THERMAL SYSTEMS (Hyd.) Pvt. Ltd., HYDERABAD - 500 055, A.P.

INDIA
PROCESS CALCULATIONS
NORMAL GAS CONDITION
STEAM GENERATION
kg/cm(a)
Deg C
50.00
420.00

Steam Pressure and temp.@ B/L

STEAM PROPERTIES:
Working Pressure, kg/cm2(a)=
Saturation Temperature =
Sensible Heat (h), Kcal/Kg =
Latent Heat (L), Kcal/Kg =
Total Heat (Enthalpy) (H), Kcal/Kg =
Superheated Enthalpy =
Density, kg/m3 =

BOILER

SH

35.00
241.40
249.35
420.20
669.55
-NA17.18

35.00
241.40
-NA669.55
774.70
12.98

ECO
35.00
241.40
249.35
420.20
669.55
-NA815.00

35.00
241.40
249.35
420.20
669.55
-NA815.00

Refer #REF!

#REF!
Blowdown Loss, % =
Feed Water inlet Temp. C =
Amount of heat required to raise
1 Kg of Steam =

2.00
103.00
674.55

Heat Duty, Kcal/h (Net)

Steam Generation, Kg/h
Feed Water Flow rate, Kg/h
Steam Temp, C

As per Client
#REF!
#REF!
#REF!
420.00

Asper TSPL
#REF!
#REF!
#REF!
420.00

Total Net Heat Available, kcal/h =

Steam Generation

#REF!
Asper Client

Asper TSPL

#REF!
#REF!
#REF!

#REF!
#REF!
#REF!

#REF!
#REF!
#REF!

#REF!
#REF!
#REF!

Water Flow
kg/h
#REF!
#REF!
#REF!

Temp.
Deg C
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!

STEAM FLOW
kg/h
#REF!

Enthalpy
kcal/kg
#REF!

In the W H Boiler
In Int DeSuper Heater
Total Steam Generation, kg/h

Additional Heat Available

0.00E+00
0.00
0.00

Amount of water flowrate,kg/h

Through Economisers
For Int Desuper Heater
Total Feed Water Through BFW Pumps

ECONOMISER WATER OUTLET TEMP.

SERIES:
ECONOMISER #4A
ECONOMISER #3B
ECONOMISER #4C
STEAM GENERATION IN ECO
STEAMING %
ECONOMISER GAS O/L TEMP BEF. STEAMING

SUPERHEATER STEAM OUTLET TEMP.

Super Heater Outlet

#REF!
Designed

Makers Nr.
K.J.V.REDDY

Appd

Eqpt
Spcn Nr.

Temp
Deg C
420.00

P02:

WHRS
-SC-002 Rev.0
SHEET 1 0F 1


Sheet

1 of 2

Status

Rev.0
Tender

Spec No.

DATA SHEET FOR STEAM DRUM / NORMAL

CLIENT : Anushakti
Water flow to the Boiler
Steam Drum Operating Pressure
Steam Drum Operating Temperature
Density of Saturated water
Density of Saturated Steam
Steam Drum Inside Diameter
Steam Drum Length (WL to WL)

Steam Drum Total Volume

Height Between Levels in mm:
Distance between NWL to CL of Drum
Distance between HHWL to CL of Drum
Distance between HWL to CL of Drum
Distance between NWL to LWL
Distance between LWL to LLWL
Distance between LWL to Empty
Distance between LLWL to Empty
Distance between Cl of DC to Empty
Partial Volumes in cu.mtrs:
HHWL to Empty
HWL to Empty
NWL to Empty
LWL to Empty
LLWL to Empty
CL of DC to Empty
Hold - up Time in Minutes:

HHWL TO CL OF DOWNCOMER
HWL TO CL OF DOWNCOMER
NWL TO CL OF DOWNCOMER
LWL TO CL OF DOWNCOMER
LLWL TO CL OF DOWNCOMER
HHWL TO HWL
HWL TO NWL
NWL TO LWL
LWL TO LLWL

