boiler tube facts book

1

BOILER TUBE FACTSUseful information and

technical data

on boilers

2

Mission

To be the undisputed first choice for boiler pressure

parts in America. The Boiler Tube Company of

America. To establish a worldwide reputation as aworld-class manufacturer in the unique specialty of

boiler tube supply. The foundation for our vision is astrong commitment to Quality, Customer Service,

Employees, Suppliers and the principles of

Continuous Improvement.

This Boiler Tube Factsbook was prepared for you—the Boiler Engineer/Operator and Plant Engineer—

as a current reference book to consult regarding

the care and preservation of your boiler. Foradditional copies or more information on our boiler

tube and pressure parts replacement services,please call Boiler Tube Company of America.

Boiler Tube Company of America

P.O. Box 517

506 Charlotte Highway

Lyman, South Carolina 29365

(864) 439-0220, 1-800-845-3052

Fax: (864) 439-8292

650 Green Lane

P.O. Box 2065

Union, NJ 07083

1-800-345-0632

TABLE OF CONTENTS

Section I

INTRODUCTION

A. Boiler Tube Company of America ............................................. 3

Section II

CAUSES AND PREVENTION OF BOILER TUBE FAILURES

A. Damage Modes ........................................................................ 5

B. Precursors to Damage—Identification and Control .................. 6

C. Condition Assessment .............................................................. 7

D. Root Cause Failure Analysis .................................................... 7

E. Corrective Actions—Engineering and Implementation ............. 7

F. Regular Inspection Prevents Tube Failure ................................ 8

G. How to Buy Replacement Boiler Tubes ..................................... 8

Section III

FABRICATION

A. Tube Fabrication ....................................................................... 9

B. Complete Tube Inventory and Engineering Library ................. 10

C. Code Assembly ...................................................................... 10

Section IV

ECONOMIZERS

A. Economizers ........................................................................... 11

Section V

BOILER TUBE SPECIFICATION AND STOCK ITEM GUIDE

A. Boiler Tube Specifications ....................................................... 12

Section VI

REFERENCE

A. Useful Boiler Calculations and Data ....................................... 14

3

INTRODUCTION


Boiler Tube Company of America (BTA) is a designer,manufacturer of replacement boiler tubes andassemblies.

When you call BTA with a boiler problem, expectsome unique services. First of all, your situation isgiven “same day” attention by experienced SalesEngineers. People who can answer your questions,discuss your options and quickly get your boiler backin operation.

At BTA, you’ll find the world’s largest tubing inven-tory with over two million feet of stock tubing in 1,350different sizes and material specifications. So younever lose time waiting for tubes to be shipped fromthe mill to your OEM. And you never have to worryabout minimum order restrictions. Because whetheryou need three feet or 1,500 feet, BTA is ready tostart your job, today.

We also have the largest boiler reference files in theindustry—over 20,000 boiler tube drawings, printsand life-size templates. Call us the next time youneed tubing or bending specifications on existing oreven discontinued boilers.

Our computerized inventory system tells us preciselywhat is in stock and the expected arrival date ofitems on order.

SECTION I We can deliver your tubes, bends, elements andassemblies to meet your outage requirements. Butjust because we’re fast, don’t assume we short-cutprecision. At BTA, you’ll always get a quality job.

You’ll never find an “assembly line mentality” at BTA.Because with each cold and hot bend, bifurcate,swage, panel and butt weld, our craftsmen demon-strate their pride and expertise. Regardless of yourrequirements or application, we can quickly fabricate,fit-up, finish and assemble any replacement tubularcomponent.

From our file copy of your boiler’s specifications, weprepare life-size, full-scale templates to ensureproper tube configuration and fit-up.

Since the mechanical and metallurgical properties ofboiler tubing can change dramatically during fabrica-tion, BTA uses technical procedures that restoreoriginal material properties. So you’re assured longtube life and serviceability even at high temperaturesand elevated pressures.

4

Before your tube or assembly gets out in the field, wemake sure it passes BTA's quality assurance tests.

Our standard for excellence, known as “Quality Whilein Process,” requires every job to pass multiple qualitycontrol points that are built into the shop fabricationplan. No one in the industry—including your OEM—pays more attention to quality than BTA.

First, we visually inspect each weld and ultrasonicallytest bends for thickness. Then we can apply magneticparticle tests, radiography and hydrostatic tests toeach panel, element and assembly.

Bottom line, Boiler Tube Company of America is theonly company that offers the quality capabilities ofan OEM with the service and quick response of analternate supplier. And that’s not just an emptypromise. We prove it every day by hustling to meetyour deadlines. By producing only top quality boilertube components at competitive prices. And byoffering the best OEM alternative in the boilermaintenance business.

Every element of BTA work must pass these qualityassurance tests, as well as the final inspection by ourQ.C. inspectors, our customers and our IndependentAuthorized Inspection Agency.

5

SECTION II

CAUSES AND PREVENTION

OF BOILER TUBE FAILURESBy S. Paterson and T. Kuntz,

Aptech Engineering Services, Inc.

To ensure that a boiler tube achieves its desiredlifetime, a comprehensive damage managementprogram is required. Key elements of such a pro-gram include: (1) knowledge of damage modes, (2)identification and control of precursors to damage,(3) periodic condition assessments, (4) root causeevaluations of failures or unanticipated damage and(5) engineering and implementation of correctiveactions to prevent repeat failures or to prevent lead-the-fleet failures. An overview of each of these follows.

Damage Modes

Boiler tubes degrade for one of four reasons: (1) theyhave been chemically attacked or have developedthick deposits/oxide scales on their fluidside, (2) theyhave experienced fireside wastage, (3) they haveexperienced short- or long-term overheating or (4)they have been stressed above their ultimatestrength or repeatedly stressed above their fatiguelimits. Numerous subsets and combinations of thesedamage modes are known. Fortunately, diagnostictools and knowledge exist which are capable ofidentifying the precursors to the damage andcorrecting or controlling them.

1. WATERSIDE CORROSION OR DEPOSITBUILDUP

Underdeposit, pitting and chemical cleaning corro-sion are the three most common causes of severewaterside corrosion in fossil-fueled utility boilertubing. Under normal circumstances, water is theprincipal reactant for the corrosion of boiler steel. Ifthe feed and boiler water chemistries are maintainedwithin accepted industry standards and circulation isproperly balanced with the heat absorption rates,fluidside corrosion and deposition should not limitthe life of boiler tubing. This can be assured bycontinuous, on-line monitoring and control of keywater chemistry parameters, such as cationconductivity, dissolved oxygen, sodium, pH andphosphate (for drum boilers using sodium phos-phates for boiler water control). Periodic wallthickness, tube sampling and deposit loadingsurveys are used to confirm that nothing has beenoverlooked by the on-line monitoring program.

Underdeposit corrosion occurs when contaminants,such as chlorides, or water treatment chemicals,such as sodium hydroxide or monosodium phos-phate, are introduced and/or allowed to concentrateto harmful levels. These species can concentrate toharmful levels by becoming trapped within thick,porous deposits or by precipitating in regions wherelocal steam blanketing occurs.

Pitting corrosion is most often a result of exposure ofthe tubing to oxygen-saturated water during out-of-service periods. Chlorides and other anions canincrease the tendency for pitting.

Chemical cleaning is performed periodically toremove deposits that build up on the fluidsidesurface of tubing, the purpose being to minimize theopportunity for tube overheating or the concentrationof corrosive chemical species. Chemical cleaning iscommonly performed using inhibited acids orchelants. Inadequate control of the cleaning processcan result in rapid attack of the tubing.

2. FIRESIDE WASTAGE

The fireside of boiler tubing is exposed to hotfurnace or flue gases which may be extremelycorrosive or erosive. When exposed to this environ-ment, even the best available tube alloys mayexperience fireside wastage. Common firesidewastage mechanisms include oxidation, ashcorrosion, ash erosion and steam erosion fromsootblowers.

Oxidation and oxide spalling will occur on steam-cooled tubing even when the fuel is not erosive orcorrosive (for example, natural gas). If the metaltemperature of the tubing is within design limits,fireside oxidation will be minor and will not result in asignificant loss of life. If there is a maldistribution inflow or heat absorption rates across or through atube bank, some of the tubes may operate withmetal temperatures well above design expectations.Under these circumstances, oxidation rates can besignificant and can result in significant wastagerates. Reheater tubes, which are relatively thin-walled, are especially sensitive to oxidation-inducedfireside wastage. Oxidation rates can be controlledby locating and reducing the temperature of thetubing operating at excessive temperatures. Thespecific approaches used are discussed under theCorrective Actions section.

Ash corrosion occurs when the temperature of thetube crown exceeds a critical temperature, oftenassociated with the melting temperature of the ash.Successful operation in the early life of the tubingdoes not assure that ash corrosion will not occur in

6

the future. During service exposure, insulatingsteamside oxide and/or fluidside deposits will buildup on the tube and increase its temperature,possibly resulting in ash corrosion. All fossil fuels,except for natural gas, can produce corrosive ashcompounds capable of fluxing away or acceleratingthe growth of fireside oxide scales. In addition toproper alloy selection, fireside ash corrosion can becontrolled by changing the composition of the fuelsand combustion gases (for example, changing theamount of excess air, using fuel additives, fuelblending) or decreasing the peak tube temperatures.

3. OVERHEATING

Long-term overheating is a tube damage mechanismresponsible for large availability losses. Over time,the tubes will slowly deform due to creep, eventhough the stress levels are well below the materialyield strength. Creep failures will eventually occur,even in the absence of corrosion, oxidation or otheractive damage mechanisms.

4. FATIGUE

Fatigue refers to the initiation and propagation ofcracks under the influence of repeated, fluctuatingstresses that can be of a magnitude that is signifi-cantly lower than the material’s strength. In boilertubes, fatigue is often associated with localizedconditions of high stresses, such as at attachmentwelds and header connections. Fatigue damage isoften exacerbated by a corrosive internal or externalenvironment, as well as by frequent startups,shutdowns and load changes which can producelarge thermal gradients.

Waterside corrosion fatigue failures initiate at thetube ID, often at locations of pitting, and are gener-ally associated with restraint at tube attachments,supports and membrane welds. The combination ofhigh stresses and a corrosive environment leads todegradation of the tube’s protective oxide scalewhich, with repeated stress applications, initiatesand propagates cracking. An example of corrosionfatigue cracking in a supercritical boiler waterwalltube is shown in Figure 1. Other fatigue failures canbe attributed to flow-induced vibration, thermalshocking from malfunctioning sootblowers andpoorly designed tube bends and welds.

Figure 1

Corrosion fatigue cracks in a waterwall tube from a

supercritical boiler.

Precursors to Damage —Identification and Control

Precursors to damage are specific characteristics oftubing which can be identified or quantified and thenused to identify and predict potential boiler tubefailures. These characteristics provide evidence thatcertain conditions and active damage mechanismsexist which may be degrading the tubing. Thedamage precursors are usually identified andquantified during the course of boiler outageinspections or normal operations and maintenance.

For example, a precursor of underdeposit corrosionis excessive waterside deposits. Periodic measure-ment of the waterside deposit loading (mass of thedeposit per tube surface area) on waterwall tubesamples removed during maintenance outages is acommon practice. As another example, thicksteamside oxide scales, which are commonlymeasured by nondestructive ultrasonic techniques,can be a precursor of long-term creep overheatfailures. Significant changes in the way a unit isoperated, particularly changes which increase thelikelihood of increased thermal cycles, can be aprecursor to fatigue-related types of damage. Once aprecursor is identified, steps can be taken to reduceor eliminate the conditions which are giving rise tothe precursor, as described beginning on page 7.

7

Condition Assessment

The long-term health of boiler tubing is best assuredby periodic inspections and condition assessments.These are typically done as part of scheduledmaintenance outages.

