Vapor Power Circulatic Steam Generator Installation Manual
STEAM GENERATORScirculatic steam generatorsinstallation manualVAPOR POWER INTERNATIONAL551 S. County Line Rd. Franklin Park, IL 60131P: 630.694.5500 F: 630.694.2230 VaporPower.com
Revised July 2005Printed in U.S.A.Bulletin No.TWM5-AM-2CIRCULATICTABLE OF CONTENTSSectionPage No.List of Figures .2List of Tables .21.0Introduction .32.0Lifting and Handling .43.0Installation .84.0Mounting .95.0Clearances .106.0Combustion and Ventilation Air Requirements.127.0Stack Installation .138.0Steam Output .179.0Feedwater System.199.1Feedwater Supply .199.2Feedwater Treatment .299.3Prevention of Scale Formation .299.4Prevention of Boiler Corrosion .329.5Water Sampling .359.6Water Analysis .369.7Testing Water Samples .3810.0 Fuel Supply .3910.1 Gas Fired Boilers .3910.2 Oil Fired Boilers (Distillate) .4310.3 Oil Fired Boilers (Residual) .4911.0 Pilot Burner Gas Requirements .5112.0 Compressed Air Requirements .5212.1 Instrument Air .5212.2 Atomizing Air .5213.0 Power Supply Requirements .5314.0 Cooling Water Requirements.5615.0 Steam Piping .5916.0 Safety Valve Piping .6217.0 Blowdowns .6317.1 Bottom Blowdown (Drum) .6317.2 Surface Blowdown (Drum) .6317.3 Water Level Control Blowdown .6518.0 New Unit Storage .66CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 1
LIST OF FIGURESFigurePage No.1Lifting by Crane .52Lifting by Forklift .63Transporting by Rollers .74Boiler Clearance Dimensions .105Recommended Stack Installation .146Exhaust Stack Installation through Combustible Roof .157Stack Installation with Horizontal Run .168Stack Rain Cone .169Factors of Evaporation .1810Water Tank Installation .1911Centrifugal Pump Installation .2112Turbine Pump Installation .2113Centrifugal Pump Selection .2314Turbine Pump Selection .2615Daily Boiler Log .3016Boiler Water Treatment Log.3117Oxygen Solubility .3318Typical Pump Piping .3519Gas Regulator Installation (For Two Regulators) .4120Typical Gas Supply System .4221“Open” Loop Fuel Oil Piping Arrangement .4522“Closed” Loop Final Oil Piping Arrangement .4623Typical Oil and Atomizing Air Supply System (Distillate) . 4824Typical Oil and Atomizing Air Supply System (Residual) . 5025Cooling Water Requirements.5626Seal Flush Piping Arrangement .5727Typical Safety Valve Piping .6228Simultaneous Surface and Bottom Blowdown Arrangement . 6429Piping Arrangement for Continuous Surface Blowdown . 6430Typical Boiler Installation . 67/68LIST OF TABLESTable12345678910111213141516Page No.Approximate Shipping Weights .4Clearance Dimensions .10Minimum Air Requirements .12Stack Requirements .13Equivalent Evaporation .17Recommended Feedwater Reserves & Tank Sizes .20Feedwater Pump Requirements .24Boiler Feedwater Requirements .36Boiler Drum Water Requirements .36Condensate Return Water Requirements .37Boiler Natural Gas Requirements .39Boiler Fuel Oil Requirements .43Fuel Atomizing Air Requirements .52Drive Motors And Boiler Feeder Line Sizes .53Kva Draw for Circulatic Boilers .55Boiler Steam Connection Sizes .60CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 2
1.0INTRODUCTION1.1The Vapor Power Circulatic is a forced circulation packaged watertube boiler thatemploys a low volume water coil as the heat exchange element. Its axis and the axis ofthe combustion system is positioned horizontally. The entire boiler assembly is mountedon a structural steel skid. All operating components and safety controls required by thegoverning body which has jurisdiction over the boiler installation (e.g. ASME, CGA, F.M.,I.R.I., NFPA, et al) are provided on the Circulatic assembly. Electrical wiring, fire testingand factory adjustments are complete.1.2This manual contains many helpful suggestions and recommendations for the properinstallation of piping, wiring, stack arrangements, and various other factors that shouldbe considered for a good installation. A well planned installation is essential to achievemaximum efficiency, ease of maintenance, and extended service life from the boiler.Figure 30 (page 67/68) illustrates a typical boiler installation of a unit that may be firedwith either gas or oil.1.3IN ORDER TO PREVENT DAMAGE THAT MAY OCCUR FROM FREEZING, STOREUNITS INDOORS IN A HEATED ENVIRONMENT WHERE TEMPERATURES REMAINABOVE FREEZING AT ALL TIMES.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 3
