TECHSTUF 4.07

Compile January 14, 1997Contents

Data Printout 05/07/2014

Data Compiled byDavid C. Farthing

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WELCOME TO TECHSTUFF!! Month Year Date of Rev.

© 1997 David C. Farthing Revision 4.07 7 04.10.07

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

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

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

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

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

Flow Measurement & Piping Calculations

Gas/Steam Flow & Steam Velocity

Single Pipe Friction Loss Calculations

Thermal Expansion of Pipe

Water Hammer Calculations

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)

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.

Volume

BTU

Refrig.

Chimne

y

BHP

FHL

AIR

Gas Valv

e

Liquid Val

Steam Val

Fan Coil

Pumps

Voltage

Pipe T.

MainsLeaks

Flow

Calcs

OHMS

TEMP

Tables

FrictionHammer

ASCOBoil

ersFSGTrapsPum

psM&CDC300#

Tank Size

O2/CO

Trim

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To Contents

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General

Calculations

Heating

Loads

Refrigeratio

nLoads

BoilerBurne

rCalculations

Valve Sizing

Pumps

andHydronics

Controls

-Transmitters & VFD

SteamStuff

Flow &

PipingData

Revision

Notes

Electric

Motor Data

Product

Selection

Guide

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To Contents

Financial

IASG

Econo

B&EEquip Ht

Comb Air

Expansion

Hallibutron

Hydronic

s

Superhe

at

Heat

Recover

y

FW Tem

pSCALE

MKUP O2

PRESSURE

DC300X

BENCHM

K

Systems

Warranty

Accuracy

Contact

Info

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To Contents

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CSD1

ENERGY

BLDOWN

VFD

Relief

Val Recover

y

FAN

DR.MAC

Pump

NPSHPUMP

VFD

Systems-

W

Steam $$

VPS

Revision Notes

Rev # Date Notes1.102 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 Charts02.7.04 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 Calculator09.14.04 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 Deposits6.21.06 6/21/2005 BTU to #2 Diesel Conversion for Halliburton Turbine Meters3.12.07 3.12.07 Add Oxygen Trim Calculator to O2 Trim Worksheet4.10.07 4.10.07 Add VPS Volume & Time Calculator

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

Warranty of Accuracy Statement© 1997 David C. Farthing

TECHSTUFF© 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 FarthingVoice 800-239-7301Fax [email protected]@advancedtech.org

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

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

Compiled January 14, 1997Tank Fluid Volumes


Data Compiled by David C. Farthing

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CAPACITY OF LIQUID IN CYLINDRICAL TANKS IN U.S. GALLONSCAPACITY of CYLINDRICAL TANKS = D^2 * L * .0043WHERE D = DIAMETER IN INCHES

L = LENGTH IN INCHES.0043 = CONSTANT

INPUT DATA MAY BE IN EITHER INCHES OR FEET. NOTE APPROPRIATE DATA TABLEDimensions INCHES FEETD = 12 1L = 12 1VOLUME = 5.88 5.88 Gallons U.S.

CAPACITY OF LIQUID IN SQUARE SIDED TANKS IN U.S. GALLONSCAPACITY of SQUARE TANKS = (D-FB) * W * L * 7.5Dimensions Depth Width Length Fluid VolumeINCHES 12 12 12 0 7.43 Gallons U.S.FEET 1 1 1 0 7.43 Gallons U.S.

Freeboard, inches

Customer Chromalloy NOTE: CUSTOMERS TANKS MUST BE INSULATEDContact Tim Johnson MINIMUM 2.0" FIBERGLASS BAT RECOMMENDED.Tank Name: Plating Open Top Tank Assumed. 0.5 F/Sec Air Velocity over top of tank.Load CalculationsNo. of Tanks Tank Configuration Type Letter S or C in box Tank Designations

1 S RM1

Square Sided Tank DataDepth Width Length Freeboard, inches Fluid Volume Total Fluid Volume

2 2 4 6 89.784 89.784Total Tank Surface Area Surface Square Feet 8.00

Cylindrical Tank DataDimensions FEETD = 0 Total Fluid VolumeL = 0 All Cylindrical Tanks Open Top Area Sq./Ft.FLUID VOLUME = 0.00 0.00 0

Fluid Data: Product: WaterFinal Temperature Sp./Gr. Sp./Ht

100 1.23 1 NOTE: PAGE DOWN FOR COMMON LIQUID DATAQ=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 $5.66 $0.03 $0.03 W= Weight of Product to Be Heated Energy Cost Electric/KW $0.0480 $0.07 $0.07 Sp./Ht = Specific Heat of ProductT2= Ending Temperature T2 100 OK

Ambient Losses T1= Beginning Temperature T1 96.5 Calculated Base Maintenance Loss.Ambient Shop Temperature TA 70

Solution for boiler loadingPer Tank Load 3,212 Maintenance Load ONLY 3,212 0Open Top Loss 1,488 Tank radiance and surface losses. 180 Open Top Radiant Loss FactorTotal Tankage Load 4,700 Total Maintenance Load Btu per hour for all tanks combined.Cold Start 30,590 Cold Heat-up Btu Required for all tanks from Cold Start of: (TA) w/ 10% Loss. 30,590 0

Note: 10% tank and process loss included.Boiler BTU Required 1 Hr Rise 4Hr Rise 6 Hr Rise 8 Hr Rise 12 Hr. RiseAssumed 80% Eff. 38,238 9,559 6,373 4,780 3,186Boiler Horsepower 80% Eff. 1 0 0 0 0Common 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/.48Acetone .79/.51 Citron Oil 1.2/.44 Naphthalene 1.14/.41Alcohol's .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47Ammonia .62/1.16 Ethyl Ether 1.16/.53 Propane .50/.59Aniline 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54Benzol 1.02/.42 Fuel Oils 2-6 .90/.45 Seawater 1.02/.94Calcium Chloride 1.2/.43 Gasoline .81/.53 Soybean Oil .93/.47Paraffin Wax 1.12/.69 Gypsum 1.21/.26 Sandstone .93/.22Plating Applications Diluted Solutions

Nickel 1.23/1Acid 1.23/1

Chrome/Fluorides 1.23/1Electro-Klean 1.12/1Soak Clean 1.12/1

Square/Cylinder

Data Compiled January 14, 1997Refrigeration Loads



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Refrigeration of LiquidsCustomer NameContactPhone Number

Refrigeration Load = Mass expressed as G/Hr.;((Flow in Gallons / Hr. *8.31)*Specific Gravity* Specific Heat * (T1-T2))/12000Flow = 1119 GPMFlow = 67140 Gallons / HourSp. Gr. 1Sp. Ht. 1T1 = 95T2 = 85Tons Refrigeration Required = 466.06

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/.48Acetone .79/.51 Citron Oil 1.2/.44 Naphthalene 1.14/.41Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47Ammonia .62/1.16 Ethyl Ether 1.16/.53 Propane .50/.59Aniline 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54Benzol 1.02/.42 Fuel Oils 2-6 .90/.45 Seawater 1.02/.94Calcium Chloride 1.2/.43 Gasoline .81/.53 Soybean Oil .93/.47

Data Compiled January 14, 1997 Rite Boiler Chimney EffectData Printout 05/07/2014


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Chimney / Stack Draft Effect CalculationsUse Boiler and Stack Index to find required stack diameter on Rite Stack Chart.

must be included for proper results.

Draft / In. H2O = .52 X P X H X (( 1/460 + T1) - (1/460 + T2))INPUT DATA

Boiler Horsepower 765Boiler Efficiency 0.8BTU Input 32,000,906Fuel G

Final Calculated Boiler Index 32.99Altitude Of Installation 774Total Number of Turns 2Total Length of Breech 24Height of Stack (Ft.) 20 As Measured from exhaust outlet.Total Stack Length+Breech LS 44Stack Diameter (FT) DS 2.33 27.96 Calculated Stack Diameter in InchesStack Length/Diameter Index A LS/DS 18.88Degrees 80.00Stack L/D + Turns Index B 2.09

Final Calculated Stack Index 9.57Atmospheric PSIA P 14.68Ambient Temp. T1 95Stack Temp. T2 325

Solution Draft In. H20 -0.0805981Recommended Minimum Drafts Negative .09 on Power Burners measured at stack inlet.

Negative .04 on Atmospheric measured at stack inlet.

a decrease of 1% in fuel consumption may be received.

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

NOTES: Gas fuel based on 9% CO2, #2 Oil fuel based on 13% CO2 emissions.Excess Air Volume=15%

Fuel Gas=1/Oil=0 1 Enter 1 or 0Flue Gas Temperature 425Boiler Horsepower 107.5Exhaust Volume 1591 Cubic Feet/Min.Emissions Make-Up Percent of FGExcess Air = 15% Mol Wt. by Volume SCF/10^6 BTU Lbs./10^6 BTU PPM

CO2 = 44 10.10 1095.44 126.84O2 = 32 3.00 306.12 25.78CO = 28 0.0020 0.2 0.015 20N2 = 28 86.900 8876.40 654.05Nox=NO2 46 0.0025 0.25 0.03 25Hydrocarbons 16 0.001 0.100 0.004 10Sox=SO2 64 0.000 0 0.00H2O = 18 2237 105.96Particulates 0.00Total 100 12515.52 912.68

Total Emissions this application = 45,024.43 3,283.37

Instructions: Input current data in 'Input Data' Column. Solution is calculated as you go. All data

Gas / Oil

NOTE: A commonly accepted ruel of thumb states that for every 0.01"WC the excess draft rate can be reduced

Compiled January 14, 1997Boiler Horsepower



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Boiler Horsepower

When Pounds Per Hour Steam Flow are known.BHP = #/Hr Steam Flow / 34.5

Steam Flow = 60000Boiler Hp = 1739 At and From 212 deg. "F"

When BTU of Burner is Known.Useful BHP = Fuel BTU Input/ 33,465 * Rated Efficiency

Fuel Input = 10,500,000Boiler Hp = 254Boiler Hp = 235

When Boiler Rated Horsepower is Known.Steam Flow #/Hr = Boiler Rated Hp * 34.7

Boiler Hp = 250Steam Flow = 8625.65 At and From 212 deg. "F"

When BTU Required by the Process is Known.Process Input = 60,000,000Boiler Hp = 2213Boiler Hp = 2391Boiler Input = 74,074,074Boiler Input = 80,000,000

When Heating Surface area is Known.Heating Surface = 10,750Fire Tube BHP = 2150.0Fire Box BHP = 2087.4Water Tube BHP = 2028.3Boiler BTU Output = 71,949,750Boiler BTU Output = 67,877,123

TURBINE to BOILER Horsepower RequirementsKW/Hr. 2200Meg.W 2.2BTU/Hr. 7,513,440 Efficiency 22.18%Boiler Hp 1012.25Steam Flow PPH 34,923 UNDER CONSTRUCTION DO NOT USE THIS CALCULATION

at 81% Eff. At and From 212 deg. "F" at 75% Eff. At and From 212 deg. "F"

Fire Tube at 81% Eff. At and From 212 deg. "F" Water Tube at 75% Eff. At and From 212 deg. "F" Fire Tube at 81% Eff. At and From 212 deg. "F" Water Tube at 75% Eff. At and From 212 deg. "F"

Fire Tube at 81% Eff. At and From 212 deg. "F" Fire Box at 80% Eff. At and From 212 deg. "F" Water Tube at 75% Eff. At and From 212 deg. "F" Fire Tube at 81% Eff. At and From 212 deg. "F" Water Tube at 75% Eff. At and From 212 deg. "F"

Compiled January 14, 1997Boiler Horsepower



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Boiler HP from BTU OutputBTU Output= 12500000Boiler HP = 373.524577917

KW/Hr. 6000BTU/Hr. 20,491,200 Boiler Hp 612.32Meg.W 6

Notes1KW = 1,000 Watts1 MW = 1,000,000 Watts1 MW = 1,000 KW

Eletric Motor Hp 16000KW/Hr. 11931.2MegW/Hr 11.9312Boiler Hp 1216.352

5.285.335.355.385.515.325.174.92

Data Source Sterling Radiator05/07/2014 09:59:53

Building Machinery Heating/Cooling LoadsData Compiled by

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BUILDING HEAT LOSS CALCULATION Changeable data WALLSCONSTRUCTION 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 PLYWOOD1" 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" VALUESBUILDING HEIGHT EVE 16 PERCENT GLASS 10% SAND / GRAVEL AGGREGATE OPEN CORE FILLED COREBUILDING 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 0.38DOOR AREA (FT SQ.) 75 DOOR U FACTOR 1.22 12" THICK (R=1.28) 0.47 0.38

CINDER AGGREGATEOUTSIDE AIR TEMPERATURE 15 BUILDING VOLUME 1173000 4" THICK (R=1.11) 0.51INSIDE AIR TEMPERATURE 73 DELTA TEMP 58 8" THICK (R=1.72) 0.39 0.18

