Boiler Calc

[A] BOILER DUTY FOR INITIAL HEATING OIL INSIDE TANK
[1] DUTY FOR HEATING HEAVY FUEL OIL [HFO] "INSIDE" STORAGE TANK
6500 m3
Service = To heat up oil temperature inside tank to specified temperature
HFO Temperature Initial = 10 o

C
HFO Temperature Final = 40 o

C
HFO Gross Volume = 6,500 m3 Refer to bid document 1.6.1. Tank Dimension
HFO Net Working Volume = 6,150 m3
HFO Mass Density = 0.991 kg/lt Refer to reference
= 991 kg/m3
HFO Specific Heat = 1,717 Joule/kg.oC 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 oC
Cp hot water inlet = 4,397 Joule/kg.oC Refer to Hysis simulation
Hot water outlet temperature = 60 oC
Cp hot water outlet = 4,329 Joule/kg.oC 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

[3] FASTEST PERIOD FOR HEATING 3 OIL STORAGE
HFO Temperature Initial = 10 C

o
HFO Temperature Final = 40 C

o
HFO Volume = 6,500 m3 Refer to bid document 1.6.1. Tank Dimension
= 991 kg/m3
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

[1] DUTY FOR HEATING UP HEAVY FUEL OIL [HFO] "OUTLET" STORAGE TANK
HFO Inlet HFO Outlet
Hot Water Inlet Hot Water

Outlet
Service = To heat up pumped oil temperature to specified value
HFO Temperature Inlet = 40 C

o
HFO Temperature Outlet = 50 C

o
HFO Mass Flow = 600 ton/hr
= 600,000 kg/hr
Heating duty = 10,302,000,000 Joule/hr
= 2.862 MW
6500 m3
Service = To maintain oil temperature inside tank to specified temperature

C

C
HFO Volume = 6,500 m3
= 991 kg/m3
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

[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 m3/hr
Condition :
Steam mass rate = 6,894 kg/hr
Steam operating pressure = 3 barg Refer to Hysis Simulation
Steam operating pressure = 143.7 oC 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

[F] HEAT BALANCE AROUND STEAM DRUM DURING NORMAL OPERATION
Steam condition = saturated
Steam mass rate = 4,680 kg/hr Calculated
Steam temperature = 143.72 oC 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 oC 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 oC 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 oC 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 oC 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
6500 m3

C

C
HFO Gross Volume = 6,500 m3 Refer to bid document 1.6.1. Tank Dimension
= 991 kg/m3
HFO Specific Heat = 1,717 Joule/kg.o C Refer to reference
Pumping frequency = 96 hr
= 345,600 sec
Heating duty = 2,725,134 Joule/sec
= 2.725 MW
Cp hot water inlet = 4,526 Joule/kg.o C Refer to Hysis simulation
Cp hot water outlet = 4,329 Joule/kg.o C Refer to Hysis simulation
[2] BOILER DUTY DURING INITIAL OPERATION

[3] FASTEST PERIOD FOR HEATING 3 OIL STORAGE

C

C
HFO Volume = 6,500 m3 Refer to bid document 1.6.1. Tank Dimension
= 991 kg/m3
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

[1] DUTY FOR HEATING UP HEAVY FUEL OIL [HFO] "OUTLET" STORAGE TANK
HFO Inlet HFO Outlet
Hot Water Inlet Hot Water

Outlet
Service = To heat up pumped oil temperature to specified value
HFO Temperature Inlet = 40 o

C
HFO Temperature Outlet = 50 o

C
HFO Mass Flow = 600 ton/hr
= 600,000 kg/hr
Heating duty = 10,302,000,000 Joule/hr
= 2.862 MW
6500 m3
Service = To maintain oil temperature inside tank to specified temperature

C

C
HFO Volume = 6,500 m3
= 991 kg/m3
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

[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 m3/hr
Condition :
Steam mass rate = 7,381 kg/hr
Steam operating pressure = 5 barg Refer to Hysis Simulation
Steam operating pressure = 159.0 oC 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
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 oC 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 oC 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 oC 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 oC 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 oC 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
Dearator Dimension Calculator
Internal Diameter : 1.000 m Select Units
Tan-Tan Length : 2.000 m m
Volume of two heads : 0.26 m³ Select Head Type
Shell Volume : 1.57 m³ 2:1
Total Volume : 1.83 m³
Heads SA : 2.17 m² Number of heads included in level calcula
Shell SA : 6.28 m² 2
Surface Area : 8.5 m²
Levels Vapour Volume Volume Wetted Area Wetted Area

