Techstuf 4.07

Warra
WELCOME TO TECHSTUFF!!
nty
1997 David C. Farthing
Revision
4.07
7
Accur
A Compilation of technical formula, solutions, and manufacturer's application notes.
Compiled by David C. Farthing as a service to those who need to know.
acy
Use Mouse to Click on Button to GO TO desired formulas.
Conta
Instructions
Fill in new data in yellow boxes.
Boiler
Pump
Gener
Refrig
Heatin
Burne
s ct
al
eratio
Valve
Contr
g
r
and
Info
Calcul
n
Sizing Produ
Compile January 14, 1997
Month
Year
Contents
Data Printout 05/07/2014
Date of Rev.
04.10.07
ols Loads Flow Electri

Calcul Revisio Hydro
ct
ations Steam Loads
-Trans
& ations
c
nics
n
Select
mitter Stuff Piping Motor
Notes
ion
s&
Data Data
General Calculations
Guide
Volu FluidVFD
Volumes in Cylindrical and Square Sided Tanks
me Water Content in an Air Stream
AIR
TEM
PRE
Temperature Conversions
P Pressure Conversions
SSU
ENE
Conversions BTU/KW KW/BTU
Fina
RE Energy
RGY
Financial Analysis of a Project
ncial
Heating Loads
BTU Load of liquid in Square & Cylindrical tanks
BTU Calculating
Fan
Steam Load Across Fan Coils
Coil Flowing Fluid Heating Loads
FHL
B&E Building + Equipment Heating Load Combination
Equi
Solid Materials & Equipment Heating Loads
p Ht
Refrigeration Loads
Refri Refrigeration loads of flowing liquids
g.
Boiler Calculations
BHP Boiler Horsepower from BTU and/or Pound Per Hour Steam Flow
Chi Fan Laws for Boiler Burner Applications
FAN
O2/C
mne Rite Boiler Index for Stack & Boiler, Atmospheric & Power Burner
Combustion Efficiency Savings with O2 Trim & CO influence
O
Tank
y Condensate & Feedwater Tank Sizing
Eco
Trim
Size Economizer Calculations
Com
FW
no Excess Air & Oxygen Analysis & Combustion Air Requirements
bTem
Air The effect of Feedwater Temperature on Boiler Horsepower
Syst
Syst The effect of Boiler Operating Pressure on System Design - Firetube Boilers
p
ems The effect of Boiler Operating Pressure on System Design - Watertube Boilers
emsSCA The effect of Scale & Soot Build-up on Heat Transfer in Boilers
DR.
W Dr. Mac Brockway's Boiler Water Chemistry Class
LE
CSD
BEN CSD-1 Fire & Water Side Control Requirements
MAC
BLD
1 Benchmarking a Boiler
CHM
Boiler Blowdown Calculations
OW
MKU
K Amount of Dissolved Oxygen in Make-up Feedwater vs. Temp.
N
P
O2 ValveProving Sequencing Test Calculation
VPS
Valve
Sizing CV Calculations
Gas
Liqu
Gas Flow Control Valve Sizing
Valv
Stea
Liquid Flow Control Valve Sizing
id
e Steam Flow Control Valve Sizing
m
Val
Pumps
Valand Hydronics
Pum
Pum
Centrifugal Pump Affinity Laws
p Pump NPSH Calculator
Exp
ps
Hydr
NPS
ansi Expansion Tank Sizing Calculations
PUM
onic
H Hydronic Zone Flow Calculations
on
Ps Pump VFD Affinity Laws & Curves
Electrical,
VFD Control and Instrumentation Stuff
Volt Controller Out Put Voltage v. Impedance and Transmitter Troubleshooter
OHM
OHMS Laws
age
IAS
S Instrument Application Selection Guide
G
VFD Variable Frequency Drive Calculations
Steam Stuff
Main
Leak
s
Hea
Reli
Tabl
Sup
s
t
ef
es
erhe
Rec
Val
at
Ste
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
over
Rec
Cost to Produce Steam in $/Kpph
am
Flow
yMeasurement & Piping Calculations
Flow
over
$$ Gas/Steam Flow & Steam Velocity
y
Frict
Calc Single Pipe Friction Loss Calculations
Bac
k
To
Cont
ents
Bac
k
To
Cont
ents
Bac
k
To
Cont
ents
Bac
k
To
Cont
ents
Pipe
ion
s Thermal Expansion of Pipe
Ham
Halli
T. Water Hammer Calculations
mer Halliburton Gas/Liquid Turbine Meter Calculations (Convert BTU to GPM #2 Diesel)
butr
Product Selection Guide
on
ASC
ASCO Solenoid Valves TOMSPAVE
Bac
Boil
O Boiler Application Guide
k
ers
FSG Flame Safety Control Selection Guide
Trap
Steam Trap Selection Guide
To
Pum
s Pump Applications
Cont
ps
Control & Recorders
M&C
DC3 Measurement,
UDC3000 Cross Reference (DC300#)
ents
DC3
00# UDC3000 Cross Reference (DC300X)
00X
Page 1
Data Compiled by
David C. Farthing
Voice 405-728-6709
Revision Notes
Rev #
1.102
2.103
6.103
8.0603
12.1.03
02.7.04
04.30.04
09.14.04
11.09.04
12.16.04
6.5.5
6.21.06
3.12.07
4.10.07
Date
1/31/2002
2/12/2003
6/30/2003
8/6/2003
12/1/2003
2/7/2004
4/30/2004
9/14/2004
11/09/04
12/16/04
6/5/2005
6/21/2005
3.12.07
4.10.07
Notes
Correct nomenclature in 02 trim calcs and add Revision Notes page.
Add VFD Drive Calcs and Motor Data.
Add Fan Laws for Burners data.
Enhanced Steam Flow Calculations with updated AGA material.
Add Dr. Mac Brochway's Boiler Water Charts
Enhanced Fan Laws for Burner data based on infor from Oneok evaluations.
Added Pitot Tube Flow Calculator
Added Effect of Co on OxyTrim Efficiency Calculations.
Cleaned up Motor Torque data in VFD calculations.
Added ABMA Boiler Water Chemcal Guidelines and Dr. Mac's pH Correction Table for TDS
National Standards Institue Heat Loss Due to Scale Deposits
BTU to #2 Diesel Conversion for Halliburton Turbine Meters
Add Oxygen Trim Calculator to O2 Trim Worksheet
Add VPS Volume & Time Calculator
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 Farthing
Voice 800-239-7301
Fax 405-232-5438
dcfarthing@federalcorp.com
dfarthing@advancedtech.org
TECHSTUFF is a Microsoft Excel 5.0 application and may be ran on Windows 95 or newer versions.
It is recommended that the application be saved as a 95/5.0 application so that the user may readily
transfer the free upgrades from www.federalcorp.com. The application is saved as a 95 version to
allow the greatest number of users to use the service.
Compiled January 14, 1997
Tank Fluid Volumes

Data Compiled by
David C. Farthing
Voice 405-239-7301
CAPACITY OF LIQUID IN CYLINDRICAL TANKS IN U.S. GALLONS

CAPACITY of CYLINDRICAL TANKS = D^2 * L * .0043
WHERE D = DIAMETER IN INCHES
L = LENGTH IN INCHES
.0043 = CONSTANT
INPUT DATA MAY BE IN EITHER INCHES OR FEET. NOTE APPROPRIATE DATA TABLE
Dimensions
INCHES
FEET
D=
12
1
L=
12
1
VOLUME =
5.88
5.88
Gallons U.S.
CAPACITY OF LIQUID IN SQUARE SIDED TANKS IN U.S. GALLONS
CAPACITY of SQUARE TANKS = (D-FB) * W * L * 7.5
Dimensions
Depth
Width
Length
Freeboard, inches Fluid Volume
INCHES
12
12
12
0
7.43
Gallons U.S.
FEET
1
1
1
0
7.43
Gallons U.S.
Page 5
Customer
Contact
Tank Name:
Load Calculations
No. of Tanks
1
Chromalloy
Tim Johnson
Plating
NOTE: CUSTOMERS TANKS MUST BE INSULATED

MINIMUM 2.0" FIBERGLASS BAT RECOMMENDED.
Open Top Tank Assumed. 0.5 F/Sec Air Velocity over top of tank.
Tank Configuration Type Letter S or C in box

Square/Cylinder
S
Tank Designations
RM1
Square Sided Tank Data

Depth
2
Width
2
Total Tank Surface Area
Cylindrical Tank Data

Dimensions
D=
L=
FLUID VOLUME =
Fluid Data:
Final Temperature
100
FEET
0
0
0.00
Product:
Sp./Gr.
1.23
Total Fluid Volume

All Cylindrical Tanks
0.00
Length
4
Freeboard, inches
6
Surface Square Feet
Fluid Volume
89.784
8.00
Total Fluid Volume

89.784
Open Top Area Sq./Ft.

0
Water
Sp./Ht
1
NOTE: PAGE DOWN FOR COMMON LIQUID DATA
Q=W X Sp./Ht. X (T2-T1)
Based on 80% Efficient Boiler
Cost to Operate Rise 8Hr. Cost to Maintain/Hr
Where
Q= Quantity of Heat in BTU
Energy Cost Gas/MMBTU
$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 Product
T2= 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 loading
Per Tank Load
3,212 Maintenance Load ONLY
3,212
0
Open Top Loss
1,488 Tank radiance and surface losses.
180 Open Top Radiant Loss Factor
Total 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. Rise
Assumed 80% Eff.
38,238
9,559
6,373
4,780
3,186
Boiler Horsepower 80% Eff.
1
0
0
0
0
Common Specific Gravity's & Specific Heats for Various Liquids.
First Number Sp.Gr. Second Number Sp.Ht.
Water
1/1
Castor Oil
1.2/.43
Kerosene
.86/.48
Acetone
.79/.51
Citron Oil
1.2/.44
Naphthalene
1.14/.41
Alcohol's
.79/.60
Diphenylamine
1.16/.46
Olive Oil
.93/.47
Ammonia
.62/1.16
Ethyl Ether
1.16/.53
Propane
.50/.59
Aniline
1.02/.52
Ethylene Glycol
1.16/.53
Pentane
.63/.54
Benzol
1.02/.42
Fuel Oils 2-6
.90/.45
Seawater
1.02/.94
Calcium Chloride
1.2/.43
Gasoline
.81/.53
Soybean Oil
.93/.47
Paraffin Wax
1.12/.69
Gypsum
1.21/.26
Sandstone
.93/.22
Plating Applications Diluted Solutions
Nickel
1.23/1
Acid
1.23/1
Chrome/Fluorides
1.23/1
Electro-Klean
1.12/1
Soak Clean
1.12/1
Data Compiled January 14, 1997
Refrigeration Loads
Refrigeration of Liquids
Customer Name
Contact
Phone Number
Refrigeration Load = Mass expressed as G/Hr.;((Flow in Gallons / Hr. *8.31)*Specific Gravity* Specific Heat * (T1-T2))/12000
Flow =
1119
GPM
Flow =
67140 Gallons / Hour
Sp. Gr.
1
Sp. Ht.
1
T1 =
95
T2 =
85
Tons Refrigeration Required =
466.06
Water
1/1
Castor Oil
1.2/.43
Acetone
.79/.51 Citron Oil
1.2/.44
Alcohols
.79/.60 Diphenylamine
1.16/.46
Ammonia
.62/1.16 Ethyl Ether
1.16/.53
Aniline
1.02/.52 Ethylene Glycol 1.16/.53
Benzol
1.02/.42 Fuel Oils 2-6
.90/.45
Calcium Chloride
1.2/.43 Gasoline
.81/.53

Kerosene
.86/.48
Naphthalene 1.14/.41
Olive Oil
.93/.47
Propane
.50/.59
Pentane
.63/.54
Seawater
1.02/.94
Soybean Oil
.93/.47
Page 7
Data Compiled by
David C. Farthing
Voice 405-728-6709
Data Compiled by
David C. Farthing
Voice 405-728-6709
Rite Boiler Chimney Effect

Data Compiled January 14, 1997
Chimney / Stack Draft Effect Calculations

Use Boiler and Stack Index to find required stack diameter on Rite Stack Chart.
Instructions: Input current data in 'Input Data' Column. Solution is calculated as you go. All data
must be included for proper results.
Boiler Horsepower
Boiler Efficiency
BTU Input
Fuel
Gas / Oil
Draft / In. H2O = .52 X P X H X (( 1/460 + T1) - (1/460 + T2))

INPUT DATA
765
0.8
32,000,906
G
Final Calculated Boiler Index
32.99
Altitude Of Installation
Total Number of Turns
Total Length of Breech
Height of Stack (Ft.)
Total Stack Length+Breech
Stack Diameter (FT)
Stack Length/Diameter Index A
Degrees
Stack L/D + Turns Index B
774
2
24
20
44
2.33
18.88
80.00
2.09
LS
DS
LS/DS
Final Calculated Stack Index

Atmospheric PSIA
Ambient Temp.
Stack Temp.
Solution
Draft In. H20
Recommended Minimum Drafts
As Measured from exhaust outlet.

27.96
Calculated Stack Diameter in Inches
9.57
P
T1
T2
14.68
95
325
-0.0805981
Negative .09 on Power Burners measured at stack inlet.
Negative .04 on Atmospheric measured at stack inlet.
NOTE: A commonly accepted ruel of thumb states that for every 0.01"WC the excess draft rate can be reduced
a decrease of 1% in fuel consumption may be received.
Exhaust Gas Volumes for Typical Boiler Operating Conditions

Result is Cubic Feet/Minute Per 100 Hp.
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 0
Flue Gas Temperature
425
Boiler Horsepower
107.5
Exhaust Volume
1591
Cubic Feet/Min.
Emissions Make-Up
Percent of FG
Excess Air = 15%
Mol Wt. by Volume
SCF/10^6 BTU
Lbs./10^6 BTU
PPM
CO2 =
44
10.10
1095.44
126.84
O2 =
32
3.00
306.12
25.78
CO =
28
0.0020
0.2
0.015
20
N2 =
28
86.900
8876.40
654.05
Nox=NO2
46
0.0025
0.25
0.03
25
Hydrocarbons
16
0.001
0.100
0.004
10
Sox=SO2
64
0.000
0
0.00
H2O =
18
2237
105.96
Particulates
0.00
Total
100
12515.52
912.68
Total Emissions this application =
45,024.43
3,283.37
NOTES:
Page 8
Boiler Horsepower
Boiler Horsepower
When Pounds Per Hour Steam Flow are known.

BHP = #/Hr Steam Flow / 34.5
Steam Flow =
60000
Boiler Hp =
1739
At and From 212 deg. "F"
When BTU of Burner is Known.
Useful BHP = Fuel BTU Input/ 33,465 * Rated Efficiency
Fuel Input =
10,500,000
Boiler Hp =
254
at 81% Eff. At and From 212 deg. "F"
Boiler Hp =
235
at 75% Eff. At and From 212 deg. "F"
When Boiler Rated Horsepower is Known.
Steam Flow #/Hr = Boiler Rated Hp * 34.7
Boiler Hp =
250
Steam Flow =
8625.65 At and From 212 deg. "F"
When BTU Required by the Process is Known.
Process Input =
60,000,000
Boiler Hp =
2213
Fire Tube at 81% Eff. At and From 212 deg. "F"
Boiler Hp =
2391
Water Tube at 75% Eff. At and From 212 deg. "F"
Boiler Input =
74,074,074 Fire Tube at 81% Eff. At and From 212 deg. "F"
Boiler Input =
80,000,000 Water Tube at 75% Eff. At and From 212 deg. "F"
When Heating Surface area is Known.
Heating Surface =
10,750
Fire Tube at 81% Eff. At and From 212 deg. "F"
Fire Tube BHP =
2150.0
Fire Box BHP =
2087.4
Fire Box at 80% Eff. At and From 212 deg. "F"
Water Tube BHP =
2028.3
Water Tube at 75% Eff. At and From 212 deg. "F"
Boiler BTU Output = 71,949,750 Fire Tube at 81% Eff. At and From 212 deg. "F"
Boiler BTU Output = 67,877,123 Water Tube at 75% Eff. At and From 212 deg. "F"
TURBINE to BOILER Horsepower Requirements

KW/Hr.
2200
Meg.W
2.2
BTU/Hr.
7,513,440
Efficiency
22.18%
Boiler Hp
1012.25
Steam Flow PPH
34,923
UNDER CONSTRUCTION DO NOT USE THIS CALCULATION
Page 9
Data Compiled by
David C. Farthing
Voice 405-728-6709
Boiler Horsepower
Boiler HP from BTU Output

BTU Output=
12500000
Boiler HP =
373.524577917
KW/Hr.
BTU/Hr.
Boiler Hp
Meg.W
6000
20,491,200
612.32
6
Notes
1KW = 1,000 Watts
1 MW = 1,000,000 Watts
1 MW = 1,000 KW
Eletric Motor Hp
KW/Hr.
MegW/Hr
Boiler Hp
16000
11931.2
11.9312
1216.352
5.28
5.33
5.35
5.38
5.51
5.32
5.17
4.92
Page 10
Data Compiled by
David C. Farthing
Voice 405-728-6709
Data Source Sterling Radiator

05/07/2014 09:59:53
BUILDING HEAT LOSS CALCULATION

CLIENT
LOCATION
BUILDING NAME
BUILDING
BUILDING
BUILDING
BUILDING
LENGTH
WIDTH
HEIGHT EVE
HEIGHT RIDGE
Changeable data
St. Greg Unv.
Shawnee
MaBee Buldg
DATE 29:Sep:04
250
276
16
18
DOOR AREA (FT SQ.)
75
OUTSIDE AIR TEMPERATURE

INSIDE AIR TEMPERATURE
15
73
AIR CHANGES PER HR
Data Compiled by
David Farthing
Voice 405-728-6709
Building Machinery Heating/Cooling Loads
SLAB U FACTOR
WALL U FACTOR
PERCENT GLASS
GLASS U FACTOR
ROOF U FACTOR
DOOR U FACTOR
BUILDING VOLUME
DELTA TEMP
0.81
0.38
10%
0.69
0.067
1.22
WALLS
CONSTRUCTION
METAL
ROCK, GLASS BATT
EXPED STYROFOAM
WOOD OR PLYWOOD
1"
2"
0
1.2
1.2
0.56
0.38
BOILER HORSE POWER
1173000
58
0.11
0.1
4
0.067
0.059
5
0.054
0.048
6
0.046
0.04
WALL
0.00
0
INS PER IN.

