boiler calc

[A] BOILER DUTY FOR INITIAL HEATING OIL INSIDE TANK

Service = To heat up oil temperature inside tank to specified temperature

HFO Temperature Initial = 10

HFO Temperature Final = 40

HFO Gross Volume = 6,500 Refer to bid document 1.6.1. Tank Dimension

HFO Net Working Volume = 6,150

HFO Mass Density = 0.991 kg/lt Refer to reference

HFO Specific Heat = 1,717 Refer to reference

HFO Mass Stock = 6,094,650 kg

Number of HFO Tank = 3 ea

Total HFO Mass Stock = 18,283,950 kg

Pumping frequency = 96 hr

= 345,600 sec

= 4 days Refer to bid document 2.2.4. Pipework

Heating duty = 2,725,134 Joule/sec

= 2.725 MW

Hot water operating pressure = 3 barg

Hot water inlet temperature = 100

Cp hot water inlet = 4,397 Refer to Hysis simulation

Hot water outlet temperature = 60

Cp hot water outlet = 4,329 Refer to Hysis simulation

Hot water mass rate = 16 kg/sec

= 56,214 kg/hr Refer to manual calculation

= 56,269 kg/hr Refer to Hysis simulation

[2] BOILER DUTY DURING INITIAL OPERATION

Boiler heating duty = 2.725 MW

Boiler heating capacity = 4.500 MW

Note = Oke becauce boiler is over capacity

[1] DUTY FOR HEATING HEAVY FUEL OIL [HFO] "INSIDE" STORAGE TANK

Joule/kg.oC

6500 m3

[3] FASTEST PERIOD FOR HEATING 3 OIL STORAGE

HFO Volume = 6,500 Refer to bid document 1.6.1. Tank Dimension

Maximum time for heating up = 58 hr

= 209,316 sec

= 2 days

Pumping frequency period = 96 hr

Note = Oke because shorther than pumping frequency period

Boiler duty = 4,499,442 Joule/sec

= 4.50 MW

Boiler design duty = 4.50 MW Refer to bid document data

Heat balance = 1

[B] BOILER DUTY DURING NORMAL OPERATION

Service = To heat up pumped oil temperature to specified value

HFO Temperature Inlet = 40

HFO Temperature Outlet = 50

HFO Mass Flow = 600 ton/hr

= 600,000 kg/hr

Heating duty = 10,302,000,000 Joule/hr

= 2.862 MW

Joule/kg.oC

[1] DUTY FOR HEATING UP HEAVY FUEL OIL [HFO] "OUTLET" STORAGE TANK

Joule/kg.oC

HFO Inlet HFO Outlet

Hot Water Inlet Hot Water Outlet

Service = To maintain oil temperature inside tank to specified temperature

HFO Volume = 6,500

Maximum time for heating up = 120 hr Refer to bid document 4.10.8. HFO Storage Tank Heating Coil

= 432,000 sec

= 5 days

Heating duty = 384,030 Joule/sec

= 0.3840 MW

[3] BOILER DUTY DURING NORMAL OPERATION

Joule/kg.oC

6500 m3

[C] HOT WATER SUMMARY

Hot water mass rate = 56,269 kg/hr Initial heating up period for 4 days

= 92,921 kg/hr Initial heating up period with maximum boiler capacity

= 67,027 kg/hr Heating up duty during normal operation

Selected hot water mass rate = 92,921 kg/hr Higher value is selected

[D] MAKE UP WATER CALCULATION

Boiler cycle of concentration = 10 Typical boiler 10 ~ 50 COC

% Blow down = 10 % Initial heating up period with maximum boiler capacity

Boiler feed water mass rate = 6,894 kg/hr Refer to Hysis Simulation

Boiler blow down mass rate = 689 kg/hr

Boiler make up water = 689 kg/hr

= 0.6894

Condition :

