Techstuff 3.09

Data Compiled by
Contents
Compile January 14, 1997 David C. Farthing
Data Printout 10/19/2020
Voice 405-728-6709
WELCOME TO TECHSTUFF!! Month Warrant

Year Date of Rev.
© 1997 David C. Farthing Revision 3.09 9 y 03.31.09
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.
Accurac
Use Mouse to Click on Button to GO TO desired formulas. y
Contact
Instructions Fill in new data in yellow boxes.
General Boiler Pumps
Refriger
Heating Burner Valve andInfo
Control Loads ation Calculat Sizing Hydron
Calculat
Loads& Electric Product
s
ions Flow ions Revision Selectio ics
Steam
-Trans Piping Motor
Stuff Notes n
mitters Data Data
General Calculations Guide
Volu Fluid & VFD
Volumes in Cylindrical and Square Sided Tanks
me
AIR Water Content in an Air Stream
TEMP
PRES Temperature Conversions
ENER Pressure Conversions
SURE Energy Conversions BTU/KW KW/BTU
Finan
GY Financial Analysis of a Project
cial
Heating Loads
BTU Calculating BTU Load of liquid in Square & Cylindrical tanks

Fan Back
Steam Load Across Fan Coils
Coil
FHL Flowing Fluid Heating Loads To
B&E Building + Equipment Heating Load Combination
Equip Conte
Solid Materials & Equipment Heating Loads
Ht nts
Refrigeration Loads
Refrig Refrigeration loads of flowing liquids
.
Boiler Calculations
FAN
BHP Boiler Horsepower from BTU and/or Pound Per Hour Steam Flow
& Fan Laws for Boiler Burner Applications and Fuel BTU Content Conversions
Chim
O2/C Rite Boiler Index for Stack & Boiler, Atmospheric & Power Burner
FUEL Back
ney
O Combustion Efficiency Savings with O2 Trim & CO influence
Tank To
Econ
Condensate & Feedwater Tank Sizing
Trim
Size Economizer Calculations
Com Conte
o Excess Air & Oxygen Analysis & Combustion Air Requirements
bFWAir The effect of Feedwater Temperature on Boiler Horsepower nts
Syste
Temp The effect of Boiler Operating Pressure on System Design - Firetube Boilers
Syste
ms The effect of Boiler Operating Pressure on System Design - Watertube Boilers
SCAL The effect of Scale & Soot Build-up on Heat Transfer in Boilers
ms-W
DR.ME Dr. Mac Brockway's Boiler Water Chemistry Class (With Conductivity Conversions)
AC CSD-1 Fire & Water Side Control Requirements
CSD1
BENC
BLDO Benchmarking a Boiler
HMK Boiler Blowdown Calculations
MKU
WN Amount of Dissolved Oxygen in Make-up Feedwater vs. Temp.
EFFIC
PVPS
O2 ValveProving Sequencing Test Calculation
EINC POWERHOUSE EFFICIENCY CALCULATIONS
Y
Valve Sizing CV Calculations
Gas
Liqui Liquid Flow Control Valve Sizing
Gas Flow Control Valve Sizing
Valve
Stea Back
d Val Steam Flow Control Valve Sizing To
m Val
Pumps and Hydronics
Pump Centrifugal Pump Affinity Laws
Pump Conte
s nts
Expan Pump NPSH Calculator
Hydr
NPSH
PUM
Expansion Tank Sizing Calculations
sion Hydronic Zone Flow Calculations
onics
P Pump VFD Affinity Laws & Curves
VFD Control and Instrumentation Stuff

Electrical,
Volta Controller Out Put Voltage v. Impedance and Transmitter Troubleshooter
OHM
ge OHMS Laws
S
IASG Instrument Application Selection Guide
VFD Variable Frequency Drive Calculations
Steam Stuff
Back
Mains Condensate Loads & Steam Main Trap Sizing To
Leaks
Table Steam Tables
Cost of Leaking Steam Traps in Lost Steam and Revenue
Super Conte
Heat
Relief
s
heat
Calculating Superheat in Pressure Reducing Stations
nts
Reco
Val Blowdown Heat Recovery
Stea
very Cost to Produce Steam in $/Kpph
Reco
Relief Valves
FLAS
m $$ Flash Steam Calculator
very
SARC
H Spirax Sarco Steam Cost Calculator
O $$
Flow Measurement & Piping Calculations
Flow Gas/Steam Flow & Steam Velocity
Fricti Single Pipe Friction Loss Calculations
Calcs
Pipe
on Thermal Expansion of Pipe
HamT. Water Hammer Calculations
Insula
mer Piping Insulation Losses
Hallib
tion Halliburton Gas/Liquid Turbine Meter Calculations (Convert BTU to GPM #2 Diesel)
utronSelection Guide
Product
ASCO
Boiler ASCO Solenoid Valves TOMSPAVE
Boiler Application Guide Back
s
FSG Flame Safety Control Selection Guide
To
Traps Steam Trap Selection Guide
Pump
Pump Applications Conte
M&C s nts
DC30 Measurement, Control & Recorders
DC30 UDC3000 Cross Reference (DC300#)

0# UDC3000 Cross Reference (DC300X)
0X
Page 1
Revision Notes
Rev # Date Notes

1.102 1/31/2002 Correct nomenclature in 02 trim calcs and add Revision Notes page.
2.103 2/12/2003 Add VFD Drive Calcs and Motor Data.
6.103 6/30/2003 Add Fan Laws for Burners data.
8.0603 8/6/2003 Enhanced Steam Flow Calculations with updated AGA material.
12.1.03 12/1/2003 Add Dr. Mac Brochway's Boiler Water Charts
02.7.04 2/7/2004 Enhanced Fan Laws for Burner data based on infor from Oneok evaluations.
04.30.04 4/30/2004 Added Pitot Tube Flow Calculator
09.14.04 9/14/2004 Added Effect of Co on OxyTrim Efficiency Calculations.
11.09.04 11/09/04 Cleaned up Motor Torque data in VFD calculations.
12.16.04 12/16/04 Added ABMA Boiler Water Chemcal Guidelines and Dr. Mac's pH Correction Table for TDS
6.5.5 6/5/2005 National Standards Institue Heat Loss Due to Scale Deposits
6.21.06 6/21/2005 BTU to #2 Diesel Conversion for Halliburton Turbine Meters
3.12.07 3.12.07 Add Oxygen Trim Calculator to O2 Trim Worksheet
4.10.07 4.10.07 Add VPS Volume & Time Calculator
7.8.7 7.8.7 Add Density Calculator to Gas Flow Meassurement calcs.
8.7 8.22.07 Unlock Pump VFD Cells and Add Pump Process Data Inputs.
8.7 8.28.07 Add Powerhouse Efficeincy Calculations
10.7 10.15.07 Add Conductivity Conversions to Dr. Mac's page.
10.7 11.28.07 Correct Expansion tank factor.
12.07 12.13.07 Changed Therms to Dekatherms on Economizer Calcs to ease reading of data.
4.08 4.30.08 Add Pipe Insulation Losses
8.08 8.19.08 Add Flash Steam Calculator
3.09 3.11.09 Finish Flash Steam Calculator
3.09 3.18.09 Add Exhaust Stack Velocitiy Calculations
3.09 3.31.09 Correct Piping Insulation Losses Calculator.
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.
Data Compiled by
Tank Fluid Volumes
Compiled January 14, 1997 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 4
Customer Johns Manville NOTE: CUSTOMERS TANKS MUST BE INSULATED
Contact Greg MINIMUM 2.0" FIBERGLASS BAT RECOMMENDED.
Tank Name: Mixer In Open Top Tank application. 0.5 F/Sec Air Velocity over top of tank.
Load Calculations
No. of Tanks Tank Configuration Type Letter S or C in box Tank Designations
12 Square/Cylinder C Mixer, 60% Powdered Lime 40% Asphalt 50 Degree Lime Temp
IS TANK OPEN or CLOSED TOP?(O/C) C Enclosed Mixer, Maintenance and Re-heat load.
Square Sided Tank Data

Depth Width Length Freeboard, inches Fluid Volume Total Fluid Volume
1 1 1 0 7.482 89.784
Total Tank Surface Area Surface Square Feet 1.00
Cylindrical Tank Data

Dimensions FEET
D= 6 Total Fluid Volume
L= 9 All Cylindrical Tanks Open Top Area Sq./Ft.
FLUID VOLUME = 1903.58 22842.94 0
Fluid Data: Product: Water

Final Temperature Sp./Gr. Sp./Ht
216 1 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 $ 12.00 $ 72.17 $ 9.97
W= Weight of Product to Be Heated Energy Cost Electric/KW $ 0.0780 $ 109.96 $ 15.18
Sp./Ht = Specific Heat of Product
T2= Ending Temperature T2 216 Caution Above Boiling Point!
Ambient Losses T1= Beginning Temperature T1 212.5 Calculated Base Maintenance Loss.
Ambient Shop Temperature TA 70
Solution for boiler loading
Per Tank Load 55,366 Maintenance Load ONLY 218 55,366
Open Top Loss - Tank radiance and surface losses. 6200 Open Top Radiant Loss Factor
Total Tankage Load 664,387 Total Maintenance Load Btu per hour for all tanks combined.
Cold Start 30,793,799 Cold Heat-up Btu Required for all tanks from Cold Start of: (TA) w/ 10% Loss. 121,035 ###
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. 38,492,249 9,623,062 6,415,375 4,811,531 3,207,687
Boiler Horsepower 80% Eff. 1150 288 192 144 96
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
Asphalt/Tar 1.2/.35
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 by
Refrigeration Loads
Data Compiled January 14, 1997 David C. Farthing
Voice 405-728-6709
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
Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47
Aniline 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54
Page 6
Data Compiled by
Rite Boiler Chimney Effect
Data Compiled January 14, 1997 David C. Farthing
Voice 405-728-6709
Exhaust Gas Volumes for Typical Boiler Operating Conditions
Result is Approximate Actual Cubic Feet/Minute Per 100 Hp.
NOTES: Gas fuel based on 9% CO2, #2 Oil fuel based on 13% CO2 emissions. 80% Thermal Efficient Boiler
85+% Efficient Combustion Excess Air Volume=15%
Fuel Gas=1/Oil=0 1 Enter 1 or 0
Flue Gas Temperature 60
Boiler Horsepower 239
Exhaust Volume 16,748.66 Actual Cubic Feet/Min. At Stack Temperature
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 = 12,512.60 912.47
Exhaust Stack Velocitiy for Typical Boiler Operating Conditions

V = (2.4Q x Vs)/A Where ...
V = Velocity in Feet per Minute
Q = Flow in Lbs/Hr.
Vs = Spicific Volume of Gas at the Flowing Pressure
A = Internal Area of the Stack
Note: Q and Vs are calculated from the above "Exhaust Gas Volumes" Calculations and automatically placed in the following equation.
Stack Internal Diameter (Inches) = 60.00

Calculated Internal Area of the Stack (Sq In)= 2,826.90
Stack Velosity Ft/Min = 10.62
NOTE: Always consult a Professional Engineer when Life Safety or Federal Standards are involved. These equations are for representitive values only.
Page 7
Data Compiled by
Boiler Horsepower
Voice 405-728-6709
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. Boiler HP from BTU Output

Useful BHP = Fuel BTU Input/ 33,465 * Rated Efficiency BTU Output= 12500000
Fuel Input = 14,500,000 Boiler HP = 374
Boiler Hp = 351 at 81% Eff. At and From 212 deg. "F"
Boiler Hp = 325 at 75% Eff. At and From 212 deg. "F" KW/Hr. 6000
BTU/Hr. 20,491,200
When Boiler Rated Horsepower is Known. Boiler Hp 612
Steam Flow #/Hr = Boiler Rated Hp * 34.7 Meg.W 6
Boiler Hp = 250 Notes
Steam Flow = 8626 At and From 212 deg. "F" 1KW = 1,000 Watts
1 MW = 1,000,000 Watts
When BTU Required by the Process is Known. 1 MW = 1,000 KW
Process Input = 60,000,000
Boiler Hp = 2213 Fire Tube at 81% Eff. At and From 212 deg. "F" Eletric Motor Hp 16000
Boiler Hp = 2391 Water Tube at 75% Eff. At and From 212 deg. "F" KW/Hr. 11931.2
Boiler Input = 74,074,074 Fire Tube at 81% Eff. At and From 212 deg. "F" MegW/Hr 11.9312
Boiler Input = 80,000,000 Water Tube at 75% Eff. At and From 212 deg. "F" Boiler Hp 1216.352
When Heating Surface area is Known.

Heating Surface = 10,750 5.28
Fire Tube BHP = 2150 Fire Tube at 81% Eff. At and From 212 deg. "F" 5.33
Fire Box BHP = 2087 Fire Box at 80% Eff. At and From 212 deg. "F" 5.35
Water Tube BHP = 2028 Water Tube at 75% Eff. At and From 212 deg. "F" 5.38
Boiler BTU Output = 71,949,750 Fire Tube at 81% Eff. At and From 212 deg. "F" 5.51
Boiler BTU Output = 67,877,123 Water Tube at 75% Eff. At and From 212 deg. "F" 5.32
5.17
4.92
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 8
Data Compiled by
10/19/2020 THEORETICAL THERMAL EFFICIENCY OF A STEAM PLANT David Farthing
From Manufacturer's Data
POWERHOUSE EFFICIENCY CALCULATIONS
SITE LiDestri Foods, Fresno CA Plant at optimum performance. (NOT AS FOUND)
BOILER TYPE (F/W) F

STEAM RATE PPH 16000
BTU INPUT @212 "f" 19,950,000 (As rated by manufacturer.)
BOILER HORSEPOWER 463.76811594
RATED EFFICIENCY 80.20%
STEAM OPERATING PRESSURE 110
STEAM TEMP AT OP PSIG 344 (From Steam Tables in TechStuff.)
BTU CONTENT OF STEAM 1191 (From Steam Tables in TechStuff.)
BLOWDOWN RATE % 1% (See BLDOWN Tab in Techstuff for calculating this number.)
PPH WATER FLOW @ BD% 160 (Not to Exceed Rated PPH of Manufacture)
MAKE-UP WATER TEMP 68
BTU AVAILABLE FOR HEAT RECOVERY 21,179 Based on MADDEN BDHR Data for Recoverable Btu in Water Side)
HEAT RECOVERY MAKE-UP FLOW RATE 1600
EXIT WATER TEMP 80 (Based on 10 Degree Approach.)
BTU RECOVERED WATER SIDE 19,061
PERCENT MAKE-UP REQUIRED 15%
MAKE-UP FLOW REQUIRED 2400
TOTAL FLOW REQUIRED 2560 Includes Blowdown
MAKE-UP WATER TEMP TO SECONDARY RECOVERY 69
ECONOMIZER INLET TEMP 227

ECONOMIZER BTU RECOVERY 238000 (See ECONO Tab in Techstuff for calculating this number.)
ECONOMIZER EXITING TEMP 320
NUMBER OF ECONOMIZERS IN SYSTEM 1
DEAERATOR INLET TEMP 109

DEAERATOR OUTLET TEMP 227
BTU REQUIRED FOR DEAERATOR 302,080
BTU RECOVERED AS FLASH FROM BDHR UNIT 26,981 Based on MADDEN BDHR Data for Recoverable Btu in Flash Steam Side)
ADDITIONAL BTU REQUIRED FROM BOILER 275,099
TOTAL PLANT HEAT OUTPUT 16,000,000