2.0LIFTING AND HANDLING2.1One of the more important steps of the installation is the careful handling of the boiler asit is moved to the installation site. Careless and rough handling can damage manycomponents that would then impair the operation of the unit or its appearance. VaporPower recommends that experienced riggers handle the packaged unit.2.2Inspect the boiler upon its arrival and make any claims for damage to the carrier withinthe allowable time limit. Vapor Power is not responsible for damage caused in transit.Inspect the boiler again after the riggers have moved it into place so that any damageclaims may be filed against them at this time. Notify Vapor Power immediately should apart be damaged so that a replacement can be obtained before start up.CAUTIONIf the boiler has timbers fastened across the skids do notremove them until the boiler is in place permanently.2.3Table 1 lists the various basic Circulatic boiler models, their approximate maximumshipping weights, and their approximate floor loadings. These weights do not includeauxiliary equipment.Table 1. Approximate Shipping WeightsModelFloorApproximateSizeLoad (wet)Shipping 036,000CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 4
2.4Boilers are built on a fabricated steel skid. BHP sizes up to and including 500 BHP havean optional two-piece skid that may be separated, and certain piping items andaccessories removed, to reduce clearance width if space restrictions are encountered.BHP size 600 is constructed on a one-piece skid only. Any Circulatic boiler may be liftedand/or moved by transporting it with an overhead crane, a forklift truck, or by rollers (ordollies) across a level floor. Never raise the boiler from one corner only; be sure it isalways raised evenly. When lifting one end only, both corners should be raiseduniformly.2.5LIFTING BY CRANEFigure 1 illustrates a method of attaching a sling for lifting the boiler from a single point.For boiler sizes up to and including 450 BHP, holes, 2-1/2 inches in diameter, areprovided on each end of the boiler skid for the insertion of lifting bars to which slings maybe attached. Vapor Power recommends that the lifting bars be a minimum of 2-1/4inches diameter and extend beyond the boiler skid a sufficient length so that slings donot apply stress to piping, the boiler casing, controls or accessories. Use spreader barsto prevent damage to the boiler when lifting. Apply collars or other type retainers toprevent the slings from slipping over the ends of the lifting bars.For 500 and 600 BHP sizes, lifting eyes are provided that are removable when theinstallation is complete. Some riggers prefer to use two cranes for lifting, one attachedto each end of the boiler.USE SPREADER BARS TOPREVENT LIFTING SLINGSFROM CRUSHING BOILERDRUMSTACKFigure 1. Lifting by CraneCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 5
2.6LIFTING BY FORKLIFTFigure 2 illustrates how lifting forks may be inserted under the fabricated skid to liftboilers up to and including 500 BHP size. Five inches of clearance are provided forinsertion of the forks. The boiler may be lifted from either end but forks inserted from theend opposite the burner is the most preferable. Forks should be at least eight feet longand adequate strength to lift the boiler (see Table 1). Vapor transports the boiler throughits shop using a heavy duty pallet truck that lifts both ends of its forks uniformly.Due to the length and weight of the 600 BHP size lifting by a single forklift is usuallyimpractical. Two forklifts (or pallet trucks) may be used with forks inserted from eachend.STACKDRUMCLFigure 2. Lifting by ForkliftCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 6
2.7TRANSPORTING BY ROLLERSFigure 3 illustrates how rollers may be placed to move the boiler from one location toanother across a level floor. Vapor Power recommends that at least four rollers be used,a minimum of 2 inches diameter, spaced equidistantly along the boiler skid length.DRUMSTACKFigure 3. Transporting by RollersCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 7