Common condition assessment inspection items fortubing include visual examination for excessiveexternal oxidation, sootblower and ash erosion,misaligned tubes, slagging and external corrosion,and magnetic particle inspection of tube-to-headerwelds and other attachment welds for cracking.Ultrasonic wall thickness measurements in areaswhere excessive thinning is expected are alsocommonly performed (for example, near sootblowersand burners, as well as slope and arch tubes).

One of the primary assessment tools for steam-cooled tubing is the nondestructive measurement ofthe internal oxide scale, which can be used to infer atube’s remaining life. In the absence of externalerosion, oxidation or corrosion, the life of steam-cooled tubing is primarily limited by its high-tempera-ture creep strength, which is a function of the metaltemperature. Tube metal temperature is directlyrelated to the thickness of the insulating oxide scalewhich forms on the internal tube surface over time.Techniques, such as Aptech’s TubeAlert™ system,combine measurement of the scale and wall thick-ness with the tube’s operating history and materialproperties to calculate an expected remainingservice life.

Root Cause Failure Analysis

When tube failures occur, a complete root causeanalysis should be performed in order to determinethe active damage mechanism and the steps thatneed to be taken to prevent additional failures.Specific aspects of a root cause failure investigationinclude a review of failure location and operatinghistory, visual examination, measurement of tubedimensions, characterization of deposits andcorrosion products, hardness testing, sectioning andmetallography, alloy verification, photodocumentationand reporting.

Corrective Actions — Engineeringand Implementation

Once a damage precursor has been identified or aroot cause failure investigation has been performed,preventative or corrective actions need to be devisedand implemented. These may involve maintenance

improvements, design changes, operationalmodifications, material upgrades or recommenda-tions for additional inspection. For example, exces-sive waterside deposit buildup indicates a need forchemical cleaning, as well as a review of waterchemistry practices to determine the source(s) ofdeposits and contaminants. Figure 2 shows thecurrent Electric Power Research Institute (EPRI)guidelines for recommended chemical cleaninglimits. Fatigue cracking may indicate a need forattachment or support redesign to relieve restraintand possible operational modifications to reducelarge or rapid thermal gradients.

Figure 2

For steam-cooled tubing, the results of a nonde-structive oxide thickness survey can be used to helpengineer a more reliable tube bank with improvedremaining life. Depending on the design, boilerstypically exhibit a distinct temperature profile acrossthe width of the furnace, and tubes operating in thehottest regions will have a reduced remaining creeplife compared to the tubes in the cooler regions. Asthe hottest tubes fail due to overheating, expensivepartial or complete replacement becomes necessary.If the steam flow can be redistributed from coolertubes with long lives to the hottest tubes, theirtemperatures can be reduced and their life increased.BTA, with its partner, Aptech, can assist you inaccomplishing this through Aptech’s patentedtechnology. The result is a more even temperatureprofile across the tube bank and a three- to five-timeincrease in tube bank life, as shown in Figure 3.

1500 2000 2500 3000 35000

10

20

30

40

50

Cleaning Required

Consider Cleaning

No Cleaning Required

PRESSURE (PSIG)

SP

EC

IFIC

DE

PO

SIT

WE

IGH

T (

GM

/SQ

. FT.

)

Electric Power Research Institute (EPRI) recommended

guidelines for waterwall chemical cleaning as a

function of boiler pressure.

8

Regular Inspection PreventsTube Failure

With regular, detailed inspection of boiler equipment,many tube failures can be prevented. Written recordsshould note changes in corrosion or deposits. Payattention to unexpected layers of deposit which flakeoff tube and drum internal surfaces and accumulatein tube bends or headers. Usually, this indicatesreduced boiler water circulation and potentialoverheating.

But be advised, water treatment is a highly technicalscience requiring careful water analysis and consid-eration of boiler design and operating conditions.“Cure all” chemicals can do more harm than good to

ELEMENTS ACROSS TUBE BANK

AFTER TUBEMODREMAINING LIVES OFSHORT-LIVED TUBES

ARE IMPROVED

TUBETEMP.

REDUCEDTEMPERATUREVARIATION

After TubeMod: The redistributed steam flow optimizes

the life of the whole section by systematically reducing

the temperature of the tubes with the shortest lives.

ELEMENTS ACROSS TUBE BANK

BEFORE TUBEMODTHESE TUBES MAY HAVE

VERY SHORTREMAINING LIVES

BULK STEAMTEMPERATURE

TUBETEMP.

VERY WIDETEMPERATUREVARIATION

THESE TUBES HAVE VERYLONG REMAINING LIVES

Before TubeMod: Tube metal temperatures can greatly

exceed the bulk steam temperature.

Figure 3 vital boiler equipment. Many reputable firms special-ize in industrial water consulting. So, don’t takechances. Consult an expert.

How to Buy ReplacementBoiler Tubes

With so many factors involved in the replacement ofboiler tubes—specification, grade, length, specialfabrication—it may not be easy to get exactly whatyou want, when you want it. By following thesesimple steps, however, you can significantly in-crease your chances for quick, quality, economicalreplacement.

• Find out exactly what is needed. If maintenanceneeds 100 feet of an item, find out if that’s theleast amount they can get by with. Are theycutting it up into little pieces or welding in longlengths? Do they need it tomorrow or can theywait a few days?

• Be flexible. Advise your supplier if you can usean alternate or upgraded ASME specification,thickness or grade. Later, you can upgradewithout altering the performance or weldingprocedures at little extra cost.

• Focus on the expensive parts of the boilertube replacement process. Not having yourboiler available is expensive. Contractors stand-ing around waiting for materials are expensive.However, tubing is usually a minor cost in thereplacement process, and the transportationcosts even less. So, don’t try to save money onunreliable suppliers when you need immediateservice. Choose a supplier with tubes on handrather than pay for exclusive trucking or airfreight.

• Get mill test certificates on all pressure tubes.Specify that they accompany the shipment. Yourinsurance inspector may not allow your contractoror maintenance personnel to install tubes until hesees the test certificates.

9

• Notify supplier of the design temperature andpressure of your boiler. If you’re buying fabri-cated tubes—bent, swaged, welded—advise yoursupplier as to the design temperature andpressure of your boiler or vessel and ensure thatall parts meet the applicable section of the ASMEBoiler Code.

Boiler Tube Company of America offers replacementservice on superheater, economizer and reheatersections at a reasonable price with shorter deliverytime than the original boiler manufacturer. Our flex-ible approach lets you duplicate originals and makedesign or material changes in existing elements. OurService Engineers will work with you on thesespecial problems. Let us show you what we can do.

SECTION III

FABRICATION

Tube Fabrication

Boiler Tube Company of America can take the righttube and turn it into the fabricated pressure part youneed: generating tubes, superheaters, reheaters,waterwall panels or economizers. If you need toeliminate a tight radius bend, make a change in wallthickness or try a higher chrome alloy in hot sec-tions, we can fabricate to your specifications—quickly.

We are equipped and staffed to offer bending, cut-ting, swaging, finning, spinning, welding and manyother fabrication services to get you the replacementparts you need.

10

Complete Tube Inventory andEngineering Library

Boiler Tube Company of America eliminates theneed for costly, spare tube stocking. We carrycomplete tubing in regular and heavy gauges. In anemer- gency, we can start bending immediately andship replacements the same or the following day.

When you call BTA, you also tap into a library of over20,000 drawings collected from almost a century inthe replacement tube business. Drawings of boilerarrangements and tube details are cataloged andcross-filed in our Engineering department. For manyboilers now out of manufacture, this information canonly be found at BTA. Inquiries should specify letterof number class or number class of boiler and tuberow number.

Our resources are at your disposal and may help getyour boiler back on line even if you cannot furnish adrawing.

Babcock & Wilcox (B & W) KeelerBadenhausen KidwellBigelow LaddCasey Hedges MaximCleaver-Brooks RileyCollins RossCombustion Engineering (CE) RustConnelly SpringfieldEdgemoor StirlingErie City TitusvilleFoster Wheeler Union Iron WorksGeneral Electric Waste Heat VogtHeine Wickes

ASME Code Assembly

During ASME Code fabrication, the tubing oftenloses the metallurgical and mechanical propertiesessential for long life at elevated temperatures andpressures.

Bending can work-harden the tubes and set upstresses. Tight radius bending may reduce wallthickness at the back of the bend below designrequirements. Attachments to tube surfaces may setup stress forces and reduce the material’s resistanceto corrosive attack.

Unless these lost properties are restored to thetubing, the units will give fewer service years andmay cause premature tube failures.

We’re aware of these factors at Boiler Tube Companyof America. That’s why all bent tubes are fitted to fullsize, shrink-free templates and carefully inspectedbefore shipment. Bends are held smooth and free ofdinges, folds or crimps. Roundness in the bend isheld to tolerances prescribed by the trade. Wallthinning, in the back of the bend, is minimized bysophisticated tooling. Then, our inspectors makeultrasonic readings of tight radius bends to assuretop quality.

We’ve built our reputation on careful review duringcode assembly. So you can count on us for depend-able, top quality, assembled tubing elements.

11

SECTION IV

ECONOMIZERS

Economizers

Boiler Tube Company of America, through itsassociation with Greens (one of the family of BalckeDurr Thermal Engineering companies) is a leader inthe field of heat recovery. Edward Green started theWaste Heat Recovery Industry in 1845 with hisinvention and patent of the fuel economizer.

The success of the Greens Economizer is primarilydue to extended surface tubing—both steel and castiron sleeved. As operating conditions vary from plantto plant, choice of surface is important.

We select the optimum surface for your applicationafter consulting with you and determining thefollowing factors: type of fuel and/or source of heat,operating hours, load variation, available draft, dustburden, gas velocity and temperature.

Greens Economizers sustain high efficiency. Straightgas passages minimize fouling of heat transfersurfaces. Our welded, “Steel-H,” parallel fin has beenproven in several thousand applications with gas, oiland coal firing, even with high particulate content.And the low resistance to gas flow with in-line finsreduces draft loss and cost of fan power.

Used worldwide in electric utility generating stations(including almost 300 coal-fired plants), waste heatunits and several thousand industrial boilers, GreensEconomizers hold the world’s best performancerecord for extended surface applications. Greensunits are used extensively in the

United States, Europe, Japan, Korea and theIndiansub-continent.

Call us for a consultation on your application, today.

Economizer Comparisons

Spiral Welded BareFin “Steel-H” Tube

Price Low Medium High

Space Small Medium Large

Gas Pressure Drop High Medium High

Weight Low Medium Medium

Number of Welds Low Low High

Availability Poor Good Good

Life Low Good Good

ECONOMIZER FUEL SAVINGS

AP

PR

OX

IMA

TE

FU

EL

SAV

ING

S %

1

2

3

4

5

6

7

8

9

10

25 50 75 100 125 150

50 100 150 200 250 300°F

°C

Coal

Natural G

asOil

FLUE GAS TEMPERATURE DROP

Approximate Comparison of Fuel Savings

and Flue Gas Temperature Drop

(Alternatively an increase in evaporation

may be obtained.)

12

SECTION V

BOILER TUBE

SPECIFICATION AND STOCK

ITEM GUIDE

Boiler Tube Specifications

Boiler tubes are made in both seamless and electricresistance weld. Tubing made by either process isrigidly controlled and tested both during and afterrolling to meet the exacting specification require-ments of a pressure tube. The boiler code approveseither method of manufacture and expresses nopreference.

When temperature ranges are near the critical pointsfor low carbon, the higher yield strength of mediumcarbon or carbon moly is sometimes used to giveadded protection. Elevated temperatures in high-output, large power boilers frequently require the useof alloy or stainless tubes.

Boiler tubes, to comply to specifications and meetallowable working pressure ratings, are alwaysexpressed and sold as minimum wall.

