Warr

Data Compiled by
Contents
Compile January 14, 1997 David C. Farthing
Data Printout 11/24/2022
Voice 405-728-6709

WELCOME TO TECHSTUFF!! Month Year anty

Date of Rev.
© 1997 David C. Farthing
Accu
Revision 4.11 11
4.28.11
A Compilation of technical formula, solutions, and manufacturer's application notes.

Boile
Compiled by David C. Farthing as a service to those who need to know.
Use Mouse to Click on Button to GO TO desired formulas.
racy
Gene
Instructions Refri r Burn ContPump
Heati
Fill in new data in yellow boxes.

ral
Contr gerati Burn er act s
ng Valve
Calc
ols - Load Flow on Elect er Mana and
InfoProdu
Sizing
ulatio
Tran Stea Load& Calcu ric geme Revisi Hydro ct
s
ns
smitt m Pipin s lationMoto nt on Selectnics
ers Stuff g rs Notes ion
VolCalculations
General
& Data Guide
Data
um
PR
Fluid Volumes in Cylindrical and Square Sided Tanks

AIR
TE VFD
Water Content in an Air Stream

ESS e Temperature Conversions

EN Pressure Conversions
MP
Fin
UR
ER Energy Conversions BTU/KW KW/BTU
anci
GYE Financial Analysis of a Project
al
Heating Loads
BT Calculating BTU Load of liquid in Square & Cylindrical tanks Bac
Fan
U k
FFH Steam Load Across Fan Coils

FG
Coil
Flowing Fluid Heating Loads
L Flowing Gas Heating Loads To
B&
Equ
HL Building + Equipment Heating Load Combination Con
ipE Solid Materials & Equipment Heating Loads
tent
Ht
Refrigeration
Refr
Loads
Refrigeration loads of flowing liquids s
ig.Calculations
FA
Boiler
BH Boiler Horsepower from BTU and/or Pound Per Hour Steam Flow
N
STA P& Fan Laws for Boiler Burner Applications and Fuel BTU Content Conversions Bac
O2/
FUE
CK
CO k Burner
EVO Approach Calcs and Rite Boiler Index for Stack & Boiler, Atmospheric & Power
TanL Combustion Efficiency Savings with O2 Trim & CO influence
S
Tri
k To
Eco
Co
Condensate & Feedwater Tank Sizing

m Economizer
Size
FW
no
Calculations
Con
mb
Sys
Excess Air & Oxygen Analysis & Combustion Air Requirements

Air The effect of Boiler Operating Pressure on System Design - Firetube Boilers tent
Te The effect of Feedwater Temperature on Boiler Horsepower
Sys
tem
mp The effect of Boiler Operating Pressure on System Design - Watertube Boilers s
tem
SC
DR.s The effect of Scale & Soot Build-up on Heat Transfer in Boilers
s-W
ALE
BE Dr. Mac Brockway's Boiler Water Chemistry Class (With Conductivity Conversions)
MA
CS
NC
BL
D1
CSD-1 Fire & Water Side Control Requirements
C Benchmarking a Boiler
MK
HM
EFF
DO Boiler Blowdown Calculations
UP
ICEI
WN K Amount of Dissolved Oxygen in Make-up Feedwater vs. Temp.
POWERHOUSE EFFICIENCY CALCULATIONS
O2
NC
Y SIL (Safety Integrity Levels) Rating Calculations
Burner Management
NFP
SIL
MA
A NFPA-87 Recommended Practices for Fired Oil and Gas Processing Heaters
XO Maxon Kinedizer OR Other Models Firing Rate Calculator
87 ValveProving Sequencing Test Calculation
VPS
Gas N
Valve Sizing CV Calculations
Liq Gas Flow Control Valve Sizing Bac
Ste
Val
uid Liquid Flow Control Valve Sizing k
am
ve Steam Flow Control Valve Sizing
Val To
Puand Hydronics
Val
Pumps

mp Centrifugal Pump Affinity Laws

Con
mp
Exp
Hyd s
Pump NPSH Calculator tent
NP Expansion Tank Sizing Calculations
ansi
PU
roni s
SH Hydronic Zone Flow Calculations
on Pump VFD Affinity Laws & Curves
MP
cs
VFD
Electrical, Control and Instrumentation Stuff
Volt Controller Out Put Voltage v. Impedance and Transmitter Troubleshooter
OH OHMS Laws
age
IAS
MS Instrument Application Selection Guide and Loop Tuning Guide
VFDG Variable Frequency Drive Calculations Bac
Steam Stuff k
Mai Condensate Loads & Steam Main Trap Sizing
Lea
He
Rel
ns To
Tab
Sup
Cost of Leaking Steam Traps and Fittings in Lost Steam and Revenue
ks Steam Tables Con
at
ief
les
erh tent
Calculating Superheat in Pressure Reducing Stations
Re
Val
Ste
eat Blowdown Heat Recovery

FL Cost to Produce Steam in $/Kpph

cov
Re
Relief Valves
s
am
AS
ery
cov
$$
Flash Steam Calculator

HMeasurement & Piping Calculations

Flo
ery
Flow
w Gas/Steam Flow & Steam Velocity
Fric
Cal Single Pipe Friction Loss Calculations
Pip
Ha Thermal Expansion of Pipe
tion
cs
Ins
e T. Water Hammer Calculations
mm
Hall
ulat Piping Insulation Losses
er Halliburton Gas/Liquid Turbine Meter Calculations (Convert BTU to GPM #2 Diesel)
ibut
ion
Product Selection Guide
ron
AS ASCO Solenoid Valves TOMSPAVE Bac
Boil
CO k
FS Flame Safety Control Selection Guide
ers
Boiler Application Guide

Tra
Pu
G Steam Trap Selection Guide To
ps Pump Applications
mp
M& Con
DC3
s Measurement,
C
Control & Recorders
tent
DC3 UDC3000 Cross Reference (DC300#)
00# UDC3000 Cross Reference (DC300X)
00X s

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.
6.09 6.10.09 Update Benchmarking a Boiler with Temp Compensation on Utility Meter Clock
8.09 8.03.09 Add Rex Warr's Loop Tuning data to Instrument Page.
8.09 8.26.09 Modify STACK Effect ot include EVO Stack Approach calculations.
11.09 11.10.09 Clean up Effects of Operating Pressure 'Water Temp' charts.
11.09 11.20.09 Change cost of electricty from $$$ to $0.00 in VFD calculator.
3.10 3.25.10 Add Total Btu Required Calculator to Flowing Heating Load Calc.
6.10 6.15.10 Add Maxon Kinedizer and other burner models Combustion Calculator Data from Conrad Baker Maxon Corp.
7.10 7.12.10 Add EPA Nox calculation to correct Nox readings to 3.0% O2 to Maxon Kinedizer and Oxygen Trim worksheets.
8.10 8.09.10 Add Spirax Sarco 'Napier Formulas' for finding PPH Steam Loss in a Pipe Leak.
9.22.10 Remove Sarco Steam Cost Calculator due to data link corrucption error.
3.11 3.14.11 Add SIL Level Calculator
3.11 3.14.11 Add NFPA-87 Check List
 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
24/7 VOICE - 405.249.9324
Alternate 800-239-7301
Alternate Fax 405-232-5438
[email protected]
[email protected]

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
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 Data Compiled by
Tank Fluid Volumes
Compiled January 14, 1997 David C. Farthing
Data Printout 11/24/2022
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
Data Printout 11/24/2022
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

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
Alcohols .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

Page 6
 Data Compiled by
Rite Boiler Chimney Effect
Data Compiled January 14, 1997 David C. Farthing
Data Printout 11/24/2022
Voice 405-728-6709

Exhaust Gas Volumes for Typical Boiler/Burner 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 325
Boiler Horsepower 1200
Exhaust Volume 126,949.14 Actual Cubic Feet/Min. At Stack Temperature
Emissions Make-Up Percent of Flue Gases
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 = 94,841.27 4,581.45

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 = 80.52

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
Compiled January 14, 1997 David C. Farthing
Data Printout 11/24/2022
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 1216.3523

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
11/24/2022 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
11/24/2022 07:52:16
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
11/24/2022 07:52:16 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 = Saturated Limestone Cement Plant (Winter Conditions)

W= 244444 Lbs.
Cp= 0.35 From Charts
L= 1 From Steam Charts
Start Temp 32
Final Temp 211
Delta T= 179
t= 1
Lbs/hr= 15314417 BTU/Hr = 15,314,416.60
Boiler Hp 457.62
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 11/24/2022 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 Heater Eff = 28.15%
Gal/Hour Gal/Minute Total Btu Input Required = 5,072,745.47
Flow = 2424 GPH 333 GPM
Sp. Gr. 1 0.8183
Sp.Ht. 0.6 0.5825
T1 = 60 427
T2 = 600 Boiler Hp Steam Flow 445 Boiler Hp Steam Flow
Load BTU/Hr. = 6,542,182.08 195.49 6,744.52 1,427,977.85 42.67 1,472.14

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
Alcohols .79/.60 Diphenylamine 1.16/.46 Olive Oil .93/.47
Ammonia .62/1.16 Ethyl Ether 1.16/.53 Propane .50/.59
Anilin 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
Therminol .8183/.5825

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 = 406.13718

Page 13
 Gas Valve
David Farthing's
Orifice -Regulated Pilot Train Thanks to Honeywell for the basic CV calculator
TechStuff Valves
11/24/2022

Courtesy of HONEYWELL, INC. - Modified by David Farthing GAS

DCP Carthage-Pilot Pilot-1 Pilot-2 Pilot-3 Pilot-4
CONDITIONS CONDITIONS CONDITIONS CONDITIONS
BASE FLOW SCFH 1,250.00 1,000.00 875.00 750.00
SAFETY FACTOR X 1.00 1.00 1.00 1.00
FLOW SCFH 1,250.00 1,000.00 875.00 750.00
INLET PRESS PSIG 3.00 3.50 4.00 5.00
OUTLET PRESSURE PSIG 0.21 0.21 0.21 0.21
PRESS DROP PSI 2.79 3.29 3.79 4.79
TEMPERATURE DG.F 68 68 68 68
SPEC GRAV 0.63 0.63 0.63 0.63
REQUIRED Cv 2.472 1.807 1.462 1.099
V-Cut Degrees Open Degrees Open Degrees Open Degrees Open
V-Bal 900Rotation 60 2.47 1.81 1.46 1.10
Percent Open Percent Open Percent Open Percent Open
CV of Installed Val 96 2.575% 1.883% 1.523% 1.145%

