4/30/2018 BOILER DESIGN SOFTWARE

BOILER DESIGN SOFTWARE

FIRE TUBE BOILER THERMODYNAMIC

CALCULATION
Instructions

15 MW, 23 t/h, 10 bar / 145 psi STEAM BOILER WITH

SUPERHEATER AND ECONOMIZER

INTRODUCTION

The procedure shown below is next to all needed to successfully use the software to calculate heat transfer in 3-PASS FIRE TUBE boiler. The data input process leads the user
step-by-step in an easy-to-follow self-explaining way. During geometry data input process a corresponding general image of particular boiler design feature is displayed
illustrating the current to-be-entered value. Safety mechanism is incorporated preventing geometrically incorrect data such as tube wall thickness that is greater than tube
inner diameter, exit water temperature that is lower than return one etc.

3-pass boiler with superheater and economizer

Step 1: Units choice (metric in this case). Use Arrow key to move up and down and Enter to Step 2: Case description data entry. In last field Enter brings up next window. Use arrow keys,
select. Mouse point + double click also works. Esc quits the program. Bottom line explains the Home and End to move up and down. Esc gets you back to Main menu.
navigation. In general UP arrow brings you back to beginning of current section.

Step 3: Fuel type choice (gaseous in this case). Step 4: Boiler type choice (steam in this case).

Step 5: Heat transfer medium choice (water in this case). Step 6: Enter absolute steam working pressure (if gage pressure is 9 bar the absolute
pressure is 10 bar).

Step 7: Boiler design choice. In this case it is 3-pass consisting of following sections: furnace Step 8: In this step general image of chosen boiler design is shown. Pressing Enter advances
(1st pass), tube set (2nd pass), front turnaround channel, 2nd tube set (3rd pass) and exit to next step.
channel with stack connector.

Step 9: Outdoor air temperature (temperature of air coming in boiler room). Step 10: Combustion air is not preheated in this case (if it is the software asks for additional
data).

Step 11: Rest oxygen in flue gas entry. It's the value displayed by flue gas analyzer and is used Step 12: Natural gas composition. Entering CH4 100% works satisfactory if exact analysis is not
to calculate excess air (lambda value). available.

Step 13: Enter gas data as displayed on gas gage (or using gas standard conditions - 0°C gas Step 14: Enter gas rate as displayed by gas gauge. Value corresponding to actual gas
temperarure, 0 mbar overpressure and 1.013 mbar atmospheric pressure). conditions on gas gauge shall be entered not recalculated to standard conditions (modern gas
gauges display both values).

http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 1/6
4/30/2018 BOILER DESIGN SOFTWARE

Step 15: Flue gas recirculation is not applied in this case (if it was software would ask for Step 16: Feed water temperature. Software displays saturated steam temperature calculated
additional data). from given steam pressure.

Step 17: Boiler load choice. It is important for calculation accuracy as different coefficients in Step 18: Enter furnace bottom area. Here so called jet impingement takes place, which
equation for heat transfer are used for various boiler loads. intensifies heat transfer. In so called dry back boilers furnace bottom area is 0 and no heat
transfer takes place there for it is not cooled.

Step 19: Enter wall thickness of furnace walls. Step 20: Enter furnace cylinder length as depicted in image.

Step 21: Enter furnace cylinder length as illustrated in image. Step 22: There is turnaround chamber at furnace rear. Image depicts this situation.

Step 23: Turnaround chamber is circular. Step 24: Enter length of turnaround chamber at furnace rear. Image illustrates it.

Step 25: Enter diameter of turnaround chamber at furnace rear. Image illustrates it. Step 26: Enter number of tubes in 1st tube set.

Step 27: Enter 1st tube set cooled length. Step 28: Enter tube inner diameter.

Step 29: Enter tube wall thickness. Step 30: There are no turbulence promoters in 1st tube set in this case.

Step 31: Enter length of front turnaround channel. Step 32: Enter front tubesheet cooled area.

http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 2/6
4/30/2018 BOILER DESIGN SOFTWARE

Step 34: Enter channel cross section in flue gas flow direction as shown in image.
Step 33: Enter front tubesheet wall thickness.

Step 35: In this case there is superheater in front turnaround channel. Step 36: Enter superheater design temperature. It is temperature to to which steam is to be
superheated.

Step 37: Enter superheater tube section length (image illustrates it). Step 38: Enter superheater tube outer diameter.

Step 39: Enter superheater tube wall thickness. Step 40: Enter superheater tubes arrangement (plain in this case-tubes in subsequent row are
in same line as those in preceding row).