Whether to use seamless or electricweld boiler tubesis largely a matter of personal preference. Electric-weld boiler tubes are fully comparable to seamlessby standards of ASME Boiler & Pressure VesselCode requirements and general acceptance.

Advocates of seamless tubing prefer no weld seamin the tube wall. There is thought to be furtherprotection in the heavier nominal walls of seamlessdue to the method of manufacture. Further, the“piercing” process in making seamless tubes impartsa tough mill scale to the tube surface which appearsto make it more resistant to corrosion.

In recent years, significant advancements have beenmade in the manufacture of hot finish boiler tubing.The appearance of the surface finish is distinct(aesthetically less appealing) from cold-drawnproduced tubing. However, there are now severalmills that produce boiler tubes by the hot finishprocess of very high quality to tight tolerances.These tolerances typically meet cold-drawn toler-ances. In certain sizes, they may be produced toslightly exceed or to be slightly less than cold-drawntolerances.

Electricweld tubes are favored because of lowercosts, more uniform wall and uniform heat transfer.Welded tubes, because they are more uniform, areeasier to roll and install.

The following specifications are in general use forboiler tubes and condenser tubes.

GRADE SPECS

Low Carbon Seamless A-192, A-179

Low Carbon Electricweld A-178, A-214, A-226

Med. Carbon Seamless A-210

Med. Carbon Electricweld A-178 Grade C

Low Alloy (Corten or A-423 (Seamless

Republic 50) or Welded)

Carbon Moly Seamless A-209

Carbon Moly Electricweld A-250

Alloy Seamless A-213 (T Series)

Stainless Seamless A-213 (TP Series)

Stainless Electricweld A-249 (TP Series)

13

A-214—Electric Resistance Welded (ERW)Carbon Steel Heat Exchanger andCondenser Tube

A-178—ERW Carbon Steel Boiler Tubing

Grade A—Low Carbon

Grade C—Medium Carbon

A-179—Seamless Cold Drawn Low Carbon SteelH.E. and Condenser Tube

A-192—Seamless Carbon Steel Boiler Tubefor High-Pressure Service

A-210—Seamless Medium Carbon Steel Boilerand Superheater Tube

Grade A1

Grade C

A-209—Seamless Carbon Moly Alloy SteelBoiler and Superheater Tube

T1

T1AT1B

BOILER TUBE STOCK ITEM GUIDE

TUBINGO.D.

INCHES SA-178 SA-179 SA-192 SA-209 SA-210 SA-213 SA-214 SA-423

(��) CHECK MARK INDICATES TUBE SPECIFICATIONS REGULARLY CARRIEDWALL

THICKNESSRANGEINCHES

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

.049

.049 to .083

.049 to .105

.083 to .134

.095 to .260

.095 to .438

.120 to .300

.095 to .480

.135 to .438

.095 to .500

.165 to .500

.105 to .500

.105 to .500

.120 to .360

.105 to .400

.120 to .300

.120 to .300

.134 to .220

1/2

5/8

3/4

1

11/4

11/2

15/8

13/4

17/8

2

21/8

21/4

21/2

23/4

3

31/4

31/2

4

SA-213—Seamless Chrome Alloy and StainlessSteel Boiler, Superheater and HeatExchanger Tubes

T2—1/2 CR, 1/2 Moly

T5—5 Cr, 1/2 Moly

T9—9 Cr, 1 Moly

T11—11/4 Cr, 1/2 Moly

T12—1 Cr, 1/2 Moly

T22—21/4 Cr, 1 Moly

Tp304H—18 Cr, 8 Ni

Tp321H––18 Cr, 8 Ni

T1 Stabilized

Tp347H—18 Cr, 8 Ni

Co. Stabilized

SA-423 Corten—ERW and Seamless Pressure Tubes

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

14

SECTION VI

REFERENCE

Useful Boiler Calculations and Data

AMOUNT OF AIR REQUIRED FORCOMBUSTION

W = Weight of air in lbs. per lb. of fuelC = Percentage of carbon in fuel by weight

H = Percentage of hydrogen in fuel by weightO2 = Percentage of oxygen in fuel by weight

S = Percentage of sulphur in fuel by weight

Air contains 23 percent of oxygen by weight, and 1 lb.of carbon requires 2.67 lb. of oxygen for its completecombustion to carbon dioxide (CO2). Similarly, 1 lb. ofhydrogen requires for its combustion 8 lb. of oxygen,or about 35 lb. of air, and 1 lb. of sulphur requires 1lb. of oxygen, or 4.35 lb. of air.

Therefore, for fuel containing C percent of carbon,

W = C x 2.67 x 100 = C x 2.67 = C x 0.116100 23 23

For fuel containing H percent of hydrogen,

W = H x 8 x 100 = H x 8 = H x 0.348100 23 23

For fuel containing C percent of carbon and Hpercent of hydrogen,

W = 0.116 C + 0.348 H

If oxygen is present,

W = 0.116 C + 0.348 (H - — )

If the sulphur, which is usually present in very smallquantities, is taken into account,

W = 0.116 C + 0.348 (H - — ) + 0.435 S

O2

8

O2

8

The heat carried away by ashes is generally a verylow percentage of the total heat of the fuel. Therefore,if the ash is not available for analysis, an allowanceof 1 to 2 percent is usually made.

Loss 6 = Btu’s loss by radiationThere is no precise method of measuring radiationlosses. Therefore, an allowance of 1 to 5 percent ofthe heat value of the fuel is normally used. Thisassumes the plant to be insulated and to be main-tained in a clean condition.

Loss 7 = Unaccounted-for lossLosses due to air ingress, boiler blowdown,instrument and observation errors, etc.

Loss 5 = Btu’s loss as combustible matter in ashes

Percent ash in fuelx Btu’s in ashes x 100

Percent loss = –––––––––––––––––––Percent ash in fuel

x cal. value of fuel as fired

K = Constant for Bituminous Coal = .35Anthracite = .37Coke = .39Oil = .31

Loss 2 = Btu’s loss in water vapor produced bycombustion of hydrogen per lb. of fuel

= 9H [212 - t5 + 970 + 0.48 (t4 - 212)]= 9H (0.48 t4 - t5 + 1080.2)

Loss 3 = Btu’s loss in water vapor produced byevaporation of moisture per lb. of fuel

= M [212 - t5 + 970 + 0.48 (t4 - 212)]= M (0.48 t4 - t5 + 1080.2)

Loss 4 = Btu’s loss by incomplete combustion ofcarbon monoxide (CO) in flue gases per lb. of fuel

= C (10150)

GENERAL FORMULA FOR CALCULATING FLUE GAS LOSS

CO2 = Percentage of carbon dioxide by volume

CO = Percentage of carbon monoxide by volumeC = Percentage of carbon by volume

H = Weight of hydrogen in 1 lb. fuel as receivedM = Weight of moisture in 1 lb. fuel as received

t4 = Temperature of exit flue gases, °Ft5 = Temperature of ambient air, °F

W = Weight in lb. of dry products of combustionper lb. of fuel

Loss 1 = Percent Btu’s loss in chimney gases per lb.of fuel burned

= K x (t4 - t5)_____CO2

(CO)

CO2 + CO

15

Heat BalanceBtu’s

Percent Equivalent____________________________________________

Heat Absorbed by Boiler 61.30 7356Heat Absorbed by Economizer 9.50 1140Heat Absorbed by Superheater 5.55 660Total Loss in Flue Gases 10.15 1218Total Loss by Hydrogen 3.74 449Total Loss by Moisture 1.14 137Total Loss by

Incomplete Combustion . . . . . .Total Loss by Ashes (assume) 1.50 180Total Loss by Radiation (assume) 5.00 600Total Unaccounted Loss 2.12 254____________________________________________

100.00 12,000

GENERAL FORMULAE FOR CALCULATINGTHE EFFICIENCIES OF BOILERS,ECONOMIZERS AND SUPERHEATERS

C = Calorific value of fuel in Btu’s per lb. as receivedd = Density of air in lb. per cubic footE = Actual evaporation, lb. of water per lb. of fuelT1 = Temperature, °F, gases economizer inletT2 = Temperature, °F, gases economizer outletg = Temperature of discharged flue gases in °FH = Btu’s to convert 1 lb. water at 32°F to dry

saturated steam at observed pressureHs = Btu’s to convert 1 lb. water at 32°F to

superheated steam at observed pressure= H + (S x S1)

h = Btu’s in 1 lb. water at economizer inlettemperature T = (1.017T – 35)

h1 = Btu’s in 1 lb. water at economizer outlettemperature t = (1.017t – 35)

S = Number of degrees of superheat in °F = t2 – t3

S1 = Specific heat of superheated steam = 0.48t = Economizer inlet water temperature, °Ft1 = Economizer outlet water temperature, °Ft2 = Outlet temperature of superheated steam, °Ft3 = Temperature of saturated steam at observed

pressure

Percentage of heat absorbed by economizer

=100 x E (h1 - h)_____________

C

Percentage saving due to economizer

= (t1 - t ) x 100

without superheater_____________H - h

= (t1 - t ) x 100

with superheater_____________Hs - h

Percentage of heat absorbed by boiler

=E x (H - h1) x 100_____________

C

Percentage of heat absorbed by boiler, economizerand superheater

=E x (Hs - h) x 100_____________

C

Percentage of heat absorbed by superheater

=100 x E (Hs - H)_____________

C

TYPICAL EXAMPLE FOR HEAT BALANCE

Coal: —Calorific value as received,12,000 Btu’s per lb.Total moisture, 11.5 percent;hydrogen, 4.2 percent

Boiler pressure, 195 lb. per sq. in. (gauge)Temperature of superheated steam, 570°FTemperature of economizer inlet water, 100°FTemperature of feedwater leaving economizer, 250°FTemperature of stack gases, 350°FAverage CO2 = 10 percentTotal water evaporated (actual), 247,500 lb.Total coal consumed, 33,000 lb.Boiler pressure = 195 psi gauge + 15 = 210 psi

absolute

1) H = Total Btu’s in saturated steam at 210 psiafrom water at 32°F = 1200 Btu’s

2) Hs= Total Btu’s in superheated steam at 210 psiaand 570°F

= 1200 + [(570 - 385) x 0.48]= 1200 + 88.8= 1288.8 Btu’s

3) Btu’s in 1 lb. water at economizerinlet temperature (h)

= (1.017 x 100) - 35= 66.7 Btu’s

4) Btu’s in 1 lb. water at economizer outlet

USEFUL FORMULAE

Approximate furnace temperature, °F

=C_____________________

0.24 ( 19 x 11.6 + 1)_________

Percent CO2

Approximate gas weight (or air weight) per lb.of fuel burned

=E (t1 - t )_________

0.24 (T1 - T2)

16

7) Percentage of heat absorbed by boiler andeconomizer

=7.5 x (1200 - 66.7) x 100____________________

12,000

= 70.83 percent

temperature (h1)= (1.017 x 250) - 35= 219.25 Btu’s

5) Actual evaporation (E) = 247,500 ÷ 33,000 = 7.56) Percentage of heat absorbed by boiler

=7.5 x (1200 - 219) x 100___________________

12,000

= 61.31 percent

10) Percentage of heat absorbed by boiler,

=7.5 x (1288.8 - 66.7) x 100_____________________

12,000

= 76.4 percent

8) Percentage of heat absorbed by economizer= 70.83 - 61.31= 9.5 percent

9) Percentage of heat absorbed by superheater

=7.5 x (1288.8 - 1200) x 100_____________________

12,000

= 5.55 percent

11) Percent Btu’s loss in stack gases

=K x (t4 - t5)________

CO2

=0.35 x (350 – 60) = 10.15 percent________

10

12) Btu’s loss per lb. of coal by water vapor producedby combustion of hydrogen

= 9 x (4.2)

[(0.48 x 350) - 60 + 1080.2]___100

= 0.378 x 1188= 449 Btu’s

Percent Loss = 449

x 100 = 3.74 ___ 12,000

13) Btu’s loss per lb. of coal by evaporationof moisture

=11.5

[(0.48 x 350) - 60 + 1080.2]___100

= 0.115 x 1188= 137 Btu’s

Percent Loss = 137

x 100 = 1.14 ___ 12,000

POWER AND HEAT

1 cal = 4.186 Joules1 cal/g = 1 kcal/kg = 1.8 Btu/lb.