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

Solae CB700 Level 100% 75% 50% 25%
CONDITIONS CONDITIONS CONDITIONS CONDITIONS
BASE FLOW GPM 48.50 36.38 24.25 12.13
SAFETY FACTOR X 1.15 1.00 1.00 1.00
ACTUAL FLOW GPM 55.78 36.38 24.25 12.13
INLET PRESS PSIG 155.00 155.00 155.00 155.00
OUTLET PRESSURE PSIG 125.00 125.00 125.00 125.00
PRESS DROP PSID 30.00 30.00 30.00 30.00
SPECIFIC GRAV 0.97 0.97 0.97 0.97
VISCOSITY CS 0.96 0.96 0.96 0.96
TEMP(WATER) DG.F 227 227 227 227
MAX ALLOW |
¸P (WATER) PSI 119.464 119.464 119.464 119.464
REQUIRED Cv 10.029 6.541 4.361 2.180
Linear V-Ball V-Cut Degrees Open Degrees Open Degrees Open Degrees Open
V-Bal Rotation 30 19.44 12.68 8.45 4.23
Percent Open Percent Open Percent Open Percent Open
CV of Installed Val 15.48 64.788% 42.253% 28.169% 14.084%
Actuator Type Yes ELECTRIC Body Materials Stainless
120 Vac VOLTAGE End Connections THREADED
4/20mA SIGNAL Stem & Seat Tekfil (600F)
Yes MANUAL OVERRIDE POSITIONER Bray 70 w/Manual
n/a PNEUMATIC
n/a AIR SUPPLY PSIG
n/a DOUBLE ACTING
n/a 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 #)
CONDITIONS CONDITIONS CONDITIONS CONDITIONS
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
OUTLET PRESSURE PSIG 25.00 25.00 50.00 50.00
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 90 Rotation
0
60 0.00 0.00 0.00 0.00
Percent Open Percent Open Percent Open Percent Open
CV of Installed Val 400 6.667% 6.524% 28.966% 21.565%

Page 16
 VPS Calculations
Complied by David Farthing
11/24/2022

VALVE PROVING SEQUENCING TEST CALCULATIONS

V1= Upstream Valve Volume

V2= Downstream Valve Volume
D= Pipe Diameter (Inches Nominal-Schd. 40)
L= Pipe Length Between V1 & V2 (Feet)
P= Inlet Gas Pressure to V1 vps
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)
GAS
Calculation of Valve Proving Test Time
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 FrictionCalculator)

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 11/24/2022 Pump Affinity Laws
11.0" Impeller

Pump Horsepower Requirements

Q= 1340
H= 158
PSIG = 77.73
Sp.Gr.= 0.88
Pump Eff. 65.00%
Minimum Motor Hp BHP= 72.38290598291

Cost to Operate Pump

$/KW/Hr = 0.044
Hours/Day = 24
Days/Month = 15
Cost Per Month = $ 855.32

Page 20
Burner Fan Laws 11/24/2022 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 15,000,000.00 BTU/Hr from Burner Data Plate
21MM Btu Input Max Gas Flow 15,000.00 Ft^3/Hr
Min Gas Flow 1,500.00 Ft^3/Hr
Max Air Flow @15% EA. 2,844.12 CFM base on 9.67 Ft^3 Air/1Ft^3 Gas at Sea Level & 80 deg "F". 15% Excess Air.
Min Air Flow 284.41 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. 16.212% 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 1848 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 3.33 Bhp at the shaft. Q1/Q2 = D1/D2 (BV) BIO-GAS VEGATABLE (C/Ft) Averaged
Original Boiler Output PPH 12,371.13 Saturated H1/H2 = (D1/D2)^2 (BL) BIO-GAS LANDFILL (C/Ft) Averaged
Original Boiler Output PPH 10,391.75 Superheated <700 Deg F Bhp1/Bhp2 = (D1/D2)^3 BTU Input of Burner =
New Boiler Output PPH 8,037.65 Saturated
New Boiler Output PPH 6,751.62 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
C1997 Combustion Efficiency Calculations
TechStuff David Farthing
Printout 11/24/2022 07:52:17

Combustion Efficiency Calculations

Boiler Type & Data CIBO PROJECT BOILER
Minimum O2 Allowed This Fuel Type
Fuel (Gas =1, Oil =2) 1 2.00%
Rated Boiler Hp 30 Steaming Rate PPH
Name Plate Efficiency 60.00% 828
Current O2 % as found 12.00%
Current Co2 % as found 6.25%
Air Diluted CO ppm as found 50.00
CO in Flue Gas ppm Corrected 117.42
Approximate Fuel Loss out stack 0.03% Cu/Ft Gas/Hr.@NFR@ As Found Eff.
NOx Reading from analyzer 60.00
EPA Corrected to 3% O2 Nox 120.674
Normal Firing Rate NFR (0-100) 80% 1,341
Recommended O2% @ NFR 6.00% Data from Ideal O2 Table or 'as Targeted'
Average Hours/Day Run Time 24
Average Days/Month Run Time 30
Fuel Cost/Dk-Therm from billings $ 4.85 Equivalent Cost / 1000 Cu/Ft = $ 4.85
Average Combustion Air Temp 80
Stack Temp at Firing Rate 640
Net Flue Gas Temp Rise 560 Performance Data
Net Efficiency Loss to Wasted Fuel as Co 0.1174% 56% Present Excess Air Mass.
As Found Combustion Efficiency 59.9% 28% New Excess Air Mass.
New Calculated Combustion Efficiency 75.1% $7.86 OLD Fuel Cost per 1,000 Lb/Steam.
New Stack Temp 498 $6.26 NEW Fuel Cost Per 1,000 Lb/Steam.
New Net Flue Gas Temp Rise 418 20.59% Percent Fuel Cost Savings.
Net Combustion Efficiency Gain 20.26%
Current Cost to Operate Per Month $ 4,683.56 Controller Output= 45
New Cost to Operate Per Month $ 3,734.53 Raw Air Flow= 100
Current Fuel Dollars Wasted as Excess CO $ 15.34 O2 Reading= 3
Savings Per Month $ 964.37 O2 Corrected Air Flow= 102.5
Savings Per Year $ 11,572.39
NOTES
 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 11/24/2022
Voice 405-728-6709

Condensate & Feedwater Tank Sizing

Boiler Hp. 1740

Evaporation Rate from and at 212 deg. F. 7223.8267 Gallons Per Hour
GPM Flow Rate Start/Stop Feedwater System 300.99278 Gallons Per Minute 2.5 Safety Factor
GPM Flow Rate Modulated Feedwater System 180.59567 Gallons Per Minute 1.5 Safety Factor
Storage Holding Time Desired, Minutes 7 Minutes Holding Time
Tank Size for Start/Stop Feedwater System 3009.9278
Tank Size for Modulated Feedwater System 1805.9567
 Data Compiled by
Compiler November 3, 1997 Steam Mains Trap Sizing David C. Farthing
Source: Spirax Sarco Data Printout 11/24/2022 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
 Sources Marks 7th Ed.
Compiled by David Farthing 11/24/2022 07:52:17
GPSA 9th Ed.

Apllication Name REGEN-2 PROCESS GAS FLOW DCP CARTHAGE

Static taken Up/Dn U Solutions
Atmospheric PSIA= 14.6959 Pf1 = 764.6959
Sp/Gr = 0.57 Pf2= 763.9383 Factors for establishing Fb
Temp of Gas Flow 68 Fb= 1842.1052 AGA3.6.5.1#61 Ko= 0.6052 AGA3.5.2.1#11
hw = 21 Fpb= 1.0023 AGA3.6.9#66 E= -5163.6485 AGA3.5.2.1#12
Static Psig = 750 Ftb = 1.0154 AGA3.6.10#67 Ke= 0.5896 AGA3.5.2.1#9
Pipe ID 4.026 Fg = 1.3245 AGA3.6.12#69
Orifice ID = 3.000 Ftf = 0.9924 AGA3.6.11#68
Compressibility = 0.998 (Default =1) Fr = 1.0006 GPSA 9th
Qh = 312,659 SCFt/Hr Y1= 0.99961 AGA3.5.2.6.2#20
Qh = 0.3126593755308 MSCFH Fpv = 1.0010 AGA3.6.9#66
Qm = 5210.99 SCFt/min. Fa = 1.0000 GPSA 9th Bibliography
QMMD = 7.5038250127398 MM/SCFD C'= 2467.2743
Flowing Density = 2.4380867061343 Beta Ratio = 0.7452
(hwPf)^.5= 126.7226
Where hw/pf Ratio = 0.0010 Flowing Density = MP/((10.73*(TZ)))
hw = differential pressure across orifice in inches of water M. Molecular Wt 18.023 Typical M.Wt at 60 Degrees "F"
Pf = Static (gauge) pressure corrected to Absolute static pressure in PSIA T. Temperature Absolute 527.67 Methane = 16.043
Fb = Calculated or See Orifice Factor from GPSA Rev. 1979 Basic Orifice Factors Table Z. Compressability Factor 0.9984 Natural Gas = 18.023
Fpb = Pressure base factor from GPSA Rev. 1979, = 14.73 / Atmospheric Pressure of Location. R. Fixed for all Gases 10.73 Propane = 44.097
Ftb = Calculated Temperature base factor P. Flowing PSIA 764.6959
Ftf = Calculated Flowing Temperature base factor Df = Flowing Density 2.4380867 (lb/cu ft)
Fg = Specific Gravity Factor = ((1/Sg)^.5) M. Molecular Wt of Natural Gas based on 95% Methane content
Fr = Reynolds Number Factor for this calculation. For this calculation = (((Beta Ratio/ )(hwpf)^.5)) **Source - American Gas Association Rev 1974 Section 16.1
Y= Expansion Factor for this calculation. Static Pressure Taken Up-Stream of orifice. FLOW CAL SETUP BASED ON FLOW TRANSMITTER MAX DP
Fpv = Supercompressability Factor = (1/Z)^.5 Sqr/Rt of Max DP = 15.811388 250 Max hw
Zb = Compressibility Factor of Gas = .9984 for Natural gas at Standardized Conditions. Flow Coefficient Cf'= 0.4745836 for readings displayed in MMCFD
Flow Coefficient Cf'= 0.0197743 for readings displayed in MCFH
 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%
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 11/24/2022
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Cost of Leaking Steam Traps in Lost Steam and Revenue

Customer
Site COST OF PIPE LEAKS TO ATMOSPHERE
INPUT DATA Based on a variant of the Napier formula
Total Number of Traps Surveyed 60 PPH Leak = 24.24 X Pa X D^2
Number of Traps Leaking 24 Pa = Line Pressure Absolute
Number of Traps Plugged 0 Trap Type Surveyed D = Diameter of leak in inches expressed as a decimal
Capacity of Traps in #/Hr. 550 1/2" TD NOTE: EXCELL WILL AUTOMATICALLY CORRECT TO DECIMAL
Steam Line Pressure 100 Diamerter of Leak (Inches) 0.125
Condensate Return Line PSI 12 Pressure in Pipe (PSIG) 150
Temperature of Condensate at Traps 245 PPH Steam Leaking 62.38
Temperature of Condensate in Tank 190 Cost per 1KP Steam $ 6.00
Hours per Day of Production 24 Hours Per Year Operation 8400
Days per Year of Production 340 Total Cost of Leak Annually $ 3,143.96
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
Compiled January 16, 1998 David C. Farthing
Data Printout 11/24/2022
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= 0.01156
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
Compiled January 16, 1998 David C. Farthing
Data Printout 11/24/2022
Voice 405-728-6709

u are looking for.

