Section – 9 : Sizing and Selection of De-aerator

Steam for Power Generation: De-aeration Steam and Water Quality

De-aeration steam quantity in steam plants is influenced by several variables such as the amount of
condensate returns, temperature, de-aerator pressure, and by feed water and boiler water quantity.
Figure below shows a boiler where a certain amount of steam taken for process is returned as con-
densate. M, C, F, B and D are the make-up water flow, condensate returns, feed water flow, blow
down and de-aeration steam, all in kilogram per hour (kg/hr).
a. Schematic Diagram

Fig. 9.1 Typical Pressurized Boiler- De-aerator Diagram (Taken from Spirax Sarco)
b. Mass Balances in Deaerator and Boiler:
b.1 Cycle of Concentration, Mass and Percentages for the Deaerator
1. Cycle of Concentration (CoC)
CoC = boiler TDS/ Feed H2O F_TDS ---
2. Percent Blowdown
%B = 100%/ CoC (normally ranges 4 – 8%) %
3. Mass of Feed water Leaving the deaerator and Mass of Blowdown
F = E/ [ 1 – (%B/100) ] Kg/Hr
B = (F – E) Kg/Hr
4. Make-up Percent (%M) and its Equivalent mass (M)
%M = F_TDS/ M_TDS is a ratio of feed water to make-up total dissolved solids %
where:
F_TDS = given or use 225 ppm (TDS value from the following 150 to 300 ppm)
 M = %M* F Kg/Hr
M_TDS = given or use 350 ppm (TDS value taken from range to 200 to 500 ppm)
b.2 Mass balance in the Deaerator and Boiler
F =M+C+D
=B+E
where:
F = Feed Water, leaving the deaerator to boiler @ 1.2 Bara and 105 C,
normally its total dissolved solids TDS @ 150 to 300 ppm Kg/Hr
C = Condensate Return, from condensate main tank @ 85 C & its total dis-
solved solids may vary from (10 to 26) TDS, use 10 TDS if not given Kg/Hr
M = Pre-heat make-up H2O from HEX @ 85 C, also its TDS ranges (200 to
500 ppm) Kg/Hr
D = After PRV station steam supply to deaerator is 11 Bara at 184 C and its Kg/Hr
TDS (in ppm) may be computed
E = Ws = Steam Generation (usually given) Kg/Hr
B = Blow-down, its percentage, mass and TDS are computed Kg/Hr
b.3 Mass and Energy Balance in Deaerator
F = M +C Eq. - a
where:
hf @ 105C = 440 Kj/Kg
hf @ 85C = 355 Kj/Kg
hg @184 = 2781 Kj/Kg, substituting these enthalpies, we get
440* F = 335* M + 335* C + D* 2781 Eq. - b
since there two unknowns and also we already have established two equations, therefore we
can start solving for two unknows, first multiply Eq. - a by 355, we get
355* F = 355* M + 355* C + 355* D
and writing down the two equations Eq. a & b
440*F = 335* M + 355* C + 2781* D
- 355* F = - 335* M - 355* C - 355* D by multiplying Eq. b w/ -1
simply and get rid of M & C we get the following final equation
85* F = 2426* D,
if F is known D can be computed
if M is known C can be computed
b.4 Cycle of Concentration, Mass and Percentages for the Deaerator
1. Cycle of Concentration (CoC)
CoC = boiler TDS/ Feed H2O F_TDS ---
2. Percent Blowdown
%B = 100%/ CoC (normally ranges 4 – 8%) %
 3. Mass of Feed water Leaving the deaerator and Mass of Blowdown
F = E/ [ 1 – (%B/100) ] Kg/Hr
B = (F – E) Kg/Hr
4. Make-up Percent (%M) and it Equivalent mass (M)
%M = F_TDS/ M_TDS is a ratio of feed water to make-up total dissolved solids %
where:
F_TDS = given or use 225 ppm (TDS value from the following 150 to 300 ppm)
M = %M* F Kg/Hr
c. Deaerator Capacity, Vent Rate, % Vent, and Control Valve Specs
c.1 Dearator storage capacity
Dcap = SVw*F*.17
c.2 Vent rate (V)
V = 2471.4 *(P2)*(Dof)2
c.3 Percentage of Vent
%V = (V/F)*100%
c.4 Steam control valve coefficient
KVs = D/(12*P1/100)
c.5 Water control valve coefficient
KVw = Q/((dP)/G).50
Q = M*SVw
c.6 Pressure drop across the valve
dP = (TDP – P2)/100
d. Recommended Boiler Water Quality