GROSS PLANT HEAT INPUT 19,950,000
TOTAL HEAT RECOVERED (284,042)
NET PLANT HEAT INPUT 19,665,958
TOTAL PLANT EFFICIENCY 81.36%
Data Compiled by
Data Source Sterling Radiator
Building Machinery Heating/Cooling Loads David Farthing
10/19/2020 14:52:12
Voice 405-728-6709
BUILDING HEAT LOSS CALCULATION Changeable data WALLS

CONSTRUCTION INSULATION THICKNESS - INCHES
CLIENT St. Greg Unv. METAL 0 1 2 3 4 5 6 WALL INS PER IN.
LOCATION Shawnee DATE 29:Sep:04 ROCK, GLASS BATT 1.2 0.23 0.13 0.088 0.067 0.054 0.046 0.00 3.50
BUILDING NAME MaBee Buldg EXPED STYROFOAM 1.2 0.21 0.11 0.078 0.059 0.048 0.04 0 4
WOOD OR PLYWOOD
1" 0.56 0.19 0.11 0.081 0.063 0.052 0.044 0.040 3.500
2" 0.38 0.16 0.1 0.076 0.060 0.050 0.042 1.880 3.500
BUILDING LENGTH 250 SLAB U FACTOR 0.81
BUILDING WIDTH 276 WALL U FACTOR 0.38 CONCRETE BLOCK (NO INSULATION) "U" VALUES
BUILDING HEIGHT EVE 16 PERCENT GLASS 10% SAND / GRAVEL AGGREGATE OPEN CORE FILLED CORE
BUILDING HEIGHT RIDGE 18 GLASS U FACTOR 0.69 4" THICK (R=0.71) 0.64 0.36
ROOF U FACTOR 0.067 8" THICK (R=1.11) 0.51 0.38
DOOR AREA (FT SQ.) 75 DOOR U FACTOR 1.22 12" THICK (R=1.28) 0.47 0.38
CINDER AGGREGATE
OUTSIDE AIR TEMPERATURE 15 BUILDING VOLUME 1173000 4" THICK (R=1.11) 0.51
INSIDE AIR TEMPERATURE 73 DELTA TEMP 58 8" THICK (R=1.72) 0.39 0.18
12" THICK (R=1.89) 0.37 0.16
AIR CHANGES PER HR 4
BRICK - COMMON NO INSULATION
VOLUME REQUIREMENT 4,898,448.00 BTU 4" THICK (R=0.8) 0.61
WALL HEAT LOSS 413,407.30 BTU 8" THICK (R=1.60) 0.48
ROOF HEAT LOSS 268,162.16 BTU 12" THICK (R=2.40) 0.31
DOOR HEAT LOSSES 5,307.00 BTU
SLAB LOSS 49,422.96 BTU
TOTAL BUILDING LOAD 5,634,747 BTU METAL AND TRANSITE NO INSULATION
CORRUGATED METAL 1.5
BOILER HORSE POWER 168.201415341546 HP COATED METAL 0.9
3/8" TRANSITE - FLAT 1.1
3/8" TRANSITE - CORRUG 1.3
HEATER CALC.S ROOFS
CONSTRUCTION INSULATION THICKNESS - INCHES
BTU CAP @ 20 DEG DROP 250000 HEATERS REQ 37.564982759612 METAL W/O BUILDUP 0 1 2 3 4 5 6 WALL INS PER IN.
CONVERSION FACTORS (1=Steam)(.6=Water) 0.6 GPM REQ ROCK, GLASS BATT 1.3 0.23 0.13 0.088 0.067 0.054 0.046 0.00 3.50
HEATER GPM REQ 40 HEAD REQ 12 EXPED STYROFOAM 1.3 0.21 0.11 0.078 0.06 0.048 0.04 0 4
PRESSURE PROP FT. WATER 2 METAL W/ PREFORMED INSULATION
HEATER PIPE LENGTH 600 1.30 0.26 0.15 0.110 0.081 0.067 0.056 0.000 2.780
PIPE SIZE 4
FRICTION /100FT 2 WOOD W/ PREFORMED INSULATION
1" 0.49 0.21 0.13 0.096 0.076 0.063 0.053 0.940 2.780
2" 0.34 0.17 0.12 0.088 0.071 0.059 0.051 1.880 2.780
MISC. "U"
INTERIOR WALLS GLASS - HORZ AIR LOSS= CFHX0.018XTD
SHEET METAL 0.74 SINGLE PANE 1.22
1/2" PLYWOOD 0.05 DOUBLE PANE 0.75 DILUTION AIR - PER 1,000 BTUH
8" CONCRETE BLOCK 0.32 NATURAL GAS - 4 CFM
3/8" GYP BOARD 0.6 EXTERIOR DOORS PROPANE GAS - 5 CFM
FLAT METAL 1.2
GLASS - VERTICAL 1" WOOD 0.64
SINGLE PANE 1.13 2" WOOD 0.43
DOUBLE PANE 0.69
TRIPLE PANE 0.47 FLOOR SLABS (BTUH/LN.FT. / DEG. F)
STORM WINDOW 0.56 UNINSULATED 0.81
INSULATED 0.55
Tech Stuff Data Compiled by
TechStuf 'C' 1997 David Farthing Heating Solid Materials David Farthing
10/19/2020 14:52:12 Voice 405-728-6709
Heating Solid Materials and Equipment
Formula = Lbs/Hr = W*Cp*Delta T/(L*t)

Where W= Weight of Material
Cp= Specific Heat of Material
L= Latent Heat of Steam (Btu/Lb)
t= Time in Hours
Material = Steel Part in Platen Heater
W= 1300 Lbs.
Cp= 0.109 From Charts
L= 344 From Steam Charts
Start Temp 80
Final Temp 190
Delta T= 110
t= 1
Lbs/hr= 45.31105 BTU/Hr = 15,587.00
Boiler Hp 0.47
Common Specific Heats of Solid Materials Water Cp = 1.0
Steel 0.12 Carbon-Coke 0.203 Glass, normal 0.2 Nickel Steel 0.109
Iron 0.12 Chalk 0.215 Gneiss 0.18 Paraffin Wax 0.69
Aluminum 0.22 Charcoal 0.2 Granite 0.2 Porcelain 0.22
Alumina 0.35 Cinders 0.18 Graphite 0.2 Quartz 0.23
Asbestos 0.2 Coal 0.3 Gypsum 0.26 Quicklime 0.217
Ashes 0.2 Concrete, Dry 0.156 Hornblend 0.2 Rose Metal 0.05
Bakelite 0.35 Constantine 0.098 Humus soil 0.44 Salt, rock 0.21
Basalt 0.2 Cork 0.485 India Rubber 0.37 Sand 0.195
Bell Metal 0.086 Corundum 0.198 Kaolin 0.224 Sandstone 0.22
Bismuth-tin 0.043 D'Arcet metal 0.05 Lead Oxide 0.055 Serpentine 0.25
Borax 0.229 Dolomite 0.222 Limestone 0.217 Silica 0.191
Brass, Y 0.088 Ebonite 0.33 Lipowitz Metal 0.04 Soda 0.231
Brass, R 0.09 German Silver 0.095 Magnesia 0.222 Sulfur 0.18
Bronze 0.104 Glass, Crown 0.16 Magnesite 0.168 Talc 0.209
Brick 0.22 Glass, flint 0.12 Marble 0.21 Tufa 0.33
Vulcanite 0.331 Wood (AVG) 0.63 Wood's metal 0.04 Type metal 0.039
Flowing Fluid Heating Data Compiled by
Compiled January 15, 1997 Data Printout 10/19/2020 David C. Farthing
Voice 405-728-6709
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
Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47
Anilin 1.02/.52 Ethylene Glycol 1.16/.53 Pentane .63/.54
Page 12
Water Content In Air Stream
Water Content in Air Streams
1# of Air at 62 "F"=13.65 CF
Datum 1CFt of Air holds .0225# Water at 65"F" and 40% RH
CFM = 2500
Total Water / Min. = 56.25 in Lbs.
Lb./Hr Water = 3375
Gallons/Hr. Water = 406.1372
Page 13
David Farthing's
Gas Valve Thanks to Honeywell for the basic CV calculator
TechStuff Valves
Courtesy of HONEYWELL, INC. - Modified by David Farthing GAS

ChemTrade SSOV-1 SSOV-2 Regulator 25%
CONDITIONS CONDITIONS CONDITIONS CONDITIONS
BASE FLOW SCFH 12,000.00 12,000.00 12,000.00 8,088.00
SAFETY FACTOR X 1.00 1.00 1.00 1.00
FLOW SCFH 12,000.00 12,000.00 12,000.00 8,088.00
INLET PRESS PSIG 1.25 1.00 40.00 14.00
OUTLET PRESSURE PSIG 1.03 0.78 1.25 0.50
PRESS DROP PSI 0.22 0.22 38.75 13.50
TEMPERATURE DG.F 68 68 68 68
SPEC GRAV 0.63 0.63 0.63 0.63
REQUIRED Cv 85.745 86.430 4.773 6.267
V-Cut Degrees Open Degrees Open Degrees Open Degrees Open
V-Bal 900Rotation 60 85.74 86.43 4.77 6.27
Percent Open Percent Open Percent Open Percent Open
CV of Installed Val 90 95.272% 96.033% 5.303% 6.964%
Page 14
David Farthing's
Liquid Valve Thanks to Honeywell for the basic CV Calculator
TechStuff Valves
Courtesy of HONEYWELL, INC. - Modified by David Farthing LIQUID

Producers COOP 100% 75% 50% 25%
BASE FLOW GPM 28.00 21.00 14.00 7.00
SAFETY FACTOR X 1.15 1.00 1.00 1.00
ACTUAL FLOW GPM 32.20 21.00 14.00 7.00
INLET PRESS PSIG 205.00 180.00 180.00 180.00
PRESS DROP PSID 42.00 30.00 30.00 30.00
SPECIFIC GRAV 0.98 0.98 0.98 0.98
VISCOSITY CS 0.96 0.96 0.96 0.96
TEMP(WATER) DG.F 227 366 366 366
MAX ALLOW |
¸P (WATER) PSI 158.964 37.162 37.162 37.162
REQUIRED Cv 4.919 3.796 2.530 1.265
Linear V-Ball V-Cut Degrees Open Degrees Open Degrees Open Degrees Open
V-Bal Rotation 60 19.67 15.18 10.12 5.06
Actuator Type N/A ELECTRIC Body Materials Cast Steel(or SS)
N/A VOLTAGE End Connections THREADED
4/20m SIGNAL Steem & Seat Per factory
N/A MANUAL OVERRIDE POSITIONER Per factory
Yes PNEUMATIC
40 AIR SUPPLY PSIG
No DOUBLE ACTING
Yes SPRING RETURN
Page 15
David Farthing's
Steam Valve Thanks to Honeywell for the basic CV Calculator
TechStuff Valves
Courtesy HONEYWELL, INC. - Modified by David Farthing STEAM

TAG # Original Design Reduction #1 Reduction #2 (ENTER TAG #)
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
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 0.00 0.00 0.00 0.00
Page 16
VPS Calculations
Complied by David Farthing
10/19/2020
VALVE PROVING SEQUENCING TEST CALCULATIONS
V1= Upstream Valve Volume

V2= Downstream Valve Volume
D= Pipe Diameter (Inches Nominal-Schd. 40)
vps
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

GAS
Test Time (Sec) = 187,000 X (P x X)/C
V1 L V2
Is Inlet Gas Pressure in InWc or PSI (I or P) p
Inlet Gas Pressure 10
P= 10
D= 4
Area Sq/In = 12.99409448
L= 2
V1= 0.08
V2= 0.08
Total Volume Cft (X)= 0.340473534
C= 52000
Min.Test Time Seconds (T) = 12.24
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
INPUT DATA
CFM = 6,000
Inlet Air Temp = 60
Exhaust Air Temp = 180
Lbs/ Hr. Steam Load 777.6
BTU Load 777,600
Page 18
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 Friction Calculator)
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 = 32.79
Vp = 57.03
p= 57.03
Ls = 0.00
Lh = 5.50
Hf = 1.39
NPSHa = 4.11 Pump must require an NPSHr less than or equal to this value.
Producers COOP
Peerless F21250AM 10/19/2020 Pump Affinity Laws
11.0" Impeller
Pump Horsepower Requirements

Q= 1840
H= 60
PSIG = 25.97
Sp.Gr.= 1
Pump Eff. 65.00%
Minimum Motor Hp BHP= 42.89044289044
Cost to Operate Pump

$/KW/Hr = 0.044
Hours/Day = 24
Days/Month = 15
Cost Per Month = $ 506.82
Page 20
Burner Fan Laws 10/19/2020 David Farthing's
by David Farthing TechStuff
Fan Laws for ESTIMATING Boiler Burner Fan Performance
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
Enter known data in Yellow Boxes Bhp = Fan Horsepower = Q X H / (6356* Eff)
BuzziUnicem Diff P = Differential Pressure Across Windbox at Firing Rate
Todd Heater -1 Eff = (ft^3/min X H) / (5263 X Motor Hp)
Pryor OK Plant Burner Input 12,000,000.00 BTU/Hr from Burner Data Plate
21MM Btu Input Max Gas Flow 12,000.00 Ft^3/Hr
Min Gas Flow 1,200.00 Ft^3/Hr
Max Air Flow @15% EA. 2,275.29 CFM base on 9.67 Ft^3 Air/1Ft^3 Gas at Sea Level & 80 deg "F". 15% Excess Air.
Min Air Flow 227.53 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. 12.970% 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 FUEL CONVERSIONS & ENERGY CONTENT
New Fan Speed 1150 RPM at Shaft Q1/Q2 = N1/N2 (N) NATURAL GAS (C/Ft) Averaged
New Fan Flow 1478 CFM H1/H2 = (N1/N2)^2 (2) #2 DIESEL (RED) (1-Gallon) API Spec.
New Fan Max SP 7.60 Inch WC Bhp1/Bhp2 = (N1/N2)^3 (1) #1 DIESEL(AUTO) (1-Gallon) API Spec.
New Fan Bhp 2.67 Bhp at the shaft. Q1/Q2 = D1/D2 (BV) BIO-GAS VEGATABLE (C/Ft) Averaged
Original Boiler Output PPH 9,896.91 Saturated H1/H2 = (D1/D2)^2 (BL) BIO-GAS LANDFILL (C/Ft) Averaged
Original Boiler Output PPH 8,313.40 Superheated <700 Deg F Bhp1/Bhp2 = (D1/D2)^3 BTU Input of Burner =
New Boiler Output PPH 6,430.12 Saturated
New Boiler Output PPH 5,401.30 Superheated <700 Deg F EQUEVELENT Fuel Flow Units/Hour
EQUEVELENT Fuel Flow Units/Minute
Note1 Data marked with an asterisk * may also be taken from manufacturer's data sheets. NOTE: 1 D/Therm = 1,000,000 Btu
Data Compiled by
Combustion Efficiency Calculations
TechStuff C1997 David Farthing
Printout 10/19/2020 14:52:12
Combustion Efficiency Calculations