3.50
4
0.081
0.076
0.063
0.060
0.052
0.050
0.044
0.042
0.040
1.880
3.500
3.500
"U" VALUES
OPEN CORE
0.64
0.51
0.47
FILLED CORE
0.36
0.38
0.38
4
0.067
0.06
5
0.054
0.048
6
0.046
0.04
WALL
0.00
0
INS PER IN.

3.50
4
0.51
0.39
0.37
0.18
0.16
1
1,224,612.00
413,407.30
268,162.16
5,307.00
49,422.96
1,960,911
58.5346690729
BTU
BTU
BTU
BTU
BTU
BTU
METAL AND TRANSITE
HP
HEATER CALC.S
BTU CAP @ 20 DEG DROP
CONVERSION FACTORS (1=Steam)(.6=Water)
HEATER GPM REQ
PRESSURE PROP FT. WATER
HEATER PIPE LENGTH
PIPE SIZE
FRICTION /100FT
0.19
0.16
CONCRETE BLOCK (NO INSULATION)

SAND / GRAVEL AGGREGATE
4" THICK (R=0.71)
8" THICK (R=1.11)
12" THICK (R=1.28)
CINDER AGGREGATE
4" THICK (R=1.11)
8" THICK (R=1.72)
12" THICK (R=1.89)
BRICK - COMMON
VOLUME REQUIREMENT
WALL HEAT LOSS
ROOF HEAT LOSS
DOOR HEAT LOSSES
SLAB LOSS
TOTAL BUILDING LOAD
INSULATION THICKNESS - INCHES

1
2
3
0.23
0.13
0.088
0.21
0.11
0.078
250000
0.6
40
2
600
4
2
HEATERS REQ 13.0727427596

GPM REQ
HEAD REQ 12
ROOFS
CONSTRUCTION
METAL W/O BUILDUP
ROCK, GLASS BATT
EXPED STYROFOAM
METAL W/ PREFORMED INSULATION
WOOD W/ PREFORMED INSULATION

1"
2"
0
1.3
1.3
NO INSULATION
4" THICK (R=0.8)
8" THICK (R=1.60)
12" THICK (R=2.40)
0.61
0.48
0.31
NO INSULATION
CORRUGATED METAL
COATED METAL
3/8" TRANSITE - FLAT
3/8" TRANSITE - CORRUG
1.5
0.9
1.1
1.3
INSULATION THICKNESS - INCHES

1
2
3
0.23
0.13
0.088
0.21
0.11
0.078
1.30
0.26
0.15
0.110
0.081
0.067
0.056
0.000
2.780
0.49
0.34
0.21
0.17
0.13
0.12
0.096
0.088
0.076
0.071
0.063
0.059
0.053
0.051
0.940
1.880
2.780
2.780
MISC. "U"
INTERIOR WALLS
SHEET METAL
1/2" PLYWOOD
8" CONCRETE BLOCK
3/8" GYP BOARD
GLASS - VERTICAL
SINGLE PANE
DOUBLE PANE
TRIPLE PANE
STORM WINDOW
0.74
0.05
0.32
0.6
1.13
0.69
0.47
0.56
GLASS - HORZ
SINGLE PANE
DOUBLE PANE
1.22
0.75
AIR LOSS= CFHX0.018XTD
EXTERIOR DOORS
FLAT METAL
1" WOOD
2" WOOD
1.2
0.64
0.43
FLOOR SLABS (BTUH/LN.FT. / DEG. F)

UNINSULATED
0.81
INSULATED
0.55
DILUTION AIR - PER 1,000 BTUH

NATURAL GAS - 4 CFM
PROPANE GAS - 5 CFM
TechStuf 'C' 1997 David Farthing
Tech Stuff
Heating Solid Materials
05/07/2014 09:59:53
Data Compiled by
David Farthing
Voice 405-728-6709
Heating Solid Materials and Equipment

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

W=
Weight of Material
Cp=
Specific Heat of Material
L=
Latent Heat of Steam (Btu/Lb)
t=
Time in Hours
Steel Part in Platen Heater
W=
Cp=
L=
Start Temp
Final Temp
Delta T=
t=
Lbs/hr=
58
Lbs.
0.12
From Charts
945
From Steam Charts
58
2000
1942
1
14.30298
BTU/Hr =
13,516.32
Boiler Hp
0.40
Common Specific Heats of Solid Materials
Water Cp = 1.0
Steel
0.12
Carbon-Coke
0.203
Glass, normal
0.2
Nickel Steel
Iron
0.12
Chalk
0.215
Gneiss
0.18
Paraffin Wax
Aluminum
0.22
Charcoal
0.2
Granite
0.2
Porcelain
Alumina
0.35
Cinders
0.18
Graphite
0.2
Quartz
Asbestos
0.2
Coal
0.3
Gypsum
0.26
Quicklime
Ashes
0.2
Concrete, Dry
0.156
Hornblend
0.2
Rose Metal
Bakelite
0.35
Constantine
0.098
Humus soil
0.44
Salt, rock
Basalt
0.2
Cork
0.485
India Rubber
0.37
Sand
Bell Metal
0.086
Corundum
0.198
Kaolin
0.224
Sandstone
Bismuth-tin
0.043
D'Arcet metal
0.05
Lead Oxide
0.055
Serpentine
Borax
0.229
Dolomite
0.222
Limestone
0.217
Silica
Brass, Y
0.088
Ebonite
0.33
Lipowitz Metal
0.04
Soda
Brass, R
0.09
German Silver
0.095
Magnesia
0.222
Sulfur
Bronze
0.104
Glass, Crown
0.16
Magnesite
0.168
Talc
Brick
0.22
Glass, flint
0.12
Marble
0.21
Tufa
Vulcanite
0.331
Wood (AVG)
0.63
Wood's metal
0.04
Type metal
0.109
0.69
0.22
0.23
0.217
0.05
0.21
0.195
0.22
0.25
0.191
0.231
0.18
0.209
0.33
0.039
Flowing Fluid Heating

Flowing Fluid Heating Loads

You may use either GPH or GPM for your problem. Be sure to use the correct data box.
Heating Load = Flow #/hr * Sp.Gr.*Sp.Ht. * Delta "T" in deg. "F"
INPUT DATA
INPUT DATA
Gal/Hour
Gal/Minute
Flow =
175000
GPH
1600
GPM
Sp. Gr.
1
1
Sp.Ht.
1
1
T1 =
97.5
88
T2 =
120
Boiler Hp
Steam Flow
95
Boiler Hp Steam Flow
Load BTU/Hr. = 32,799,375.00
980.11
33,813.79
5,597,760.00
167.27
5,770.89
Water
1/1
Castor Oil
1.2/.43
Kerosene
Acetone
.79/.51
Citron Oil
1.2/.44
Naphthalene
Alcohols
.79/.60
Diphenylamine
1.16/.46
Olive Oil
Ammonia
.62/1.16
Ethyl Ether
1.16/.53
Propane
Anilin
1.02/.52
Ethylene Glycol
1.16/.53
Pentane
Benzol
1.02/.42
Fuel Oils 2-6
.90/.45
Seawater
Calcium Chloride
1.2/.43
Gasoline
.81/.53
Soybean Oil
Page 13

.86/.48
1.14/.41
.93/.47
.50/.59
.63/.54
1.02/.94
.93/.47
Data Compiled by
David C. Farthing
Voice 405-728-6709
Water Content In Air Stream
Water Content in Air Streams

Datum
1# of Air at 62 "F"=13.65 CF
1CFt of Air holds .0225# Water at 65"F" and 40% RH
CFM =
Total Water / Min. =
Lb./Hr Water =
Gallons/Hr. Water =
2500
56.25 in Lbs.
3375
406.1372
Page 14
David Farthing's
TechStuff Valves
Gas Valve
Courtesy of HONEYWELL, INC. - Modified by David Farthing

CITGO 725 BOILER
100%
75%
CONDITIONS
CONDITIONS
BASE FLOW
SCFH
32,350.00
24,262.00
SAFETY FACTOR
X
1.10
1.00
FLOW
SCFH
35,585.00
24,262.00
INLET PRESS
PSIG
10.00
11.00
OUTLET PRESSURE
PSIG
3.00
2.00
PRESS DROP
PSI
7.00
9.00
TEMPERATURE
DG.F
68
68
SPEC GRAV
0.63
0.63
REQUIRED Cv
38.964
23.429
V-Cut
Degrees Open
Degrees Open
V-Bal 900Rotation
60
CV of Installed Val
90
38.96
Percent Open
43.294%
23.43
Percent Open
26.032%
Page 15
Thanks to Honeywell for the basic CV calculator
GAS
50%
CONDITIONS
16,175.00
1.00
16,175.00
12.00
1.00
11.00
68
0.63
14.128
Degrees Open
14.13
Percent Open
15.698%
25%
CONDITIONS
8,088.00
1.00
8,088.00
14.00
0.50
13.50
68
0.63
6.267
Degrees Open
6.27
Percent Open
6.964%
David Farthing's
TechStuff Valves
Liquid Valve
Courtesy of HONEYWELL, INC. - Modified by David Farthing

OUHSC 2006
OUHSC@100%
OUHSC@75%
CONDITIONS
CONDITIONS
BASE FLOW
GPM
17.00
12.75
SAFETY FACTOR
X
1.25
1.00
ACTUAL FLOW
GPM
21.25
12.75
INLET PRESS
PSIG
200.00
350.00
OUTLET PRESSURE
PSIG
125.00
322.00
PRESS DROP
PSID
75.00
28.00
SPECIFIC GRAV
0.98
0.98
VISCOSITY
CS
0.96
0.96
TEMP(WATER)
DG.F
227
227
MAX ALLOW
P (WATER)
PSI
155.014
273.514
REQUIRED Cv
2.429
2.385
Linear V-Ball
V-Cut Degrees Open
Degrees Open
30
7.29
7.16
V-Bal Rotation
Percent Open
Percent Open
CV of Installed Val
10
24.291%
23.853%
Page 16
Thanks to Honeywell for the basic CV Calculator
OUHSC@50%
CONDITIONS
8.50
1.00
8.50
350.00
322.00
28.00
0.98
0.96
227
LIQUID
OUHSC@25%
CONDITIONS
4.25
1.00
4.25
350.00
322.00
28.00
0.98
0.96
227
|
273.514
1.590
Degrees Open
4.77
Percent Open
15.902%
273.514
0.795
Degrees Open
2.39
Percent Open
7.951%
David Farthing's
TechStuff Valves
Steam Valve
Thanks to Honeywell for the basic CV Calculator
Courtesy HONEYWELL, INC. - Modified by David Farthing

STEAM
TAG #
Original Design
Reduction #1
Reduction #2
(ENTER TAG #)
CONDITIONS
CONDITIONS
CONDITIONS
CONDITIONS
BASE FLOW
#/HR
7,300.00
5,800.00
16,000.00
12,000.00
SAFETY FACTOR
X
1.00
1.00
1.00
1.00
DESIGN FLOW
#/HR
7,300.00
5,800.00
16,000.00
12,000.00
INLET PRESS
PSIG
125.00
100.00
75.00
75.00
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
V-Bal 900Rotation
60
CV of Installed Val
400
0.00
Percent Open
6.667%
0.00
Percent Open
6.524%
Page 17
0.00
Percent Open
28.966%
0.00
Percent Open
21.565%
VPS Calculations
05/07/2014
Complied by David Farthing
VALVE PROVING SEQUENCING TEST CALCULATIONS

V1= Upstream Valve Volume
V2= Downstream Valve Volume
D= Pipe Diameter (Inches Nominal-Schd. 40)
L= Pipe Length Between V1 & V2 (Feet)
P= Inlet Gas Pressure to V1
C= Burner Maximum Firing Capacity (CFH)
X= Calculated Test Valve Train Volume
T= Minimum Test Time in Seconds
Calculation of Valve Train Volume
X= V1+V2+((A x L)/144)
Calculation of Valve Proving Test Time
Test Time (Sec) = 187,000 X (P x X)/C
Is Inlet Gas Pressure in InWc or PSI (I or P)
i
Inlet Gas Pressure
40
P= 1.444043321
D=
2
Area Sq/In = 3.357236479
L=
0.25
V1=
0.0227
V2=
0.0245
Total Volume Cft (X)= 0.053028536
C=
2500
Min.Test Time Seconds (T) =
10.00
vps
GAS
V1
V2
Fan Coils
Steam Demand in a Fan Coil

Formula used for calculations
Q=( CFM X 1.08 X TD ) / 1000
Where
Q = Air flow across fan coil in cfm
TD = Temperature Differential across fan coil
1000 = Latent heat of 15 PSI Steam
1.08 = Correction factor for fouling of coils
CFM =
Inlet Air Temp =
Exhaust Air Temp =
Lbs/ Hr. Steam Load
BTU Load
INPUT DATA
6,000
60
180
777.6
777,600
Page 19
Calculating NPSHa (Available) for Centrifugal Pump Applications

ENTER "X" to Select Formula
Suction Lift Open Tank
NPSHa = Pb - (Vp + Ls + Hf)
Suction Lift Closed Tank
NPSHa = p - (Ls + Vp + Hf)
Suction Head Open Tank
NPSHa = Pb + Lh - (Vp + Hf)
X
Suction Head Closed Tank
NPSHa = p + Lh - (Vp + Hf)
Suction Head and Lift are meassured from the liquid surface to the pump centerline.
Where
Pb = Barometric pressure in feet absolute (Fa)
Vp = Vapor Pressure of the liquid at maximum pumping temperature, in feet absolute (Fa)
p = Pressure on surface of liquid in closed suction tank in feet absolute (Fa)
Ls = Maximum stactic suction lift in feet.
Lh = Maximum stactic suction head in feet
Hf = Friction loss in feet in suction pipe at required capacity. (Go to
FrictionCalculator)
Feet Absolute Calculator - Enter Data in Guage Readings to get Feet Absolute
Guage Reading
Fa
Pb =
29
32.79
Vp =
10
57.03
p=
10
57.03
Input Data
Pb =
Vp =
p=
Ls =
Lh =
Hf =
NPSHa =
32.79
57.03
57.03
0.00
5.50
1.39
4.11
Pump must require an NPSHr less than or equal to this value.
Producers COOP
Peerless F21250AM
11.0" Impeller
05/07/2014
Pump Horsepower Requirements

Q=
1840
H=
60
PSIG =
25.97
Sp.Gr.=
Pump Eff.
Minimum Motor Hp BHP=
65.00%
42.8904428904
Cost to Operate Pump

$/KW/Hr =
0.044
Hours/Day =
24
Days/Month =
15
Cost Per Month =
$506.82
Page 21
Pump Affinity Laws
Burner Fan Laws

by David Farthing
05/07/2014
Fan Laws for ESTIMATING Boiler Burner Fan Performance
Enter known data in Yellow Boxes

OUHSC
CB Watertube
60,000 at 275 PSIG
CFM Estimates based on 950 But/ft^3 fuel, 9.67 ft^3 Air per 1 ft^3 Fuel at Sea Level and 100 deg "F" Combustion Air.
Q = Fan Volume Flow Rate CFM or ft^3/Min
Assumed Data
D = Fan Diameter in Inches
Air Density = 0.0584
N = Fan Shaft RPM
Air Temp = 100
H = Static Pressure of Fan at Design Point, Inch/WC
Elevation = <1700 Ft/ASL
Bhp = Fan Horsepower = Q X H / (6356* Eff)
Diff P = Differential Pressure Across Windbox at Firing Rate
Eff = (ft^3/min X H) / (5263 X Motor Hp)
Burner Input
65,800,000.00
BTU/Hr from Burner Data Plate
Max Gas Flow