12" THICK (R=1.89) 0.37 0.16AIR CHANGES PER HR 1

BRICK - COMMON NO INSULATIONVOLUME REQUIREMENT 1,224,612.00 BTU 4" THICK (R=0.8) 0.61WALL HEAT LOSS 413,407.30 BTU 8" THICK (R=1.60) 0.48ROOF HEAT LOSS 268,162.16 BTU 12" THICK (R=2.40) 0.31DOOR HEAT LOSSES 5,307.00 BTUSLAB LOSS 49,422.96 BTU

TOTAL BUILDING LOAD 1,960,911 BTU METAL AND TRANSITE NO INSULATIONCORRUGATED METAL 1.5

BOILER HORSE POWER 58.5346690729 HP COATED METAL 0.93/8" TRANSITE - FLAT 1.13/8" TRANSITE - CORRUG 1.3

HEATER CALC.S ROOFSCONSTRUCTION INSULATION THICKNESS - INCHES

BTU CAP @ 20 DEG DROP 250000 HEATERS REQ 13.0727427596 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 4PRESSURE 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 1.221/2" PLYWOOD 0.05 DOUBLE PANE 0.75 DILUTION AIR - PER 1,000 BTUH

8" CONCRETE BLOCK 0.32 NATURAL GAS - 4 CFM3/8" GYP BOARD 0.6 EXTERIOR DOORS PROPANE GAS - 5 CFM

FLAT METAL 1.2GLASS - VERTICAL 1" WOOD 0.64

SINGLE PANE 1.13 2" WOOD 0.43DOUBLE 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 FarthingTech Stuff

Heating Solid Materials05/07/2014 09:59:53

Data Compiled by David Farthing

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Heating Solid Materials and Equipment

Formula = Lbs/Hr = W*Cp*Delta T/(L*t)Where W= Weight of Material

Cp= Specific Heat of MaterialL= Latent Heat of Steam (Btu/Lb)t= Time in Hours

Material = Steel Part in Platen Heater

W= 58 Lbs.Cp= 0.12 From ChartsL= 945 From Steam ChartsStart Temp 58Final Temp 2000Delta T= 1942t= 1Lbs/hr= 14.30298 BTU/Hr = 13,516.32

Boiler Hp 0.40Common Specific Heats of Solid Materials Water Cp = 1.0

Steel 0.12 Carbon-Coke 0.203 Glass, normal 0.2 Nickel Steel 0.109Iron 0.12 Chalk 0.215 Gneiss 0.18 Paraffin Wax 0.69

Aluminum 0.22 Charcoal 0.2 Granite 0.2 Porcelain 0.22Alumina 0.35 Cinders 0.18 Graphite 0.2 Quartz 0.23

Asbestos 0.2 Coal 0.3 Gypsum 0.26 Quicklime 0.217Ashes 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 0.21Basalt 0.2 Cork 0.485 India Rubber 0.37 Sand 0.195

Bell Metal 0.086 Corundum 0.198 Kaolin 0.224 Sandstone 0.22Bismuth-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 0.191Brass, Y 0.088 Ebonite 0.33 Lipowitz Metal 0.04 Soda 0.231Brass, R 0.09 German Silver 0.095 Magnesia 0.222 Sulfur 0.18Bronze 0.104 Glass, Crown 0.16 Magnesite 0.168 Talc 0.209Brick 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

Compiled January 15, 1997Flowing Fluid Heating

Data Printout 05/07/2014Data Compiled byDavid C. Farthing

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Flowing Fluid Heating Loads

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

Gal/Hour Gal/MinuteFlow = 175000 GPH 1600 GPMSp. Gr. 1 1Sp.Ht. 1 1T1 = 97.5 88T2 = 120 Boiler Hp Steam Flow 95 Boiler Hp Steam FlowLoad BTU/Hr. = 32,799,375.00 980.11 33,813.79 5,597,760.00 167.27 5,770.89

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/.48Acetone .79/.51 Citron Oil 1.2/.44 Naphthalene 1.14/.41Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47Ammonia .62/1.16 Ethyl Ether 1.16/.53 Propane .50/.59Anilin 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54Benzol 1.02/.42 Fuel Oils 2-6 .90/.45 Seawater 1.02/.94Calcium Chloride 1.2/.43 Gasoline .81/.53 Soybean Oil .93/.47

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

Water Content In Air Stream

Water Content in Air Streams

1# of Air at 62 "F"=13.65 CFDatum 1CFt of Air holds .0225# Water at 65"F" and 40% RH

CFM = 2500Total Water / Min. = 56.25 in Lbs.Lb./Hr Water = 3375Gallons/Hr. Water = 406.1372

David Farthing'sTechStuff Valves

Gas Valve Thanks to Honeywell for the basic CV calculator

Courtesy of HONEYWELL, INC. - Modified by David Farthing GASCITGO 725 BOILER 100% 75% 50% 25%

CONDITIONS CONDITIONS CONDITIONS CONDITIONSBASE FLOW SCFH 32,350.00 24,262.00 16,175.00 8,088.00 SAFETY FACTOR X 1.10 1.00 1.00 1.00 FLOW SCFH 35,585.00 24,262.00 16,175.00 8,088.00 INLET PRESS PSIG 10.00 11.00 12.00 14.00 OUTLET PRESSURE PSIG 3.00 2.00 1.00 0.50 PRESS DROP PSI 7.00 9.00 11.00 13.50 TEMPERATURE DG.F 68 68 68 68 SPEC GRAV 0.63 0.63 0.63 0.63

REQUIRED Cv 38.964 23.429 14.128 6.267

V-Cut Degrees Open Degrees Open Degrees Open Degrees Open

60 38.96 23.43 14.13 6.27Percent Open Percent Open Percent Open Percent Open

CV of Installed Val 90 43.294% 26.032% 15.698% 6.964%

V-Bal 900Rotation


Liquid Valve Thanks to Honeywell for the basic CV Calculator

Courtesy of HONEYWELL, INC. - Modified by David Farthing LIQUIDOUHSC 2006 OUHSC@100% OUHSC@75% OUHSC@50% OUHSC@25%

CONDITIONS CONDITIONS CONDITIONS CONDITIONS BASE FLOW GPM 17.00 12.75 8.50 4.25 SAFETY FACTOR X 1.25 1.00 1.00 1.00 ACTUAL FLOW GPM 21.25 12.75 8.50 4.25 INLET PRESS PSIG 200.00 350.00 350.00 350.00 OUTLET PRESSURE PSIG 125.00 322.00 322.00 322.00 PRESS DROP PSID 75.00 28.00 28.00 28.00 SPECIFIC GRAV 0.98 0.98 0.98 0.98 VISCOSITY CS 0.96 0.96 0.96 0.96 TEMP(WATER) DG.F 227 227 227 227 MAX ALLOW | ¸P (WATER) PSI 155.014 273.514 273.514 273.514

REQUIRED Cv 2.429 2.385 1.590 0.795

Linear V-Ball V-Cut Degrees Open Degrees Open Degrees Open Degrees Open30 7.29 7.16 4.77 2.39

Percent Open Percent Open Percent Open Percent OpenCV of Installed Val 10 24.291% 23.853% 15.902% 7.951%

V-Bal Rotation


Steam Valve Thanks to Honeywell for the basic CV Calculator

Courtesy HONEYWELL, INC. - Modified by David Farthing STEAMTAG # Original Design Reduction #1 Reduction #2 (ENTER TAG #)

CONDITIONS CONDITIONS CONDITIONS CONDITIONSBASE 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 OUTLET PRESSURE PSIG 25.00 25.00 50.00 50.00 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

60 0.00 0.00 0.00 0.00Percent Open Percent Open Percent Open Percent Open

CV of Installed Val 400 6.667% 6.524% 28.966% 21.565%

V-Bal 900Rotation

VPS Calculations05/07/2014 Complied by David Farthing

VALVE PROVING SEQUENCING TEST CALCULATIONS

V1= Upstream Valve VolumeV2= Downstream Valve VolumeD= Pipe Diameter (Inches Nominal-Schd. 40)L= Pipe Length Between V1 & V2 (Feet)P= Inlet Gas Pressure to V1C= Burner Maximum Firing Capacity (CFH)X= Calculated Test Valve Train VolumeT= Minimum Test Time in Seconds

Calculation of Valve Train VolumeX= V1+V2+((A x L)/144)

Calculation of Valve Proving Test TimeTest Time (Sec) = 187,000 X (P x X)/C

Is Inlet Gas Pressure in InWc or PSI (I or P) iInlet Gas Pressure 40

P= 1.444043321D= 2

Area Sq/In = 3.357236479L= 0.25

V1= 0.0227V2= 0.0245

Total Volume Cft (X)= 0.053028536C= 2500

Min.Test Time Seconds (T) = 10.00

GAS

V2V1

vps

L

Fan Coils

Steam Demand in a Fan Coil

Formula used for calculationsWhere Q = Air flow across fan coil in cfm

TD = Temperature Differential across fan coil1000 = Latent heat of 15 PSI Steam1.08 = Correction factor for fouling of coils

INPUT DATACFM = 6,000Inlet Air Temp = 60Exhaust Air Temp = 180Lbs/ Hr. Steam Load 777.6BTU Load 777,600

Q=( CFM X 1.08 X TD ) / 1000

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

Feet Absolute Calculator - Enter Data in Guage Readings to get Feet AbsoluteGuage Reading Fa

Pb = 29 32.79Vp = 10 57.03p = 10 57.03

Input DataPb = 32.79Vp = 57.03p = 57.03Ls = 0.00Lh = 5.50Hf = 1.39NPSHa = 4.11 Pump must require an NPSHr less than or equal to this value.

Friction

Producers COOPPeerless F21250AM11.0" Impeller

05/07/2014 Pump Affinity Laws

Pump Horsepower Requirements

Q= 1840

H = 60

PSIG = 25.97

Sp.Gr.= 1

Pump Eff. 65.00%

Minimum Motor Hp BHP= 42.8904428904

Cost to Operate Pump

$/KW/Hr = 0.044

Hours/Day = 24

Days/Month = 15

Cost Per Month = $506.82

Burner Fan Lawsby David Farthing

05/07/2014 David Farthing'sTechStuffFan Laws for ESTIMATING Boiler Burner Fan Performance

Q = Assumed DataD = Fan Diameter in Inches Air Density = 0.0584N = Fan Shaft RPM Air Temp = 100H = 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)OUHSC Diff P = Differential Pressure Across Windbox at Firing Rate

CB Watertube Eff =Burner Input 65,800,000.00 BTU/Hr from Burner Data Plate

60,000 at 275 PSIG Max Gas Flow 65,800.00

Min Gas Flow 6,580.00

Max Air Flow @15% EA. 12,476.20 Min Air Flow 1,247.62 CFM at LOW (10%) FIRE.

Fan Motor HP 60.00 Taken from Fan Motor Data PlateFan Static Pressure H 18.00 *At Stall 0 Flow Fan Damper CLOSED taken at fan discharge ahead of dampers.

Calculated Fan Eff. 71.116% 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 performanceOriginal Fan Speed 1770 RPM at Shaft FAN LAWS

New Fan Speed 1150 RPM at Shaft Q1/Q2 = N1/N2New Fan Flow 8106 CFM H1/H2 = (N1/N2)^2

New Fan Max SP 7.60 Inch WC Bhp1/Bhp2 = (N1/N2)^3New Fan Bhp 14.63 Bhp at the shaft. Q1/Q2 = D1/D2

Original Boiler Output PPH 54,268.04 Saturated H1/H2 = (D1/D2)^2Original Boiler Output PPH 45,585.15 Superheated <700 Deg F Bhp1/Bhp2 = (D1/D2)^3

New Boiler Output PPH 35,258.48 SaturatedNew Boiler Output PPH 29,617.12 Superheated <700 Deg F

Note1 Data marked with an asterisk * may also be taken from manufacturer's data sheets.

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.

Fan Volume Flow Rate CFM or ft^3/Min

(ft^3/min X H) / (5263 X Motor Hp)

Ft^3/Hr

Ft^3/Hr

CFM base on 9.67 Ft^3 Air/1Ft^3 Gas at Sea Level & 80 deg "F". 15% Excess Air.

TechStuff C1997 Combustion Efficiency CalculationsPrintout 05/07/2014 09:59:54

Data Compiled byDavid Farthing

Combustion Efficiency Calculations

Boiler Type & Data Kodak PolyGraphicsMinimum O2 Allowed This Fuel Type

Fuel (Gas =1, Oil =2) 1 2.00%Rated Boiler Hp 956 Steaming Rate PPHName Plate Efficiency 78.00% 16491Current O2 % as found 7.80%Current Co2 % as found 5.30%Air Diluted CO ppm as found 45.00CO in Flue Gas ppm Corrected 71.79Approximate Fuel Loss out stack 0.02% Cu/Ft Gas/Hr.@NFR@ As Found Eff.