Steam mass rate = 6,894 kg/hr

Steam operating pressure = 3 barg Refer to Hysis Simulation

Steam operating pressure = 143.7 Refer to Hysis Simulation

[E] WASTE HEAT RECOVERY IN FORT VICTORIA POWER STATION

[1] FORT VICTORIA POWER STATION

Fort Victoria power plant capacity = 90 MW Refer to data googling

Fort Victoria power plant capacity for design heat recovery = 45 MW Assume

Machine = diesel engine generator Refer to data googling

Engine brand = Wartsila

Number of engine = 6 ea Refer to data googling

Capacity each engine = 15 MW Refer to data googling

Efficiency = 45 % Refer to product bulletin (if no data use value 30 ~ 35 %)

Total fuel heat combustion = 100 MW

Total heat loss = 55 MW

Heat loss carried by flue gas = 60 % total heat loss Refer to reference

= 33 MW

Heat loss carried by engine cooling system = 40 % total heat loss Refer to reference

= 22 MW

Net caloric value = 40 MJ/kg Refer to reference

Total HFO mass rate to engine = 2.5 kg/sec

= 9,000 kg/hr

[2] PRE-HEATER DUTY

Max hot water mass rate = 92,921 kg/hr Refer to Hysis simulation

Preheater duty = 8,070,203,531 Joule/hr

= 2.242 MW Refer to manual calculation

= 2.241 MW Refer to Hysis simulation

Heat available in Fort Victoria Power Plant = 22 MW

Note = Heat recovery is available

Joule/kg.oC

[F] HEAT BALANCE AROUND STEAM DRUM DURING NORMAL OPERATION

Steam condition = saturated

Steam mass rate = 4,680 kg/hr Calculated

Steam temperature = 143.72 Refer to Hysis simulation

Steam pressure = 3.00 barg Refer to Hysis simulation

Make up water condition = subcooled

Make up water mass rate = 689 kg/hr Refer to Hysis simulation

Make up water temperature = 20.00 Assume

Make up water pressure = 3.00 barg Refer to Hysis simulation

Hot water inlet tank condition = subcooled

Hot water inlet water mass rate = 67,027 kg/hr Refer to Hysis simulation

Hot water inlet water temperature = 100.00 Assume

Hot water inlet water pressure = 3.00 barg Refer to Hysis simulation

Hot water outlet tank condition = subcooled

Hot water outlet water mass rate = 62,347 kg/hr Calculated

Hot water outlet water temperature = 60.00 Assume

Hot water outlet water pressure = 3.00 barg Refer to Hysis simulation

Blow down water condition = subcooled

Blow down water mass rate = 689 kg/hr Refer to Hysis simulation

Blow down water temperature = 100.00 Assume

Blow down water pressure = 3.00 barg Refer to Hysis simulation

Steam mass flow rate during normal condition = 4,680 kg/hr Refer to Hysis simulation