3.0INSTALLATION3.1Local authorities and your insurance company have jurisdiction over the installation ofthe boiler, related equipment and stack. They should be consulted before the installationis started, and any permits needed should be obtained.3.2Many insurance companies require boiler installations to be in accordance with theNational Fire Protection Association (NFPA). Listed below are two of the applicablestandards.3.33.2.1NFPA STANDARD NO. 54, NATIONAL FUEL GAS CODE3.2.2NFPA STANDARD NO. 31, INSTALLATION OF OIL-BURNINGEQUIPMENT3.2.3Other applicable standards should be consulted as necessary. These maybe determined by contacting the NFPA office in Quincy, MA 02269.Installations in Canada must comply with Canadian Gas Association (CSA) Codes listedfor oil, natural gas or propane appliances or equipment. Applicable ProvincialRegulations should be carefully followed in all cases. As noted in paragraph 3.1,authorities having jurisdiction should be consulted before installations are started. Listedbelow are two applicable standards.3.3.1Gas equipment must be installed in accordance with current CSA standardCAN1-B149 “Installation Codes for Gas Burning Appliances and Equipment”.3.3.2Oil equipment must be installed per current Canadian Standards Association(C.S.A.) standard B139 “Installation Code for Oil Burning Equipment”.3.4Consult your gas supplier regarding inlet gas pressure and capacity (CFM).3.5The contractor/installer should identify all emergency gas, oil and electrical shut offdevices upon completion of the installation.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 8
4.0MOUNTING4.1No special masonry support is necessary except to keep the boiler level. The boiler ismounted on a heavy structural steel base but MUST BE LEVEL. If necessary, level theboiler with shims and grout with stiff cement. Make sure the base is in contact with floorat all points. The floor loading will be approximately as indicated in Table 1. Check yourbuilding specifications for the permissible floor loading.4.2Secure the boiler with bolts through the mounting holes in the skid. Bolts should be nolarger than 3/4” diameter to allow for tolerances in the mounting hole and bolt locations.4.3The boiler must be mounted on a floor of noncombustible material that is pitched towarda sewer to provide for drainage.4.4Some customers prefer to elevate the boiler as additional protection from drainage or tofacilitate installation. A concrete pad (see Figure 1) approximately four inches thick isthe usual practice in such instances.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 9
5.05.1CLEARANCESTable 2, as illustrated by Figure 4, gives the dimensions Vapor Power considers asminimum to provide reasonable accessibility for maintenance work on the heatingsurfaces; removal of burners and combustion components; replacing working parts; andfor adjusting, cleaning, and lubricating parts which require attention.CSTACKDRUMEDABFigure 4. Boiler Clearance DimensionsTable 2. Clearance DimensionsModel 50500600* 48 inches when area is used as an aisleCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 10D*E*123636
5.2The authority having jurisdiction over the boiler installation to determine acceptabilitymay be Federal, state, local or insurance company. Any of these organizations maybase their acceptance on compliance with the standards of the National Fire ProtectionAssociation (NFPA). In the absence of other standards Vapor Power recommendsclearance spacings as presented in NFPA standard No. 31, Installation of Oil-BurningEquipment. Where the jurisdiction standards are in conflict with Table 2 the varianceshould always be on the side for safety.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 11