50% 19,790Recommended O2% @ NFR 4.25% Data from Ideal O2 TableAverage Hours/Day Run Time 24Average Days/Month Run Time 22Fuel Cost/Therm from billings 0.6 Equivalent Cost / 1000 Cu/Ft = $6.00 Average Combustion Air Temp 80Stack Temp at Firing Rate 390Net Flue Gas Temp Rise 310 Performance DataNet Efficiency Loss to Wasted Fuel as Co 0.0718% 36% Present Excess Air Mass.As Found Combustion Efficiency 80.8% 20% New Excess Air Mass.New Calculated Combustion Efficiency 82.5% $7.20 OLD Fuel Cost per 1,000 Lb/Steam.New Stack Temp 384 $7.05 NEW Fuel Cost Per 1,000 Lb/Steam.New Net Flue Gas Temp Rise 304 2.05% Percent Fuel Cost Savings.Net Combustion Efficiency Gain 2.03%Current Cost to Operate Per Month $62,696.16 New Cost to Operate Per Month $61,425.68 Current Fuel Dollars Wasted as Excess CO $12.56 Savings Per Month $1,283.04 Controller Output= 45Savings Per Year $15,396.53 Raw Air Flow= 100NOTES O2 Reading= 3

O2 Corrected Air Flow= 102.5

Normal Firing Rate NFR (0-100)

Voltage

#DIV/0!

CONTROLLER IMPEDANCE VS. VOLTAGE

Impedance of Device Controller is Controlling 250 OHMSMa output of controlling Device 20Out Put Voltage You Should Read at Controller Output 5When Controller Out Put = Ma in Cell 'F6'.

Common Control Device Impedance and their associated VoltageImpedance Control Voltage250 Ohms 5 VDC120 Ohms 2.4 VDC100 Ohms 2.0 VDC

TRANSMITTER TROUBLESHOOTER

HIGH SIDE 0LOWSIDE -22

4/20 MA READING 12 (NOTE: Max Value = 19.99 otherwise DIV/0 Error)RATIO 1 This is any RATIO applied by the display device.BIAS 20 This is any BIAS applied by the display device.

DISPLAY READS 9

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 SizePipe Run Length 361Operating Temperature = 347 Expansion CoefficientsThermal 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, 1997Source: Skidmore/ASME

Condensate Tank SizingData Printout 05/07/2014


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Condensate & Feedwater Tank Sizing

Boiler Hp. 1740Evaporation Rate from and at 212 deg. F. 7223.827 Gallons Per HourGPM Flow Rate Start/Stop Feedwater System 300.9928 Gallons Per Minute 2.5 Safety FactorGPM Flow Rate Modulated Feedwater System 180.5957 Gallons Per Minute 1.5 Safety FactorStorage Holding Time Desired, Minutes 7 Minutes Holding TimeTank Size for Start/Stop Feedwater System 3009.928Tank Size for Modulated Feedwater System 1805.957

Compiler November 3, 1997Source: Spirax Sarco

Steam Mains Trap SizingData Printout 05/07/2014


James W. CarrVoice 405-728-6709

Steam Mains Trap Sizing

Steam Main Data Assumes 2.0" of Fiberglass InsulationPipe Diameter 6Steam Header Pressure(PSIG) 20Ambient Air Temperature 70Warm-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. 31Feet Between Trap Points 100Total Trap Warm-up Load Per Trap Point 75 #/Hr Condensate LoadTotal 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 1.55.00 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 1.4120.00 8.4 13.4 17.5 24.9 33.8 44 66 93 124 146 191 241 284 396 1.3740.00 9.9 15.8 20.6 29.3 39.7 52 78 110 145 172 225 284 334 465 1.3260.00 11 17.5 22.9 32.6 44 57 86 122 162 192 250 316 372 518 1.2980.00 12 19 24.9 35.3 48 62 93 132 175 208 271 342 403 561 1.27100.00 12.8 20.3 26.6 37.8 51 67 100 142 188 222 290 366 431 600 1.26125.00 13.7 21.7 28.4 40 55 71 107 152 200 238 310 391 461 642 1.25150.00 14.5 23 30 43 58 75 113 160 212 251 328 414 487 679 1.24175.00 15.3 24.2 31.7 45 61 79 119 169 224 265 347 437 514 716 1.23200.00 16 25.3 33.1 47 64 83 125 177 234 277 362 456 537 748 1.22250.00 17.2 27.3 35.8 51 69 89 134 191 252 299 390 492 579 807 1.21300.00 25 38.3 51 75 104 143 217 322 443 531 682 854 1045 1182 1.2400.00 27.8 43 57 83 116 159 241 358 493 590 759 971 1163 1650 1.18500.00 30.2 46 62 91 126 173 262 389 535 642 825 1033 1263 1793 1.17600.00 32.7 50 67 98 136 187 284 421 579 694 893 1118 1367 1939 1.16800.00 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 1.1471200.00 52 72 96 140 253 340 566 833 1172 1407 1796 2280 2767 4010 1.141400.00 62 79 106 155 280 376 626 922 1297 1558 1988 2524 3064 4440 1.1351600.00 71 87 117 171 309 415 692 1018 1432 1720 2194 2786 3382 4901 1.131750.00 78 94 126 184 333 448 746 1098 1544 1855 2367 3006 3648 5285 1.1281800.00 80 97 129 189 341 459 764 1125 1584 1902 2427 3082 3741 5420 1.127

Compiled by David Farthing 05/07/2014 09:59:54Sources Marks 7th Ed.

GPSA 9th Ed.

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

Cf = 0.651 from Manufacturer's Model 301Cf' = 233.78712 Cf' = (359.12 * cf)D = 8.385 Inside Pipe DiameterFp = 150 Flowing Pressure in PSIG used to look up "wf" from Steam Tableswf = 0.282 Specific Weight at Flowing Conditions from Steam TablesLb/h 50000 Flow Rate Expecteddp= 32.8123602194 Calculated dp from formula

Lb/H = 50142.7604459098 Proofing #error = 0.285%

dp = 33.000HC900 Math Block Assignments

a = dp 32.8123602b = Cf' 233.78712c = D^2 70.308225d = wf^.5 0.53103672

Dp Flow Dp Flow Dp Flow e = 21 32982 11 109389 21 151142 f = 0.52 46643 12 114253 22 154699 g = off3 57126 13 118918 23 158176 h = off4 65964 14 123407 24 161578 (a^f)*(((b*c*d)^e)^f)5 73750 15 127739 25 n/a Math Block Function Proof = 50000.00 PPH6 80789 16 131928 26 n/a7 87262 17 135988 27 n/a8 93287 18 139931 27.5 n/a9 98946 19 143765

10 104298 20 147500

Compiled by David Farthing 05/07/2014 09:59:54Sources Marks 7th Ed.

GPSA 9th Ed.

Fan Laws for ESTIMATING Boiler Burner Fan Pressures/FlowsQ = Volume Flow RateD = Fan DiameterN = RPMP = PressureDiff P = Differential Pressure Across Fan at Firing RateH = Fan HorsepowerEff = ft^3/min X P (in H20)/(6356 X Motor Hp)Burner Input 29,400,000.00 MMBTUMax Gas Flow 29,400.00 Ft^3/HrMin Gas Flow 2,940.00 Ft^3/HrMax 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 PlateFan Stall Pressure 29.00 At Stall 0 Flow Fan Damper CLOSEDCalculated 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 PlateFan Performance OK

Q = C' * (P^.5) Air Flow at varying pressures measured down stream of damper vanesC' = 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 DamperQ = 29400.000 Must Equal MAX AIR FLOW!! Adjust C' as needed to correct.% Flow 100%DP = 99 88 77 66 55Q = 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 54Q = 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 53Q = 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 52Q = 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 51Q = 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 49Q = 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 12.5Q = 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 5Q = 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 0.137Q = 28045.813 26296.159 24421.474 22390.373 4157.788

% Flow 95.394% 89.443% 83.066% 76.158% 14.142% 1.49DP = 90 79 68 57 1Q = 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 0.025Q = 27735.905 25965.377 24064.937 22000.945 464.855% Flow 94.340% 88.318% 81.854% 74.833% 1.581%

Differential Pressure Across Fan at Firing Rate

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

Taken from Fan Motor Data PlateAt Stall 0 Flow Fan Damper CLOSEDAs 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, 1997Source: Simple Math Context

Revenue LossData Printout 05/07/2014

Compiled byDavid Farthing

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Cost of Leaking Steam Traps in Lost Steam and RevenueCustomer

SiteINPUT DATA

Total Number of Traps Surveyed 226Number of Traps Leaking 60Number of Traps Plugged 1 Trap Type SurveyedCapacity of Traps in #/Hr. 370 1/2" TDSteam Line Pressure 100Condensate Return Line PSI 12Temperature of Condensate at Traps 245 Temperature of Condensate in Tank 190 Hours per Day of Production 24Days per Year of Production 340Rated Boiler Horsepower 700Cost of Fuel/Therm $5.50 Cost of Steam Production / 1,000# $6.59 Results of SurveyPercent Traps Leaking 26.55%Percent Traps Plugged 0.44%Percent of Traps Operational 73.01%# Lost Steam To Leaking Traps 18,543,600 AnnuallyBTU Lost to Flash Steam Venting 1,019,898,000 AnnuallyLost Revenue to Wasted Steam $127,745.37 Annually

Steam Trap Survey FormCustomer NameLocationPlant ContactContacts PhoneContacts e-mail

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

Back toCost of Leaks

Compiled January 16, 1998Ohms Law



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OHMS Laws of ElectricityFill 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 = 0.04 To Find WATTS = 17280 Kw=

Voltage 24 Voltage 480OHMS 330 OHMS 1Watts 1 Amps 36

To Find VOLTS = 1 To Find OHMS = 1.00Watts 1 Voltage 1OHMS 1 Amps 1Amps 1 Watts 1

To Find KVA = 0.00# of Phases 1Amps 1Voltage 1

Compiled January 16, 1998Ohms Law



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

17.28

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

Degree F Degree CINPUT DATA 60 15.56Degrees C = 15.56Degrees K = 288.71Degrees R = 519.69Degrees F= 60.01

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

Rated Boiler Output in Kpph 75Thermal Efficiency of Boiler 82

MMBTU/Hr Input 91.46 at Stated Boiler Thermal EfficiencyTotal Operating Electric Horsepower 130 Fan and Feedwater Pumps

Hours Per Year Operation 8000Cost of Fuel per MMBTU $6.66

Fuel Cost per Kpph $8.12 Contribution of Secondary Waste Fuel Stream 30%Fuel Cost per Kpph w/ Contributed Waste Fuel $5.69

Cost of Electricity per KWH $0.14 Electrical Cost per Kpph $0.18

Cost of Water per 10,000 Gal $2.33 Percent Make-up to Boiler 100%

Calculated Water Treatment Cost per 1000 Pounds $0.23 Operators Annual Salary $40,000.00

Overhead and Benefits of Operator $14,400.00 Percentage of Operator Cost to Operation of Boiler 12%

Annual Maintenance & Inspection $1,165.00 Cost to Produce 1Kpph $7.06

Depreciation on Equipment as % 20.00%Cost to Produce 1Kpph w/ Depreciation $8.47

Cost of Purchased Steam from Outside source $9.65 Saving(+)/Cost(-) to Operate Owners On-Site Plant $706,065.47

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

at Stated Boiler Thermal EfficiencyFan and Feedwater Pumps

PROPERTIES OF SATURATED STEAM

SpecificGauge Temp- Volume Gauge Temp-

Pressure erature Heat in Btu/lb. Cu. ft. Pressure erature Heat in Btu/lb.PSIG Deg F Sensible Latent Total per lb. PSIG Deg F Sensible Latent Total

IN V

AC

25 134 102 1017 1119 142 185 382 355 843 119820 162 129 1001 1130 73.90 190 384 358 841 119915 179 147 990 1137 51.30 195 386 360 839 119910 192 160 982 1142 39.40 200 388 362 837 11995 203 171 976 1147 31.80 205 390 364 836 12000 212 180 970 1150 26.80 210 392 366 834 12001 215 183 968 1151 25.20 215 394 368 832 12002 219 187 966 1153 23.50 220 396 370 830 12003 222 190 964 1154 22.30 225 397 372 828 12004 224 192 962 1154 21.40 230 399 374 827 12015 227 195 960 1155 20.10 235 401 376 825 12016 230 198 959 1157 19.40 240 403 378 823 12017 232 200 957 1157 18.70 245 404 380 822 12028 233 201 956 1157 18.40 250 406 382 820 12029 237 205 954 1159 17.10 255 408 383 819 120210 239 207 953 1160 16.50 260 409 385 817 120212 244 212 949 1161 15.30 265 411 387 815 120214 248 216 947 1163 14.30 270 413 389 814 120316 252 220 944 1164 13.40 275 414 391 812 120318 256 224 941 1165 12.60 280 416 392 811 120320 259 227 939 1166 11.90 285 417 394 809 120322 262 230 937 1167 11.30 290 418 395 808 120324 265 233 934 1167 10.80 295 420 397 806 1203