1 foot-pound (ft. lb.) ...... = 0.1383 meter kilogram(mkg)

1 Btu.............................. = 107.6 mkg= 0.2520 kilocalorie (kcal)

1 Btu/lb. ......................... = 0.556 kcal/kg1 Btu/cu. ft. .................... = 8.90 kcal/cu. m.1 Btu/sq. ft. .................... = 2.712 kcal/sq. m.1 Btu/ft2 °F..................... = 4.88 kcal/m2 °C1 Btu/hr. ft2 (°F/ft.) ......... = 1.488 kcal/hr. m2 (°C/m)1 Btu/hr. ft2 (°F/in.) ........ = 0.1240 kcal/hr m2 (°C/m)1 Btu/sec. in2 (°F/in.) ..... = 0.1786 kcal/sec. cm2

(°C/cm)1 meter kilogram ........... = 7.23 ft.-lb.1 kilogram calorie (kcal) = 3088 ft.-lb.

= 427 mkg= 3.968 Btu

1 kcal/kg........................ = 1.8 Btu/lb.1 kcal/cu. m. .................. = 0.1124 Btu/cu. ft.1 kcal/sq. m. .................. = 0.3687 Btu/sq. ft.1 kcal/m2 °C .................. = 0.2048 Btu/ft2 °F1 kcal/hr. m2 (°C/m) ....... = 0.672 Btu/hr. ft2 (°F/ft.)

= 8.06 Btu/hr. ft2 (°F/in.)1 cal/sec. cm2 (°C/cm) .. = 0.0560 Btu/sec. in2

= (°F/in.)1 boiler horsepower ...... = 10 sq. ft. of boiler

heating surface1 megawatt (MW) ......... = 1000 kilowatt1 kilowatt (kW) .............. = 738 ft. lb./sec.

= 102 mkg/sec.= 1.341 hp= 1.360 metric hp

1 horsepower (hp) ........ = 33,000 ft. lb./min.= 550 ft. lb./sec.= 76.0 mkg/sec.= 0.746 kW= 1.014 metric hp

1 metric horsepower ..... = 32,550 ft. lb./min.= 542 ft. lb./sec.= 75 mkg/sec.= 0.735 kW= 0.986 hp

1 kilowatt hour (kWh) .... = 3413 Btu’s= 860 kcal

1 horsepower hour ........ = 2544 Btu’s1 metric horsepower hour ............................ = 632 kcal1 lb./hp hour .................. = 0.447 kg/metric hp

hour1 kg/metric hp hour ....... = 2.235 lb./hp hour1 electron-volt (eV) ....... = 1.6 x 1012 ergs

17

1 joule ........................... = 107 ergs= 0.000948 Btu= 0.7375 ft. lb.= 1 watt sec.

1 Btu.............................. = Heat necessary to raise1 lb. water through 1°F

= 778 ft. lb.= 0.252 kcal

GENERAL EQUIVALENTS

1 gal. of water ............... = 2.31 cu. in. (approx.)1 gal. of water at 62°F .. = 8.34 lb.1 cu. ft. of water ............ = 7.48 gal.

= 62.3 lb.1 in. of water ................. = 0.036 lb. per sq. in.

= 5.2 lb. per sq. ft.Column of water

1 ft. high..................... = 0.434 lb. per sq. in.2.31 ft. high ............... = 1 lb. per sq. in.

Lb. per sq. in. x 0.068 ... = AtmospheresLb. per sq. in. x 2.31 ..... = Ft. of waterLb. per sq. in. x 2.04 ..... = In. of mercuryLb. per sq. in. x 27.7 ..... = In. of waterAtmosphere x 14.7 ....... = Lb. per sq. in.In. of mercury x 0.49 ..... = Lb. per sq. in.In. of water x 0.036 ....... = Lb. per sq. in.1 Atmosphere ............... = 14.7 lb. per sq. in.

= 2116.8 lb. per sq. ft.= 33.9 ft. of water

Absolute temperaturein °F ........................... = 461 + ordinary

temperature °FAbsolute temperature

in °C .......................... = 273 + ordinarytemperature°C

1 cu. ft. of air at 32°F .... = 0.0807 lb.1 cu. ft. of air at 62° ...... = 0.076 lb., or 13.14 cu.

ft. per lb.Air (by weight) ............... = 23 percent oxygen and

77 percent nitrogenAir (by volume).............. = 21 percent oxygen and

79 percent nitrogen1 lb. of carbon ............... = Requires 11.6 lb. of air

for combustionLb. of carbon dioxide

(CO2) ......................... = Carbon in 1 lb. of coalx 3.66

Lb. water ....................... = Hydrogen in 1 lb. ofcoal x 9

1 lb. hydrogen ............... = 62,000 Btu’s calorificvalue

1 lb. sulphur .................. = 4000 Btu’s calorificvalue

1lb. sulphur ................... = Requires 1 lb. of oxygenor 4.35 lb. of air

Btu’s carried awayas latent heat bycombustion of 1 lb.hydrogen ................... = 970 x 9

= 8730 Btu’sNet gain from

combustion of 1 lb.hydrogen ................... = 62,000 minus 8730

= 53,270 Btu’sWeight of air required

for burning 1 lb.hydrogen ................... = 34.8 lb. of air

Volume of air requiredfor burning 1 lb.hydrogen ................... = 452 cu. ft. of air

Weight of air requiredfor burning 1 lb.carbon ....................... = 11.6 lb. of air

Volume of air requiredfor burning 1 lb.carbon ....................... = 152.4 cu. ft. of air

Btu’s released when1 lb. carbon isburned to CO2 ........... = 14,550 Btu’s

Btu’s released when1 lb. carbon isburned to CO ............ = 4400 Btu’s

Btu’s lost by incompletecombustion of 1 lb.of carbon ................... = 10,150 Btu’s

Latent heat of steam..... = 970 Btu’s per lb.

ODD RULES

1 lb. molecule of any gas occupies 359 cu. ft. at N.T. P. and 378

cu. ft. at 60°F/30 in. Hg. dry.

1 gm. molecule of any gas occupies 22.4 litres and

1 oz. molecule of any gas occupies 22.4 cu. ft.

Any gas with one carbon atom per molecule contains 0.54 oz.

C. per cu. ft. of gas at N.T.P.—and pro rata.

The partial pressure of water vapor (e.g. in any gas) at 60°F is

.58 in. Hg.

1 kg. per cu. meter = 1 oz. per cu. ft.

For most fuels, the theoretical air requirement is 7.6 - 7.9 lb. air

for each 10,000 Btu available. For gaseous fuels it is C.V./115 cu.

ft. air/cu. ft. gas approximately.

Lb. air/lb. coal (actual) – 3 x (net C.V.)/200 x (%CO2).

For coal, 1220 lb. of flue gas per million Btu are produced at,

approximately, 12.2% CO2 (50% excess air); and at a C.V. of

12,200 Btu/lb.

For oil, 1100 lb. of flue gas per million Btu are produced at,

approximately, 11% CO2 (40% excess air).

For shell boilers 1 c.f.m. and for watertube boilers 1/2 c.f.m. are

common actual flue gas flow rates, per 1 lb./hr. steam rating.

~

~

18

FUEL

Wood waste

Peat

Coke

Coke breeze

Oil shale

Pulv’d pitch

Tanbark

Bagasse

Rice hulls

Sewage

Sludge

Straw

HEATINGVALUE

BTU

Proximate Analysis

% % % % % % % % % % %

MOIST ASH VOL. FC H2 C N2 O2 S MOIST ASH

8900* 25-60 1.0* 82.0* 17.0* 6.2* 50.3* 0.04* 43.1* — — 0.4

3586 56.7 6.0 26.1 11.2 8.3 21.0 1.1 62.9 — — —

12,600* 8.5 12.5 1.0* 86.5 — — — — 0.9 — —

9500 6.5 25.0 3.4 65.1 — — — — — — —

6300* 15.0 43.0 42.0 — — — — — — — —

16,000 0.2 0.1 53.8 46.1 4.1 93.7* 1.0* 0.7* 0.5* 0.1 0.1

8000* 30-60 — — — 6.0 50.0 40.0 — — — 4.0

8300* — — — — 5.8 46.3 0.3 45.8 — — 1.8

6100 7.4 19.8 59.0 13.8 — — — — — — —

7500 20 26.9 47.6 5.5 5.0 37.0 1.5 8.9 0.7 20.0 26.9

56-6700 — — — — 5.0 36.0 0.5 38.0 — 15.7 4.8

CHARACTERISTICS OF OTHER SOLID FUELS

*Indicates analysis on dry basis all others “as fired” or “as received.” FC abbreviation for fixed carbon.

FormulaSubstance

Carbon burned tocarbon monoxide C

Carbon burned tocarbon dioxide C

Carbon monoxide burned to

carbon dioxide CO

Sulphur S

Hydrogen H2

Hydrogen sulphide H2S

Methane CH4

Acetylene C2H2

Ethylene C2H4

Ethane C2H6

O2 Air CO2 CO N2 H2O SO2

SubstanceRequired

(lb.)

Theoretical Productsof Combustion

(lb.)

THEORETICAL COMBUSTION DATA

1.33 5.75 — 2.33 4.42 — —

2.67 11.49 3.67 — 8.82 — —

0.57 2.46 1.57 — 1.89 — —

1.00 4.31 — — 3.31 — 2.00

8.00 34.48 — — 26.48 9.00 —

1.41 6.09 — — 4.68 0.53 1.88

4.00 17.24 2.75 — 13.24 2.25 —

3.08 13.26 3.38 — 10.18 0.69 —

3.43 14.78 3.14 — 11.35 1.29 —

3.73 16.09 2.93 — 12.36 1.80 —

Ultimate Analysis

FormulaSubstance

Carbon monoxide CO

Hydrogen H2

Hydrogen sulphide H2S

Methane CH4

Acetylene C2H2

Ethylene C2H4

Ethane C2H6

O2 Air CO2 CO N2 H2O SO2

SubstanceRequired

(ft.3)

Theoretical Productsof Combustion

(ft.3)

0.5 2.38 1.0 — 1.88 — —

0.5 2.38 — — 1.88 1.0 —

1.5 7.14 — — 5.64 1.0 1.0

2.0 9.52 1.0 — 7.52 2.0 —

2.5 11.91 2.0 — 9.41 1.0 —

3.0 14.29 2.0 — 11.29 2.0 —

3.5 16.67 2.0 — 13.17 3.0 —

19

2.8 2.6 2.4 2.2

280

300

260

240

220

200

180

160

140

120

80

60

100

2

1.8

1.6

1.4

1.2

12

7

89

10

11

13

14

15

16

NET CAL.VALUE 13,000 BTU/LB.

11,0009000

7000

5000

3000

EX

CE

SS

AIR

n

= 2

1.9

1.7

1.8

1.6

1.5

1.4

1.3

1.2

1.1

1

va °

vg °

3000 4000 5000 6000 7000 8000 9000 10,000 11,000 12,000 13,000

50

100

150

200

250

WASTE GASES AND AIRREQUIREMENTS FOR SOLID FUELS

(ACC. TO W. BOIE)

AVERAGE CO2 MAX 18.9%, AVERAGE ASH CONTENT 7.5%

THIS DIAGRAM IS NOT VALID FOR COKE, WOOD OR PEAT

EXAMPLE:

N. CAL VAL = 10,000 BTU/LB.

EXCESS AIR n = 1.4

va° = 98 CU. FT./LB.

vg° = 147 CU. FT/LB.

vg

(va°)

CU

. F

T./

LB

.