65,800.00
Ft^3/Hr
Min Gas Flow
6,580.00
Ft^3/Hr
Max Air Flow @15% EA.
12,476.20
CFM base on 9.67 Ft^3 Air/1Ft^3 Gas at Sea Level & 80 deg "F". 15% Excess Air.
Min Air Flow
1,247.62
CFM at LOW (10%) FIRE.
Fan Motor HP
60.00
Taken from Fan Motor Data Plate
Fan Static Pressure H
18.00
*At Stall 0 Flow Fan Damper CLOSED taken at fan discharge ahead of dampers.
Calculated Fan Eff.
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 performance
Original Fan Speed
1770
RPM at Shaft
FAN LAWS
New Fan Speed
1150
RPM at Shaft
Q1/Q2 = N1/N2
New Fan Flow
8106
CFM
H1/H2 = (N1/N2)^2
New Fan Max SP
7.60
Inch WC
Bhp1/Bhp2 = (N1/N2)^3
New Fan Bhp
14.63
Bhp at the shaft.
Q1/Q2 = D1/D2
Original Boiler Output PPH
54,268.04
Saturated
H1/H2 = (D1/D2)^2
Original Boiler Output PPH
45,585.15
Superheated <700 Deg F
Bhp1/Bhp2 = (D1/D2)^3
New Boiler Output PPH
35,258.48
Saturated
New 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.
David Farthing's
TechStuff
TechStuff C1997
Combustion Efficiency Calculations

Printout 05/07/2014 09:59:54
Data Compiled by
David Farthing
Combustion Efficiency Calculations

Boiler Type & Data
Fuel (Gas =1, Oil =2)
Rated Boiler Hp
Name Plate Efficiency
Current O2 % as found
Current Co2 % as found
Air Diluted CO ppm as found
CO in Flue Gas ppm Corrected
Approximate Fuel Loss out stack
Normal Firing Rate NFR (0-100)
Recommended O2% @ NFR
Average Hours/Day Run Time
Average Days/Month Run Time
Fuel Cost/Therm from billings
Average Combustion Air Temp
Stack Temp at Firing Rate
Net Flue Gas Temp Rise
Net Efficiency Loss to Wasted Fuel as Co
As Found Combustion Efficiency
New Calculated Combustion Efficiency
New Stack Temp
New Net Flue Gas Temp Rise
Net Combustion Efficiency Gain
Current Cost to Operate Per Month
New Cost to Operate Per Month
Current Fuel Dollars Wasted as Excess CO
Savings Per Month
Savings Per Year
NOTES
Kodak PolyGraphics
Minimum O2 Allowed This Fuel Type
1
2.00%
956
Steaming Rate PPH
78.00%
16491
7.80%
5.30%
45.00
71.79
0.02%
Cu/Ft Gas/Hr.@NFR@ As Found Eff.
50%
19,790
4.25%
Data from Ideal O2 Table
24
22
0.6
Equivalent Cost / 1000 Cu/Ft =
$6.00
80
390
310
Performance Data
0.0718%
36%
Present Excess Air Mass.
80.8%
20%
New Excess Air Mass.
82.5%
$7.20
OLD Fuel Cost per 1,000 Lb/Steam.
384
$7.05
NEW Fuel Cost Per 1,000 Lb/Steam.
304
2.05%
Percent Fuel Cost Savings.
2.03%
$62,696.16
$61,425.68
$12.56
$1,283.04
Controller Output=
45
$15,396.53
Raw Air Flow=
100
O2 Reading=
3
O2 Corrected Air Flow=
102.5
Voltage
#DIV/0!
CONTROLLER IMPEDANCE VS. VOLTAGE

Impedance of Device Controller is Controlling
Ma output of controlling Device
Out Put Voltage You Should Read at Controller Output
When Controller Out Put = Ma in Cell 'F6'.
250
20
5
OHMS
Common Control Device Impedance and their associated Voltage

Impedance Control Voltage
250 Ohms
5 VDC
120 Ohms
2.4 VDC
100 Ohms
2.0 VDC
TRANSMITTER TROUBLESHOOTER
HIGH SIDE
LOWSIDE
4/20 MA READING
RATIO
BIAS
DISPLAY READS
0
-22
12 (NOTE: Max Value = 19.99 otherwise DIV/0 Error)
1 This is any RATIO applied by the display device.
20 This is any BIAS applied by the display device.
NOTES:
1] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING HIGH AND PROCESS IS LOW THEN CHECK LOW (REFERENCE
2] IF TRANSMITTER IS 'DP' AND DISPLAY IS READING LOW AND PROCESS IS HIGH THEN CHECK HIGH SIDE FOR PL
3] ATTACH A 'Ma' METER IN SERIES TO THE TRANSMIITER NEGITIVE SIGNAL LEG AND READ Ma. INCERT IN 4/20 MA
Page 24
Voltage
S. VOLTAGE
HECK LOW (REFERENCE) SIDE FOR PLUGGED LEG.

HECK HIGH SIDE FOR PLUGGED LEG.
D Ma. INCERT IN 4/20 MA CELL IN FORMULA
Page 25
Pipe Expansion
PIPE THERMAL EXPANSION CALCULATIONS

Calculations good for Carbon Steel and Carbon Molybdeum Steel Pipe.
Pipe Size
Pipe Run Length
Operating Temperature =
Thermal Expansion per 100 ft =
TOTAL Thermal Expansion =
361
347
9.99
36.08
Coeff.
2.88
212-250
1.61
Expansion Coefficients
251-359
360+
Temp.
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.
Page 26
Compiled October 10, 1997

Source: Skidmore/ASME
Condensate Tank Sizing

Condensate & Feedwater Tank Sizing

Boiler Hp.
Evaporation Rate from and at 212 deg. F.
GPM Flow Rate Start/Stop Feedwater System
GPM Flow Rate Modulated Feedwater System
Storage Holding Time Desired, Minutes
Tank Size for Start/Stop Feedwater System
Tank Size for Modulated Feedwater System
1740
7223.827
300.9928
180.5957
7
3009.928
1805.957
Gallons Per Hour

Gallons Per Minute 2.5 Safety Factor
Gallons Per Minute 1.5 Safety Factor
Minutes Holding Time
Data Compiled by
David C. Farthing
Voice 405-728-6709
Compiler November 3, 1997

Source: Spirax Sarco
Data Compiled by
David C. Farthing
James W. Carr
Voice 405-728-6709
Steam Mains Trap Sizing

Steam Mains Trap Sizing

Steam Main Data
Assumes 2.0" of Fiberglass Insulation
Pipe Diameter
6
Steam Header Pressure(PSIG)
20
Ambient Air Temperature
70
Warm-up Load / #Steam(Condensate) per 100 Ft. of Pipe
75
Running Load / #Steam (Condensate) per 100 ft. of Pipe.
31
Feet Between Trap Points
100
Total Trap Warm-up Load Per Trap Point
75
Total Trap Running Load Per Trap Point
30.75
From Spirax Sarco Look-up Tables below.
#/Hr Condensate Load

#/Hr Condensate Load
Pressure vs. Pipe Size Look-up Table

Steam Pressure (psi)
2.00
0.00
6.2
6.9
7.5
8.4
9.9
11
12
12.8
13.7
14.5
15.3
16
17.2
25
27.8
30.2
32.7
38
45
52
62
71
78
80
5.00
10.00
20.00
40.00
60.00
80.00
100.00
125.00
150.00
175.00
200.00
250.00
300.00
400.00
500.00
600.00
800.00
1000.00
1200.00
1400.00
1600.00
1750.00
1800.00
2.50
9.7
11
11.8
13.4
15.8
17.5
19
20.3
21.7
23
24.2
25.3
27.3
38.3
43
46
50
58
64
72
79
87
94
97
3.00
12.8
14.4
15.5
17.5
20.6
22.9
24.9
26.6
28.4
30
31.7
33.1
35.8
51
57
62
67
77
86
96
106
117
126
129
4.00
18.2
20.4
22
24.9
29.3
32.6
35.3
37.8
40
43
45
47
51
75
83
91
98
113
126
140
155
171
184
189
5.00
24.6
27.7
29.9
33.8
39.7
44
48
51
55
58
61
64
69
104
116
126
136
203
227
253
280
309
333
341
6.00
31.9
35.9
38.8
44
52
57
62
67
71
75
79
83
89
143
159
173
187
274
305
340
376
415
448
459
8.00
48
48
58
66
78
86
93
100
107
113
119
125
134
217
241
262
284
455
508
566
626
692
746
764
10.00
68
77
83
93
110
122
132
142
152
160
169
177
191
322
358
389
421
670
748
833
922
1018
1098
1125
12.00
90
101
109
124
145
162
175
188
200
212
224
234
252
443
493
535
579
943
1052
1172
1297
1432
1544
1584
14.00
107
120
130
146
172
192
208
222
238
251
265
277
299
531
590
642
694
1132
1263
1407
1558
1720
1855
1902
16.00
140
157
169
191
225
250
271
290
310
328
347
362
390
682
759
825
893
1445
1612
1796
1988
2194
2367
2427
18.00
176
198
213
241
284
316
342
366
391
414
437
456
492
854
971
1033
1118
1835
2047
2280
2524
2786
3006
3082
20.00
207
233
251
284
334
372
403
431
461
487
514
537
579
1045
1163
1263
1367
2227
2485
2767
3064
3382
3648
3741
24.00
208
324
350
396
465
518
561
600
642
679
716
748
807
1182
1650
1793
1939
3227
3601
4010
4440
4901
5285
5420
0F Correction Factor *
1.5
1.44
1.41
1.37
1.32
1.29
1.27
1.26
1.25
1.24
1.23
1.22
1.21
1.2
1.18
1.17
1.16
1.156
1.147
1.14
1.135
1.13
1.128
1.127
So urces Marks 7 th Ed .
GPSA 9 th Ed .
Co mpil ed by Da vid Farthin g
West Instruments Delta-Tube Flow Calculator

dp= (Lb/H/(359.12*Cf*(D^2)*(wf^.5)))^2
Lb/h = (dp^.5)*(((359.12*Cf*(D^2)*(wf^.5))^2)^.5)
Cf =
Cf' =
D=
Fp =
wf =
Lb/h
dp=
Lb/H =
dp =
Dp
1
2
3
4
5
6
7
8
9
10
Flow
32982
46643
57126
65964
73750
80789
87262
93287
98946
104298
0.651 from Manufacturer's Model 301

233.78712 Cf' = (359.12 * cf)
8.385 Inside Pipe Diameter
150 Flowing Pressure in PSIG used to look up "wf" from Steam Tables
0.282 Specific Weight at Flowing Conditions from Steam Tables
50000 Flow Rate Expected
32.8123602194 Calculated dp from formula
50142.7604459098 Proofing #
error = 0.285%
33.000
Dp
11
12
13
14
15
16
17
18
19
20
Flow
109389
114253
118918
123407
127739
131928
135988
139931
143765
147500
Dp
21
22
23
24
25
26
27
27.5
Flow
151142
154699
158176
161578
n/a
n/a
n/a
n/a
HC900 Math Block Assignments

a = dp
32.8123602
b = Cf'
233.78712
c = D^2
70.308225
d = wf^.5
0.53103672
e= 2
f = 0.5
g = off
h = off
(a^f)*(((b*c*d)^e)^f)
Math Block Function Proof =
50000.00 PPH
05/07/2014 09:59:54
GPSA 9 th Ed .
05/07/2014 09:59:54
GPSA 9 th Ed .
05/07/2014 09:59:54
Fan Laws for ESTIMATING Boiler Burner Fan Pressures/Flows

Q=
Volume Flow Rate
D=
Fan Diameter
N=
RPM
P=
Pressure
Diff P =
Differential Pressure Across Fan at Firing Rate
H=
Fan Horsepower
Eff =
ft^3/min X P (in H20)/(6356 X Motor Hp)
Burner Input
29,400,000.00 MMBTU
Max Gas Flow
29,400.00 Ft^3/Hr
Min Gas Flow
2,940.00 Ft^3/Hr
Max Air Flow
4,738.30 CFM base on 9.67 Ft^3 Air/1Ft^3 Gas.
Min Air Flow
473.83 CFM at LOW (10%) FIRE.
Fan Motor HP
30.00 Taken from Fan Motor Data Plate
Fan Stall Pressure
29.00 At Stall 0 Flow Fan Damper CLOSED
Calculated Fan Eff.
72.064% As a check this number should be 72-75% w/72% A
Calculated Fan HP
30.03 Check against actual Fan Motor Data Plate
Fan Performance OK
Q = C' * (P^.5)
C' =
2940
Diff P =
100
Q=
29400.000
% Flow
100%
DP =
99
Q=
29252.631
% Flow
99.499%
DP =
98
Q=
29104.515
% Flow
98.995%
DP =
97
Q=
28955.642
% Flow
98.489%
DP =
96
Q=
28805.999
% Flow
97.980%
DP =
95
Q=
28655.575
% Flow
97.468%
DP =
94
Q=
28504.358
% Flow
96.954%
DP =
93
Q=
28352.333
% Flow
96.437%
DP =
92
Q=
28199.489
% Flow
95.917%
DP =
91
Q=
28045.813
Air Flow at varying pressures measured down stream of damper vanes

Arbitrary C' to reach necessary air flow shown in Max Air Flow in above cell.
Differential Inches H20 Across Fan At Maximum Flow High Fire Position of Fan Damper
Must Equal MAX AIR FLOW!! Adjust C' as needed to correct.
88
27579.645
93.808%
87
27422.494
93.274%
86
27264.438
92.736%
85
27105.461
92.195%
84
26945.545
91.652%
83
26784.675
91.104%
82
26622.832
90.554%
81
26460.000
90.000%
80
26296.159
77
25798.395
87.750%
76
25630.326
87.178%
75
25461.147
86.603%
74
25290.836
86.023%
73
25119.371
85.440%
72
24946.727
84.853%
71
24772.880
84.261%
70
24597.805
83.666%
69
24421.474
66
23884.673
81.240%
65
23703.038
80.623%
64
23520.000
80.000%
63
23335.527
79.373%
62
23149.583
78.740%
61
22962.134
78.102%
60
22773.142
77.460%
59
22582.568
76.811%
58
22390.373
55
21803.624
74.162%
54
21604.500
73.485%
53
21403.523
72.801%
52
21200.641
72.111%
51
20995.800
71.414%
49
20580.000
70.000%
12.5
10394.470
35.355%
5
6574.040
22.361%
2
4157.788
0.137
% Flow
DP =
Q=
% Flow
DP =
Q=
% Flow
95.394%
89.443%
90
79
27891.289 26131.292
94.868%
88.882%
89
78
27735.905 25965.377
94.340%
88.318%
83.066%
68
24243.861
82.462%
67
24064.937
81.854%
76.158%
57
22196.513
75.498%
56
22000.945
74.833%
14.142%
1
2940.000
10.000%
0.025
464.855
1.581%
1.49
t Firing Rate
7 Ft^3 Air/1Ft^3 Gas.
Motor Data Plate

an Damper CLOSED
umber should be 72-75% w/72% Average)
tual Fan Motor Data Plate
sition of Fan Damper
Compiled November 4, 1997

Source: Simple Math Context
Revenue Loss
Cost of Leaking Steam Traps in Lost Steam and Revenue
Total Number of Traps Surveyed

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

1/2" TD
Compiled by
David Farthing
Voice 405-728-6709
Back to
Cost of Leaks
Steam Trap Survey Form

Customer Name
Location
Plant Contact
Contacts Phone
Contacts e-mail
Location Trap # Trap Style Temp IN Temp OUT Status Test Means Comments and Notes
Data Compiled by
David C. Farthing
Voice 405-728-6709
Ohms Law
OHMS Laws of Electricity

Fill in any TWO (2) known pieces of data under the factor you are looking for.
E = Voltage
I = Current/Amps
R = Ohms Resistance
Input the known data from your application.