Boiler design capacity = 6,894 kg/hr Refer to Hysis simulation

Note = Oke due to steam demand is lower than steam design capacity

[A] BOILER DUTY FOR INITIAL HEATING OIL INSIDE TANK

HFO Gross Volume = 6,500 Refer to bid document 1.6.1. Tank Dimension

Pumping frequency = 96 hr

= 345,600 sec

Heating duty = 2,725,134 Joule/sec

= 2.725 MW

[2] BOILER DUTY DURING INITIAL OPERATION

Joule/kg.oC

6500 m3

[3] FASTEST PERIOD FOR HEATING 3 OIL STORAGE

HFO Volume = 6,500 Refer to bid document 1.6.1. Tank Dimension

Maximum time for heating up = 58 hr

= 209,316 sec

= 2 days

Pumping frequency period = 96 hr

Note = Oke because shorther than pumping frequency period

Boiler duty = 4,499,442 Joule/sec

= 4.50 MW

Boiler design duty = 4.50 MW Refer to bid document data

Heat balance = 1

[B] BOILER DUTY DURING NORMAL OPERATION

Service = To heat up pumped oil temperature to specified value

HFO Temperature Inlet = 40

HFO Temperature Outlet = 50

HFO Mass Flow = 600 ton/hr

= 600,000 kg/hr

Heating duty = 10,302,000,000 Joule/hr

= 2.862 MW

Joule/kg.oC

[1] DUTY FOR HEATING UP HEAVY FUEL OIL [HFO] "OUTLET" STORAGE TANK

Joule/kg.oC

HFO Inlet HFO Outlet

Hot Water Inlet Hot Water Outlet

Service = To maintain oil temperature inside tank to specified temperature

HFO Volume = 6,500

Maximum time for heating up = 120 hr Refer to bid document 4.10.8. HFO Storage Tank Heating Coil

= 432,000 sec

= 5 days

Heating duty = 384,030 Joule/sec

= 0.3840 MW

Hot water mass rate = 1.08 kg/sec

Joule/kg.oC

6500 m3

[3] BOILER DUTY DURING NORMAL OPERATION

[C] HOT WATER SUMMARY

Hot water mass rate = 27,830 kg/hr Initial heating up period for 4 days

= 45,955 kg/hr Initial heating up period with maximum boiler capacity

= 33,162 kg/hr Heating up duty during normal operation

Selected hot water mass rate = 45,955 kg/hr Higher value is selected

[D] MAKE UP WATER CALCULATION

Boiler cycle of concentration = 10 Typical boiler 10 ~ 50 COC

% Blow down = 10 % Initial heating up period with maximum boiler capacity

Boiler feed water mass rate = 7,381 kg/hr Refer to Hysis Simulation

Boiler blow down mass rate = 738 kg/hr

Boiler make up water = 738 kg/hr

= 0.7381

Condition :

Steam mass rate = 7,381 kg/hr

Steam operating pressure = 5 barg Refer to Hysis Simulation

Steam operating pressure = 159.0 Refer to Hysis Simulation

[E] WASTE HEAT RECOVERY IN FORT VICTORIA POWER STATION

[1] FORT VICTORIA POWER STATION

Fort Victoria power plant capacity = 90 MW Refer to data googling

Fort Victoria power plant capacity for design heat recovery = 45 MW Assume

Machine = diesel engine generator Refer to data googling

Engine brand = Wartsila

Number of engine = 6 ea Refer to data googling

Capacity each engine = 15 MW Refer to data googling

Efficiency = 45 % Refer to product bulletin (if no data use value 30 ~ 35 %)

Total fuel heat combustion = 100 MW

Total heat loss = 55 MW

Heat loss carried by flue gas = 60 % total heat loss Refer to reference

= 33 MW

Heat loss carried by engine cooling system = 40 % total heat loss Refer to reference