Boiler Type & Data LiDestri Foods Fresno CA CB500 (475)
Minimum O2 Allowed This Fuel Type
Fuel (Gas =1, Oil =2) 1 2.00%
Rated Boiler Hp 475 Steaming Rate PPH
Name Plate Efficiency 80.00% 13110
Current O2 % as found 9.82%
Current Co2 % as found 6.25%
Air Diluted CO ppm as found 90.00
CO in Flue Gas ppm Corrected 169.77
Approximate Fuel Loss out stack 0.05% Cu/Ft Gas/Hr.@NFR@ As Found Eff.
Normal Firing Rate NFR (0-100) 80% 15,870
Recommended O2% @ NFR 2.75% Data from Ideal O2 Table
Average Hours/Day Run Time 24
Average Days/Month Run Time 22
Fuel Cost/Dk-Therm from billings $ 6.36 Equivalent Cost / 1000 Cu/Ft = $ 6.36
Average Combustion Air Temp 80
Stack Temp at Firing Rate 376
Net Flue Gas Temp Rise 296 Performance Data
Net Efficiency Loss to Wasted Fuel as Co 0.1698% 46% Present Excess Air Mass.
As Found Combustion Efficiency 80.1% 13% New Excess Air Mass.
New Calculated Combustion Efficiency 83.5% $7.70 OLD Fuel Cost per 1,000 Lb/Steam.
New Stack Temp 364 $7.39 NEW Fuel Cost Per 1,000 Lb/Steam.
New Net Flue Gas Temp Rise 284 4.51% Percent Fuel Cost Savings.
Net Combustion Efficiency Gain 4.04%
Current Cost to Operate Per Month $ 53,292.86
New Cost to Operate Per Month $ 51,142.15
Current Fuel Dollars Wasted as Excess CO $ 252.42
Savings Per Month $ 2,403.13 Controller Output= 45
Savings Per Year $ 28,837.57 Raw Air Flow= 100
NOTES O2 Reading= 3
O2 Corrected Air Flow= 102.5
Voltage
#DIV/0!
CONTROLLER IMPEDANCE VS. VOLTAGE
Impedance of Device Controller is Controlling 250 OHMS

Ma output of controlling Device 4
Out Put Voltage You Should Read at Controller Output 1
When Controller Out Put = Ma in Cell 'F6'.
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 0.00
LOWSIDE -22.00
4/20 MA READING 12.00 (NOTE: Max Value = 19.99 otherwise DIV/0 Error)
RATIO 1.00 This is any RATIO applied by the display device.
BIAS 20.00 This is any BIAS applied by the display device.
DISPLAY READS 9.00

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 23
Voltage
VS. 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 24
Pipe Expansion
PIPE THERMAL EXPANSION CALCULATIONS

Calculations good for Carbon Steel and Carbon Molybdeum Steel Pipe.
Pipe Size
Pipe Run Length 361
Operating Temperature = 347 Expansion Coefficients
Thermal Expansion per 100 ft = 9.99 Coeff. 212-250 251-359 360+ Temp.
TOTAL Thermal Expansion = 36.08 2.88 1.61 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 25
Data Compiled by
Compiled October 10, 1997 Condensate Tank Sizing
David C. Farthing
Source: Skidmore/ASME Data Printout 10/19/2020
Voice 405-728-6709
Condensate & Feedwater Tank Sizing
Boiler Hp. 1740

Evaporation Rate from and at 212 deg. F. 7223.827 Gallons Per Hour
GPM Flow Rate Start/Stop Feedwater System 300.9928 Gallons Per Minute 2.5 Safety Factor
GPM Flow Rate Modulated Feedwater System 180.5957 Gallons Per Minute 1.5 Safety Factor
Storage Holding Time Desired, Minutes 7 Minutes Holding Time
Tank Size for Start/Stop Feedwater System 3009.928
Tank Size for Modulated Feedwater System 1805.957
Data Compiled by
Compiler November 3, 1997 Steam Mains Trap Sizing David C. Farthing
Source: Spirax Sarco Data Printout 10/19/2020 James W. Carr
Voice 405-728-6709
Steam Mains Trap Sizing
Steam Main Data Assumes 2.0" of Fiberglass Insulation

Pipe Diameter 6
Steam Header Pressure(PSIG) 150
Ambient Air Temperature 70
Warm-up Load / #Steam(Condensate) per 100 Ft. of Pipe 75 From Spirax Sarco Look-up Tables below.
Running Load / #Steam (Condensate) per 100 ft. of Pipe. 31
Feet Between Trap Points 100
Total Trap Warm-up Load Per Trap Point 75 #/Hr Condensate Load
Total Trap Running Load Per Trap Point 30.75 #/Hr Condensate Load
Pressure vs. Pipe Size Look-up Table

Steam Pressure (psi) 2.00 2.50 3.00 4.00 5.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 24.00 0F Correction Factor *
0.00 6.2 9.7 12.8 18.2 24.6 31.9 48 68 90 107 140 176 207 208 1.5
5.00 6.9 11 14.4 20.4 27.7 35.9 48 77 101 120 157 198 233 324 1.44
10.00 7.5 11.8 15.5 22 29.9 38.8 58 83 109 130 169 213 251 350 1.41
20.00 8.4 13.4 17.5 24.9 33.8 44 66 93 124 146 191 241 284 396 1.37
40.00 9.9 15.8 20.6 29.3 39.7 52 78 110 145 172 225 284 334 465 1.32
60.00 11 17.5 22.9 32.6 44 57 86 122 162 192 250 316 372 518 1.29
80.00 12 19 24.9 35.3 48 62 93 132 175 208 271 342 403 561 1.27
100.00 12.8 20.3 26.6 37.8 51 67 100 142 188 222 290 366 431 600 1.26
125.00 13.7 21.7 28.4 40 55 71 107 152 200 238 310 391 461 642 1.25
150.00 14.5 23 30 43 58 75 113 160 212 251 328 414 487 679 1.24
175.00 15.3 24.2 31.7 45 61 79 119 169 224 265 347 437 514 716 1.23
200.00 16 25.3 33.1 47 64 83 125 177 234 277 362 456 537 748 1.22
250.00 17.2 27.3 35.8 51 69 89 134 191 252 299 390 492 579 807 1.21
300.00 25 38.3 51 75 104 143 217 322 443 531 682 854 1045 1182 1.2
400.00 27.8 43 57 83 116 159 241 358 493 590 759 971 1163 1650 1.18
500.00 30.2 46 62 91 126 173 262 389 535 642 825 1033 1263 1793 1.17
600.00 32.7 50 67 98 136 187 284 421 579 694 893 1118 1367 1939 1.16
800.00 38 58 77 113 203 274 455 670 943 1132 1445 1835 2227 3227 1.156
1000.00 45 64 86 126 227 305 508 748 1052 1263 1612 2047 2485 3601 1.147
1200.00 52 72 96 140 253 340 566 833 1172 1407 1796 2280 2767 4010 1.14
1400.00 62 79 106 155 280 376 626 922 1297 1558 1988 2524 3064 4440 1.135
1600.00 71 87 117 171 309 415 692 1018 1432 1720 2194 2786 3382 4901 1.13
1750.00 78 94 126 184 333 448 746 1098 1544 1855 2367 3006 3648 5285 1.128
1800.00 80 97 129 189 341 459 764 1125 1584 1902 2427 3082 3741 5420 1.127
So urces Marks 7th Ed.
Compi led by D avid Farthi ng 1 0/19/20 20 14 :5 2:12
GPSA 9th Ed.
Mid-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 = 0.672 from Manufacturer's Model 301

Cf' = 241.32864 Cf' = (359.12 * cf)
D= 3.826 Inside Pipe Diameter
Fp = 100 Flowing Pressure in PSIG used to look up "wf" from Steam Tables
wf = 0.3635 Specific Weight at Flowing Conditions from Steam Tables
Lb/h 13339 Flow Rate Expected
dp= 39.223336721496 Calculated dp from formula
Lb/H = 13339.962943896 Proofing #
error = 0.007%
dp = 39.229
HC900 Math Block Assignments
Typical 'wf' @ 150 PSI a = dp 39.2233367
Flow = 5000 9000 12000 25000 40000 b = Cf' 241.32864
wf = 0.310 0.364 0.3635 0.364 0.384 c = D^2 14.638276
d = wf^.5 0.3635
Dp Flow Dp Flow Dp Flow e= 2
1 32982 11 109389 21 151142 f = 0.5
2 46643 12 114253 22 154699 g = off
3 57126 13 118918 23 158176 h = off
4 65964 14 123407 24 161578 (a^f)*((b*c*(d^f))^e)^f
5 73750 15 127739 25 n/a Math Block Function Proof = 13339.00 PPH
6 80789 16 131928 26 n/a
7 87262 17 135988 27 n/a
8 93287 18 139931 27.5 n/a
9 98946 19 143765
10 104298 20 147500
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) Air Flow at varying pressures measured down stream of damper vanes
C' = 2940 Arbitrary C' to reach necessary air flow shown in Max Air Flow in above cell.
Diff P = 100 Differential Inches H20 Across Fan At Maximum Flow High Fire Position of Fan Damper
Q= 29400.000 Must Equal MAX AIR FLOW!! Adjust C' as needed to correct.
% Flow 100%
DP = 99 88 77 66 55
Q= 29252.631 27579.645 25798.395 23884.673 21803.624
% Flow 99.499% 93.808% 87.750% 81.240% 74.162%
DP = 98 87 76 65 54
Q= 29104.515 27422.494 25630.326 23703.038 21604.500
% Flow 98.995% 93.274% 87.178% 80.623% 73.485%
DP = 97 86 75 64 53
Q= 28955.642 27264.438 25461.147 23520.000 21403.523
% Flow 98.489% 92.736% 86.603% 80.000% 72.801%
DP = 96 85 74 63 52
Q= 28805.999 27105.461 25290.836 23335.527 21200.641
% Flow 97.980% 92.195% 86.023% 79.373% 72.111%
DP = 95 84 73 62 51
Q= 28655.575 26945.545 25119.371 23149.583 20995.800
% Flow 97.468% 91.652% 85.440% 78.740% 71.414%
DP = 94 83 72 61 49
Q= 28504.358 26784.675 24946.727 22962.134 20580.000
% Flow 96.954% 91.104% 84.853% 78.102% 70.000%
DP = 93 82 71 60 12.5
Q= 28352.333 26622.832 24772.880 22773.142 10394.470
% Flow 96.437% 90.554% 84.261% 77.460% 35.355%
DP = 92 81 70 59 5
Q= 28199.489 26460.000 24597.805 22582.568 6574.040
% Flow 95.917% 90.000% 83.666% 76.811% 22.361%
DP = 91 80 69 58 2 0.137
Q= 28045.813 26296.159 24421.474 22390.373 4157.788
% Flow 95.394% 89.443% 83.066% 76.158% 14.142% 1.49
DP = 90 79 68 57 1
Q= 27891.289 26131.292 24243.861 22196.513 2940.000
% Flow 94.868% 88.882% 82.462% 75.498% 10.000%
DP = 89 78 67 56 0.025
Q= 27735.905 25965.377 24064.937 22000.945 464.855
% Flow 94.340% 88.318% 81.854% 74.833% 1.581%
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 by
Compiled November 4, 1997 Revenue Loss
David Farthing
Source: Simple Math Context Data Printout 10/19/2020
Voice 405-728-6709
Cost of Leaking Steam Traps in Lost Steam and Revenue
Customer
Site
INPUT DATA
Total Number of Traps Surveyed 60
Number of Traps Leaking 24
Number of Traps Plugged 0 Trap Type Surveyed
Capacity of Traps in #/Hr. 550 1/2" TD
Steam Line Pressure 100
Condensate Return Line PSI 12
Temperature of Condensate at Traps 245
Temperature of Condensate in Tank 190
Hours per Day of Production 24
Days per Year of Production 340
Rated Boiler Horsepower 700
Cost of Fuel/Therm $ 6.36
Cost of Steam Production / 1,000# $ 7.62
Results of Survey
Percent Traps Leaking 40.00%
Percent Traps Plugged 0.00%
Percent of Traps Operational 60.00%
# Lost Steam To Leaking Traps 7,417,440 Annually
BTU Lost to Flash Steam Venting 407,959,200 Annually
Lost Revenue to Wasted Steam $ 59,088.04 Annually
Back to Steam Trap Survey Form
Cost of Leaks
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
Ohms Law
Voice 405-728-6709
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 W = Watts
Input the known data from your application.

To Find AMPS = 0.0417 To Find WATTS = 11.560 Kw=
Voltage 24 Voltage 110
OHMS 330 OHMS 100
Watts 1 Amps 0.34
To Find VOLTS = 1.000 To Find OHMS = 1.000

Watts 1 Voltage 1
OHMS 1 Amps 1
Amps 1 Watts 1
To Find KVA = 0.001

# of Phases 1
Amps 1
Voltage 1
Data Compiled by
Ohms Law
Voice 405-728-6709
ctor you are looking for.
0.01156
Temperature Conversions
Enter Known Temperature in 'F' or 'C' for results.
Degree F Degree C
INPUT DATA 60 15.56
Degrees C = 15.56
Degrees K = 288.71
Degrees R = 519.69
Degrees F= 60.01
Calculating Flash Steam for Secondary Use
Formula = ((SH1 - SH2)/LH2) X 100 = % Flash Steam
SH1 = Temperature of High Pressure Steam from Steam Tables
SH2 = Temperature of Steam at Flash Pressure from Steam Tables
LH2 = Latent Heat of Flash Steam at Flash Pressure From Steam Tables
SH1 = 338
SH2 = 227
LH2 = 960
Flash % 11.56%
Boiler Blowdown going to Flash Tank in PPH = 828
Total PPH Flash Available for Work = 95.74
Btu/Hr Available for Work = 91,908
Example: A 800 Bhp (27,600 PPH) operating at 100 PSIG has a surface blowdown rate of 3%. Calculate the Flash
SH1 = 338
SH2 = 227
LH2 = 960
Blow Down = 27,600 * 3% = 828 PPH
Steam Tables
From Steam Tables
of 3%. Calculate the Flash Steam available to the DA at 5 PSIG.