 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.

 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
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
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
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
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.
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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 45 Ells 0.00
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 45 Ells Short 0.31 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 45 Ells 0.00 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
11/24/2022
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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 and Application Tun
A guide to help you select the equipment needed to accomplish an instrumen

What is the Application? 1

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

The following is courtiousy of Rex Warr, Technical Operations Automation Team, DCP Midstream
Typical Tunning for Specific Loop Applications
FLOW PRESS TEMP LEVEL
Gain 0.6-0.8 5 1 to 2 0.8-1.2
Reset 20-30 0.5-1.0 0.5-2.0 0.1-0.2
Rate 0 0 0.1-0.2 .01-.02
Reset Units in Repeats/Minutes
Rate Units in Minutes
These numbers are starting points for single phase (homogenous) materials.
They do not hold up when the process is multi-phased such as Steam Boiler Level
which is two-phase, i.e. Water/Vapor.

Gain represented as Proportional Band (PB)

Gain = 0.250 0.500 1.000 2.000 4.000 10.000
PB = 400.000 200.000 100.000 50.000 25.000 10.000

If Gain is 5.000 5.000

If PB is 20.000 20.000
n Guide and Application Tuning Suggestions
needed to accomplish an instrument application.

ocouple - Control Valve and thermal extionsion wire

DCP Midstream

us) materials.
Steam Boiler Level
 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

ansfer calculations.
David Farthing's TechStuff 11/24/2022 Helpful Boiler Burner Calculations

Combustion Air Requirements in Sq./Ft for Atmospheric and Power Burners

IN PUT DATA
Boiler Horsepower 800
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

Ideal Excess Oxygen Curve for Natural Gas

Ideal O2
6
Firing Rate
20
Ideal Excess Oxygen Natural Gas
5.75 30 7
4.75
3.6
40
50
6
3.3 60 5
Excess Oxygen %

3.05 70 4
2.8 80
2.5 90 3
2.3 100 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
Boiler Type Watertube/Firetube F
Fuel Type 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 11/24/2022 07:52:17 David Farthing
Federal Corporation

Economizer Energy Calculations

Customer Solae repaired Heatmizer Economizers
Feeding Econ with DA Water
Boiler Type Watertube/Firetube F
Fuel Type Gas or Oil G
Boiler Rated Horsepower 1169
Boiler Rated Efficiency 82.00%
Normal Firing Rate (NFR) 80.0%
Boiler Operating Pressure PSIG 155
Combustion Make-up Air Temperature 80
As Found 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) 368.00 Fuel Dewpoint Minimum Minimum
Firing Boiler Horsepower @ NFR 935.2 Stack Temp Feedwater
Boiler Fuel Input @ NFR 38,166,424 Inlet Temp.
BTU Output @ NFR 31,296,468 Natural Gas 150 250 210
Net Operating Efficiencies as found 83.27%
Actual BTU Input 37,585,210
Theoretical Entering Stack Temperature 456.00 Default #2 Diesel Fuel 180 275 210
Actual Observed Stack Temperature 456.00 Low Sulfur Oil 200 300 220
Entering Feedwater to Economizer 227.00
Temperature Rise Across Econ. 229.00
Water Flow #/Hr 32,264.40
Gross BTU to Feedwater/Hr 1,518,374.75
Exiting Feedwater Temperature "F" 274.06
Exiting Stack Temperature 358.45 Application OK, Stack Temp Above Dew Point.
Gain in Efficiency 3.18% .
New Net Calculated Thermal Efficiency 86.45%
Fuel Savings/Hr $ 7.65
Annual Current Cost of Operation $ 1,777,395.12
Total Annual Savings w/ Economizer $ 56,568.08 Based on Gain in Efficiency
Annual Cost of Operation w/ Economizer $ 1,720,827.03
Economizer Equipment Cost $ 57,600.00
Economizer Estimated Installation $ 46,080.00
Actual Economizer Installation Quote $ 13,785.00
Simple Pay-Back in Years 1.26

Economizer Efficiencies

Condensing

100%Condensing Vertical 100%

Efficiency
85% 85% 80% Firetube Firing Rate
80% 77% 75% 75% 80%
85% 68% 77% 20
60% 85% Conventional 60% 65%
75%55% 60% 57%
50% 45%
60%40
40% 80% 68% 50
Non-Condensing Economizers

40%
75% 60% 60
20% 65% 55% 20%75
Condensing Economizers

0% 60% 50% 0%90

57% 40 50 60 45%
20 75 90 100 100

Firing Rate
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 10.03

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 EQUIPME 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)

FT/SLR TD Range BPT SM Thermoton

B1 B1 B
B B
B1 A2
A2
B1 A2

B A3 B B
FT/SLR TD Range BPT SM Thermoton
B1 A
FT/SLR TD Range BPT SM Thermoton
B B
B A
B1
B
 B1
FT/SLR TD Range BPT SM Thermoton
A
B1 B1 B
B
B1
FT/SLR TD Range BPT SM Thermoton

A1
A B
FT/SLR TD Range BPT SM Thermoton
B1 B1 B
B
B1
B1
B1
B A

A1
A
FT/SLR TD Range BPT SM Thermoton
B1
B1
B1 B1
A B
A
FT/SLR TD Range BPT SM Thermoton
A B2
B B2
A1 B2

B3 A
FT/SLR TD Range BPT SM Thermoton

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 65 High Pressure System 2 1
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 7
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 High 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 81.25 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 purge
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
ered to select FSG.

gas flow to determine purge time.

 Suction Piping Calculations
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.
System Size 3.068 It is helpful to input actual pipe ID.
Specific Gravity for other than 68 deg Water 1.000 1.0 is default for 68 degree water.
Linear Feet Suction Pipe 6.00
Number of 90 Ells 1.00
Number of 45 Ells 0.00
Number of Valves 0.00
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
Federal Catalog Velocity 14.32 Feet Per Second
Pages 265-266 Effective Reynolds Number 339025.26 Flow is no longer laminar!
K Factor 90 Ells Short 0.8 Averaged for pipe size range
K Factor 45 Ells Short 0.25 Averaged for pipe size range
K Factor Valves Globe 5.25 Averaged for pipe size range
Head Velocity V2/2G 3.19
Total Loss Line Pipe 1.58 Feet Head Formula
Total Loss from 90 Ells 2.55 Feet Head h=K*(V2/2G)
Total Loss from 45 Ells 0.00 Feet Head h=K*(V2/2G)
Total Loss from Valves 0.00 Feet Head h=K*(V2/2G)
Total Head Loss 4.13 Feet of Head Loss
Total Head loss corrected for Specific Gravity 4.13

Discharge Piping Calculations

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.
System Size 3.068 It is helpful to input actual pipe ID.
Linear Feet Discharge Pipe 100.00
Number of 90 Ells 4.00
Number of 45 Ells 0.00
Number of Valves 1.00
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
Federal Catalog Velocity 14.32 Feet Per Second
Pages 265-266 Effective Reynolds Number 339025.26 Flow is no longer laminar!
K Factor 90 Ells Short 0.8 Averaged for pipe size range
K Factor 45 Ells Short 0.25 Averaged for pipe size range
K Factor Valves Globe 5.25 Averaged for pipe size range
Head Velocity V2/2G 3.19
Total Loss Line Pipe 26.30 Feet Head Formula
Total Loss from 90 Ells 10.20 Feet Head h=K*(V2/2G)
Total Loss from 45 Ells 0.00 Feet Head h=K*(V2/2G)
Total Loss from Valves 16.74 Feet Head h=K*(V2/2G)
Back Pressure Valve Setting 0 0.00 Feet Head
Total Head Loss 53.24 Feet of Head Loss
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 = 611.4721279 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

0/Hr, 60/Min)
ASME formula
11/24/2022 07:52:17
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 160

Vs= Volume of Water in System, Gallons 265
Pf= Make-up Fill Water Pressure PSIG 45
Po= Maximum Operating Pressure of System PSIG 50
Vt= Minimum Volume Expansion Tank Required 26.43 Plain Steel Tank
Boyle's Law Acceptance Factor 1.08 This is a Safety Factor used by many Engineers
Minimum Tank Volume using Boyle's Factor 28
 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
T 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 45.833333 466.35417 10.01331 40
Point 2 70 540 14.4 58 Point 2 64.166667 453.75 11.091667 58
Point 3 90 520 20.4 65 Point 3 82.5 436.94444 15.713194 65
Point 4 110 500 21.6 75 Point 4 100.83333 420.13889 16.6375 75
Point 5 BEP 130 475 23 76 Point 5 BEP 119.16667 399.13194 17.715856 76
Point 6 150 450 24 75 Point 6 137.5 378.125 18.486111 75
Point 7 EOC 170 410 25 76 Point 7 EOC 155.83333 344.51389 19.256366 76

Speed 3 50 Hz. Speed 4 45 Hz.

Flow Head HP Eff Flow Head HP Eff

Point 1 41.666667 385.41667 7.5231481 40 Point 1 37.5 312.1875 5.484375 40
Point 2 58.333333 375 8.3333333 58 Point 2 52.5 303.75 6.075 58
Point 3 75 361.11111 11.805556 65 Point 3 67.5 292.5 8.60625 65
Point 4 91.666667 347.22222 12.5 75 Point 4 82.5 281.25 9.1125 75
Point 5 BEP 108.33333 329.86111 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 141.66667 284.72222 14.467593 76 Point 7 EOC 127.5 230.625 10.546875 76

Speed 5 40 Hz. Speed 6 35 Hz.

Flow Head HP Eff Flow Head HP Eff

Point 1 33.333333 246.66667 2.2290809 40 Point 1 29.166667 188.85417 2.5804398 40
Point 2 46.666667 240 2.4691358 58 Point 2 40.833333 183.75 2.8583333 58
Point 3 60 231.11111 3.4979424 65 Point 3 52.5 176.94444 4.0493056 65
Point 4 73.333333 222.22222 3.7037037 75 Point 4 64.166667 170.13889 4.2875 75
Point 5 BEP 86.666667 211.11111 3.9437586 76 Point 5 BEP 75.833333 161.63194 4.5653935 76
Point 6 100 200 4.1152263 75 Point 6 87.5 153.125 4.7638889 75
Point 7 EOC 113.33333 182.22222 4.2866941 76 Point 7 EOC 99.166667 139.51389 4.9623843 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
Application)
 Data Compiled by
Boiler Heat Recovery Calculations
David Farthing
Printout 11/24/2022 07:52:17
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 11/24/2022 07:52:17 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
11/24/2022 / 07:52:17
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
3,899 BTU @ Current Pressure Btu Differential 621
3,278 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
Boiler Horsepower 476
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.
 Data Compiled by
Printout
David Farthing's TechStuff David Farthing
11/24/2022 / 07:52:17
Voice 405-728-6709

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.