= 22 MW

Net caloric value = 40 MJ/kg Refer to reference

Total HFO mass rate to engine = 2.5 kg/sec

= 9,000 kg/hr

[2] PRE-HEATER DUTY

Max hot water mass rate = 45,955 kg/hr Refer to Hysis simulation

Preheater duty = 3,991,155,665 Joule/hr

= 1.109 MW Refer to manual calculation

= 1.108 MW Refer to Hysis simulation

Heat available in Fort Victoria Power Plant = 22 MW

Joule/kg.oC

Note = Heat recovery is available

[F] HEAT BALANCE AROUND STEAM DRUM DURING NORMAL OPERATION

Steam condition = saturated

Steam mass rate = 4,640 kg/hr Calculated

Steam temperature = 158.96 Refer to Hysis simulation

Steam pressure = 5.00 barg Refer to Hysis simulation

Make up water condition = subcooled

Make up water mass rate = 738 kg/hr Refer to Hysis simulation

Make up water temperature = 20.00 Assume

Make up water pressure = 5.00 barg Refer to Hysis simulation

Hot water inlet tank condition = subcooled

Hot water inlet water mass rate = 33,162 kg/hr Refer to Hysis simulation

Hot water inlet water temperature = 140.00 Assume

Hot water inlet water pressure = 5.00 barg Refer to Hysis simulation

Hot water outlet tank condition = subcooled

Hot water outlet water mass rate = 28,522 kg/hr Calculated

Hot water outlet water temperature = 60.00 Assume

Hot water outlet water pressure = 5.00 barg Refer to Hysis simulation

Blow down water condition = subcooled

Blow down water mass rate = 738 kg/hr Refer to Hysis simulation

Blow down water temperature = 140.00 Assume

Blow down water pressure = 5.00 barg Refer to Hysis simulation

Steam mass flow rate during normal condition = 4,640 kg/hr Refer to Hysis simulation

Boiler design capacity = 7,381 kg/hr Refer to Hysis simulation

Note = Oke due to steam demand is lower than steam design capacity

Joule/kg.oC

Dearator Dimension Calculator

Internal Diameter : 1.000 m Select Units

Tan-Tan Length : 2.000 m

Volume of two heads : 0.26 m³ Select Head Type

Shell Volume : 1.57 m³

Total Volume : 1.83 m³

Heads SA : 2.17 m² Number of heads included in level calcula

Shell SA : 6.28 m²

Surface Area : 8.5 m²

Level SettingLevels Vapour Volume Volume Wetted Area

m m m³ % m²

Low low 0.100 0.90 0.089 4.9 1.40

Low 0.200 0.80 0.251 13.7 2.16

Normal 0.500 0.50 0.916 50.0 4.23

High 0.850 0.15 1.669 91.1 6.66

High High 0.900 0.10 1.744 95.1 7.05

Overflow 1.000 0.00 1.833 100.0 8.45

Total Residence Time :

Working Volume : 1.42 m³

Utilisation : 77.4 %

Flowrate : 0.74

Residence Time : 128.43 minutes Oke

Residence Time Specified by Client : 10.00 minutes

Venting

® BETWEEN LLL AND HLL (LV ON/OFF ACTION)

® For accomodating surge and hold up

Refer to Spiraxsarco (Typical 10 ~ 20 minutes)

Vendor to Advice

ID = 1000 mm

(L/ID) = 2

L = 2000 mm

Dearator Inlet Water Flow

Dearator Inlet Steam Flow

Wetted AreaTotal Vol. Retention Time Retention Time

From LALL Between Level Between Level

% m³ hours Minutes

16.6 - 0.121 7.24

25.6 0.2 0.219 13.15

50.0 0.8 0.902 54.09

78.8 1.6 1.020 61.18

83.4 1.7 0.101 6.06

100.0 1.7 0.121 7.24

Total Residence Time : 2.483 148.97

Volume of one head

Venting

BETWEEN LLL AND HLL (LV ON/OFF ACTION)