SPIRAX SARCO STEAM COST CALCULATOR
STEAM COST CALCULATOR
COST OF NATURAL GAS 12.65 $/MMBTU
BOILER OPERATING PRESSURE 150 psig
STEAM TOTAL ENTHALPY 1196 Hg (BTU/LB)
BOILER BLOWDOWN ENTHALPY 339 Hf (BTU/LB)
STEAM LATENT ENTHALPY 857 Hfg (BTU/LB)
BOILER EFFICIENCY (GAS) 82.0% %
BOILER BLOWDOWN RATE 2% %
CONDENSATE RETURN 80% %
CONDENSATE RETURN TEMPERATURE 165 °F
MAKE UP WATER TEMPERATURE 60 °F
BOILER FEED WATER TEMPERATURE 144 °F
BOILER FEED WATER ENTHALPY 112 BTU/LB
MAKE UP WATER COST 3.00 $/1000 GALLS
MAKE UP WATER TREATMENT COST 1.25 $/1000 GALLS
ENERGY REQUIRED PER LB OF STEAM 1088.6 BTU/LB
STEAM ENERGY COST 16.79 $/1000 LBS
STEAM WATER & CHEMICALS COST 0.52 $/1000 LBS

TOTAL STEAM COST 17.31 $/1000 LBS
SPIRAX SARCO INC · 203 GEORGIA AVE. · DEER PARK, TX 77536 · TEL:(281) 478 4002 · FAX:(281) 478 4615
ALCULATOR
1000 GALLS
1000 GALLS
AX:(281) 478 4615
Calculated Total Cost to Produce Steam-Natural Gas Fired Plant w/ Possible Seconda
Rated Boiler Output in Kpph 18

Thermal Efficiency of Boiler 82
MMBTU/Hr Input 21.95 at Stated Boiler Thermal E
Total Operating Electric Horsepower 45 Fan and Feedwater Pump
Hours Per Year Operation 8000
Cost of Fuel per MMBTU $ 12.00
Fuel Cost per Kpph $ 14.63
Contribution of Secondary Waste Fuel Stream 30%
Fuel Cost per Kpph w/ Contributed Waste Fuel $10.24
Cost of Electricity per KWH $ 0.14
Electrical Cost per Kpph $ 0.26
Cost of Water per 10,000 Gal $ 2.33
Percent Make-up to Boiler 3%
Calculated Water Treatment Cost per 1000 Pounds $ 0.01
Operators Annual Salary $ 40,000.00
Overhead and Benefits of Operator $ 14,400.00
Percentage of Operator Cost to Operation of Boiler 6%
Annual Maintenance & Inspection $ 1,165.00
Cost to Produce 1Kpph $ 11.07
Depreciation on Equipment as % 5.00%
Cost to Produce 1Kpph w/ Depreciation $ 11.62
Cost of Purchased Steam from Outside source $ 9.56
Saving(+)/Cost(-) to Operate Owners On-Site Plant ($296,481.36)
Plant w/ Possible Secondary Waste Fuel Stream
at Stated Boiler Thermal Efficiency

Fan and Feedwater Pumps
PROPERTIES OF SATURATED STEAM
Specific
Gauge Temp- Volume Gauge Temp-
Pressure erature Heat in Btu/lb. Cu. ft. Pressure erature Heat in Btu/lb.
PSIG Deg F Sensible Latent Total per lb. PSIG Deg F Sensible Latent Total
25 134 102 1017 1119 142 185 382 355 843 1198
20 162 129 1001 1130 73.90 190 384 358 841 1199
IN VAC
15 179 147 990 1137 51.30 195 386 360 839 1199
10 192 160 982 1142 39.40 200 388 362 837 1199
5 203 171 976 1147 31.80 205 390 364 836 1200
0 212 180 970 1150 26.80 210 392 366 834 1200
1 215 183 968 1151 25.20 215 394 368 832 1200
2 219 187 966 1153 23.50 220 396 370 830 1200
3 222 190 964 1154 22.30 225 397 372 828 1200
4 224 192 962 1154 21.40 230 399 374 827 1201
5 227 195 960 1155 20.10 235 401 376 825 1201
6 230 198 959 1157 19.40 240 403 378 823 1201
7 232 200 957 1157 18.70 245 404 380 822 1202
8 233 201 956 1157 18.40 250 406 382 820 1202
9 237 205 954 1159 17.10 255 408 383 819 1202
10 239 207 953 1160 16.50 260 409 385 817 1202
12 244 212 949 1161 15.30 265 411 387 815 1202
14 248 216 947 1163 14.30 270 413 389 814 1203
16 252 220 944 1164 13.40 275 414 391 812 1203
18 256 224 941 1165 12.60 280 416 392 811 1203
20 259 227 939 1166 11.90 285 417 394 809 1203
22 262 230 937 1167 11.30 290 418 395 808 1203
24 265 233 934 1167 10.80 295 420 397 806 1203
Specific
26 268 236 933 1169 10.30 300 421 398 805 1203
28 271 239 930 1169 9.85 305 423 400 803 1203
30 274 243 929 1172 9.46 310 425 402 802 1204
32 277 246 927 1173 9.10 315 426 404 800 1204
34 279 248 925 1173 8.75 320 427 405 799 1204
36 282 251 923 1174 8.42 325 429 407 797 1204
38 284 253 922 1175 8.08 330 430 408 796 1204
40 286 256 920 1176 7.82 335 432 410 794 1204
42 289 258 918 1176 7.57 340 433 411 793 1204
44 291 260 917 1177 7.31 345 434 413 791 1204
46 293 262 915 1177 7.14 350 435 414 790 1204
48 295 264 914 1178 6.94 355 437 416 789 1205
50 298 267 912 1179 6.68 360 438 417 788 1205
55 300 271 909 1180 6.27 365 440 419 786 1205
60 307 277 906 1183 5.84 370 441 420 785 1205
65 312 282 901 1183 5.49 375 442 421 784 1205
70 316 286 898 1184 5.18 380 443 422 783 1205
75 320 290 895 1185 4.91 385 445 424 781 1205
80 324 294 891 1185 4.67 390 446 425 780 1205
85 328 298 889 1187 4.44 395 447 427 778 1205
90 331 302 886 1188 4.24 400 448 428 777 1205
95 335 305 883 1188 4.05 450 460 439 766 1205
100 338 309 880 1189 3.89 500 470 453 751 1204
105 341 312 878 1190 3.74 550 479 464 740 1204
110 344 316 875 1191 3.59 600 489 473 730 1203
Specific
115 347 319 873 1192 3.46 650 497 483 719 1202
120 350 322 871 1193 3.34 700 505 491 710 1201
125 353 325 868 1193 3.23 750 513 504 696 1200
130 356 328 866 1194 3.12 800 520 512 686 1198
135 358 330 864 1194 3.02 900 534 529 666 1195
140 361 333 861 1194 2.92 1000 546 544 647 1191
145 363 336 859 1195 2.84 1250 574 580 600 1180
150 366 339 857 1196 2.74 1500 597 610 557 1167
155 368 341 855 1196 2.68 1750 618 642 509 1151
160 371 344 853 1197 2.60 2000 636 672 462 1134
165 373 346 851 1197 2.54 2250 654 701 413 1114
170 375 348 849 1197 2.47 2500 669 733 358 1091
175 377 351 847 1198 2.41 2750 683 764 295 1059
180 380 353 845 1198 2.34 3000 696 804 213 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
Compiled by:
Technical Source
Piping Friction Loss Analysis David C. Farthing
National Hydraulic Inst.
Voice 405-728-6709
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 ? S
System Size 2.064 It is helpful to input actual pipe ID.
Linear Feet Pipe 6.00
Number of 90 Ells 1.00
Number of Valves 1.00
Flow Rate Required 35.00 GPM
Pipe Schd 40.00
Lookup Table > Friction Loss/100 Ft 1.00 Head Friction Loss/100 Feet of Pipe
Federal Catalog Velocity 3.33 Feet Per Second
Pages 265-266 Effective Reynolds Number 53027.89 Flow is no longer laminar!
K Factor 90 Ells Short 0.98 Averaged for pipe size range
K Factor Valves Globe 6.75 Averaged for pipe size range
Head Velocity V2/2G 0.17
Total Loss Line Pipe 0.06 Feet Head Formula
Total Loss from 90 Ells 0.17 Feet Head h=K*(V2/2G)
Total Loss from Valves 1.16 Feet Head h=K*(V2/2G)
Back Pressure Valve Setting 0 0.00 Feet Head
Total Head Loss 1.39 Feet of Head Loss
Pump NPSH
Compiled by
Financial Analysis
David C. Farthing
10/19/2020
Voice 405-728-6709
Financial Analysis of a Project
Project Name ABC Processors

OXYGEN TRIM TO CROSS LIMITED F/A
Initial Cost of Investment Materials $ 5,000.00
Initial Cost of Investment Installation $ 3,850.00
Annual Pay Back Expected from this investment $ 19,429.00
Base Line Years to Payout 0.46
Fixed Cost of Money in percent to be used for this exercise 6.85%
How many Years will the Project be Amortized over? 0
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 0.46
Expected Life Span of Investment 15.00
*Total Dollars Returned Over Life of Investment $ 282,585.00
*Note: Return on investment includes paying off original equipment investment.

Original Investment $ 8,850.00 Interest Rate 6.85% Interest Paid $ -
Hydronic Load Calculations
Process Recovery v Tank Size
Heater Size Selected 1825 Tank Size 3000

Usage Recovery Percent
Time Load In-Temp Out-Temp Time Rate Heat Heater Recovery of Tank Vol.
0.00 300 50 165 0.083 3,454,157 1,460,000 10%
0.25 255 50 165 243,691 1,460,000 9%
0.50 365 50 165 348,812 1,460,000 12%
0.75 255 50 165 243,691 1,460,000 9%
1.00 365 50 165 348,812 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? 1 Under Construction Do Not Use This Pa

Heating = 1
Level = 2
Pressure = 3
Flow = 4
Vaccum = 5
Cooling = 6
Equipment Needed 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 60 74.65 Calculated Pf GPM

Discharge Pressure 10 24.65 Corrected to PSIA Pressure Drop
Calculated HW 1386 Inches Water Differential Specific Gravity
ID of Orifice 1.55 CV=
ID of Pipe 4 Orifice Size
GPM= 299.82
Average 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
fer calculations.
David Farthing's TechStuff 10/19/2020 Helpful Boiler Burner Calculations
Combustion Air Requirements in Sq./Ft for Atmospheric and Power Burners
IN PUT DATA
Boiler Eff. 80%
Boiler Input BTUH 33,476,923
Combustion Air Area Requirements 27.9 Square Feet Free Air Flow Area
Authority Oklahoma Boiler and Pressure Vessel Safety Act 1982, Edition 1993
Table 380:25-7-18(b)
Combustion Analysis This section under construction DO NOT USE THIS FUNCTION!
Stack Temperature 525
Ambient Temperature 90
Net Temperature Rise 435
Excess O2 Reading 4%
Calculated Efficiency 79.1 Examples Only!
Calculated Excess Air 21.1 Examples Only!
Gas Analysis for Natural Gas
%O2 0.0 0.5 1.0 1.5 2.0 2.5 3.0
% Excess Air 0.0 2.1 4.5 7.1 9.8 12.2 15.1
% Co2 11.9 11.6 11.3 11.0 10.7 10.5 10.2
%O2 3.5 4.0 4.5 5.0 5.5 6.0 6.5

% Excess Air 18.1 21.2 24.5 28.2 32.0 36.1 40.4
% Co2 9.9 9.6 9.3 9.0 8.7 8.5 8.2
%O2 7.0 7.5 8.0 8.5 9.0 9.5 10.0

% Excess Air 45.0 50.2 55.5 61.2 67.8 74.6 82.0
% Co2 7.9 7.6 7.3 7.0 6.8 6.5 6.2
%O2 10.5 11.0 11.5 12.0 12.5 13.0 13.5

% Excess Air 90.4 100.4 109.2 120.6 133.0 146.8 163.1
% Co2 5.9 5.6 5.3 5.1 4.8 4.5 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
E xcess O xygen %
Ideal Excess Oxygen Curve for Natural Gas
Ideal O2 Firing Rate

6 20
5.75 30
4.75 40
3.6 50
3.3 60
Ideal Excess Oxygen Natural Gas
7
3.05 70
2.8 80 6
2.5 90 5
2.3 100 4
3
2
1
0
20 30 40 50 60 70 80 90 100
Firing Rate
Fuel Oil 2
Molectular Make-up Ideal Air = 144*(8.01*Carbon+23.86*(Hydrogen-(Ox/8)+3*Sulfur)/HV/Lb
Carbon % 87.30 Ideal Air for this fuel oil per 10,000 Btu = 7.572031
Hydrogen % 12.50 Ideal Combustion Air Ft^3/Gallon = 1355.562
Oxygen % 0.00 Gallon/Min @ High Fire = 4.074046
Sulfur % 0.20 Combustion Air for this Oil CFM = 6497.201 at 15% EA
Specific Gravity 0.865 Combustion Air for Gas CFM = 6249.026 at 15% EA
Heating Val/Gal 136952 Controller Ratio Factor Oil/Gas Bias = 1.039714
Heating Val/Lb 18981.6583
Air Density @ 70F Lb/Ft^3 0.0765
Condensing Economizer for Deaerators Energy Calculations
Customer Cargill Feed Mills
Firetube Dryback
Boile r Ty pe Wate rtube /Firetube F
Fuel Ty pe Gas or Oil G
Boiler Rated Horsepower 700
Boiler Rated Efficiency 82.00%
Normal Firing Rate (NFR) 50.0%
Boiler Operating Pressure PSIG 110
Combustion Make-up Air Temperature 70
Entering Feedwater Temperature 240 Equivalent Fuel Cost/1000 CF
Fuel Cost per D/Therm $ 9.500 $ 9.50 Per 1000 CF
Hours/Day Operation 22
Days/Month Operation 28 Acid Dewpoint Tables
Operating Steam Temperature (Saturated) 344.00 Fuel Dewpoint Minimum Minimum
Firing Boiler Horsepower @ NFR 350 Stack Temp Feedwater
Boiler Fuel Input @ NFR 14,283,841.46 Inlet Temp.
BTU Output @ NFR 11,712,750 Natural Gas 150 250 210
Net Operating Efficiencies as found 84.37%
Theoretical Entering Stack Temperature 399.00 Default #2 Diesel Fuel 180 275 210
Actual Observed Stack Temperature 341.00 Low Sulfur Oil 200 300 220
Entering Make-Up Water Temperature 68.00
Temperature Rise Across Econ. 273.00
Water Flow #/Hr 12,075.00
Gross BTU to Feedwater/Hr 921,315.96
Exiting Make-Up Water Temperature "F" 144.30
Exiting Stack Temperature 182.83 Caution Stack Temp Below Dew Point!
Gain in Efficiency 3.23% Condensing Economizer Required
New Net Calculated Thermal Efficiency 87.59%
Fuel Savings/Hr $ 4.38
Annual Current Cost of Operation $ 1,003,068.48
Total Annual Savings w/ Economizer $ 32,349.25 Based on Gain in Efficiency
Annual Cost of Operation w/ Economizer $ 970,719.24
Economizer Equipment Cost $ 23,000.00
Economizer Estimated Installation $ 11,500.00
Actual Economizer Installation Quote $ 13,785.00
Simple Pay-Back in Years 1.14
Data Compiled by
Economizer Heat Recovery Calculations 10/19/2020 14:52:12 David Farthing
Federal Corporation
Economizer Energy Calculations
Customer LiDestri Foods, Fresno
CB500 @ 467Bhp
Boiler Type Watertube/Firetube F
Fuel Type Gas or Oil G
Boiler Rated Horsepower 467
Boiler Rated Efficiency 79.00%
Normal Firing Rate (NFR) 80.0%
Boiler Operating Pressure PSIG 120
Combustion Make-up Air Temperature 80
Entering Feedwater Temperature 227 Equivalent Fuel Cost/1000 CF
Fuel Cost per D/Therm $ 6.300 $ 6.30 Per 1000 CF
Hours/Day Operation 22
Days/Month Operation 28 Acid Dewpoint Tables
Operating Steam Temperature (Saturated) 350.00 Fuel Dewpoint Minimum Minimum
Firing Boiler Horsepower @ NFR 373.6 Stack Temp Feedwater
Boiler Fuel Input @ NFR 15,825,980 Inlet Temp.
BTU Output @ NFR 12,502,524 Natural Gas 150 250 210
Net Operating Efficiencies as found 80.22%
Actual BTU Input 15,584,975
Theoretical Entering Stack Temperature 438.00 Default #2 Diesel Fuel 180 275 210
Actual Observed Stack Temperature 405.00 Low Sulfur Oil 200 300 220
Temperature Rise Across Econ. 178.00
Water Flow #/Hr 12,889.20
Gross BTU to Feedwater/Hr 489,387.22
Exiting Feedwater Temperature "F" 264.97
Exiting Stack Temperature 329.17 Application OK, Stack Temp Above Dew Point.
Gain in Efficiency 2.47% .
New Net Calculated Thermal Efficiency 82.70%
Fuel Savings/Hr $ 2.47
Annual Current Cost of Operation $ 737,009.55
Total Annual Savings w/ Economizer $ 18,232.45 Based on Gain in Efficiency
Annual Cost of Operation w/ Economizer $ 718,777.09
Economizer Equipment Cost $ 13,850.00
Economizer Estimated Installation $ 11,080.00
Actual Economizer Installation Quote $ 13,785.00
Simple Pay-Back in Years 1.52
Condensing Economizers
Non-Condensing Economizers
90% Economizer Efficiencies 90%