Additional BTU Required to Develop 1 Boiler Horsepower vs. Feedwater Temperature

Feedwater Boiler Operating Pressure
Temperature 0 25 50 75 100 125 150 175 200 225 250
Additional BTU Input Required to Bring Feedwater to Steaming Temperature
50 5,589 7,487 8,556 9,315 9,936 10,454 10,902 11,282 11,661 11,972 12,282
100 3,864 5,762 6,831 7,590 8,211 8,729 9,177 9,557 9,936 10,247 10,557
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
175 1,277 3,174 4,244 5,003 5,624 6,141 6,590 6,969 7,349 7,659 7,970
200 414 2,312 3,381 4,140 4,761 5,279 5,727 6,107 6,486 6,797 7,107
212 0 1,898 2,967 3,726 4,347 4,865 5,313 5,693 6,072 6,383 6,693
225 1,449 2,519 3,278 3,899 4,416 4,865 5,244 5,624 5,934 6,245
230 1,277 2,346 3,105 3,726 4,244 4,692 5,072 5,451 5,762 6,072
240 932 2,001 2,760 3,381 3,899 4,347 4,727 5,106 5,417 5,727
250 587 1,656 2,415 3,036 3,554 4,002 4,382 4,761 5,072 5,382
260 242 1,311 2,070 2,691 3,209 3,657 4,037 4,416 4,727 5,037
270 0 966 1,725 2,346 2,864 3,312 3,692 4,071 4,382 4,692
275 794 1,553 2,174 2,691 3,140 3,519 3,899 4,209 4,520
280 621 1,380 2,001 2,519 2,967 3,347 3,726 4,037 4,347
 Source
TechStuff
11/24/2022 David Farthing's
Computer Aided Boiler Room Solutions
TechStuff Rev. 11.09

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 32000
Rated Boiler Horsepower 928 Distribution line Diameter 10
Boiler Outlet Diameter 8 Distribution Velocity Ft./Min. 3383.9924
Current Operating Pressure 115 Distribution Velosity OK
Feedwater Temperature 227
Steam Volume Cft/# 3.46
Boiler Outlet Velocity 5287.4881 Ft./Min.
Nozzle Velocity OK
New Velocity Across the Boiler Outlet New Velocity in the distribution line
New Operating Pressure 70 Distribution line Diameter 10
Steam Volume Cft/# 5.18 Distribution Velocity Ft./Min. 5066.2082
New Boiler Outlet Velocity 7915.9503 Ft./Min. Distribution Velosity OK
Nozzle Velocity OK

Additional or Reduction Btu/Bhp Required to Raise Pressure above 0 PSIG Theoretical Savings from Lowering Operating Pressure
3,899 BTU @ Current Pressure Btu Differential 1,380
2,519 BTU @ New Pressure Boiler Horsepower 927.53623188
1,380 Btu @ Horsepower/Hr Differential Cost of Fuel (Decatherm) $ 5.29
Hrs/Day Operation 20
Days/Month/Operation 22
$$ Saved or Expended/Mth. $ 2,979.33
$$ Saved or Expended/Yr. $ 35,751.94
 Data Compiled by
11/24/2022 / 07:52:17 '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 Typical Application Temperature 0 25 50 75 100 125 150 175 200 225 250
Contact Additional BTU Input Required to Bring Feedwater to Steaming Temperature
Plant Location 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 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 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 150 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 20,060,498.80 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 212 160 227 242 240 932 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) 79.24 275 794 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 2,523,675 3,539,700 2,310,638 2,064,825
BTU Lost/Gained Per Hour 0.00 -852,150.00 245,812.50 491,625.00
Boiler HP Lost or Gained/ Hr. 0.00 (25.46) 7.35 14.69
Net Boiler Horsepower 475 450 482 490
Net Steam Output 16387.5 15509.0 16640.9 16894.3
Net Efficiency 79.24 74.99 80.47 81.69
Percent Increase/Decrease Energy Use 0.00 4.25% -1.23% -2.45%
Percent Increase/Decrease BHP 0.000% -5.361% 1.546% 3.093%
Practical Effect of Feedwater Temperature NOTES:

Enter typical Normal Firing Rate % 100%

# Water Displacement Per Cycle 16387.5
Enter Feed Water Temp 175
BTU Required to reach 212 606337.5
Total BTU Lost/Day 12,126,750
Enter Cost of Fuel/Dtherm $ 3.33
Cost of Lost Btu/Month $ 888.41
Cost of Lost Btu/Year due to SubCooled Feedwater $ 10,660.87
 Data Compiled by
11/24/2022 07:52:17 Scale vs. Heat Transfer David Farthing
Voice 405-728-6709

The effect of Scale on Heat Transfer in Boilers

Additional Heat Input Required Due to Calcium Salt Scale

Watertube Boiler Full Circumferance Tube Contact
0.60

0.50

0.40
Calcium Scale Thickness = Inch

0.30

0.20

0.10

0.00
5% 10% 15% 30% 66% 150%
Additional Heat Input Reqired to Make Boiler Horsepower
Source: 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 11/24/2022 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 11/24/2022
Boiler / Burner Data Sheet
Today's Date 2.24.10 Certificate Exp. Date
Company Name Chesapeak North Desoto Sweetening Plant
Location Gravel Road Insurance Carrier FM Global
City Fireson State La Zip 71111 Inspector No.

Boiler MFG Name NEWPOINT THERMAL Burner MFG Name Maxon Kenedizer - 10.0" 25MMBtu
Model No. DH-H 40/30 Model No. KDZERLE100NFB
Serial No. PROJECT #7114-2009 Serial No. SO-809591
Hot Water OIL Steam Atmosperic (Natural Draft)
Operating Pressure (PSI) 80 Power/Mechanical Draft NYB #D03115100-2612
Date Installed 7/1/1905 BTU/Hr. Input 24.8 MMBtu NFPA 85 SPEC

Power & Mechanical Draft Burners Atmospheric (Natural Draft) Burners

INPUT in BTU/HOUR INPUT in BTU/HOUR

Fax (405) 232-5438

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
400,000 to to to 400,000 to to to
CONTROL & SAFETY DEVICES GUIDELINES (Including 2,500,000 5,000,000 250 MMBtu (Including 2,500,000 5,000,000 250 MMBtU
FOR AUTOMATICALLY GAS FIRED BURNERS
Modular Boilers Modular Boilers Associated
w/ max. input of w/ max. input of
Standard
120 East Main Street -- Post Office Box 26408

NOT 400,000) 400,000)

INSTALLED NOT INSTALLED System Control Specifications
REQUIRED Paragraph
INTERLOCKS / LIMITS
NA Approved Operating CR-220(a)(1)(2) CW-
Controllers Steam Boilers Required Required (Note Required Required (Note Required Required Required
Required (Note 1) 310(b) CW-
(Pressure) (Note 1) 1) (Note 1) 1) (Note 1) (Note 1) (Note 1)
620(b)
CR-220(b)(1)(2) CW-
(800) 289-3331 (405) 239-7301

Honeywell Required Required (Note Required Required (Note Required Required Required
Hot Water Boilers (Temp) Required (Note 2) 410(b)
UDC2500-CE (Note 2) 2) (Note 2) 2) (Note 2) (Note 2) (Note 2)
Oklahoma City, Oklahoma 73126

CW-640(b)
High Limits CR-220(a)(1)(3) CW-
Required Required (Note Required Required (Note Required Required Required
NA Steam boiler (Pressure) Required (Note 3) 310(c) CW-
(Note 3) 3) (Note 3) 3) (Note 3) (Note 3) (Note 3)
(Manual Reset) 620(a)
Hot Water Boilers (Temp) CR-220(b)(1)(3) CW-
Honeywell Required Required (Note Required Required (Note Required Required Required
(Manual Required (Note 4) 410(c) CW-
UDC1200L -FM (Note 4) 4) (Note 4) 4) (Note 4) (Note 4) (Note 4)
Reset) 640(a)
CF-162(a), CF-910,
High Gas Pressure
UE H117 (Note 5) Required Required Required Required CR-410 Table CF-
(MANUAL RESET)
1,CF-2
Low Gas Pressure CF-162(a), CF-910,
UE H117 (Note 5) Required Required Required Required
(Manual Reset) CR-410 Table CF-
MAXON Valve Seal Overtravel 1,CF-2 CF-180(b)(2)
(Note 6) (Note 6) (Note 7) (3)
250CMA12 Interlocks
CF-210(a)(2) CF910,
BETTIS EM110 High Fire Switch (Note 8) (Note 9) (Note 9) (Note 10) (Note 10) (Note 10) CR-410, Tables CF-1,
CF-2
BETTIS EM110 Low Fire Switch Required Required Required Required CF-610
Required (Note Required Required Required Required CR210(a)(b)(c) Tables
UE H117 Supervised Purge Air Required (Note 9)
9) (Note 9) (Note 10) (Note 10) (Note 10) CF-1, CF-2
Tables CF-1, CF-2
UE H117 Proven Combustion Air Required Required Required Required
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 CE-120(a)(b) CR-
Low Water 2 Required (1 (2) Required (2) Required (Note (2) Required (2) Required (2) Required
Tulsa

NA (Notes 11,12, Required (Notes 210(a)(b), CW-610(a)

w/MANUAL RESET) (Note 11) 11) (Note 11) (Note 11) (Note 11)
13) (Note 11) 11,12, 13) (b)
(1) Required (1) Required CR-210(c), CW-
11361 East 61st. Street, Broken Arrow,

Hot Water Boilers (1)

NA (Notes 14 (1) Required (1) Required (Notes 14 (1) Required (1) Required (1) Required 130(a), CW-630(a)
(918) 955-1918 Fax (918)249-9014

(MANUAL RESET) Required

& 15) & 15) (b)
UE8W2D
Forced Circulation CR-210(e), CW-
FORCED (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16) (Note 16)
(MANUAL RESET) 210(a)(b)
CIRCULATION
(800)955-1918,

PILOT VALVE TRAIN (Note 12)

MAXON Approved Safety Shutoff
Required Required Required Required Required Required Required Required CR-180(C)
150CMA12 Valve(s)
Pilot Cock 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
RV12LT 180, cf-161(b) Figs B-1,
2,3,4

MAIN VALVE TRAIN

(2) (1) or (2)
Oklahoma 74012

MAXON Approved Safety Shutoff (2) Required (1) or (2) Required (2) Required (2) Required CF-180(b) (1)
(1) Required Required (1) Required Required
250CMA12 Valve(s) (Note 19) (Note 20) (Note 19) (Note 21) (2)(3)
(Note 21) (Note 20)
(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) Required (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 ANSI221.13 1114
CF-160, CF-161(b),
FISHER 1098-
Gas Pressure Regulator Required Required Required Required Required Required Required Required ANSI221.13 1.15.1
EDR
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 RM7840L1075 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 CR-
(Note 8)
60 1, CR-2
CF-210(a)(1)(2)(c)
deral Corporation