26 268 236 933 1169 10.30 300 421 398 805 120328 271 239 930 1169 9.85 305 423 400 803 120330 274 243 929 1172 9.46 310 425 402 802 120432 277 246 927 1173 9.10 315 426 404 800 120434 279 248 925 1173 8.75 320 427 405 799 120436 282 251 923 1174 8.42 325 429 407 797 120438 284 253 922 1175 8.08 330 430 408 796 120440 286 256 920 1176 7.82 335 432 410 794 120442 289 258 918 1176 7.57 340 433 411 793 120444 291 260 917 1177 7.31 345 434 413 791 120446 293 262 915 1177 7.14 350 435 414 790 120448 295 264 914 1178 6.94 355 437 416 789 120550 298 267 912 1179 6.68 360 438 417 788 120555 300 271 909 1180 6.27 365 440 419 786 120560 307 277 906 1183 5.84 370 441 420 785 120565 312 282 901 1183 5.49 375 442 421 784 120570 316 286 898 1184 5.18 380 443 422 783 120575 320 290 895 1185 4.91 385 445 424 781 120580 324 294 891 1185 4.67 390 446 425 780 120585 328 298 889 1187 4.44 395 447 427 778 120590 331 302 886 1188 4.24 400 448 428 777 120595 335 305 883 1188 4.05 450 460 439 766 1205100 338 309 880 1189 3.89 500 470 453 751 1204105 341 312 878 1190 3.74 550 479 464 740 1204110 344 316 875 1191 3.59 600 489 473 730 1203



115 347 319 873 1192 3.46 650 497 483 719 1202120 350 322 871 1193 3.34 700 505 491 710 1201125 353 325 868 1193 3.23 750 513 504 696 1200130 356 328 866 1194 3.12 800 520 512 686 1198135 358 330 864 1194 3.02 900 534 529 666 1195140 361 333 861 1194 2.92 1000 546 544 647 1191145 363 336 859 1195 2.84 1250 574 580 600 1180150 366 339 857 1196 2.74 1500 597 610 557 1167155 368 341 855 1196 2.68 1750 618 642 509 1151160 371 344 853 1197 2.60 2000 636 672 462 1134165 373 346 851 1197 2.54 2250 654 701 413 1114170 375 348 849 1197 2.47 2500 669 733 358 1091175 377 351 847 1198 2.41 2750 683 764 295 1059180 380 353 845 1198 2.34 3000 696 804 213 1017

Total per lb.Calculating Superheat in Pressure Reducing Stations

High Pressure Point 250Reduced Pressure 14High Pressure Volume/CuFt 1.75 From Tabels aboveReduced Pressure Volume/CuFt 14.3 From Tabels aboveHigh Pressure Temperature 406 From Tabels aboveReduce Pressure Normal Temperature 248 From Tabels aboveResultant Superheat 19.33566Temperature of Reduced Pressure Steam 267.3357

SpecificVolumeCu. ft.per lb.2.292.242.192.142.092.052.001.961.921.891.851.811.781.751.721.691.661.631.601.571.551.531.49

SpecificVolumeCu. ft.per lb.1.471.451.431.411.381.361.341.331.311.291.281.261.241.221.201.191.181.161.141.131.121.000.890.820.75

SpecificVolumeCu. ft.per lb.0.690.640.600.560.490.440.340.230.220.190.160.130.110.08

Technical SourceNational Hydraulic Inst.

Piping Friction Loss AnalysisCompiled by:

David C. FarthingVoice 405-728-6709

68 Degree Water Data!! Piping Friction Loss and Velocity AnalysisSingle pipe system. For multiple pipe sizes in a single run calculate each section and addall section total losses together to get Total Head Loss for system.Lookup Tables are available from most any pump/pipe manufacturer.

SSystem Size 2.064 It is helpful to input actual pipe ID.Linear Feet Pipe 6.00Number of 90 Ells 1.00Number of 45 Ells 0.00Number of Valves 1.00Flow Rate Required 35.00 GPMPipe Schd 40.00

Lookup Table > Friction Loss/100 Ft 1.00 Head Friction Loss/100 Feet of PipeFederal Catalog Velocity 3.33 Feet Per SecondPages 265-266 Effective Reynolds Number 53027.89 Flow is no longer laminar!

K Factor 90 Ells Short 0.98 Averaged for pipe size rangeK Factor 45 Ells Short 0.31 Averaged for pipe size rangeK Factor Valves Globe 6.75 Averaged for pipe size rangeHead Velocity V2/2G 0.17Total Loss Line Pipe 0.06 Feet Head FormulaTotal Loss from 90 Ells 0.17 Feet Head h=K*(V2/2G)Total Loss from 45 Ells 0.00 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 HeadTotal Head Loss 1.39 Feet of Head Loss

IS this calculation for Suction or Discharge Pipe S or D ?

Pump NPSH

Financial Analysis05/07/2014

Compiled byDavid C. Farthing

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Financial Analysis of a Project

Project Name Kodak PolyGraphicsBoiler Combustion Control EXAMPLE #1

Initial Cost of Investment Materials $19,295.00 Initial Cost of Investment Installation $19,285.00 Annual Pay Back Expected from this investment $15,396.00 Base Line Years to Payout 2.51Fixed Cost of Money in percent to be used for this exercise 6.85%How many Years will the Project be Amortized over? 3First Year Cost of Money $1,588.10 Second Year Cost of Money $707.19 Third Year Cost of Money $(173.72)Fourth Year Cost of Money $- Fifth Year Cost of Money $- Estimated Cost of Perishables during first five years of ownership $- NET Years to Payout 2.64 Expected Life Span of Investment 20.00 *Total Dollars Returned Over Life of Investment $267,218.42

*Note: Return on investment includes paying off original equipment investment.Original Investment $38,580.00 Interest Rate 6.85% Interest Paid $2,121.58

Hydronic Load CalculationsProcess Recovery v Tank Size

Heater Size Selected 1825 Tank Size 3000Usage 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 TimeMinutes

874,518.3710.0114.3310.0114.33

874,567.07

Instrument Application Selection GuideA guide to help you select the equipment needed toaccomplish an instrumentation application.

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

Level = 2Pressure = 3

Flow = 4Vaccum = 5Cooling = 6

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

Controller Reverse ActionTransmitter Use a Thermocouple or RTD for Temperature MeasurementControl ValveSpecial 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)^.5Qh= Lbs/Hr Mass Flow UNDER CONSTRUCTIONC' = Flow Constant DO NOT USE FOR DEFINITIVE DATA!!Hw = Differential in Inches WaterPf = Static Gauge Pressure in PSIAAssumed Factors for WaterFb Orifice FactorFr Reynolds NumberY Expansion Factor

CV = GPM / DP^.5 x SG.

Inlet Pressure, PSIG 60 74.65 Calculated Pf GPMDischarge Pressure 10 24.65 Corrected to PSIA Pressure DropCalculated HW 1386 Inches Water Differential Specific GravityID of Orifice 1.55 CV=ID of Pipe 4 Orifice SizeGPM= 299.82

Average Orifice Size 1.80

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

CV = GPM / DP^.5 x SG.

30050

142.43

2.05

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

David Farthing's TechStuff 05/07/2014 Helpful Boiler Burner Calculations

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

IN PUT DATABoiler Horsepower 400Boiler Eff. 80%Boiler Input BTUH 16,738,462

Combustion Air Area Requirements 13.9 Square Feet Free Air Flow Area

Authority Oklahoma Boiler and Pressure Vessel Safety Act 1982, Edition 1993Table 380:25-7-18(b)

Combustion Analysis This section under construction DO NOT USE THIS FUNCTION!Stack Temperature 525Ambient Temperature 90Net Temperature Rise 435Excess 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 NotesHigh "C" Carbon (soot) need more air.High "CO" Carbon Monoxide, need more air.High "CO2" Carbon Dioxide, need LESS air.Typical Safe Oxygen StandardsHigh Fire 2.0-4.5% Excess O2Mid Fire 3.5-5.0% Excess O2Low Fire 6.0-8.0% Excess O2

Ideal Excess Oxygen Curve for Natural Gas

Ideal O2 Firing Rate6 20

5.75 304.75 403.6 503.3 603.05 702.8 802.5 902.3 100

Fuel Oil 2Molectular Make-up Ideal Air = 144*(8.01*Carbon+23.86*(Hydrogen-(Ox/8)+3*Sulfur)/HV/LbCarbon % 87.30 Ideal Air for this fuel oil per 10,000 Btu = 7.572031Hydrogen % 12.50 Ideal Combustion Air Ft^3/Gallon = 1355.562Oxygen % 0.00 Gallon/Min @ High Fire = 2.037023Sulfur % 0.20 Combustion Air for this Oil CFM = 3248.601 at 15% EASpecific Gravity 0.865 Combustion Air for Gas CFM = 3124.513 at 15% EAHeating Val/Gal 136952 Controller Ratio Factor Oil/Gas Bias = 1.039714Heating Val/Lb 18981.6583Air Density @ 70F Lb/Ft^3 0.0765

20 30 40 50 60 70 80 90 10001234567

Ideal Excess Oxygen Natural Gas

Firing Rate

Exc

ess

Oxy

ge

n %

Economizer Heat Recovery Calculations 05/07/2014 09:59:55Data Compiled by

David FarthingFederal Corporation

Economizer Energy CalculationsCustomer Xerox OKC

WatertubeWG

Boiler Rated Horsepower 1623Boiler Rated Efficiency 76.00%

Normal Firing Rate (NFR) 36.0%Boiler Operating Pressure PSIG 120

Combustion Make-up Air Temperature 80Entering Feedwater Temperature 240 Equivalent Fuel Cost/1000 CF

Fuel Cost per Therm $0.640 $6.40 Per 1000 CFHours/Day Operation 24

Days/Month Operation 28 Acid Dewpoint TablesOperating Steam Temperature (Saturated) 350.00 Fuel Dewpoint Minimum Minimum

Firing Boiler Horsepower @ NFR 584.28 Stack Temp FeedwaterBoiler Fuel Input @ NFR 25,727,539.74 Inlet Temp.

BTU Output @ NFR 19,552,930.20 Natural Gas 150 250 210Net Operating Efficiencies as found 78.19%

Theoretical Entering Stack Temperature 405.00 Default #2 Diesel Fuel 180 275 210Actual Observed Stack Temperature 380.00 Low Sulfur Oil 200 300 220

Temperature Rise Across Econ. 140.00Water Flow #/Hr 20,157.66

Gross BTU to Feedwater/Hr 1,101,640.70 Exiting Feedwater Temperature "F" 294.65

Exiting Stack Temperature 275.00 Application OK, Stack Temp Above Dew Point.Gain in Efficiency 1.54% .

New Net Calculated Thermal Efficiency 79.74%Fuel Savings/Hr $7.05

Annual Current Cost of Operation $1,327,788.03 Total Annual Savings w/ Economizer $56,855.24

Annual Cost of Operation w/ Economizer $1,270,932.80 Economizer Equipment Cost $18,700.00

Economizer Estimated Installation $14,960.00 Actual Economizer Installation Quote

Simple Pay-Back in Years 0.59

Condensing VerticalEfficiency Firetube Firing Rate

85% 77% 2085% 75% 4080% 68% 5075% 60% 6065% 55% 7560% 50% 9057% 45% 100

Boiler Type Watertube/FiretubeFuel Type Gas or Oil

20 40 50 60 75 90 1000%

10%

20%

30%

40%

50%

60%

70%

80%

90%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%85% 85%

80%75%

65%60%

57%

77% 75%

68%

60%55%

50%45%

Economizer Efficiencies

Firing Rate

Co

nd

en

sin

g E

con

om

ize

rs

No

n-C

on

de

nsi

ng

Eco

no

miz

ers

Conventional

Condensing

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 velocityV= maximum velocity change, ft/Sec (V= Q/A) Pipe Area =0.785398 * d^2 g= acceleration of gravity, 32.2 ft/Sec ^2k=di= inside pipe diameter in inchesE= modulus of elasticity of the pipe,

420,000 psi PVC, 360,000 psi CPVC, t= pipe wall thickness, inchesQ=

INPUT DATAQ= 450di= 4.025 Results for "a" a= 1021.10V= 11.26 Results for Pressure Surge 155 PSIGK= 300000 NOTE: Maximum safe Pressure Surge for PVC pipe = 98 PSIG.E= 420000t= 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= 450P= 100 Results for Pressure Surge 775.4471 PSIGdi= 4.025V= 11.26

fluid bulk modulus, 300,000 psi for water

Flow Through Pipe, GPM

ASCO Solenoid Valve Application GuideTOMSPAVE

Application 25 degree f chiller service

T Type of Valve 2

O Operation of Valve NC

M Media LGo to Liquid Valve Sizing Guide

S Size of Flowing Pipe 1 CV From Valve Sizing Guide 2.43

P Pressure Minimum Maximum Drop Across Valve10 15 5

A Clean

V Voltage Requirements 115

EFluid Temperature 25Ambient Temperature 90

2-Way, 3-Way, 4-Way

Universal, NC, NO

Liquid. Gas, Steam

Atmosphere Valve will Operate In.