85% 85% Condensing
80% 80% 80%
77% 75% Condensing75% Vertical
70% 68%
Efficiency Firetube Firing Rate 70%
85% 77%65% 20
60% Conventional 85% 60% 75% 60%
40 60%
57%
80% 68%55% 50
50% 75% 60% 50%
60 50%
45%
65% 55% 75
40% 40%
60% 50% 90
30% 57% 45% 100 30%
20% 20%
10% 10%
0% 0%
20 40 50 Firing
60 Rate 75 90 100
David Farthing's TechStuff
Piping Insulation Losses Data Compiled by David Farthing
Worksheet by Stephen Youngblood, P.E.
PIPING INSULATION LOSSES

NOTE-1: Emistivity based on Steel Pipe between 130 and 530 Deg 'C' = .78
See Mark's Engineering Handbook 9th Edition McGraw-Hill
Emistivity Loss Calculates as (((T1+460)-(T2+460))/.78)/ Ins. Eff% X Surface Area
NOTE-2 This Calculator returns a relatively LOW result in order to not over state the loss in the pipe work.
One should always contact a Professional Engineer expert in Thermodynamics when considering insulated piping losses.
Pipe Run Data Main Condensate Line Outside of Building
Diameter Inches 84
Length Feet 12
Total Surface Area Sq Ft 461.8152
Insulation Eff % 54%
Ambient Temp 'F' 72
Fluid Temp 'F' 160
Emisitivity 208.93 Btu/Sq Ft
Pipe Loss = 96,485.61 Btu/Hr
Annual Operating Hours 8,760
Annualized BTU Loss 845,213,916
Total DkTherms 845
Cost/DkTherm $ 6.36
Cost of Inadequate Insulation $ 5,375.56
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 775.4471 PSIG
di= 4.025
V= 11.26
ASCO Solenoid Valve Application Guide
TOMSPAVE
Application 25 degree f chiller service
T Type of Valve 2
2-Way, 3-Way, 4-Way
O Operation of Valve NC
Universal, NC, NO
M Media L
Liquid. Gas, Steam Go to Liquid Valve Sizing Guide
S Size of Flowing Pipe 1 CV From Valve Sizing Guide 4.92
P Pressure Minimum Maximum Drop Across Valve

10 15 5
A Atmosphere Valve will Operate In. Clean
V Voltage Requirements 115

24 VDC, 115 VAC
E Extras for this application.
Fluid Temperature 25 http://www.ascovalve.com/products/html/valve_selector.htm
Ambient Temperature 90
STEAM TRAP SELECTION GUIDE
The chart below lists various steam trapping applications and enables the correct choice of trap to
A = First choice
B = Alternate choice Spirax Sarco Spirax Sarco
F & T Range FT/TV/SLR
(Float/ (Float/Thermo-
Thermostatic) static with
Steam Lock
Application Release)
CANTEEN EQUIPMENT F & T Range FT/TV/SLR
Boiling Pans-Fixed A B
Boiling Pens-Tilting A
Boiling Pans-Pedestal B B
Steaming Ovens
Hot Plates B B
FUEL OIL HEATING
Bulk Oil Storage Tanks
Line Heaters A
Outtlom Heaters A
Tracer Lines & Jacketed Pipes
HOSPITAL EQUIPMENT F & T Range FT/TV/SLR
Autoclaves and Sterilizers B B
INDUSTRIAL DRYERS F & T Range FT/TV/SLR
Drying Coils (continuous) A
Drying Coils (grid)
Drying Cylinders B A
Multi Bank Pipe Dryers A
Multi Cylinder Sizing Machin B A
LAUNDRY EQUIPMENT F & T Range FT/TV/SLR
Garment Presses B
Ironers and Calendars B A
Solvent Recovery Units A
Tumbler Dryers A B
PRESSES F & T Range FT/TV/SLR
Multi Platan Presses
(parallel connections) B
Multi Platen Presses
(series connections)
Tire Molds B
PROCESS EQUIPMENT F & T Range FT/TV/SLR
Boiling Pans-Fixed A B
Boiling Pan-Tilted A
Brewing Coppers A B
Digesters A
Evaporators A B
Hot Tables
Retorts A
Bulk Storage Tanks
Vulcanizers B
SPACE HEATING EQUIPM F & T Range FT/TV/SLR
Shell & tube Heat Exchanger A B
Heating Coils & Unit Heaters A B
Radiant Panels & Strips A B
Radiators & Convection Cabi B
Overhead Pipe Coils B
STEAM MAINS F & T Range FT/TV/SLR
Horizontal Runs B
Separators A
Terminal Ends B
Shut Down Drain
(Frost Protection)
TANKS AND VATS F & T Range FT/TV/SLR
Process Vats
(Rising Discharge Pipe) B
Process Vats
(Discharge Pipe at Base) A
Small Coil Heated Tanks
(quick boiling) A
Small Coil Heated Tanks
(slow boiling)
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.
he correct choice of trap to be made.
Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco Spirax Sarco
FT/SLR TD Range BPT SM Thermoton
(Float/Steam (Thermo- (Balanced (Bimetallic) (Liquid
Lock Release) dynamic) Pressure Expansion)
Thermostatic)

B1 B1 B
B B
B1 A2
A2
B1 A2
B A3 B B
B1 A
B B
B A
B1
B
B1
A
B1 B1 B
B
B1
A1
A B
B1 B1 B
B
B1
B1
B1
B A
A1
A
B1
B1
B1 B1
A B
A
A B2
B B2
A1 B2
B3 A
A B
B B
B
A
Spirax Sarco
lB Range
(Inverted
Bucket)
lB Range
B1
B1
B1
lB Range
B
lB Range
B
B1
B1
B1
B1
lB Range
B
B1
B
B1
lB Range
B1
B
lB Range
B1
B1
B1
B1
B1
B1
lB Range
B1
B1
B1
B1
lB Range
B
B
B1
lB Range
B
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 s Steam Boiler Application 0

Operating Pressure 12 Low Pressure System 1 0
Is the load Continuous or Cyclic? Cont./ Cyc. Cont.
How Much Steam or Hot Water is needed?
Water Applications BTU 0 NO ENTRY REQUIRED Water applications only
Operating Temperature (Water) 210 0 0
Steam Flow #/Hr. 10,000 Please enter Steam Load 1 1
Burner Type Power or Atmospheric p Power Burner Selected 1 1
Fuel Oil/Gas or Oil & Gas g Gas 2
What pressure is the Primary fuel 1 I Inches/PSI 2 0
Feed Water System desired? m Start/Stop or Modulating 1 1
Boiler Hp Required 6
Steam 289.86
Water 0.00
Net BTU Output 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
Select a boiler shell with a minimum working pressure of 15 PSIG
Flame Safety Selection Guide
This application helps you answer the questions that need to be answered to select FSG.
Application B
Boiler, Oven, Furnace
BTU Input 3,465,000 IRI Codes Required
Operation A You have selected Automatic Operation
Automatic, Semi-Automatic, Manual
Pre-Purge Required Y
Yes / No
Purge Time Specified By Manufacturer This Application guide uses gas flow to determine purg
Purge Time Recommended if not specified. 2.31 Minutes
Pilot Style I
Interrupted, InTermittent, Standing
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
Specific Gravity for other than 68 deg Water 1.000 1.0 is default for 68 degree water.
Linear Feet Suction Pipe 6.00
Flow Rate Required GPM 330.00 From Pump work sheet
Pipe Schd 40.00
Lookup Table Friction Loss/100 Ft from look-up tables 26.30 Head Friction Loss/100 Feet of Pipe
Total Head loss corrected for Specific Gravity 4.13
Discharge Piping Calculations

Linear Feet Discharge Pipe 100.00
Flow Rate Required 330.00 GPM
Pipe Schd 40.00
Lookup Table Friction Loss/100 Ft 26.30 Head Friction Loss/100 Feet of Pipe
Back Pressure Valve Setting 0 0.00 Feet Head
Total Head loss corrected for Specific Gravity 53.24
Halliburton Turbin Gas Flow Meter Calculations
Flowing Pressure 15
Flowing Temperature 60
Observed Flow Rate 19250 Actual Cubic Feet
Corrected SCF Flow 38852.851 Standard Cubic Feet
Totalizer Divisor
Factory Calibration Factor 123.42 Actual
Set Totalizer Read Out Divisor to = 61.147 Registers in Standard Cubic Feet
Set Totalizer Read Out Divisor to = 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
Factory Calibration Factor 123.42
Time Base Conversion Factor 3600 Seconds Per Time Base (86400/day, 3600/Hr, 60/Min)
Full Scale Frequency = 659.056
K-Factor
Factory Calibration Factor 123.42
K-Factor = 61.147
Temperature Effects
Plus or Minus Temperature Change 22 Degree F
Calculation for Plus 37274.838
Percent Effect 4.062
Calculation for Minus 40570.380
Percent Effect -4.421
Presure Effects
Plus or Minus Presure Change 5 PSIG
Calculation for Plus 45387.135
Percent Effect 16.818
Calculation for Minus 32318.568
Percent Effect -16.818
Halliburton Oil Meter Calculator for known Btu Input
#2 Diesel Oil
BTU Input 72000000
Btu/Gal/Oil 139000
Total Gal/Oil 517.9856
Total Lbs./Oil 74.02967
GPM FLOW 8.633094
ASME formula
10/19/2020 14:52:13
Ref: Marks9th, p12-69/12.4.2
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)
Vt= Minimum volume of expansion tank, gallons
Vs= Volume of water in system less expansion tank, gallons
T= Maximum Average Operating Temperature of system, degrees 'F'
Pa= Atmospheric pressure fixed at 14.73 in this calculation.
Pf= Filling pressure (psig).
Po= Maximum operating pressure (psig).
NOTE Calculations correct Pa,Pf, and Po to Feet Absolute for you.
System Temperatures between 160 to 280 degrees 'F'.
T= Average System Operating Temperature, Degrees F 300

Vs= Volume of Water in System, Gallons 5000
Pf= Make-up Fill Water Pressure PSIG 45
Po= Maximum Operating Pressure of System PSIG 75
Vt= Minimum Volume Expansion Tank Required 463.31 Plain Steel Tank
Boyle's Law Acceptance Factor 1.33 This is a Safety Factor used by many Engineers
Minimum Tank Volume using Boyle's Factor 618
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

Grunfos CR32.6 Process Requirements
Enter Pump Speeds Desired (HZ) Normal Maximum
Speed 1 60 RPM 3550 Speed 2 55 RPM 3254 Flow 50 96
Speed 3 50 RPM 2958.3333 Speed 4 45 RPM 2663 Head 427 485
Speed 5 40 RPM 2367 Speed 6 35 RPM 2071
Speed 1 60 Hz. Original Pump Curve Data Speed 2 55 Hz.
Flow Head HP Eff Flow Head HP Eff

Point 1 50 555 13 40 Point 1 45.83333 466.3542 10.01331 40
Point 2 70 540 14.4 58 Point 2 64.16667 453.75 11.09167 58
Point 3 90 520 20.4 65 Point 3 82.5 436.9444 15.71319 65
Point 4 110 500 21.6 75 Point 4 100.8333 420.1389 16.6375 75
Point 5 BEP 130 475 23 76 Point 5 BEP 119.1667 399.1319 17.71586 76
Point 6 150 450 24 75 Point 6 137.5 378.125 18.48611 75
Point 7 EOC 170 410 25 76 Point 7 EOC 155.8333 344.5139 19.25637 76
Speed 3 50 Hz. Speed 4 45 Hz.

Point 1 41.66667 385.4167 7.5231481 40 Point 1 37.5 312.1875 5.484375 40
Point 2 58.33333 375 8.3333333 58 Point 2 52.5 303.75 6.075 58
Point 3 75 361.1111 11.805556 65 Point 3 67.5 292.5 8.60625 65
Point 4 91.66667 347.2222 12.5 75 Point 4 82.5 281.25 9.1125 75
Point 5 BEP 108.3333 329.8611 13.310185 76 Point 5 BEP 97.5 267.1875 9.703125 76
Point 6 125 312.5 13.888889 75 Point 6 112.5 253.125 10.125 75
Point 7 EOC 141.6667 284.7222 14.467593 76 Point 7 EOC 127.5 230.625 10.54688 76
Speed 5 40 Hz. Speed 6 35 Hz.