Step 41: Enter number of superheater tubes in individual row. Software will determine needed Step 42: Enter distance between superheater tubes center lines. Note that smaller distance
number of tube rows and by that size of superheater to meet set superheated steam design between tubes results in higher the flue gas velocity between tubes, which leads to more
temperature (if it can not be reached software will inform about that in results). intense heat transfer and smaller size.

Step 43: Enter number of superheater tubes connected to manifold (in this case it is same as Step 44: Enter number of tubes in 2nd tube set.
number of tubes in row). This is needed to calculate steam velocity in tubes.

Step 45: Enter 2nd tube set cooled length. Step 46: Enter tube inner diameter.

Step 47: Enter tube wall thickness. Step 48: There are no turbulence promoters in tubes in 2nd tube set in this case.

Step 49: Exit channel is rectangular in this case (image may differ from actual case). Step 50: Enter cooled area in exit channel (actually net area of rear tubesheet).

http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 3/6
4/30/2018 BOILER DESIGN SOFTWARE

Step 51: Enter wall thickness in exit channel. Step 52: Enter length of exit channel.

Step 53: Enter exit channel cross section in flue gas direction. Step 54: Enter stack connector cross section area (needed to calculate static pressure drop
and flue gas velocity in it).

Step 56: Economizer tube section length.

Step 55: In this case boiler gas economizer attached.

Step 57: Enter economizer tube section length (image illustrates it). Step 58: Enter economizer tube outer diameter.

Step 59: Enter economizer tube wall thickness. Step 60: There are no fins on economizer tube (in case of solid fuel this question will not
appear).

Step 61: Enter economizer tubes arrangement (plain in this case-tubes in subsequent row are Step 62: Enter number economizer tubes in individual row.
in same line as those in preceding row).

Step 63: Enter distance between economizer tubes center lines. Note that smaller distance
between tubes results in higher the flue gas velocity between tubes, which leads to more
intense heat transfer and smaller size.

Step 65: Enter number of economizer tubes connected to manifold (in this case it is same as
number of tubes in row). This is needed to calculate water velocity in tubes.

Previous step was the last one in data entry process. Pressing Enter commences calculation Results display folows (provided geometry and operation data entered were correct and
process. around. Pressing Esc brings up Final menu. Move up and down with PgUp/PhDown, arrow
up/down keys, End key to jump to the end of results pages and Home to return to first results
page. Actual complete printout of results is shown at the bottom below.

http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 4/6
4/30/2018 BOILER DESIGN SOFTWARE

Final menu displays various options. Input data can be changed till results meet user desire. There are two graphs available.
Results can be saved to file in folder where main program was installed to
(c:\BoilerDesignSoftware). Choose file name with txt extension (test.txt).

Flue gas enthalpy diagram shows flue gases energy flow starting with enthalpy at adiabatic Flue gas temperature decrease in boiler diagram shows how flue gas temperature decreases
combustion temperature (temperature at which flue gases contain heat released from as gases pass over cooled area in boiler sections starting with adiabatic combustion
combustion). Pressing Enter brings back Graphs menu. temperature. First break represents furnace exit, second break represents exit from 1st tube
set (line drops there steeply because of superheater in turnaround channel). In reality line is
smooth (logarithmic).

HEAT TRANSFER IN FIRE TUBE BOILER (METRIC UNITS) HEAT TRANSFER IN FIRE TUBE BOILER (ENGLISH UNITS)
================================================ =================================================

DATE :SEPTEMBER 12,2016 DATE :SEPTEMBER 12,2016

SUBJECT:3-PASS FIRE TUBE BOILER SUBJECT:3-PASS FIRE TUBE BOILER
MAKE :- MAKE :-
REMARK :DEMO CALCULATION REMARK :DEMO CALCULATION

