BOILER DESIGN SOFTWARE

FOR FIRE-TUBE BOILERS

INTRODUCTION

Presented software bases on new theoretical findings on heat transfer in boilers. It

delivers unprecedented proven +/-2% uncertainty. It can be used to carry out tasks like
these:
 heat transfer calculations in boilers.
 boiler design optimization.

 retrofit of installed boilers.

Software calculates heat transfer in fossil fuel fired fire-tube steam, hot water and waste
heat boilers of arbitrary geometry and for arbitrary operating conditions (excess air,
pressure up to 40bar...). Boiler can consist of multiple segments such as furnace,
channels, chambers and tubes, with or without front or/and rear cooled door. Following
design configurations can be calculated:

1. Tubular boiler
- single pass or double pass
- horizontal or vertical
- with or without coiled-wire turbulators in tubes.

2. Furnace (combustion chamber)

- round or rectangular
- horizontal or vertical
- with or without fins of different shapes (trapezoidal, triangular, rectangular)
- wetback or dry back
- with or without cooled door (if any).

3. Channel(s) after furnace (if any)

- one or more
- round or rectangular
- horizontal or vertical
- with or without fins of different shapes (trapezoidal, triangular, rectangular)
- with or without baffles.

4. Boiler with 1, 2 or 3 tube assemblies after furnace (2-pass, 2-pass reverse flue, 3-
pass, 4-pass)
- horizontal or vertical
- with or without coiled-wire turbulators.

5. One or two turnaround chambers / redirection channel between two tube sets (3-pass
and 4-pass boilers)
- one or more in same level
- round or rectangular
- horizontal or vertical.

6. Channel before boiler exit

- one or more
- round or rectangular
- horizontal or vertical
- with cooled rear door (if any).

7. Tubular economizer with or without fins of different shapes (circular or rectangular).

Can also be calculated separately, as can stoichiometry of combustion.

Boiler and economizer can be made of following materials:

- boiler steel
- cast iron
- stainless steel
- copper
- aluminum.

Input and output values can be in Metric or English units.

Order of calculations

1. A stoichiometry of the combustion, determination of the adiabatic combustion

temperature, an flue-gases enthalpy at that temperature, and a first estimation of the
furnace exit temperature are calculated;

2. Convective and radiant parts of the heat transfer are considered to be simultaneously
coexistent. For convection, the relevant temperature is mean logarithmic, for radiation the
mean radiant temperature;

3. The impact of the turbulators is taken into account according to the proprietary
developed procedure;

4. The convective and radiant parts of the heat transfer in the furnace are summed-up
and deducted from the flue-gases enthalpy at the adiabatic combustion temperature. The
result is a temperature at the furnace exit;

5. The calculated flue-gases exit temperature is compared to the estimated one in step 1.
If they do not meet the minimum difference set (for instance 0.1°C), a new estimation is
calculated as the average of assumed one in step 1 and calculated one; the procedure is
then repeated;

6. This same procedure is applied to every boiler segment using the exit temperature of
flue-gases from one segment as being the initial temperature in the next section. Thus,
the initial temperature in next boiler section is equivalent to the exit temperature from
preceding section;

7. The sum of the heat transferred in all boiler sections represents its heat output which,
when divided by heat released from fuel, yields the boiler efficiency.

Discrepancy sources between measured and calculated values

In all situations, there are differences between calculated and actual values. In the case
of heat transfer calculations in the boilers, the discrepancies are of an operational
(fouling, scaling either on gas or water side) and of mathematical / physical nature
(equations are derived from experiments). The boiler operation related conditions cause
the computed boiler output to be greater than the measured values, while the equations
related conditions might cause it to be either greater or smaller. In general, on new and
well maintained boilers, the accuracy of calculation is higher than 98% (boiler output,
steam capacity).
 BOILER DESIGN SOFTWARE
FOR FIRE-TUBE BOILERS

BOILER TYPES
Most common fire tube boiler types on markets calculable with presented software

2-pass reverse flue (Ygnis type)

3-pass wet back (industry standard, in USA called Scotch Marine)

3-pass dry back (sold mostly in USA)
4-wet back (sold mostly in USA)
 Tubular waste heat recovery boilers

Waste heat recovery boilers

 http://www.firecad.net/
http://www.firecad.net/boilerforum/forum.asp?FORUM_ID=5

FireCAD Technologies has carved a niche for itself with expertise in consultancy and software
development for industrial steam boilers and Captive Power Plants. For the first time in the
Engineering world, all our Boiler Design software is made available as Web applications.
FireCAD's emphasis is on developing user friendly Software. Our satisfied clientele over the
globe using FireCAD Software has encouraged a greater commitment.