Type of Boiler TDS Level Parts per million (ppm) TDS Level Parts per million (ppm)
Water tube – High pressure 1000 Modern Packaged Boiler 3 – pass 3000 -
Medium pressure water tube 3250 2500
Water tube - Low pressure 5000 Vertical Shell
note: TDS = total dissolve solid
e. ASME Water Boiler Quality Guidelines
working pressure(KPag) TDS Level Parts per million ppm
0 – 2067 3500 (7000 mmho)
20 68 – 3100 3000 (6000 mmho)
3101 – 4135 2500 (5000 mmho) note: mmho – conductivity of water
f. ABMA Water Boiler Quality Guidelines
Drum KPag per ABMA ppm Drum KPag per ABMA ppm
0 – 2067 700 – 2067 4135 – 5167 200 – 1000
2068 – 3100 600 – 3000 5168 – 6201 150 – 750
3102 – 4134 500 – 2500 6202 – 6890 125 – 625
Section 9: Design Problem - 9.1 :
Size and Specify a deaerator capable of matching the following load and specifications:
Boiler supply steam (E) is 113636.4 Kg/Hr (or 31.6 Kg/s)
Deaerator Operating Conditions:
1. Maximum Boiler total dissolved solids (TDS) is 2500 ppm
2. Feed water (F) is maintained at 105 C with TDS = 138 ppm
3. Preheated Make-up (M) water @ 85C with TDS = 300 ppm
4. Heated Condensate (C) return @ 85 C with TDS = 10 ppm
5. Steam supply for heating (D) @ 11 Bara and 184 C
Determine the following:
1. COC, %B, %M and masses of F, B, & M
Cycles of concentration (COC) and
% Blow down using the given TDS
Mass of Feed water (F) and Blowdown (B)
Make-up in percent and in mass flow rate
2. Supply steam (D) and condensate (C)
3. Deaerator Capacity, Vent Rate, and % Vent
Solution:
1. Blow down using the given TDS and also Cycles of concentration (COC)
COC = Boiler TDS/F TDS = 2500/138 = 18.12
%B = 100* F TDS/(Boiler TDS – F TDS) = 100* 138/(2500 - 138) = 5.84 %
%M = F_TDS/M_TDS = 100* 138/300 = 46 %
F = E/ [ 1 – (%B/100%) ] = 113636.4/ [1 – (5.84/100) ] = 120,684.37 Kg/Hr
B = (F – E) = 120684.37 – 113636.4 = 7074.97 Kg/Hr
M = %/100 * F = .46* 120684.37 = 55514.81 Kg/Hr
2. Supply steam (D) and condensate (C)
Using mass and energy balance, we obtain the following equation
Using Steam Table
hf @ 105C = 440 Kj/Kg - F
hf @ 85C = 355Kj/Kg - C
hg @ 184C = 2781Kj/Kg - D
440* F = 355* M + 355* C + 2781*D Eq. - a
since there two unknowns we need another equation, therefore, using the mass balance
in the dearator we have the following
F = M + C + D Eq. - b
355* F = 355* M + 355*C + 355* D if we multiply Eq. – b by 355 we get
and writing down the two equations Eq. a & b we get
+ 440*F = + 335* M + 355* C + 2781* D
 – 355* F = – 335* M – 355* C – 355 * D by multiplying Eq. b by –1
simply by cancelling M & C we get the following final equation
85* F = 2426* D , if F = 120684.37 Kg/Hr and solving for D we get
D = 85* 120684.37/ 2426 = 4228.43 Kg/Hr
C = F – M – D = 120684.37 – 55514.81 – 4228.43 = 60941.13 Kg/Hr
3. Deaerator Capacity, Vent Rate, and % Vent
a. Dearator storage capacity (Dcap)
Dcap = SVw* F* .17
Specific volume of feedwater in deaerator (SVw) at 85 °C (From Steam Table)
Svw = .001032 m3/kg or Denw = 1/Svw = 967 kg/m3
Dcap = .00103*120684.37 *.17 = 21.13 m3
b. Vent rate (V)
V = 5450.34*(P2)*(Dof)2
where
Deaeration pressure (P2) = 1100 KPaa
Dof = Orifice diameter inside the vent = .025 m (25mm)
V = 5450.34*(1100)*(.025)2 = 3747.11 Kg/Hr
b. Percentage of Vent, %V
%V = (V/F)*100%= (3747.11/120684.37)*100% = 3.10 %
Design Problem - 9.2: Sizing of control valves
Using the same deaerator above problem, size the steam and water control valves with given
specific gravity of water SPGR = 1. Compute for the following:
a. Draw the schematic diagram with labels.
b. Steam control valve coefficient (Kvs).
c. Water control valve coefficient (Kvw).