SUMMARY SUMMARY
_______ _______

TRANSFERRED HEAT IN BOILER = 15009.6 kW TRANSFERRED HEAT IN BOILER = 1531.1 HP

STEAM RATE = 22.4 t/h TRANSFERRED HEAT IN BOILER = 51.25 MMBTU/h
BOILER I/O EFFICIENCY (FUEL LHV) = 88.6 % STEAM RATE = 24.7 short tons/h
BOILER I/O EFFICIENCY (FUEL HHV) = 79.6 % BOILER I/O EFFICIENCY (FUEL HHV) = 79.6 %
WATER EXIT TEMP. FROM ECONOMIZER = 117.4 °C FLUE GAS EXIT TEMP. FROM ECONOMIZER= 308.1 F
FLUE GAS EXIT TEMP. FROM ECONOMIZER= 153.4 °C FEED WATER EXIT TEMP. FROM ECO. = 243.3 F
COMBUSTION AIR MASS RATE = 24056.98 kg/h COMBUSTION AIR RATE = 657207.9 st.cu.ft./h
RELEASED FLUE GAS MASS RATE = 27024.14 kg/h RELEASED FLUE GAS RATE = 724100.65 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 3.34 t/h CO2 MASS RATE IN FLUE GAS = 0 short tons/h
SUPERHEATED STEAM TEMPERATURE = 32 F
INPUT DATA
__________ INPUT DATA
__________
BOILER TYPE: STEAM
ABSOLUTE WORKING PRESSURE: 10 bar BOILER TYPE: STEAM
HEAT TRANSFER MEDIUM: WATER ABSOLUTE WORKING PRESSURE: 145 psi
BOILER FAMILY: FIRE TUBE HEAT TRANSFER MEDIUM: WATER
BOILER DESIGN: 3-PASS BOILER FAMILY: FIRE TUBE
BOILER LOAD: 100% BOILER DESIGN: 3-PASS
BOILER MATERIAL: CARBON STEEL BOILER LOAD: 100%
BOILER MATERIAL: CARBON STEEL
FUEL TYPE: GAS
FUEL TYPE: GAS
GAS DATA
________ GAS DATA
________
CH4-CONTENT = 100 vol%
CH4-CONTENT = 100 vol%
CONVERSION FACTOR TO NORM CONDITIONS= .9814
CONVERSION FACTOR TO NORM CONDITIONS= .9643
LOWER NORM HEATING VALUE = 35883 kJ/m3
LOWER NORM HEATING VALUE = 10 kWh/m3 LOWER NORM HEATING VALUE = 963.1 BTU/cu.ft.
HIGHER NORM HEATING VALUE= 1068.8 BTU/cu.ft.
HIGHER NORM HEATING VALUE= 39819 kJ/m3
HIGHER NORM HEATING VALUE= 11.1 kWh/m3 LOWER WOBBE INDEX = 4555.8 BTU/cu.ft.
HIGHER WOBBE INDEX = 5055.5 BTU/cu.ft.
LOWER WOBBE INDEX = 42413.3 kJ/m3
HIGHER WOBBE INDEX = 47065.6 kJ/m3 GAS NORM DENSITY = .045 lb/cu.ft.
GAS DENSITY ACTUAL = .043 lb/cu.ft.
GAS NORM DENSITY = .716 kg/m3 GAS OVERPRESSURE = .29 psi
GAS DENSITY ACTUAL = .69 kg/m3 ATMOSPHERIC PRESSURE= 14.7 psi
GAS OVERPRESSURE = .02 bar GAS TEMPERATURE = 50 F
ATMOSPHERIC PRESSURE= 1.013 bar
GAS TEMPERATURE = 10 °C GAS RATE= 60034.9 cu.ft./h

GAS RATE= 1700 m3/h OUTDOOR AIR TEMPERATURE = 59 F

FEED WATER TEMPERATURE = 221 F
OUTDOOR AIR TEMPERATURE = 15 °C REST O2 IN FLUE GAS = 3 %
FEED WATER TEMPERATURE = 105 °C EXCESS AIR/LAMBDA VALUE = 1.15 -
REST O2 IN FLUE GAS = 3 % TOTAL COOLED AREA IN BOILER= 4352.595 sq.ft.
EXCESS AIR/LAMBDA VALUE = 1.15 - TUBES/FURNACE AREA RATIO = 8.27
TOTAL COOLED AREA IN BOILER= 404.369 m2
TUBES/FURNACE AREA RATIO = 8.27 FURNACE GEOMETRY DATA
_____________________
FURNACE GEOMETRY DATA
_____________________ FURNACE IS HORIZONTAL
FURNACE IS CIRCULAR
FURNACE IS HORIZONTAL
FURNACE IS CIRCULAR FURNACE BOTTOM AREA = 40.903 sq.ft.
WALL THICKNESS = .984 in
FURNACE BOTTOM AREA = 3.8 m2 LENGTH IN FLUE GAS FLOW DIRECTION = 21.325 ft.
WALL THICKNESS = .025 m FURNACE COOLED AREA = 466.898 sq.ft.
LENGTH IN FLUE GAS FLOW DIRECTION = 6.5 m INNER DIAMETER = 59.055 in
FURNACE COOLED AREA = 43.376 m2
INNER DIAMETER = 1.5 m THERE IS CIRCULAR TURNAROUND CHAMBER AT FURNACE EXIT