6.06.1COMBUSTION AND VENTILATION AIR REQUIREMENTSTable 3 lists the minimum combustion air requirements per boiler.Table 3. Minimum Air RequirementsModelCombustionSizeAir 33002663350311240036004504050500425060051006.2The boiler room must be properly ventilated. Lack of adequate combustion air will resultin smoke and sooted heat transfer surfaces. Accumulation of hot air (125 F max.) nearthe boiler can cause overload elements to trip, relay malfunctions and other componentfailures that will disrupt the operation of the boiler(s).6.3Some building codes, e.g. the National Fire Protection Association (NFPA) specify thenumber and size of air supply vent openings required, depending upon the type of fuelused and the type of enclosure in which the boiler is to be located. Before installing theboiler the authority having jurisdiction over the installation should be consulted. In theabsence of a jurisdictional authority, Vapor Power recommends that the requirements ofNFPA be met.6.4Some jurisdictional authorities may approve the use of blowers to supply sufficient air tothe boiler room in lieu of ventilation openings. If the air supply is dependent upon ablower, an interlock switch should be provided to prevent the boiler from firing if theblower fails.6.5When the boiler enclosure room contains exhaust fans, the size of vent openings, or theair makeup blower, must be increased to compensate for the cubic feet per minute of airbeing exhausted. The increase will be dependent upon the capacity of the fans.6.6A method of heating the boiler room, water piping, and the system equipment should beprovided in the event the boiler is shut down and the ambient temperatures are belowfreezing.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 12
7.0STACK INSTALLATION7.1The Vapor Circulatic boiler has a forced draft combustion system that is supplied by itsown blower; therefore the stack installation does not need to add draft through the boiler.However, the boiler blower is not designed to overcome positive stack pressures;therefore, the stack should be of sufficient size to provide free discharge of exhaustgases without back pressure.7.2Ideally, stack draft at the boiler outlet should be maintained at 0 to –.05 inches of watercolumn at all boiler firing rates. Stack draft should not be more negative than –0.3 in.W.C. when the boiler is operating at high fire and the stack temperature has reached asteady value.7.3In areas where unusually high draft conditions prevail a method of reducing the draft isnecessary. An orifice, barometric damper or adjustable damper must then be installed inthe exhaust stack to reduce the draft to the limits indicated in paragraph 7.2.7.4The ideal draft regulator is an electric or hydraulic automatic positioning type. Theseregulators maintain a constant draft on the boiler under all variances of boiler firing ratesand atmospheric conditions. The next best draft regulator is a barometric damper whichis in common use in many boiler installations. When it is necessary to increase draftfrom what is available the height of the stack must be increased or an induced draft faninstalled in the exhaust system.7.5If more than one boiler is to be connected to a single main stack, the cross sectionalarea of the main stack must be equal to, or greater than, the sum of the areas of allconnecting stacks. See Table 4 for the stack requirements of the various model sizes 500600CIRCULATIC INSTALLATION MANUAL 2015.DOCTable 4. Stack RequirementsStackStackDiameterArea(In. O.D.)(Sq. 861532798Page 13
7.6The best stack installation is one that is supported independent of the boiler and runstraight up to the outside with drainage provided at the bottom. The boiler connectingstack is then brought into the main stack not less than 45 above horizontal. All stacksshould be at least 5 feet above any wind obstructions and not less than 10 feet abovethe roof (see Figure 5). The next best stack installation is one which is vertical directlyup from the boiler that is supported independent of the boiler also.STACKRAINCONE5'WIND OBSTRUCTION10'THIMBLESUPPORTSTRAP45 ORGREATERDRAWBANDBAROMETRICDAMPERDRAINFigure 5. Recommended Stack InstallationCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 14