For accomodating surge and hold up

Vendor to Advice

Overflow = 1000 mm

High high level = 900 mm

High level = 850 mm

Normal level = 500 mm

Low level = 200 mm

Low low level = 100 mm

Pressure 760 mmHg = 1 atm

Temperature

ppm ppm

0 14.4 14.425

10 11.3 11.219

20 8.85 8.839

30 7.2 7.172

40 6.2 6.036

50 5.6 5.213

60 4.95 4.482

70 4 3.661

80 3.05 2.639

90 1.8 1.414

100 0 0.125

A = 3.00E-09

B = -6.00E-07

C = 1.00E-05

D = 0.0042

E = -0.363

F = 14.425

Pressure 760 mmHg = 1 atm

Temperature Air solubility

gr/liter gr/liter ppm = mg/liter

40 4 0.0258 0.023 22.611

50 10 0.0223 0.022 21.500

60 16 0.0197 0.020 20.389

70 21 0.0177 0.019 19.278

80 27 0.0161 0.018 18.167

90 32 0.0147 0.017 17.056

100 38 0.0136 0.016 15.944

110 43 0.0126 0.015 14.833

120 49 0.0117 0.014 13.722

130 54 0.0107 0.013 12.611

140 60 0.0098 0.012 11.500

150 66 0.0089 0.010 10.389

160 71 0.0079 0.009 9.278

170 77 0.0068 0.008 8.167

180 82 0.0055 0.007 7.056

190 88 0.0041 0.006 5.944

200 93 0.0024 0.005 4.833

210 99 0.0004 0.004 3.722

A = -2.00E-04

B = 2.35E-02

O2 solubilityoC

0 10 20 30 40 50 60 70 80 90 100

f(x) = 0.00000000288462 x⁵ − 0.000000622086 x⁴ + 0.0000128059 x³ + 0.00424636 x² − 0.3630111 x + 14.425175R² = 0.999694182664363

O2 solubility vs temperature

temperature, oC

0 10 20 30 40 50 60 70 80 90 100 110

0.0000

0.0050

0.0100

0.0150

0.0200

0.0250

0.0300

f(x) = − 0.000228761609907121 x + 0.0235249054007568R² = 0.971841437190846

air solubility vs temperature

temp, C

0 10 20 30 40 50 60 70 80 90 100

f(x) = 0.00000000288462 x⁵ − 0.000000622086 x⁴ + 0.0000128059 x³ + 0.00424636 x² − 0.3630111 x + 14.425175R² = 0.999694182664363

O2 solubility vs temperature

temperature, oC

0 10 20 30 40 50 60 70 80 90 100 110

0.0000

0.0050

0.0100

0.0150

0.0200

0.0250

0.0300

f(x) = − 0.000228761609907121 x + 0.0235249054007568R² = 0.971841437190846

air solubility vs temperature

temp, C

21962,Water-pp414-416

Wartsila-O-E-RT-WHR

steam9_blowdown

presentation4-casestudyboiler

Power-Plants-Product-Catalogue-2012-2nd-edition

GTMEIC

5510-0136-00pp_low

21962,Water-pp414-416

Basic_Water_ocr

e481017

Nalco Water Handbook

The Nalco Guide to Boiler Failure Analysis

GPSA Sect 18

http://www.gc3.com/Default.aspx?tabid=92

http://www.cewater.com/A55_BoilerSystem.html

http://gc3.com/Default.aspx?tabid=91

24_WaterTreatment_BoilerWater

http://www.cleaverbrooks.com/Reference-Center/Boiler-Basics/Steam-or-Hot-Water.aspx

http://books.google.co.id/books?id=gK03hTP7NNcC&pg=PA84&lpg=PA84&dq=heat+losses+in+diesel+engine&source=bl&ots=_r4JXBz2Ls&sig=Y3urFd1KU7TfJZmVI_Enhu8W_Bo&hl=en&sa=X&ei=2MrxU6nHB4K3uAShk4CgDA&ved=0CDIQ6AEwAw#v=onepage&q=heat%20losses%20in%20diesel%20engine&f=false

214091248-Diesel-Engine-Power-Plants

http://www.engineeringtoolbox.com/air-solubility-water-d_639.html

Deaerator in steam industrial system

http://www.spiraxsarco.com/resources/steam-engineering-tutorials/the-boiler-house/pressurised-deaerators.asp

Power-Plants-Product-Catalogue-2012-2nd-edition

GTMEIC

5510-0136-00pp_low

GPSA Sect 18

http://www.gc3.com/Default.aspx?tabid=92

http://www.cewater.com/A55_BoilerSystem.html

http://gc3.com/Default.aspx?tabid=91

EBMUD_WaterSmart_Guide_Thermodynamic_Processes

Essentials for a Sound Boiler Water Treatment Program

http://www.cleaverbrooks.com/Reference-Center/Boiler-Basics/Steam-or-Hot-Water.aspx

http://www.engineeringtoolbox.com/air-solubility-water-d_639.html

Deaerator in steam industrial system

boiler calc

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