Solution:
a. Schematic diagram with labels

Fig. 9.2 Steam and Water Contral Valve Sizing (Taken from Spirax Sarco)

b. Steam control valve coefficient (Kvs)

Kvs = D/(11.2*P1)
Kvs = 4029.45 /(11.2*1.103) = 323.8 Kg/hr/Bar
c. Water Control valve coefficient (Kvw)
Kvw = Qw/(dP/SPGR).50
where
dP = 1.2 - .58 = .62
Qw = Svw* (M + C) = .00103 * (120684.37 – 4029.45 ) = 120 .2 m3/kg
= 120.2/ (.62/.97)^.50
= 150.47 m^3/Hr/ Bar
Section – 10 : Sizing and Selection of Boiler Water Pump
A boiler feed-water pump is a specific type of pump used to pump feed-water into a steam boiler.
The objective when sizing a boiler feed water pump is to determine its required operations. The
following steps to design and select for the BFW pump that will satisfy the ASME BFW pump sizing
requirements are as follow:
1. Number of pumps required (NP)
The number of pump is based on the load conditions
a. If the boiler is used as base load – use 1 pump
b. If 2 or more boilers with variable loads – choose at least 1 pump per boiler
2. Select the type of feed water control of the pump
a. Modulating feed-water control
b. On-off control
It is recommended to use modulating feed-water control for all steam boiler
3. Calculate the pump net mass rate and net flow rate(MP_NET and QP_NET)
MP_NET = system load + blow-down % + steam to deaerator 8% + catch-up 25 %
+ minimum flow protection 25%
QP_NET = MP_NET *SVw
SVw = specific volume of inlet feedwater at temp. in °C (m3/Kg)
4. Calculate the pump total discharge pressure (TDP) & total pump dynamic head (TDH)
5. Get the preliminary net positive suction head absolute (NPSHA) of the pump
6. Compute the other requirements of the BFW pump
a. Determine the RPM of the pump
b. Compute for specific speed (NQ) of the pump
NQ = RPM*(Q).5/(TDH).75
c. Select the type of pump by using a graph given the Q and NQ
d. Compute for the pump efficiency (PP_Eff) and net positive suction head required (NPSHR) for
the pump:
Pump efficiency (PP_Eff)
PP_Eff = .94 - .048*(Q)-.32 - .29*[log(NQ/44)]2
Net positive suction head required (NPSHR)
NPSHR = TDH*Kp*NQ1.33/1,000,000 m
7. Correct pump selection with 3 percent above the boiler safety valve setting.
Correct pump selection and achieving a shutoff head (the head at zero flow) 3 percent above the
boiler-safety-valve setting. Therefore, the pump corrected TDH is ,
TDH = TDP*.102344*1.03 m
 Chart 10.1 Type of Pump Selection