THERE IS CIRCULAR TURNAROUND CHAMBER AT FURNACE EXIT TURNAROUND CHAMBER LENGTH = 3.281 ft.
INNER DIAM. OF TURNAROUND CHAMBER= 86.614 in
TURNAROUND CHAMBER LENGTH = 1 m TURNAROUND CHAMBER COOLED AREA = 137.193 sq.ft.
INNER DIAM. OF TURNAROUND CHAMBER= 2.2 m
FRONT TUBESHEET COOLED AREA = 12.746 m2 GEOMETRY DATA OF TUBE ASSEMBLY AFTER FURNACE
____________________________________________
GEOMETRY DATA OF TUBE ASSEMBLY AFTER FURNACE
____________________________________________ TUBES ARE HORIZONTAL

TUBES ARE HORIZONTAL NUMBER OF TUBES = 143

COOLED TUBE LENGTH = 21.325 ft.
NUMBER OF TUBES = 143 TUBE INNER DIAMETER= 2.461 in
COOLED TUBE LENGTH = 6.5 m TUBE WALL THICKNESS= .146 in
TUBE INNER DIAMETER= .0625 m COOLED AREA = 1964.487 sq.ft.
TUBE WALL THICKNESS= .0037 m
COOLED AREA = 182.507 m2 GEOMETRY DATA OF TURNAROUND CHANNEL
___________________________________
GEOMETRY DATA OF TURNAROUND CHANNEL
___________________________________ FRONT TUBESHEET COOLED AREA = 47.244 in
WALL THICKNESS = .866 in
FRONT TUBESHEET COOLED AREA = 1.2 m2 LENGTH IN GAS FLOW DIRECTION = 1.312 ft.
WALL THICKNESS = .022 m CROSS SECTION IN GAS FLOW DIRECTION= 29.063 sq.ft.
LENGTH IN GAS FLOW DIRECTION = .4 m
CROSS SECTION IN GAS FLOW DIRECTION= 2.7 m2 THERE IS SUPERHEATER IN TURNAROUND CHANNEL
TUBE ROWS HAVE PLAIN ARRANGEMENT
THERE IS SUPERHEATER IN TURNAROUND CHANNEL
TUBE ROWS HAVE PLAIN ARRANGEMENT SUPERHEATED STEAM DESIGN TEMPERATURE = 410 F
TUBE SECTION LENGTH = 3.281 ft.
SUPERHEATED STEAM DESIGN TEMPERATURE = 210 °C NEEDED TOTAL TUBE LENGTH = 1804.5 ft.
TUBE SECTION LENGTH = 1 m NEEDED TOTAL TUBE AREA = 706.751 sq.ft.
NEEDED TOTAL TUBE LENGTH = 550 m TUBE OUTER DIAMETER = 1.496 in
NEEDED TOTAL TUBE AREA = 65.7 m2 TUBE WALL THICKNESS = .118 in
TUBE OUTER DIAMETER = .038 m NUMBER OF TUBES IN ROW = 25
TUBE WALL THICKNESS = .003 m NEEDED NUMBER OF TUBE ROWS = 23
NUMBER OF TUBES IN ROW = 25 DISTANCE BETWEEN TUBES IN ROW = 3.937 in
NEEDED NUMBER OF TUBE ROWS = 23 NUMBER OF TUBES CONNECTED TO MANIFOLD= 25
DISTANCE BETWEEN TUBES IN ROW = .1 m
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25 GEOMETRY DATA OF SECOND TUBE ASSEMBLY
_____________________________________
GEOMETRY DATA OF SECOND TUBE ASSEMBLY
_____________________________________ TUBES ARE HORIZONTAL

