pa,Pf, and Po to Feet Absolute for you.

System Temperatures between 160 to 280 degrees 'F'.

T= Average System Operating Temperature, Degrees F 300

Vs= Volume of Water in System, Gallons 5000

Pf= Make-up Fill Water Pressure PSIG 45

Po= Maximum Operating Pressure of System PSIG 75

Vt= Minimum Volume Expansion Tank Required 463.31 Plain Steel Tank

Boyle's Law Acceptance Factor 1.33 This is a Safety Factor used by many Engineers

Minimum Tank Volume using Boyle's Factor 618

Measurement, Controllers & Recorders

UNDER CONSTRUCTION - APPLICATION NOT YET AVAILABLE

Measurement

Level, Pressure, Temperature or Flow? F L,P,T,F

Flow Measurement uses either a Differential Pressure Transmitter or Flow Meter

Areyou using a Differential Transmitter or a Meter? Selece DT or M in the yellow box below

DT

Differential Transmitters meassure flow in inches water pressure across an orifice plate

UNDER CONSTRUCTION - APPLICATION NOT YET AVAILABLE

VFD Pump Affiniity Laws and Curve Effect

Variable Speed Pump Curves

Process Requirements

Normal Maximum

Speed 1 60 RPM 3550 Speed 2 55 RPM 3254 Flow 50 96

Speed 3 50 RPM 2958.333 Speed 4 45 RPM 2663 Head 427 485

Speed 5 40 RPM 2367 Speed 6 35 RPM 2071

Speed 1 60 Hz. Original Pump Curve Data Speed 2 55 Hz.

Flow Head HP Eff Flow Head HP Eff

Point 1 50 555 13 40 Point 1 45.83333 466.3542 10.01331 40

Point 2 70 540 14.4 58 Point 2 64.16667 453.75 11.09167 58

Point 3 90 520 20.4 65 Point 3 82.5 436.9444 15.71319 65

Point 4 110 500 21.6 75 Point 4 100.8333 420.1389 16.6375 75

Point 5 BEP 130 475 23 76 Point 5 BEP 119.1667 399.1319 17.71586 76

Point 6 150 450 24 75 Point 6 137.5 378.125 18.48611 75

Point 7 EOC 170 410 25 76 Point 7 EOC 155.8333 344.5139 19.25637 76

Speed 3 50 Hz. Speed 4 45 Hz.


Point 1 41.66667 385.4167 7.523148 40 Point 1 37.5 312.1875 5.484375 40

Point 2 58.33333 375 8.333333 58 Point 2 52.5 303.75 6.075 58

Point 3 75 361.1111 11.80556 65 Point 3 67.5 292.5 8.60625 65

Point 4 91.66667 347.2222 12.5 75 Point 4 82.5 281.25 9.1125 75

Point 5 BEP 108.3333 329.8611 13.31019 76 Point 5 BEP 97.5 267.1875 9.703125 76

Point 6 125 312.5 13.88889 75 Point 6 112.5 253.125 10.125 75

Point 7 EOC 141.6667 284.7222 14.46759 76 Point 7 EOC 127.5 230.625 10.54688 76

Speed 5 40 Hz. Speed 6 35 Hz.


Point 1 33.33333 246.6667 2.229081 40 Point 1 29.16667 188.8542 2.58044 40

Point 2 46.66667 240 2.469136 58 Point 2 40.83333 183.75 2.858333 58

Point 3 60 231.1111 3.497942 65 Point 3 52.5 176.9444 4.049306 65

Point 4 73.33333 222.2222 3.703704 75 Point 4 64.16667 170.1389 4.2875 75

Point 5 BEP 86.66667 211.1111 3.943759 76 Point 5 BEP 75.83333 161.6319 4.565394 76

Point 6 100 200 4.115226 75 Point 6 87.5 153.125 4.763889 75

Point 7 EOC 113.3333 182.2222 4.286694 76 Point 7 EOC 99.16667 139.5139 4.962384 76

Grunfos CR32.6

Enter Pump Speeds Desired (HZ)

Larrs Hydronic Zone Loads Calculation

Source: Laars Technical Data

All data based on 20 degree 'F' temperature drop across coil.

Minimum 140 degree supply.Calculating Required Flow Rate in GPM through the Zone.

NET BTU Load of Zone = 27,000

Total Flow Rate to Zone in GPM 2.7

Calculating Pump Head Required to Circulate Loop. (Closed Loop Application)

Longest pipe run in Feet = 250

Total Estimated pumping head required = 15

Calculated Copper Pipe Size Required for Heating Capacity

Copper Pipe Size Required for Zone 0.75

Calculating Pump Head Required to Circulate Loop. (Closed Loop Application)

Boiler Heat Recovery Calculations

Printout 5/22/2014 4:05 PM

Data Compiled by

David Farthing

voice 405-728-6709

Blowdown Heat Recovery

Using waste heat from surface blowdown to pre-heat make-up water to DA or boiler.

Boiler Type FT or WT FT FT=Fire Tube, WT=Water Tube

Steam Boiler Flow PPH at Capacity 41400 1200 Calculated Boiler Hp.

TDS of Make-up Water 350

Desired TDS in Boiler Water 4000

Operating Pressure 150

Operating Temperature 366

Boiler Rated Efficiency 82%

Normal Firing Rate 100%

Hours/Day Run Time 24

Days/Month Run 30

Make-up as % of Steaming Rate 100%

Blowdown as % of Steaming Rate 9.59% Blowdown within normal limits

Make-up + Blowdown as % of Steaming Rate 109.59%

Fuel Cost per Therm include transport cost 0.67$ Equivalent Fuel Cost per 1000 CF 6.66$

Deaerator Operating Temperature 227

Calculated Boiler Horsepower 1,200 At Operating Firing Rate

Fuel Input at rated efficiency & firing rate 48,973.17 Cubic Feet/Hr

Therms per hour at efficiency & firing rate 489.73

Calculated Cost to Operate per 30 day billing 234,836.15$

Blowdown in PPH 3,969.86

Equivalent Boiler Horsepower Loss 115.07

Total Heat Available for Recovery 1,307,673 BTU/Hr.

Equivalent Boiler Horsepower Recovered 39.08

31,384,149 BTU/Day

941,524,471 BTU/Billing Period

11,298,293,655 BTU/Year

Total Annual Cost for Blowdown & Make-up 75,246.64$

BTU Heat for Recovery to Make-Up 477,336,329 Per Billing Period

Total Monthly Savings for Recovery 3,179.06$ Per Billing Period

Total Annual Savings for Recovery 38,148.72$ Cost for Recovery Equipment 23,000.00$ Estimates Only Actual Cost must be quoted.

Cost for Installation L&M 12,000.00$ Estimates Only Actual Cost must be quoted.

Months to Payback 11.01 Project Payback within normal limits.

David Farthing's Tech Stuff 5/22/2014 4:05 PM Relief Valve Data

Relief Valve Sizing and Selection

User Data ABC Company

1234 Powerhouse Lane

Smokin, PA 123456

Boiler Data

Steam (S) or Hot Water (W)? S

MAWP 200

Operating Pressure 150

Btu Input 48,000,000

Steam PPH Output 41,400

USE STEAM DATA ONLY -

How Many Safety Valves 2

Safety Valve Port Size

Port 1 2

Port 2 2

Port 3 2

Steam Recommendations PPH Set Pressure

Safety Valve #1 13,662 190

Safety Valve #2 27,738 200

Safety Valve #3 - 0

Hot Water Recommendations Btu/Hr Set Pressure

Relief Valve #1 - 190

Relief Valve #2 - 200

Relief Valve #3 - 0

NOTES:

1] Use only water or steam input data.

2] MAWP is the Maximum Allowable Vessel Pressure NOT the Operating Pressure

3] Recommended "Set Pressure " is 20% Above Operating Pressure.