Prepurge Air Changes

4 Changes 4 Changes 4 Changes Tables CF-1, CF-2 CR-
Required
4 1, CR-2
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
YES 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 Required (Note Required Required Required
Proved Pilot Required (Note 25) CF-320(a)(1)
YES (Note 25) 25) (Note 25) 25) (Note 25) (Note 25) (Note 25)

Pilot Flame Establishment 10 Seconds

15 Seconds 15 Seconds 10 Seconds Tables CF-1, CF-2
Period (PFEP) None Not Permitted Maximum None 10 Seconds
(Note 26) (Note 26) (Note 26) CR-1, CR-2
Continuous Pilot (Note 31)
15
Not Tables CF-1, CF-2
Intermittent Pilot 15 Seconds 15 Seconds Not Permitted 15 Seconds 15 Seconds 10 Seconds 10 Seconds
Permitted CR-1, CR-2
10 Tables CF-1, CF-2
Interrupted Pilot 15 Seconds 15 Seconds 10 Seconds 15 Seconds 15 Seconds 10 Seconds 10 Seconds
YES 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
 Federal C
Intermittent Pilot Print Out 11/24/2022 15 Seconds
(Note 28) (Note 29) (Note 30)
Tables CF-1, CF-2
Maximum CR-1, CR-2

10 Seconds
15 Seconds 15 Seconds 10 Seconds 15 Seconds Tables CF-1, CF-2
Interrupted Pilot Maximum (Note 28) (Note 29) (Note 30)
Maximum Maximum Maximum (Note 31) Maximum CR-1, CR-2
(Note 31)
YES
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 (Note
(FFRT) Maximum Maximum Maximum Maximum Maximum Maximum CR-1, CR-2
3 Sec (Note 36) 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
Action On Limit Opening Safety Shutdown CW-130(d), CE-310(c),
Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown
CW-410(c), CF-910
Recycle

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
7 overtravel (Proof-of-closure)
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 fuel
12 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 modular
13 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).

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
16 inadequate to protect the 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. Print Out 11/24/2022
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
21 overtravel (Proof-of-closure)
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.
Pilot only: 15 seconds
maximum if interrupted pilot is
28 used. 25 to 30 seconds if
safety shutoff valve has full
opening.
Pilot only: 10 seconds
29 maximum for modulating or
high-low firing.
Pilot only: 10 seconds
30 maximum.
31 Interrupted pilot only.

Maximum input at light off shall

32 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 resetting
37 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 minute
40 time delay.
Select proper safety control
41 according to system
requirements.
 Date of Printout Data Compiled by
TechStuff - Boiler Benchmarking David Farthing
11/24/2022 / 07:52:17
Voice 405-760-2831

BENCHMARKING A BOILER/OVEN OR BURNER

AMBR = American Boiler Manufactuers Recommendations
$ 6.36 Cost per Therm Customer St John Med Industry Medical
Utility Fuel Btu = 950 Contact Adam Gas Pressure after the Train = 3.8 InWc
Pf =(GP+Pc)/Pb Base Temp = 60 Address 61st & Elm, Broken Arrow Air At Burner =
Guage PSI(GP) = 5 Temp Factor (Pt) = 0.9763058090196 City/State/Zip Broken Arrow, OK Gas at Burner =
Site Barometric (Pc) = 14.735 notes Date 9.28.09 Burner Data GP S16-GO-75
Sea Level (Pb) = 14.700 Boiler Mfg Hurst Operating PSI 0 Economizer NO
PSI Correction Factor (Pf) = 1.343 Mfg Rated Eff. 82% BHP = 306.3 Mfg
Clocked Metered Fuel Flow = (((100 SCFt/Time)*60)*Pf)*(Pt) Fuels Natural Gas Gas PSI = 5 Nominal Steam Temp 366
Gas Flowing Temp = 72.62 Rated BTU Input/Hr 12,500,000 Fan Voltage 480 BTU/Lb Steam 1100
Average Rate Rated Steaming Capacity/Hr 0 Fan Amp Rating 9 Feedwater Pump Amp Rating
High Fire Utility Meter
Valve % Firing Rate Time/100 Cf Fuel Flow Burner InWc Steam Flow Rated Steam %/ Rated Flow Stack Temp Actual Ex O2 ABMR Ex O2 Actual Ex CO
10% 1250 6.250 1258 0.0000 1066 1064 99.78% 345 6.00% 6.00% 0
15% 1875 15.000 524 7.50 0 443 #DIV/0! 6.00% 0
20% 2500 9.660 814 8.250 0 688 #DIV/0! 6.00% 0
25% 3125 2.595 3031 0.00 0 2562 #DIV/0! 6.00% 0
30% 3750 1.522 5169 0 0 4369 #DIV/0! 5.50% 0
35% 4375 1.483 5302 0.000 0 4482 #DIV/0! 5.00% 0
40% 5000 1.257 6255 0 0 5287 #DIV/0! 4.75% 0
45% 5625 2.239 3513 0 0 2970 #DIV/0! 4.50% 0
50% 6250 1.101 7145 0.00 0 6040 #DIV/0! 4.25% 0
55% 6875 0.826 9525 0 0 8052 #DIV/0! 4.00% 0
60% 7500 0.800 10069 0 0 8512 #DIV/0! 3.50% 0
65% 8125 0.750 10740 0 0 9079 #DIV/0! 3.25% 0
70% 8750 0.720 11188 0 0 9458 #DIV/0! 3.00% 0
75% 9375 0.680 11846 0.000 0 10014 #DIV/0! 2.75% 0
80% 10000 0.600 13425 0 0 11349 #DIV/0! 2.50% 0
85% 10625 0.450 17900 0.000 0 15132 #DIV/0! 2.25% 0
90% 11250 0.320 25172 0 0 21280 #DIV/0! 2.00% 0
100% 12500 1.616 4985 0.00 0 4214 #DIV/0! 424 18.80% 2.00% 0
 Data Compiled by
11/24/2022 07:52:17 Dissolved Oxygen In Make-up Water David Farthing
Voice 405-728-6709

Amount of Dissolved Oxygen in Make-up Feedwater vs. Temperature

PPB Dissolved Oxygen

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
11/24/2022 07:52:17
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 @ 0
PSI OzSI PASCAL kPa BAR mBAR mm H2O cm H2O ATM Cm Hg mm Hg TORR
4C/39F 60F 20C/68F C
PSI 2.885 2.89 46.2 19,891 19.89 0.199 198.91 79.9 79.9 80.0 2,028.4 202.8 0.196 5.87 14.92 149.2 149.2

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 920.47023 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
11/24/2022 TechStuf

Variable Frequency Drive Applications

Customer Baptist Medical Center
Application Combustion Air Fan Control

Need to know Motor Horsepower 30

Motor Speed as supplied 3450
Hertz - Name Plate 60
Rated Torque Ft/Lb. 46
New Hertz 37
New Motor Speed 2128
New Torque Ft/Lb. 46 NOTE: Torque should remain constant but Horsepower will change.
Change in Motor Speed % 38.33%
New Horsepower @ New Speed 18.50
Prefer to know Original Amp Draw 32
Cost of kW of Electricity $ 0.0733
Total Hours of Operation/Year 8760
Is Application Pump or Fan? (P or F) F
Control Methods Code - See List Below OD
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 26.592 Kilowatt Usage Standard Motor No Control
kWhb 13.801 Kilowatt usage using VFD at New Horsepower
kWhc 23.401 Kilowatt Usage Using Current Control Method
kWhd 9.600 Kilowatt Savings Converting from Current Control Method to VFD
Savings $ 6,164.21 Annual Energy Cost Savings By Converting to VFD
 Nestle Flagstaff Data Compiled by David Farthing Federal Services and Conrad Baker, Maxon Corp.
Maxo 412 M
Shreads Dryer Data
Firing Rate Worksheet
11/24/2022 Techs - David Farthing Federal Services LLC
BURNER CAPACITY CALCULATIONS

Data Taken From Burner Specification Sheet FURNACE PRESSURE AT % EXCESS AIR FROM MFG
Standard Capacity of Burner MMBtu/Hr. - 1,200,000.00 Btu/Hr. For PRESSURE change through the same nozzle: p2 = p1(Q2/Q1)2
Max Burner Pressure - 2.80 "wc Furnace Pressure at Standard Capacity 2.65 " WC
Max Air Pressure - 7.96 "wc Where: Q2 = Final Flow = C19 1104 SCFM Final Fluid = Air
Burner Model - Maxon 412 M ELEVATION 7000 FEET Q1 = Initial Flow = C10 1430 SCFM Initial Fluid = Air
Standard Ratings: From Burner Specification Sheet p1 = Initial pressure = 2.65 Inches W.C.
Input Data From Maxon Spec Sheet Capacity: 1,200,000 Btu hr Calculated p2 = Final Furnace Pressure (FP) = 1.58 Inches W.C. @ SEA LEVEL
Fuel: Natural Gas Furnace Pressure at PURGE "w.c.= 2.65 Combustion Air ONLY- Field Reading
Input Data From Burner Spec Sheet @ Gas Pressure: 2.80 Inches W.C. @ Burner inlet fitting
Input Data From Burner Spec Sheet Rated Combustion Air: 230 SCFM Note 1. Plug in Capacity Btu hr values into cell C18 to get Gas Ring Pressure expected at Burner.
Input Data From Burner Spec Sheet @ Air Pressure: 7.3 Inches W.C. @ Air pipe inlet fitting Note 2. Plug in %XSAIR from Specification chart for specific burner into cell C20.
On-Ratio Combustion Air: 200 SCFM Note 3. Chart air pressure may not match exactly. See SITE data. Measured %O2 is key.
Excess Air: 15 % Note 4. Input "w.c. Gas and Air from calculations at MMBtu/Hr. %O2 Analyzer %XSAIR is calculated.
Note 5. Remember to ADD "Final Furnace Pressure" to both AIR and GAS Pressures after each calculation.
Design Ratings: FUEL 1000 Btu/SCF HHV, 0.65 SG EXPECTED MEASUREMENTS w/FP
Change this # for additional firing Rates Capacity: 924,000 Btu hr See Note 1 Actual Btu GAS RING Gas Position AIR Air Position FURNACE %O2 %XSAIR CO NOx Reading NOx Corrected Stack Temp Media Temp Thermal Eff
On-Ratio Combustion Air: 154 SCFM CAM MM/Btu/Hr PSIG % " w.c. % "w.c. Analyzer @ %O2 Analyzer Analyzer to 3% O2 EPA F F %
Excess Air: 15.00 % See Note 2 Min 60.00 0.010 0.18 0 6 30.00 66 na #VALUE! #DIV/0!
Total Combustion Air: 177 SCFM 1 120.00 0.030 0.85 0 6 30.00 18 na #VALUE! #DIV/0!
Total Combustion Air: 10,626 SCFH 2 240.00 0.110 1.00 0 6 30.00 5 na #VALUE! #DIV/0!
3 360.00 0.250 1.35 0 6 30.00 2 na #VALUE! #DIV/0!
GAS PRESSURE 4 480.00 0.450 2.21 0 6 30.00 2 na #VALUE! #DIV/0!
For PRESSURE change through the same nozzle: p2 = p1(Q2/Q1)2 * g2/g1 5 600.00 0.700 2.36 0 6 30.00 6 na #VALUE! #DIV/0!
HHV = 1000 Btu/ft3 6 720.00 1.000 2.82 0 6 30.00 26 na #VALUE! #DIV/0!
Where: Q2 = Final Flow = 924 SCFH Final Fluid = Natural gas 7 840.00 1.370 3.70 0 6 30.00 10 na #VALUE! #DIV/0!
Q1 = Initial Flow = 1200 SCFH Initial Fluid = Natural gas 8 924.00 1.660 ELEVATION 4.15 0 6 30.00 11 na #VALUE! #DIV/0!
p1 = Initial pressure = 2.80 Inches W.C. 9 924.00 1.660 LIMITED 5.68 0 6 30.00 4 na #VALUE! #DIV/0!
g1 = Initial Specific Gravity = 0.65 Note 5: 0.65 is Default for Natural Gas 10 924.00 1.660 ELEVATION 0.00 0 6 30.00 1 na #VALUE! #DIV/0!
g2 = Final Specific Gravity = 0.65 Max 924.00 1.660 LIMITED 0.00 0 6 30.00 1 na #VALUE! #DIV/0!
Calculated p2 = Final Gas Pressure = 1.66 Inches W.C. 0.06 PSIG
Calculated Performance Curve
COMBUSTION AIR PRESSURE AT % EXCESS AIR
For PRESSURE change through the same nozzle: p2 = p1(Q2/Q1)2 1,000.00 1.800
Where: Q2 = Final Flow = C19 177 SCFM Final Fluid = Air 1.660 1.660 1.660 1.660
900.00 1.600
Q1 = Initial Flow = C10 230 SCFM Initial Fluid = Air