TUBES ARE HORIZONTAL NUMBER OF TUBES = 118

COOLED TUBE LENGTH = 24.934 ft.
NUMBER OF TUBES = 118 TUBE INNER DIAMETER= 2.461 in
TUBE INNER DIAMETER= .0625 m TUBE WALL THICKNESS= .146 in
TUBE WALL THICKNESS= .0037 m COOLED AREA = 1895.376 sq.ft.
COOLED AREA = 176.086 m2
GEOMETRY DATA OF CHANNEL AT BOILER EXIT
GEOMETRY DATA OF CHANNEL AT BOILER EXIT _______________________________________
_______________________________________
CHANNEL IS RECTANGULAR
CHANNEL IS RECTANGULAR
COOLED AREA = 12.917 sq.ft.
COOLED AREA = 1.2 m2 WALL THICKNESS = .866 in
WALL THICKNESS = .022 m LENGTH IN GAS FLOW DIRECTION = 1.312 ft.
LENGTH IN GAS FLOW DIRECTION = .4 m CROSS SECTION IN GAS FLOW DIRECTION= 29.063 sq.ft.
CROSS SECTION IN GAS FLOW DIRECTION= 2.7 m2
GEOMETRY DATA OF TUBE ARRAY ECONOMIZER
GEOMETRY DATA OF TUBE ARRAY ECONOMIZER ______________________________________
______________________________________
TUBE ROWS ARE IN PLAIN ARRANGEMENT
TUBE ROWS HAVE PLAIN ARRANGEMENT
WATER TEMPERATURE ENTERING ECONOMIZER= 221 F
WATER TEMPERATURE ENTERING ECONOMIZER= 105 °C TUBE SECTION LENGTH = 7.874 ft.
TUBE SECTION LENGTH = 2.4 m TOTAL TUBE LENGTH = 3937.008 ft.
TOTAL TUBE LENGTH = 1200 m TOTAL TUBE AREA = 1228.913 sq.ft.
TOTAL TUBE AREA = 113.1 m2 TUBE OUTER DIAMETER = 1.181 in
TUBE OUTER DIAMETER = .03 m TUBE WALL THICKNESS = .118 in
TUBE WALL THICKNESS = .003 m NUMBER OF TUBES IN ROW = 20
NUMBER OF TUBES IN ROW = 20 NUMBER OF TUBE ROWS = 25
NUMBER OF TUBE ROWS = 25 DISTANCE BETWEEN TUBES IN ROW = 3.937 in
DISTANCE BETWEEN TUBES IN ROW = .1 m NUMBER OF TUBES CONNECTED TO MANIFOLD= 25
NUMBER OF TUBES CONNECTED TO MANIFOLD= 25
STACK CONNECTOR CROSS SECTION AREA= 5.382 sq.ft.
STACK CONNECTOR CROSS SECTION AREA= .5 m2
CALCULATION RESULTS (CLEAN SURFACES ASSUMED)
CALCULATION RESULTS (CLEAN SURFACES ASSUMED) ____________________________________________
____________________________________________
ADIABATIC COMBUSTION TEMPERATURE = 3202.4 F
ADIABATIC COMBUSTION TEMPERATURE = 1761 °C
COMBUSTION AIR RATE = 657207.9 st.cu.ft./h
COMBUSTION AIR RATE = 18605.56 mn3/h COMBUSTION AIR MASS RATE = 53047.37 lb/h
COMBUSTION AIR MASS RATE = 24056.98 kg/h COMBUSTION AIR RATE AT GIVEN TEMP. = 657207.9 cu.ft./h
COMBUSTION AIR RATE AT GIVEN TEMP. = 18605.56 m3/h RELEASED FLUE GAS RATE = 724100.65 st.cu.ft./h
RELEASED FLUE GAS RATE = 20499.29 mn3/h RELEASED FLUE GAS MASS RATE = 59590.17 lb/h
RELEASED FLUE MASS GAS RATE = 27024.14 kg/h FLUE GAS NORM DENSITY = .082 lb/cu.ft.
FLUE GAS NORM DENSITY = 1.32 kg/m3 FLUE GAS RATE AT STACK TEMPERATURE = 1130965.17 cu.ft./h
FLUE GAS RATE AT BOILER EXIT TEMP. = 32017.62 m3/h DEW POINT OF WATER VAPOR IN FLUE GAS= 135.06 F
DEW POINT OF WATER VAPOR IN FLUE GAS= 57.26 °C CONDENSATE (LATENT) HEAT = 194.06 HP
CONDENSATE (LATENT) HEAT = 1902.32 kW CONDENSATE (LATENT) HEAT = 6.5 MMBTU/h
CONDENSATE MASS RATE IN FLUE GAS = 2888.51 kg/h CONDENSATE MASS RATE IN FLUE GAS = 6369.36 lb/h
CO2 RATE IN FLUE GAS = 1700 mn3/h CO2 RATE IN FLUE GAS = 60049.45 st.cu.ft./h
CO2 MASS RATE IN FLUE GAS = 3338 kg/h CO2 MASS RATE IN FLUE GAS = 7360.54 lb/h
SPECIFIC CO2 EMISSION = 1.96 kg/m3 SPECIFIC CO2 EMISSION = 1.96 lb/st.cu.ft.
CO2 CONCENTRATION IN FLUE GAS = 8.29 vol% CO2 CONCENTRATION IN FLUE GAS = 8.29 vol%
MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol% MAX. CO2 CONCENTRATION IN FLUE GAS = 11.73 vol%
H2O RATE IN FLUE GAS = 3593.73 mn3/h H2O RATE IN FLUE GAS = 126942.19 st.cu.ft./h
WATER MASS RATE DELIVERED WITH AIR = 13.93 kg/h WATER MASS RATE DELIVERED WITH AIR = 30.72 lb/h
H2O CONCENTRATION IN FLUE GAS = 17.53 vol% H2O CONCENTRATION IN FLUE GAS = 17.53 vol%
N2 RATE IN FLUE GAS = 14698.39 mn3/h N2 RATE IN FLUE GAS = 519194.25 st.cu.ft./h
N2 CONCENTRATION IN FLUE GAS = 71.7 vol% N2 CONCENTRATION IN FLUE GAS = 71.7 vol%
O2 RATE IN FLUE GAS = 507.17 mn3/h O2 RATE IN FLUE GAS = 17914.75 st.cu.ft./h
O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol% O2 CONCENTRATION IN FLUE GAS (WET) = 2.47 vol%