4] Always use a Drip-Pan Ell on Steam Safety Valve discharge piping.

David Farthing's TechStuff Printout

5/22/2014 / 4:05 PM

Data Compiled by

David Farthing

Voice 405-728-6709

The effect of Boiler Operating Pressure on System Performance

Firetube Boiers - Saturated Steam

Designed Velocity Across the Boiler Outlet Design Velocity in the distribution line

Rated Boiler Horsepower 476 Distribution line Diameter 8

Boiler Outlet Diameter 6 Distribution Velocity Ft./Min. 2619.3639

Current Operating Pressure 120 Distribution Velosity OK

Feedwater Temperature 227

Steam Volume Cft/# 3.34

Boiler Outlet Velocity 4656.6469 Ft./Min.

Nozzle Velocity OK

New Velocity Across the Boiler Outlet New Velocity in the distribution line

New Operating Pressure 90 Distribution line Diameter 8

Steam Volume Cft/# 4.24 Distribution Velocity Ft./Min. 3325.1805

New Boiler Outlet Velocity 5911.4320 Ft./Min. Distribution Velosity OK

Danger Outlet Nozzle Velocity Above Safety Limits - Priming and Carry Over Will Occur!

Additional or Reduction Btu/Bhp Required to Raise Pressure above 0 PSIG Theoretical Savings from Lowering Operating Pressure

4,076 BTU @ Current Pressure Btu Differential 621

3,455 BTU @ New Pressure Boiler Horsepower 476

621 Btu @ Horsepower/Hr Differential Cost of Fuel (Decatherm) 6.36$

Hrs/Day Operation 20

Days/Month/Operation 22

$$ Saved or Expended/Mth. Misapplication

Feedwater Pump vs. Relief Valve Performance Requirements $$ Saved or Expended/Yr. Misapplication

Design At New


Maximum Allowable Working Pressure 350

Normal Operating Pressure 120 90

Minimum Safety Relief Valve Setting 138 104

Minimum Pump Head Requirements

Feet Head 338 253

Pressure Drop Across Feed Valve 50 See Liquid Valve Calcs.

Feedwater Piping Losses - PSI 12 See Friction Losses in Piping.

Economizer Losses-PSI 5 See Manufacturer's Data sheet.

Pump Discharge Pressure PSI 213 177

Minimum Pump Flow Capacity GPM 41.17

Danger Outlet Nozzle Velocity Above Safety Limits - Priming and Carry Over Will Occur!

Minimum Pump Head Requirements are based on Minimum Safety Relief Valve Setting

ADD SYSTEM LOSSES TO MINIMUM HEAD TO GET TOAL DYNAMIC HEAD PUMP MUST PRODUCE.

The effect of Boiler Operating Pressure on System Performance

Watertube Boiler - Saturated Steam

Designed Velocity Across the Boiler Outlet Design Velocity in the distribution line

Pounds/Hr Steam Flow 10000

Rated Boiler Horsepower 290 Distribution line Diameter

Boiler Outlet Diameter 8 Distribution Velocity Ft./Min.

Current Operating Pressure 100 Distribution Velosity OK

Feedwater Temperature 227

Steam Volume Cft/# 3.89

Boiler Outlet Velocity 1857.6886 Ft./Min.

Nozzle Velocity OK

New Velocity Across the Boiler Outlet New Velocity in the distribution line

New Operating Pressure 115 Distribution line Diameter

Steam Volume Cft/# 3.46 Distribution Velocity Ft./Min.

New Boiler Outlet Velocity 1652.3400 Ft./Min. Distribution Velosity OK

Nozzle Velocity OK

Additional or Reduction Btu/Bhp Required to Raise Pressure above 0 PSIG Theoretical Savings from Lowering Operating Pressure

4,076 BTU @ Current Pressure Btu Differential

4,076 BTU @ New Pressure Boiler Horsepower

0 Btu @ Horsepower/Hr Differential Cost of Fuel (Decatherm)

Hrs/Day Operation

Days/Month/Operation

$$ Saved or Expended/Mth.

$$ Saved or Expended/Yr.

Feedwater Pump vs. Relief Valve Performance Requirements

Design At New


Maximum Allowable Working Pressure 250

Normal Operating Pressure 100 115

Minimum Safety Relief Valve Setting 115 132

Minimum Pump Head Requirements

Safety Valve Requirement Feet Head 282 324

Pressure Drop Across Feed Valve 20 See Liquid Valve Calcs.

Feedwater Piping Losses - PSI 10 See Friction Losses in Piping.

Economizer Losses-PSI 4 See Manufacturer's Data sheet.

Pump Discharge Pressure - PSI 156 174

Minimum Pump Flow Capacity GPM 25.07

Nozzle Velocity OK

Minimum Pump Head Requirements are based on Minimum Safety Relief Valve Setting

ADD SYSTEM LOSSES TO MINIMUM HEAD TO GET TOTAL DYNAMIC HEAD PUMP MUST PRODUCE.

Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature

Feedwater Boiler Operating Pressure

Temperature 0 25 50 75 100 125 150

Additional BTU Input Required to Bring Feedwater to Steaming Temperature

50 5,766 7,664 8,733 9,492 10,113 10,631 11,079

100 4,041 5,939 7,008 7,767 8,388 8,906 9,354

125 3,179 5,076 6,146 6,905 7,526 8,043 8,492

150 2,316 4,214 5,283 6,042 6,663 7,181 7,629

175 1,454 3,351 4,421 5,180 5,801 6,318 6,767

200 591 2,489 3,558 4,317 4,938 5,456 5,904

212 177 2,075 3,144 3,903 4,524 5,042 5,490

225 1,626 2,696 3,455 4,076 4,593 5,042

230 1,454 2,523 3,282 3,903 4,421 4,869

240 1,109 2,178 2,937 3,558 4,076 4,524

250 764 1,833 2,592 3,213 3,731 4,179

260 419 1,488 2,247 2,868 3,386 3,834

270 74 1,143 1,902 2,523 3,041 3,489

275 971 1,730 2,351 2,868 3,317

280 798 1,557 2,178 2,696 3,144

230

235

240

245

250

255

260

265

270

275

280

285

290

295

300

305

310

315

320

325

330

335

340

345

350

355

360

365

370

375

380

385

390

395

400

450

500

550

600

650

700

750

800

900

1000

1250

1500

1750

2000

2250

2500

2750

3000

Temp-

erature

Deg F Sensible

Design Velocity in the distribution line 25 134 102

14 20 162 129

606.5922 15 179 147

10 192 160

5 203 171

0 212 180

1 215 183

2 219 187

New Velocity in the distribution line 3 222 190

14 4 224 192

539.5396 5 227 195

6 230 198

7 232 200

8 233 201

Theoretical Savings from Lowering Operating Pressure 9 237 205

Btu Differential 0 10 239 207

Boiler Horsepower 289.8550725 12 244 212

Cost of Fuel (Decatherm) 5.29$ 14 248 216

Hrs/Day Operation 20 16 252 220

Days/Month/Operation 22 18 256 224

$$ Saved or Expended/Mth. -$ 20 259 227

$$ Saved or Expended/Yr. -$ 22 262 230

24 265 233

26 268 236

28 271 239

30 274 243

32 277 246

34 279 248

36 282 251

38 284 253

40 286 256

42 289 258

44 291 260

PSIG

IN V

AC

Gauge

Pressure Heat in Btu/lb.