24 VDC, 115 VACExtras for this application.

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

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 choiceB = Alternate choice Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco

F & T Range FT/TV/SLR FT/SLR TD Range (Float/ (Float/Thermo- (Float/Steam (Thermo-Thermostatic) static with Lock Release)dynamic)

Steam LockApplication Release)

CANTEEN EQUIPMENT F & T Range FT/TV/SLR FT/SLR TD RangeBoiling Pans-Fixed A B B1 B1Boiling Pens-Tilting A BBoiling Pans-Pedestal B B B1Steaming OvensHot Plates B B B1

FUEL OIL HEATINGBulk Oil Storage Tanks ALine Heaters AOuttlom Heaters ATracer Lines & Jacketed Pipes B

HOSPITAL EQUIPMENT F & T Range FT/TV/SLR FT/SLR TD RangeAutoclaves and Sterilizers B B B1

INDUSTRIAL DRYERS F & T Range FT/TV/SLR FT/SLR TD RangeDrying Coils (continuous) ADrying Coils (grid)Drying Cylinders B A B1Multi Bank Pipe Dryers AMulti Cylinder Sizing Machines B A B1

LAUNDRY EQUIPMENT F & T Range FT/TV/SLR FT/SLR TD RangeGarment Presses B AIroners and Calendars B A B1 B1Solvent Recovery Units A BTumbler Dryers A B B1

PRESSES F & T Range FT/TV/SLR FT/SLR TD Range

Multi Platan Presses (parallel connections) B AMulti Platen Presses (series connections) A1Tire Molds B A

PROCESS EQUIPMENT F & T Range FT/TV/SLR FT/SLR TD RangeBoiling Pans-Fixed A B B1 B1Boiling Pan-Tilted A BBrewing Coppers A B B1Digesters A B1Evaporators A B B1Hot Tables BRetorts ABulk Storage Tanks A1Vulcanizers B A

SPACE HEATING EQUIPMENT F & T Range FT/TV/SLR FT/SLR TD RangeShell & tube Heat Exchangers A B B1Heating Coils & Unit Heaters A B B1Radiant Panels & Strips A B B1 B1Radiators & Convection Cabinet Heaters BOverhead Pipe Coils B

STEAM MAINS F & T Range FT/TV/SLR FT/SLR TD RangeHorizontal Runs B ASeparators A BTerminal Ends B A1Shut Down Drain (Frost Protection)

TANKS AND VATS F & T Range FT/TV/SLR FT/SLR TD RangeProcess Vats (Rising Discharge Pipe) B AProcess Vats (Discharge Pipe at Base) A BSmall Coil Heated Tanks (quick boiling) ASmall 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

BPT SM Thermoton lB Range(Balanced (Bimetallic) (Liquid (Inverted Pressure Expansion) Bucket)Thermostatic)

BPT SM Thermoton lB RangeBBA2A2A2

B1B1B1

A3 B B

BPT SM Thermoton lB RangeA B

BPT SM Thermoton lB RangeB B BB A B1

B1B B1

B1

BPT SM Thermoton lB RangeB

B B1B

B1

BPT SM Thermoton lB Range

B

B1B B

BPT SM Thermoton lB RangeB

B1B1B1

AB1B1B1

BPT SM Thermoton lB RangeB1B1B1

A BA B1

BPT SM Thermoton lB RangeB2 BB2 BB2 B1

B3 A

BPT SM Thermoton lB Range

B B

B B

B B

A

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 0Operating Pressure 12 Low Pressure System 1 0Is 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 onlyOperating Temperature (Water) 210 0 0Steam Flow #/Hr. 10,000 Please enter Steam Load 1 1

p Power Burner Selected 1 1Fuel g Gas 2What pressure is the Primary fuel 1 I Inches/PSI 2 0Feed Water System desired? m 1 1Boiler Hp Required 6Steam 289.86Water 0.00Net BTU Output 9,700,000

Special Note 1 NoneBoiler Types To Look At Steam Boilers Kewanee Rite or PeerlessApplication Note 1 Steam ApplicationApplication Note 2 Low Pressure Steam ApplicationApplication Note 3 noneApplication Note 4 Modulating Feedwater System Selected, Price Boiler AccordinglyApplication Note 5 IRI Fuel Train RequiredApplication Note 6 Gas Fired BurnerApplication Note 7 Low Pressure Gas Train Required, Check Pressure Drops in Gas Train

15 PSIG

Burner Type Power or AtmosphericOil/Gas or Oil & Gas

Start/Stop or Modulating

Select a boiler shell with a minimum working pressure of

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

Application B

BTU Input 3,465,000 IRI Codes RequiredOperation A You have selected Automatic Operation

Pre-Purge Required Y

Purge Time Specified By Manufacturer This Application guide uses gas flow to determine purge time.Purge Time Recommended if not specified. 2.31 MinutesPilot Style I

Results of your questions.Use Programming Controller such as a RM7800 or RM7840Use RM 7800 or 7840 series Programmers on Automatic Boiler ApplicationsPurging Relay required, RM7800 / 7840 on automatcis, and RM7895 on Semi-AutomaticsUse Interupted Amplifier & Relay Combinations

Boiler, Oven, Furnace

Automatic, Semi-Automatic, Manual

Yes / No

Interrupted, InTermittent, Standing

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 AnalysisSingle pipe system. For multiple pipe sizes in a single run calculate each section and addall section total losses together to get Total Head Loss for system.Lookup Tables are available from most any pump/pipe manufacturer.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 6.00Number of 90 Ells 1.00Number of 45 Ells 0.00Number of Valves 0.00Flow Rate Required GPM 330.00 From Pump work sheetPipe Schd 40.00

Lookup Table Friction Loss/100 Ft from look-up tables 26.30 Head Friction Loss/100 Feet of PipeFederal Catalog Velocity 14.32 Feet Per SecondPages 265-266 Effective Reynolds Number 339025.26 Flow is no longer laminar!

K Factor 90 Ells Short 0.8 Averaged for pipe size rangeK Factor 45 Ells Short 0.25 Averaged for pipe size rangeK Factor Valves Globe 5.25 Averaged for pipe size rangeHead Velocity V2/2G 3.19Total Loss Line Pipe 1.58 Feet Head FormulaTotal Loss from 90 Ells 2.55 Feet Head h=K*(V2/2G)Total Loss from 45 Ells 0.00 Feet Head h=K*(V2/2G)Total Loss from Valves 0.00 Feet Head h=K*(V2/2G)Total Head Loss 4.13 Feet of Head LossTotal Head loss corrected for Specific Gravity 4.13

Discharge Piping Calculations68 Degree Water Data!! Piping Friction Loss and Velocity AnalysisSingle pipe system. For multiple pipe sizes in a single run calculate each section and addall section total losses together to get Total Head Loss for system.Lookup Tables are available from most any pump/pipe manufacturer.System Size 3.068 It is helpful to input actual pipe ID.Linear Feet Discharge Pipe 100.00Number of 90 Ells 4.00Number of 45 Ells 0.00Number of Valves 1.00Flow Rate Required 330.00 GPMPipe Schd 40.00

Lookup Table Friction Loss/100 Ft 26.30 Head Friction Loss/100 Feet of PipeFederal Catalog Velocity 14.32 Feet Per SecondPages 265-266 Effective Reynolds Number 339025.26 Flow is no longer laminar!

K Factor 90 Ells Short 0.8 Averaged for pipe size rangeK Factor 45 Ells Short 0.25 Averaged for pipe size rangeK Factor Valves Globe 5.25 Averaged for pipe size rangeHead Velocity V2/2G 3.19Total Loss Line Pipe 26.30 Feet Head FormulaTotal Loss from 90 Ells 10.20 Feet Head h=K*(V2/2G)Total Loss from 45 Ells 0.00 Feet Head h=K*(V2/2G)Total Loss from Valves 16.74 Feet Head h=K*(V2/2G)Back Pressure Valve Setting 0 0.00 Feet HeadTotal Head Loss 53.24 Feet of Head LossTotal Head loss corrected for Specific Gravity 53.24

Halliburton Turbin Gas Flow Meter Calculations

Flowing Pressure 15Flowing Temperature 60Observed Flow Rate 19250 Actual Cubic FeetCorrected SCF Flow 38852.851 Standard Cubic Feet

Totalizer DivisorFactory Calibration Factor 123.42 ActualSet Totalizer Read Out Divisor to = 61.147 Registers in Standard Cubic FeetSet Totalizer Read Out Divisor to = 611.472128 Registers in TENTHS of a Standard Cubic Foot

Flow Rate Indicator Full Sacle Frequency FactorFull Scale Flow Rate 38800 SCF/ Time BaseFactory Calibration Factor 123.42Time Base Conversion Factor 3600 Seconds Per Time Base (86400/day, 3600/Hr, 60/Min)Full Scale Frequency = 659.056

K-FactorFactory Calibration Factor 123.42K-Factor = 61.147

Temperature EffectsPlus or Minus Temperature Change 22 Degree FCalculation for Plus 37274.838Percent Effect 4.062Calculation for Minus 40570.380Percent Effect -4.421

Presure EffectsPlus or Minus Presure Change 5 PSIGCalculation for Plus 45387.135Percent Effect 16.818Calculation for Minus 32318.568Percent Effect -16.818

Halliburton Oil Meter Calculator for known Btu Input#2 Diesel Oil

BTU Input 72000000Btu/Lb/Oil 136000

Total Lbs/Oil 529.4118Total Gal Oil 75.66268GPM FLOW 1.261045

ASME formulaRef: Marks9th, p12-69/12.4.2 05/07/2014 09:59:55

Hot Water Boiler Expansion Tank Sizing Non-Bladder Air Charged Steel TankInternational Mechanical Code 1009.2 and ASMEAll 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, gallonsVs= Volume of water in system less expansion tank, gallonsT= 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 160Vs= Volume of Water in System, Gallons 200Pf= Make-up Fill Water Pressure PSIG 45Po= Maximum Operating Pressure of System PSIG 75Vt= Minimum Volume Expansion Tank Required 46.09 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 62

Measurement, Controllers & Recorders

UNDER CONSTRUCTION - APPLICATION NOT YET AVAILABLE

MeasurementLevel, Pressure, Temperature or Flow? F L,P,T,FFlow Measurement uses either a Differential Pressure Transmitter or Flow MeterAreyou using a Differential Transmitter or a Meter? Selece DT or M in the yellow box below

DTDifferential 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 Enter Data in "Yellow Boxes"

Enter Pump Speeds Desired (HZ) Speed 1 60 RPM 1800 Speed 2 55 RPM 1650Speed 3 50 RPM 1500 Speed 4 45 RPM 1350Speed 5 40 RPM 1200 Speed 6 35 RPM 1050

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

Flow Head HP Eff FlowPoint 1 0 0 0 0 Point 1 0Point 2 5 140 60 45 Point 2 4.583333Point 3 10 118 75 66 Point 3 9.166667Point 4 15 86 95 77.5 Point 4 13.75

1100 300 105 81 1008.333Point 6 1400 260 111 80 Point 6 1283.333

1600 200 115 70 1466.667

Speed 3 50 Hz. Speed 4 45

Flow Head HP Eff FlowPoint 1 0 0 0 0 Point 1 0Point 2 4.166667 97.22222 34.722222 45 Point 2 3.75Point 3 8.333333 81.94444 43.402778 66 Point 3 7.5Point 4 12.5 59.72222 54.976852 77.5 Point 4 11.25

916.6667 208.3333 60.763889 81 825Point 6 1166.667 180.5556 64.236111 80 Point 6 1050

1333.333 138.8889 66.550926 70 1200

Speed 5 40 Hz. Speed 6 35

Flow Head HP Eff FlowPoint 1 0 0 0 0 Point 1 0Point 2 3.333333 62.22222 10.288066 45 Point 2 2.916667Point 3 6.666667 52.44444 12.860082 66 Point 3 5.833333Point 4 10 38.22222 16.289438 77.5 Point 4 8.75

733.3333 133.3333 18.004115 81 641.6667Point 6 933.3333 115.5556 19.032922 80 Point 6 816.6667

1066.667 88.88889 19.718793 70 933.3333

Point 5 BEP Point 5 BEP

Point 7 EOC Point 7 EOC





Hz.

Head HP Eff 0 0 0

117.6389 46.21528 4599.15278 57.7691 6672.26389 73.17419 77.5252.0833 80.87674 81218.4722 85.49826 80168.0556 88.57928 70

Hz.

Head HP Eff 0 0 0

78.75 25.3125 4566.375 31.64063 6648.375 40.07813 77.5168.75 44.29688 81146.25 46.82813 80

112.5 48.51563 70

Hz.