FireCAD software is being used by Steam Boiler manufacturers and Engineering consultants
across the globe from over 30 countries. Design software for Grate Fired Boilers, Water Tube
Package Boilers, Fire Tube Boilers both fired and waste heat type (Steam Boiler and Hot Water
Boiler), Combi boilers, Economizers, Air heaters and Superheaters is available. We offer design
consultancy for various Industrial Boilers like Oil fired Boiler, Gas Boiler, Wood boiler, hot water
boiler and Combi boiler.

 
Boiler Forum Boiler Blog Boiler Calculations

At Boiler Forum you can
discuss the problems faced
during boiler opeartions or
maintenance. You can put
some queries regarding
design and get quick solutions
from a panel of experts. With
close to 600 members, Boiler
forum is the right place to put
in your queries and get
answers.
Boiler Images
At Boiler Blog, you can find
useful articles on basic boiler
design. There are articles on
Boiler combustion
calculations, Efficiency
calcualtions and sizing of
Boiler accessories like Boiler
pumps and ID / FD Fans.
Check it out for new articles
regularly.
Boiler News
All FireCAD software is now
available as online web
applications. That means, you
can run these software online.
There are many free
calcualtions on combustion,
efficiency, gas/water/steam
properties available at our
Boiler Calcualtions secion.
Boiler Books

We have added a few boiler Latest news from boiler field Latest editions of standard
images in Boiler Image gallery. and Power plants updated books on boiler design,
You can find some interesting streamingly from all sources. operations, maintanance,
photographs of Fire tube accessories, codes, power
boilers and water tube boilers. plants, Boiler regulations ..etc
 

Boiler Drawings

Many sample Steam Generators drawings are available at Boiler Drawings section. General
Arrangement drawings and Pressure Part assembly drawings of Bagasse boilers, Coal fired
boilers, Oil/Gas fired boilers, Boiler Structure, Steam Drum, Economizer, Superheater
manufacturing drawings are available. We will be updating this Steam Generators drawing
section regularly. Important : Requires AutoDesk's DWF Viewer plugin to view the drawings (runs
only on Internet Explorer).

Client Talk
We have been very pleased with the software, it is very intuitive to use ..... We are using it
extensively analyzing the various sizes of Boilers we are involved with and are now able to
quickly run alternative scenarios of tube configuration.. Thank you very much for an excellent and
reasonably priced product.
 -  Mark Soderberg, SRS Inc. , USA

We bought FireCAD software three years ago. Calculations that took several hours now take a
few minutes and are more accurate. We, since then, have built several units based on
calculations made with your software and all of them are working fine. We are very thankful to
you for the software.
 - Leopoldo Cabieses, Recovery Heat Engineering S.A. de C.V. , Mexico
FireCAD Products List :
Grate Fired Boiler Software:
Grate Fired boiler software is used to design all types of stoker fired boilers up to a steam
capacity of 200,000 Kg/hr (440,000 Lb/hr) . The type of Boilers that can be desgined include Coal
fired boiler, Lignite fired boiler, Bagasse, Rice husk and other Bio-mass fuel boilers and Wood
fired boiler. Combination boilers or Combi boilers, which have water tube furnace and fire tube
evapoartor can also be designed.   More info |  Run online..
Water Tube Package Boiler Software:
Water tube boiler design software is meant for Bi-drum water tube package boilers. The type of
boilers that can be designed include all Oil fired boiler (fuel oil nos 1..6.., Furnace Oil, LSHS, Low
Speed and High Speed Diesel Oil ..etc) and Gas fired boiler (Natural Gas boilers, BF gas,
refinery gas ..etc). Both High pressure and low pressure boilers up to a steam rating of 150,000
kg/hr (330,000 kg/hr) can be designed.   More info |  Run online..
Fire Tube Boiler Software:
Fire Tube boiler software is useful for designing Scotch mairne type boilers for any capacity and
pressure. The type of boilers that can be designed include all solid fuel fired boilers, oil boiler and
gas boiler with 2-pass, 3-pass and four-pass configuration. The boiler can be elevated drum type
or integral steam space type. Multi-pass heat recovery or waste heat fire tube boiler can also be
designed.   More info | Run online
Economizer Software:
Water Tube economizers either for stand alone applications or for retrofit to exisiting boilers or for
heat recovery applications can be designed. All types of Bare tube, Fin tube and Gill tube
Economisers can be designed.   More info | Run online
Airheater Software:
Airheaters for stand alone applications, retrofit to exisiting boilers or for heat recovery
applications can be designed. Bare tube, Fin tube and Gill tube Airheaters can be designed.
More info | Run online
Superheater Software:
Superheaters for stand alone applications, retrofit to exisiting boilers or for heat recovery
applications can be designed. All types of Bare tube, Fin tube and Gill tube Superheaters can be
designed.   More info | Run online