N.C.V. BTU/LB.

va° = 8.896 N.C.V. + 8800 CU. FT./LB. THEOR.

990 AIR QUANTITY

vg° = 8.N.C.V. + 26144 CU. FT./LB. THEOR.

990 GAS QUANTITY

n ³ ________

va = n . va° (ACT. AIR QUANTITY)

vg = vg° + (n -1) va

° (ACT. GAS QUANTITY)

n = CO2 MAX

CO2

WASTE GAS VOLUMEFOR COKE AND WOOD

EX

CE

SS

AIR

n

EXAMPLE: FUEL N.C.V. = 10,800 BTU/LB.

CO2 MAX. = 19.55%

CO2 = 11%

RESULT: n = 1.79

194.5 = CU. FT. WASTE

GASES/LB. FUEL

WA

ST

E G

AS

VO

LU

ME

CU

. F

T./

LB

. F

UE

L N

.T.P

.

CO

2—

CO

NT

EN

T

CO2 MAX FOR:

BROWN COAL = 17.9

BROWN COAL = 19.05

BROWN COAL = 19.55

COKE AND WOOD = 20.7

(AIR DRIED)

20

EX

CE

SS

AIR

n

= 2

1.9

1.7

1.8

1.6

1.5

1.4

1.3

1.2

1.1

n =

1

va°

vg°

vg°

vg °va °

va°

COKE OVEN GAS

PR

OD

UC

ER

GA

S

BLA

ST

FU

RN

AC

E G

AS

1

2

3

4

5

6

7

8

9

10

600100 150 200 250 300 350 400 450 500 550 650

1n

= 2

1.5

WASTE GASES AND AIRREQUIREMENTS FOR GASEOUS

FUELS (ACC. TO K. RUMMEL)

N.C.V. BTU/CU. FT.

vg° = THEORETICAL GAS QUANTITY

va° = THEORETICAL AIR QUANTITY

n = EXCESS AIR

vg = ACTUAL GAS QUANTITY

va = ACTUAL AIR QUANTITY

EXAMPLE: COKE OVEN GAS

N.C.V. = 500 BTU/CU.FT.

n = 1.2

va° = 4.58 CU. FT./CU. FT.

vg = 6.20 CU. FT./CU. FT.

vg

(va°)

CU

. F

T./

LB

.

1) BLAST-FURNACE GAS

vg° = .929 + .636 N.C.V. CU. FT.

100 CU. FT.

va° = .771 N.C.V. – .0614 CU. FT.

100 CU.FT.

2) PRODUCER GAS

vg° = .7575 + .825 N.C.V. CU. FT.

100 CU. FT.

va° = .886 N.C.V. – .173 CU. FT.

100 CU.FT.

3) COKE OVEN GAS

vg° = .486 + .966 N.C.V. CU. FT.

100 CU. FT.

va° = .968 N.C.V. – .239 CU. FT.

100 CU.FT.

4) NATURAL GAS (EUROPE)

N.C.V. = 960 BTU/CU. FT.

vg° = 10 CU. FT./CU.FT.

va° = 9.07 CU. FT./CU. FT.

AIR REQUIRED va = n.va°

W.GAS QUANT..vg = vg°+(n -1) va

°

17,000 18,000 19,000 20,000 21,000

250

300

350

400

450

150

200

EXCESS AIR

n =

2

1.9

1.8

1.7

1.6

1.5

1.4

1.3

1.2

1.1

1

vg °

va °

N.C.V. BTU/LB.

vg° = THEORETICAL GAS QUANTITY va

° = THEORETICAL AIR QUANTITY

vg = ACTUAL GAS QUANTITY va = ACTUAL AIR QUANTITY

n = EXCESS AIR

vg

(va°)

CU

. F

T./

LB

.

n = ___________

va° = 8.896 N.C.V. – 17,850 CU. FT./LB.

808

vg° = 11.1 N.C.V. – 48,900 CU. FT./LB.

808

va = n.va°

vg = vg° + (n –1) . va

°

n = 1 CO2 (σ – 1) . 0.21

CO2 . ß

σ = 1.87 N.C.V. – 3760

30930 – .556N.C.V.

EXAMPLE:

N.C.V. = 19,000 BTU/LB.

n = 1.6

vg = 313 CU. FT./LB.

va° = 186 CU. FT./LB.

WASTE GASES AND AIR REQUIREMENTS FOR LIQUID FUELS

(ACC. TO W. BOIE)

21

EXCESS AIR, CO2 – AND O2 – CONTENTOF THE WASTE GASES FORSOLID AND LIQUID FUELS

% C

O2

% O2

EXAMPLE: FUEL BITUMINOUS COAL

CO2— CONTENT OF THE WASTE GASES 10%

(MEASURED)

RESULT: n = 1.9

O2 = 10% OXYGEN IN THE WASTE GASES

FOR THE DETERMINATION OF UNBURNED FUEL

REFER TO EXAMPLE ON SCHEDULE B 8n =

CO2 MAX_______CO2

n = EXCESS AIR

CARBON

WOOD

PEAT

BROWN COAL

BITUMINOUSCOAL

BENZOLE

COAL TAR FUEL

PETROLEUM SPIRITAND PETROL

n = 1.25

1.5

1.6

1.7

1.81.9

2

2.2

2.42.6

2.8

1.1

1

0

2

4

6

8

10

12

14

16

18

20

22

24

2 4 6 8 10 12 14 16 18 20

BLA

ST

FU

RN

AC

E

PR

OD

UC

ER

CO

KE

OV

EN

AIR

1.6

1.8

1.4

1.2 1.61.8

1.41.2

1.6

1.8

1.4

1.2

1.6

1.8

1.4

1.2

1

11

1

2

n=

.0182 .019 .02 .021 .022GAS FUEL OIL COAL

.02

.019

.021

.022

.023

.024

2000°2200°

1200°

1000°800°

1800°

1600°

1400°

600°400°200°

tg1 °F

2000

°22

00°

1200

°

1000

°

800°

1800

°

1600

°

1400

°

600°

400°

200°

tg (t

g 2)°F

1816

1412

108 6 4205 34 2 1

X102 X103

100°

1

1.2

1.4

1.61.8

MEAN SPECIFIC HEAT OFWASTE GASES AND AIR

(ACC. TO JUSTI)

N.C.V. BTU/CU. FT. BTU/LB.

BT

U/C

U. F

T./°

F

MEAN SPECIFIC HEAT BTU’s/CU. FT./°F

FOR AIR tg MUST BE

REPLACED BY ta

(SEE EXAMPLE)

n = EXCESS AIR

EXAMPLE: COAL

N.C.V. = 1200 BTU’s

n = 1.4 tg1 = 900° F

n = 1.4 tg2 = 1450° F

cpm/ tg2 = .02072 BTU/CU.FT./° Fcpm /°

cpm/ tg1 = .01997 BTU/CU.FT./° Fcpm /°

cpm/ tg1 = .02198 BTU/CU.FT./° Fcpm tg2

EXAMPLE: AIR

ta1 = 200° F

ta2 = 900° F

cpm/ ta2 = .01875 BTU/CU.FT./° Fcpm /°

cpm/ ta1 = .01822 BTU/CU.FT./° Fcpm /°

cpm/ ta1 = .01881 BTU/CU.FT./° Fcpm ta2

22

AB

SO

LUT

E

WATERSA

TU

RA

TIO

NT

EM

PE

RAT

UR

E(D

EG

RE

ES

FA

HR

)

150° 200° 250° 300° 350° 400° 450° 500°

1 lb. 27.96" 101.7 v = 0.0161 333.0 362.0 391.9 421.7 451.4 481.3 511.1 540.9 570.6h = 69.5 1102.4 1125.6 1149.6 1173.5 1197.4 1221.4 1245.2 1269.1 1293.0

2 lb. 25.91" 126.1 v = 0.0162 173.5 180.7 195.6 210.6 225.5 240.5 255.4 270.4 285.2h = 93.9 1113.6 1125.2 1149.2 1173.3 1197.2 1221.2 1245.1 1268.9 1292.8

3 lb. 23.87" 141.5 v = 0.0163 118.6 120.3 130.3 140.4 150.3 160.3 170.3 180.2 190.2h = 109.3 1120.6 1124.7 1148.9 1173.0 1197.0 1221.0 1244.9 1268.9 1292.8

4 lb. 21.83" 153.0 v = 0.0164 90.52 90.01 97.60 105.2 112.7 120.2 127.7 135.1 142.6h = 120.8 1125.7 1124.2 1148.5 1172.7 1196.8 1220.8 1244.8 1263.8 1292.7

5 lb. 19.79" 162.3 v = 0.0164 73.42 — 78.00 84.06 90.07 96.07 102.0 108.1 114.0h = 130.1 1129.8 — 1148.2 1172.4 1196.6 1220.6 1244.7 1268.6 1292.6

6 lb. 17.75" 170.1 v = 0.0164 61.89 — 64.93 69.99 75.01 80.02 85.01 90.00 94.99h = 137.8 1133.2 — 1147.8 1172.1 1196.3 1220.5 1244.5 1268.5 1292.5

7 lb. 15.70" 176.9 v = 0.0165 53.57 — 55.58 59.94 64.26 68.57 72.86 77.13 81.40h = 144.6 1136.1 — 1147.4 1171.9 1196.1 1220.3 1244.4 1268.4 1292.4

8 lb. 13.66" 182.9 v = 0.0165 47.26 — 48.58 52.40 56.19 59.97 63.72 67.47 71.21h = 150.7 1138.6 — 1147.1 1171.6 1195.9 1220.1 1244.2 1268.3 1292.3

9 lb. 11.62" 188.3 v = 0.0166 42.32 — 43.12 46.53 49.91 53.26 56.61 59.94 63.27h = 156.2 1140.9 — 1146.7 1171.3 1195.7 1219.9 1244.1 1268.2 1292.2

10 lb. 9.58" 193.2 v = 0.0166 38.37 — 38.77 41.84 44.89 47.92 50.93 53.93 56.93h = 161.1 1143.0 — 1146.4 1171.0 1195.5 1219.7 1243.9 1268.0 1292.1

11 lb. 7.54" 197.8 v = 0.0166 35.09 — 35.22 38.01 40.79 43.55 46.30 49.04 51.77h = 165.7 1144.9 — 1146.0 1170.7 1195.2 1219.6 1243.8 1267.9 1292.0

12 lb. 5.49" 202.0 v = 0.0166 32.35 — 32.25 34.82 37.37 39.91 42.42 44.93 47.43h = 169.9 1146.6 — 1145.7 1170.5 1195.0 1219.4 1243.6 1267.8 1291.9

13 lb. 3.45" 205.9 v = 0.0167 30.01 — 29.72 32.11 34.47 36.81 39.14 41.46 43.77h = 173.9 1148.2 — 1145.3 1170.2 1194.8 1219.2 1243.5 1267.7 1291.8

14 lb. 1.41" 209.6 v = 0.0167 28.00 — 27.57 29.79 31.99 34.17 36.33 38.48 40.63h = 177.6 1149.8 — 1145.0 1169.9 1194.6 1219.0 1243.4 1267.6 1291.7

15 lb. 0.31 lb. 213.0 v = 0.0167 26.25 — — 27.78 29.83 31.87 33.89 35.91 37.92h = 181.0 1151.2 — — 1169.6 1194.3 1218.9 1243.2 1267.4 1291.6