Chart 10.2 NQ vs Pump Impeller Type and Optimum Efficiency

 Chart 10.3 NPSHA Pump Capacity vs RPM

Recommended Max. Operating Speeds for Single – Suction Pumps (From Hydraulic Institute used w/ permission)

Chart 10.4 NPSHA Pump Capacity vs Rpm

Recommended Max. Operating Speeds for Double – Suction Pumps (From Hydraulic Institute used w/ permission)
Section 10: Design Problem 10 - 1
Size and select the needed boiler feed water (BFW) pump for a coal-fired water-tube boiler generating
steam of 113,636.4 Kg/Hr(31.6 Kg/s) and operated at 31 Bar (P1) and temperature at 350 °C that will
satisfy the ASME BFW pump sizing requirements. Other given pressures and temperatures:
Deaerator Operating Condition
Temperature (Ts) : 105 °C
Pressure(Ps) : 1.2 Bar

Determine the following:

a. Draw the process diagram
b. Number of pumps required (NP).
c. Pump net mass rate and net flow rate (MP_NET and QP_NET).
d. Total pump discharge pressure (TDP) & total pump dynamic head (TDH).
e. Preliminary net positive suction head available (NPSHA) of pump.
f. NQ and selection for type of pump.
g. Pump Efficiency (PP_Eff).
h. Net positive suction head required (NPSHR) for each pump.
i. Will the pump cavitate?
Solution:
a. Process Diagram

b. Number of pumps required (NP)