46 293 262

48 295 264

50 298 267

55 300 271

60 307 277

65 312 282

Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature 70 316 286

Boiler Operating Pressure 75 320 290

175 200 225 250 80 324 294

Additional BTU Input Required to Bring Feedwater to Steaming Temperature 85 328 298

11,459 11,838 12,149 12,459 90 331 302

9,734 10,113 10,424 10,734 95 335 305

8,871 9,251 9,561 9,872 100 338 309

8,009 8,388 8,699 9,009 105 341 312

7,146 7,526 7,836 8,147 110 344 316

6,284 6,663 6,974 7,284 115 347 319

5,870 6,249 6,560 6,870 120 350 322

5,421 5,801 6,111 6,422 125 353 325

5,249 5,628 5,939 6,249 130 356 328

4,904 5,283 5,594 5,904 135 358 330

4,559 4,938 5,249 5,559 140 361 333

4,214 4,593 4,904 5,214 145 363 336

3,869 4,248 4,559 4,869 150 366 339

3,696 4,076 4,386 4,697 155 368 341

3,524 3,903 4,214 4,524 160 371 344

165 373 346

170 375 348

175 377 351

180 380 353

185 382 355

190 384 358

195 386 360

200 388 362

205 390 364

210 392 366

215 394 368

220 396 370

225 397 372

230 399 374

235 401 376

240 403 378

245 404 380

250 406 382

255 408 383

260 409 385

265 411 387

270 413 389

275 414 391

280 416 392

285 417 394

290 418 395

295 420 397

300 421 398

305 423 400

310 425 402

315 426 404

320 427 405

325 429 407

330 430 408

335 432 410

340 433 411

345 434 413

350 435 414

355 437 416

360 438 417

365 440 419

370 441 420

375 442 421

380 443 422

385 445 424

390 446 425

395 447 427

400 448 428

450 460 439

500 470 453

550 479 464

600 489 473

650 497 483

700 505 491

750 513 504

800 520 512

900 534 529

1000 546 544

1250 574 580

1500 597 610

1750 618 642

2000 636 672

2250 654 701

2500 669 733

2750 683 764

3000 696 804

Specific

Volume

Cu. ft.

Latent Total per lb.

1017 1119 142

1001 1130 73.90

990 1137 51.30

982 1142 39.40

976 1147 31.80

970 1150 26.80

968 1151 25.20

966 1153 23.50

964 1154 22.30

962 1154 21.40

960 1155 20.10

959 1157 19.40

957 1157 18.70

956 1157 18.40

954 1159 17.10

953 1160 16.50

949 1161 15.30

947 1163 14.30

944 1164 13.40

941 1165 12.60

939 1166 11.90

937 1167 11.30

934 1167 10.80

933 1169 10.30

930 1169 9.85

929 1172 9.46

927 1173 9.10

925 1173 8.75

923 1174 8.42

922 1175 8.08

920 1176 7.82

918 1176 7.57

917 1177 7.31

Heat in Btu/lb.

915 1177 7.14

914 1178 6.94

912 1179 6.68

909 1180 6.27

906 1183 5.84

901 1183 5.49

898 1184 5.18

895 1185 4.91

891 1185 4.67

889 1187 4.44

886 1188 4.24

883 1188 4.05

880 1189 3.89

878 1190 3.74

875 1191 3.59

873 1192 3.46

871 1193 3.34

868 1193 3.23

866 1194 3.12

864 1194 3.02

861 1194 2.92

859 1195 2.84

857 1196 2.74

855 1196 2.68

853 1197 2.60

851 1197 2.54

849 1197 2.47

847 1198 2.41

845 1198 2.34

843 1198 2.29

841 1199 2.24

839 1199 2.19

837 1199 2.14

836 1200 2.09

834 1200 2.05

832 1200 2.00

830 1200 1.96

828 1200 1.92

827 1201 1.89

825 1201 1.85

823 1201 1.81

822 1202 1.78

820 1202 1.75

819 1202 1.72

817 1202 1.69

815 1202 1.66

814 1203 1.63

812 1203 1.60

811 1203 1.57

809 1203 1.55

808 1203 1.53

806 1203 1.49

805 1203 1.47

803 1203 1.45

802 1204 1.43

800 1204 1.41

799 1204 1.38

797 1204 1.36

796 1204 1.34

794 1204 1.33

793 1204 1.31

791 1204 1.29

790 1204 1.28

789 1205 1.26

788 1205 1.24

786 1205 1.22

785 1205 1.20

784 1205 1.19

783 1205 1.18

781 1205 1.16

780 1205 1.14

778 1205 1.13

777 1205 1.12

766 1205 1.00

751 1204 0.89

740 1204 0.82

730 1203 0.75

719 1202 0.69

710 1201 0.64

696 1200 0.60

686 1198 0.56

666 1195 0.49

647 1191 0.44

600 1180 0.34

557 1167 0.23

509 1151 0.22

462 1134 0.19

413 1114 0.16

358 1091 0.13

295 1059 0.11

213 1017 0.08

5/22/2014 / 4:05 PM 'c' Federal Corporation Data Compiled by

David C. Farthing

Voice 405-728-6709

The effect of Feedwater Temperature on Boiler Horsepower Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature

Feedwater Boiler Operating Pressure

Customer LiDestri Foods Temperature 0 25 50 75 100 125 150 175 200 225 250

Contact Henry Marroquin Additional BTU Input Required to Bring Feedwater to Steaming Temperature

Plant Location Fresno, CA 50 5,589 7,487 8,556 9,315 9,936 10,454 10,902 11,282 11,661 11,972 12,282

Boiler Mfg Clever Brooks 100 3,864 5,762 6,831 7,590 8,211 8,729 9,177 9,557 9,936 10,247 10,557

Boiler Type 500 (475) Firetube w/ Alzeta 19.95mmbtu LN Burner 125 3,002 4,899 5,969 6,728 7,349 7,866 8,315 8,694 9,074 9,384 9,695

150 2,139 4,037 5,106 5,865 6,486 7,004 7,452 7,832 8,211 8,522 8,832

Factory Design 175 1,277 3,174 4,244 5,003 5,624 6,141 6,590 6,969 7,349 7,659 7,970

Boiler Type Watertube/Firetube F. 200 414 2,312 3,381 4,140 4,761 5,279 5,727 6,107 6,486 6,797 7,107

Name Plate Rated Boiler BHP 475 212 0 1,898 2,967 3,726 4,347 4,865 5,313 5,693 6,072 6,383 6,693

Normal Operating Pressure 140 FW Temp Deaerator or Typical 225 1,449 2,519 3,278 3,899 4,416 4,865 5,244 5,624 5,934 6,245

Calculated BTU Input for boiler type 19,828,482.36 As Observed First Recovery Economizer 230 1,277 2,346 3,105 3,726 4,244 4,692 5,072 5,451 5,762 6,072

Observed Feedwater Temp 212 80 100 227 240 932 2,001 2,760 3,381 3,899 4,347 4,727 5,106 5,417 5,727

Hours Day Operated 20 20 20 20 250 587 1,656 2,415 3,036 3,554 4,002 4,382 4,761 5,072 5,382

Days per Month 22 22 22 22 260 242 1,311 2,070 2,691 3,209 3,657 4,037 4,416 4,727 5,037

Calculated Bhp BTU Output Bhp 15,895,875.00 270 -104 966 1,725 2,346 2,864 3,312 3,692 4,071 4,382 4,692

Calculated Efficiency (Input/Output) 80.17 275 794 1,553 2,174 2,691 3,140 3,519 3,899 4,209 4,520

Calculated Bhp 475.00 280 621 1,380 2,001 2,519 2,967 3,347 3,726 4,037 4,347

Rated Steam PPH at 100% Firing 16387.5

BTU addition for Operating Pressure 2,310,638 4,965,413 4,146,038 2,097,600

BTU Lost/Gained Per Hour 0.00 -2,163,150.00 -1,835,400.00 245,812.50

Boiler HP Lost or Gained/ Hr. 0.00 (64.64) (54.85) 7.35

Net Boiler Horsepower 475 410 420 482

Net Steam Output 16387.5 14157.4 14495.3 16640.9

Net Efficiency 80.17 69.26 70.91 81.41

Percent Increase/Decrease Energy Use 0.00 -10.91% -9.26% 1.24%

Percent Increase/Decrease BHP 0.000% -13.608% -11.546% 1.546%

UNDER CONSTRUCTION UNDER CONSTRUCTION Note Wate Level Originally Very High in sight glass,. Sight Glass FLOODED!!