Fuel Pressure @ Burner Inlet

p1 = Initial pressure = 7.30 Inches W.C. 800.00 FUEL FLOW 1.400
1.370

MM Btu/Day Input
Calculated p2 = Final Air Pressure = 4.33 Inches W.C. @ SEA LEVEL See Note 3 700.00
1.200
600.00
SITE CORRECTION FACTORS FOR COMBUSTION AIR FLOW & PRESSURE 1.000 1.000
At Burner Standard Capacity 1,200,000 Btu hr 500.00 RING PSI
Elevation = 500 ft. AMSL 0.800
Air Specific Gravity at Elevation = 0.984 400.00 0.700
Flow at Elevation = 234 SCFM 0.600
300.00
Air Pressure at Elevation = 7.42 Inches W.C. 0.450
200.00 0.400

At Burner Operating Capacity 924,000 Btu hr 0.250

100.00 0.200
Elevation = 500 ft. AMSL 0.110
- 0.010 0.030 0.000
Air Specific Gravity at Elevation = 0.984
Flow at Elevation = 180 SCFM 1 2 3 4 5 6 7 8 9 10 11 12
Air Pressure at Elevation = 4.40 Inches W.C. @ LOCATION ELEVATION
CAM Position
This is the Field Reading you might expect
at the given firing rate "At Burner Capacity"
Useful Air Data
Specific Gravity of Air at Various Elevations
NOTES: Sea Level 1.000 @ 60 Degrees "F"
Tuned with Oxygen Trim in OFF position. Manual Output at 42.9% 500 Ft 0.984 @ 57.2 Degrees "F"
1000 Ft 0.970 @ 55.4 Degrees "F"
1500 Ft 0.957 @ 53.7 Degrees "F"
2000 Ft 0.941 @ 51.9 Degrees "F"
2500 Ft 0.928 @ 50.1 Degrees "F"
3000 Ft 0.915 @ 48.3 Degrees "F"
3500 Ft 0.902 @ 46.5 Degrees "F"
4000 Ft 0.886 @ 44.7 Degrees "F"
Source: North American Burner Handbook
Calculations based on the following references
Safety Integrity Level Selection, Marszal and Scharpf,ISA 2002 11/24/2022
SIL Selection for BMS Systems, Mike D. Scott, P.E., Principal Safety System Specialist
AE Solutions, Greenville, SC 29616
SIL (Safety Integrity Level) Calculator
Natural Gas Burning Equipment
Customer's Site BP America Hemphill Gas Processing Plant, Canadian, Tx, Tim Pierce
Equipment ID Regen Heater H740
Btu Input to Burner 7.0 MM/Btu/Hr Maxon 784 Oven-Pak
Calculate the TNT Yield Factor
Combustion Chamber Length, ft: 25
Combustion Chamber Height, ft: 8
Combustion Chamber Width, ft: 8
Combustion Chamber Volume, ft^3: 1600
Fuel Weight/ft^3: 0.04243 Typical for Natural Gas = 0.04243
Fuel Weight, lbs: 67.9
Flammable Mass, lbs: 67.9
Heat of Combustion (Btu/Cft): 11859 Typical for Natural Gas = 11859 Btu/ CFt.
Explosive Yield Factor, Yf: 10% EPA defined at 10%
Equivalent Weight of TNT: 70

Calculate the radius for the circular impact zone

Equivalent Weight of TNT: 70
Peak Overpressure, psi: 3 Pressure for calculation of fatalities
Distance to given overpressure, d(ft): 64.7

Calculate the Vapor Cloud Effect Zone

VCEEffect Zone,ft^2: 13170 ft^2
Mean Effective Zone (MEFZA) Area,ft^2: 13170 ft^2

Calculate the Probable Loss of Life (PLL)

Indoors(i) or Outdoors(o): O
Vulnerability Factor: 0.3
People Near Device: 4 This can be a fraction such as 0.25 for a site that is visited only 4 time per day and is otherwise un-manned.
Area of Effect, ft^2: 13170 This is the area in which the blast is contained. The area of a building if the blast is indoors or the MEFZA if an outdoor location.
Personnel Density, people/ft^2: 0.000303720577069096
Probable Loss of Life, PLL: 1.20002410569483
Calculate the Probable Loss of Asset (PLA)
Indoors(i) or Outdoors(o): O
Vulnerability Factor: 0.3
Assets Near Device: 1 This can be any number from 0-N.
Area of Effect, ft^2: 13170
Asset Density, assets/ft^2: 7.59301442672741E-05
Probable Loss of Asset, PLA: 0.300006026423708
Total Loss Exposure Human + Assets: 1.50003013211854

Perform a Layer of Protection Analysis (LOPA)

What is the most susceptible device? Interlock 120 VAC Interposing Relay Welds Closed
MTBF of Most Susceptible Device 250000 MTBF = Mean Time Between Failure in Hours of Operation, Data from Manufacturer
Probable Number of Cycles Between Failure 10000
Probability of an Initiating Event: 2.500E+01 MTBF/Number of Cycles
Protection Layer #1: 4.00% Probability of Ignition
Protection Layer #2: 1 Use Factor, 1= Every Day, 0.75=Regularly, 0.5= Every Other Day, 0.25= 2 Days Per Week
Outcome, FLOPA: 1.00E+00 Expected Explosions/Yr.
Determine the Probability of Failure on Demand (PFD)
FIndividualRisk,failures/yr: 2.85E-04
FTarget,failures/yr: 1.90E-04
PFD: 1.90E-04
Determine the Risk Reduction Factor and required Safety Integrity Level
Risk Reduction Factor, RFF: 5256
SIL Level based on RFF: SIL 3
Calculations based on the following references
Safety Integrity Level Selection, Marszal and Scharpf,ISA 2002 11/24/2022
SIL Selection for BMS Systems, Mike D. Scott, P.E., Principal Safety System Specialist
AE Solutions, Greenville, SC 29616 MINIMUM 'SAFETY INSTRUMENTED FUNCTIONS (SIF)' REQUIRED BY NFPA-87
Deviation From Normal Operation Cause Consequence Result Recommended Safeguards Recommendations
1.0 Excessive High or Low Pressure
1.1 Hi Fuel Gas Pressure Burner Over Fired Over heated furnace *See High Temperature Interlock
Flame Lift-Off Explosion High Fuel PSI Sw or Transmitter
Rich Furnace Explosion
1.2 Low Fuel Gas Pressure Flame front collapse Explosion Low Fuel PSI Sw or Transmitter
Lean Furnace Explosion
1.3 Excessive Process PSI Vessel Mechanical Failure Release of process Hi Process PSI SW or Transmitter
Tube Mechanical Failure media and secondary
fire or explosion.
2.0 Failure to Detect Flame or Flame Present during OFF Cycle
2.1 Flame Scanner Failure Fail to detect flame during Sudden ignition of any a] Self-Checking Scanner and
OFF cycle leaking fuel in to furnace b] Listed Burner Controller
and explosion.
2.2 Flame Scanner Failure Fail to detect flame during Sudden ignition of any a] Self-Checking Scanner and
ignition, pilot, or run cycle. leaking fuel in to furnace b] Listed Burner Controller
and explosion.
2.3 Flame Scanner Failure Flame detected when no Fuel Valves open with no a] Self-Checking Scanner and
flame is present in furnace. source of ignition resulting b] Listed Burner Controller
in fuel rich furnace and
subsequent explosion.
3.0 Failure to Purge Combustion Chamber prior to Ignition Trials
3.1 Draft Dampers Fuel Vapor accumulate in Explosion on Ignition a] Draft Damper PROOF OPEN Sw
Fail Closed the furnace prior to ignition b] Combustibles Analyzer in Stack*
*(Natural Drafted Systems)
3.2 Combustion Fan Failure Fuel Vapor accumulate in Explosion on Ignition a] Motor Run Proof Sw
Mechanically Drafted Sys. the furnace prior to ignition b] Air Flow Proof Sw
c] Air Flow Proof Trans
Optional Process Combustion Interlocks 3.3 Interruption of Fuel/Air Ratio Fuel Rich Furnace Delayed Ignition and Explosion a]Combustibles or Oxygen Interlock
Control Strategy Analyzer in Stack
b] Cross Limited Fuel/Air Ratio Control
c] Fuel Flow Meter
4.0 Failure to Maintain Fluid Inside Heated Tubes or Vessels
4.1 Inlet Valves CLOSED Overheating of tubes and/or Mechanical failure of tubes a] Inlet Valve PROOF OPEN Sw
during burner operation vessel and vessels and release of b] Minimum Flow Sw in Media line
vessel contents
4.2 Media Pump Fails Overheating of tubes and/or Mechanical failure of tubes a] Minimum Flow Sw in Media line
vessel and vessels and release of b] Minimum Flow Trans in Media Line
vessel contents c] Pump Motor Run Ax Sw.
4.3 Heating Surfaces Exposed Overheating of tubes and/or Mechanical failure of tubes a] Low Level Burner Cut-Off Sw
vessel and vessels and release of b] Low Level Burner Cut-Off Transmitter
vessel contents c] Tube Skin Temp Interlock
Boiling Liquid Vapor Explosion
5.0 Excessive or High Temperatures
5.1 Firing Rate Valve Hangs Overheating of process fluid Thermal breakdown of heat High Media Temperature Interlock
in OPEN position transfer fluid.