The number of pumps is based on the load conditions
1. If the boiler is used as base load – use 1 pump
2. If 2 or more boilers with variable loads – choose at least 1 pump per boiler
Note: Use modulating feed–water control as recommended for all steam boilers
c. Pump net mass rate and net flow rate (MP_NET and QP_NET)
MP_NET = System load + blow-down 3% + steam to deaerator 8% + catch-up 25 %
+ minimum flow protection 25%
= 120684 Kg/Hr* (1 + .03 + .08 + .25 + .25)
F(MP_NET) = 120,684*(1.61) = 194,301.84 kg/hr
QP_NET = MP_NET*SVw
 From steam table the following density and specific volume of water at 105 °C are;
Denw = 952.4 Kg/m^3 (from steam table)
SVw = 1/Denw = 1/955.11 = .001047 m 3/Kg
Qcap = 194,301.84*.00104 = 202.07 m^3/hr
Specific Gravity of water 952.4/1000 = .952
d. Total pump discharge pressure (TDP) & total pump dynamic head (TDH)
Boiler operating pressure = 31 Bar
Non – return valve = .1 Bar
Modulating level control valve = 2.1 Bar
Piping Loss to Boiler = .5 Bar
Pump discharge Loss = .5 Bar
Safety Margin =.7 Bar
Total (TDP) = 35 Bar
TDP/.952 = 35/.952 = 36.76
TDH = 36.46*(10.37 m/1 Bar) = 381.25 m,
say use 400 m in unticipation of adjusting the static head to get the right NPSHA vs NPSHR
e. Preliminary net positive suction head available (NPSHA) of pump
In the absence of actual piping layout, for the time being use graphical method given the RPM
(3600) and flow rate (.056 m3/s or 56 L/s)
Using Chart 10.3, NPSHA (QP = 56 L/s vs 3600 RPM) =9m
NPSHA = Hatm + Hsh – Hvp – hf
where : Hatm = 10.37m @ 1 Bar
Hsh = 18m (after several trial value of the required static head)
Hvp = 1.4 Bar *(10.31 m/1 Bar) = 14.5 m
Hf = .5 Bar *(10.31 m/1 Bar) = 5.2 m
NPSHA = 10.37 + 18 – 14.5 – 5.2 = 8.67 m
f. NQ and selection for type of pump
Specific Speed (NQ) for multi-stage
NQ = RPM*(Q).5/ (TDH).75
Use RPM = 3600
TDH = 400/8 = 50 m per stage
NQ = 3,600*(.056).5/ (50).75 = 45.31 RPM
Using Chart 10.1, given 200 m^3/hr vs 400m, type of pump is Multi-stage radial flow
g. Pump Efficiency (PP_Eff)
Using Chart 10.2, we obtained the following PP_Eff = 85.5%
h. Net positive suction head required (NPSHR) for each pump
NPSHR = TDH*Kp*NQ1.33/1,000,000
 Where:
Kp = 4964 – 4650*PP_Eff
Kp = 4964 – 4650*.855 = 988.25
1.33
NPSHR = 50 *988.25 *(45.31) / 1,000,000 = 7.88 m
i. Will the pump cavitate?
Since NPSHR < = NPSHA the selection and future usage of the above pump will not cavitate
Section 10: Design Problem 10 - 2:
Size and select the needed De-aerator Pump for a typical de-aerator generating steam of 4234.5 Kg/hr
(1.18 Kg/s) and operated at 1.2 Bar(Pd1) and temperature at 105 °C that will satisfy the ASME De-
aerator pump sizing requirements. Other given pressures and temperatures:
De-aerator Operating Condition : Temperature (Ts) : 45.83 °C and Pressure(Ps) : .103 Bar
Determine the following:
a. Number of pumps required (NP).
b. Pump net mass rate and net flow rate (MP_NET and QP_NET).
c. Total pump discharge pressure (TDP) & total pump dynamic head (TDH).
d. Preliminary net positive suction head absolute (NPSHA) of pump.
e. NQ and selection for type of pump.
f. Pump Efficiency (PP_Eff).
g. Net positive suction head required (NPSHR) for each pump.
i. Will the pump cavitate?