Point 1 33.33333 246.6667 2.2290809 40 Point 1 29.16667 188.8542 2.58044 40
Point 2 46.66667 240 2.4691358 58 Point 2 40.83333 183.75 2.858333 58
Point 3 60 231.1111 3.4979424 65 Point 3 52.5 176.9444 4.049306 65
Point 4 73.33333 222.2222 3.7037037 75 Point 4 64.16667 170.1389 4.2875 75
Point 5 BEP 86.66667 211.1111 3.9437586 76 Point 5 BEP 75.83333 161.6319 4.565394 76
Point 6 100 200 4.1152263 75 Point 6 87.5 153.125 4.763889 75
Point 7 EOC 113.3333 182.2222 4.2866941 76 Point 7 EOC 99.16667 139.5139 4.962384 76
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
p Application)
Data Compiled by
Boiler Heat Recovery Calculations
David Farthing
Printout 10/19/2020 14:52:13
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 FT FT=Fire Tube, WT=Water Tube

Steam Boiler Flow PPH at Capacity 41400 1200 Calculated Boiler Hp.
TDS of Make-up Water 350
Desired TDS in Boiler Water 4000
Operating Pressure 150
Operating Temperature 366
Boiler Rated Efficiency 82%
Normal Firing Rate 100%
Hours/Day Run Time 24
Days/Month Run 30
Make-up as % of Steaming Rate 100%
Blowdown as % of Steaming Rate 9.59% Blowdown within normal limits
Make-up + Blowdown as % of Steaming Rate 109.59%
Fuel Cost per Therm include transport cost $ 0.67 Equivalent Fuel Cost per 1000 CF $ 6.66
Deaerator Operating Temperature 227
Calculated Boiler Horsepower 1,200 At Operating Firing Rate
Fuel Input at rated efficiency & firing rate 48,973.17 Cubic Feet/Hr
Therms per hour at efficiency & firing rate 489.73
Calculated Cost to Operate per 30 day billing $ 234,836.15
Blowdown in PPH 3,969.86
Equivalent Boiler Horsepower Loss 115.07
Total Heat Available for Recovery 1,307,673 BTU/Hr.
Equivalent Boiler Horsepower Recovered 39.08
31,384,149 BTU/Day
941,524,471 BTU/Billing Period
11,298,293,655 BTU/Year
Total Annual Cost for Blowdown & Make-up $ 75,246.64
BTU Heat for Recovery to Make-Up 477,336,329 Per Billing Period
Total Monthly Savings for Recovery $ 3,179.06 Per Billing Period
Total Annual Savings for Recovery $ 38,148.72
Cost for Recovery Equipment $ 23,000.00 Estimates Only Actual Cost must be quoted.
Cost for Installation L&M $ 12,000.00 Estimates Only Actual Cost must be quoted.
Months to Payback 11.01 Project Payback within normal limits.
David Farthing's Tech Stuff 10/19/2020 14:52:13 Relief Valve Data
Relief Valve Sizing and Selection
User Data ABC Company

1234 Powerhouse Lane
Smokin, PA 123456
Boiler Data
Steam (S) or Hot Water (W)? S
MAWP 200
Operating Pressure 150
Btu Input 48,000,000
Steam PPH Output 41,400
USE STEAM DATA ONLY -
How Many Safety Valves 2
Safety Valve Port Size
Port 1 2
Port 2 2
Port 3 2
Steam Recommendations PPH Set Pressure

Safety Valve #1 13,662 190
Safety Valve #2 27,738 200
Safety Valve #3 - 0
Hot Water Recommendations Btu/Hr Set Pressure

Relief Valve #1 - 190
Relief Valve #2 - 200
Relief Valve #3 - 0
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.
Data Compiled by
Printout
David Farthing's TechStuff David Farthing
10/19/2020 / 14:52:13
Voice 405-728-6709
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
Rated Boiler Horsepower 476 Distribution line Diameter 8
Boiler Outlet Diameter 6 Distribution Velocity Ft./Min. 2619.3639
Current Operating Pressure 120 Distribution Velosity OK
Feedwater Temperature 227
Steam Volume Cft/# 3.34
Boiler Outlet Velocity 4656.6469 Ft./Min.
Nozzle Velocity OK
New Velocity Across the Boiler Outlet New Velocity in the distribution line
New Operating Pressure 90 Distribution line Diameter 8
Steam Volume Cft/# 4.24 Distribution Velocity Ft./Min. 3325.1805
New Boiler Outlet Velocity 5911.4320 Ft./Min. Distribution Velosity OK
Danger Outlet Nozzle Velocity Above Safety Limits - Priming and Carry Over Will Occur!
Additional or Reduction Btu/Bhp Required to Raise Pressure above 0 PSIG Theoretical Savings from Lowering Operating Pressure
4,076 BTU @ Current Pressure Btu Differential 621
3,455 BTU @ New Pressure Boiler Horsepower 476
621 Btu @ Horsepower/Hr Differential Cost of Fuel (Decatherm) $ 6.36
Hrs/Day Operation 20
Days/Month/Operation 22
$$ Saved or Expended/Mth. Misapplication
Feedwater Pump vs. Relief Valve Performance Requirements $$ Saved or Expended/Yr. Misapplication
Design At New
Maximum Allowable Working Pressure 350
Normal Operating Pressure 120 90
Minimum Safety Relief Valve Setting 138 104
Minimum Pump Head Requirements
Feet Head 338 253
Pressure Drop Across Feed Valve 50 See Liquid Valve Calcs.
Feedwater Piping Losses - PSI 12 See Friction Losses in Piping.
Economizer Losses-PSI 5 See Manufacturer's Data sheet.
Pump Discharge Pressure PSI 213 177
Minimum Pump Flow Capacity GPM 41.17
Danger Outlet Nozzle Velocity Above Safety Limits - Priming and Carry Over Will Occur!
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.
The effect of Boiler Operating Pressure on System Performance
Watertube Boiler - Saturated Steam
Designed Velocity Across the Boiler Outlet Design Velocity in the distribution line
Pounds/Hr Steam Flow 10000
Rated Boiler Horsepower 290 Distribution line Diameter
Boiler Outlet Diameter 8 Distribution Velocity Ft./Min.
Current Operating Pressure 100 Distribution Velosity OK
Feedwater Temperature 227
Steam Volume Cft/# 3.89
Boiler Outlet Velocity 1857.6886 Ft./Min.
Nozzle Velocity OK
New Velocity Across the Boiler Outlet New Velocity in the distribution line
New Operating Pressure 115 Distribution line Diameter
Steam Volume Cft/# 3.46 Distribution Velocity Ft./Min.
New Boiler Outlet Velocity 1652.3400 Ft./Min. Distribution Velosity OK
Nozzle Velocity OK
Additional or Reduction Btu/Bhp Required to Raise Pressure above 0 PSIG Theoretical Savings f
4,076 BTU @ Current Pressure Btu Differential
4,076 BTU @ New Pressure Boiler Horsepower
0 Btu @ Horsepower/Hr Differential Cost of Fuel (Decather
Hrs/Day Operation
Days/Month/Operation
$$ Saved or Expended
$$ Saved or Expended
Feedwater Pump vs. Relief Valve Performance Requirements
Design At New
Maximum Allowable Working Pressure 250
Normal Operating Pressure 100 115
Minimum Safety Relief Valve Setting 115 132
Minimum Pump Head Requirements
Safety Valve Requirement Feet Head 282 324
Pressure Drop Across Feed Valve 20 See Liquid Valve Calcs.
Feedwater Piping Losses - PSI 10 See Friction Losses in Piping.
Economizer Losses-PSI 4 See Manufacturer's Data sheet.
Pump Discharge Pressure - PSI 156 174
Minimum Pump Flow Capacity GPM 25.07
Nozzle Velocity OK
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 Boiler Operating Pressure
Temperature 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 Temp-
Pressure erature Heat in Btu/lb.
PSIG Deg F Sensible
n the distribution line 25 134 102
IN VAC
14 20 162 129
606.5922 15 179 147
10 192 160
5 203 171
0 212 180
1 215 183
2 219 187
the distribution line 3 222 190
14 4 224 192
539.5396 5 227 195
6 230 198
7 232 200
8 233 201
Theoretical Savings from Lowering Operating Pressure 9 237 205
Btu Differential 0 10 239 207
Boiler Horsepower 289.8550725 12 244 212
Cost of Fuel (Decatherm) $ 5.29 14 248 216
Hrs/Day Operation 20 16 252 220
Days/Month/Operation 22 18 256 224
$$ Saved or Expended/Mth. $ - 20 259 227
$$ Saved or Expended/Yr. $ - 22 262 230
24 265 233
26 268 236
28 271 239
30 274 243
32 277 246
34 279 248
36 282 251
38 284 253
40 286 256
42 289 258
44 291 260
46 293 262
48 295 264
50 298 267
55 300 271
60 307 277
65 312 282
water Temperature 70 316 286
ng Pressure 75 320 290
175 200 225 250 80 324 294
Bring Feedwater to Steaming Temperature 85 328 298
11,459 11,838 12,149 12,459 90 331 302
9,734 10,113 10,424 10,734 95 335 305
8,871 9,251 9,561 9,872 100 338 309
8,009 8,388 8,699 9,009 105 341 312
7,146 7,526 7,836 8,147 110 344 316
6,284 6,663 6,974 7,284 115 347 319
5,870 6,249 6,560 6,870 120 350 322
5,421 5,801 6,111 6,422 125 353 325
5,249 5,628 5,939 6,249 130 356 328
4,904 5,283 5,594 5,904 135 358 330
4,559 4,938 5,249 5,559 140 361 333
4,214 4,593 4,904 5,214 145 363 336
3,869 4,248 4,559 4,869 150 366 339
3,696 4,076 4,386 4,697 155 368 341
3,524 3,903 4,214 4,524 160 371 344
165 373 346
170 375 348
175 377 351
180 380 353
185 382 355
190 384 358
195 386 360
200 388 362
205 390 364
210 392 366
215 394 368
220 396 370
225 397 372
230 399 374
235 401 376
240 403 378
245 404 380
250 406 382
255 408 383
260 409 385
265 411 387
270 413 389
275 414 391
280 416 392
285 417 394
290 418 395
295 420 397
300 421 398
305 423 400
310 425 402
315 426 404
320 427 405
325 429 407
330 430 408
335 432 410
340 433 411
345 434 413
350 435 414
355 437 416
360 438 417
365 440 419
370 441 420
375 442 421
380 443 422
385 445 424
390 446 425
395 447 427
400 448 428
450 460 439
500 470 453
550 479 464
600 489 473
650 497 483
700 505 491
750 513 504
800 520 512
900 534 529
1000 546 544
1250 574 580
1500 597 610
1750 618 642
2000 636 672
2250 654 701
2500 669 733
2750 683 764
3000 696 804
Specific
Volume
Heat in Btu/lb. Cu. ft.
Latent Total per lb.
1017 1119 142
1001 1130 73.90

990 1137 51.30
982 1142 39.40
976 1147 31.80
970 1150 26.80
968 1151 25.20
966 1153 23.50
964 1154 22.30
962 1154 21.40
960 1155 20.10
959 1157 19.40
957 1157 18.70
956 1157 18.40
954 1159 17.10
953 1160 16.50
949 1161 15.30
947 1163 14.30
944 1164 13.40
941 1165 12.60
939 1166 11.90
937 1167 11.30
934 1167 10.80

933 1169 10.30
930 1169 9.85
929 1172 9.46
927 1173 9.10
925 1173 8.75
923 1174 8.42

922 1175 8.08
920 1176 7.82
918 1176 7.57
917 1177 7.31
915 1177 7.14
914 1178 6.94
912 1179 6.68
909 1180 6.27
906 1183 5.84
901 1183 5.49
898 1184 5.18
895 1185 4.91
891 1185 4.67
889 1187 4.44
886 1188 4.24
883 1188 4.05
880 1189 3.89
878 1190 3.74
875 1191 3.59
873 1192 3.46
871 1193 3.34
868 1193 3.23
866 1194 3.12
864 1194 3.02
861 1194 2.92
859 1195 2.84
857 1196 2.74
855 1196 2.68
853 1197 2.60
851 1197 2.54
849 1197 2.47
847 1198 2.41
845 1198 2.34
843 1198 2.29
841 1199 2.24
839 1199 2.19
837 1199 2.14
836 1200 2.09
834 1200 2.05
832 1200 2.00
830 1200 1.96
828 1200 1.92
827 1201 1.89
825 1201 1.85
823 1201 1.81
822 1202 1.78
820 1202 1.75
819 1202 1.72
817 1202 1.69
815 1202 1.66
814 1203 1.63
812 1203 1.60
811 1203 1.57
809 1203 1.55
808 1203 1.53
806 1203 1.49
805 1203 1.47
803 1203 1.45
802 1204 1.43
800 1204 1.41
799 1204 1.38
797 1204 1.36
796 1204 1.34
794 1204 1.33
793 1204 1.31
791 1204 1.29
790 1204 1.28
789 1205 1.26
788 1205 1.24
786 1205 1.22
785 1205 1.20
784 1205 1.19
783 1205 1.18
781 1205 1.16
780 1205 1.14
778 1205 1.13
777 1205 1.12
766 1205 1.00
751 1204 0.89
740 1204 0.82
730 1203 0.75
719 1202 0.69
710 1201 0.64
696 1200 0.60
686 1198 0.56
666 1195 0.49
647 1191 0.44
600 1180 0.34
557 1167 0.23
509 1151 0.22
462 1134 0.19
413 1114 0.16
358 1091 0.13
295 1059 0.11
213 1017 0.08
Data Compiled by
10/19/2020 / 14:52:13 'c' Federal Corporation David C. Farthing
Voice 405-728-6709
The effect of Feedwater Temperature on Boiler Horsepower Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature
Feedwater Boiler Operating Pressure
Customer LiDestri Foods Temperature 0 25 50 75 100 125 150 175 200 225 250
Contact Henry Marroquin Additional BTU Input Required to Bring Feedwater to Steaming Temperature
Plant Location Fresno, CA 50 5,589 7,487 8,556 9,315 9,936 10,454 10,902 11,282 11,661 11,972 12,282
Boiler Mfg Clever Brooks 100 3,864 5,762 6,831 7,590 8,211 8,729 9,177 9,557 9,936 10,247 10,557
Boiler Type 500 (475) Firetube w/ Alzeta 19.95mmbtu LN Burner 125 3,002 4,899 5,969 6,728 7,349 7,866 8,315 8,694 9,074 9,384 9,695
150 2,139 4,037 5,106 5,865 6,486 7,004 7,452 7,832 8,211 8,522 8,832
Factory Design 175 1,277 3,174 4,244 5,003 5,624 6,141 6,590 6,969 7,349 7,659 7,970
Boiler Type Watertube/Firetube F. 200 414 2,312 3,381 4,140 4,761 5,279 5,727 6,107 6,486 6,797 7,107
Name Plate Rated Boiler BHP 475 212 0 1,898 2,967 3,726 4,347 4,865 5,313 5,693 6,072 6,383 6,693
Normal Operating Pressure 140 FW Temp Deaerator or Typical 225 1,449 2,519 3,278 3,899 4,416 4,865 5,244 5,624 5,934 6,245
Calculated BTU Input for boiler type 19,828,482.36 As Observed First Recovery Economizer 230 1,277 2,346 3,105 3,726 4,244 4,692 5,072 5,451 5,762 6,072
Observed Feedwater Temp 212 80 100 227 240 932 2,001 2,760 3,381 3,899 4,347 4,727 5,106 5,417 5,727
Hours Day Operated 20 20 20 20 250 587 1,656 2,415 3,036 3,554 4,002 4,382 4,761 5,072 5,382
Days per Month 22 22 22 22 260 242 1,311 2,070 2,691 3,209 3,657 4,037 4,416 4,727 5,037
Calculated Bhp BTU Output Bhp 15,895,875.00 270 -104 966 1,725 2,346 2,864 3,312 3,692 4,071 4,382 4,692
Calculated Efficiency (Input/Output) 80.17 275 794 1,553 2,174 2,691 3,140 3,519 3,899 4,209 4,520
Calculated Bhp 475.00 280 621 1,380 2,001 2,519 2,967 3,347 3,726 4,037 4,347
Rated Steam PPH at 100% Firing 16387.5
BTU addition for Operating Pressure 2,310,638 4,965,413 4,146,038 2,097,600
BTU Lost/Gained Per Hour 0.00 -2,163,150.00 -1,835,400.00 245,812.50
Boiler HP Lost or Gained/ Hr. 0.00 (64.64) (54.85) 7.35
Net Boiler Horsepower 475 410 420 482
Net Steam Output 16387.5 14157.4 14495.3 16640.9
Net Efficiency 80.17 69.26 70.91 81.41
Percent Increase/Decrease Energy Use 0.00 -10.91% -9.26% 1.24%
Percent Increase/Decrease BHP 0.000% -13.608% -11.546% 1.546%
UNDER CONSTRUCTION UNDER CONSTRUCTION Note Wate Level Originally Very High in sight glass,. Sight Glass FLOODED!!
ON/OFF Feedwater Effect Wate Level Correcte by closing by-pass valve and reading re-checked.
On/Off Cycle Time 10
Normal Firing Rate % 88%
Displacement Per Cycle 2884.2
FW Temp 180
BTU Required to reach 212 92294.4
Total BTU Lost/Day 11,075,328.00
Cost of Fuel/Dtherm $ 12.60
Cost of Lost Btu/Month $ 3,070.08
Cost of Lost Btu/Year $ 36,840.97
UNDER CONSTRUCTION UNDER CONSTRUCTION
D ata Comp ile d by
10/19 /2 020 1 4:52:13 Sca le vs. H eat Tra nsfer Da vid Farthin g
Voi ce 405 -728 -670 9
The effect of Scale on Heat Transfer in Boilers
Cal ci um S cal e Th i ckn ess = I n ch