ON/OFF Feedwater Effect Wate Level Correcte by closing by-pass valve and reading re-checked.

On/Off Cycle Time 10

Normal Firing Rate % 88%

Displacement Per Cycle 2884.2

FW Temp 180

BTU Required to reach 212 92294.4

Total BTU Lost/Day 11,075,328.00

Cost of Fuel/Dtherm 12.60$

Cost of Lost Btu/Month 3,070.08$

Cost of Lost Btu/Year 36,840.97$

UNDER CONSTRUCTION UNDER CONSTRUCTION

5/22/2014 4:05 PM Scale vs. Heat Transfer Data Compiled by

David Farthing

Voice 405-728-6709

The effect of Scale on Heat Transfer in Boilers

0.00

0.10

0.20

0.30

0.40

0.50

0.60

5% 10% 15% 30% 66% 150%Calc

ium

Scale

Th

ickn

ess =

In

ch

Additional Heat Input Reqired to Make Boiler Horsepower

Additional Heat Input Required Due to Calcium Salt Scale Watertube Boiler Full Circumferance Tube Contact

Dr. Mac Brockway's Boiler Water Chemistry(Contact Dr Mac at 405-737-3740 for the Companion White Paper that accompanies this chart)

(Dr. Brockway is a Phd Chemical Engineer specializing in water chemistry.)

1 Grain = 17 PPM of soluable hardness Steam Boiler (<300 PSI) Water Treatment

Principle Benefit Pre- Internal Testing Want to Prevent Action Comment

Treatment Treatment What You Want Chemistry Chemistry YOU WANT

Eliminate No Water Phosphate (PO4) HARDNESS SOFT Good Heat Transfer

Hardness Scale Softner Precipitation Hardness = 0 Ca++ +CO3 = CaCO3 3Ca++ + 2PO4 = Cay(PO4)2 Lower Energy Cost

Removes Calcium or PO4 =30-60 ppm Great! Calcium + Carbonate = Calcium Carbonate Calcium + Phosphate = Soft Sludge Longer Boiler life

and Magnesium Chelant or Slow Reaction results in hard formation Fast reaction results in a soft formation

salts only Solubilizer Chelant = 10-30 ppm

Hardness Test Treat at the Feedwater Tank

SOAP TEST HACH 5B REAGENT

1 Drop = Soft (<1 Grain) Pink = Hard

2 Drops = Hard (1-2 Grains) Blue = Soft <1 Grain

3 Drops = Hard (2-3 Grains) Each drop of reagent = 1 Grain

Run Sample COLD

Eliminate No Deareate Sulfite Oxygen = 0 Fe + 1/2O2 = FeO 2SO3 + O2 = 2SO4

Oxygen Corrosion or SO3 = 30-60 ppm Great! Iron Metal + Oxygen = Rust Sulfite + Oxygen = Sulfate Longer Boiler Life

Hot Feedwater

Sulfite Residual Test Treat at the Feedwater Tank

1 Drop = 10 ppm May be injected directly into the boiler

Desired 30-60 ppm but don't forget the feedwater tank

Run Sample HOT

Run this TEST FIRST!

Save Fuel $$

Add Soft N/A NaOH OH = 300-600 ppm Hard Crystalline solids Elevate pH Clean Boiler

Alkalinity Solids Sodium pH = 11.0 - 12.0 Avoid runing pH too low this OH = Elevated Alkalinity Good Heat

Hydroxide pH = 11.56 Perfect will result in Hard Calcium Phosphate Result Soft Solids Transfer

Add Soft N/A Polymer Normal Hard Crystalline solids Polymer + Hard Soild = Soft Sludge Clean Boiler

Polymer Solids Poly = 10-50 ppm

Control TDS Pure Steam Reverse Osmosis Blowdown TDS = 3,000 - 5,000ppm Prevent Boiler Water Carry Over Pure Steam Clean Boiler

"Total or Manual TDS <= 3,000 Great! Priming and Impure or Wet Steam and Good Heat Treansfer

Disolved Solids" De-Ionizer and/or uMhos = 4,000 - 6,0000 Wet Steam robs energy from your Solids Removal Saved Fuel $$$

Automatic steam line!

Nutralizing

Boost Eliminate De-Alkalizer Amine Condensate CO2 + H20 = H2CO3 (Carbonic Acid! pH=4-6) Amine(A) + H2CO3 = A~H+HCO3 (pH=8-9) No Rust or iron

Condensate pH Steam Line and or Volatile Chemical pH = 8 - 9.0 Great! H2CO3 + Fe = FeCO3 (Iron Scale!) Amine(A) + H2O = A~H+OH (pH = 8-9) brought back to boiler

Condensate Line Reverse Osmosis travels with steam Iron Test <0.1ppm Rot out distribution and condensate lines! Amine combines with H2CO3 to nutralize by condensate.

Corrosion the acid and raise the pH to 8-9 and Longer distribution

protects condensate lines. line life.

ABMA Water Chemistry Guidelines 5/22/2014 Compiled by

David Farthing

405-249-9324

American Boiler Manufacturers Association **

Boiler Water Chemistry Guidelines** As adopted from the American Society of Mechanical Engineers

Boiler Water Chemical Limits Boiler Water Chemical Limits

Includes SUPERHEATER, Turbine Drives, or Process Restriction on Steam Quality NO Superheater, Turbine Drives, or Process Restrictions on Steam Quality.

Boiler Operating Pressure (psig) Boiler Operating Pressure (psig)

15 150 300 600 900 1200 1500 15 150 300 600 900 1200 1500

Parameter Chemical Concentration (mg/liter) PPM Parameter Chemical Concentration (mg/liter) PPM

TDS (Unnutralized) 700-2800 700-3500 700-3500 500-2500 150-750 150-500 150-300 TDS (Unnutralized) 700-5595 700-5505 700-4545 500-4545 150-750 150-500 150-300

Phosphate (PO4) 30-60 30-60 30-60 20-40 15-20 10-15 5-10 Phosphate (PO4) 30-60 30-60 30-60 20-40 15-20 10-15 5-10

Hydroxide (CaCO3) 300-400 300-400 250-300 150-200 120-150 100-120 80-100 Hydroxide (CaCO3) 300-400 300-400 250-300 150-200 120-150 100-120 80-100

Sulfite 30-60 30-60 30-40 20-30 15-20 10-15 5-10 Sulfite 30-60 30-60 30-40 20-30 15-20 10-15 5-10

Silica (SiO2) 150 100 50 30 10 5 3 Silica (SiO2) 150 <150 <150 <90 <30 5 3

Total Iron (Fe) mg/l <0.1 <0.1 <0.05 <0.03 <0.02 <0.02 <0.01 Total Iron (Fe) <0.1 <0.1 <0.05 <0.03 <0.02 <0.02 <0.01

Organics 70-100 70-100 70-100 70-100 50-70 50-70 50-70 Organics 70-100 70-100 70-100 70-100 50-70 50-70 50-70

NOTES:TDS - Unnutralized TDS readings are affected by pH. Use the pH Correction table below to correct TDS to sample pH.

The Higher number in the TDS column represents the maximum limits for safe boiler operation at the indicated operating pressure.

Depending on publication some authorities allow for upto 4000 TDS in Water Tube boilers operating from 0-150 psig.