AMPS =
0.04
To Find
Voltage
24
OHMS
330
Watts
1
WATTS =
Voltage
OHMS
Amps
To Find
VOLTS =
Watts
OHMS
Amps
OHMS =
Voltage
Amps
Watts
To Find
KVA =
# of Phases
Amps
Voltage
To Find
1
1
1
1
0.00
1
1
1
To Find
W = Watts
17280
480
1
36
1.00
1
1
1
Kw=
ctor you are looking for.
17.28
Ohms Law
Data Compiled by
David C. Farthing
Voice 405-728-6709
INPUT DATA
Degrees C =
Degrees K =
Degrees R =
Degrees F=
Degree F
60
15.56
288.71
519.69
Temperature Conversions
Enter Known Temperature in 'F' or 'C' for results.
Degree C
15.56
60.01
Calculated Total Cost to Produce Steam-Natural Gas Fired Plant w/ Possible Seconda
Rated Boiler Output in Kpph
Thermal Efficiency of Boiler
MMBTU/Hr Input
Total Operating Electric Horsepower
Hours Per Year Operation
Cost of Fuel per MMBTU
Fuel Cost per Kpph
Contribution of Secondary Waste Fuel Stream
Fuel Cost per Kpph w/ Contributed Waste Fuel
Cost of Electricity per KWH
Electrical Cost per Kpph
Cost of Water per 10,000 Gal
Percent Make-up to Boiler
Calculated Water Treatment Cost per 1000 Pounds
Operators Annual Salary
Overhead and Benefits of Operator
Percentage of Operator Cost to Operation of Boiler
Annual Maintenance & Inspection
Cost to Produce 1Kpph
Depreciation on Equipment as %
Cost to Produce 1Kpph w/ Depreciation
Cost of Purchased Steam from Outside source
Saving(+)/Cost(-) to Operate Owners On-Site Plant
75
82
91.46
at Stated Boiler Thermal E
130
Fan and Feedwater Pump
8000
$6.66
$8.12
30%
$5.69
$0.14
$0.18
$2.33
100%
$0.23
$40,000.00
$14,400.00
12%
$1,165.00
$7.06
20.00%
$8.47
$9.65
$706,065.47
Plant w/ Possible Secondary Waste Fuel Stream
at Stated Boiler Thermal Efficiency

Fan and Feedwater Pumps
PROPERTIES OF SATURATED STEAM
IN VAC
Gauge
Pressure
PSIG
25
20
15
10
5
0
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
24
Temperature
Deg F
134
162
179
192
203
212
215
219
222
224
227
230
232
233
237
239
244
248
252
256
259
262
265
Heat in Btu/lb.
Sensible Latent
Total
102
1017
1119
129
1001
1130
147
990
1137
160
982
1142
171
976
1147
180
970
1150
183
968
1151
187
966
1153
190
964
1154
192
962
1154
195
960
1155
198
959
1157
200
957
1157
201
956
1157
205
954
1159
207
953
1160
212
949
1161
216
947
1163
220
944
1164
224
941
1165
227
939
1166
230
937
1167
233
934
1167
Specific
Volume Gauge
Cu. ft. Pressure
per lb.
PSIG
142
185
73.90
190
51.30
195
39.40
200
31.80
205
26.80
210
25.20
215
23.50
220
22.30
225
21.40
230
20.10
235
19.40
240
18.70
245
18.40
250
17.10
255
16.50
260
15.30
265
14.30
270
13.40
275
12.60
280
11.90
285
11.30
290
10.80
295
Temperature
Deg F
382
384
386
388
390
392
394
396
397
399
401
403
404
406
408
409
411
413
414
416
417
418
420
Heat in Btu/lb.
Sensible Latent
Total
355
843
1198
358
841
1199
360
839
1199
362
837
1199
364
836
1200
366
834
1200
368
832
1200
370
830
1200
372
828
1200
374
827
1201
376
825
1201
378
823
1201
380
822
1202
382
820
1202
383
819
1202
385
817
1202
387
815
1202
389
814
1203
391
812
1203
392
811
1203
394
809
1203
395
808
1203
397
806
1203
Gauge
Pressure
PSIG
26
28
30
32
34
36
38
40
42
44
46
48
50
55
60
65
70
75
80
85
90
95
100
105
110
Temperature
Deg F
268
271
274
277
279
282
284
286
289
291
293
295
298
300
307
312
316
320
324
328
331
335
338
341
344
Heat in Btu/lb.
Sensible Latent
Total
236
933
1169
239
930
1169
243
929
1172
246
927
1173
248
925
1173
251
923
1174
253
922
1175
256
920
1176
258
918
1176
260
917
1177
262
915
1177
264
914
1178
267
912
1179
271
909
1180
277
906
1183
282
901
1183
286
898
1184
290
895
1185
294
891
1185
298
889
1187
302
886
1188
305
883
1188
309
880
1189
312
878
1190
316
875
1191
Specific
Volume Gauge
Cu. ft. Pressure
per lb.
PSIG
10.30
300
9.85
305
9.46
310
9.10
315
8.75
320
8.42
325
8.08
330
7.82
335
7.57
340
7.31
345
7.14
350
6.94
355
6.68
360
6.27
365
5.84
370
5.49
375
5.18
380
4.91
385
4.67
390
4.44
395
4.24
400
4.05
450
3.89
500
3.74
550
3.59
600
Temperature
Deg F
421
423
425
426
427
429
430
432
433
434
435
437
438
440
441
442
443
445
446
447
448
460
470
479
489
Heat in Btu/lb.
Sensible Latent
Total
398
805
1203
400
803
1203
402
802
1204
404
800
1204
405
799
1204
407
797
1204
408
796
1204
410
794
1204
411
793
1204
413
791
1204
414
790
1204
416
789
1205
417
788
1205
419
786
1205
420
785
1205
421
784
1205
422
783
1205
424
781
1205
425
780
1205
427
778
1205
428
777
1205
439
766
1205
453
751
1204
464
740
1204
473
730
1203
Gauge
Pressure
PSIG
115
120
125
130
135
140
145
150
155
160
165
170
175
180
Temperature
Deg F
347
350
353
356
358
361
363
366
368
371
373
375
377
380
Heat in Btu/lb.
Sensible Latent
Total
319
873
1192
322
871
1193
325
868
1193
328
866
1194
330
864
1194
333
861
1194
336
859
1195
339
857
1196
341
855
1196
344
853
1197
346
851
1197
348
849
1197
351
847
1198
353
845
1198
Specific
Volume Gauge
Cu. ft. Pressure
per lb.
PSIG
3.46
650
3.34
700
3.23
750
3.12
800
3.02
900
2.92
1000
2.84
1250
2.74
1500
2.68
1750
2.60
2000
2.54
2250
2.47
2500
2.41
2750
2.34
3000
Temperature
Deg F
497
505
513
520
534
546
574
597
618
636
654
669
683
696
Heat in Btu/lb.
Sensible Latent
Total
483
719
1202
491
710
1201
504
696
1200
512
686
1198
529
666
1195
544
647
1191
580
600
1180
610
557
1167
642
509
1151
672
462
1134
701
413
1114
733
358
1091
764
295
1059
804
213
1017
Total per lb.

Calculating Superheat in Pressure Reducing Stations
High Pressure Point
250
Reduced Pressure
14
High Pressure Volume/CuFt
1.75 From Tabels above
Reduced Pressure Volume/CuFt
14.3 From Tabels above
High Pressure Temperature
406 From Tabels above
Reduce Pressure Normal Temperature
248 From Tabels above
Resultant Superheat
19.33566
Temperature of Reduced Pressure Steam
267.3357
Specific
Volume
Cu. ft.
per lb.
2.29
2.24
2.19
2.14
2.09
2.05
2.00
1.96
1.92
1.89
1.85
1.81
1.78
1.75
1.72
1.69
1.66
1.63
1.60
1.57
1.55
1.53
1.49
Specific
Volume
Cu. ft.
per lb.
1.47
1.45
1.43
1.41
1.38
1.36
1.34
1.33
1.31
1.29
1.28
1.26
1.24
1.22
1.20
1.19
1.18
1.16
1.14
1.13
1.12
1.00
0.89
0.82
0.75
Specific
Volume
Cu. ft.
per lb.
0.69
0.64
0.60
0.56
0.49
0.44
0.34
0.23
0.22
0.19
0.16
0.13
0.11
0.08
Technical Source
National Hydraulic Inst.
Compiled by:
David C. Farthing
Voice 405-728-6709
Piping Friction Loss Analysis
68 Degree Water Data!!

Piping Friction Loss and Velocity Analysis
Single pipe system. For multiple pipe sizes in a single run calculate each section and add
all section total losses together to get Total Head Loss for system.
Lookup Tables are available from most any pump/pipe manufacturer.
IS this calculation for Suction or Discharge Pipe S or D ?
Lookup Table >

Federal Catalog
Pages 265-266
System Size
Linear Feet Pipe
Number of 90 Ells
Number of 45 Ells
Number of Valves
Flow Rate Required
Pipe Schd
Friction Loss/100 Ft
Velocity
Effective Reynolds Number
K Factor 90 Ells
K Factor 45 Ells
K Factor Valves
Head Velocity V2/2G
Total Loss Line Pipe
Total Loss from 90 Ells
Total Loss from Valves
Back Pressure Valve Setting
Total Head Loss
Pump NPSH
Short
Short
Globe
2.064
6.00
1.00
0.00
1.00
35.00
40.00
1.00
3.33
53027.89
0.98
0.31
6.75
0.17
0.06
0.17
0.00
1.16
0.00
1.39
It is helpful to input actual pipe ID.
GPM
Head Friction Loss/100 Feet of Pipe
Feet Per Second
Flow is no longer laminar!
Averaged for pipe size range
Feet Head
Feet Head
Feet Head
Feet Head
Feet Head
Feet of Head Loss
Formula
h=K*(V2/2G)
h=K*(V2/2G)
h=K*(V2/2G)
Compiled by
David C. Farthing
Voice 405-728-6709
Financial Analysis
05/07/2014
Financial Analysis of a Project
Project Name
Kodak PolyGraphics
Boiler Combustion Control EXAMPLE #1
Initial Cost of Investment Materials

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

Process Recovery v Tank Size
Heater Size Selected
Time
0.00
0.25
0.50
0.75
1.00
Load
300
255
365
255
365
1825
Usage
In-Temp Out-Temp Time Rate
50
165
0.083
50
165
50
165
50
165
50
165
Tank Size
Recovery
Heat
3,454,157
243,691
348,812
243,691
348,812
3000
Percent
Heater Recovery of Tank Vol.
1,460,000
10%
1,460,000
9%
1,460,000
12%
1,460,000
9%
1,460,000
12%
Recovery Time
Minutes
874,518.37
10.01
14.33
10.01
14.33
874,567.07
Instrument Application Selection Guide

A guide to help you select the equipment needed to
accomplish an instrumentation application.
What is the Application?
Heating = 1
Level = 2
Pressure = 3
Flow = 4
Vaccum = 5
Cooling = 6
Equipment Needed
Under Construction Do Not Use This Pa
Controller Reverse Action - Thermal element RTD or Thermocouple - Control Valve and ther
Controller
Reverse Action
Transmitter
Use a Thermocouple or RTD for Temperature Measurement
Control Valve
Special Equipment
Do Not Use This Page.
ouple - Control Valve and thermal extionsion wire
Water Flow Through an Orifice

Qh=C' X (Hw*Pf)^.5
Qh= Lbs/Hr Mass Flow
UNDER CONSTRUCTION
C' = Flow Constant
DO NOT USE FOR DEFINITIVE DATA!!
Hw = Differential in Inches Water
Pf = Static Gauge Pressure in PSIA
Assumed Factors for Water
Fb Orifice Factor
Fr Reynolds Number
Y Expansion Factor
CV = GPM / DP^.5 x SG.
Inlet Pressure, PSIG
Discharge Pressure
Calculated HW
ID of Orifice
ID of Pipe
GPM=
60
74.65 Calculated Pf
10
24.65 Corrected to PSIA
1386 Inches Water Differential
1.55
4
299.82
Average Orifice Size
GPM
Pressure Drop
Specific Gravity
CV=
Orifice Size
1.80
These Values are ONLY Approximate and are not to be used for custody transfer calculations.
M / DP^.5 x SG.
300
50
1
42.43
2.05
er 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 DATA
400
80%
16,738,462
13.9
Square Feet Free Air Flow Area
Boiler Horsepower
Boiler Eff.
Boiler Input BTUH
Combustion Air Area Requirements
Authority Oklahoma Boiler and Pressure Vessel Safety Act 1982, Edition 1993
Table 380:25-7-18(b)
Combustion Analysis
Stack Temperature
Ambient Temperature
Net Temperature Rise
Excess O2 Reading
Calculated Efficiency
Calculated Excess Air
This section under construction DO NOT USE THIS FUNCTION!

525
90
435
4%
79.1
Examples Only!
21.1
Examples Only!
Gas Analysis for Natural Gas
%O2
0.0
0.5
1.0
1.5
2.0
% Excess Air
0.0
2.1
4.5
7.1
9.8
% Co2
11.9
11.6
11.3
11.0
10.7
2.5
12.2
10.5
3.0
15.1
10.2
%O2
% Excess Air
% Co2
3.5
18.1
9.9
4.0
21.2
9.6
4.5
24.5
9.3
5.0
28.2
9.0
5.5
32.0
8.7
6.0
36.1
8.5
6.5
40.4
8.2
%O2
% Excess Air
% Co2
7.0
45.0
7.9
7.5
50.2
7.6
8.0
55.5
7.3
8.5
61.2
7.0
9.0
67.8
6.8
9.5
74.6
6.5
10.0
82.0
6.2
%O2
% Excess Air
% Co2
10.5
90.4
5.9
11.0
100.4
5.6
11.5
109.2
5.3
12.0
120.6
5.1
12.5
133.0
4.8
13.0
146.8
4.5
13.5
163.1
4.2
General Notes
High "C" Carbon (soot) need more air.
High "CO" Carbon Monoxide, need more air.
High "CO2" Carbon Dioxide, need LESS air.
Typical Safe Oxygen Standards
High Fire 2.0-4.5% Excess O2
Mid Fire 3.5-5.0% Excess O2
Low Fire 6.0-8.0% Excess O2
Ideal Excess Oxygen Curve for Natural Gas

Firing Rate
20
30
40
50
60
70
80
90
100
Ideal Excess Oxygen Natural Gas
7
6
5
4
3
2
1
0
20
Excess Oxygen %
Ideal O2
6
5.75
4.75
3.6
3.3
3.05
2.8
2.5
2.3
30
40
50
60
70
80
90
Firing Rate
Fuel Oil
Molectular Make-up
Carbon %
Hydrogen %
Oxygen %
Sulfur %
Specific Gravity
Heating Val/Gal
Heating Val/Lb
Air Density @ 70F Lb/Ft^3
2
87.30
12.50
0.00
0.20
0.865
136952
18981.6583
0.0765
Ideal Air = 144*(8.01*Carbon+23.86*(Hydrogen-(Ox/8)+3*Sulfur)/HV/Lb

Ideal Air for this fuel oil per 10,000 Btu =
7.572031
Ideal Combustion Air Ft^3/Gallon =
1355.562
Gallon/Min @ High Fire =
2.037023
Combustion Air for this Oil CFM =
3248.601 at 15% EA
Combustion Air for Gas CFM =
3124.513 at 15% EA
Controller Ratio Factor Oil/Gas Bias = 1.039714
100
Economizer Heat Recovery Calculations
Data Compiled by
David Farthing
Federal Corporation
05/07/2014 09:59:55
Economizer Energy Calculations

Customer
Boiler Type Watertube/Firetube
Fuel Type Gas or Oil
Boiler Rated Horsepower
Boiler Rated Efficiency
Normal Firing Rate (NFR)
Boiler Operating Pressure PSIG
Combustion Make-up Air Temperature
Entering Feedwater Temperature
Fuel Cost per Therm
Hours/Day Operation
Days/Month Operation
Operating Steam Temperature (Saturated)
Firing Boiler Horsepower @ NFR
Boiler Fuel Input @ NFR
BTU Output @ NFR
Net Operating Efficiencies as found
Theoretical Entering Stack Temperature
Actual Observed Stack Temperature
Temperature Rise Across Econ.
Water Flow #/Hr
Gross BTU to Feedwater/Hr
Exiting Feedwater Temperature "F"
Exiting Stack Temperature
Gain in Efficiency
New Net Calculated Thermal Efficiency
Fuel Savings/Hr
Annual Current Cost of Operation
Total Annual Savings w/ Economizer
Annual Cost of Operation w/ Economizer
Economizer Equipment Cost
Economizer Estimated Installation
Actual Economizer Installation Quote
Simple Pay-Back in Years
Xerox OKC
Watertube
W
G
1623
76.00%
36.0%
120
80
240
$0.640
24
28
350.00
584.28
25,727,539.74
19,552,930.20
78.19%
405.00
380.00
140.00
20,157.66
1,101,640.70
294.65
275.00
1.54%
79.74%
$7.05
$1,327,788.03
$56,855.24
$1,270,932.80
$18,700.00
$14,960.00
Equivalent Fuel Cost/1000 CF

$6.40 Per 1000 CF
Fuel
Default
Acid Dewpoint Tables

Dewpoint
Minimum
Stack Temp
Natural Gas
150
250
Minimum
Feedwater
Inlet Temp.
210
#2 Diesel Fuel
Low Sulfur Oil
180
200
275
300
210
220
Application OK, Stack Temp Above Dew Point.