Level Setting
m m m³ % m² %
Low low 0.100 0.90 0.089 4.9 1.40 16.6
Low 0.200 0.80 0.251 13.7 2.16 25.6
Normal 0.500 0.50 0.916 50.0 4.23 50.0
High 0.850 0.15 1.669 91.1 6.66 78.8
High High 0.900 0.10 1.744 95.1 7.05 83.4
Overflow 1.000 0.00 1.833 100.0 8.45 100.0
Total Residence Tim
Working Volume : 1.42 m³ ® BETWEEN LLL AND HLL (LV ON/OFF ACTION)
Utilisation : 77.4 %
Flowrate : 0.74 m3/hr
Residence Time : 128.43 minutes Oke ® For accomodating surge and hold up
Refer to Spiraxsarco (Typical 10 ~ 20

Residence Time Specified by Client : 10.00 minutes
minutes)
Venting
Vendor to Advice
Dearator Inlet Water Flow
Vendor to Advice
Dearator Inlet Steam Flow
ID = 1000 mm
(L/ID) = 2
L = 2000 mm
Total Vol. Retention Time Retention Time
From LALL Between Level Between Level
m³ hours Minutes
- 0.121 7.24
0.2 0.219 13.15
0.8 0.902 54.09
1.6 1.020 61.18
1.7 0.101 6.06
1.7 0.121 7.24
Total Residence Time : 2.483 148.97
ge 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 O2 solubility
o
C ppm ppm
O2 solubility vs tem
0 14.4 14.425
10 11.3 11.219
16
o2 solubility, ppm
20 8.85 8.839
30 7.2 7.172
40 6.2 6.036 f(x) =14
2.88461538461532E-09x^5 - 6.22086247086228E-
50 5.6 5.213 R² = 0.9996941827
60 4.95 4.482 12
70 4 3.661
80 3.05 2.639 10
90 1.8 1.414
100 0 0.125 8
A= 3.00E-09 6
B= -6.00E-07
C= 1.00E-05
4
D= 0.0042
E= -0.363
F= 14.425 2
0
0 10 20 30 40 50
temperatu
Pressure 760 mmHg = 1 atm
air solubility, gr/liter

Temperature Air solubility
o
F o
C gr/liter gr/liter ppm = mg/liter air solu
40 4 0.0258 0.023 22.611
50 10 0.0223 0.022 21.500 0.0300
60 16 0.0197 0.020 20.389
70 21 0.0177 0.019 19.278
0.0250
80 27 0.0161 0.018 18.167
90 32 0.0147 0.017 17.056 f(x) = - 0.00022876
0.0200
R² = 0.9718414372
100 38 0.0136 0.016 15.944
110 43 0.0126 0.015 14.833 0.0150
120 49 0.0117 0.014 13.722
130 54 0.0107 0.013 12.611 0.0100
140 60 0.0098 0.012 11.500
150 66 0.0089 0.010 10.389 0.0050
160 71 0.0079 0.009 9.278
170 77 0.0068 0.008 8.167 0.0000
0 10 20 30
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 solubility vs temperature
4
2.88461538461532E-09x^5 - 6.22086247086228E-07x^4 + 1.28059440559421E-05x^3 + 0.0042463578x^2 - 0.3630110723x + 14.4251748252
.9996941827
2
0
0 10 20 30 40 50 60 70 80 90 100
temperature, oC
air solubility vs temperature
0.0300
0.0250
f(x) = - 0.0002287616x + 0.0235249054

0.0200
R² = 0.9718414372
0.0150
0.0100
0.0050
0.0000
0 10 20 30 40 50 60 70 80 90 100 110
temp, C
21962,Water-pp414-416
Wartsila-O-E-RT-WHR
steam9_blowdown
steam9_blowdown
presentation4-casestudyboiler
Power-Plants-Product-Catalogue-2012-2nd-edition
Power-Plants-Product-Catalogue-2012-2
GTMEIC
5510-0136-00pp_low
5510-0136-00pp_low
ater-pp414-416
21962,Water-pp414-416
21962,Water-pp414-416
21962,Water-pp414-416
21962,Water-pp414-416
21962,Water-pp414-416
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
http://www.cewater.com/A55_BoilerSystem.html
http://gc3.com/Default.aspx?tabid=91
24_WaterTreatment_BoilerWater
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+los
214091248-Diesel-Engine-Power-Plants
http://www.engineeringtoolbox.com/air-solubility-water-d_639.html
http://www.engineeringtoolbox.com/air-solubility-water-d_639.html
Deaerator in steam industrial system