7.7Some Building Codes, e.g. National Fire Protection Association (NFPA) and/or CanadianStandards Association (CSA) and/or others, require that where a metal stack passesthrough a combustible roof such roof shall be guarded by a metal sleeve or thimble oftheir specific dimensions. In the absence of any jurisdictional requirements Vapor Powerrecommends that such a thimble be used that extends not less than nine inches aboveand below the roof and provide not less than eighteen inches clearance on all sides ofthe stack. (See Figure 6.)EXHAUST STACK14 GA. MINIMUMCOMBUSTIBLEROOF9"18"9"DFigure 6. Exhaust Stack Installation Through Combustible Roof7.8Horizontal runs in the stack, when necessary should be pitched up 1/4 inch per foot, andthe diameter of the pipe should be increased 5% over the preceding pipe diameter ateach 10 foot interval in the horizontal run. A 10% increase in pipe diameter over thepreceding diameter must be made at each elbow. (See Figure 7.) Horizontal runsshould be provided with a clean out door. Round stacks and breeching are preferred.7.9The stack should be designed with the required bracing, or hangers to be selfsupporting. (See Figure 5.) A section of the stack should be removable to permitinspection for corrosion and soot buildup. An inspection door or panel may be inserted ifremoval of a section of the stack will be difficult. The minimum recommended materialthickness for stacks and breeching is 14 gauge.7.10The stack should be protected against down drafts, back drafts, and rain with a simpleflat or cone-shaped cap. (See Figure 8.) Make sure the area between the cap andstack is at least equal to the area of the stack. Protect all steel work from corrosion.7.11In cold climate regions and/or regions of high humidity, a shutoff damper must beinstalled in each stack. When closed, the shutoff damper will prevent the boiler coilsfrom freezing or sweating by outside air that is drawn into the boiler when it is shutdown.This is applicable to a boiler installation with multiple stacks or an installation with asingle stack in a building with depressed atmospheric pressure.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 15
5% INCREASE IN DIAMETERWINDCOMBUSTIBLE ROOF10% INCREASEIN DIA.DRAIN1/4" PER FOOTSUITABLE BEND5% INCREASEIN DIA.CLEAN SUITABLE BENDOUT10% INCREASEIN DIA.Figure 7. Stack Installation with Horizontal Run2D7/8 D3/16 DD3D2D4DFigure 8. Stack Rain ConeCIRCULATIC INSTALLATION MANUAL 2015.DOCPage 16
8.08.1STEAM OUTPUTAn adequate supply of water must be available to operate the boiler. Table 5 indicatesthe equivalent evaporation rates of various boiler models rated from and at 212 F.Table 5. Equivalent Evaporation8.2Model Size(BHP)Evaporation Lbs./Hr.(From and at 212 l evaporation rates or steam output, depend upon the feedwater (water enteringthe boiler) temperature and the boiler operating pressure. To determine your actualevaporation refer to Figure 9 and follow the example below.If you have a 300 BHP boiler operating at 100 psig with 200 F feedwater, enter Figure 9at the 100 psig point and proceed upward until that grid intersects the curve for 200 Ffeedwater. Read the scale at left which indicates an actual evaporation of 32.8 poundsof steam per boiler horsepower. Multiplying by 300 BHP equals 9840 pounds of steam.This means that the actual evaporation for a 300 BHP boiler operating at 100 psig is9840 pounds of steam per hour when the feedwater temperature is 200 F.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 17
CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 18ACT. EVAP. LBS STEAM/BHP2526272829303132333435360100BOILER OPERATING PR.-PSIG300Figure 9. Factors of Evaporation200400FACTORS OF EVAPORATION500600230 F212 F200 F180 F160 F140 F120 F100 F80 F60 F
9.0 FEEDWATER SYSTEM9.1FEEDWATER SUPPLY9.1.1The boiler feedwater pump must not be directly connected to a city watermain or to any apparatus that is directly connected to a water main. Thefeedwater pump should be connected to a deaerator or a supply make-uptank that will serve as a reservoir for system condensate return, chemicaltreatment, bypass return and makeup water.9.1.2The best method for handling boiler feedwater is a well designed deaerator.The next best method is a well designed feedwater tank such as is illustratedin Figure 10.MAKE-UP WATERCHEMICAL FEEDSYSTEMCONDENSATERETURNMIXERBY-PASS RETURNLOW LEVEL CONTROLCO2 AND O2 VENTLIQUIDLEVELCONTROLOVERFLOWSIGHT GLASSTEMP.GAUGEFEEDWATER HEATER(STEAM OR ELECTRIC)FEEDWATERSUPPLYDRAINFigure 10. Water Tank InstallationFor either a deaerator or a simple feedwater tank the reservoir should belarge enough to provide a sufficient quantity of water for approximately ten totwenty minutes of operation when little or no condensate is being returnedfrom the system. The reservoir should also be large enough to accommodatea quantity of system condensate being returned after a boiler and/or systemshutdown, plus the expansion that occurs on startup when the feedwater isheated. Table 6 indicates the recommended feedwater reserve quantities attwenty minutes storage and feedwater tank capacities for the different boilersizes.CIRCULATIC INSTALLATION MANUAL 2015.DOCPage 19