.
0.59
Economizer Efficiencies
Condensing Economizers
80%
85%
85%
77%
75%
70%
60%
Conventional
50%
40%
30%
20%
90%
Condensing
80%
75%
Condensing
68% Efficiency
85%
60%
85%
80%
75%
65%
60%
57%
Vertical
Firetube
65%
77%
75%
55%
68%
60%
55%
50%
45%
80%
70%
Firing Rate
20 60%
60%
4057%
50%
50 50%
6045%
40%
75
90 30%
100
20%
10%
10%
0%
20
40
50
60
Firing Rate
75
90
0%
100
Non-Condensing Economizers
90%
Water Flow Characteristics - Water Hammer

PVC and CPVC Pipe Calculation
Pressure Surge = aV/ 2.31g = Shock Pressure pipe is exposed to.
a=
4660/ (((1+ (Kdi/Et))^.5)
Where
a=
wave velocity, ft/Sec Calculated factor see results below.
p=
pressure surge caused by the sudden change in velocity
V=
maximum velocity change, ft/Sec (V= Q/A) Pipe Area =0.785398 * d^2
g=
acceleration of gravity, 32.2 ft/Sec ^2
k=
fluid bulk modulus, 300,000 psi for water
di=
inside pipe diameter in inches
E=
modulus of elasticity of the pipe,
420,000 psi PVC, 360,000 psi CPVC,
t=
pipe wall thickness, inches
Q=
Flow Through Pipe, GPM
INPUT DATA
Q=
450
di=
4.025
Results for "a"
a=
1021.10
V=
11.26
Results for Pressure Surge
155
PSIG
K=
300000
NOTE: Maximum safe Pressure Surge for PVC pipe = 98 PSIG.
E=
420000
t=
0.145
Steel Pipe Water Hammer Calculations

Source Tube-Turn
Pressure Surge = P + (60V)
Where
P=
Flowing Pressure in PSIG
V=
Flowing Velocity in ft/Sec.
INPUT DATA
Q=
450
P=
100
Results for Pressure Surge
di=
4.025
V=
11.26
775.4471 PSIG
ASCO Solenoid Valve Application Guide

Application
T
Type of Valve
2-Way, 3-Way, 4-Way
Operation of Valve
Universal, NC, NO
Media
Liquid. Gas, Steam
Size of Flowing Pipe
Pressure
O
M
A
V
E
2
NC
L
1
Minimum
10
Atmosphere Valve will Operate In.
Voltage Requirements
24 VDC, 115 VAC
Extras for this application.
Fluid Temperature
Ambient Temperature
TOMSPAVE
25 degree f chiller service
Go to Liquid Valve Sizing Guide

CV From Valve Sizing Guide
2.43
Maximum
15
Clean
Drop Across Valve

5
115
25
90
http://www.ascovalve.com/products/html/valve_selector.htm
STEAM TRAP SELECTION GUIDE
The chart below lists various steam trapping applications and enables the correct choice of trap to be made.
A = First choice
B = Alternate choice
Spirax Sarco
F & T Range
(Float/
Thermostatic)
Application
CANTEEN EQUIPMENT
Boiling Pans-Fixed
Boiling Pens-Tilting
Boiling Pans-Pedestal
Steaming Ovens
Hot Plates
Spirax Sarco
FT/TV/SLR
Spirax Sarco Spirax Sarco
FT/SLR
TD Range
(Float/Thermo- (Float/Steam (Thermostatic with

Lock Release)dynamic)
Steam Lock
Release)
F & T Range
FT/TV/SLR
FT/SLR
TD Range
B1
B
B1
B1
B
A
B
B1
FUEL OIL HEATING

Bulk Oil Storage Tanks
Line Heaters
Outtlom Heaters
Tracer Lines & Jacketed Pipes
A
A
HOSPITAL EQUIPMENT
F & T Range
FT/TV/SLR
FT/SLR
B1
F & T Range
FT/TV/SLR
FT/SLR
B1
Autoclaves and Sterilizers
INDUSTRIAL DRYERS
TD Range
TD Range
Drying Coils (continuous)

Drying Coils (grid)
Drying Cylinders
Multi Bank Pipe Dryers
Multi Cylinder Sizing Machines
B
A
B
A
A
B1
LAUNDRY EQUIPMENT
F & T Range
FT/TV/SLR
FT/SLR
TD Range
A
B1
B
Garment Presses
Ironers and Calendars
Solvent Recovery Units
Tumbler Dryers
PRESSES
B
B
A
A
B1
B1
F & T Range
FT/TV/SLR
FT/SLR
TD Range
Multi Platan Presses

(parallel connections)
Multi Platen Presses
(series connections)
Tire Molds
PROCESS EQUIPMENT
Boiling Pans-Fixed
Boiling Pan-Tilted
Brewing Coppers
Digesters
Evaporators
Hot Tables
Retorts
Bulk Storage Tanks
Vulcanizers
SPACE HEATING EQUIPMENT

Shell & tube Heat Exchangers
Heating Coils & Unit Heaters
Radiant Panels & Strips
Radiators & Convection Cabinet Heaters
Overhead Pipe Coils
STEAM MAINS
Horizontal Runs
Separators
Terminal Ends
Shut Down Drain
(Frost Protection)
TANKS AND VATS

Process Vats
(Rising Discharge Pipe)
Process Vats
(Discharge Pipe at Base)
Small Coil Heated Tanks
(quick boiling)
Small Coil Heated Tanks
(slow boiling)
A1
A
F & T Range
FT/TV/SLR
FT/SLR
TD Range
B
A
B
B1
B
B1
B1
B1
A
A
A
B1
B
A
A1
A
F & T Range
FT/TV/SLR
FT/SLR
TD Range
A
A
A
B
B
B
B
B
B1
B1
B1
B1
F & T Range
FT/TV/SLR
FT/SLR
TD Range
B
A
B
F & T Range
A
B
A1
FT/TV/SLR
FT/SLR
TD Range
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.
e of trap to be made.
Spirax Sarco Spirax Sarco Spirax Sarco
BPT
SM
(Balanced
(Bimetallic)
Pressure
Thermostatic)
BPT
SM
Thermoton
(Liquid
Expansion)
Thermoton
Spirax Sarco
lB Range
(Inverted
Bucket)
lB Range
B
B
A2
A2
A2
B1
B1
B1
A3
BPT
SM
Thermoton
BPT
B
B
SM
Thermoton
B
A
SM
Thermoton
lB Range
B
B1
B
B1
BPT
lB Range
B
B1
B1
B1
B1
BPT
lB Range
SM
Thermoton
lB Range
B
B1
B
BPT
SM
Thermoton
lB Range
B
B1
B1
B1
A
B1
B1
B1
BPT
SM
Thermoton
lB Range
B1
B1
B1
A
A
BPT
B
B1
SM
Thermoton
B2
B2
B2
B
B
B1
B3
BPT
lB Range
SM
Thermoton
lB Range
B
A
Courtesy of Spirax-Sarco
Boiler Application Guide

This application helps you select the vender and type of boiler you might use.
Do you need Steam = S or Water = W
Operating Pressure
Is the load Continuous or Cyclic? Cont./ Cyc.
How Much Steam or Hot Water is needed?
Water Applications
BTU
Operating Temperature (Water)
Steam Flow #/Hr.
Burner Type Power or Atmospheric
Fuel
Oil/Gas or Oil & Gas
What pressure is the Primary fuel
Feed Water System desired?
Boiler Hp Required
Steam
Water
Net BTU Output
s
12
Cont.
Steam Boiler Application

Low Pressure System
0
210
10,000
p
g
1
m
NO ENTRY REQUIRED Water applications only

Please enter Steam Load
Power Burner Selected
Gas
I
Inches/PSI
Start/Stop or Modulating
289.86
0.00
9,700,000
Special Note 1
None
Boiler Types To Look At
Steam Boilers Kewanee Rite or Peerless
Application Note 1
Steam Application
Application Note 2
Low Pressure Steam Application
Application Note 3
none
Application Note 4
Modulating Feedwater System Selected, Price Boiler Accordingly
Application Note 5
IRI Fuel Train Required
Application Note 6
Gas Fired Burner
Application Note 7
Low Pressure Gas Train Required, Check Pressure Drops in Gas Train
15 PSIG
Select a boiler shell with a minimum working pressure of
0
1
1
2
1
6
0
0
0
1
1
2
0
1
Flame Safety Selection Guide

This application helps you answer the questions that need to be answered to select FSG.
Application
Boiler, Oven, Furnace
BTU Input
Operation
Automatic, Semi-Automatic, Manual
Pre-Purge Required
Yes / No
Purge Time Specified By Manufacturer
Purge Time Recommended if not specified.
Pilot Style
Interrupted, InTermittent, Standing
B
3,465,000
A
IRI Codes Required

You have selected Automatic Operation
2.31
I
This Application guide uses gas flow to determine purg

Minutes
Results of your questions.

Use Programming Controller such as a RM7800 or RM7840
Use RM 7800 or 7840 series Programmers on Automatic Boiler Applications
Purging Relay required, RM7800 / 7840 on automatcis, and RM7895 on Semi-Automatics
Use Interupted Amplifier & Relay Combinations
d to select FSG.
as flow to determine purge time.
Suction Piping Calculations
Lookup Table
Federal Catalog
Pages 265-266

System Size
3.068
Specific Gravity for other than 68 deg Water
1.000
1.0 is default for 68 degree water.
Linear Feet Suction Pipe
6.00
Number of 90 Ells
1.00
Number of 45 Ells
0.00
Number of Valves
0.00
Flow Rate Required
GPM
330.00
From Pump work sheet
Pipe Schd
40.00
Friction Loss/100 Ft from look-up tables
26.30
Velocity
14.32
Feet Per Second
339025.26 Flow is no longer laminar!
K Factor 90 Ells
Short
0.8
K Factor 45 Ells
Short
0.25
K Factor Valves
Globe
5.25
Head Velocity V2/2G
3.19
1.58
Feet Head
Formula
2.55
Feet Head
h=K*(V2/2G)
0.00
Feet Head
h=K*(V2/2G)
0.00
Feet Head
h=K*(V2/2G)
Total Head Loss
4.13
Feet of Head Loss
Total Head loss corrected for Specific Gravity
4.13
Discharge Piping Calculations
Lookup Table
Federal Catalog
Pages 265-266

System Size
3.068
Linear Feet Discharge Pipe
100.00
Number of 90 Ells
4.00
Number of 45 Ells
0.00
Number of Valves
1.00
Flow Rate Required
330.00
GPM
Pipe Schd
40.00
Friction Loss/100 Ft
26.30
Velocity
14.32
Feet Per Second
339025.26 Flow is no longer laminar!
K Factor 90 Ells
Short
0.8
K Factor 45 Ells
Short
0.25
K Factor Valves
Globe
5.25
Head Velocity V2/2G
3.19
26.30
Feet Head
Formula
10.20
Feet Head
h=K*(V2/2G)
0.00
Feet Head
h=K*(V2/2G)
16.74
Feet Head
h=K*(V2/2G)
Back Pressure Valve Setting
0
0.00
Feet Head
Total Head Loss
53.24
Feet of Head Loss
Total Head loss corrected for Specific Gravity
53.24
Halliburton Turbin Gas Flow Meter Calculations

Flowing Pressure
Flowing Temperature
Observed Flow Rate
Corrected SCF Flow
15
60
19250
38852.851
Totalizer Divisor
Factory Calibration Factor
Set Totalizer Read Out Divisor to =
Set Totalizer Read Out Divisor to =
Actual Cubic Feet

Standard Cubic Feet
123.42
Actual
61.147
Registers in Standard Cubic Feet
611.472128 Registers in TENTHS of a Standard Cubic Foot
Flow Rate Indicator Full Sacle Frequency Factor

Full Scale Flow Rate
38800
SCF/ Time Base
123.42
Time Base Conversion Factor
3600
Seconds Per Time Base (86400/day, 3600/Hr, 60/Min)
Full Scale Frequency =
659.056
K-Factor
K-Factor =
123.42
61.147
Temperature Effects
Plus or Minus Temperature Change
Calculation for Plus
Percent Effect
Calculation for Minus
Percent Effect
22
Degree F
37274.838
4.062
40570.380
-4.421
Presure Effects
Plus or Minus Presure Change
Calculation for Plus
Percent Effect
Calculation for Minus
Percent Effect
5
PSIG
45387.135
16.818
32318.568
-16.818
BTU Input
Btu/Lb/Oil
Total Lbs/Oil
Total Gal Oil
GPM FLOW
Halliburton Oil Meter Calculator for known Btu Input

#2 Diesel Oil
72000000
136000
529.4118
75.66268
1.261045
ASME formula
Ref: Marks9th, p12-69/12.4.2
Vt=
Vs=
T=
Pa=
Pf=
Po=
NOTE
T=
Vs=
Pf=
Po=
Vt=
05/07/2014 09:59:55
Hot Water Boiler Expansion Tank Sizing Non-Bladder Air Charged Steel Tank
International Mechanical Code 1009.2 and ASME
All Calculations based on 14.73 PSIA Sea Level 40 degree make-up water.
Vt=((0.00041T-0.0466) X Vs) / (Pa/Pf)-(Pa/Po)
Minimum volume of expansion tank, gallons
Volume of water in system less expansion tank, gallons
Maximum Average Operating Temperature of system, degrees 'F'
Atmospheric pressure fixed at 14.73 in this calculation.
Filling pressure (psig).
Maximum operating pressure (psig).
Calculations correct Pa,Pf, and Po to Feet Absolute for you.
System Temperatures between 160 to 280 degrees 'F'.
Average System Operating Temperature, Degrees F

Volume of Water in System, Gallons
Make-up Fill Water Pressure PSIG
Maximum Operating Pressure of System PSIG
Minimum Volume Expansion Tank Required
Boyle's Law Acceptance Factor
Minimum Tank Volume using Boyle's Factor
160
200
45
75
46.09
1.33
62
Plain Steel Tank

This is a Safety Factor used by many Engineers
Measurement, Controllers & Recorders

UNDER CONSTRUCTION - APPLICATION NOT YET AVAILABLE
Measurement
Level, Pressure, Temperature or Flow?
F
L,P,T,F
Flow Measurement uses either a Differential Pressure Transmitter or Flow Meter
Areyou using a Differential Transmitter or a Meter? Selece DT or M in the yellow box below
DT
Differential Transmitters meassure flow in inches water pressure across an orifice plate
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 3
50
RPM 1500
Speed 5
40
RPM 1200
Speed 1
60
Flow
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
Speed 3
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
Speed 5
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
Hz.
50
HP
0
140
118
86
300
260
200
RPM
RPM
RPM
1650
1350
1050
Speed 2
Eff
0
60
75
95
105
111
115
0
45
66
77.5
81
80
70
Hz.
Head
HP
0
4.166667
8.333333
12.5
916.6667
1166.667
1333.333
0
97.22222
81.94444
59.72222
208.3333
180.5556
138.8889
0
34.722222
43.402778
54.976852
60.763889
64.236111
66.550926
Eff
0
45
66
77.5
81
80
70
Hz.
Head
HP
0
3.333333
6.666667
10
733.3333
933.3333
1066.667
0
62.22222
52.44444
38.22222
133.3333
115.5556
88.88889
0
10.288066
12.860082
16.289438
18.004115
19.032922
19.718793
Eff
0
45
66
77.5
81
80
70
0
4.583333
9.166667
13.75
1008.333
1283.333
1466.667
45
Flow
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
Speed 6
Flow
55
Flow
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
Speed 4
Flow
40
55
45
35
Original Pump Curve Data
Head
0
5
10
15
1100
1400
1600
Speed 2
Speed 4
Speed 6
0
3.75
7.5
11.25
825
1050
1200
35
Flow
Point 1
Point 2
Point 3
Point 4
Point 5 BEP
Point 6
Point 7 EOC
0
2.916667
5.833333
8.75
641.6667
816.6667
933.3333
Hz.
Head
HP
0
117.6389
99.15278
72.26389
252.0833
218.4722
168.0556
0
46.21528
57.7691
73.17419
80.87674
85.49826
88.57928
Eff
0
45
66
77.5
81
80
70
Hz.
Head
0
78.75
66.375
48.375
168.75
146.25
112.5
HP
0
25.3125
31.64063
40.07813
44.29688
46.82813
48.51563
Eff
0
45
66
77.5
81
80
70
Hz.
Head
HP
0
47.63889
40.15278
29.26389
102.0833
88.47222
68.05556
0
11.90972
14.88715
18.85706
20.84201
22.03299
22.82697
Eff
0
45
66
77.5
81
80
70
Larrs Hydronic Zone Loads Calculation

Source: Laars Technical Data
All data based on 20 degree 'F' temperature drop across coil.