Head HP Eff 0 0 0

47.63889 11.90972 4540.15278 14.88715 6629.26389 18.85706 77.5102.0833 20.84201 8188.47222 22.03299 8068.05556 22.82697 70

Larrs Hydronic Zone Loads CalculationSource: 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 = 27,000Total Flow Rate to Zone in GPM 2.7

Calculating Pump Head Required to Circulate Loop. (Closed Loop Application)Longest pipe run in Feet = 250Total Estimated pumping head required = 15

Calculated Copper Pipe Size Required for Heating CapacityCopper Pipe Size Required for Zone 0.75

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

Boiler Heat Recovery CalculationsPrintout 05/07/2014 09:59:55


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Blowdown Heat Recovery

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

Boiler Type FT or WT wt FT=Fire Tube, WT=Water TubeSteam Boiler Flow PPH at Capacity 50000 1449 Calculated Boiler Hp.TDS of Make-up Water 125Desired TDS in Boiler Water 4500Operating Pressure 165Operating Temperature 341Boiler Rated Efficiency 75%Normal Firing Rate 60%Hours/Day Run Time 24Days/Month Run 30Make-up as % of Steaming Rate 100%Blowdown as % of Steaming Rate 2.86% Blowdown within normal limitsMake-up + Blowdown as % of Steaming Rate 102.86%Fuel Cost per Therm include transport cost $0.67 Equivalent Fuel Cost per 1000 CF $6.66 Deaerator Operating Temperature 227 Calculated Boiler Horsepower 870 At Operating Firing RateFuel Input at rated efficiency & firing rate 38,800.00 Cubic Feet/HrTherms per hour at efficiency & firing rate 388.00 Calculated Cost to Operate per 30 day billing $186,053.76 Blowdown in PPH 30,857.14 Equivalent Boiler Horsepower Loss 894.41Total Heat Available for Recovery 6,202,286 BTU/Hr.Equivalent Boiler Horsepower Recovered 185.34

148,854,857 BTU/Day4,465,645,714 BTU/Billing Period

53,587,748,571 BTU/YearTotal Annual Cost for Blowdown & Make-up $356,894.41 BTU Heat for Recovery to Make-Up 3,710,262,857 Per Billing Period

Total Monthly Savings for Recovery $24,710.35 Per Billing Period

Total Annual Savings for Recovery $296,524.21 Cost for Recovery Equipment $23,000.00 Estimates Only Actual Cost must be quoted.Cost for Installation L&M $12,365.00 Estimates Only Actual Cost must be quoted.

Months to Payback 1.43 Project Payback within normal limits.

David Farthing's Tech Stuff 05/07/2014 09:59:55 Relief Valve Data

Relief Valve Sizing and Selection

User Data ABC Company1234 Powerhouse LaneSmokin, PA 123456

Boiler DataS

MAWP 250Operating Pressure 160

Btu Input 12,500,000 Steam PPH Output 10,309

USE STEAM DATA ONLY 10,000,000 How Many Safety Valves 3

Safety Valve Port SizePort 1 2Port 2 2Port 3 2

Steam Recommendations PPH Set PressureSafety Valve #1 3,402 192Safety Valve #2 3,402 192Safety Valve #3 3,402 192

Hot Water Recommendations Btu/Hr Set PressureRelief Valve #1 - 192Relief Valve #2 - 192Relief Valve #3 - 192

NOTES:1] Use only water or steam input data.2] MAWP is the Maximum Allowable Vessel Pressure NOT the Operating Pressure

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

Steam (S) or Hot Water (W)?

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

David Farthing's TechStuffPrintout

05/07/2014 / 09:59:55


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The effect of Boiler Operating Pressure on System PerformanceFiretube Boiers - Saturated Steam

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

Rated Boiler Horsepower 1739 Distribution line Diameter 8

Boiler Outlet Diameter 6 Distribution Velocity Ft./Min. 4842.0437

Current Operating Pressure 260 Distibution Velocity OK

Feedwater Temperature 227

Steam Volume Cft/# 1.69

Boiler Outlet Velocity 8608.0777 Ft./Min.

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

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

New Operating Pressure 200 Distribution line Diameter 8

Steam Volume Cft/# 2.14 Distribution Velocity Ft./Min. 6131.3453

New Boiler Outlet Velocity 10900.1694 Ft./Min. Caution Distribution Velocity Abnormally High!


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

6,422 BTU @ Current Pressure Btu Differential 621

5,801 BTU @ New Pressure Boiler Horsepower 1739

621 Btu @ Horsepower/Hr Differential Cost of Fuel (Decatherm) $5.56

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

Boiler Horsepower 1739

Maximum Allowable Working Pressure 350

Normal Operating Pressure 260 200

Minimum Safety Relief Valve Setting 299 230

Minimum Pump Head Requirements

Feet Head 732 563

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 384 311

Minimum Pump Flow Capacity GPM 150.41


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 PerformanceWatertube Boiler - Saturated Steam

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

Pounds/Hr Steam Flow 30000

Rated Boiler Horsepower 870 Distribution line Diameter

Boiler Outlet Diameter 6 Distribution Velocity Ft./Min.

Current Operating Pressure 275 Distribution Velosity OK

Feedwater Temperature 227

Steam Volume Cft/# 1.6

Boiler Outlet Velocity 4075.1353 Ft./Min.

Nozzle Velocity OK

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

New Operating Pressure 125 Distribution line Diameter

Steam Volume Cft/# 3.23 Distribution Velocity Ft./Min.

New Boiler Outlet Velocity 8226.6794 Ft./Min. Distribution Velosity OK

Caution Outlet Nozzel Velocity Above 8000 Ft/Min - Priming May Occur!

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

6,422 BTU @ Current Pressure Btu Differential

4,593 BTU @ New Pressure Boiler Horsepower

1,829 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

Boiler Horsepower 870

Maximum Allowable Working Pressure 350

Normal Operating Pressure 275 125

Minimum Safety Relief Valve Setting 316 144

Minimum Pump Head Requirements

Safety Valve RequirementFeet Head 774 352

Pressure Drop Across Feed Valve 28 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 377 194

Minimum Pump Flow Capacity GPM 75.21

Distibution 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

Gauge Temp-Pressure erature Heat in Btu/lb.

PSIG Deg F SensibleDesign Velocity in the distribution line

IN V

AC

25 134 102

14 20 162 129748.4942 15 179 147

10 192 1605 203 1710 212 1801 215 1832 219 187

New Velocity in the distribution line 3 222 19014 4 224 192

1511.0227 5 227 1956 230 1987 232 2008 233 201

Theoretical Savings from Lowering Operating Pressure 9 237 205Btu Differential 1,829 10 239 207

Boiler Horsepower 869.5652174 12 244 212

Cost of Fuel (Decatherm) $5.29 14 248 216Hrs/Day Operation 20 16 252 220Days/Month/Operation 22 18 256 224$$ Saved or Expended/Mth. $3,700.88 20 259 227$$ Saved or Expended/Yr. $44,410.61 22 262 230

24 265 23326 268 23628 271 23930 274 24332 277 24634 279 248

36 282 25138 284 25340 286 25642 289 258

44 291 26046 293 26248 295 26450 298 26755 300 27160 307 27765 312 282

Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature 70 316 286Boiler 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 3029,734 10,113 10,424 10,734 95 335 3058,871 9,251 9,561 9,872 100 338 3098,009 8,388 8,699 9,009 105 341 3127,146 7,526 7,836 8,147 110 344 3166,284 6,663 6,974 7,284 115 347 3195,870 6,249 6,560 6,870 120 350 3225,421 5,801 6,111 6,422 125 353 3255,249 5,628 5,939 6,249 130 356 3284,904 5,283 5,594 5,904 135 358 3304,559 4,938 5,249 5,559 140 361 3334,214 4,593 4,904 5,214 145 363 3363,869 4,248 4,559 4,869 150 366 3393,696 4,076 4,386 4,697 155 368 3413,524 3,903 4,214 4,524 160 371 344

165 373 346170 375 348175 377 351180 380 353185 382 355190 384 358195 386 360200 388 362205 390 364210 392 366215 394 368220 396 370225 397 372230 399 374235 401 376

240 403 378245 404 380250 406 382255 408 383260 409 385265 411 387270 413 389275 414 391280 416 392285 417 394290 418 395295 420 397300 421 398305 423 400310 425 402315 426 404320 427 405325 429 407330 430 408335 432 410340 433 411345 434 413350 435 414355 437 416360 438 417365 440 419370 441 420375 442 421380 443 422385 445 424390 446 425395 447 427400 448 428450 460 439500 470 453550 479 464600 489 473650 497 483700 505 491750 513 504800 520 512

900 534 5291000 546 5441250 574 5801500 597 6101750 618 6422000 636 6722250 654 7012500 669 7332750 683 7643000 696 804

SpecificVolume

Heat in Btu/lb. Cu. ft.Latent Total per lb.1017 1119 142

1001 1130 73.90990 1137 51.30982 1142 39.40976 1147 31.80970 1150 26.80968 1151 25.20966 1153 23.50964 1154 22.30962 1154 21.40960 1155 20.10959 1157 19.40957 1157 18.70956 1157 18.40954 1159 17.10953 1160 16.50949 1161 15.30947 1163 14.30944 1164 13.40941 1165 12.60939 1166 11.90937 1167 11.30

934 1167 10.80933 1169 10.30930 1169 9.85929 1172 9.46927 1173 9.10925 1173 8.75

923 1174 8.42922 1175 8.08920 1176 7.82918 1176 7.57

917 1177 7.31915 1177 7.14914 1178 6.94912 1179 6.68909 1180 6.27906 1183 5.84901 1183 5.49898 1184 5.18895 1185 4.91891 1185 4.67889 1187 4.44886 1188 4.24883 1188 4.05880 1189 3.89878 1190 3.74875 1191 3.59873 1192 3.46871 1193 3.34868 1193 3.23866 1194 3.12864 1194 3.02861 1194 2.92859 1195 2.84857 1196 2.74855 1196 2.68853 1197 2.60851 1197 2.54849 1197 2.47847 1198 2.41845 1198 2.34843 1198 2.29841 1199 2.24839 1199 2.19837 1199 2.14836 1200 2.09834 1200 2.05832 1200 2.00830 1200 1.96828 1200 1.92827 1201 1.89825 1201 1.85

823 1201 1.81822 1202 1.78820 1202 1.75819 1202 1.72817 1202 1.69815 1202 1.66814 1203 1.63812 1203 1.60811 1203 1.57809 1203 1.55808 1203 1.53806 1203 1.49805 1203 1.47803 1203 1.45802 1204 1.43800 1204 1.41799 1204 1.38797 1204 1.36796 1204 1.34794 1204 1.33793 1204 1.31791 1204 1.29790 1204 1.28789 1205 1.26788 1205 1.24786 1205 1.22785 1205 1.20784 1205 1.19783 1205 1.18781 1205 1.16780 1205 1.14778 1205 1.13777 1205 1.12766 1205 1.00751 1204 0.89740 1204 0.82730 1203 0.75719 1202 0.69710 1201 0.64696 1200 0.60686 1198 0.56

666 1195 0.49647 1191 0.44600 1180 0.34557 1167 0.23509 1151 0.22462 1134 0.19413 1114 0.16358 1091 0.13295 1059 0.11213 1017 0.08

05/07/2014 / 09:59:56 'c' Federal CorporationData Compiled byDavid C. Farthing

Voice 405-728-6709

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

Customer My Boiler Plant Temperature 0 25 50 75 100 125 150 175 200 225 250Contact Plant Eng Additional BTU Input Required to Bring Feedwater to Steaming Temperature Plant Location Chickasha, OK 50 6,559 7,664 8,733 9,492 10,113 10,631 11,079 11,459 11,838 12,149 12,459Boiler Mfg Kewanee H3S500G 100 4,834 5,939 7,008 7,767 8,388 8,906 9,354 9,734 10,113 10,424 10,734Boiler Type Fire Tube 125 3,972 5,076 6,146 6,905 7,526 8,043 8,492 8,871 9,251 9,561 9,872

150 3,109 4,214 5,283 6,042 6,663 7,181 7,629 8,009 8,388 8,699 9,009Factory Design 175 2,247 3,351 4,421 5,180 5,801 6,318 6,767 7,146 7,526 7,836 8,147

F. 200 1,384 2,489 3,558 4,317 4,938 5,456 5,904 6,284 6,663 6,974 7,284Name Plate Rated Boiler BHP 500 212 970 2,075 3,144 3,903 4,524 5,042 5,490 5,870 6,249 6,560 6,870Normal Operating Pressure 125 FW Temp Deaerator or Typical 225 1,626 2,696 3,455 4,076 4,593 5,042 5,421 5,801 6,111 6,422Calculated BTU Input for boiler type 20,968,470.92 As Observed First Recovery Economizer 230 1,454 2,523 3,282 3,903 4,421 4,869 5,249 5,628 5,939 6,249Observed Feedwater Temp 212 180 227 252 240 1,109 2,178 2,937 3,558 4,076 4,524 4,904 5,283 5,594 5,904Hours Day Operated 10 10 10 10 250 764 1,833 2,592 3,213 3,731 4,179 4,559 4,938 5,249 5,559Days per Month 22 22 22 22 260 419 1,488 2,247 2,868 3,386 3,834 4,214 4,593 4,904 5,214Calculated Bhp BTU Output Bhp 16,732,500.00 270 74 1,143 1,902 2,523 3,041 3,489 3,869 4,248 4,559 4,869Calculated Efficiency (Input/Output) 79.80 275 971 1,730 2,351 2,868 3,317 3,696 4,076 4,386 4,697Calculated Bhp 500.00 280 798 1,557 2,178 2,696 3,144 3,524 3,903 4,214 4,524Rated Steam PPH at 100% Firing 17250BTU addition for Operating Pressure 2,520,750 3,159,000 2,296,500 1,865,250 BTU Lost/Gained Per Hour 0.00 -552,000.00 258,750.00 690,000.00Boiler HP Lost or Gained/ Hr. 0.00 (16.49) 7.73 20.62 Net Boiler Horsepower 500 484 508 521Net Steam Output 17250.0 16680.9 17516.8 17961.3Net Efficiency 79.80 77.17 81.03 83.09Percent Increase/Decrease Energy Use 0.00 -2.63% 1.23% 3.29%Percent Increase/Decrease BHP 0.000% -3.299% 1.546% 4.124%

Boiler Type Watertube/Firetube

05/07/2014 09:59:56 Scale vs. Heat TransferData Compiled by


The effect of Scale on Heat Transfer in Boilers

5% 10% 15% 30% 66% 150%0.00

0.10

0.20

0.30

0.40

0.50

0.60

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

Additional Heat Input Reqired to Make Boiler HorsepowerSource: Cooper Tool Mfg.