ASME for Saturated Steam Boilers allows for upto 5595 TDS (8000 Conductivity) up to 300 PSI and 4545 TDS (6500 Conductivity) above 300 but at or below 600 PSIG

TDS Error due to High pH

If Nutralizing Agents are not available then Subtract the 'Error' number from the TDS reading to arrive at 'Neutralized TDS' number.

pH Error (High)

9.0 0 CONDUCTIVITY to mMHO or TDS Converstions

9.5 10

10.0 25 CONDUCTIVITY (KNOWN) 6500 4545.5 TDS Resulting (Non-Neutralized)

10.5 60 TDS (KNOWN) 5000 7150 Conductivity (mMHO) Resulting

11.0 150 mMHO (KNOWN) 2000 1398.6 TDS Resulting (Non-Neutralized)

11.2 220 mS(Siemans) (KNOWN) 20 13986 TDS Resulting (Non-Neutralized)

11.4 310 Note the Honeywell DL423-10 Graphite Sensor reads 0-20 mS.

11.6 460 The 4-20mA signal(PV) to the recvieing device is ranged 0-20

11.8 700 This is then converted to TDS as follows

12.0 1050 (PV/1.43) *1000 = TDS Reading (Non-Nutralized)

12.2 1500 If you want to correct for pH (which should be 11.56 in boilers)

12.4 2400 subtract 455 from your calculation as follows.

12.6 3800 ((PV/1.43) *1000) - 455 = TDS Reading (Nutralized to 11.56pH)

12.8 6100

13.0 10,000

EXAMPLE1] TDS Reading of 2850 and an operating pH of 11.56 (normal) would be corrected to 2390 (I.e. 2850-460=2390)

2] TDS Reading of 2850 and an operating pH of 9.0* (low) would be corrected to 2850 (I.e. 2850-0=2850)

* NOTE a pH of 9.0 is considered LOW. Normal Operating pH is recommended to be at 11.56.

Go Back To DR.MAC

Print Out 5/22/2014Boiler / Burner Data Sheet

Today's Date 10/29/2008 Certificate Exp. Date

Company Name Federal Court House

Location 5th & E Street Insurance Carrier FM Global

City Lawton State OK Zip 73501 Inspector No.

Boiler MFG Name Peerless Burner MFG Name Gordon Piatt

Model No. LC-10 Model No. R8.2-G-07 RM7895A-H4.15HS-UL-CSD1

Serial No. 72566/ NB#28696 Yr Blt 2004 Serial No. an57303

Hot Water 50 Steam Atmosperic (Natural Draft) NA

Operating Pressure (PSI) 44 Power/Mechanical Draft 120 VAC 9.2 Amp

Date Installed 7/7/1997 BTU/Hr. Input 1.860 MMBtu

INSTALLED NOT INSTALLEDNOT

REQUIRED System Control Specifications

Approved Operating

Controllers Steam Boilers

(Pressure)

Required

(Note 1)

Required (Note

1)Required (Note 1)

Required

(Note 1)

Required

(Note 1)

Required

(Note 1)

Required

(Note 1)

Required

(Note 1)

CR-220(a)(1)(2) CW-

310(b) CW-

620(b)

Honeywell

L4006E1117

Hot Water Boilers

(Temp)

Required

(Note 2)

Required (Note

2)Required (Note 2)

Required

(Note 2)

Required

(Note 2)

Required

(Note 2)

Required

(Note 2)

Required

(Note 2)

CR-220(b)(1)(2) CW-

410(b)

CW-640(b)

High Limits

Steam boiler (Pressure)

(Manual Reset)

Required

(Note 3)

Required (Note

3)Required (Note 3)

Required

(Note 3)

Required

(Note 3)

Required

(Note 3)

Required

(Note 3)

Required

(Note 3)

CR-220(a)(1)(3) CW-

310(c) CW-

620(a)

Hot Water Boilers

(Temp)

(Manual Reset)

Required

(Note 4)

Required (Note

4)Required (Note 4)

Required

(Note 4)

Required

(Note 4)

Required

(Note 4)

Required

(Note 4)

Required

(Note 4)

CR-220(b)(1)(3) CW-

410(c) CW-

640(a)

NOT INSTALLED

High Gas Pressure

(MANUAL RESET)(Note 5) Required Required Required Required

CF-162(a), CF-910,

CR-410 Table CF-

1,CF-2

NOT INSTALLEDLow Gas Pressure

(Manual Reset) (Note 5) Required Required Required Required

Honeywell

V4062A1131

Valve Seal Overtravel

Interlocks(Note 6) (Note 6) (Note 7)

Honeywell

V4062A1131High Fire Switch (Note 8) (Note 9) (Note 9) (Note 10) (Note 10) (Note 10)

CF-210(a)(2) CF910,

CR-410, Tables CF-1,

CF-2

Honeywell

V4062A1131Low Fire Switch Required Required Required Required CF-610

ANTUNE Air

Flow SwitchSupervised Purge Air

Required

(Note 9)Required (Note 9)

Required

(Note 9)

Required

(Note 10)

Required

(Note 10)

Required

(Note 10)

CR210(a)(b)(c)

Tables CF-1, CF-2

ANTUNE Air

Flow SwitchProven Combustion Air Required Required Required Required

Tables CF-1, CF-2

CR-1, CR-2

LOCKOUTAction on Loss of Combustion

Air (Note 17) (Note 18) Safety Shutdown

Safety

Shutdown

Tables CF-1,

CR-1, CR-2

McDonnel Miller

No 64

Low Water 2 Required (1

w/MANUAL RESET)

(2) Required

(Notes 11,12,

13)

(2) Required

(Note 11)

(2) Required (Note

11)

(2)

Required

(Note 11)

(2) Required

(Notes

11,12, 13)

(2) Required

(Note 11)

(2) Required

(Note 11)

(2) Required

(Note 11)

CE-120(a)(b) CR-

210(a)(b), CW-

610(a)(b)

HydroLevel

Mdl550

Hot Water Boilers

(MANUAL RESET)

(1) Required

(Notes 14

& 15)

(1) Required (1) Required (1)

Required

(1) Required

(Notes 14

& 15)

(1) Required (1) Required (1) Required

CR-210(c), CW-

130(a), CW-

630(a)(b)

Forced Circulation

(MANUAL RESET)(Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16)

CR-210(e), CW-

210(a)(b)

ASCO 8040H8Approved Safety Shutoff

Valve(s)Required Required Required Required Required Required Required Required CR-180(C)

1-Ball Valve Manual Shutoff Valve(s) Required Required Required Required Required Required Required Required CF-150(C)

MAXATROL

RV47LGas Pressure Regulator Required Required Required Required Required Required Required Required

CF-110(a)(1), UL795-

25 15, CF-

180, cf-161(b) Figs B-

1, 2,3,4

ASCO

JB821480 and

Honeywell

V4062A1131

Approved Safety Shutoff

Valve(s)(1) Required

(2) Required

(Note 19)

(1) or (2) Required

(Note 20)

(2)

Required

(Note 21)

(1) Required (2) Required

(Note 19)

(1) or (2)

Required

(Note 20)

(2) Required

(Note 21)

CF-180(b)

(1)(2)(3)

YES

Manually Operated Leak Test

Valve(s)

(1) or (2)

Required (Note

22)

(1) or (2) Required

(Note 22)

(1) or (2)

Required

(Note 22)

(1) or (2)

Required

(Note 22)

(1) or (2)

Required

(Note 22)

(1) or (2)

Required

(Note 22)

CF-150(d)

1-Gas Cock 1-BallManual Shutoff Valve(s) (1) Required (2) Required (2) Required

(2)

Required (1) Required (2) Required (2) Required (2) Required

CF-150(b)(d)

ANSI221.13 1114

MAXATROL

RV81 Set at

6.0"

Gas Pressure Regulator Required Required Required Required Required Required Required Required

CF-160, CF-161(b),

ANSI221.13 1.15.1

Fig. B-1, 2,3, 4

Honeywell RM7895A1014 OEMRebuilt Flame Safeguard /

Burner ControlNot Permitted Not Permitted Not Permitted

Not

Permitted Not Permitted

Not

Permitted

Not

Permitted Not Permitted

60 Sec Prepurge Timing

90 Seconds

(Note 8)(Note 9) (Note 9) (Note 10) (Note 10) (Note 10)