16 lb. 1.31 lb. 216.3 v = 0.0167 24.71 — — 26.03 27.95 29.87 31.77 33.66 35.54h = 184.3 1152.5 — — 1169.4 1194.1 1218.7 1243.1 1267.3 1291.5

17 lb. 2.31 lb. 219.5 v = 0.0168 23.35 — — 24.47 26.29 28.09 29.88 31.67 33.44h = 187.5 1153.7 — — 1169.1 1193.9 1218.5 1242.9 1267.2 1291.4

18 lb. 3.31 lb. 222.4 v = 0.0168 22.14 — — 23.10 24.82 26.52 28.22 29.91 31.59h = 190.5 1154.9 — — 1168.8 1193.7 1218.3 1242.8 1267.0 1291.3

19 lb. 4.31 lb. 225.2 v = 0.0168 21.04 — — 21.86 23.50 25.11 26.72 28.32 29.90h = 193.3 1156.0 — — 1168.5 1193.4 1218.1 1242.6 1266.9 1291.1

20 lb. 5.31 lb. 228.0 v = 0.0168 20.06 — — 20.75 22.31 23.85 25.38 26.89 28.40h = 196.1 1157.1 — — 1168.2 1193.2 1217.9 1242.4 1266.8 1291.0

22 lb. 7.31 lb. 233.1 v = 0.0169 18.35 — — 18.83 20.26 21.66 23.06 24.44 25.81h = 201.3 1159.1 — — 1167.6 1192.7 1217.5 1242.1 1266.5 1290.8

24 lb. 9.31 lb. 237.8 v = 0.0169 16.91 — — 17.23 18.54 19.83 21.12 22.39 23.65h = 206.1 1160.9 — — 1167.0 1192.3 1217.2 1241.8 1266.3 1290.6

26 lb. 11.31 lb. 242.2 v = 0.0169 15.69 — — 15.58 17.09 18.29 19.48 20.65 21.82h = 210.6 1162.5 — — 1166.5 1191.8 1216.8 1241.5 1266.0 1290.4

28 lb. 13.31 lb. 246.4 v = 0.0170 14.01 — — 14.72 15.86 16.97 18.07 19.17 20.25h = 214.8 1164.0 — — 1165.9 1191.4 1216.4 1241.2 1265.8 1290.2

PRESSURELB. PER SQ. IN.

ORVACUUM

IN. OF MERCURY

GAUGE

SA

TUR

ATE

DS

TE

AM

PROPERTIES OF STEAM

VOLUME IN CUBIC FEET PER LB. (v) ANDTOTAL HEAT IN BTU PER LB. (h) OF

STEAM AT A TOTAL TEMPERATURE (FAHRENHEIT) OF

23

WATERGAUGE SA

TU

RA

TIO

NT

EM

PE

RAT

UR

E(D

EG

RE

ES

FA

HR

)


30 15.31 250.3 v = 0.0170 13.72 15.82 16.86 17.88 18.89 19.90 20.91 21.92 22.92h = 218.8 1165.5 1216.1 1240.9 1265.5 1290.0 1314.4 1338.6 1362.8 1386.9

32 17.31 254.0 v = 0.0170 12.92 14.81 15.79 16.75 17.70 18.65 19.59 20.54 21.48h = 222.5 1166.9 1215.7 1240.6 1265.3 1289.8 1314.2 1338.4 1362.6 1386.8

34 19.31 257.6 v = 0.0171 12.20 13.93 14.85 15.75 16.65 17.54 18.44 19.33 20.21h = 226.1 1168.2 1215.3 1240.3 1265.0 1289.6 1314.0 1338.3 1362.5 1386.7

36 21.31 260.9 v = 0.0171 11.37 13.15 14.02 14.87 13.72 16.57 17.41 18.25 19.09h = 229.5 1169.4 1215.0 1240.0 1264.8 1289.4 1313.8 1338.1 1362.4 1386.6

38 23.31 264.1 v = 0.0171 11.00 12.44 13.27 14.08 14.89 15.69 16.49 17.29 18.08h = 232.8 1170.5 1214.6 1239.7 1264.6 1289.2 1313.6 1338.0 1362.3 1386.5

40 25.31 267.2 v = 0.0171 10.48 11.81 12.59 13.36 14.13 14.90 15.66 16.42 17.17h = 236.0 1171.6 1214.2 1239.4 1266.3 1289.0 1313.5 1337.8 1362.1 1386.3

42 27.31 270.2 v = 0.0172 10.01 11.23 11.98 12.72 13.46 14.18 14.91 15.63 16.35h = 239.0 1172.6 1213.9 1239.1 1264.1 1288.5 1313.3 1337.7 1362.0 1386.2

44 29.31 273.0 v = 0.0172 9.582 10.71 11.43 12.14 12.84 13.53 14.22 14.92 15.60h = 241.9 1173.6 1213.5 1238.8 1263.8 1288.6 1313.1 1337.6 1361.9 1386.1

46 31.31 275.7 v = 0.0172 9.191 10.24 10.92 11.60 12.27 12.94 13.60 14.26 14.92h = 244.7 1174.5 1213.1 1238.5 1263.6 1288.4 1312.9 1337.4 1361.8 1386.0

48 33.31 278.4 v = 0.0172 8.832 9.803 10.46 11.11 11.76 12.40 13.03 13.67 14.30h = 247.4 1175.4 1212.8 1238.2 1263.3 1288.1 1312.8 1337.3 1361.6 1385.9

50 35.31 287.9 v = 0.0173 8.500 94.00 10.03 10.66 11.28 11.90 12.51 13.12 13.72h = 250.0 1176.3 1212.4 1237.9 1263.1 1287.9 1312.6 1337.1 1361.5 1385.8

60 45.31 292.6 v = 0.0174 7.162 77.95 8.333 8.660 9.380 9.896 10.41 10.92 11.42h = 262.0 1180.1 1210.6 1236.4 1261.8 1286.9 1311.7 1336.4 1360.9 1385.2

70 55.31` 302.8 v = 0.0175 6.196 66.49 7.115 7.572 8.022 8.467 8.908 9.346 9.783h = 272.4 1183.3 1208.7 1234.9 1260.6 1285.9 1310.8 1335.6 1360.2 1384.7

80 65.31 311.9 v = 0.0176 5.466 5.788 6.202 6.606 7.004 7.394 7.784 8.168 8.550h = 281.9 1186.1 1206.9 1233.4 1289.4 1284.8 1310.0 1334.9 1359.6 1384.1

90 75.31 320.2 v = 0.0176 4.891 5.119 5.492 5.854 6.210 6.561 6.907 7.281 7.592h = 290.5 1188.5 1205.0 1231.9 1258.1 1283.8 1309.1 1334.1 1358.9 1383.6

100 85.31 327.9 v = 0.0177 4.429 4.584 4.923 5.253 5.576 5.894 6.207 6.518 6.826h = 298.5 1190.7 1203.1 1230.4 1256.8 1282.7 1308.2 1333.4 1358.3 1383.0

110 95.31 334.8 v = 0.0178 4.043 4.145 4.458 4.761 5.057 5.348 5.634 5.917 6.198h = 305.7 1192.6 1201.2 1228.9 1255.6 1281.7 1307.3 1332.6 1357.6 1382.5

120 105.3 341.3 v = 0.0179 3.727 3.780 4.071 4.351 4.625 4.893 5.157 5.418 5.677h = 312.5 1194.3 1199.3 1227.3 1254.3 1280.6 1306.5 1331.9 1357.0 1381.9

130 115.3 347.3 v = 0.0180 3.435 3.470 3.743 4.004 4.259 4.508 4.753 4.994 5.234h = 318.8 1195.8 1197.4 1225.8 1253.1 1279.6 1305.6 1331.1 1356.4 1381.4

140 125.3 353.0 v = 0.0180 3.221 3.204 3.461 3.707 3.945 4.178 4.406 4.632 4.856h = 324.9 1197.2 2295.4 1224.2 1251.8 1278.5 1304.7 1330.4 1355.7 1380.8

150 135.3 358.4 v = 0.0181 3.016 2.975 3.217 3.449 3.673 3.892 4.106 4.318 4.527h = 330.6 1198.5 1193.4 1222.7 1250.5 1277.5 1303.8 1329.6 1355.1 1380.2

160 145.3 363.6 v = 0.0182 2.836 — 3.004 3.223 3.435 3.641 3.844 4.043 4.240h = 336.0 1199.7 — 1221.1 1249.2 1276.5 1302.9 1328.9 1354.4 1379.7

170 155.3 368.4 v = 0.0182 2.678 — 2.816 3.024 3.225 3.421 3.612 3.800 3.986h = 341.2 1200.7 — 1219.5 1248.0 1275.4 1302.0 1328.1 1353.8 1379.1

180 165.3 373.1 v = 0.0183 2.536 — 2.648 2.847 3.039 3.224 3.406 3.584 3.760h = 346.1 1201.7 — 1217.9 1246.7 1274.3 1301.1 1327.4 1353.1 1378.6

190 175.3 377.5 v = 0.0184 2.409 — 2.498 2.689 2.871 3.049 3.222 3.391 3.559h = 350.9 1202.7 — 1216.3 1245.4 1273.3 1300.3 1326.6 1352.5 1378.0

AB

SO

LUT

E

SA

TUR

ATE

DS

TE

AM

350° 400° 450° 500° 550° 600° 650° 700°

PROPERTIES OF STEAM



24

GAUGE SA

TU

RA

TIO

NT

EM

PE

RAT

UR

E(D

EG

RE

ES

FA

HR

)

200 185.3 381.8 v = 0.0184 2.293 2.363 2.546 2.721 2.891 3.056 3.218 3.377 3.535h = 355.5 1203.5 1214.7 1244.1 1272.2 1299.4 1325.9 1351.9 1377.5 1402.8

210 195.3 385.9 v = 0.0185 2.189 2.241 2.417 2.585 2.747 2.906 3.061 3.213 3.364h = 360.0 1204.4 1213.0 1242.8 1271.1 1298.5 1325.1 1351.2 1376.9 1402.3

220 205.3 389.9 v = 0.0185 2.093 2.129 2.300 2.461 2.617 2.769 2.918 3.064 3.208h = 364.2 1205.1 1211.4 1241.5 1270.0 1297.6 1324.3 1350.6 1376.4 1401.8

230 215.3 393.7 v = 0.0186 2.006 2.027 2.192 2.349 2.499 2.645 2.787 2.928 3.066h = 368.4 1205.8 1209.7 1240.1 1269.0 1296.7 1323.6 1349.9 1375.8 1401.3

240 225.3 397.4 v = 0.0187 1.926 1.934 2.094 2.245 2.390 2.530 2.668 2.803 2.935h = 372.4 1206.4 1208.0 1238.8 1267.9 1295.8 1322.8 1349.3 1375.2 1400.8

250 235.3 401.0 v = 0.0187 1.852 1.848 2.003 2.150 2.290 2.425 2.558 2.688 2.816h = 376.3 1207.0 1206.3 1237.5 1266.8 1294.9 1322.1 1348.6 1374.7 1400.4

260 245.3 404.5 v = 0.0188 1.783 1.769 1.920 2.062 2.197 2.328 2.456 2.581 2.705h = 380.1 1207.5 1204.6 1236.1 1265.7 1294.0 1321.3 1348.0 1374.1 1399.9

270 255.3 407.9 v = 0.0188 1.719 1.695 1.842 1.980 2.111 2.238 2.362 2.483 2.602h = 383.7 1208.0 1202.8 1234.8 1264.6 1293.1 1320.5 1347.3 1373.6 1399.4

280 265.3 411.1 v = 0.0189 1.660 — 1.771 1.904 2.032 2.155 2.275 2.392 2.507h = 387.3 1208.5 — 1233.4 1263.5 1292.1 1319.8 1346.7 1373.0 1398.9