Ca

lciu

m S

cale

Thi

ckn

ess

= I

nch

05/07/2014 09:59:56 Scale vs. Heat TransferData Compiled by


1 Grain = 17 PPM of soluable hardness

Principle Benefit

Eliminate No

Hardness Scale

Hardness TestSOAP TEST HACH 5B REAGENT

1 Drop = Soft (<1 Grain) Pink = Hard2 Drops = Hard (1-2 Grains) Blue = Soft <1 Grain3 Drops = Hard (2-3 Grains) Each drop of reagent = 1 Grain

Run Sample COLD

Eliminate No

Oxygen Corrosion

Sulfite Residual Test1 Drop = 10 ppm

Desired 30-60 ppmRun Sample HOT

Run this TEST FIRST!

Add SoftAlkalinity Solids

Add SoftPolymer Solids

Control TDS Pure Steam"Total

Disolved Solids"

Boost Eliminate

Condensate pH Steam Line and

Condensate LineCorrosion

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.)

Steam Boiler (<300 PSI) Water Treatment

Pre- Internal TestingTreatment Treatment What You Want

Water

Softner Precipitation Hardness = 0

Removes Calcium orand Magnesium Chelant or

salts only Solubilizer Chelant = 10-30 ppmTreat at the Feedwater Tank

Deareate Sulfite Oxygen = 0

orHot Feedwater

Treat at the Feedwater TankMay be injected directly into the boiler

but don't forget the feedwater tank

N/A NaOH OH = 300-600 ppmSodium pH = 11.0 - 12.0

Hydroxide pH = 11.56 Perfect

N/A Polymer NormalPoly = 10-50 ppm

Reverse Osmosis Blowdown TDS = 3,000 - 5,000ppmor Manual TDS <= 3,000 Great!

De-Ionizer and/or uMhos = 4,000 - 6,0000AutomaticNutralizing

De-Alkalizer Amine Condensate

or Volatile Chemical pH = 8 - 9.0 Great!

Reverse Osmosis travels with steam Iron Test <0.1ppm

Phosphate (PO4)

PO4 =30-60 ppm Great!

SO3 = 30-60 ppm Great!

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.)

Steam Boiler (<300 PSI) Water Treatment

Want to PreventChemistry

HARDNESS

Calcium + Carbonate = Calcium CarbonateSlow Reaction results in hard formation

Fe + 1/2O2 = FeO

Iron Metal + Oxygen = Rust

Hard Crystalline solidsAvoid runing pH too low this

Hard Crystalline solids

Prevent Boiler Water Carry OverPriming and Impure or Wet SteamWet Steam robs energy from your

steam line!

Rot out distribution and condensate lines!

Ca++ +CO3 = CaCO

3

will result in Hard Calcium Phosphate

CO2 + H20 = H2CO3 (Carbonic Acid! pH=4-6)

H2CO3 + Fe = FeCO3 (Iron Scale!)

Action CommentChemistry YOU WANT

SOFT Good Heat Transfer

Lower Energy Cost

Calcium + Phosphate = Soft Sludge Longer Boiler lifeFast reaction results in a soft formation

Sulfite + Oxygen = Sulfate Longer Boiler Life

Save Fuel $$Elevate pH Clean Boiler

OH = Elevated Alkalinity Good HeatResult Soft Solids Transfer

Polymer + Hard Soild = Soft Sludge Clean Boiler

Pure Steam Clean Boilerand Good Heat Treansfer

Solids Removal Saved Fuel $$$

No Rust or iron

brought back to boiler

by condensate.the acid and raise the pH to 8-9 and Longer distribution

protects condensate lines. line life.

3Ca++ + 2PO4 = Cay(PO

4)2

2SO3 + O2 = 2SO

4

Amine(A) + H2CO3 = A~H+HCO3 (pH=8-9)

Amine(A) + H2O = A~H+OH (pH = 8-9)

Amine combines with H2CO

3 to nutralize

ABMA Water Chemistry Guidelines 05/07/2014Compiled by

David Farthing405-249-9324

American Boiler Manufacturers Association **Boiler Water Chemistry Guidelines

** As adopted from the American Society of Mechanical Engineers

Boiler Water Chemical LimitsBoiler Operating Pressure (psig)

15 150 300 600 900 1200 1500Parameter Chemical Concentration (mg/liter) PPM

Phosphate (PO4) 30-60 30-60 30-60 20-40 15-20 10-15 5-10Hydroxide (CaCO3) 300-400 300-400 250-300 150-200 120-150 100-120 80-100Sulfite 30-60 30-60 30-40 20-30 15-20 10-15 5-10Silica (SiO2) 150 100 50 30 10 5 3Total Iron (Fe) 10 10 5 3 2 2 1Organics 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.

TDS Error due to High pHIf 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 09.5 10

10.0 2510.5 6011.0 15011.2 22011.4 31011.6 46011.8 70012.0 105012.2 150012.4 240012.6 380012.8 610013.0 10,000

EXAMPLE

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

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

1] 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)

Go Back ToDR.MAC

Print Out 05/07/2014Boiler / Burner Data SheetToday's Date 12/6/2004 Certificate Exp. Date

Company Name SW Medical

Location 4401 S. Western Insurance Carrier FM Global

City Oklahoma City State OK Zip 73109 Inspector No.

Boiler MFG Name Burnham Burner MFG Name Industrial Combustion

Model No. LN5P-400-GO-IC Model No. LNDLG-210P-30

Serial No. 72566/ NB#28696 Yr Blt 2004 Serial No. 41966-1

Hot Water Steam 150 PSI Atmosperic (Natural Draft) NA

Operating Pressure (PSI) 80 Power/Mechanical Draft 30 HP w/ FGR

Date Installed 11/20/2004 BTU/Hr. Input 16738 MMBTU/Hr

Power & Mechanical Draft Burners Atmospheric (Natural Draft) Burners

INPUT in BTU/HOUR INPUT in BTU/HOURASME SAFETY STANDARDS No. CSD-1

CONTROL & SAFETY DEVICES GUIDELINESFOR AUTOMATICALLY GAS FIRED BURNERS

INSTALLED NOT INSTALLED System Control Specifications

INTERLOCKS / LIMITS

Required (Note 1)

NRRequired (Note 2)

Required (Note 3)

NRRequired (Note 4)

(Note 5) Required Required Required Required

(Note 5) Required Required Required Required

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

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

Low Fire Switch Required Required Required Required CF-610

Supervised Purge Air Required (Note 9)

Proven Combustion Air Required Required Required Required

LOCKOUT (Note 17) (Note 18) Safety Shutdown

Low Water Fuel Cutoffs

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

NR (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16)

PILOT VALVE TRAIN (Note 12)

Required Required Required Required Required Required Required Required CR-180(C)

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

Gas Pressure Regulator Required Required Required Required Required Required Required Required

MAIN VALVE TRAIN

(1) Required (1) Required

YESCF-150(d)

YES Manual Shutoff Valve(s) (1) Required (2) Required (2) Required (1) Required

Gas Pressure Regulator Required Required Required Required Required Required Required Required

APPROVED SAFETY CONTROL SPECIFICATIONS

Fed

eral

Co

rpo

rati

on

NO Not Permitted Not Permitted Not Permitted Not Permitted

90 Sec Prepurge Timing (Note 9) (Note 9) (Note 10) (Note 10) (Note 10)

120

Eas

t M

ain

Str

eet

--

Po

st O

ffic

e B

ox

2640

8

Okl

aho

ma

Cit

y,

Okl

aho

ma

7312

6

(8

00)

28

9-33

31

(40

5) 2

39-7

301

Fa

x (4

05)

232

-54

38

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

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

5,000,000 to

12,500,000 Associated Standard

ParagraphNOT

REQUIRED

NEXUS NX1030-150PSI

Transmitter

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)

CR-220(a)(1)(2) CW-310(b) CW-

620(b)

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)

CR-220(b)(1)(2) CW-410(b)

CW-640(b)

Honeywell L404C1162

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)

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)

CR-220(b)(1)(3) CW-410(c)

CW-640(a)

NEXUS NX1030 Gas

PSI Transmitter

High Gas Pressure (MANUAL RESET)

CF-162(a), CF-910, CR-410 Table CF-

1,CF-2

NEXUS NX1030 Gas

PSI Transmitter

Low Gas Pressure (Manual Reset) CF-162(a), CF-910,

CR-410 Table CF-1,CF-2 CF-180(b)(2)

(3)ASCO T300417-22 Valvew/OTS

Valve Seal Overtravel Interlocks

NEXUS 4100 w/NX20-1 Air

Position Indicator

CF-210(a)(2) CF910, CR-410,

Tables CF-1, CF-2

NEXUS 4100 w/NX10-1 Gas/Oil Position Indicator

NEXUS 4100 w/Antun

SMD8024 Dual Point Air Switch

Required (Note 9)

Required (Note 9)

Required (Note 10)

Required (Note 10)

Required (Note 10)

CR210(a)(b)(c) Tables CF-1, CF-2

NEXUS 4100 w/Antun

SMD8024 Dual Point Air Switch

Tables CF-1, CF-2 CR-1, CR-2

Action on Loss of Combustion Air

Safety Shutdown

Tables CF-1, CR-1, CR-2

113

61 E

ast

61st

. S

tree

t, B

roke

n A

rro

w,

Ok

lah

om

a

7401

2

(8

00)9

55-1

918,

T

uls

a (9

18)

955

-191

8

F

ax (

918)

249

-90

14

MM 193-D First LWCO Recycle

MM750-MT LWCO MR

Low Water 2 Required (1 w/MANUAL RESET)

(2) Required (Notes 11,12,

13)

(2) Required (Note 11)



(2) Required (Notes 11,12, 13)




CE-120(a)(b) CR-210(a)(b), CW-

610(a)(b)

Hot Water Boilers (MANUAL RESET)

(1) Required (Notes 14

& 15)

(1) Required

(1) Required (Notes 14

& 15)

(1) Required

(1) Required CR-210(c), CW-

130(a), CW-630(a)(b)

Forced Circulation (MANUAL RESET)

CR-210(e), CW-210(a)(b)

ASCO 8211 DBB

Approved Safety Shutoff Valve(s)

MAXATROL 325-3

CF-110(a)(1), UL795-25 15, CF-

180, cf-161(b) Figs B-1, 2,3,4

ASCO V762LCA DBB

Approved Safety Shutoff Valve(s)


(1) or (2) Required (Note 20)





CF-180(b) (1)(2)(3)

Manually Operated Leak Test Valve(s)

(1) or (2) Required (Note

22)






(2) Required

(2) Required

(2) Required

(2) Required

CF-150(b)(d) ANSI221.13 1114

MAXATROL 210G

CF-160, CF-161(b), ANSI221.13 1.15.1

Fig. B-1, 2,3, 4

Rebuilt Flame Safeguard / Burner Control

Not Permitted

Not Permitted

Not Permitted

Not Permitted

90 Seconds (Note 8)

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

CR-1, CR-2

Print Out 05/07/2014

Fed

eral

Co

rpo

rati

on

44 Changes 4 Changes 4 Changes

YES (Note 8) Required Required (Note 10) (Note 10) (Note 10)

YES Low Fire Start Circuit Required Required Required Required CF-610

NO Continuous Pilot Optional Optional Not Permitted Optional Optional Not Permitted

NO Intermittent Pilot Optional Optional Not Permitted Required Optional Optional Optional Optional

YES Interrupted Pilot Optional Optional Not Permitted Optional Optional Optional Optional

YES Proved Pilot CF-320(a)(1)

10 Sec

None Not Permitted None 10 Seconds

Intermittent Pilot 15 Seconds 15 Seconds Not Permitted 15 Seconds 10 Seconds

Interrupted Pilot 15 Seconds 15 Seconds 10 Seconds 15 Seconds 15 Seconds 10 Seconds

10 SECNone (Note 27) None (Note 28) (Note 29) (Note 30)

Intermittent Pilot (Note 28) (Note 29) (Note 30)

Interrupted Pilot (Note 28) (Note 29) (Note 30)

Direct Ignition

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

Action on Flame Failure Safety Shutdown

Action On Limit Opening Safety Shutdown

FOOTNOTES:

1

2

3

4

5

6

7

8

9

10

11

Prepurge Air Changes Required

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

CR-1, CR-2

High Fire Purge Proving Circuit

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

Not Permitted

Not Permitted



Not Permitted


Required (Note 25)

Required (Note 25)

Required (Note 25)

Required (Note 25)

Required (Note 25)

Required (Note 25)

Required (Note 25)

Required (Note 25)

Pilot Flame Establishment Period (PFEP)

Continuous Pilot

15 Seconds (Note 26)

10 Seconds Maximum (Note 31)




Not Permitted

15 Seconds

10 Seconds


10 Seconds

10 Seconds


Main Flame Establishment Period (MFEP)

Continuous Pilot

10 Seconds


15 Seconds Maximum


15 Seconds Maximum

15 Seconds Maximum

10 Seconds Maximum (Note

31)


15 Seconds Maximum


15 Seconds Maximum

4 Seconds Maximum

4 Seconds Maximum (Note

32)

15 Seconds Maximum


CF-310(d) (1)(2)(3)(4)

Flame Failure Response Time (FFRT)


4 Seconds Maximum

4 Seconds Maximum

4 Seconds Maximum

4 Seconds Maximum

(Note 35, 36)

4 Seconds Maximum

4 Seconds Maximum

4 Seconds Maximum


Safety Shutdown

(Note 37,38)

Safety Shutdown (Note

39)

Safety Shutdown

Safety Shutdown

(Note 37,38)

Safety Shutdown (Note 40)




Safety Shutdown

Safety 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

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

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.