http://www.spiraxsarco.com/reso
lants-Product-Catalogue-2012-2nd-edition
GTMEIC
5510-0136-00pp_low
ater Handbook
ater Handbook
ater Handbook
ater Handbook
GPSA Sect 18
AWT-2
ww.gc3.com/Default.aspx?tabid=92
r.com/A55_BoilerSystem.html
ault.aspx?tabid=91
ault.aspx?tabid=91
ault.aspx?tabid=91
ault.aspx?tabid=91
3.com/Default.aspx?tabid=91
3.com/Default.aspx?tabid=91
EBMUD_WaterSmart_Guide_Thermodynamic_Processes
EBMUD_WaterSmart_Guide_Thermodynamic_Processes
Essentials for a Sound Boiler Water Treatment Program
asics/Steam-or-Hot-Water.aspx
PA84&lpg=PA84&dq=heat+losses+in+diesel+engine&source=bl&ots=_r4JXBz2Ls&sig=Y3urFd1KU7TfJZmVI_Enhu8
ater-d_639.html
ter Handbook
r in steam industrial system

http://www.spiraxsarco.com/resources/steam-engineering-tutorials/the-boiler-house/pressurised-deaerators.asp
Y3urFd1KU7TfJZmVI_Enhu8W_Bo&hl=en&sa=X&ei=2MrxU6nHB4K3uAShk4CgDA&ved=0CDIQ6AEwAw#v=onep
ed-deaerators.asp
&ved=0CDIQ6AEwAw#v=onepage&q=heat%20losses%20in%20diesel%20engine&f=false

Boiler Calc

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[A] BOILER DUTY FOR INITIAL HEATING OIL INSIDE TANK

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

HFO Temperature Initial = 10 o

HFO Temperature Final = 40 o

HFO Net Working Volume = 6,150 m3

HFO Mass Density = 0.991 kg/lt Refer to reference

HFO Specific Heat = 1,717 Joule/kg.oC Refer to reference

HFO Mass Stock = 6,094,650 kg

Number of HFO Tank = 3 ea

Total HFO Mass Stock = 18,283,950 kg

= 4 days Refer to bid document 2.2.4. Pipework

Heating duty = 2,725,134 Joule/sec

Hot water operating pressure = 3 barg

Hot water inlet temperature = 100 oC

Cp hot water inlet = 4,397 Joule/kg.oC Refer to Hysis simulation

Hot water outlet temperature = 60 oC

Cp hot water outlet = 4,329 Joule/kg.oC 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

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

HFO Temperature Initial = 10 C

HFO Temperature Final = 40 C

HFO Volume = 6,500 m3 Refer to bid document 1.6.1. Tank Dimension

HFO Net Working Volume = 6,150 m3

HFO Mass Density = 0.991 kg/lt Refer to reference

HFO Specific Heat = 1,717 Joule/kg.oC Refer to reference

HFO Mass Stock = 6,094,650 kg

Number of HFO Tank = 3 ea

Total HFO Mass Stock = 18,283,950 kg

Maximum time for heating up = 58 hr

Pumping frequency period = 96 hr

= 4 days Refer to bid document 2.2.4. Pipework

Note = Oke because shorther than pumping frequency period

Boiler duty = 4,499,442 Joule/sec

Boiler design duty = 4.50 MW Refer to bid document data

Hot water operating pressure = 3 barg

Hot water inlet temperature = 100 oC

Cp hot water inlet = 4,397 Joule/kg.oC Refer to Hysis simulation

Hot water outlet temperature = 60 oC

Cp hot water outlet = 4,329 Joule/kg.oC Refer to Hysis simulation

Hot water mass rate = 26 kg/sec

= 92,826 kg/hr Refer to manual calculation

= 92,921 kg/hr Refer to Hysis simulation

[B] BOILER DUTY DURING NORMAL OPERATION

HFO Inlet HFO Outlet

Hot Water Inlet Hot Water

Service = To heat up pumped oil temperature to specified value

HFO Temperature Inlet = 40 C

HFO Temperature Outlet = 50 C

HFO Mass Flow = 600 ton/hr

HFO Specific Heat = 1,717 Joule/kg.oC Refer to reference

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

Hot water inlet temperature = 100 oC

Cp hot water inlet = 4,397 Joule/kg.oC Refer to Hysis simulation

Hot water outlet temperature = 60 oC

Cp hot water outlet = 4,329 Joule/kg.oC Refer to Hysis simulation

Hot water mass rate = 16 kg/sec

= 59,030 kg/hr Refer to manual calculation

= 59,098 kg/hr Refer to Hysis simulation