STEAM TEMPERATURE IN BOILER = 179.9 °C STEAM TEMPERATURE IN BOILER = 355.8 F

VELOCITY IN BOILER FLUE APERTURE = 17.8 m/s VELOCITY IN BOILER FLUE APERTURE = 58.36 ft/s
STATIC PRESSURE DROP IN BOILER = 22.55 mbar STATIC PRESSURE DROP IN BOILER = 9.05 inWC
STATIC PRESSURE DROP WITH ECONOMIZER = 23.1 mbar STATIC PRESSURE DROP WITH ECONOMIZER = 9.27 inWC
TRANSFERRED HEAT = 15009.6 kW TRANSFERRED HEAT = 1531.1 HP
STEAM RATE = 22424.4 kg/h STEAM RATE = 49447.4 lb/h
FEED WATER RATE = 23488.3 l/h STEAM RATE = 24.7 short tons/h
AREA THERMAL LOAD = 35.96 kW/m2 FEED WATER RATE = 6204.96 gal/h
PART OF HEAT TAKEN UP BY FURNACE WALLS= 38.16 % HEAT TRANSFER INTENSITY = 2.934 sq.ft./HP
FLUE GAS TEMPERATURE FROM BOILER = 194.6 °C PART OF HEAT TAKEN UP BY FURNACE WALLS= 38.16 %
FLUE GAS TEMPERATURE FROM BOILER = 382.3 F
TRANSFERRED HEAT IN ECONOMIZER = 327.6 kW
FLUE GAS EXIT TEMP. FROM ECONOMIZER = 153.4 °C TRANSFERRED HEAT IN ECONOMIZER = 33.4 HP
http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 5/6
4/30/2018 BOILER DESIGN SOFTWARE

WATER EXIT TEMP. FROM ECONOMIZER = 117.4 °C TRANSFERRED HEAT IN ECONOMIZER = 1.12 MMBTU/h
STATIC PRESSURE DROP IN ECONOMIZER = .55 mbar FLUE GAS EXIT TEMP. FROM ECONOMIZER = 308.1 F
WATER EXIT TEMPERATURE FROM ECONOMIZER= 243.3 F
BOILER I/O EFFICIENCY (FUEL LHV)= 88.6 % STATIC PRESSURE DROP IN ECONOMIZER = .22 inWC

HEAT BALANCE BOILER I/O EFFICIENCY (FUEL HHV)= 79.6 %

____________
HEAT BALANCE
DELIVERED HEAT WITH FUEL = 16945 kW ____________
TRANSFERRED HEAT IN BOILER= 15010 kW
DISSOCIATION LOSS = 754 kW DELIVERED HEAT WITH FUEL = 1922.6 HP
DISSOCIATION LOSS = 4.45 % DELIVERED HEAT WITH FUEL = 64.36 MMBTU/h
STACK LOSS = 1081 kW TRANSFERRED HEAT IN BOILER= 1531.1 HP
STACK LOSS = 6.38 % TRANSFERRED HEAT IN BOILER= 51.25 MMBTU/h
BOILER JACKET LOSSES (est)= 85 kW DISSOCIATION LOSS = 76.9 HP
BOILER JACKET LOSSES (est)= .5 % DISSOCIATION LOSS = 2.57 MMBTU/h
UNACCOUNTED LOSS = 15.2 kW DISSOCIATION LOSS = 4 %
UNACCOUNTED LOSS = .09 % STACK LOSS = 304.4 HP
STACK LOSS = 10.19 MMBTU/h
HEAT TRANSFER IN FURNACE STACK LOSS = 15.83 %
________________________ BOILER JACKET LOSSES (est)= 9.6 HP
BOILER JACKET LOSSES (est)= .32 MMBTU/h
FLUE GAS EXIT TEMPERATURE = 1110.7 °C BOILER JACKET LOSSES (est)= .5 %
MEAN FLUE GAS TEMPERATURE = 1411.1 °C UNACCOUNTED LOSS = 1.6 HP
THERMAL RADIATION = 4398.5 kW UNACCOUNTED LOSS = .05 MMBTU/h
CONVECTION = 2885.7 kW UNACCOUNTED LOSS = .08 %
HEAT TRANSFERRED TO WALLS = 7284.2 kW
AREA THERMAL LOAD = 167.93 kW/m2 HEAT TRANSFER IN FURNACE
VOLUME THERMAL LOAD = 1114.99 kW/m3 ________________________
FLUE GAS VELOCITY = 19.88 m/s
FLUE GAS EXIT TEMPERATURE = 2031.3 F
HEAT TRANSFER ON FURNACE BOTTOM= 1906.1 kW MEAN FLUE GAS TEMPERATURE = 2572 F
WALL TEMP. ON FLUE GAS SIDE = 478.3 °C VOLUME THERMAL LOAD = 3.22 HP/cu.ft.
HEAT TRANSFER INTENSITY = .628 sq.ft./HP
HEAT TRANSFER ON CIRCULAR PART = 4328.9 kW THERMAL RADIATION = 448.7 HP
WALL TEMP. ON FLUE GAS SIDE = 261.9 °C CONVECTION = 294.4 HP
HEAT TRANSFERRED TO WALLS = 743.1 HP
HEAT TRANSFER IN FURNACE TURNAROUND CHAMBER GAS VELOCITY = 65.217 ft/s