:
:
:
:
:
:

:
:
:
:
:
:
:
:

20000
34.0
241.40
815.0
17.2
960
4000.00

kg/h
kg/cm g
c
kg/m3
kg/m3

mm
mm

1164.325

3.13 m3
0
300
150
250
150
230
80
50

3125.448

Steam Loading
:
:
:
:
:
:

2.73
2.18
1.56
0.57
0.12
0.06
6.53
5.19
3.68
1.24
0.15
1.34
1.51
2.44
1.09

:m3/m3h

2936
1234
745
455
387

2.44 Minutes
LWL
1.09 Minutes

C/LOFDRUM

250

1.51 Minutes

NWL

150

1.34 Minutes

HWL

150 150

HHWL

0.15 Minutes

Size:

80

LLWL

ID960 mm x 4000 mm Lg

The Retention time indicated above is Upto CL of DownComer


Sheet
Status

2 of 2

Rev.0
Tender

Spec No.

DATA SHEET FOR STEAM DRUM

CLIENT : Anushakti
20 thk
20 thk

OD

1000

(nom)

4000 (WL to WL)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Design Code
Working Pressure , kg/cm,g
Design Pressure , kg/cm,g
Working Temperature , c
Design Temperature , c
Corrosion Allowance , mm
Stress Relieving
Radiography
Test Pressure , kg/cm g
Shape of Head
Inspection
Certification

IBR 1950 LATEST

34.0
37.4
241.4
269.4
1.60
Yes
Yes
56.1
Ellipsoidal
CIB (A.P)
Asper Code

25
26
27
28
29
30
31
32
33
34

Safety Valve Connection

Steam Outlet Connection
Aux. Steam outlet
BFW inlet
Blow down
Riser Stubs
Down Commer Stubs

35
36
37
38
39
40

Steam Space Loading, m3/m3-h (Upto NWL)

Hold-up Time:
HHWL TO CL OF DOWNCOMER
HWL TO CL OF DOWNCOMER
NWL TO CL OF DOWNCOMER
LWL TO CL OF DOWNCOMER
LLWL TO CL OF DOWNCOMER

0.750

MATERIAL OF CONSTRUCTION
Shell
Dished End
Nozzles
Flanges

A 516 gr 70
A 516 gr 70
A 106 gr B
A 516 gr 70 / A 105

SERVICE DATA

Steam Capacity
Drum Total Volume

PPD

SIZE
DN

QTY
Nr

100
250
200
50
150
80-150

2
1
1
1
8
8

RATING
CLASS
600 #

20000 kg/h
3.13 m3

CKD

745
6.53
5.19
3.68
1.24
0.15

>
Minutes
Minutes
Minutes
Minutes
Minutes

400

; Not Okay

APPD

MECHANICAL DESIGN
BOILER
MATERIAL SELECTION : (TYPE 1 to 22)
TYPE(1 FOR HE TYPE, 2 FOR IS TYPE)
NO.OF TUBES
TUBE OD,MM
TUBE PITCH(73 FOR 50.8OD,80FOR 63.5 OD)

SHELL ID PROVIDED , MM
Accomodated Tubes

SA516GR70
2.00
1.00
#REF!
0.00
73
1800
462

STEAM DRUM
SHELL IN SIDE DIAMETER ,MM
DESIGN PRESSURE, Kg/CM2=
DESIGN TEMP, Deg C
SHELL MOC
ALLOWABLE STRESS @ DT,Kg/cm2
SHELL THK CALCULATED,MM
SHELL THK PROVIDED,MM
BOILER TUBES: REG 579
MATERIAL SELECTION : (TYPE 1 to 22)
MATERIAL SELECTED
TUBE DIAMETER, MM
ALLOWABLE STRESS @ DT,Kg/cm2
THK REQD FOR EXT. PR., MM
THK REQD FOR INT. PR., MM
THK REQUIRED,MM
THK PROVIDED,MM