Solution:
a. Number of pumps required (NP)
The number of pumps is based on the load conditions
1. If the boiler is used as base load – use 1 pump
2. If 2 or more boilers with variable loads – choose at least 1 pump per boiler
Note: Use modulating feed–water control as recommended for all steam boilers
b. Pump net mass rate and net flow rate (MP_NET and QP_NET)
D(MP_NET) = 4228.43 Kg/Hr
QP_NET = MP_NET*SVw
using the following for density and specific volume of water at 45.83 °C
Denw = 952.4 Kg/m^3 (from steam table)
SVw = 1/Denw = 1/952.4 = .00105 m3/Kg
= 4228.43 Kg/Hr *00105 = 4.44 m^3/hr
c. Total pump discharge pressure (TDP) & total pump dynamic head (TDH)
Deaerator operating pressure = 1.2 Bar
Check valve(Non – return valve) = .1 Bar
Piping Losses = .5 Bar
Pump discharge loss = .5 Bar
Safety Margin = .7 Bar
Total (TDP) = 3 Bar
TDP/.952 = 3/.952 = 3.15
TDH = 3.15*(10.37 m/1 Bar) = 32.66, say 40 m
Note: the specific gravity of water .952 (952.4/1000)
d. Preliminary net positive suction head absolute (NPSHA) of pump
In the absence of actual piping layout, for the time being use graphical method given the RPM
(3600) and flow rate (.001233 m3/s)
NPSHA = Hatm + Hsh – Hvp – hf
Where : Hatm = 10.37m @ 1 Bar
Hsh = .15 m
Hvp = .103 *(10.31 m/1 Bar) = 1.068m
Hf = .5 Bar *(10.31 m/1 Bar) = 5.2 m
NPSHA = 10.37 + .15 – 1.068 – 5.2 = 4.25 m
Using Chart 10.3, NPSHA (QP = 1.233 L/s vs 3600 RPM) =3m
e. NQ and selection for type of pump
Specific Speed (NQ) for multi-stage
NQ = RPM*(Q).5/ (TDH).75
Use RPM = 3600 and try different no. of stages and specific speed to satisfy NPSHA>NPSHR
TDH = 40/1 = 40 m per stage
TDH = 40/2 = 20 m per stage
TDH = 40/3 =13.33 m per stage
NQ = 3,600*(.001233).5/ (40).75 = 7.95 RPM
NQ = 3,600*(.001233).5/ (20).75 = 13.37 RPM
NQ = 3,600*(.001233).5/ (13.33).75 = 18.12 RPM
finally, selecting 13.33 m per stage and NQ = 18.12
f. Pump Efficiency (PP_Eff)
Using Chart 10.2, PP_Eff = = 77%
g. Net positive suction head required (NPSHR) for each pump
NPSHR = TDH*Kp*NQ1.33/1,000,000
Where:
Kp = 4964 – 4650*PP_Eff
Kp = 4964 – 4650*.77 = 1383.5
NPSHR = 40 *1383.5*(20)1.33/ 1,000,000 = 2.97 m
i. Will the pump cavitate?
Since NPSHR < = NPSHA the selection and future usage of the above pump will not cavitate
Section – 11 : Sizing and Selection of Blow-down and Flash Tanks
A blow down tank is designed to collect the intermittent blow-down from the bottom blow-off connec-
tions (or mud drum) and from the surface blow off connections. The word “intermittent blow-down”
is stressed because the blow-down tank is best suited for intermittent operation. The blow-down tank
provides a safe method of collecting blow-down water while allowing the flash steam generated to be
safely vented to de-aerator. The water remains in the blow-down tank is held until it cools to accepta-
ble levels before it is discharged to drain. Why used a blow-down tank? Some facilities use blow-down
tank to conserve water and energy . If a blow-down tank is used for intermittent blow-down, the facility
will reduce the use of water since no cooling water will be used. This will also reduce the volume of
water sent to the sewer which can reduce water treatment expenses and sewer.