HEAT TRANSFER ON CIRCULAR PART = 817.4 kW HEAT TRANSFER ON FURNACE BOTTOM= 194.4 HP
WALL TEMP. ON FLUE GAS SIDE = 249.7 °C WALL TEMP. ON FLUE GAS SIDE = 892.9 F
HEAT TRANSFER ON INNER TUBESHEET= 231.8 kW
WALL TEMP. ON FLUE GAS SIDE = 248 °C HEAT TRANSFER ON CIRCULAR PART = 441.6 HP
WALL TEMP. ON FLUE GAS SIDE = 295.7 F
HEAT TRANSFER IN TUBE ASSEMBLY AFTER FURNACE
____________________________________________ HEAT TRANSFER IN FURNACE TURNAROUND CHAMBER

FLUE GAS EXIT TEMPERATURE = 323.5 °C HEAT TRANSFER ON CIRCULAR PART = 83.4 HP
MEAN FLUE GAS TEMPERATURE = 638.2 °C WALL TEMP. ON FLUE GAS SIDE = 481.5 F
AREA THERMAL LOAD = 39.18 kW/m2 HEAT TRANSFER ON INNER TUBESHEET= 23.6 HP
FLUE GAS VELOCITY = 43.32 m/s WALL TEMP. ON FLUE GAS SIDE = 478.5 F
THERMAL RADIATION = 640.1 kW
CONVECTION = 6510.8 kW HEAT TRANSFER IN TUBE ASSEMBLY AFTER FURNACE
HEAT TRANSFERRED = 7150.9 kW ____________________________________________
WALL TEMP. ON FLUE GAS SIDE= 187.4 °C
STATIC PRESSURE DROP = 11 mbar FLUE GAS EXIT TEMPERATURE = 614.3 F
MEAN FLUE GAS TEMPERATURE = 1180.7 F
HEAT TRANSFER IN TURNAROUND CHANNEL HEAT TRANSFER INTENSITY = 2.693 sq.ft./HP
___________________________________ FLUE GAS VELOCITY = 142.128 ft/s
THERMAL RADIATION = 65.3 HP
FLUE GAS EXIT TEMPERATURE = 266.2 °C CONVECTION = 664.2 HP
MEAN FLUE GAS TEMPERATURE = 294 °C HEAT TRANSFERRED = 729.5 HP
FLUE GAS VELOCITY = 4.38 m/s WALL TEMP. ON FLUE GAS SIDE= 369.3 F
THERMAL RADIATION = 1.01 kW STATIC PRESSURE DROP = 4.41 inWC
CONVECTION = 1.93 kW
HEAT TRANSFERRED TO WALLS = 2.94 kW HEAT TRANSFER IN TURNAROUND CHANNEL
WALL TEMP. ON FLUE GAS SIDE= 183.6 °C ___________________________________