5.2 Breach in process tube Process media fire inside Furnace Explosion or Media High Stack Temperature Interlock
or vessel releasing media furnace. Process Explosion
in to furnace area and
catching fire.
6.0 Fuel Leak in to Furnace during OFF Cycle
6.1 Failed Fuel Shutoff Valve Fuel leaking into furnace Furnace Explosion a] Listed Fuel Safety Shutoff Valves
with no immediate ignition b] Fuel Valve Proof of Closure Sw
source. c] Double Block & Bleed Fuel Train
d] Valve Proving System on Fuel Train
Calculations based on the following references
Safety Integrity Level Selection, Marszal and Scharpf,ISA 2002 11/24/2022
SIL Selection for BMS Systems, Mike D. Scott, P.E., Principal Safety System Specialist
AE Solutions, Greenville, SC 29616
 NFPA87 Check List
11/24/2022

NFPA-87 Heater / Burner Data Sheet Heater Type Definitions

Today's Date 4.11.2011 Certificate Exp. Date F= Fluid in Tube, Combustion Surrounding Tubes

G = Modulated Fluid in Tube, Combustion Surrounding Tubes

Company Name Eagle Rock Energy H = Combustion in Tube, Fluid surrounding Tubes
Location Pheonix Plant Regen Heaer Insurance Carrier/ SIL Level Self Insured - Sil-2 with SIL-3 Burner Controller and Fuel Train
City Canadian State Texas Zip Inspector No.

Heater MFG Name G.C. Broach Burner MFG Name John Zink (Six Burners)
Model No. Gas Regen Model No. PMF-7-7
Serial No. 62031.C Serial No.
Fluid Gas NFPA TYPE F Atmospheric (Natural Draft) Yes
Operating Pressure (PSI) 600 Power/Mechanical Draft
Date Installed 10.23.2010 BTU/Hr. Input

Power & Mechanical Draft Burners Atmospheric (Natural Draft) Burners

INPUT in BTU/HOUR INPUT in BTU/HOUR

Fax (405) 232-
Oklahoma City, Oklahoma

NFPA-87 Recommended Practices Less Than 400,000 400,000 to 2,500,000 to 5,000,000 to Less Than 400,000 400,000 to 2,500,000 to 5,000,000 to
2,500,000 5,000,000 12.50 MMBtu and (Including Modular 2,500,000 5,000,000 12.50 MMBtu and
CONTROL & SAFETY DEVICES GUIDELINES above Boilers w/ max. input above
FOR AUTOMATICALLY FIRED BURNERS of 400,000) Associated
Standard
INSTALLED P&ID FUNCTION Comments System Control Specifications
Paragraph
INTERLOCKS / LIMITS/CONTROLLERS
Approved Operating
(405) 239-7301

Controllers
YES E-Stop is not Hardwired Manual E-Stop Hardwired to
to Safety Shutoff Valves Safety Shutoff Valves 8.2.9, 8.4.2.4, and
Required Required Required Required Required Required Required Required
8.4.2.8
NOT OK
Allen Bradley Programmable Logic
Optional Optional Optional Optional Optional Optional Optional Optional 8.2.2 and 8.4 Etal
CompactLogix L35E TIC702A OK Controller
Safety Rated
See Burner Controller Optional Optional Optional Optional Optional Optional Optional Optional SIL-3 Applications
NOT INSTALLED Programmable Logic Solver
Allen Bradley High Media Temperature
Required Required Required Required Required Required Required Required Temperature Controller
CompactLogix L35E TT702A OK Recycle Limit
(800) 289-3331

High Pressure
120 East Main Street -- Post Office Box 26408

NA Process Media Required Required Required Required Required Required Required Required Pressure Controller
Recycle Limit
5438

Allen Bradley 9.3.1.1

Low Media Flow Limit Required Required Required Required Required Required Required Required
CompactLogix L35E See Low Cutoff Class F Heater
NA 9.2.5.4.2 & 9.3.1.3
Low Media Level Interlock Required Required Required Required Required Required Required Required
Class F Heater
Allen Bradley FT700 NOTE Hi From DCS System.
CompactLogix L35E Interlock SP is out of FT Double Check Logic 9.3.1.2
High Media Flow Interlock Optional Optional Optional Optional Optional Optional Optional Optional
Range settings Class F Heater

Allen Bradley TT702 OK High Media Temperature

8.2.2, 8.4.2.8 and 8.16
CompactLogix L35E Interlock Required Required Required Required Required Required Required Required
etal
(Manual Reset)
Allen Bradley High Stack Temperature
CompactLogix L35E 8.2.2, 8.4.2.8, and 8.15
Interlock Required Required Required Required Required Required Required Required
etal
TT700 & TT701 (Manual Reset)
NA Device is inplace Open Circuit Failure of
Check for FailSafe trip Temperature Sensing Element Required Required Required Required Required Required Required Required 8.17.2.4
NOT INSTALLED Interlock

SOR500-139 Check for compatible High Fuel Pressure Interlock

Required Required Required Required Required Required Required Required 8.8.2
6AH.EF3.M2.C1A.TT PSHH710 with service (MANUAL RESET)
SOR500-139 Check for compatible Low Fuel Pressure Interlock
Required Required Required Required Required Required Required Required 8.8.1
6AH.EF3.M2.C1A.TT PSLL709 with service (Manual Reset)
73126

See Approved Safety

High Purge Proof Switch Required Required Required Required Required Required
NOT INSTALLED NOT REQUIRED Controls
NOT INSTALLED Recommended Low Fire Start Switch Required Required Required Required 8.14
No Combustables
Analyzer interlocked to 8.5.1.1 and 8.5.1.2.1
Supervised Purge Air Required Required Required Required Required
8.6.5, 8.6.6
NOT INSTALLED BMS
Combustion Air Motor Running
NA Required Required Required Required 8.6.4
Interlock
 NFPA87 Check List
11/24/2022

Proven Combustion Air

NA Required Required Required Required 8.6.2, 8.6.3, 8.6.5
Interlock
Action on Loss of Combustion
NA Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown 8.6.2
Air
Low Media Fuel Cutoffs
Allen Bradley FT700 From DCS System.
Low Media Flow Limit Required Required Required Required Required Required Required Required
9.3.1.1
CompactLogix L35E Double Check Logic Class F Heater
NA 9.2.5.4.2 & 9.3.1.3
Low Media Level Interlock Required Required Required Required Required Required Required Required
120 East Main Street, Oklahoma City, Oklahoma 73104
Class F Heater
Allen Bradley FT700 From DCS System.
Low Media Flow Interlock Required Required Required Required Required Required Required Required
9.3.1.2
CompactLogix L35E Double Check Logic Class F Heater
Forced Circulation
NA Required Required Required Required Required Required Required Required
(MANUAL RESET)
(800)289-3331 or TULSA (800)955-1918

PILOT VALVE TRAIN (Note 12)

Approved Safety Shutoff
ASCO EF8215G020 Required Required Required Required Required Required Required Required 8.7.2.1
Shold be 1.0" Valve(s) - 2 Required
Approved Safety Shutoff One Pilot w/Proof of One Pilot w/Proof of One Pilot w/Proof of One Pilot w/Proof of One Pilot w/Proof of One Pilot w/Proof of
8.7.2.2A1 or
ASCO EF8215G020 Valve(s) - 2 Required Pilots Closure Interlock Closure Interlock Closure Interlock Closure Interlock Closure Interlock Closure Interlock
8.7.2.2A2
OK over 400,000 Btu ONLY Required Required Required Required Required Required
As Installed OK Manual Shutoff Valve(s) Required Required Required Required Required Required Required Required
Fisher OK Gas Pressure Regulator Required Required Required Required Required Required Required Required
MAIN VALVE TRAIN
Flowserve w/ NOT AN APPROVED Install Double Block Approved Safety Shutoff
Required Required Required Required Required Required Required Required 8.7.2.1
Open/Close Sw VALVE Maxon SSOV Valve(s)
Valve Seal Overtravel
Required Required Required Required Required Required 8.7.2.2.A1
NO NOT INSTALLED Interlocks
Manually Operated Leak Test
(1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required 8.7.2.3
NO NOT INSTALLED Valve(s)
ORBIT Manual Shutoff Valve(s) (2) Required (2) Required (2) Required (2) Required (1) Required (2) Required (2) Required (2) Required
FISHER 1098-EDR Gas Pressure Regulator Required Required Required Required Required Required Required Required
INCORRECTLY
DB&B Valve Proving System Optional Optional Optional Optional Optional Optional Optional Optional 8.7.2.2.A2 and 8.7.2.3
INSTALLED
MULTIPLE BURNER VALVE TRAIN
OK with Maxon DB (1) Required Plus (1) Required Plus (1) Required Plus (1) Required Plus (1) Required Plus (1) Required Plus (1) Required Plus (1) Required Plus
Flowserve w/ NOT AN APPROVED Approved Safety Shutoff Valve
SSOV other wise Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as Main Fuel Shutoff as 8.7.1.3
Open/Close Sw VALVE at Burner
change to Maxon above above above above above above above above
Manually Operated Leak Test
(1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required (1) or (2) Required 8.7.2.3
YES Dual Purpose Drain & Test Valve(s)
ORBIT Manual Shutoff Valve(s) (1) Required (1) Required (1) Required (1) Required (1) Required (1) Required (1) Required (1) Required 8.7.2.3
NO Valve Proving System Optional Optional Optional Optional Optional Optional Optional Optional 8.7.2.3
APPROVED SAFETY CONTROL SPECIFICATIONS
Needs to be an
Interuppted Pilot not an Flame Safeguard / Burner 8.3.1.1, 8.4.2.8, 8.4.2.9,
Required Required Required Required Required Required Required Required
Control 8.9.1
Honeywell RM7890B1014 Intermittant Pilot
No Combustables
Federal Services LLC