CF-210(a)(1)(2)(c)

Tables CF-1, CF-2 CR-

1, CR-2

4

Prepurge Air Changes

Required4 Changes 4 Changes 4 Changes

CF-210(a)(1)(2)(c)

Tables CF-1, CF-2 CR-

1, CR-2

YESHigh Fire Purge Proving

Circuit(Note 8) Required Required (Note 10) (Note 10) (Note 10)

CF-210(a)(1)(2)(c)

Tables CF-1, CF-2

NO Low Fire Start Circuit Required Required Required Required CF-610

NOContinuous Pilot Optional Optional Not Permitted

Not

PermittedOptional Optional

Not

PermittedNot Permitted

Tables CF-1, CF-2

CR-1, CR-2

NOIntermittent Pilot Optional Optional Not Permitted Required Optional Optional Optional Optional

Tables CF-1, CF-2

CR-1, CR-2

YESInterrupted Pilot Optional Optional Not Permitted

Not

PermittedOptional Optional Optional Optional

Tables CF-1, CF-2

CR-1, CR-2

YESProved Pilot

Required

(Note 25)

Required (Note

25)Required (Note 25)

Required

(Note 25)

Required

(Note 25)

Required

(Note 25)

Required

(Note 25)

Required

(Note 25)CF-320(a)(1)

10 Sec

Pilot Flame Establishment

Period (PFEP)

Continuous Pilot

None15 Seconds

(Note 26)Not Permitted

10

Seconds

Maximum

(Note 31)

None15 Seconds

(Note 26)

10 Seconds

(Note 26)10 Seconds

Tables CF-1, CF-2

CR-1, CR-2

Intermittent Pilot 15 Seconds 15 Seconds Not PermittedNot

Permitted

15

Seconds15 Seconds

10

Seconds10 Seconds

Tables CF-1, CF-2

CR-1, CR-2

YESInterrupted Pilot 15 Seconds 15 Seconds 10 Seconds

10

Seconds15 Seconds 15 Seconds

10

Seconds10 Seconds

Tables CF-1, CF-2

CR-1, CR-2

Fed

era

l C

orp

ora

tio

n

INTERLOCKS / LIMITS

CF-162(a), CF-910,

CR-410 Table CF-

1,CF-2 CF-

180(b)(2)(3)

Low Water Fuel Cutoffs

11

36

1 E

as

t 6

1s

t. S

tre

et,

B

rok

en

Arr

ow

, O

kla

ho

ma

74

01

2

(80

0)9

55

-19

18,

Tu

lsa

(9

18

) 9

55

-19

18

Fa

x (

91

8)2

49

-90

14

PILOT VALVE TRAIN (Note 12)

MAIN VALVE TRAIN

APPROVED SAFETY CONTROL SPECIFICATIONS

5,000,000

to

12,500,000 Associated

Standard

Paragraph

CONTROL & SAFETY DEVICES GUIDELINES

FOR AUTOMATICALLY GAS FIRED BURNERS

5,000,000

to

12,500,000

Less Than

400,000

(Including

Modular Boilers

w/ max. input of

400,000)

400,000

to

2,500,000

2,500,000

to

5,000,000

Power & Mechanical Draft Burners Atmospheric (Natural Draft) Burners

120 E

ast

Main

Str

eet

--

Po

st

Off

ice B

ox 2

6408

Okla

ho

ma C

ity, O

kla

ho

ma 7

3126

(80

0)

28

9-3

33

1

(

40

5)

23

9-7

30

1

F

ax

(4

05)

23

2-5

43

8

INPUT in BTU/HOUR INPUT in BTU/HOUR

ASME SAFETY STANDARDS No. CSD-1 Less Than

400,000

(Including

Modular Boilers

w/ max. input of

400,000)

400,000

to

2,500,000

2,500,000

to

5,000,000

Print Out 5/22/2014

10 SEC

Main Flame Establishment

Period (MFEP)

Continuous Pilot

None (Note 27)10

SecondsNone (Note 28) (Note 29) (Note 30)

Tables CF-1, CF-2

CR-1, CR-2

Intermittent Pilot15 Seconds

Maximum(Note 28) (Note 29) (Note 30)

Tables CF-1, CF-2

CR-1, CR-2

YES

Interrupted Pilot 15 Seconds

Maximum

15 Seconds

Maximum

10 Seconds

Maximum (Note 31)

10

Seconds

Maximum

(Note 31)

15 Seconds

Maximum(Note 28) (Note 29) (Note 30)

Tables CF-1, CF-2

CR-1, CR-2

Direct Ignition15 Seconds

Maximum

4 Seconds

Maximum

4 Seconds

Maximum (Note

32)

15 Seconds

Maximum

Tables CF-1, CF-2

CR-1, CR-2

YESSupervised Main Flame (Note 34) Required Required Required (Note 34) (Note 34) (Note 33) Required

CF-310(d)

(1)(2)(3)(4)

3 Sec

Flame Failure Response Time

(FFRT)

4 Seconds

Maximum

(Note 36)

4 Seconds

Maximum

4 Seconds

Maximum

4 Seconds

Maximum

4 Seconds

Maximum

(Note 35, 36)

4 Seconds

Maximum

4 Seconds

Maximum

4 Seconds

Maximum

Tables CF-1, CF-2

CR-1, CR-2

LockoutAction on Flame Failure

Safety

Shutdown

(Note 37,38)

Safety

Shutdown (Note

39)

Safety ShutdownSafety

Shutdown

Safety

Shutdown

(Note 37,38)

Safety

Shutdown

(Note 40)

Safety

Shutdown

(Note 40)

Safety

Shutdown

(Note 40)

Tables CF-1, CF-2

CR-1, CR-2

Recycle

Action On Limit OpeningSafety

Shutdown

Safety

ShutdownSafety Shutdown

Safety

Shutdown

Safety

Shutdown

Safety

Shutdown

Safety

Shutdown

Safety

Shutdown

CF-162(a), CR-220(a)

CW-130(d), CE-

310(c), CW-410(c), CF-

910

1

For modular boilers, each

module shall have a pressure

control that will shut off the fuel

supply when the steam

pressure reaches a preset

operating pressure

2

For modular boilers, each

module shall have at least one

temperature actuated control

to shut off the fuel supply when

the system water reaches a

preset operating temperature.

3

The assembled modular boiler

shall have a high steam

pressure limit control that will

prevent the generation of

steam pressure in excess of

the maximum allowable

working pressure.

4

The assembled modular hot

water boiler shall have a high

temperature limit control that

will prevent the water

temperature from exceeding

the maximum allowable

temperature.

5Required for direct ignition

systems. Not required for

ignition systems with pilots

6Optional one safety shutoff

valve with valve seal overtravel

(Proof-of-closure) interlock.

7

One of the safety shutoff

valves with valve seal

overtravel (Proof-of-closure)

interlock.

8

Four air changes at 60%

damper opening with both air

flow and damper opening with

both air flow and damper

position proven.

9

Four air changes at 60%

damper opening with both air

flow and damper position

proven.

10

Units equipped with automatic

operating air shutters or

dampers which are closed or

positioned to restrict air when

burner is not firing, shall

provide means to open the air

shutter or damper the high fire

position for at least 90

seconds prior to light off.

11One of the two low-water fuel

cutoffs may be a combined

feeder / cutoff device.

12

For low pressure steam units

with inputs of 400,000 Btu/Hr.

or less, only one low-water fuel

cutoff is required gravity return

units installed in residences as

defined by the authority having

jurisdiction.

13

For modular low pressure

steam boilers, each module

shall be equipped with an

automatic low-water fuel

cutoff. The assembled

modular boiler shall have a

second low-water cutoff.