Minimum 140 degree supply.
Calculating Required Flow Rate in GPM through the Zone.
NET BTU Load of Zone =
27,000
Total Flow Rate to Zone in GPM
2.7
Calculating Pump Head Required to Circulate Loop. (Closed Loop Application)
Longest pipe run in Feet =
250
Total Estimated pumping head required =
15
Calculated Copper Pipe Size Required for Heating Capacity
Copper Pipe Size Required for Zone
0.75
Application)
Boiler Heat Recovery Calculations

Printout 05/07/2014 09:59:55
Data Compiled by
David Farthing
voice 405-728-6709
Blowdown Heat Recovery

Using waste heat from surface blowdown to pre-heat make-up water to DA or boiler.
Boiler Type FT or WT
Steam Boiler Flow PPH at Capacity
TDS of Make-up Water
Desired TDS in Boiler Water
Operating Pressure
Operating Temperature
Boiler Rated Efficiency
Normal Firing Rate
Hours/Day Run Time
Days/Month Run
Make-up as % of Steaming Rate
Blowdown as % of Steaming Rate
Make-up + Blowdown as % of Steaming Rate
Fuel Cost per Therm include transport cost
Deaerator Operating Temperature
Calculated Boiler Horsepower
Fuel Input at rated efficiency & firing rate
Therms per hour at efficiency & firing rate
Calculated Cost to Operate per 30 day billing
Blowdown in PPH
Equivalent Boiler Horsepower Loss
Total Heat Available for Recovery
Equivalent Boiler Horsepower Recovered
FT=Fire Tube, WT=Water Tube

1449 Calculated Boiler Hp.
Total Annual Cost for Blowdown & Make-up

BTU Heat for Recovery to Make-Up
wt
50000
125
4500
165
341
75%
60%
24
30
100%
2.86%
102.86%
$0.67
227
870
38,800.00
388.00
$186,053.76
30,857.14
894.41
6,202,286
185.34
148,854,857
4,465,645,714
53,587,748,571
$356,894.41
3,710,262,857
Total Monthly Savings for Recovery

Total Annual Savings for Recovery
$24,710.35
$296,524.21
Per Billing Period
Cost for Recovery Equipment

Cost for Installation L&M
Months to Payback
$23,000.00
$12,365.00
1.43
Blowdown within normal limits

Equivalent Fuel Cost per 1000 CF
$6.66
At Operating Firing Rate

Cubic Feet/Hr
BTU/Hr.
BTU/Day
BTU/Billing Period
BTU/Year
Per Billing Period
Estimates Only Actual Cost must be quoted.

Estimates Only Actual Cost must be quoted.
Project Payback within normal limits.
David Farthing's Tech Stuff
05/07/2014 09:59:55
Relief Valve Sizing and Selection

User Data ABC Company
1234 Powerhouse Lane
Smokin, PA 123456
Boiler Data
Steam (S) or Hot Water (W)?
MAWP
Operating Pressure
Btu Input
Steam PPH Output
USE STEAM DATA ONLY
How Many Safety Valves
Safety Valve Port Size
Port 1
Port 2
Port 3
Steam Recommendations
Safety Valve #1
Safety Valve #2
Safety Valve #3
Hot Water Recommendations
Relief Valve #1
Relief Valve #2
Relief Valve #3
S
250
160
12,500,000
10,309
10,000,000
3
2
2
2
PPH Set Pressure
3,402
192
3,402
192
3,402
192
Btu/Hr
-
Set Pressure
192
192
192
NOTES:
1] Use only water or steam input data.
2] MAWP is the Maximum Allowable Vessel Pressure NOT the Operating Pressure
3] Recommended "Set Pressure" is 20% Above Operating Pressure.
4] Always use a Drip-Pan Ell on Steam Safety Valve discharge piping.
Relief Valve Data
Data Compiled by
David Farthing
Voice 405-728-6709
Printout
05/07/2014 / 09:59:55
David Farthing's TechStuff
The effect of Boiler Operating Pressure on System Performance

Firetube Boiers - Saturated Steam
Designed Velocity Across the Boiler Outlet
Design Velocity in the distribution line

1739
Boiler Outlet Diameter
Distribution line Diameter
Current Operating Pressure
260
Feedwater Temperature
227
Steam Volume Cft/#
1.69
Boiler Outlet Velocity
8608.0777
Distribution Velocity Ft./Min.
8
4842.0437
Distibution Velocity OK
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
Steam Volume Cft/#
2.14
New Boiler Outlet Velocity
10900.1694
Ft./Min.
8
6131.3453
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
Days/Month/Operation
$$ Saved or Expended/Mth.
Feedwater Pump vs. Relief Valve Performance Requirements
Design
$$ Saved or Expended/Yr.
At New
Boiler Horsepower
1739
Maximum Allowable Working Pressure
350
Normal Operating Pressure
260
200
Minimum Safety Relief Valve Setting
299
230
732
563
Minimum Pump Head Requirements

Feet Head
Pressure Drop Across Feed Valve
50
See Liquid Valve Calcs.
Feedwater Piping Losses - PSI
12
See Friction Losses in Piping.
Economizer Losses-PSI
Pump Discharge Pressure PSI

Minimum Pump Flow Capacity
GPM
384
See Manufacturer's Data sheet.

311
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.
20
22
Misapplication
Misapplication
The effect of Boiler Operating Pressure on System Performance

Watertube Boiler - Saturated Steam
Designed Velocity Across the Boiler Outlet
Pounds/Hr Steam Flow
Design Velocity in the distribution line
30000
870
Boiler Outlet Diameter
Current Operating Pressure
275
Feedwater Temperature
227
Steam Volume Cft/#
1.6
Boiler Outlet Velocity
4075.1353

Distribution Velosity OK
Ft./Min.
Nozzle Velocity OK
New Velocity Across the Boiler Outlet
New Velocity in the distribution line
New Operating Pressure
125
Steam Volume Cft/#
3.23
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 f
6,422
BTU @ Current Pressure
Btu Differential
4,593
BTU @ New Pressure
Boiler Horsepower
1,829
Btu @ Horsepower/Hr Differential
Cost of Fuel (Decather

Hrs/Day Operation
$$ Saved or Expended
$$ Saved or Expended
Feedwater Pump vs. Relief Valve Performance Requirements
Design
At New
Boiler Horsepower
870
Maximum Allowable Working Pressure
350
275
125
Minimum Safety Relief Valve Setting
316
144
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.
Minimum Pump Head Requirements
Economizer Losses-PSI
Pump Discharge Pressure - PSI

Minimum Pump Flow Capacity
Distibution Velocity OK
377
GPM
75.21
See Manufacturer's Data sheet.

194
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
Temperature
Boiler Operating Pressure

0
25
50
75
100
125
150
Additional BTU Input Required to Bring Feedwater to Steami

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
Pressure
PSIG
25
IN VAC
n the distribution line

14
748.4942
the distribution line

14
1511.0227
Theoretical Savings from Lowering Operating Pressure

Btu Differential
Boiler Horsepower
Cost of Fuel (Decatherm)
1,829
869.5652174
$5.29
Hrs/Day Operation
20
22
$$ Saved or Expended/Mth.
$3,700.88
$$ Saved or Expended/Yr.
$44,410.61
Temperature
Deg F
134
Heat in Btu/lb.
Sensible
102
20
15
10
5
0
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
22
162
179
192
203
212
215
219
222
224
227
230
232
233
237
239
244
248
252
256
259
262
129
147
160
171
180
183
187
190
192
195
198
200
201
205
207
212
216
220
224
227
230
24
26
28
30
32
34
265
268
271
274
277
279
233
236
239
243
246
248
36
38
40
42
282
284
286
289
251
253
256
258
ater Temperature
ng Pressure
175
200
225
250
Bring Feedwater to Steaming Temperature

11,459
11,838
12,149
12,459
9,734
10,113
10,424
10,734
8,871
9,251
9,561
9,872
8,009
8,388
8,699
9,009
7,146
7,526
7,836
8,147
6,284
6,663
6,974
7,284
5,870
6,249
6,560
6,870
5,421
5,801
6,111
6,422
5,249
5,628
5,939
6,249
4,904
5,283
5,594
5,904
4,559
4,938
5,249
5,559
4,214
4,593
4,904
5,214
3,869
4,248
4,559
4,869
3,696
4,076
4,386
4,697
3,524
3,903
4,214
4,524
44
46
48
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
291
293
295
298
300
307
312
316
320
324
328
331
335
338
341
344
347
350
353
356
358
361
363
366
368
371
373
375
377
380
382
384
386
388
390
392
394
396
397
399
401
260
262
264
267
271
277
282
286
290
294
298
302
305
309
312
316
319
322
325
328
330
333
336
339
341
344
346
348
351
353
355
358
360
362
364
366
368
370
372
374
376
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
450
500
550
600
650
700
750
800
403
404
406
408
409
411
413
414
416
417
418
420
421
423
425
426
427
429
430
432
433
434
435
437
438
440
441
442
443
445
446
447
448
460
470
479
489
497
505
513
520
378
380
382
383
385
387
389
391
392
394
395
397
398
400
402
404
405
407
408
410
411
413
414
416
417
419
420
421
422
424
425
427
428
439
453
464
473
483
491
504
512
900
1000
1250
1500
1750
2000
2250
2500
2750
3000
534
546
574
597
618
636
654
669
683
696
529
544
580
610
642
672
701
733
764
804
Heat in Btu/lb.
Latent
Total
1017
1119
Specific
Volume
Cu. ft.
per lb.
142
1001
990
982
976
970
968
966
964
962
960
959
957
956
954
953
949
947
944
941
939
937
1130
1137
1142
1147
1150
1151
1153
1154
1154
1155
1157
1157
1157
1159
1160
1161
1163
1164
1165
1166
1167
73.90
51.30
39.40
31.80
26.80
25.20
23.50
22.30
21.40
20.10
19.40
18.70
18.40
17.10
16.50
15.30
14.30
13.40
12.60
11.90
11.30
934
933
930
929
927
925
1167
1169
1169
1172
1173
1173
10.80
10.30
9.85
9.46
9.10
8.75
923
922
920
918
1174
1175
1176
1176
8.42
8.08
7.82
7.57
917
915
914
912
909
906
901
898
895
891
889
886
883
880
878
875
873
871
868
866
864
861
859
857
855
853
851
849
847
845
843
841
839
837
836
834
832
830
828
827
825
1177
1177
1178
1179
1180
1183
1183
1184
1185
1185
1187
1188
1188
1189
1190
1191
1192
1193
1193
1194
1194
1194
1195
1196
1196
1197
1197
1197
1198
1198
1198
1199
1199
1199
1200
1200
1200
1200
1200
1201
1201
7.31
7.14
6.94
6.68
6.27
5.84
5.49
5.18
4.91
4.67
4.44
4.24
4.05
3.89
3.74
3.59
3.46
3.34
3.23
3.12
3.02
2.92
2.84
2.74
2.68
2.60
2.54
2.47
2.41
2.34
2.29
2.24
2.19
2.14
2.09
2.05
2.00
1.96
1.92
1.89
1.85
823
822
820
819
817
815
814
812
811
809
808
806
805
803
802
800
799
797
796
794
793
791
790
789
788
786
785
784
783
781
780
778
777
766
751
740
730
719
710
696
686
1201
1202
1202
1202
1202
1202
1203
1203
1203
1203
1203
1203
1203
1203
1204
1204
1204
1204
1204
1204
1204
1204
1204
1205
1205
1205
1205
1205
1205
1205
1205
1205
1205
1205
1204
1204
1203
1202
1201
1200
1198
1.81
1.78
1.75
1.72
1.69
1.66
1.63
1.60
1.57
1.55
1.53
1.49
1.47
1.45
1.43
1.41
1.38
1.36
1.34
1.33
1.31
1.29
1.28
1.26
1.24
1.22
1.20
1.19
1.18
1.16
1.14
1.13
1.12
1.00
0.89
0.82
0.75
0.69
0.64
0.60
0.56
666
647
600
557
509
462
413
358
295
213
1195
1191
1180
1167
1151
1134
1114
1091
1059
1017
0.49
0.44
0.34
0.23
0.22
0.19
0.16
0.13
0.11
0.08
05/07/2014 / 09:59:56
'c' Federal Corporation
The effect of Feedwater Temperature on Boiler Horsepower

Customer
Contact
Plant Location
Boiler Mfg
Boiler Type
Boiler Type Watertube/Firetube

Name Plate Rated Boiler BHP
Calculated BTU Input for boiler type
Observed Feedwater Temp
Hours Day Operated
Days per Month
Calculated Bhp BTU Output Bhp
Calculated Efficiency (Input/Output)
Calculated Bhp
Rated Steam PPH at 100% Firing
BTU addition for Operating Pressure
BTU Lost/Gained Per Hour
Boiler HP Lost or Gained/ Hr.
Net Boiler Horsepower
Net Steam Output
Net Efficiency
Percent Increase/Decrease Energy Use
Percent Increase/Decrease BHP
My Boiler Plant
Plant Eng
Chickasha, OK
Kewanee H3S500G
Fire Tube
Factory Design
F.
500
125
20,968,470.92
212
10
22
16,732,500.00
79.80
500.00
17250
2,520,750
0.00
0.00
500
17250.0
79.80
0.00
0.000%
FW Temp
Deaerator or
As Observed First Recovery
180
227
10
10
22
22
3,159,000
-552,000.00
(16.49)
484
16680.9
77.17
-2.63%
-3.299%
2,296,500
258,750.00
7.73
508
17516.8
81.03
1.23%
1.546%
Typical
Economizer
252
10
22
1,865,250
690,000.00
20.62
521
17961.3
83.09
3.29%
4.124%
Data Compiled by
David C. Farthing
Voice 405-728-6709
Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature

Feedwater
Boiler Operating Pressure
Temperature
0
25
50
75
100
125
150
175
200
225
250
Additional BTU Input Required to Bring Feedwater to Steaming Temperature
50
6,559 7,664 8,733 9,492 10,113 10,631 11,079 11,459 11,838 12,149
12,459
100
4,834 5,939 7,008 7,767 8,388 8,906 9,354 9,734 10,113 10,424
10,734
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
9,009
175
2,247 3,351 4,421 5,180 5,801 6,318 6,767 7,146 7,526 7,836
8,147
200
1,384 2,489 3,558 4,317 4,938 5,456 5,904 6,284 6,663 6,974
7,284
212
970 2,075 3,144 3,903 4,524 5,042 5,490 5,870 6,249 6,560
6,870
225
1,626 2,696 3,455 4,076 4,593 5,042 5,421 5,801 6,111
6,422
230
1,454 2,523 3,282 3,903 4,421 4,869 5,249 5,628 5,939
6,249
240
1,109 2,178 2,937 3,558 4,076 4,524 4,904 5,283 5,594
5,904
250
764 1,833 2,592 3,213 3,731 4,179 4,559 4,938 5,249
5,559
260
419 1,488 2,247 2,868 3,386 3,834 4,214 4,593 4,904
5,214
270
74 1,143 1,902 2,523 3,041 3,489 3,869 4,248 4,559
4,869
275
971 1,730 2,351 2,868 3,317 3,696 4,076 4,386
4,697
280
798 1,557 2,178 2,696 3,144 3,524 3,903 4,214
4,524
D ata Co mpil ed by
D avid Farthi ng
Voi ce 405 -72 8-67 09
05/07/2014 09:59:56
The effect of Scale on Heat Transfer in Boilers

Ad ditio nal Heat In pu t Req uired Du e to C alciu m Salt Scale
Watertub e B oiler F ull Circum ferance T ub e C on tact
Ca lc ium Sca le Thickne ss = Inch
0.60
0.50
0.40
0.30
0.20
0.10
0.00
5%
10%A dditiona l Hea t Input

15% Reqired to Ma ke
30%
Boile r Horsepowe r66%
Sourc e: Cooper Tool Mfg.
150%
Sca le vs. H eat Tra nsfer
05/07/2014 09:59:56
D ata Co mpil ed by
D avid Farthi ng
Voi ce 405 -72 8-67 09
05/07/2014 09:59:56
D ata Co mpil ed by
D avid Farthi ng
Voi ce 405 -72 8-67 09
1 Grain = 17 PPM of soluable hardness

Principle
Benefit
Eliminate
Hardness
No
Scale
Hardness Test
SOAP TEST
1 Drop = Soft (<1 Grain)
2 Drops = Hard (1-2 Grains)
3 Drops = Hard (2-3 Grains)
Run Sample COLD
Eliminate
Oxygen
HACH 5B REAGENT
Pink = Hard
Blue = Soft <1 Grain
Each drop of reagent = 1 Grain
No
Corrosion
Sulfite Residual Test

1 Drop = 10 ppm
Desired 30-60 ppm
Run Sample HOT
Run this TEST FIRST!
Add
Alkalinity
Soft
Solids
Add
Polymer
Soft
Solids
Control TDS
"Total
Disolved Solids"
Pure Steam
Boost
Condensate pH
Eliminate
Steam Line and
Condensate Line
Corrosion
Dr. Mac Brockway's Boiler Water Chemistry
(Contact Dr Mac at 405-737-3740 for the Companion White Paper that accompanies this char
(Dr. Brockway is a Phd Chemical Engineer specializing in water chemistry.)
Steam Boiler (<300 PSI) Water Treatment