Additional Hea t Input R equ ired Due to Ca lc ium Sa lt Sca le
Wat ertub e Boiler Fu l Circum fe rance Tube Contac t
0.60
0.50
0.40
0.30
0.20
0.10
0.00
5% 10% Add iti onal Hea15% 30%Boi ler Horsepo wer
t I np ut Req ired to Make 66 % 150%
Sou rce: Cooper Tool Mfg .
Dr. Mac Brockway's Boiler Water Chemistry
(Contact Dr Mac at 405-737-3740 for the Companion White Paper that accompanies this chart)
(Dr. Brockway is a Phd Chemical Engineer specializing in water chemistry.)
1 Grain = 17 PPM of soluable hardness Steam Boiler (<300 PSI) Water Treatment
Principle Benefit Pre- Internal Testing Want to Prevent Action Comment

Treatment Treatment What You Want Chemistry Chemistry YOU WANT
Eliminate No Water Phosphate (PO4) HARDNESS SOFT Good Heat Transfer
Hardness Scale Softner Precipitation Hardness = 0 Ca++ +CO3 = CaCO3 3Ca++ + 2PO4 = Cay(PO4)2 Lower Energy Cost
Removes Calcium or PO4 =30-60 ppm Great! Calcium + Carbonate = Calcium Carbonate Calcium + Phosphate = Soft Sludge Longer Boiler life
and Magnesium Chelant or Slow Reaction results in hard formation Fast reaction results in a soft formation
salts only Solubilizer Chelant = 10-30 ppm
Hardness Test Treat at the Feedwater Tank
SOAP TEST HACH 5B REAGENT
1 Drop = Soft (<1 Grain) Pink = Hard
2 Drops = Hard (1-2 Grains) Blue = Soft <1 Grain
3 Drops = Hard (2-3 Grains) Each drop of reagent = 1 Grain
Run Sample COLD
Eliminate No Deareate Sulfite Oxygen = 0 Fe + 1/2O2 = FeO 2SO3 + O2 = 2SO4
Oxygen Corrosion or SO3 = 30-60 ppm Great! Iron Metal + Oxygen = Rust Sulfite + Oxygen = Sulfate Longer Boiler Life
Hot Feedwater
Sulfite Residual Test Treat at the Feedwater Tank
1 Drop = 10 ppm May be injected directly into the boiler
Desired 30-60 ppm but don't forget the feedwater tank
Run Sample HOT
Run this TEST FIRST!
Save Fuel $$
Add Soft N/A NaOH OH = 300-600 ppm Hard Crystalline solids Elevate pH Clean Boiler
Alkalinity Solids Sodium pH = 11.0 - 12.0 Avoid runing pH too low this OH = Elevated Alkalinity Good Heat
Hydroxide pH = 11.56 Perfect will result in Hard Calcium Phosphate Result Soft Solids Transfer
Add Soft N/A Polymer Normal Hard Crystalline solids Polymer + Hard Soild = Soft Sludge Clean Boiler
Polymer Solids Poly = 10-50 ppm
Control TDS Pure Steam Reverse Osmosis Blowdown TDS = 3,000 - 5,000ppm Prevent Boiler Water Carry Over Pure Steam Clean Boiler
"Total or Manual TDS <= 3,000 Great! Priming and Impure or Wet Steam and Good Heat Treansfer
Disolved Solids" De-Ionizer and/or uMhos = 4,000 - 6,0000 Wet Steam robs energy from your Solids Removal Saved Fuel $$$
Automatic steam line!
Nutralizing
Boost Eliminate De-Alkalizer Amine Condensate CO2 + H20 = H2CO3 (Carbonic Acid! pH=4-6) Amine(A) + H2CO3 = A~H+HCO3 (pH=8-9) No Rust or iron
Condensate pH Steam Line and or Volatile Chemical pH = 8 - 9.0 Great! H2CO3 + Fe = FeCO3 (Iron Scale!) Amine(A) + H2O = A~H+OH (pH = 8-9) brought back to boiler
Condensate Line Reverse Osmosis travels with steam Iron Test <0.1ppm Rot out distribution and condensate lines! Amine combines with H2CO3 to nutralize by condensate.
Corrosion the acid and raise the pH to 8-9 and Longer distribution
protects condensate lines. line life.
Compiled by
ABMA Water Chemistry Guidelines 10/19/2020 David Farthing
405-249-9324
Go Back To American Boiler Manufacturers Association **

DR.MAC Boiler Water Chemistry Guidelines
** As adopted from the American Society of Mechanical Engineers
Boiler Water Chemical Limits Boiler Water Chemical Limits
Includes SUPERHEATER, Turbine Drives, or Process Restriction on Steam Quality NO Superheater, Turbine Drives, or Process Restrictions on Steam Quality.
Boiler Operating Pressure (psig) Boiler Operating Pressure (psig)
15 150 300 600 900 1200 1500 15 150 300 600 900 1200 1500
Parameter Chemical Concentration (mg/liter) PPM Parameter Chemical Concentration (mg/liter) PPM
TDS (Unnutralized) 700-2800 700-3500 700-3500 500-2500 150-750 150-500 150-300 TDS (Unnutralized) 700-5595 700-5505 700-4545 500-4545 150-750 150-500 150-300
Phosphate (PO4) 30-60 30-60 30-60 20-40 15-20 10-15 5-10 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 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 Sulfite 30-60 30-60 30-40 20-30 15-20 10-15 5-10
Silica (SiO2) 150 100 50 30 10 5 3 Silica (SiO2) 150 <150 <150 <90 <30 5 3
Total Iron (Fe) mg/l <0.1 <0.1 <0.05 <0.03 <0.02 <0.02 <0.01 Total Iron (Fe) <0.1 <0.1 <0.05 <0.03 <0.02 <0.02 <0.01
Organics 70-100 70-100 70-100 70-100 50-70 50-70 50-70 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.
ASME for Saturated Steam Boilers allows for upto 5595 TDS (8000 Conductivity) up to 300 PSI and 4545 TDS (6500 Conductivity) above 300 but at or below 600 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 CONDUCTIVITY to mMHO or TDS Converstions
9.5 10
10.0 25 CONDUCTIVITY (KNOWN) 6500 4545.45 TDS Resulting (Non-Neutralized)
10.5 60 TDS (KNOWN) 5000 7150 Conductivity (mMHO) Resulting
11.0 150 mMHO (KNOWN) 2000 1398.6 TDS Resulting (Non-Neutralized)
11.2 220 mS(Siemans) (KNOWN) 20 13986 TDS Resulting (Non-Neutralized)
11.4 310 Note the Honeywell DL423-10 Graphite Sensor reads 0-20 mS.
11.6 460 The 4-20mA signal(PV) to the recvieing device is ranged 0-20
11.8 700 This is then converted to TDS as follows
12.0 1050 (PV/1.43) *1000 = TDS Reading (Non-Nutralized)
12.2 1500 If you want to correct for pH (which should be 11.56 in boilers)
12.4 2400 subtract 455 from your calculation as follows.
12.6 3800 ((PV/1.43) *1000) - 455 = TDS Reading (Nutralized to 11.56pH)
12.8 6100
13.0 10,000
EXAMPL1] 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.
Print Out 10/19/2020
Boiler / Burner Data Sheet
Today's Date 10/29/2008 Certificate Exp. Date
Company Name Federal Court House
Location 5th & E Street Insurance Carrier FM Global
City Lawton State OK Zip 73501 Inspector No.
Boiler MFG Name Peerless Burner MFG Name Gordon Piatt

Model No. LC-10 Model No. R8.2-G-07 RM7895A-H4.15HS-UL-CSD1
Serial No. 72566/ NB#28696 Yr Blt 2004 Serial No. an57303
Hot Water 50 Steam Atmosperic (Natural Draft) NA
Operating Pressure (PSI) 44 Power/Mechanical Draft 120 VAC 9.2 Amp
Date Installed 7/7/1997 BTU/Hr. Input 1.860 MMBtu
Power & Mechanical Draft Burners Atmospheric (Natural Draft) Burners
INPUT in BTU/HOUR INPUT in BTU/HOUR

ASME SAFETY STANDARDS No. CSD-1 Less Than 400,000 2,500,000 5,000,000 Less Than 400,000 2,500,000 5,000,000
Fax (405) 232-5438
400,000 to to to 400,000 to to to
CONTROL & SAFETY DEVICES GUIDELINES (Including 2,500,000 5,000,000 12,500,000 (Including 2,500,000 5,000,000 12,500,000
FOR AUTOMATICALLY GAS FIRED BURNERS Modular Boilers Modular Boilers Associated
NOT
w/ max. input of w/ max. input of Standard
INSTALLED NOT INSTALLED System Control Specifications 400,000) 400,000)
REQUIRED Paragraph
120 East Main Street -- Post Office Box 26408
INTERLOCKS / LIMITS
Approved Operating CR-220(a)(1)(2) CW-
Controllers Steam Boilers Required Required (Note Required Required Required Required Required
Required (Note 1) 310(b) CW-
(Pressure) (Note 1) 1) (Note 1) (Note 1) (Note 1) (Note 1) (Note 1)
620(b)
CR-220(b)(1)(2) CW-
Honeywell Hot Water Boilers Required Required (Note Required Required Required Required Required
Required (Note 2) 410(b)
L4006E1117 (Temp) (Note 2) 2) (Note 2) (Note 2) (Note 2) (Note 2) (Note 2)
CW-640(b)
(800) 289-3331 (405) 239-7301
High Limits CR-220(a)(1)(3) CW-

Oklahoma City, Oklahoma 73126
Required Required (Note Required Required Required Required Required

Steam boiler (Pressure) Required (Note 3) 310(c)
(Note 3) 3) (Note 3) (Note 3) (Note 3) (Note 3) (Note 3)
(Manual Reset) CW-620(a)
Hot Water Boilers CR-220(b)(1)(3) CW-
Required Required (Note Required Required Required Required Required
(Temp) Required (Note 4) 410(c)
(Note 4) 4) (Note 4) (Note 4) (Note 4) (Note 4) (Note 4)
(Manual Reset) CW-640(a)
CF-162(a), CF-910,
High Gas Pressure
(Note 5) Required Required Required Required CR-410 Table CF-
(MANUAL RESET)
NOT INSTALLED 1,CF-2
Low Gas Pressure CF-162(a), CF-910,
(Note 5) Required Required Required Required
NOT INSTALLED (Manual Reset) CR-410 Table CF-
Honeywell Valve Seal Overtravel 1,CF-2 CF-180(b)(2)
(Note 6) (Note 6) (Note 7) (3)
V4062A1131 Interlocks
CF-210(a)(2) CF910,
Honeywell
High Fire Switch (Note 8) (Note 9) (Note 9) (Note 10) (Note 10) (Note 10) CR-410, Tables CF-1,
V4062A1131
CF-2
Honeywell
Low Fire Switch Required Required Required Required CF-610
V4062A1131
ANTUNE Air Required Required Required Required Required CR210(a)(b)(c)
Supervised Purge Air Required (Note 9)
Flow Switch (Note 9) (Note 9) (Note 10) (Note 10) (Note 10) Tables CF-1, CF-2
ANTUNE Air Tables CF-1, CF-2
Proven Combustion Air Required Required Required Required
Flow Switch CR-1, CR-2
Action on Loss of Combustion Safety Tables CF-1,
(Note 17) (Note 18) Safety Shutdown
LOCKOUT Air Shutdown CR-1, CR-2
Low Water Fuel Cutoffs
(2) Required (2) (2) Required (2) CE-120(a)(b) CR-
McDonnel Miller Low Water 2 Required (1 (2) Required (2) Required (Note (2) Required (2) Required
11361 East 61st. Street, Broken Arrow, Oklahoma
(Notes 11,12, Required (Notes Required 210(a)(b), CW-610(a)

Tulsa (918) 955-1918
No 64 w/MANUAL RESET) (Note 11) 11) (Note 11) (Note 11)

13) (Note 11) 11,12, 13) (Note 11) (b)
(1) Required (1) Required CR-210(c), CW-

HydroLevel Hot Water Boilers (1) (1)
(Notes 14 (1) Required (1) Required (Notes 14 (1) Required (1) Required 130(a), CW-
Mdl550 (MANUAL RESET) Required Required
& 15) & 15) 630(a)(b)
Forced Circulation CR-210(e), CW-
(Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16)
(MANUAL RESET) 210(a)(b)
PILOT VALVE TRAIN (Note 12)

Approved Safety Shutoff
ASCO 8040H8 Required Required Required Required Required Required Required Required CR-180(C)
Fax (918)249-9014
Valve(s)
1-Ball Valve Manual Shutoff Valve(s) Required Required Required Required Required Required Required Required CF-150(C)
CF-110(a)(1), UL795-
MAXATROL 25 15, CF-
Gas Pressure Regulator Required Required Required Required Required Required Required Required
RV47L 180, cf-161(b) Figs B-
1, 2,3,4
MAIN VALVE TRAIN

(800)955-1918,
ASCO
(2) (2) (1) or (2)
JB821480 and Approved Safety Shutoff (2) Required (1) or (2) Required (2) Required CF-180(b) (1)
(1) Required Required (1) Required Required Required
Honeywell Valve(s) (Note 19) (Note 20) (Note 21) (2)(3)
(Note 21) (Note 19) (Note 20)
V4062A1131
(1) or (2) (1) or (2) (1) or (2) (1) or (2) (1) or (2)
Manually Operated Leak Test (1) or (2) Required
Required (Note Required Required Required Required CF-150(d)
Valve(s) (Note 22)
YES 22) (Note 22) (Note 22) (Note 22) (Note 22)
(2) (2) (2) Required CF-150(b)(d)
Manual Shutoff Valve(s) (1) Required (2) Required (2) Required (1) Required (2) Required
1-Gas Cock 1-Ball Required Required ANSI221.13 1114
MAXATROL CF-160, CF-161(b),
74012
RV81 Set at Gas Pressure Regulator Required Required Required Required Required Required Required Required ANSI221.13 1.15.1
6.0" Fig. B-1, 2,3, 4
APPROVED SAFETY CONTROL SPECIFICATIONS

Rebuilt Flame Safeguard / Not Not Not
Not Permitted Not Permitted Not Permitted Not Permitted Not Permitted
Honeywell RM7895A1014 OEM Burner Control Permitted Permitted Permitted
CF-210(a)(1)(2)(c)
90 Seconds
Prepurge Timing (Note 9) (Note 9) (Note 10) (Note 10) (Note 10) Tables CF-1, CF-2
(Note 8)
60 Sec CR-1, CR-2
CF-210(a)(1)(2)(c)
Prepurge Air Changes
4 Changes 4 Changes 4 Changes Tables CF-1, CF-2
Required
4 CR-1, CR-2
l Corporation
High Fire Purge Proving CF-210(a)(1)(2)(c)