960.00
37.40
269.40
SA516GR70
1330.88
16.04
20.00
20.00
SA210GRA1
50.80
1292.87
2.53
0.76
2.53
0.00

FIRE TUBE BOILER WITH DRUM

RISERS AND DOWN COMERS SIZES
FLOW RATE
kg/h
OP PRESSURE
kg/cm g

20000
34.0

CIRCULATION RATIO
SAT WATER ENTHALPY @ 41 bar, kcal/kg,
VAPOUR ENTHALPY @ 41 bar,g kcal/kg,
SP VOL OF SAT WATER
m3/kg,
SP VOL OF VAPOUR
m3/kg,

1 / ' 15
249.4
669.6
0.00123
0.05822

MIXTURE OF STEAM & WATER SP VOL, m3/kg,

'= 1x sp vol of vapour + 15x sp vol of water

15
1 '=
x 0.0582162704882863 + 15 x 0.00123
15

MIXTURE OF STEAM & WATER ENTHALPY, kcal/kg,

LATENT HEAT
MIXTURE OF STEAM & WATER SP VOL, m3/kg,

'=

420.2

'=

0.005

Vel of water for Down Comers, m/s

vel of water for Risers, m/s
No of Risers each bank
No of Downcomers each bank

'=
'=
'=
'=

1.5
3.5
2.0
2.0

TOTAL STEAM GENERATED

80 DIA BANK
HEAT LOAD, Q
STEAM GENERATED PER BANK

kcal/kg,
kg/h

7749221
Q/LATENT HEAT
18441.744 kg/h

FROM KED

88.9 DIA BANK

HEAT LOAD, Q
STEAM GENERATED PER BANK

kcal/kg,
kg/h

2206199
Q/LATENT HEAT
5250.354 kg/h

FROM KED

117 DIA BANK

HEAT LOAD, Q
STEAM GENERATED PER BANK

kcal/kg,
kg/h

1289620
Q/LATENT HEAT
3069.063 kg/h

FROM KED

127 DIA BANK

HEAT LOAD, Q
STEAM GENERATED PER BANK

kcal/kg,
kg/h

929393
Q/LATENT HEAT
2211.787 kg/h

FROM KED

TOTAL STEAM GENERAT

RISER AND DOWN COMER SIZES
80 DIA BANK
ID OF DOWN COMER

=1000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

ID of DC
ID OF RISER

ID of Riser

ID

28972.948 kg/h

= 141.4

mm

4.00 nos

000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

of Riser 188.9

mm

4.00 nos

88.9 DIA BANK

ID OF DOWN COMER

=1000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

ID of DC
ID OF RISER

ID of Riser

ID

= 106.7

mm

2.00 nos

000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

of Riser 142.6

mm

2.00 nos

117 DIA BANK

ID OF DOWN COMER

=1000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

ID of DC
ID OF RISER

ID of Riser

ID

= 115.4

mm

1.00 nos

000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

of Riser 154.2

mm

1.00 nos

127 DIA BANK

ID OF DOWN COMER

=1000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

ID of DC
ID OF RISER

ID of Riser

ID

RISERS
DOWNCOMERS

98.0

1.00 nos

000 x (Flow rate kg/hr of bank x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

of Riser 130.9

154.130
115.390

mm

8
7.0

mm

1.00 nos

FIRE TUBE BOILER WITH DRUM

RISERS AND DOWN COMERS SIZES
FLOW RATE
kg/h
OP PRESSURE
kg/cm g
CIRCULATION RATIO
SP VOL OF SAT WATE m3/kg,
SP VOL OF VAPOUR m3/kg,

20000
34.0
1 / ' 15
0.00123
0.05822

MIXTURE OF STEAM & WATER SP VOL, m1x sp vol of vapour + 15x sp vol of water
15
1 x=0.0582162704882863 + 15 x 0.00123
15