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.

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.

Required for direct ignition systems. Not required for ignition systems with pilots

Optional one safety shutoff valve with valve seal overtravel (Proof-of-closure) interlock.

One of the safety shutoff valves with valve seal overtravel (Proof-of-closure) interlock.

Four air changes at 60% damper opening with both air flow and damper opening with both air flow and damper position proven.

Four air changes at 60% damper opening with both air flow and damper position proven.

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.

One of the two low-water fuel cutoffs may be a combined feeder / cutoff device.


12

13

14

15

16

17 Close main valve and recycle.

18

19

20

21

22

23

24

25 When pilot is used.

26 Initial start only.

27

28

29

30

31 Interrupted pilot only.

32

33

34 Required if interrupted pilot.

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.

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.

Except those installed in residences (as defined by the authority having jurisdiction).

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.

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.

One recycle for piloted systems.

Two safety shutoff valves in series. May be in single control body.

Two safety shutoff valves in series on one safety shutoff valve with valve seal overtravel (Proof-of-closure) interlock.

One safety shutoff valve to incorporate valve seal overtravel (Proof-of-closure) interlock.

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.

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.

Water level control alarms, when used, shall be distinctly audible above the ambient noise level and may be used in conjunction with indicating lights.

Pilot only: 15 seconds maximum if interrupted pilot is used.

Pilot only: 15 seconds maximum if interrupted pilot is used. 25 to 30 seconds if safety shutoff valve has full opening.

Pilot only: 10 seconds maximum for modulating or high-low firing.

Pilot only: 10 seconds maximum.

Maximum input at light off shall not exceed 2,500,000 Btu/Hr.

Required with modulating or high-low firing.


35

36

37

38

39

40

41

If ignition system includes a relight feature, the relight attempt shall be initiated within 0.8 seconds upon loss of flame.

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.

If system has intermittent pilot, wait 5 minutes before resetting ignition system (Instructional requirement).

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.

A single recycle is allowed on for

Or, recylce once after 5 minute time delay.

Select proper safety control according to system requirements.

TechStuff - Boiler Benchmarking Date of Printout05/07/2014 / 09:59:56


Voice 405-728-6709

BENCHMARKING A BOILERAMBR = American Boiler Manufactuers Recommendations

Customer AC Humco Industry Food ProcessingContact Joe Treska - 901.381.2925 FAX 901.381.3136Address 1201 East Morton Rd

City/State/Zip Jacksonville, Il. 62650Date 7/20/2006 Burner Data Zurn SAO-MJ S/ 5456 (49,500KBTU/Hr)Boiler Mfg Zurn NB18952 Operating PSI 150 Economizer Yes

Type O-Type Water tube MfgFuels Natural Gas Steam Temp 366

Rated BTU Input/Hr 87,500,000 Fan Voltage 480 BTU/Lb Steam 1000Rated Steaming Capacity/Hr 70000 Fan Amp Rating 60 Feedwater Pump Amp Rating 65

Utility Meter

Firing Rate Fuel Flow 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%0 0 0 0.00% 6.00% N0X/CO 0.00 #DIV/0! #DIV/0!0 0 0 0.00% 6.00% 0.00 #DIV/0! #DIV/0!0 0 0 0.00% 6.00% 0.00 #DIV/0! #DIV/0!0 0 0 0.00% 6.00% 0.00 #DIV/0! #DIV/0!

45120 47874000 39440 56.34% 358 5.00% 5.50% na 0.00 82.3 49 82.38% 82.193%0 0 0 0.00% 5.00% 0.00 #DIV/0! #DIV/0!

54820 58820000 46500 66.43% 368.7 3.35% 4.75% 83/4ppm 0.02 80.9 50 79.05% 78.904%0 0 0 0.00% 4.50% 0.02 #DIV/0! #DIV/0!

65800 70443000 48250 68.93% 376 3.50% 4.25% 86/6ppm 0.03 81.1 51 68.50% 68.384%0 0 0 0.00% 4.00% 0.03 #DIV/0! #DIV/0!0 0 0 0.00% 3.75% 0.03 #DIV/0! #DIV/0!

722000 76194000 51151 73.07% 504 5.50% 3.50% 1ppm 0.03 81.2 67.13% 67.018%0 0 0 0.00% 3.25% 0.04 #DIV/0! 0.000%

74840 79067000 52063 74.38% 501 1.90% 3.00% 86/19ppm 0.04 82.9 53 65.85% 65.747%74400 80285000 52700 75.29% 386 1.86% 2.75% 96/13ppm 0.04 53 65.64% 65.428%

0 0 0 0.00% 2.50% 0.05 #DIV/0! #DIV/0!0 0 0 0.00% 2.25% 0.05 #DIV/0! #DIV/0!0 0 0 0.00% 2.00% 0.06 #DIV/0! #DIV/0!

80000 86235000 55550 79.36% 510.8 1.00% 2.00% 163ppm 0.08 83 64.42% 64.309%NOTE: GAS FLOW METER JUST STOPPED INDICATING AT 80000. NO FLUCTUATION IN READING AT THIS POINT.

Economizer Data

Valve % Water Flow Inlet Temp Outlet Temp BTU Recovered Fuel Savings % FW Pump Amps10% 7000 224 -1568000 -1.792%15% 8500 224 -1904000 -2.176%20% 13500 224 -3024000 -3.456%25% 17500 224 -3920000 -4.480%30% 21000 224 -4704000 -5.376%35% 24000 224 -5376000 -6.144%40% 27500 224 -6160000 -7.040%45% 31000 224 -6944000 -7.936%50% 34780 224 -7790720 -8.904%55% 37500 224 -8400000 -9.600%60% 41700 224 -9340800 -10.675%79% 44000 224 277 2332000 2.665% 4642% 47500 224 261 1757500 2.009% 47.775% 51000 224 -11424000 -13.056%80% 55000 224 275 2805000 3.206% 5085% 57600 224 -12902400 -14.746%90% 63000 224 -14112000 -16.128%95% 67000 224 -15008000 -17.152%100% 69800 224 285 4257800 4.866% 51

05/07/2014 09:59:56 Dissolved Oxygen In Make-up WaterData Compiled by


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

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

Temperature Dissolved O250 2000058 1500060 1200072 8800

125 5000180 3000200 2000212 1000227 44242 7

50 58 60 72 125 180 200 212 227 2420

5000

10000

15000

20000

Temperature

PP

B D

iss

olv

ed

Ox

yge

n

Pressure CoversionsDate of Printout

05/07/2014 09:59:56

Data Compiled byKarl Pierson

KMCS

Enter value to be converted in column D The converted values will then be shown in the same row

From Value

To Values

PSI OzSI PASCAL kPa BAR mBAR ATM Cm Hg mm Hg TORR

PSI

OzSI

PASCAL

kPa

BAR

mBAR

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

TORR

In. H2O @

4C/39FIn. H

2O @

60FIn. H

2O @

20C/68Fmm H

2O cm H

2O In. Hg @

0 C

In.H2O @ 4 C

In. H2O @ 60F

In. H2O @ 20C

mm H2O

cm H2O

Cm Hg @ 0 C

mm Hg @ 0 C

Required Boiler Blowdown for proper TDSNormal TDS should be between 3,000-5,000 ppmTDS= Total Dissolved Solids in boiler water.

Blowdown Rate = (F/(B-F))*SWhere: F= Feedwater TDS in ppm

B= Desired boiler water TDS RequirementS= Steam Generation Rate in lbs/hr

F= 300B= 4000S= 55000Blowdown 4459.459 Lbs/HrPercent 8% 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 = BTU29,010.00 8.50 8.50 29,010.24

AMPS VOLTAGE 3Ph/KW43.00 480.00 35.71

Cost of Energy Cost/Hr to OperateGas per MMBTU $8.95 $0.26 Electric per KW $0.044 $0.37

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

BTU = Kw/.0002930

GO TO VFD CALCULATIONS FOR MORE DETAILED INFORMATION

CALCULATING APPROXIMATE HP WHEN VOLTS AND AMPS ARE KNOWN

Voltage 480Amps 65

NP Eff% 80%# Phases 3

57.95

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

VFD

Replacing DC3000 Versa-Pro with

OLD DC300C- useOLD DC300K- useOLD DC300E- useOLD DC300A- useOLD DC300T- useOLD DC300L- use

Table 1 O useE useA useT useL use

Table 2 1_ _ use2_ _ use4_ _ use_A_ use_B_ use_ _3 use

Table 3 Same on 3300

Table 4 First digit (zero) useSecond digit useThird digit useForth digit usen/a 5th digitn/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-CODC330B-K_DC330B-E_DC330B-A_DC330B-T_DC330B-E_

-_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)

Always zero (0_ _0_0)

Aways -00-

Always -0-

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

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

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

Replacing DC3000 W/ Table 1 with

DC3001-0-DC3002-0-DC3003-0-DC3004-0-DC3005-0-DC3006-0-

Table 2 1st -0_ _- -1_ _- -2_ _- -3_ _- -4_ _-

2nd -_0_- -_1_- -_2_-

3rd -_ _0- -_ _A- -_ _B-

Table 3 -1- -2- -3-

Table 4 -00-(multiple avail.) -35-

-DIN- -FM- -UL-

Table 5 ID code 4 digitsTable 6 Not used

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

use use use use use use

use use use use use use use use use use use

use use use

use use use use use

use use

DC3300 W/ Table 1

DC330B-C0-DC330B-KE-DC330B-EE-

DC330L-E0-DC330L-E0-

-0_ _- -1_ _- -2_ _-

-4_ _- -_0_-

-_ _0- -_ _0-

-10- -20- -30-

-000T00-

-0F0000- -0F0000-

Always use -00-Always use -0-

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

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

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

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

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

-000000- Multiple options available in this table.

-0000D0-

VFD Calculations05/07/2014

David Farthing'sTechStuf

Variable Frequency Drive ApplicationsCustomer Kodak PolyGraphicsApplication VFD Draft Fan 33KPPH Boiler

Need to know Motor Horsepower 30Motor Speed as supplied 1750

Hertz - Name Plate 60Rated Torque Ft/Lb. 90

New Hertz 33New Motor Speed 963

New Torque Ft/Lb. 90 NOTE: Torque should remain constant but Horsepower will change.Change in Motor Speed % 45.00%

New Horsepower @ New Speed 16.50Prefer to know Original Amp Draw 0

Cost of kW of Electricity $6.800 Total Hours of Operation/Year 8000

Is Application Pump or Fan? (P or F) FControl Methods Code - See List Below FC

Variable Frequency Drive VFD 0.28Discharge Control Valve DV 0.94

Bypass Valve BV 1Inlet Guide Vane IG 0.62

Outlet Damper OD 0.88Fan Curve FC 0.88

No Control NA 1

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

22.380 Kilowatt Usage Standard Motor No Control

12.309 Kilowatt usage using VFD at New Horsepower

19.694 Kilowatt Usage Using Current Control Method

7.385 Kilowatt Savings Converting from Current Control Method to VFDSavings $4,017.66 Annual Energy Cost Savings By Converting to VFD

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

kWha

kWhb

kWhc

kWhd

TECHSTUF 4.07

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