Operation of this low-water

fuel cutoff shall shut off the fuel

supply to all modules.

14Except those installed in

residences (as defined by the

authority having jurisdiction).

Fed

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FOOTNOTES:

Print Out 5/22/2014

15

An assembled modular boiler

shall be protected by a low-

water fuel cutoff located so

that it will detect a low-water

condition before the level falls

below the lowest safe

waterline in any module.

Operation of the low-water fuel

cutoff shall shutoff the fuel to

all modules.

16

In Lieu of the requirements for

low-water fuel cutoff in a water

tube or coil-type boiler

requiring forced circulation,

they shall have an accepted

sensing device to prevent

burner operational a flow rate

inadequate to protect the

boiler from overheating.

Where there is a definitive

waterline, a low-water fuel

cutoff shall be provided in

addition to the sensing device.

Functioning of the low-water

fuel cutoff shall cause a safety

shutdown.

17 Close main valve and recycle.

18One recycle for piloted

systems.

19Two safety shutoff valves in

series. May be in single control

body.

20

Two safety shutoff valves in

series on one safety shutoff

valve with valve seal overtravel

(Proof-of-closure) interlock.

21

One safety shutoff valve to

incorporate valve seal

overtravel (Proof-of-closure)

interlock.

22

When two safety valves are

provided in the fuel train, an

additional leak test valve is

required so that each safety

shutoff valve may be tested

independently of the other.

23

Gas pressure relief valves,

where required, shall be

located upstream of all

operating and safety controls

and downstream of the gas

pressure regulator I both the

main and pilot gas supply

systems. The relief valve in is

to directed to the atmosphere.

24

Water level control alarms,

when used, shall be distinctly

audible above the ambient

noise level and may be used in

conjunction with indicating

lights.

25 When pilot is used.

26 Initial start only.

27Pilot only: 15 seconds

maximum if interrupted pilot is

used.

28

Pilot only: 15 seconds

maximum if interrupted pilot is

used. 25 to 30 seconds if

safety shutoff valve has full

opening.


maximum for modulating or

high-low firing.


maximum.

31 Interrupted pilot only.

32Maximum input at light off shall

not exceed 2,500,000 Btu/Hr.

33Required with modulating or

high-low firing.

34 Required if interrupted pilot.

35

If ignition system includes a

relight feature, the relight

attempt shall be initiated within

0.8 seconds upon loss of

flame.

36

For power, and mechanical

draft, burner and natural draft

burners with inputs less than

400,000 Btu/Hr. and continuos

pilot, 180 seconds maximum

for pilot flame failure.

37

If system has intermittent pilot,

wait 5 minutes before resetting

ignition system (Instructional

requirement).

38

If system has interrupted pilot

or direct ignition and the

ignition includes a relight

feature, the relight attempt

shall be initiated within 0.8

seconds of loss of flame.

39A single recycle is allowed on

for

40Or, recylce once after 5

minute time delay.

41Select proper safety control

according to system

requirements.

TechStuff - Boiler Benchmarking Date of Printout

5/22/2014 / 4:05 PM

Data Compiled by

David Farthing

Voice 405-760-2831

BENCHMARKING A BOILER

AMBR = American Boiler Manufactuers Recommendations

6.36$ Therm Customer ChemTrade Industry Sulphuric Acid

Utility Fuel Btu = 975.609 Contact Mike Miller Gas After the Train = 33.02 InWc

Pf=(GP+Pc)/Pb Address 5201 W. 21st Street Air At Burner = 16.9 InWc

Guage PSI(GP) = 33.84 Actual PSIG City/State/Zip Tulsa, OK 74107 Gas at Burner = 16.2 InWc

Site Barometric (Pc) = 14.735 Location/Elevation Date 3.17.09 Burner Data Maxon EB6 0

Sea Level (Pb) = 14.700 Average Daily Rate = 326.709 MCF Boiler Mfg Operating PSI 0 Economizer NO

PSI Correction Factor (Pf) = 3.304 12/31/08-01/31/09= 10127.979 Mfg Rated Eff. 0% BHP = 0.0 Mfg

Clocked Metered Fuel Flow = ((100 SCFt/Time)*60)*Pf Fuels Natural Gas Gas PSI = 52InWc Steam Temp 0

Gas Flowing Temp = 56 Rated BTU Input/Hr 12,000,000 Fan Voltage 460 BTU/Lb Steam 0

Average Rate Rated Steaming Capacity/Hr 0 Fan Amp Rating 11.5 Feedwater Pump Amp Rating 0

High Fire Utility Meter BtuOut

/BtuIn

Eout

/Ein

Valve % Firing Rate Time/100 Cf Fuel Flow Burner InWc Rated Steam Steam Flow %/ Rated Flow Stack Temp Actual Ex O2 ABMR Ex O2 Actual Ex CO ABMR Ex CO Comb Eff % Fan Amps Boiler Thermal Eff % System Total Eff% EXCESS AIR % FLAME COLOR/PATTERN

10% 1200 0.000 #DIV/0! 0.0000 0 #DIV/0! #DIV/0! 6.00% N0X/CO 64/0ppm 45 #DIV/0! #DIV/0!

15% 1800 0.000 #DIV/0! 0.00 0 #DIV/0! #DIV/0! 6.00% 0.00 45 #DIV/0! #DIV/0!

20% 2400 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 6.00% 0.00 46.8 #DIV/0! #DIV/0!

25% 3000 0.000 #DIV/0! 0.00 0 #DIV/0! #DIV/0! 6.00% 0.00 48.08 #DIV/0! #DIV/0!




45% 5400 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 4.50% 0.00 #DIV/0! #DIV/0!50% 6000 0.000 #DIV/0! 0.00 0 #DIV/0! #DIV/0! 4.25% 0.00 48.5 #DIV/0! #DIV/0!






80% 9600 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 2.50% 0.00 #DIV/0! #DIV/0!


90% 10800 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 2.00% 0.00 7.05 #DIV/0! #DIV/0! Bright blue/hugging burner

100% 12000 1.616 12269 16.20 0 0 #DIV/0! 424 18.80% 2.00% 13/0 ppm 0.00 0 9.4 0.00% 0.000% 780% Duct Fan ON

100% 12000 1.616 12269 16.20 0 0 #DIV/0! 424 13.11% 2.00% 5/0 ppm 0.00 0 9.4 0.00% 0.000% 178% Duct Fan OFF

Economizer Data

Valve % Water Flow BDHR DeltaT TDS mS Inlet Temp Outlet Temp BTU Recovered Fuel Savings % FW Pump Amps10% 0.000 0.000 0.000 212 120 0 0.000% 0

15% 0.000 0.000 0.000 212 120 0 0.000% 0

20% 0.000 0.000 0.000 212 120 0 0.000% 0

25% 0.000 0.000 0.000 212 120 0 0.000% 0

30% 0.000 0.000 0.000 212 120 0 0.000% 0

35% 0.000 0.000 0.000 212 120 0 0.000% 0

40% 0.000 0.000 0.000 212 120 0 0.000% 0

45% 0.000 0.000 0.000 212 120 0 0.000% 0

50% 0.000 0.000 0.000 212 120 0 0.000% 0

55% 0.000 0.000 0.000 212 120 0 0.000% 0

60% 0.000 0.000 0.000 212 120 0 0.000% 0

79% 0.000 0.000 0.000 212 120 0 0.000% 0

42% 0.000 0.000 0.000 212 120 0 0.000% 0

75% 0.000 0.000 0.000 212 120 0 0.000% 0

80% 0.000 0.000 0.000 212 120 0 0.000% 0

85% 0.000 0.000 0.000 212 120 0 0.000% 0

90% 0.000 0.000 0.000 212 120 0 0.000% 0

95% 0.000 0.000 0.000 212 120 0 0.000% 0

100% 0.000 0.000 0.000 212 120 0 0.000% 0

High Gas PSI Switch Set at = 60 InWc

Low Gas Pressure Switch Set at = 12 InWc

Air Flow Switch Set at = 10 InWc

High Temp Controller Set at = 1065 C

Normal Operating Setpoint = 900 C

Theoretical Flame Length = 8' 6"

5/22/2014 4:05 PM Dissolved Oxygen In Make-up Water Data Compiled by

David Farthing

Voice 405-728-6709

Amount of Dissolved Oxygen in Make-up Feedwater vs. Temperature

NOTE: 227 and 242 degree 'F' water is presumed to be deaerated.