MIXTURE OF STEAM & WATER SP VOL, m

0.005

Vel of water for Down Comers, m/s

vel of water for Risers, m/s
No of Risers
No of Downcomers

1.5
3.5
4.0
6.0

ID of Riser =1000 (Flow rate kg/hr x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

ID

of Rise196.8 mm

ID of DC

120.3 mm

CIRCULATION RATIO FOR FIRE TUBE BOILER

STEAM FLOW, Kg/hr

STEAM PRESSURE, Kg/cm2
FEED WATER INLET TEMP, C
CIRCULATION RATIO
value of `r4' from fig 3.7
PROPERTIES FROM STEAM TABLES

20000.00
53.30
269.50
15.00
0.000

SATURATION TEMPERATURE, C
ENTHALPY OF F WATER,Kcal/Kg
ENTHALPY OF SAT. LIQUID
ENTHALPY OF SAT. STEAM(H)
ENTHALPY OF MIXTURE,Kcal/Kg
SPE. VOLUME OF SAT. LIQUID
SPE. VOLUME OF SAT. STEAM
SPE. VOLUME OF MIXTURE
SPE.VOLUME AT MIXT ENTHALPY
SPE. VOLUME FOR CALCULATION
RISER/DOWNCOMMER DETAILS

269.50
282.90
282.90
666.30
282.90
0.001
0.036
0.004
0.004
0.004

DOWN COMMER SIZE, NB

QTY
NO.OF BENDS/DC
LENGTH,MM
EQ.LENGTH OF BEND
FRICTION FACTOR
RISER SIZE, NB
QTY
NO.OF BENDS/RISER
LENGTH,MM
EQ.LENGTH OF BEND
FRICTION FACTOR
BOILER DIAMETER, MM
C/CDISTANCE(BOILER TO DRUM)

300.00
10
2
5000
3000
0.013
150.00
4
0
1000.00
0
0.016
1320.00
3500.00

ENTHALPY OF STEAM LEAVING

ENTHALPY OF MIXTURE

308.46
282.90

1) HEAD AVAILABLE, Kg/cm2

0.32

2) LOSSES IN DOWN COMMERS

a) WATER VELOCITY
INLET PLUS EXIT LOSSES = 1.5 VELOCITY HEAD

0.15
0.000138

b) TOTAL DEV. LENGTH

11000.00

FRICTIONAL PRESSURE DROP

0.000041

TOTAL DOWN COMMER LOSSES

PROJECT
Designed

OMAN
K.J.V.REDDY

0.0001789

Makers Nr. Appd

Eqpt.
Spcn Nr.

W H BOILER
Sheet 1 OF 2

0.0000
CIRCULATION RATIO FOR FIRE TUBE BOILER
0.0000

3) FRICTION AND ACCELERATION

LOSSES IN EXCHANGER

0.000

4) GRAVITY LOSSES IN THE EXCHANGER

Pg, Kg/cm2

0.05

5) GRAVITY LOSSES IN RISER PIPE

Pg, Kg/cm2

0.20

6) FRICTION LOSS IN RISER;

VELOCITY
INLET PLUS EXIT LOSS

4.237
0.038

1.5 X V.HEAD

FRICTION LOSS

0.003

7) LOSSES IN DRUM INTERNALS , Kg/cm

0.000

TOTAL LOSSES , Kg/cm

AVAILABLE HEAD, Kg/cm

0.291
0.320

Total losses should be less than available head

MIXTURE OF STEAM & WATER SP VOL, m3/kg, =

0.004

Vel of water for Down Comers, m/s

vel of water for Risers, m/s
No of Risers
No of Downcomers

ID of Riser

0.153
4.237
4.000
10.000

=1000 x

Required ID of Riser =
Required ID of DC =

PROJECT
Designed

OMAN
Anith

Makers Nr. Appd

(Flow rate kg/hr x 15 x Mix of sp vol

4/pi() x 3600 x vel of water in risers x no of risers)

150.000 mm
300.00 mm

Eqpt.
Spcn Nr.

W H BOILER
Sheet 2 OF 2