PreTreatment
Water
Softner
Removes Calcium
and Magnesium
salts only
Deareate
or
Hot Feedwater
Internal
Treatment
Phosphate (PO4)
Testing
What You Want
Precipitation
or
Chelant
Solubilizer
Treat at the Feedwater Tank
Hardness = 0
PO4 =30-60 ppm Great!
Sulfite
Oxygen = 0
SO3 = 30-60 ppm Great!
or
Chelant = 10-30 ppm
Treat at the Feedwater Tank

May be injected directly into the boiler
but don't forget the feedwater tank
N/A
NaOH
Sodium
Hydroxide
OH = 300-600 ppm
pH = 11.0 - 12.0
pH = 11.56 Perfect
N/A
Polymer
Normal
Poly = 10-50 ppm
Reverse Osmosis
or
De-Ionizer
Blowdown
Manual
and/or
Automatic
Nutralizing
Amine
Volatile Chemical
travels with steam
TDS = 3,000 - 5,000ppm

TDS <= 3,000 Great!
uMhos = 4,000 - 6,0000
De-Alkalizer
or
Reverse Osmosis
Condensate
pH = 8 - 9.0 Great!
Iron Test <0.1ppm
Water Chemistry
White Paper that accompanies this chart)

specializing in water chemistry.)
Water Treatment
Ca++
Want to Prevent
Chemistry
HARDNESS
+CO3 =
CaCO3
Calcium + Carbonate = Calcium Carbonate

Slow Reaction results in hard formation
Fe + 1/2O2 = FeO
Iron Metal + Oxygen = Rust
Hard Crystalline solids

Avoid runing pH too low this
will result in Hard Calcium Phosphate
Hard Crystalline solids
Prevent Boiler Water Carry Over

Priming and Impure or Wet Steam
Wet Steam robs energy from your
steam line!
CO2 + H20 = H2CO3 (Carbonic Acid! pH=4-6)
H2CO3 + Fe = FeCO3 (Iron Scale!)
Rot out distribution and condensate lines!
Action
Chemistry YOU WANT
SOFT
3Ca++ + 2PO4 = Cay(PO4)2
Calcium + Phosphate = Soft Sludge
Fast reaction results in a soft formation
2SO3
+ O2
Comment
Good Heat Transfer
Lower Energy Cost
Longer Boiler life
= 2SO4
Sulfite + Oxygen = Sulfate
Longer Boiler Life
Elevate pH
OH = Elevated Alkalinity
Result Soft Solids
Save Fuel $$
Clean Boiler
Good Heat
Transfer
Polymer + Hard Soild = Soft Sludge
Clean Boiler
Pure Steam
and
Solids Removal
Clean Boiler
Good Heat Treansfer
Saved Fuel $$$
Amine(A) + H2CO3 = A~H+HCO3 (pH=8-9)

Amine(A) + H2O = A~H+OH (pH = 8-9)
Amine combines with H2CO3 to nutralize
No Rust or iron
brought back to boiler
by condensate.
Longer distribution
line life.
the acid and raise the pH to 8-9 and

protects condensate lines.
ABMA Water Chemistry Guidelines
Go Back To
DR.MAC
05/07/2014
American Boiler Manufacturers Association **

Boiler Water Chemistry Guidelines
** As adopted from the American Society of Mechanical Engineers
Boiler Water Chemical Limits
Boiler Operating Pressure (psig)
15
150
300
600
900
1200
1500
Parameter
Chemical Concentration (mg/liter) PPM
TDS (Unnutralized) 700-2800 700-3500 700-3500 500-2500 150-750 150-500 150-300
Phosphate (PO4)
30-60
30-60
30-60
20-40
15-20
10-15
5-10
Hydroxide (CaCO3)
300-400
300-400
250-300 150-200 120-150 100-120 80-100
Sulfite
30-60
30-60
30-40
20-30
15-20
10-15
5-10
Silica (SiO2)
150
100
50
30
10
5
3
Total Iron (Fe)
10
10
5
3
2
2
1
Organics
70-100
70-100
70-100
70-100
50-70
50-70
50-70
NOTES:
TDS - Unnutralized TDS readings are affected by pH. Use the pH Correction table below to correct TDS to sample pH.
The Higher number in the TDS column represents the maximum limits for safe boiler operation at the indicated operating pressure.
Depending on publication some authorities allow for upto 4000 TDS in Water Tube boilers operating from 0-150 psig.
TDS Error due to High pH
If Nutralizing Agents are not available then Subtract the 'Error' number from the TDS reading to arrive at 'Neutralized TDS' number.
pH
Error (High)
9.0
0
9.5
10
10.0
25
10.5
60
11.0
150
11.2
220
11.4
310
11.6
460
11.8
700
12.0
1050
12.2
1500
12.4
2400
12.6
3800
12.8
6100
13.0
10,000
EXAMPLE 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)
* NOTE a pH of 9.0 is considered LOW. Normal Operating pH is recommended to be at 11.56.
Compiled by
David Farthing
405-249-9324
Boiler / Burner Data Sheet Print Out 05/07/2014

Today's Date
12/6/2004
Certificate Exp. Date
Company Name
SW Medical
Location
4401 S. Western
City
State OK
Zip
Oklahoma City
73109
Boiler MFG Name Burnham
Model No.
LN5P-400-GO-IC
Serial No.
72566/ NB#28696 Yr Blt 2004
Hot Water
Steam 150 PSI
Operating Pressure (PSI)
80
Date Installed
11/20/2004
Insurance Carrier
FM Global
Inspector No.
Burner MFG Name

Industrial Combustion
Model No.
LNDLG-210P-30
Serial No.
41966-1
Atmosperic (Natural Draft)
NA
Power/Mechanical Draft
30 HP w/ FGR
BTU/Hr. Input
16738 MMBTU/Hr
Power & Mechanical Draft Burners
Atmospheric (Natural Draft) Burners
120 East Main Street -- Post Office Box 26408

Oklahoma City,
Oklahoma 73126
(800) 289-3331 (405) 239-7301
Fax (405) 232-5438
INPUT in BTU/HOUR
ASME SAFETY STANDARDS No. CSD-1
Less Than
400,000
400,000
to
CONTROL & SAFETY DEVICES GUIDELINES
(Including
2,500,000
Modular Boilers
FOR AUTOMATICALLY GAS FIRED BURNERS
w/ max. input of
NOT
400,000)
INSTALLED
NOT INSTALLED
System Control Specifications
REQUIRED
2,500,000
to
5,000,000
INPUT in BTU/HOUR
5,000,000
to
12,500,000
Less Than
400,000
400,000
to
(Including
2,500,000
Modular Boilers
w/ max. input of
400,000)
2,500,000
to
5,000,000
5,000,000
to
12,500,000
Associated
Standard
Paragraph
INTERLOCKS / LIMITS
NEXUS
NX1030150PSI
Transmitter
Approved Operating
Controllers Steam Boilers
(Pressure)
NR
Hot Water Boilers

(Temp)
High Limits
Steam boiler (Pressure)
(Manual Reset)
Honeywell
L404C1162
NR
NEXUS
NX1030 Gas
PSI
Transmitter
Hot Water Boilers

(Temp)
(Manual Reset)
Required
(Note 1)
Required (Note
Required (Note 1)
1)
Required
(Note 1)
Required
(Note 1)
Required
(Note 1)
Required
(Note 1)
Required
(Note 1)
CR-220(a)(1)(2) CW310(b)
CW620(b)
Required
(Note 2)
Required (Note
Required (Note 2)
2)
Required
(Note 2)
Required
(Note 2)
Required
(Note 2)
Required
(Note 2)
Required
(Note 2)
CR-220(b)(1)(2) CW410(b)
CW-640(b)
Required
(Note 3)
Required (Note
Required (Note 3)
3)
Required
(Note 3)
Required
(Note 3)
Required
(Note 3)
Required
(Note 3)
Required
(Note 3)
CR-220(a)(1)(3) CW310(c)
CW-620(a)
Required
(Note 4)
Required (Note
Required (Note 4)
4)
Required
(Note 4)
Required
(Note 4)
Required
(Note 4)
Required
(Note 4)
Required
(Note 4)
CR-220(b)(1)(3) CW410(c)
CW-640(a)
CF-162(a), CF-910,
CR-410 Table CF1,CF-2
High Gas Pressure

(MANUAL RESET)
NEXUS
NX1030 Gas
PSI
Transmitter
Low Gas Pressure

(Manual Reset)
ASCO
T300417-22
Valvew/OTS
Valve Seal Overtravel

Interlocks
NEXUS 4100
w/NX20-1 Air
Position
Indicator
High Fire Switch
NEXUS 4100
w/NX10-1
Gas/Oil
Position
Indicator
Low Fire Switch
NEXUS 4100
w/Antun
SMD8024 Dual
Point Air
Switch
Supervised Purge Air
NEXUS 4100
w/Antun
SMD8024 Dual
Point Air
Switch
Proven Combustion Air
Action on Loss of Combustion

Air
LOCKOUT
(Note 5)
Required
Required
Required
Required
(Note 5)
Required
Required
Required
Required
(Note 6)
(Note 7)
(Note 10)
(Note 10)
CF-210(a)(2)
CF910, CR-410,
Tables CF-1, CF-2
Required
Required
CF-610
Required
(Note 10)
Required
(Note 10)
CR210(a)(b)(c)
Tables CF-1, CF-2
(Note 6)
(Note 8)
(Note 10)
CF-162(a), CF-910,
CR-410 Table CF1,CF-2 CF-180(b)(2)
(3)
(Note 9)
(Note 9)
Required
Required
Required
(Note 9)
Required (Note 9)
Required
(Note 9)
Required
Required
Required
Required
Tables CF-1, CF-2

CR-1, CR-2
(Note 17)
(Note 18)
Safety Shutdown
Safety
Shutdown
Tables CF-1,
CR-1, CR-2
Required
(Note 10)
11361 East 61st. Street, Broken Arrow, Oklahoma

74012
(800)955-1918,
Tulsa (918) 955-1918
Fax (918)249-9014
Low Water Fuel Cutoffs

MM 193-D First
LWCO Recycle
MM750-MT
LWCO MR
NR
NR
(2) Required
(Note 11)
Hot Water Boilers

(MANUAL RESET)
(1) Required
(Notes
14
& 15)
(1) Required
(1) Required
Forced Circulation
(MANUAL RESET)
(Note 16)
(Note 16)
PILOT VALVE TRAIN

ASCO 8211
DBB
Ball
MAXATROL
325-3
(2)
(2) Required (Note
Required
11)
(Note 11)
(2) Required
(Notes
11,12, 13)
(2)
Required
(Note 11)
(2) Required (2) Required

(Note 11)
(Note 11)
CE-120(a)(b) CR210(a)(b), CW610(a)(b)
(1)
Required
(1) Required
(Notes
14
& 15)
(1)
Required
CR-210(c),
CW130(a),
CW630(a)(b)
(Note 16)
(Note 16)
(Note 16)
(Note 16)
(Note 16)
(Note 16)
CR-210(e),
CW210(a)(b)
CR-180(C)
(Note 12)
Approved Safety Shutoff

Valve(s)
Required
Required
Required
Required
Required
Required
Required
Required
Manual Shutoff Valve(s)
Required
Required
Required
Required
Required
Required
Required
Required
CF-150(C)
CF-110(a)(1), UL79525 15,
CF180, cf-161(b) Figs B1, 2,3,4
Gas Pressure Regulator
Required
Required
Required
Required
Required
Required
Required
Required
(1) Required
(2) Required
(Note 19)
(1) or (2) Required

(Note 20)
(2)
Required
(Note 21)
(1) Required
(2)
Required
(Note 19)
(1) or (2)
Required
(Note 20)
(2) Required
(Note 21)
(1) or (2)
(1) or (2) Required
Required (Note
(Note 22)
22)
(1) or (2)
Required
(Note 22)
(1) or (2)
Required
(Note 22)
(1) or (2)
Required
(Note 22)
(1) or (2)
Required
(Note 22)
MAIN VALVE TRAIN

ASCO
V762LCA DBB
YES
YES
MAXATROL
210G
Approved Safety Shutoff

Valve(s)
Manually Operated Leak Test
Valve(s)
Manual Shutoff Valve(s)
Gas Pressure Regulator
(1) Required
Required
(2) Required
Required
(2) Required
Required
(2)
Required
(1) Required
(2)
Required
Required
Required
Required
Required
Required
Not Permitted
Not
Permitted
Not
Permitted
Not
Permitted
(Note 10)
(Note 10)
(Note 10)
CF-180(b)
(1)(2)(3)
CF-150(d)
CF-150(b)(d)
ANSI221.13 1114
CF-160, CF-161(b),
ANSI221.13 1.15.1
Fig. B-1, 2,3, 4
APPROVED SAFETY CONTROL SPECIFICATIONS

NO
90 Sec
ion
(2) Required
(Notes 11,12,
13)
Low Water 2 Required

(1
w/MANUAL RESET)
Rebuilt Flame Safeguard /

Burner Control
Prepurge Timing
Not Permitted
Not Permitted
Not Permitted
Not
Permitted
90 Seconds
(Note 8)
(Note 9)
(Note 9)
CF-210(a)(1)(2)(c)
Tables CF-1, CF-2
CR-1, CR-2
Federal Corporation
4
YES
YES
High Fire Purge Proving

Circuit
4 Changes
4 Changes
4 Changes
(Note 8)
Required
Required
Required
Required
Low Fire Start Circuit
CF-210(a)(1)(2)(c)
Tables CF-1, CF-2
CR-1, CR-2
(Note 10)
CF-210(a)(1)(2)(c)
Tables CF-1, CF-2
(Note 10)
(Note 10)
Required
Required
CF-610
NO
Continuous Pilot
Optional
Optional
Not Permitted
Not
Permitted
Optional
Optional
Not
Permitted
Not Permitted
Tables CF-1, CF-2

CR-1, CR-2
NO
Intermittent Pilot
Optional
Optional
Not Permitted
Required
Optional
Optional
Optional
Optional
Tables CF-1, CF-2

CR-1, CR-2
YES
YES
10 Sec
Interrupted Pilot
Optional
Optional
Not Permitted
Not
Permitted
Optional
Optional
Optional
Optional
Tables CF-1, CF-2

CR-1, CR-2
Proved Pilot
Required
(Note 25)
Required (Note
25)
Required (Note
25)
Required
(Note 25)
Required
(Note 25)
Required
(Note 25)
Required
(Note 25)
Required
(Note 25)
CF-320(a)(1)
15 Seconds
(Note 26)
Not Permitted
10
Seconds
Maximum
(Note 31)
None
10 Seconds
Tables CF-1, CF-2

CR-1, CR-2
15 Seconds
Not Permitted
Not
Permitted
15
Seconds
10 Seconds
10
Seconds
Pilot Flame Establishment

Period (PFEP)
Continuous Pilot
Intermittent Pilot
Interrupted Pilot
10 SEC
Main Flame Establishment

Period (MFEP)
Continuous Pilot
None
15
15
Seconds
Seconds
None
15 Seconds
(Note 27)
10
Seconds
10
Seconds
Maximum
(Note 31)
Intermittent Pilot
Interrupted Pilot
15 Seconds
Maximum
15 Seconds
Maximum
10 Seconds
Maximum (Note
31)
Direct Ignition
15 Seconds
Maximum
4 Seconds
Maximum
4 Seconds
Maximum (Note
32)
15
15 Seconds 10 Seconds
(Note 26)
(Note 26)
15 Seconds
10
Seconds
10 Seconds
Tables CF-1, CF-2

CR-1, CR-2
Seconds 15 Seconds
10
Seconds
10 Seconds
Tables CF-1, CF-2

CR-1, CR-2
None
(Note 28)
(Note 29)
(Note 30)
Tables CF-1, CF-2

CR-1, CR-2
15 Seconds
Maximum
(Note 28)
(Note 29)
(Note 30)
Tables CF-1, CF-2

CR-1, CR-2
15 Seconds
Maximum
(Note 28)
(Note 29)
(Note 30)
Tables CF-1, CF-2

CR-1, CR-2
15 Seconds
Maximum
Tables CF-1, CF-2

CR-1, CR-2
Supervised Main Flame
(Note 34)
Required
Required
Required
(Note 34)
(Note 34)
(Note 33)
Required
CF-310(d)
(1)(2)(3)
(4)
Flame Failure Response

Time (FFRT)
4 Seconds
Maximum
(Note 36)
4 Seconds
Maximum
4 Seconds
Maximum
4 Seconds
Maximum
4 Seconds
Maximum
(Note 35, 36)
4 Seconds
Maximum
4 Seconds
Maximum
4 Seconds
Maximum
Tables CF-1, CF-2

CR-1, CR-2
Action on Flame Failure
Safety
Shutdown
(Note 37,38)
Safety
Shutdown (Note
39)
Safety Shutdown
Safety
Shutdown
Safety
Shutdown
(Note 37,38)
Safety
Shutdown
(Note 40)
Safety
Shutdown
(Note 40)
Safety
Shutdown
(Note 40)
Tables CF-1, CF-2