Mechanical Draft
Analyzer interlocked to 8.5.1, 8.5.1.1
BMS Prepurge Timing Required Required Required Required Required Required Required Required Required
Natural Draft
??? 8.5.1.2, 8.5.1.2.1
YES Safe Start Check Required Required Required Required Required Required Required Required Required Natural Draft
Prepurge Air Changes 8.5.1.1 - 8.5.1.2,
4 Changes 4 Changes 4 Changes 4 Changes 4 Changes 4 Changes 4 Changes 4 Changes
4 Required 8.5.1.2.1
High Purge Proving Circuit 8.5.1.1 - 8.5.1.2,
Required Required Required Required Required Required Required
NO NOT INSTALLED Required 8.5.1.2.1
Low Fire Start Circuit Required Optional Optional Required Required Optional Optional Required Required
NO NOT INSTALLED REQUIRED
NO Direct Ignition Optional Optional Not Permitted Not Permitted Optional Optional Not Permitted Not Permitted 8.5.2.4
YES Intermittent Pilot Optional Optional Not Permitted Not Permitted Optional Optional Not Permitted Not Permitted
NO Interrupted Pilot Optional Optional Required Required Optional Optional Required Required

Proved Pilot Required Required Required Required Required Required Required Required 8.91.1 or .2
YES
Pilot Flame Establishment Direct Spark Ignition Direct Spark Ignition 15 Seconds (Note
15 Seconds (Note 26) 15 Seconds (Note 26) 15 Seconds (Note 26) 15 Seconds (Note 26) 15 Seconds (Note 26) 8.5.2
15 Period (PFEP) None None 26)
10 SEC Intermittent Pilot 15 Seconds 15 Seconds Not Permitted Not Permitted 15 Seconds 15 Seconds 10 Seconds 10 Seconds
NO Interrupted Pilot 15 Seconds 15 Seconds 10 Seconds 10 Seconds 15 Seconds 15 Seconds 10 Seconds 10 Seconds
15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds
Direct Ignition of Pilot
NO Maximum Maximum Maximum Maximum Maximum Maximum Maximum Maximum
Main Flame Establishment 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds 15 Seconds
YES Period (MFEP) Maximum Maximum Maximum Maximum Maximum Maximum Maximum Maximum
Honeywell C7061 w/
Supervised Main Flame Required Required Required Required Required Required Required Required 8.91.1 or .2
SelfCheck Supervises PILOT only
Flame Failure Response Time
4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum 4 Seconds Maximum
3 Sec (FFRT)
Lockout Action on Flame Failure Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown 8.91.1 or .2
See individual Interlock
Action On Interlock Opening Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown Safety Shutdown
Lockout Safeties
 NFPA87 Check List
11/24/2022

Safety Instrumented Functions - NFPA87 Type-F Heater Application

Deviation From Normal Operation Tag PID Cause Consequence Result Recommended Safeguards Action Taken
1.0 Excessive High or Low Pressure
1.1 PSHH112 GO2319.J.2 Hi Fuel Gas Pressure (Burner) Burner Over Fired Over heated furnace *See High Temperature Interlock
PSHH112 Flame Lift-Off Delayed Ignition Explosion High Fuel PSI Sw backed up by PT107 Fuel PSI TransHoneywell STG94L FM/SIL Rated Transmitter
MI761/762 GO2319.J.2 Rich Furnace Explosion BMS950 Fuel/Air Deviation Alarm Dwyer BHGPS Integrated to BMS950
1.2 PT107 Low Fuel Gas Pressure Flame front collapse Delayed Ignition Explosion Low Fuel PSI Sw or Transmitter Honeywell STG94L FM/SIL Rated Transmitter
Lean Furnace Integrated to BMS950.
1.3 NA Excessive Process PSI Vessel Mechanical Failure Release of process Hi Process PSI SW or Transmitter
Tube Mechanical Failure media and secondary
fire or explosion.
2.0 Failure to Detect Flame or Flame Present during OFF Cycle
2.1 BE760 GO2319.J.2 Flame Scanner Failure Fail to detect flame during Sudden ignition of any a] Self-Checking Scanner and RM7840 with Safe Start Check and
OFF cycle leaking fuel in to furnace b] Listed Burner Controller C7061 Cycling Self-Check UV Scanner
and explosion.
2.2 BE760 Flame Scanner Failure Fail to detect flame during Sudden ignition of any a] Self-Checking Scanner and RM7840 with Safe Start Check and
ignition, pilot, or run cycle. leaking fuel in to furnace b] Listed Burner Controller C7061 Cycling Self-Check UV Scanner
and explosion.
2.3 BE760 Flame Scanner Failure Flame detected when no Fuel Valves open with no a] Self-Checking Scanner and C7061 Cycling Self-Check UV Scanner
flame is present in furnace. source of ignition resulting b] Listed Burner Controller
in fuel rich furnace and
subsequent explosion.
3.0 Failure to Purge Combustion Chamber prior to Ignition Trials
3.1 ZSH111 GO2319.J.2 Draft Dampers Failed Closed Fuel Vapor accumulate in Explosion on Ignition a] Draft Damper PROOF OPEN Sw Integrate ZSH111 and MI760 Feedback Signal to
the furnace prior to ignition b] Combustibles Analyzer in Stack* BMS950.
*(Natural Drafted Systems)
3.2 AX111 Combustion Fan Failure Fuel Vapor accumulate in Explosion on Ignition a] Motor Run Proof Sw Integrate MS Aux-Contact and MI760 Feedback
Mechanically Drafted Sys. the furnace prior to ignition b] Air Flow Proof Sw signal in BMS950.
c] Air Flow Proof Trans
Process Combustion Interlocks 3.3 MI762 GO2319.J.2 Interruption of Fuel/Air Ratio Fuel Rich Furnace Delayed Ignition and Explosion a]Combustibles or Oxygen Interlock Integrate FT7604 with MI762 and Deviation Alarm MI761
Control Strategy Analyzer in Stack as Check & Balance of Air to Fuel To Field Element Position.
FT7604 b] Cross Limited Fuel/Air Ratio Control
c] Fuel Flow Meter
4.0 Failure to Maintain Fluid Inside Heated Tubes or Vessels
4.1 ZSC761 GO2319.J.2 Inlet Valves CLOSED Overheating of tubes and/or Mechanical failure of tubes a] Inlet Valve PROOF OPEN Sw Integrate ZSC762 Proof of Closure Switch toBMS
Valve Proof OPEN during burner operation vessel and vessels and release of b] Minimum Flow Sw in Media line to Proof Valve Position prior to ignition and Interlock on ESD.
Switch vessel contents
4.2 FT761A-D GO2319.J.2 Media Pump Fails Overheating of tubes and/or Mechanical failure of tubes a] Minimum Flow Sw in Media line Integrate FT761A-D to BMS for Min/Max Media Flow Interlock
FT762 Media vessel and vessels and release of b] Minimum Flow Trans in Media Line Integrate FT762 to BMS for Min/Max Media Flow Interlock
vessel contents c] Pump Motor Run Ax Sw.
4.3 NA Heating Surfaces Exposed Overheating of tubes and/or Mechanical failure of tubes a] Low Level Burner Cut-Off Sw
vessel and vessels and release of b] Low Level Burner Cut-Off Transmitter
vessel contents c] Tube Skin Temp Interlock
Boiling Liquid Vapor Explosion
5.0 Excessive or High Temperatures
5.1 MI762 Firing Rate Valve Hangs Overheating of process fluid Thermal breakdown of heat High Media Temperature Interlock Valve Positions and Valve Deviation alarms cause BMS
MI761 in OPEN position transfer fluid. Interlock trip on High Deviation.
See Hi Temp Interlock for Overfiring Temp Shutdown.
5.2 TE762A &B GO2319.J.2 Breach in process tube Process media fire inside Furnace Explosion or Media High Stack Temperature Interlock Redundant TE762 A&B Interlocked to BMS to Safety Shutdowns.
or vessel releasing media furnace. Process Explosion Shutdown fuel on High Stack Temp Interlock.
in to furnace area and
catching fire.
6.0 Fuel Leak in to Furnace during OFF Cycle
6.1 ZSC108 GO2319.J.2 Failed Fuel Shutoff Valve Fuel leaking into furnace Furnace Explosion a] Listed Fuel Safety Shutoff Valves FM and SIL3 Rated Proof of Closure
ZSC110 with no immediate ignition b] Fuel Valve Proof of Closure Sw Perform Safety Valve Z21.21 Tightness Integrity Test prior to
Valve Proving source. c] Double Block & Bleed Fuel Train each main burner light off.
d] Valve Proving System on Fuel Train Perform Preignition Valve Proofed Closed prior to Pilot ignition.
 Basic Flow Gas Heat Load Calculator
11/24/2022

FLOWING GAS HEATING LOADS

AS USED IN REGEN HEATERS AND OTHER GAS PROCESSING APPLICATIONS
NOTE: This calculation gives a simple 'Basic Heat Load' only.
All results based on correcting flow to Standard Cubic Feet.
What is the Gas? Methane (Flow stated by Control Room)

CUTOMER DCP Midstream BURNER MFG JZ

SITE LOCATION Carthage Plant-1 Regen MDL/Serial No. PM7-4HC w PM10-75 Orifice Spud (20 PSI Gas Pressure)
HEATER No. H1B DRAFT TYPE Aspirated
MFG/Serial No. Loveco Inc.

Use the GPSA Engineering Data Book for typical "Physical Properties" of the gas under consideration

FLOW = 18,000,000 IN "SCF/DAY"

MOL WT = 16 (USE 16.93 AS A DEFAULT FOR NATURAL GAS AND 16.0 FOR METHANE)
0.0484 Calculated Density at Sea Level and 60 Deg "F"
36300.00 Lbs/Hr Total Flow for this application
Sp/Ht of Gas = 0.6 (USE 0.62 AS A DEFAULT FOR NATURAL GAS AND 0.60 FOR METHANE)
T1= 60 Inlet Temperature
T2= 600 Exit Temperature
11,761,200 Btu/Hr Heat absorption (Duty)
Heater Eff. = 84% This is from the Mfg Rated Heater Efficiency statement, or your best estimate based on fuel gas input readings.
14,001,429 Total Btu/Hr Heat Input (release from burner) required based on Mfg Rated Heater Efficiency statement.
Actual Btu/Input = From Fuel Meter Readings (If Available)
Actual Heater Eff = #DIV/0!
Fouling Factor = #DIV/0! #DIV/0!

TYPICAL MOL WT OF COMMON GASES Calculated MOL WT

Source GPSA Engineering Data Book GAS Constituents MOL WT By % MOL WT By %
MOL WT Sp/Ht CH4 16.042 0.00% 0
CH4 Methane 16.042 0.52725 N2 28.01 0.00% 0
CO2 Carbon Dioxide 44.01 0.19875 C3H8 44.096 0.00% 0
N2 Nitrogen 28.0135 0.2489 C2H6 30.069 0.00% 0
C2H6 Ethane 30.069 0.4088 C4H10 58.122 0.00% 0
C3H8 Propane 44.096 0.3897 H20 18.0153 0.00% 0
C4H10 Isobutane 58.122 0.38798 0
C4H10 n-Butane 58.122 0.39649 0
H2O Water (Vapor) 18.0153 0.44476 0
0
0
0.00% 0.0000 = MOL WT