Temperature Dissolved O2

50 20000

58 15000

60 12000

72 8800

125 5000

180 3000

200 2000

212 1000

227 44

242 7

0

5000

10000

15000

20000

50 58 60 72 125 180 200 212 227 242PP

B D

iss

olv

ed

Oxyg

en

Temperature

Pressure Coversions Date of Printout

5/22/2014 4:05 PM

Data Compiled by

Karl Pierson

KMCS

Enter value to be converted in column D

The converted values will then be shown in the same row

PSI OzSI PASCAL kPa BAR mBARIn. H2O @

4C/39F

In. H2O @

60F

In. H2O @

20C/68Fmm H2O cm H2O ATM

In. Hg @

0 CCm Hg mm Hg TORR

PSI

OzSI

PASCAL

kPa

BAR

mBAR

In.H2O @ 4 C

In. H2O @ 60F 6.00 0.22 3.5 1,493 1.49 0.015 14.93 6.0 6.0 6.0 152.3 15.2 0.015 0.44 1.12 11.2 11.2

In. H2O @ 20C

mm H2O

cm H2O

ATM

In. Hg 8.00 3.93 62.9 27,091 27.09 0.271 270.91 108.8 108.9 109.0 2,762.6 276.3 0.267 8.00 20.32 203.2 203.2

Cm Hg @ 0 C

mm Hg @ 0 C

TORR

From Value

To Values

Required Boiler Blowdown for proper TDSNormal TDS should be between 3,000-5,000 ppm

TDS= Total Dissolved Solids in boiler water.

Blowdown Rate = (F/(B-F))*S

Where: F= Feedwater TDS in ppm

B= Desired boiler water TDS Requirement

S= Steam Generation Rate in lbs/hr

F= 87

B= 4000

S= 41400

Blowdown 920.4702 Lbs/Hr

Percent 2% of Production Capacity

NOTES: Blowdown within acceptable limits

Be sure to see HEAT in the contents for possible Heat Recovery Savings.

Energy Conversions

BTU = KW KW = BTU

29,010.00 8.50 8.50 29,010.24

AMPS VOLTAGE 3Ph/KW

43.00 480.00 35.71

Cost of Energy Cost/Hr to Operate

Gas per MMBTU 8.95$ 0.26$

Electric per KW 0.044$ 0.37$

NOTE: Gas Cost is per Decatherm (1,000,000 BTU)

1 KW = BTU * 0.0002930 (Source NATCO Engineering Handbook of Conversion Factors 1988)

BTU = Kw/.0002930

GO TO VFD CALCULATIONS FOR MORE DETAILED INFORMATION

CALCULATING APPROXIMATE HP WHEN VOLTS AND AMPS ARE KNOWN

Voltage 480

Amps 69

NP Eff% 80%

# Phases 3

61.52

VFD

Replacing DC3000 Versa-Pro with

OLD DC300C- use

OLD DC300K- use

OLD DC300E- use

OLD DC300A- use

OLD DC300T- use

OLD DC300L- use

Table 1 O use

E use

A use

T use

L use

Table 2 1_ _ use

2_ _ use

4_ _ use

_A_ use

_B_ use

_ _3 use

Table 3 Same on 3300

Table 4 First digit (zero) use

Second digit use

Third digit use

Forth digit use

n/a 5th digit

n/a 6th Digit

Table 5 Always -0- use

Table 6 Not used use

Note…. "DIN" is almost never used on replacement controllers.!!!

DC3300 Base plus w/ 1st Digit of Table 1

DC330B-CO

DC330B-K_

DC330B-E_

DC330B-A_

DC330B-T_

DC330B-E_

-_O- Place as 2nd digit of table 1.

-_E-

-_A-

-_T-

-_L-

1_ _

2_ _

4_ _

_0_

_B_

_ _3

No change. Use DC3000 table

Always zero (0_ _0_0)

Same (0X_0_0)

Same (0_X0_0)

Always Zero (0_ _0_0)

Zero or D if DIN adapter required (0_ _000)

Always zero (0_ _0_0)

Aways -00-

Always -0-

Note…. "DIN" is almost never used on replacement controllers.!!!

Replacing DC3000 W/ Table 1 with

DC3001-0- use

DC3002-0- use

DC3003-0- use

DC3004-0- use

DC3005-0- use

DC3006-0- use

Table 2 1st -0_ _- use

-1_ _- use

-2_ _- use

-3_ _- use

-4_ _- use

2nd -_0_- use

-_1_- use

-_2_- use

3rd -_ _0- use

-_ _A- use

-_ _B- use

Table 3 -1- use

-2- use

-3- use

Table 4 -00- use

(multiple avail.) -35- use

-DIN- use

-FM- use

-UL- use

Table 5 ID code 4 digits use

Table 6 Not used use

Note…. DIN or "D" is almost never used on replacement controllers.!!!

DC3300 W/ Table 1

DC330B-C0-

DC330B-KE-

DC330B-EE-DC330B-EE-Also change 2nd digit of table 3 to "2"

DC330L-E0-

DC330L-E0-

-0_ _-

-1_ _-

-2_ _- -0 _ 3- No misprint, it goes as 3rd digit

-4_ _-

-_0_- -_0_- Also change 2nd digit of table 3 to "1".

-_0_- Also change 2nd digit of table 3 to "1".

-_ _0-

-_ _0- -_B_- No misprint, it goes as 2nd digit.

-10-

-20-

-30-

-000000- Multiple options available in this table.

-000T00- -0000D0-

-0F0000-

-0F0000-

Always use -00-

Always use -0-

Note…. DIN or "D" is almost never used on replacement controllers.!!!

VFD Calculations

5/22/2014

David Farthing's

TechStuf

Variable Frequency Drive Applications

Customer American Airline Service Center

Application Combustion Air Fan Control

Need to know Motor Horsepower 5

Motor Speed as supplied 3450

Hertz - Name Plate 60

Rated Torque Ft/Lb. 8

New Hertz 37

New Motor Speed 2128

New Torque Ft/Lb. 8 NOTE: Torque should remain constant but Horsepower will change.

Change in Motor Speed % 38.33%

New Horsepower @ New Speed 3.08

Prefer to know Original Amp Draw 6.5

Cost of kW of Electricity 4.500$

Total Hours of Operation/Year 4000

Is Application Pump or Fan? (P or F) F

Control Methods Code - See List Below IG

Variable Frequency Drive VFD 0.28

Discharge Control Valve DV 0.94

Bypass Valve BV 1

Inlet Guide Vane IG 0.62

Outlet Damper OD 0.88

Fan Curve FC 0.88

No Control NA 1

NOTE: WHEN USING KNOWN AMP DRAW MOTOR HORSEPOWER ENTRY IS IGNORED.

IF YOU WANT TO COMPARE MOTOR HORSEPOWER ENTER A "0" IN AMP DRAW TO JUST REVIEW MOTOR DATA ONLY.

Results

kWha 5.402 Kilowatt Usage Standard Motor No Control

kWhb 2.300 Kilowatt usage using VFD at New Horsepower

kWhc 3.349 Kilowatt Usage Using Current Control Method

kWhd 1.049 Kilowatt Savings Converting from Current Control Method to VFD

Savings 188.78$ Annual Energy Cost Savings By Converting to VFD

techstuff 3.09

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