(Note 8) Required Required (Note 10) (Note 10) (Note 10)
YES Circuit Tables CF-1, CF-2
NO Low Fire Start Circuit Required Required Required Required CF-610
Not Not Tables CF-1, CF-2
Continuous Pilot Optional Optional Not Permitted Optional Optional Not Permitted
NO Permitted Permitted CR-1, CR-2
Tables CF-1, CF-2
Intermittent Pilot Optional Optional Not Permitted Required Optional Optional Optional Optional
NO CR-1, CR-2
Not Tables CF-1, CF-2
Interrupted Pilot Optional Optional Not Permitted Optional Optional Optional Optional
YES Permitted CR-1, CR-2
Required Required (Note Required (Note Required Required Required Required Required
Proved Pilot CF-320(a)(1)
YES (Note 25) 25) 25) (Note 25) (Note 25) (Note 25) (Note 25) (Note 25)
10
Pilot Flame Establishment
15 Seconds Seconds 15 Seconds 10 Seconds Tables CF-1, CF-2
Period (PFEP) None Not Permitted None 10 Seconds
(Note 26) Maximum (Note 26) (Note 26) CR-1, CR-2
Continuous Pilot
10 Sec (Note 31)
Federal Corp
Intermittent Pilot 15
Print Out
Seconds
10/19/2020
15 Seconds Not Permitted
Not 15
15 Seconds
10
10 Seconds
Tables CF-1, CF-2
Permitted Seconds Seconds CR-1, CR-2
10 10 Tables CF-1, CF-2
Interrupted Pilot 15 Seconds 15 Seconds 10 Seconds 15 Seconds 15 Seconds 10 Seconds
YES Seconds Seconds CR-1, CR-2
Main Flame Establishment
10 Tables CF-1, CF-2
Period (MFEP) None (Note 27) None (Note 28) (Note 29) (Note 30)
Seconds CR-1, CR-2
10 SEC Continuous Pilot
15 Seconds Tables CF-1, CF-2
Intermittent Pilot (Note 28) (Note 29) (Note 30)
Maximum CR-1, CR-2
10
10 Seconds
15 Seconds 15 Seconds Seconds 15 Seconds Tables CF-1, CF-2
Interrupted Pilot Maximum (Note (Note 28) (Note 29) (Note 30)
Maximum Maximum Maximum Maximum CR-1, CR-2
31)
YES (Note 31)
4 Seconds
15 Seconds 4 Seconds 15 Seconds Tables CF-1, CF-2
Direct Ignition Maximum (Note
Maximum Maximum Maximum CR-1, CR-2
32)
CF-310(d) (1)(2)(3)
Supervised Main Flame (Note 34) Required Required Required (Note 34) (Note 34) (Note 33) Required
YES (4)
4 Seconds 4 Seconds
Flame Failure Response Time 4 Seconds 4 Seconds 4 Seconds 4 Seconds 4 Seconds 4 Seconds Tables CF-1, CF-2
Maximum Maximum
(FFRT) Maximum Maximum Maximum Maximum Maximum Maximum CR-1, CR-2
3 Sec (Note 36) (Note 35, 36)
Safety Safety Safety Safety Safety Safety
Safety Tables CF-1, CF-2
Action on Flame Failure Shutdown Shutdown (Note Safety Shutdown Shutdown Shutdown Shutdown Shutdown
Shutdown CR-1, CR-2
Lockout (Note 37,38) 39) (Note 37,38) (Note 40) (Note 40) (Note 40)
CF-162(a), CR-220(a)
Safety Safety Safety Safety Safety Safety Safety CW-130(d), CE-
Action On Limit Opening Safety Shutdown
Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown 310(c), CW-410(c),
Recycle CF-910
FOOTNOTES:
For modular boilers, each

1 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
2 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
3 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
4 will prevent the water
temperature from exceeding
the maximum allowable
temperature.
Required for direct ignition

5 systems. Not required for
ignition systems with pilots
Optional one safety shutoff

valve with valve seal
6 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
8 flow and damper opening with
both air flow and damper
position proven.
Four air changes at 60%

damper opening with both air
9 flow and damper position
proven.
Units equipped with automatic

operating air shutters or
dampers which are closed or
positioned to restrict air when
10 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.
One of the two low-water fuel

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

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

steam boilers, each module
shall be equipped with an
automatic low-water fuel
cutoff. The assembled
13 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.
Except those installed in

14 residences (as defined by the
authority having jurisdiction).
Print Out 10/19/2020
An assembled modular boiler
shall be protected by a low-
water fuel cutoff located so
that it will detect a low-water
condition before the level falls
15 below the lowest safe
waterline in any module.
Operation of the low-water
fuel cutoff shall shutoff the fuel
to all modules.
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
16 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.
One recycle for piloted

18 systems.
Two safety shutoff valves in
19 series. May be in single
control body.
Two safety shutoff valves in

series on one safety shutoff
20 valve with valve seal
overtravel (Proof-of-closure)
interlock.
One safety shutoff valve to

incorporate valve seal
interlock.
When two safety valves are

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

where required, shall be
located upstream of all
operating and safety controls
23 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.
Water level control alarms,

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

26 Initial start only.
Pilot only: 15 seconds
27 maximum if interrupted pilot is
used.

maximum if interrupted pilot is
28 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.
Maximum input at light off
32 shall not exceed 2,500,000
Btu/Hr.
Required with modulating or
33 high-low firing.
34 Required if interrupted pilot.
If ignition system includes a

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

draft, burner and natural draft
burners with inputs less than
36 400,000 Btu/Hr. and continuos
pilot, 180 seconds maximum
for pilot flame failure.
If system has intermittent pilot,

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

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

39 for
Or, recylce once after 5
40 minute time delay.
Select proper safety control Print Out 10/19/2020
41 according to system
requirements.
Date of Printout Data Compiled by
TechStuff - Boiler Benchmarking David Farthing
10/19/2020 / 14:52:14
Voice 405-760-2831
BENCHMARKING A BOILER
AMBR = American Boiler Manufactuers Recommendations
$ 6.36 Therm Customer ChemTrade Industry Sulphuric Acid
Utility Fuel Btu = 975.609 Contact Mike Miller Gas After the Train = 33.02 InWc
Pf=(GP+Pc)/Pb Address 5201 W. 21st Street Air At Burner = 16.9 InWc
Guage PSI(GP) = 33.84 Actual PSIG City/State/Zip Tulsa, OK 74107 Gas at Burner = 16.2 InWc
Site Barometric (Pc) = 14.735 Location/Elevation Date 3.17.09 Burner Data Maxon EB6 0
Sea Level (Pb) = 14.700 Average Daily Rate = 326.709 MCF Boiler Mfg Operating PSI 0 Economizer NO
PSI Correction Factor (Pf) = 3.304 12/31/08-01/31/09= 10127.979 Mfg Rated Eff. 0% BHP = 0.0 Mfg
Clocked Metered Fuel Flow = ((100 SCFt/Time)*60)*Pf Fuels Natural Gas Gas PSI = 52InWc Steam Temp 0
Gas Flowing Temp = 56 Rated BTU Input/Hr 12,000,000 Fan Voltage 460 BTU/Lb Steam 0
Average Rate Rated Steaming Capacity/Hr 0 Fan Amp Rating 11.5 Feedwater Pump Amp Rating 0
High Fire Utility Meter BtuOut/BtuIn Eout/Ein
Valve % Firing Rate Time/100 Cf Fuel Flow Burner InWc Rated Steam Steam Flow %/ Rated Flow Stack Temp Actual Ex O2 ABMR Ex O2 Actual Ex CO ABMR Ex CO Comb Eff % Fan Amps Boiler Thermal Eff % System Total Eff% EXCESS AIR % FLAME COLOR/PATTERN
10% 1200 0.000 #DIV/0! 0.0000 0 #DIV/0! #DIV/0! 6.00% N0X/CO 64/0ppm 45 #DIV/0! #DIV/0!
15% 1800 0.000 #DIV/0! 0.00 0 #DIV/0! #DIV/0! 6.00% 0.00 45 #DIV/0! #DIV/0!
20% 2400 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 6.00% 0.00 46.8 #DIV/0! #DIV/0!
25% 3000 0.000 #DIV/0! 0.00 0 #DIV/0! #DIV/0! 6.00% 0.00 48.08 #DIV/0! #DIV/0!
45% 5400 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 4.50% 0.00 #DIV/0! #DIV/0!
80% 9600 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 2.50% 0.00 #DIV/0! #DIV/0!
90% 10800 0.000 #DIV/0! 0 0 #DIV/0! #DIV/0! 2.00% 0.00 7.05 #DIV/0! #DIV/0! Bright blue/hugging burner
100% 12000 1.616 12269 16.20 0 0 #DIV/0! 424 18.80% 2.00% 13/0 ppm 0.00 0 9.4 0.00% 0.000% 780% Duct Fan ON
100% 12000 1.616 12269 16.20 0 0 #DIV/0! 424 13.11% 2.00% 5/0 ppm 0.00 0 9.4 0.00% 0.000% 178% Duct Fan OFF
Economizer Data
Valve % Water Flow BDHR DeltaT TDS mS Inlet Temp Outlet Temp BTU Recovered Fuel Savings % FW Pump Amps
10% 0.000 0.000 0.000 212 120 0 0.000% 0
15% 0.000 0.000 0.000 212 120 0 0.000% 0
20% 0.000 0.000 0.000 212 120 0 0.000% 0
25% 0.000 0.000 0.000 212 120 0 0.000% 0
30% 0.000 0.000 0.000 212 120 0 0.000% 0
35% 0.000 0.000 0.000 212 120 0 0.000% 0
40% 0.000 0.000 0.000 212 120 0 0.000% 0
45% 0.000 0.000 0.000 212 120 0 0.000% 0
50% 0.000 0.000 0.000 212 120 0 0.000% 0
55% 0.000 0.000 0.000 212 120 0 0.000% 0
60% 0.000 0.000 0.000 212 120 0 0.000% 0
79% 0.000 0.000 0.000 212 120 0 0.000% 0
42% 0.000 0.000 0.000 212 120 0 0.000% 0
75% 0.000 0.000 0.000 212 120 0 0.000% 0
80% 0.000 0.000 0.000 212 120 0 0.000% 0
85% 0.000 0.000 0.000 212 120 0 0.000% 0
90% 0.000 0.000 0.000 212 120 0 0.000% 0
95% 0.000 0.000 0.000 212 120 0 0.000% 0
100% 0.000 0.000 0.000 212 120 0 0.000% 0
High Gas PSI Switch Set at = 60 InWc
Low Gas Pressure Switch Set at = 12 InWc
Air Flow Switch Set at = 10 InWc
High Temp Controller Set at = 1065 C
Normal Operating Setpoint = 900 C
Theoretical Flame Length = 8' 6"
Data Compiled by
10/19/2020 14:52:14 Dissolved Oxygen In Make-up Water David Farthing
P P B D is s o lv e d O x y g e n
Voice 405-728-6709
Amount of Dissolved Oxygen in Make-up Feedwater vs. Temperature
20000
15000
10000
5000
0
50 58 60 72 125 180 200 212 227 242
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
Data Compiled by
Date of Printout
Pressure Coversions Karl Pierson
10/19/2020 14:52:14
KMCS
Enter value to be converted in column D

The converted values will then be shown in the same row
To Values
From Value In. H2O @ In. H2O @ In. H2O @ In. Hg @
PSI OzSI PASCAL kPa BAR mBAR mm H2O cm H2O ATM Cm Hg mm Hg TORR
4C/39F 60F 20C/68F 0C
PSI
OzSI
PASCAL
kPa
BAR
mBAR
In.H2O @ 4 C
In. H2O @ 60F 6.00 0.22 3.5 1,493 1.49 0.015 14.93 6.0 6.0 6.0 152.3 15.2 0.015 0.44 1.12 11.2 11.2
In. H2O @ 20C
mm H2O
cm H2O
ATM
In. Hg 8.00 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 8.00 20.32 203.2 203.2
Cm Hg @ 0 C
mm Hg @ 0 C
TORR
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
F= 87
B= 4000
S= 41400
Blowdown 920.4702 Lbs/Hr
Percent 2% of Production Capacity
NOTES: Blowdown within acceptable limits
Be sure to see HEAT in the contents for possible Heat Recovery Savings.
Energy Conversions
BTU = KW KW = BTU
29,010.00 8.50 8.50 29,010.24
AMPS VOLTAGE 3Ph/KW

43.00 480.00 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 VFD
CALCULATING APPROXIMATE HP WHEN VOLTS AND AMPS ARE KNOWN
Voltage 480
Amps 69
NP Eff% 80%
# Phases 3
61.52
VFD
Replacing DC3000 Versa-Pro with
OLD DC300C- use

OLD DC300K- use
OLD DC300E- use
OLD DC300A- use
OLD DC300T- use
OLD DC300L- use
Table 1 O use
E use
A use
T use
L use
Table 2 1_ _ use
2_ _ use
4_ _ use
_A_ use
_B_ use
_ _3 use
Table 3 Same on 3300
Table 4 First digit (zero) use

Second digit use
Third digit use
Forth digit use
n/a 5th digit
n/a 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-
-_L-
1_ _
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 -00-
Always -0-
er used on replacement controllers.!!!

Replacing DC3000 W/ Table 1 with
DC3001-0- use
DC3002-0- use
DC3003-0- use
DC3004-0- use
DC3005-0- use
DC3006-0- use
Table 2 1st -0_ _- use

-1_ _- use
-2_ _- use
-3_ _- use
-4_ _- use
2nd -_0_- use
-_1_- use
-_2_- use
3rd -_ _0- use
-_ _A- use
-_ _B- use
Table 3 -1- use

-2- use
-3- use
Table 4 -00- use

(multiple avail.) -35- use
-DIN- use
-FM- use
-UL- use
Table 5 ID code 4 digits use

Table 6 Not used use
Note…. DIN or "D" is almost never used on replacement controllers.!!!

DC3300 W/ Table 1
DC330B-C0-
DC330B-KE-
DC330B-EE-
DC330B-EE-Also change 2nd digit of table 3 to "2"
DC330L-E0-
DC330L-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-
-0F0000-
Always use -00-

Always use -0-
" is almost never used on replacement controllers.!!!

VFD Calculations David Farthing's
10/19/2020 TechStuf
Variable Frequency Drive Applications

Customer American Airline Service Center
Application Combustion Air Fan Control
Need to know Motor Horsepower 5

Motor Speed as supplied 3450
Hertz - Name Plate 60
Rated Torque Ft/Lb. 8
New Hertz 37
New Motor Speed 2128
New Torque Ft/Lb. 8 NOTE: Torque should remain constant but Horsepower will change.
Change in Motor Speed % 38.33%
New Horsepower @ New Speed 3.08
Prefer to know Original Amp Draw 6.5
Cost of kW of Electricity $ 4.500
Total Hours of Operation/Year 4000
Is Application Pump or Fan? (P or F) F
Control Methods Code - See List Below IG
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 5.402 Kilowatt Usage Standard Motor No Control
kWhb 2.300 Kilowatt usage using VFD at New Horsepower
kWhc 3.349 Kilowatt Usage Using Current Control Method
kWhd 1.049 Kilowatt Savings Converting from Current Control Method to VFD
Savings $ 188.78 Annual Energy Cost Savings By Converting to VFD

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STEAM TOTAL ENTHALPY 1196 Hg (BTU/LB)

BOILER BLOWDOWN ENTHALPY 339 Hf (BTU/LB)

STEAM LATENT ENTHALPY 857 Hfg (BTU/LB)

BOILER EFFICIENCY (GAS) 82.0% %

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