Table 6. Recommended Feedwater Reserves & Tank SizesModelFeedwaterFeedwaterSizeReserve QuantitiesTank Size(BHP)(U.S. Gallons)(U.S. 0084015009.1.3A feedwater pump is necessary to make up the water in the Circulatic boilerdrum/separator that has been evaporated. A multi-staged centrifugal pump isthe usual preferred choice for this application although a regenerative turbinepump is often used. With proper sizing, piping, and valving a single pumpmay supply more than one boiler at one time. The pump should be installedas close as possible to the deaerator or makeup tank where piping lossesle
VAPOR POWER INTERNATIONAL circulatic steam generators installation manual 551 S. County Line Rd. Franklin Park, IL 60131 P: 630.694.5500 F: 630.694.2230 VaporPower.com. CIRCULATIC INSTALLATION MANUAL 2015.DOC Page 1 Revised July 2005 Bulletin No. Printed in U.S.A. TWM5-AM-2 .
regional sales at Vapor Power International, 90% of the water is converted into steam in the coils. Dry steam is then produced in the steam separator. The water remaining is re-moved by a steam trap. The Circulatic, also from Vapor Power International, is a forced recirculation watertube boiler that uses a drum as a steam separa-
17 Table 3. Compressed Water and Superheated Steam (continued) 0.01 MPa (ts 45.806 C) 0.02 MPa (t s 60.058 C) 0.03 MPa (t s 69.095 C) v ρh s t, C v h s t, C v ρ h s 26 446. 0.037 814 3076.7 9.2827 300 13 220. 0.075 645 3076.5 8.9625 300 8811.0 0.113 49 File Size: 630KBPage Count: 60Explore furtherCalculator: Superheated Steam Table TLV - A Steam .www.tlv.comSuperheated Steam Tables - Gilson Enggilsoneng.comCalculator: Superheated Steam Table TLV - A Steam .www.tlv.comCalculator: Superheated Steam Table TLV - A Steam .www.tlv.comSteam Table Calculator Superheated Steam Region Spirax .www.spiraxsarco.comRecommended to you b
Steam Generator Operating Manual EN 1 SS77USSG 4 3 2. EN 4 SS77USSG d) the tool plug must fit into the socket-outlet. the plug may not be modified in any form. Do not use adaptor plugs together with . The Steam Generator is designed to provide 90 mins of steam. If you require less steam time, half fill the Steam Generator.
Page 2 June 2015 Large Steam Power Plants Siemens Steam Turbines for coal-fired Steam Power Plants Power output 120 MW to 700 MW Max. steam parameters Main steam / Hot reheat steam 177 bar / 600 ºC / 620 ºC 2,570 psi / 1,110 ºF / 1,150 ºF SST-5000 series for coal-fired Steam Power Plants
For two hundred years, steam power has fueled progress. Since 1903, Vapor Power International has been an industry leading innovator in the boiler and steam generation industry. With over a century of experience generating steam and heat for the most demanding applications, Vapor Power has a deep knowledge of steam requirements, which
related to oilfield steam generation should be decided at the national level by use of the cost of the marginal fuel. This paper calculates the steam cost for three methods: once-through steam generator, once-through heat-recovery steam generator, and solar steam gen-erator. Detailed performance and economic models of the steam-
The steam generator can be installed up to 3 meters away from the steam shower in a neighbouring room or one floor higher or lower. The steam generator can be fed with cold or hot water. The steam generator has a solenoid valve which automatically controls the amount of water being fed (steam generator water consumption 2 l/30 min
kadar asam folat di bawah normal, yaitu folat serum 3 ng/ml dan folat eritrosit 130 ng/mL (Mayes, 2007). Defisiensi folat ini dapat terjadi karena akibat langsung dari kurangnya konsumsi .