290 275.3 414.3 v = 0.0189 1.604 — 1.703 1.834 1.958 2.077 2.193 2.307 2.419h = 390.8 1209.0 — 1232.0 1262.4 1291.2 1319.0 1346.0 1372.4 1398.4

300 285.3 417.4 v = 0.0190 1.552 — 1.641 1.768 1.889 2.005 2.117 2.228 2.336h = 394.2 1209.4 — 1230.6 1261.3 1290.3 1318.2 1345.4 1371.9 1397.9

310 295.3 420.4 v = 0.0190 1.504 — 1.582 1.706 1.824 1.937 2.047 2.154 2.259h = 397.5 1209.8 — 1229.2 1260.1 1289.4 1317.5 1344.7 1371.3 1397.5

320 305.3 423.4 v = 0.0191 1.458 — 1.527 1.649 1.763 1.873 1.980 2.084 2.186h = 400.8 1210.2 — 1227.8 1259.0 1288.5 1316.7 1344.1 1370.8 1397.0

330 315.3 426.3 v = 0.0191 1.415 — 1.475 1.594 1.706 1.814 1.917 2.019 2.118h = 404.0 1210.5 — 1226.4 1257.9 1287.5 1315.9 1343.4 1370.2 1396.5

340 325.3 429.1 v = 0.0192 1.374 — 1.427 1.543 1.653 1.757 1.858 1.957 2.054h = 407.1 1210.8 — 1224.9 1256.8 1286.6 1315.2 1342.8 1369.6 1396.0

350 335.3 431.8 v = 0.0192 1.336 — 1.380 1.495 1.602 1.704 1.803 1.899 1.993h = 410.1 1211.1 — 1223.5 1255.6 1285.7 1314.4 1342.1 1369.1 1395.5

360 345.5 434.5 v = 0.0193 1.300 — 1.337 1.450 1.554 1.654 1.750 1.844 1.936h = 413.1 1211.4 — 1222.0 1254.5 1284.7 1313.6 1341.4 1368.5 1395.0

370 355.3 437.1 v= 0.0193 1.266 — 1.296 1.406 1.509 1.607 1.701 1.793 1.882h = 416.1 1211.6 — 1220.5 1253.3 1283.8 1312.8 1340.8 1368.0 1394.5

380 365.3 439.7 v = 0.0193 1.233 — 1.257 1.365 1.466 1.562 1.654 1.743 1.831h = 419.0 1211.8 — 1219.0 1252.1 1282.9 1312.0 1340.1 1367.4 1394.0

390 375.3 442.2 v = 0.0194 1.202 — 1.220 1.327 1.426 1.519 1.609 1.697 1.782h = 421.8 1212.0 — 1217.5 1251.0 1281.9 1311.2 1339.5 1366.8 1393.5

400 385.3 444.7 v = 0.0194 1.172 — 1.184 1.289 1.387 1.479 1.567 1.653 1.736h = 424.6 1212.1 — 1216.0 1249.8 1281.0 1310.5 1338.8 1366.2 1393.1

SA

TUR

ATE

DS

TE

AM

AB

SO

LUT

E

400° 450° 500° 550° 600° 650° 700° 750°


PROPERTIES OF STEAM



WATER

25

AB

SO

LUT

E

WATERGAUGE

SA

TUR

ATE

DS

TE

AM

550° 600° 650° 700° 750° 800° 850° 900°

PROPERTIES OF STEAM


420 405.3 449.5 v = 0.0195 1.118 1.315 1.404 1.488 1.570 1.651 1.729 1.806 1.882h = 430.0 1212.4 1279.0 1308.9 1337.4 1365.1 1392.1 1418.5 1444.5 1470.2

440 425.3 454.1 v = 0.0196 1.068 1.250 1.335 1.417 1.496 1.573 1.648 1.722 1.795h = 435.2 1212.7 1277.1 1307.3 1336.1 1363.9 1391.1 1417.7 1443.8 1469.6

460 445.3 458.6 v = 0.0197 1.022 1.190 1.273 1.352 1.427 1.501 1.574 1.645 1.715h = 440.3 1212.9 1275.1 1305.7 1334.7 1362.8 1390.1 1416.8 1443.0 1468.9

480 465.3 462.9 v = 0.0198 0.979 1.135 1.215 1.292 1.365 1.436 1.506 1.574 1.642h = 445.3 1213.1 1273.2 1304.1 1333.4 1361.7 1389.1 1416.0 1442.3 1468.2

500 485.3 467.1 v = 0.0199 0.940 1.085 1.163 1.236 1.307 1.376 1.443 1.509 1.574h = 450.1 1213.2 1271.2 1302.4 1332.0 1360.5 1388.1 1415.1 1441.5 1467.6

520 505.3 471.2 v = 0.0200 0.904 1.038 1.114 1.186 1.254 1.321 1.386 1.449 1.512h = 454.8 1213.2 1269.1 1300.8 1330.7 1359.4 1387.2 1414.2 1440.8 1466.9

540 525.3 475.1 v = 0.0200 0.871 0.995 1.069 1.138 1.205 1.270 1.332 1.394 1.454h = 459.4 1213.2 1267.1 1299.1 1329.3 1358.2 1386.1 1413.4 1440.0 1466.2

560 545.3 479.0 v = 0.0201 0.839 0.955 1.027 1.095 1.159 1.222 1.283 1.342 1.401h = 463.9 1213.1 1265.0 1297.5 1327.9 1357.0 1385.2 1412.5 1439.3 1465.6

580 565.3 482.7 v = 0.0202 0.810 0.917 0.998 1.054 1.117 1.177 1.237 1.294 1.351h = 468.3 1213.0 1262.9 1295.8 1326.6 1355.9 1384.2 1411.7 1438.5 1464.9

600 585.3 486.3 v = 0.0203 0.783 0.882 0.951 1.016 1.077 1.136 1.194 1.250 1.305h = 472.5 1212.9 1260.8 1294.1 1325.2 1354.7 1383.2 1410.8 1437.8 1464.3

650 635.3 495.0 v = 0.0205 0.721 0.804 0.870 0.931 0.988 1.044 1.097 1.149 1.201h = 482.8 1212.5 1255.4 1289.8 1321.7 1351.7 1380.6 1408.6 1435.9 1462.6

700 685.3 503.2 v = 0.0207 0.668 0.736 0.799 0.858 0.912 0.965 1.015 1.064 1.112h = 492.6 1211.8 1249.7 1285.4 1318.1 1348.8 1378.1 1406.4 1434.0 1460.9

750 735.3 511.0 v = 0.0209 0.622 0.677 0.739 0.794 0.846 0.896 0.944 0.900 1.035h = 502.0 1210.9 1243.9 1280.9 1314.4 1345.8 1375.6 1404.2 1432.1 1459.2

800 785.3 518.3 v = 0.0211 0.581 0.625 0.685 0.739 0.789 0.836 0.881 0.925 0.968h = 511.0 1209.8 1237.7 1276.2 1310.7 1342.7 1373.0 1402.0 1430.2 1457.6

850 835.3 525.3 v = 0.0213 0.545 0.579 0.637 0.690 0.737 0.783 0.826 0.867 0.908h = 519.7 1208.6 1231.3 1271.5 1307.0 1339.6 1370.4 1399.8 1428.2 1455.9

900 885.3 532.1 v = 0.0215 0.513 0.537 0.595 0.646 0.692 0.735 0.777 0.816 0.855h = 528.1 1207.3 1224.5 1266.5 1303.1 1336.5 1367.7 1397.6 1426.3 1454.2

950 935/3 538.5 v = 0.0217 0.484 0.499 0.557 0.607 0.651 0.693 0.733 0.771 0.808h = 536.2 1205.9 1217.4 1261.4 1299.2 1333.3 1365.1 1395.3 1424.4 1452.5

1000 985.3 544.7 v = 0.0219 0.458 0.465 0.523 0.571 0.615 0.655 0.693 0.730 0.765h = 544.1 1204.3 1209.9 1256.1 1295.1 1330.0 1362.4 1393.0 1422.4 1450.8

1100 1085.3 556.5 v = 0.0223 0.412 0.404 0.462 0.509 0.551 0.589 0.625 0.659 0.691h = 559.4 1200.8 1193.3 1244.9 1286.7 1323.4 1357.0 1388.5 1418.4 1447.4

1200 1185.3 567.4 v = 0.0227 0.373 — 0.411 0.458 0.498 0.534 0.568 0.600 0.630h = 574.0 1196.8 — 1232.7 1277.9 1316.5 1351.3 1383.7 1414.5 1443.9

1300 1285.3 577.6 v = 0.0232 0.340 — 0.366 0.413 0.452 0.487 0.519 0.549 0.578h = 587.9 1192.3 — 1219.2 1268.4 1309.3 1345.6 1379.0 1410.4 1440.4

1400 1385.3 587.2 v = 0.0236 0.311 — 0.326 0.375 0.413 0.447 0.478 0.506 0.534h = 601.3 1187.4 — 1204.2 1258.3 1301.8 1339.7 1374.1 1406.3 1436.9



SA

TU

RA

TIO

NT

EM

PE

RAT

UR

E(D

EG

RE

ES

FA

HR

)

26

590 350 … … … … … … … … … … … … … … … …

1090 670 470 410 350 … … … … … … … … … … … … …

1600 1000 720 620 550 430 … … … … … … … … … … … …

… 1340 960 840 740 590 490 410 … … … … … … … … … …

… … … 1990 1760 760 630 530 460 400 350 … … … … … … …

… … … … 1980 1600 1340 1150 570 500 440 390 … … … … … …

… … … … … 1870 1570 1340 1170 1040 930 840 460 420 390 … … …

… … … … … … 1790 1540 1340 1190 1060 960 880 800 740 680 … …

… … … … … … 2020 1740 1520 1340 1200 1090 990 910 840 780 670 590

… … … … … … … 1940 1690 1500 1340 1210 1100 1020 940 870 760 670

… … … … … … … … 1870 1660 1480 1340 1220 1120 1040 960 840 740

… … … … … … … … … 1870 1670 1520 1380 1270 1170 1090 950 840

… … … … … … … … … … 1870 1690 1540 1420 1310 1210 1060 940

… … … … … … … … … … … 1870 1700 1570 1450 1340 1170 1040

… … … … … … … … … … … … 1870 1720 1590 1470 1290 1140

… … … … … … … … … … … … 2040 1870 1730 1600 1400 1240

… … … … … … … … … … … … … 2020 1870 1740 1520 1340

… … … … … … … … … … … … … … 2010 1870 1630 1450

… … … … … … … … … … … … … … … 2000 1750 1550

… … … … … … … … … … … … … … … … 1870 1660

… … … … … … … … … … … … … … … … 1990 1760

… … … … … … … … … … … … … … … … … 1870

… … … … … … … … … … … … … … … … … 1980

1/2 3/4 1 11/16 11/4 11/2 13/4 2 21/4 21/2 23/4 3 31/4 31/2 33/4 4 41/2 5

MAXIMUM WORKING PRESSURES FOR WATERTUBE BOILERSMaximum allowable working pressures for seamless steel and electric resistance welded steel tubes or nipples for watertube

boilers, where expanded into drums or headers, for different diameters and gages of tubes conforming to the requirements of

specifications SA-178 Grade A, SA-192 and SA-226.

Tube Outside Diameter, in.

0.055

0.065

0.075

0.085

0.095

0.105

0.120

0.135

0.150

0.165

0.180

0.200

0.220

0.240

0.260

0.280

0.300

0.320

0.340

0.360

0.380

0.400

0.420

NearestBwg.No.

WallThickness,

in.