HEAT TRANSFER ON SUPERHEATER FLUE GAS EXIT TEMPERATURE = 511.2 F

MEAN FLUE GAS TEMPERATURE = 561.1 F
SUPERHEATED STEAM TEMPERATURE = 210 °C FLUE GAS VELOCITY = 14.369 ft/s
FLUE GAS EXIT TEMPERATURE = 268.1 °C THERMAL RADIATION = .1 HP
THERMAL RADIATION = 26.4 kW CONVECTION = .2 HP
CONVECTION = 441.8 kW HEAT TRANSFERRED TO WALLS = .3 HP
HEAT TRANSFERRED = 468.2 kW WALL TEMP. ON FLUE GAS SIDE= 362.48 F
STEAM VELOCITY IN TUBES = 62.89 m/s
FLUE GAS VELOCITY AROUND TUBES= 7.46 m/s HEAT TRANSFER ON SUPERHEATER
WALL TEMP. ON FLUE GAS SIDE = 217.1 °C
STATIC PRESSURE DROP = .76 mbar SUPERHEATED STEAM TEMPERATURE = 410 F
FLUE GAS EXIT TEMPERATURE = 32 F
HEAT TRANSFER IN SECOND TUBE ASSEMBLY THERMAL RADIATION = 2.69 HP
_____________________________________ CONVECTION = 45.07 HP
HEAT TRANSFERRED = 47.76 HP
FLUE GAS EXIT TEMPERATURE = 194.5 °C STEAM VELOCITY IN TUBES = 206.317 ft/s
MEAN FLUE GAS TEMPERATURE = 228.5 °C FLUE GAS VELOCITY AROUND TUBES= 24.474 ft/s
AREA THERMAL LOAD = 3.37 kW/m2 WALL TEMP. ON FLUE GAS SIDE = 422.8 F
FLUE GAS VELOCITY = 28.9 m/s STATIC PRESSURE DROP = .31 inWC
THERMAL RADIATION = 14.5 kW
CONVECTION = 578.6 kW HEAT TRANSFER IN SECOND TUBE ASSEMBLY
HEAT TRANSFERRED = 593.1 kW _____________________________________
WALL TEMP. ON FLUE GAS SIDE= 182.6 °C
STATIC PRESSURE DROP = 9.71 mbar FLUE GAS EXIT TEMPERATURE = 382.2 F
MEAN FLUE GAS TEMPERATURE = 443.3 F
HEAT TRANSFER IN CHANNEL AT BOILER EXIT HEAT TRANSFER INTENSITY = 31.327 sq.ft./HP
_______________________________________ FLUE GAS VELOCITY = 94.802 ft/s
THERMAL RADIATION = 1.5 HP
FLUE GAS EXIT TEMPERATURE = 194.6 °C CONVECTION = 59 HP
MEAN FLUE GAS TEMPERATURE = 194.6 °C HEAT TRANSFERRED = 60.5 HP
AREA THERMAL LOAD = .004 kW/m2 WALL TEMP. ON FLUE GAS SIDE= 360.7 F
FLUE GAS VELOCITY = 3.61 m/s STATIC PRESSURE DROP = 3.9 inWC
THERMAL RADIATION = 0 kW
CONVECTION = .005 kW HEAT TRANSFER IN CHANNEL AT BOILER EXIT
HEAT TRANSFERRED TO WALLS = .005 kW _______________________________________
WALL TEMP. ON FLUE GAS SIDE= 194.9 °C
FLUE GAS EXIT TEMPERATURE = 382.3 F
HEAT TRANSFER ON TUBE ARRAY ECONOMIZER MEAN FLUE GAS TEMPERATURE = 382.2 F
______________________________________ FLUE GAS VELOCITY = 11.851 ft/s
THERMAL RADIATION = 0 HP
WATER EXIT TEMPERATURE = 117.4 °C CONVECTION = .001 HP
MEAN FLUE GAS TEMPERATURE = 173.2 °C HEAT TRANSFERRED TO WALLS = .001 HP
FLUE GAS EXIT TEMPERATURE = 153.4 °C WALL TEMP. ON FLUE GAS SIDE= 382.8 F
THERMAL RADIATION = 19.2 kW
CONVECTION = 308.4 kW HEAT TRANSFER ON TUBE ARRAY ECONOMIZER
HEAT TRANSFERRED = 327.6 kW ______________________________________
WATER VELOCITY IN TUBES = .581 m/s
FLUE GAS VELOCITY AROUND TUBES= 2.75 m/s WATER EXIT TEMPERATURE = 243.3 F
WALL TEMP. ON FLUE GAS SIDE = 118.3 °C MEAN FLUE GAS TEMPERATURE = 343.7 F
STATIC PRESSURE DROP = .55 mbar FLUE GAS EXIT TEMPERATURE = 308.1 F
THERMAL RADIATION = 2 HP
CONVECTION = 31.5 HP
HEAT TRANSFERRED = 33.4 HP
WATER VELOCITY IN TUBES = 1.907 ft/s
FLUE GAS VELOCITY AROUND TUBES= 9.007 ft/s
WALL TEMP. ON FLUE GAS SIDE = 245 F
STATIC PRESSURE DROP = .22 inWC

http://boilerdesignsoftware.com/SampleCalculations/3-passFireTubeBoilerSample.html 6/6