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Boiler Calculations Manual PDF
Boiler Calculations Manual PDF
Instruments
2 Pressure gauges
1 Drain Valve
1 Pressure safety Valve
1 Feed check valve
1 Pressure relief valve
1 Water gauge
Name Plate
Ring heaters
1 Thermostat
Insulation/Lagging
Mains control switch
Flexible Wire
Materials
The method that will be used for the designing and constructing of the electric steam boiler
is the Direct Coding Method.
A) Generating the Power needed to produce steam at the desired Mass Flowrate
Basis: 300cl/s
Density of steam;
From Steam Tables, The Specific Enthalpies of saturated steam and water are given in the
table below;
By interpolation;
Where;
= 24.3Kg/hr
At 145oC (418.15K)
T (K) P (kpa)
T1= 417.15 P1= 404.20
T= 418.15 P= ?
T2= 419.15 P2= 427.09
Therefore; taking into consideration that the water level in the boiler is 80%
Then;
For welded vessels, the efficiency in UW-12 (of ASME BPV code section VIII D.1)
The max. allowable stress value, S, for carbon and low alloy steel at temp between 20 and
650oF 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 Part UW-12j
R = 23cm = 9.1in
The C.A factor is 0.079in based on ASME BPV code (for non-severe corrosion)
D) Determining the design pressure
The design pressure is the pressure used in the design of the vessel.
The design pressure is gotten by making the operating pressure higher by either 30psi or
10%; whichever is higher.
There are two (2) formulae that can be used based on their constraints;
i. From the ASME BPV code (sec. VIII D. 1) (Circular Flat Heads)
Therefore;
E = Joint efficiency.
S = 17500 psi
E = 0.85
d = 18.2
Therefore, this formula cannot be used due to the contradiction between the result and the
boundary conditions.
Where,
Cmin = 0.20
tr = 0.24 in
ts = 0.134 in
maintained along the distance inwardly from the inside face of the head equal to at
least .
Testing;
is satisfactory
Due to the large amount of power needed to produce 300cl/s of saturated steam at 145°C, the
production rate of the saturated steam has to be reduced so as to make the project attainable
on a laboratory scale.
The modeled laboratory scale electric steam boiler’s production rate is taken to be a quarter
of the original basis of 300cl/s.
A) Generating the Power needed to produce steam at the desired Mass Flowrate
Density of steam;
From Steam Tables, The Specific Enthalpies of saturated steam and water are given in the
table below;
By interpolation;
Where;
= 6.075Kg/hr
At 145oC (418.15K)
T (K) P (kpa)
T= 418.15 P= ?
Therefore; taking into consideration that the water level in the boiler is 75%
Then;
Taking the radius, r of the cylinder to be = 14.71cm = 5.79in
Under the ASME BPV code (section VIII D.1 Part UG-27)
For welded vessels, the efficiency in UW-12 (of ASME BPV code section VIII D.1)
The max. allowable stress value, S, for carbon and low alloy steel at temp between 20 and
650oF 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 Part UW-12j
R = 14.71cm = 5.79in
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)
The design pressure is the pressure used in the design of the vessel.
The design pressure is gotten by making the operating pressure higher by either 30psi or
10%; whichever is higher.
There are two (2) formulae that can be used based on their constraints;
i. From the ASME BPV code (sec. VIII D. 1) (Circular Flat Heads)
b. th/d is not less than 0.05 nor greater than 0.25 i.e.
Therefore;
P = Design pressure, psi
E = Joint efficiency.
P = 90.29 psi
S = 17500 psi
E = 0.85
d = 11.58in
Therefore, this formula cannot be used due to the contradiction between the result and the
boundary conditions.
ii. Using the second formula which states;
Where,
Cmin = 0.20
tr = 0.24 in
ts = 0.1117 in
maintained along the distance inwardly from the inside face of the head equal to at
least .
Testing;
The Operating pressure that will be exerted by the saturated steam at 145°C is 415.65 kPa.
Therefore, the spring has to be pulled to a force of 816.13N enclosed in a circular area that
has a diameter of 5cm so that the force exerted by the saturated steam can counter balance the
force acting on the spring.