–

+

+

–

+

+

–

+

+

–

DECIMAL AND MILLIMETER EQUIVALENTS OF B.W.G.AND FRACTIONS FOR ROUND SEAMLESS STEEL TUBING

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

…

…

…

…

…

…

…

B.W.G.OR

FRACTION DECIMAL MM

11/32 .344 8.73

3/8 .375 9.52

00 .380 9.65

000 .425 10.80

7/16 .438 11.12

0000 .454 11.53

1/2 .500 12.70

17/32 .531 13.48

9/16 .563 14.30

19/32 .594 15.10

5/8 .625 15.87

11/16 .688 17.47

3/4 .750 19.00

13/16 .813 20.65

7/8 .875 22.22

15/16 .938 23.82

1 1.000 25.40

B.W.G.OR

FRACTION DECIMAL MM

20 .035 .889

19 .042 1.06

3/64 .047 1.19

18 .049 1.24

17 .058 1.47

1/16 .063 1.6

16 .065 1.65

15 .072 1.82

5/64 .078 1.98

14 .083 2.10

3/32 .094 2.38

13 .095 2.41

7/64 .109 2.76

12 .109 2.76

11 .120 3.04

1/8 .125 3.17

10 .134 3.4

9/64 .141 3.58

B.W.G.OR

FRACTION DECIMAL MM

9 .148 3.75

5/32 .156 3.96

8 .165 4.19

11/64 .172 4.36

7 .180 4.57

3/16 .188 4.77

13/64 .203 5.15

6 .203 5.15

7/32 .219 5.56

5 .220 5.58

4 .238 6.04

1/4 .250 6.35

3 .259 6.57

9/32 .281 7.13

2 .284 7.21

1 .300 7.62

5/16 .313 7.95

0 .340 8.63

B.W.G.OR

FRACTION DECIMAL MM

36 .004 .101

35 .005 .127

34 .007 .177

33 .008 .203

32 .009 .228

31 .010 .254

30 .012 .304

29 .013 .330

28 .014 .355

1/64 .016 .406

27 .016 .406

26 .018 .457

25 .020 .508

24 .022 .558

23 .025 .635

22 .028 .711

1/32 .031 .787

21 .032 .812

27

FROM 32°F TO 1°F IN B. TH. U./LB/°F

N2 andCO CO2 Steam

Temp.(t°C)

Temp.(t°F) O2Air H2

100 212 0.2406 0.2490 0.2179 0.2034 0.5048 3.409

200 392 0.2410 0.2494 0.2182 0.2080 0.4964 3.426

300 572 0.2414 0.2498 0.2186 0.2126 0.4909 3.443

400 752 0.2419 0.2504 0.2191 0.2171 0.4881 3.461

500 932 0.2425 0.2510 0.2196 0.2219 0.4871 3.478

600 1112 0.2432 0.2517 0.2202 0.2256 0.4873 3.496

700 1292 0.2439 0.2524 0.2209 0.2297 0.4888 3.513

800 1472 0.2447 0.2533 0.2217 0.2336 0.4913 3.530

900 1652 0.2457 0.2543 0.2225 0.2374 0.4949 3.548

1000 1832 0.2466 0.2552 0.2233 0.2410 0.5000 3.565

1100 2012 0.2477 0.2563 0.2243 0.2445 0.5050 3.582

1200 2192 0.2488 0.2575 0.2253 0.2478 0.5112 3.600

1300 2372 0.2499 0.2587 0.2264 0.2510 0.5185 3.617

1400 2552 0.2512 0.2600 0.2275 0.2540 0.5268 3.635

1500 2732 0.2525 0.2613 0.2287 0.2569 0.5357 3.652

1600 2912 0.2539 0.2628 0.2299 0.2596 0.5458 3.669

1700 3092 0.2554 0.2643 0.2313 0.2621 0.5566 3.687

1800 3272 0.2569 0.2659 0.2327 0.2645 0.5666 3.704

1900 3452 0.2585 0.2675 0.2341 0.2668 0.5790 3.721

2000 3632 0.2602 0.2693 0.2356 0.2689 0.5911 3.739

MEAN SPECIFIC HEAT OF GASESAT CONSTANT PRESSURE

1-800-845-3052

Natural Gas 1097 993

Coke Oven Gas 561 500

Raw Prod. Gas 147 137.3

Clean Prod. Gas 138 129

Towns Gas 545 499

Commercial Butane 3190 2935

Blue Water Gas 301 276

Blast Furnace Gas 92.3 90.6

Commercial Propane 2550 —

Ethane 1760 —

No. 1 Fuel Oil 19,800 18,650

No. 2 Fuel Oil 19,600 18,400

No. 3 Fuel Oil 19,350 18,350

No. 6 Fuel Oil 18,300 17,340

CALCULATION OF HEATING VALUESFOR LIQUID AND GAS FUELS

I. LIQUID FUELS—(UNCRACKED DISTILLATE OR RESIDUE)

A. HF = Gross heating value = 17,600 + 69 (A.P.I. Deg.), (Btu/lb.)

(CRACKED DISTILLATE)

B. HF = Gross heating value = 17,780 + 54 (A.P.I. Deg.), (Btu/lb.)

NOTE: Avg., difference between gross and net heating values of

fuel oils is 6%.

II. GASEOUS FUELS

A. Paraffin hydrocarbons (CN H2N + 2)

BTU_________ = 745N + 258 = Gross heating valueCu. Ft. Gas

III. TABLE OF HEATING VALUES FOR TYPICAL FUELS

NET HEATING VALUE

BTU/CU. FT. FOR GASES

BTU/LB. FOR LIQUIDS

GROSS HEATING VALUE

BTU/CU. FT. FOR GASES

BTU/LB. FOR LIQUIDS

FUEL

B. Unsaturated hydrocarbons (CA HB)

BTU_________ = 459A + 132B +135 = Gross heating valueCu. Ft. Gas

28

ASTM Schedule 10 thru 160

Welded and Seamless Carbon .30 max. 45,000 - 60,000 psi 30,000 - 35,000 psi 30% Yes 1/8" - 26" IPS Standard Wall Tolerance

A-53 Carbon Steel Pipe Phosphorous .05 max. X Heavy, XX Heavy – 121/2% max.

Grade B:

Seamless Carbon .30 max. Schedule 40 thru 160

A-106 Carbon Steel Pipe Manganese 1.06 max. 60,000 min. psi Grade B 30% Yes 1/8" - 26" IPS Standard Wall Tolerance

Silicon .10 min. 35,000 min. psi X Heavy, XX Heavy – 131/2% max.

Welded and Seamless

A-120 Galvanized Steel Pipe Nonspecified Nonspecified Nonspecified Yes 1/2" - 16" IPS All

Grade A:

A-178 Electric Resistance Welded Carbon .06 - .18 60,000 min. psi 37,000 min. psi 30% Optional 1/2" - 5" OD Min. Wall ASTM A-450 Applies

Carbon Steel Boiler Tubes Manganese .27 - .63 .035" - .320"

Seamless

A-179 Cold Drawn Carbon Steel Carbon .06 -.18 60,000 min. psi 37,000 min. psi 30% Optional 1/8" - 3" OD None Specified ASTM A-450 Applies

Condenser and Heat Exchanger Tubes Manganese .27 - .63

Seamless Carbon .06 - .18 Maximum Hardness

A-192 Carbon Steel Boiler Tubes Manganese .27 - .63 Under 200° Wall, Not to Exceed Rockwell B-77 35% Optional 1/2" - 7" OD Min. Wall ASTM A-450 Applies

for High Pressure Service Silicon 25 max. 200° Wall and Over, Not to Exceed Brinell 137 .085" - 1.000"

26,000 min. psi 30% Optional .155 - 5" OD Min. Wall ASTM A-450 Applies

Seamless Stainless and Alloy Ferritic All 400 Series 47,000 min. psi .015" - .500"

A-213 Boiler, Superheater and 30,000 min. psi 35% Optional .555 - 5" OD Min. Wall ASTM A-450 Applies

Heat Exchanger Tubes Austenitic All 300 Series 75,000 min. psi

Welded Not to Exceed Not to Exceed

A-214 Carbon Steel Heat Exchanger and Carbon .18 max. Rockwell B-90 max. Rockwell B-90 max. Optional 1/8" - 3" OD Min. Wall Only ASTM A-450 Applies

Condenser Tubes Manganese .27 - .63 Brinell 200 max. Brinell 200 max.

Welded

Austenitic Stainless Steel Boiler Min. Wall

A-249 Superheater, Heat Exchanger and All 300 Series 70,000 min. psi 25,000 min. psi 35% Optional .155 - 5" OD .015" - .320"

Condenser Tubes

Welded and Seamless

A-269 Austenitic Stainless Steel All 300 Series 75,000 min. psi 30,000 min. psi 35% Optional Under 8" OD Average Wall ASTM A-450 Applies

Tubing for General Service

MIL-T specifications are approved by the Naval SEA System Command and are available for use by all Departments and Agencies of the Department of Defense

MIL-T Chemical and Mech-

Seamless Carbon .06 - .18 anical Properties

16286 E Carbon Steel Boiler Tubes Manganese .27 - .63 47,000 min. psi 26,000 min. psi 35% Yes — Min. Wall Only are Similar to

Class A Silicon .25 max. ASTM A-192

Seamless Carbon 0.8 max.

Class C Stainless Steel Boiler Tubes Manganese 2.0 max. 75,000 min. psi 30,000 min. psi 35% Yes — Min. Wall Only ASTM A-213

18% CR 8% NI Silicon .75 max. GR T321 - T347

Seamless Carbon .15 max.

Class E Alloy Steel Boiler Tubes Manganese .30 - .60 50,000 min. psi 30,000 min. psi 30% Yes — Min. Wall Only ASTM A-213

21/4% CR 1% Moly Silicon .50 max. GR T22

Seamless Carbon .27 max.

Class G Medium Carbon Boiler Tubes Manganese .93 max. 50,000 min. psi 37,000 min. psi 30% Yes — Min. Wall Only ASTM A-210

Silicon .10 min. Grade A-1

MIL-T

Welded Carbon .06 - .08

17188 Carbon Steel Boiler Tubes Manganese .27 - .63 60,000 min. psi 37,000 min. psi 30% Yes — Min. Wall Only ASTM A-226

Class A Silicon .050 max.

SPECIFICATIONS FOR STEEL TUBING AND PIPETYPICAL PHYSICAL PROPERTIES

PARTIAL elongation pressure

SPEC DESCRIPTION ANALYSIS tensile yield (0.0 in. 2°) tested* OD WALL OTHER

29

BOILER TUBE COMPANY OF AMERICA

KEEPS YOUR BOILER OPERATING

Whether you need to get a boiler back on line fast or plan a retrofit for improved efficiency,

depend on Boiler Tube Company of America—the boiler fabrication specialists who havereturned thousands of boilers to service all across the globe.

• The largest stock of boiler tubes in the world.

• Hot and cold bending facilities with a full range of tooling.

• Complete fabrication facilities to expedite your order.

• Code weld assembly plant with multiple stamp approval and complete facilities to hydro test,

heat treat and ultrasonic test, and radiograph after assembly.

• A file of over 40,000 drawings of tube details and tube arrangements for nearly every type of

boiler ever built. Your boiler probably matches one already in our files.

• Over 60 years in the business. Years devoted exclusively to supply replacement boiler tubes

and tube arrangements to keep existing units operating with a minimum of interruption.

• We offer on-site design and engineering capability for redesign. We are also the only company

in America able to supply extended surface Economizers.


P.O. Box 517

506 Charlotte Highway

Lyman, South Carolina 29365

(864) 439-0220, 1-800-845-3052

Fax: (864) 439-8292

650 Green Lane

P.O. Box 2065

Union, NJ 07083

1-800-345-0632

©1999 Boiler Tube Company of America

boiler tube facts book

Documents