CR-1, CR-2
Action On Limit Opening
Safety
Shutdown
Safety
Shutdown
Safety Shutdown
Safety
Shutdown
Safety
Shutdown
Safety
Shutdown
Safety
Shutdown
Safety
Shutdown
CF-162(a), CR-220(a)
CW-130(d), CE310(c), CW-410(c),
CF-910
FOOTNOTES:
Print Out 05/07/2014
Prepurge Air Changes

Required
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
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.
10
Units equipped with automatic

operating air shutters or
dampers which are closed or
positioned to restrict air when
burner is not firing, shall
provide means to open the air
shutter or damper the high
fire position for at least 90
seconds prior to light off.
11
One of the two low-water fuel

cutoffs may be a combined
feeder / cutoff device.
12
For low pressure steam units

with inputs of 400,000 Btu/Hr.
or less, only one low-water
fuel cutoff is required gravity
return units installed in
residences as defined by the
authority having jurisdiction.
13
For modular low pressure

steam boilers, each module
shall be equipped with an
automatic low-water fuel
cutoff. The assembled
modular boiler shall have a
second low-water cutoff.
Operation of this low-water
fuel cutoff shall shut off the
fuel supply to all modules.
14
Except those installed in

residences (as defined by the
authority having jurisdiction).
15
An assembled modular boiler

shall be protected by a lowwater fuel cutoff located so
that it will detect a low-water
condition before the level falls
below the lowest safe
waterline in any module.
Operation of the low-water
fuel cutoff shall shutoff the
fuel to all modules.
16
In Lieu of the requirements for

low-water fuel cutoff in a
water tube or coil-type boiler
requiring forced circulation,
they shall have an accepted
sensing device to prevent
burner operational a flow rate
inadequate to protect the
boiler from overheating.
Where there is a definitive
waterline, a low-water fuel
cutoff shall be provided in
addition to the sensing
device. Functioning of the
low-water fuel cutoff shall
cause a safety shutdown.
17
Close main valve and recycle.
18
One recycle for piloted

systems.
19
Two safety shutoff valves in

series. May be in single
control body.
20
Two safety shutoff valves in

series on one safety shutoff
valve with valve seal
interlock.
21
One safety shutoff valve to

incorporate valve seal
interlock.
22
When two safety valves are

provided in the fuel train, an
additional leak test valve is
required so that each safety
shutoff valve may be tested
independently of the other.
23
Gas pressure relief valves,

where required, shall be
located upstream of all
operating and safety controls
and downstream of the gas
pressure regulator I both the
main and pilot gas supply
systems. The relief valve in is
to directed to the atmosphere.
24
Water level control alarms,

when used, shall be distinctly
audible above the ambient
noise level and may be used
in conjunction with indicating
lights.
25
26
When pilot is used.

Initial start only.
27
Pilot only: 15 seconds

maximum if interrupted pilot is
used.
28

maximum if interrupted pilot is
used. 25 to 30 seconds if
safety shutoff valve has full
opening.
29

maximum for modulating or
high-low firing.
30

maximum.
31
Interrupted pilot only.
32
Maximum input at light off

shall not exceed 2,500,000
Btu/Hr.
33
Required with modulating or

high-low firing.
34
Required if interrupted pilot.
35
If ignition system includes a

relight feature, the relight
attempt shall be initiated
within 0.8 seconds upon loss
of flame.
36
For power, and mechanical

draft, burner and natural draft
burners with inputs less than
400,000 Btu/Hr. and
continuos pilot, 180 seconds
maximum for pilot flame
failure.
37
If system has intermittent

pilot, wait 5 minutes before
resetting ignition system
(Instructional requirement).
38
If system has interrupted pilot

or direct ignition and the
ignition includes a relight
feature, the relight attempt
shall be initiated within 0.8
seconds of loss of flame.
39
A single recycle is allowed on

for
40
Or, recylce once after 5

minute time delay.
41
Select proper safety control

according to system
requirements.
Data Compiled by
David Farthing
Voice 405-728-6709
Date of Printout
05/07/2014 / 09:59:56
TechStuff - Boiler Benchmarking

BENCHMARKING A BOILER
Customer
Contact
Address
City/State/Zip
Date
Boiler Mfg
Type
Fuels
Rated BTU Input/Hr
Rated Steaming Capacity/Hr
Utility Meter
Firing Rate
Fuel Flow
AMBR = American Boiler Manufactuers Recommendations

AC Humco
Industry
Food Processing
Joe Treska - 901.381.2925 FAX 901.381.3136
1201 East Morton Rd
Jacksonville, Il. 62650
7/20/2006
Burner Data Zurn SAO-MJ S/ 5456 (49,500KBTU/Hr)
Zurn NB18952
Operating PSI
150
Economizer Yes
O-Type Water tube
Mfg
Natural Gas
Steam Temp
366
87,500,000
Fan Voltage
480
BTU/Lb Steam
1000
70000
Fan Amp Rating
60
Feedwater Pump Amp Rating
Steam Flow %/ Rated Flow
Stack Temp
Actual Ex O2
ABMR Ex O2
0
0
0
0.00%
6.00%
0
0
0
0.00%
6.00%
0
0
0
0.00%
6.00%
0
0
0
0.00%
6.00%
45120
47874000
39440
56.34%
358
5.00%
5.50%
0
0
0
0.00%
5.00%
54820
58820000
46500
66.43%
368.7
3.35%
4.75%
0
0
0
0.00%
4.50%
65800
70443000
48250
68.93%
376
3.50%
4.25%
0
0
0
0.00%
4.00%
0
0
0
0.00%
3.75%
722000
76194000
51151
73.07%
504
5.50%
3.50%
0
0
0
0.00%
3.25%
74840
79067000
52063
74.38%
501
1.90%
3.00%
74400
80285000
52700
75.29%
386
1.86%
2.75%
0
0
0
0.00%
2.50%
0
0
0
0.00%
2.25%
0
0
0
0.00%
2.00%
80000
86235000
55550
79.36%
510.8
1.00%
2.00%
NOTE: GAS FLOW METER JUST STOPPED INDICATING AT 80000. NO FLUCTUATION IN READING AT THIS POINT.
Economizer Data
Valve %
Water Flow
Inlet Temp
10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%
79%
42%
75%
80%
85%
90%
95%
100%
7000
8500
13500
17500
21000
24000
27500
31000
34780
37500
41700
44000
47500
51000
55000
57600
63000
67000
69800
224
224
224
224
224
224
224
224
224
224
224
224
224
224
224
224
224
224
224
Outlet Temp
277
261
275
285
BTU Recovered Fuel Savings % FW Pump Amps

-1568000
-1904000
-3024000
-3920000
-4704000
-5376000
-6160000
-6944000
-7790720
-8400000
-9340800
2332000
1757500
-11424000
2805000
-12902400
-14112000
-15008000
4257800
-1.792%
-2.176%
-3.456%
-4.480%
-5.376%
-6.144%
-7.040%
-7.936%
-8.904%
-9.600%
-10.675%
2.665%
2.009%
-13.056%
3.206%
-14.746%
-16.128%
-17.152%
4.866%
46
47.7
50
51
65
Actual Ex CO ABMR Ex CO Comb Eff %

N0X/CO
na
83/4ppm
86/6ppm
1ppm
86/19ppm
96/13ppm
163ppm
0.00
0.00
0.00
0.00
0.00
0.00
0.02
0.02
0.03
0.03
0.03
0.03
0.04
0.04
0.04
0.05
0.05
0.06
0.08
Fan Amps
82.3
49
80.9
50
81.1
51
81.2
82.9
83
53
53
Boiler Thermal Eff % System Total Eff%

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
82.38%
#DIV/0!
79.05%
#DIV/0!
68.50%
#DIV/0!
#DIV/0!
67.13%
#DIV/0!
65.85%
65.64%
#DIV/0!
#DIV/0!
#DIV/0!
64.42%
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
82.193%
#DIV/0!
78.904%
#DIV/0!
68.384%
#DIV/0!
#DIV/0!
67.018%
0.000%
65.747%
65.428%
#DIV/0!
#DIV/0!
#DIV/0!
64.309%
05/07/2014 09:59:56
Data Compiled by
David Farthing
Voice 405-728-6709
Dissolved Oxygen In Make-up Water
PPB Dissolved Oxygen
Amount of Dissolved Oxygen in Make-up Feedwater vs. Temperature
20000
15000
10000
5000
0
50
58
60
72
125 180 200

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

Temperature Dissolved O2
50
20000
58
15000
60
12000
72
8800
125
5000
180
3000
200
2000
212
1000
227
44
242
7
212
227
242
Data Compiled by
Karl Pierson
KMCS
Date of Printout
05/07/2014 09:59:56
Pressure Coversions
Enter value to be converted in column D

The converted values will then be shown in the same row
To Values
From Value
PSI
OzSI
PASCAL
kPa
BAR
mBAR
In. H2O @
4C/39F
In. H2O @
60F
In. H2O @
20C/68F
mm H2O
cm H2O
ATM
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
In. Hg @
0C
Cm Hg
mm Hg
TORR
20.32
203.2
203.2
PSI
OzSI
PASCAL
kPa
BAR
mBAR
In.H2O @ 4 C
In. H2O @ 60F
In. H2O @ 20C
mm H2O
cm H2O
ATM
In. Hg
Cm Hg @ 0 C
mm Hg @ 0 C
TORR
8.00
8.00
Required Boiler Blowdown for proper TDS

Normal TDS should be between 3,000-5,000 ppm
TDS= Total Dissolved Solids in boiler water.
Blowdown Rate = (F/(B-F))*S
Where:
F=
Feedwater TDS in ppm
B=
Desired boiler water TDS Requirement
S=
Steam Generation Rate in lbs/hr
NOTES:
F=
300
B=
4000
S=
55000
Blowdown 4459.459 Lbs/Hr
Percent
8% of Production Capacity
Blowdown within acceptable limits
Be sure to see HEAT in the contents for possible Heat Recovery Savings.
Energy Conversions
BTU =
29,010.00
AMPS
43.00
KW
8.50
KW =
8.50
BTU
29,010.24
VOLTAGE 3Ph/KW
480.00
35.71
Cost of Energy
Cost/Hr to Operate
Gas per MMBTU
$8.95
$0.26
Electric per KW
$0.044
$0.37
NOTE:
Gas Cost is per Decatherm (1,000,000 BTU)

1 KW = BTU * 0.0002930 (Source NATCO Engineering Handbook of Conversion Factors 1988)
BTU = Kw/.0002930
GO TO VFD CALCULATIONS FOR MORE DETAILED INFORMATION
CALCULATING APPROXIMATE HP WHEN VOLTS AND AMPS ARE KNOWN

Voltage
Amps
NP Eff%
# Phases
480
65
80%
3
57.95
VFD
VFD
Replacing DC3000 Versa-Pro
with
OLD
OLD
OLD
OLD
OLD
OLD
DC300CDC300KDC300EDC300ADC300TDC300L-
use
use
use
use
use
use
Table 1
O
E
A
T
L
use
use
use
use
use
Table 2
1_ _
2_ _
4_ _
_A_
_B_
_ _3
use
use
use
use
use
use
Table 3
Same on 3300
Table 4
First digit (zero)

Second digit
Third digit
Forth digit
n/a
n/a
use
use
use
use
5th digit
6th Digit
Table 5
Always -0-
use
Table 6
Not used
use
Note. "DIN" is almost never used on replacement controllers.!!!
DC3300 Base plus w/ 1st Digit of Table 1

DC330B-CO
DC330B-K_
DC330B-E_
DC330B-A_
DC330B-T_
DC330B-E_
-_O- Place as 2nd digit of table 1.
-_E-_A-_T-_L1_ _
2_ _
4_ _
_0_
_B_
_ _3
No change. Use DC3000 table
Always zero (0_ _0_0)
Same (0X_0_0)
Same (0_X0_0)
Always Zero (0_ _0_0)
Zero or D if DIN adapter required (0_ _000)
Always zero (0_ _0_0)
Aways -00Always -0-
er used on replacement controllers.!!!
Replacing
Table 2
Table 3
DC3000 W/ Table 1
with
DC3001-0DC3002-0DC3003-0DC3004-0DC3005-0DC3006-0-
use
use
use
use
use
use
1st -0_ _-1_ _-2_ _-3_ _-4_ _2nd -_0_-_1_-_2_3rd -_ _0-_ _A-_ _B-1-2-3-
use
use
use
use
use
use
use
use
use
use
use
use
use
use
Table 4
-00(multiple avail.) -35-DIN-FM-UL-
use
use
use
use
use
Table 5
Table 6
use
use
ID code 4 digits
Not used
Note. DIN or "D" is almost never used on replacement controllers.!!!
DC3300 W/ Table 1
DC330B-C0DC330B-KEDC330B-EEDC330B-EE-Also change 2nd digit of table 3 to "2"
DC330L-E0DC330L-E0-0_ _-1_ _-2_ _-0 _ 3- No misprint, it goes as 3rd digit
-4_ _-_0_-_0_- Also change 2nd digit of table 3 to "1".
-_0_- Also change 2nd digit of table 3 to "1".
-_ _0-_ _0-_B_- No misprint, it goes as 2nd digit.
-10-20-30-000000- Multiple options available in this table.
-000T00-0000D0-0F0000-0F0000Always use -00Always use -0-
" is almost never used on replacement controllers.!!!
VFD Calculations
05/07/2014
David Farthing's
TechStuf
Variable Frequency Drive Applications

Kodak PolyGraphics
Application VFD Draft Fan 33KPPH Boiler
Customer
Need to know
Motor Horsepower
30
Motor Speed as supplied
1750
Hertz - Name Plate
60
Rated Torque Ft/Lb.
90
New Hertz
33
New 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 16.50
Prefer 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)
F
Control Methods Code - See List Below
FC
Variable Frequency Drive
VFD
0.28
Discharge Control Valve
DV
0.94
Bypass Valve
BV
1
Inlet Guide Vane
IG
0.62
Outlet Damper
OD
0.88
Fan Curve
FC
0.88
No Control
NA
1
NOTE: WHEN USING KNOWN AMP DRAW MOTOR HORSEPOWER ENTRY IS IGNORED.
IF YOU WANT TO COMPARE MOTOR HORSEPOWER ENTER A "0" IN AMP DRAW TO JUST REVIEW MOTOR DATA ONLY.
Results
kWha
22.380
Kilowatt Usage Standard Motor No Control
kWhb
12.309
Kilowatt usage using VFD at New Horsepower
kWhc
19.694
Kilowatt Usage Using Current Control Method
kWhd
7.385
$4,017.66
Savings
Kilowatt Savings Converting from Current Control Method to VFD

Annual Energy Cost Savings By Converting to VFD

Techstuf 4.07

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Warra

Compile January 14, 1997

ols Loads Flow Electri

Condensate Loads & Steam Main Trap Sizing

Correction Table for TDS

Warranty of Accuracy Statement

Compiled January 14, 1997

Tank Fluid Volumes

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

NOTE: CUSTOMERS TANKS MUST BE INSULATED

Tank Configuration Type Letter S or C in box

Square Sided Tank Data

Total Tank Surface Area

Cylindrical Tank Data

Total Fluid Volume

Total Fluid Volume

Open Top Area Sq./Ft.

Data Compiled January 14, 1997

First Number Sp.Gr. Second Number Sp.Ht.

Rite Boiler Chimney Effect

Data Compiled January 14, 1997

Chimney / Stack Draft Effect Calculations

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

Final Calculated Boiler Index

Final Calculated Stack Index

As Measured from exhaust outlet.

Calculated Stack Diameter in Inches

Exhaust Gas Volumes for Typical Boiler Operating Conditions

Compiled January 14, 1997

When Pounds Per Hour Steam Flow are known.

TURBINE to BOILER Horsepower Requirements

Compiled January 14, 1997

Boiler HP from BTU Output

Data Source Sterling Radiator

BUILDING HEAT LOSS CALCULATION

DOOR AREA (FT SQ.)

OUTSIDE AIR TEMPERATURE

AIR CHANGES PER HR

Building Machinery Heating/Cooling Loads

BOILER HORSE POWER

INS PER IN.

INS PER IN.

METAL AND TRANSITE

CONCRETE BLOCK (NO INSULATION)

INSULATION THICKNESS - INCHES

HEATERS REQ 13.0727427596

WOOD W/ PREFORMED INSULATION

INSULATION THICKNESS - INCHES

AIR LOSS= CFHX0.018XTD

FLOOR SLABS (BTUH/LN.FT. / DEG. F)

DILUTION AIR - PER 1,000 BTUH

TechStuf 'C' 1997 David Farthing

Heating Solid Materials and Equipment

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

Compiled January 15, 1997

Flowing Fluid Heating

Flowing Fluid Heating Loads

First Number Sp.Gr. Second Number Sp.Ht.

Water Content In Air Stream

Water Content in Air Streams

Courtesy of HONEYWELL, INC. - Modified by David Farthing

Thanks to Honeywell for the basic CV calculator

Courtesy of HONEYWELL, INC. - Modified by David Farthing

Lbs/Hr = WCpDelta T/(L*t)