Boiler Equipment Design

Generating the power needed to produce steam at the desired mass flowrate
Basis: 1 m3/h
Volumetric flow rate

v =25 m3 / h
steam =2.25

kg
m3

Mass flow rate;

m=v steam=25 ( 2.25 )=56.25

kg
of saturated steam
h

From steam tables: The specific enthalpy of saturated steam and water are given in the table below.
T (K)
423.15

Hsteam (KJ/kg)
2111.8

Hwater (KJ/kg)
631.5

Power = heat needed from room temp to 423.15K + heat needed to evaporate at 423.15K

mC
( p , avg T + m H )
Power=
Power=Q1+Q2
Where;

m=1000 kg /h

Cp water (25 C )=4.179

o

KJ
kgk

Cpwater (150 C) =4.183

o

C p , avg=

KJ
kgk

KJ
( 4.179+2 4.183 )=4.181 kgK

 T =423.15303.15=120 K

H=2111.8631.5=1480.30 KJkg

Q1=m Cp avg T =1000 x 4.181 x 120=501720

Q2=m H=1000 x 1480.30=1480300

Power=501720+ 1480300=1982020

KJ
hr

KJ
hr

KJ
550.56 KW
hr

Generating Saturated Steam at 150oC

From steam table;
At 150oC (423.15K)
The pressure exerted by saturated steam at 150oC is 476 KPa;

operating pressure=476 KPa

Calculating the internal thickness under normal operating pressure

The steam boiler to be designed is cylindrical.

Volume of cylinder , V r= r 2 h
Volume of water , V w =

of produciton x time
( rate density
)
of water

The boiler is to be designed to operate for 5 hours

Rate of production, m = 56.25 kg/hr
Time = 5hrs

Density of water,

V w=

w =1000

x5
=5 m
( 1000
1000 )

kg
m3

Therefore; taking into consideration that the water level in the boiler is 80%
Then, volume of cylinder

V r=

5
=6.25 m3
0.8

Taking the radius, r of the cylinder to be = 1m

V r = r 2 h

h=

Vr
r

6.25
=1.99 m
2
(1)

Under the ASME BPV code (section VIII D.1 Part UG-27)
The minimum thickness, t, of a pressure vessel hat is cylindrical is given as;

t=

PR
SEo .6 P

Where
t = minimum required thickness of shell
P = internal design pressure
R = inside radius of the shell course when consideration
E = joint efficiency for, or the efficiency of appropriate joint in cylindrical or spherical shells or
Spherical shells or the efficiency of ligaments between openings.
For welded vessels, the efficiency in UW-12 (of ASME BPV code section VIII D.1)
S = max. allowable stress value (from UG-23)

Operating pressure = 476KPa (69.04psi)

The max. allowable stress value, S, for carbon and low alloy steel at temp between 20 and 650 oF
for grade SA-515 70 = 17500psi
The steam boiler is fabricated by welding; therefore, the efficiency of the welded joint is gotten
from section VIII D.1 UW-12j
E = 0.85, efficiency of spot-examined joints of shell
R = 1m = 39.37inches

t=

69.04 x 39.37
=0.1832
(17500 x 0.85 )0 .6( 60.29)

Assuming a corroded condition, a corrosion allowance, C.A factor is used

The C.A factor is 0.079in based on ASME BPV code (for non-severe corrosion)

t=( 0.1832+0.079 ) 0.2622 0.67 cm 0.70 cm

Determining the design pressure

The design pressure is the pressure used in the design vessel.
The design pressure is gotten by making the operating pressure higher by either 30psi or 10%
whichever is higher.
Therefore:

10
69.04
100
+69.04=75.94 psi
1

Or (69.04 + 30)psi = 99.04psi

Thus, the design pressure is taken to be 99.04psi

Determining the minimum thickness under the design pressure

t=

PR
99.04 x 39.37
=
=0.263
SEo .6 P (17500 x 0.85 )0.6 ( 99.04 )

Under non-severe corroded conditions;

t=0.263+CA=0.263+0.079=0.342
t=0.869 cm 1 cm

Determining MAWP for 0.342in;

Pmax=

SEt
17500 x 0.85 x 0.342
=
=128.55 psi
R +0.6 t 39.37+(0.6 x 0.342)

Determining MAWP for 0.1832in;

Pmax=

SEt
17500 x 0.85 x 0.1832
=
=69.02 psi
R +0.6 t 39.37+(0.6 x 0.1832)

Determining the thickness of the head

From the ASME BPV code (sec. VIII D.1) (Circular Flat Heads)

t=d

( CSEP )

Where;

Cmin =0.33

tr
ts

Cmin =0.20
Where tr = required thickness of seamless shell under pressure
ts = actual thickness of shell

t r=0.342
t s=0. 2 62
Cmin =0.33

t =d

0.342
=0.431
0. 262

0.431 x 99.04
=39.37 (
( CP
)
SE
17500 x 0.85 )=2.11

Conditions for applying this formula include;

- If a value of tr/ts less than 1 is used in calculation, t, the shell thickness t s shall be
maintained long the distance inwardly from the inside face of the head equal to at least

2 dt s .

Testing;

t r 0.342
=
=1.31
t s 0.262
Since, 1.31 is not less than 1 therefore,
t = 2.11in is satisfactory

t h=2.11+0.079=2.189
t h=5.56 cm