The tables and chart below are used in sizing and selecting blow-down tank :

Table 11.1 Blow-down Tank Design Working Pressure

If P1 (boiler Pressure) <= 10350 KPag
Pb2 = 4.532* P1^.645485 else;
Pb2 = 461.585*[.1451*P1 – 840.9472)^.217976

Chart 11.1 Blow-down Line Sizing

 Table 11.2 Blow-down Tank and Pipe conn. Sizing Table
Blow-down
Boiler Blown-down Vent H2O Inlet H2O Outlet
Tank Dia x Ht
Pressure KPag Size (mm) Size (mm) Size (mm) Size (mm)
mm x m
20 50 20 38 350 x 1.68
25 50 25 38 350 x 1.68
38 50 32 63 350 x 1.68
138 - 345
38 63 32 63 350 x 1.68
50 75 50 100 450 x 1.83
63 100 50 100 500 x 1.83
20 50 25 38 350 x 1.68
25 63 32 50 350 x 1.68
32 75 38 75 450 x 1.83
350 - 690 38 100 50 100 450 x 1.83
50 125 63 100 600 x 1.83
63 150 63 125 750 x 1.98
20 63 25 50 350 x 1.68
25 75 32 75 350 x 1.68
32 100 38 75 500 x 1.83
691 - 1035
38 125 50 100 600 x 1.83
50 150 63 100 825 x 1.83
63 200 75 125 975 x 1.98
20 75 25 50 350 x 1.68
25 100 32 63 450 x 1.83
32 125 50 75 600 x 1.83
1036 - 1380 38 150 50 100 750 x 1.98
50 200 63 100 975 x 1.98
63 200 75 125 1200 x 1.98
20 100 32 50 450 x 1.83
25 125 38 63 600 x 1.83
32 150 50 100 750 x 1.98
1380 - 2067
38 150 50 100 900 x 1.98
50 200 63 125 1200 x 1.98
63 250 75 150 1350 x 2.13
20 100 32 63 500 x 1.83
25 125 38 75 600 x 1.83
32 150 50 100 825 x 1.98
2068 - 2756 38 200 63 100 1050 x 1.98
50 250 75 125 1350 x 2.13
63 250 100 150 1650 x 2.13
20 100 32 63 500 x 1.83
25 125 38 75 600 x 1.83
32 150 50 100 825 x 1.98
2068 - 2756 38 200 63 100 1050 x 1.98
50 250 75 125 1350 x 2.13
63 250 100 150 1650 x 2.13
cont’d Table 11.2
Blowdown **
Boiler Blowndown * Vent H2O Inlet H2O Outlet
Tank Dia x Ht
Pressure KPag Size (mm) Size (mm) Size (mm) Size (mm)
mm x m
20 100 32 63 500 x 1.83
25 125 38 75 675 x 1.98
38 200 50 100 975 x 1.98
2757 - 3450
38 200 63 100 1200 x 1.98
50 250 75 125 1500 x 2.13
63 300 100 200 1800 x 2.13
20 125 32 63 600 x 1.83
25 150 38 75 750 x 1.98
32 200 63 100 1050 x 1.98
3451 - 4134 38 250 63 125 1350 x 2.13
50 300 75 150 1650 x 2.13
63 300 100 200 1850 x 2.13
20 125 32 63 675 x 1.98
25 150 38 75 900 x 1.98
32 200 50 100 1200 x 1.98
4135 - 5512 38 250 63 125 1500 x 2.13
50 300 75 150 1800 x 2.13
63 300 100 200 1800 x 2.13
20 125 32 63 675 x 1.98
25 150 38 75 900 x 1.98
5513 - 6890 32 200 50 100 1200 x 1.98
38 250 63 125 1500 x 2.13
50 300 75 150 1800 x 2.13
20 200 32 63 900 x 1.98
25 200 50 100 1200 x 1.98
6891 - 10335 32 250 63 100 1650 x 2.13
38 300 75 125 1800 x 2.13
20 200 32 63 1050 x 1.98
25 250 38 100 1200 x 1.98
10336 - 13780 32 250 63 125 1650 x 2.13
38 300 75 125 1800 x 2.13
20 200 38 100 1200 x 1.98
25 250 50 100 1650 x 2.13
13781 - 17225 32 300 63 125 1800 x 2.13
38 300 75 150 1800 x 2.13
* Size of blow-off connection on boiler or size of blow-off header, w/c is larger
** The sizes tabulated are based on the minimum diameter and minimum volume that can be use
be used. Larger diameter tanks with equivalent or larger volume may be used.
Taken from Guy Gowyer – Introduction to Power Plant
 Table 11.3 - Sizing Flash Tank (Vertical Type)
FLASH STEAM (Kg/Hr)
CONDENSATE

11364

15909
1364

5455

8182

9546
1818

3636
45.5

455
227

318

909
(Kg/Hr)

Height (m) 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743 2.743
Diameter (m) .762 .762 .762 .762 .762 .762 .762 .762 .762 .762 .762 .915 .915
45,454.55
Drain (mm) 125 125 125 125 125 125 125 125 125 125 125 100 100
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400 450
Height (m) 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44
Diameter (m) .762 .762 .762 .762 .762 .762 .762 .762 .762 .762 .762 .915 .915
40,909.1
Drain (mm) 125 125 125 125 125 125 125 125 125 125 125 100 100
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400 450
Height (m) 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44 2.44
Diameter (m) .609 .609 .609 .609 .609 .609 .609 .609 .609 .609 .762 .915 .915
36,363.64
Drain (mm) 125 125 125 125 125 125 125 125 100 100 100 100 100
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400 450
Height (m) 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83
Diameter (m) .609 .609 .609 .609 .609 .609 .609 .609 .609 .609 .762 .915 .915
31,818.2
Drain (mm) 100 100 100 100 100 100 100 100 100 100 100 100 100
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400 450
Height (m) 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42
Diameter (m) .609 .609 .609 .609 .609 .609 .609 .609 .609 .609 .762 .915
27,272.73
Drain (mm) 100 100 100 100 100 100 100 100 100 100 100 100
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400
Height (m) 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83
Diameter (m) .508 .508 .508 .508 .508 .508 .508 .508 .508 .609 .762 .915
22,727.3
Drain (mm) 100 100 100 100 100 100 100 100 100 100 75 75
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350 400
Height (m) 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42
Diameter (m) .508 .508 .508 .508 .508 .508 .508 .508 .508 .609 762
18,181.82
Drain (mm) 100 100 100 100 100 100 100 100 75 75 75
Vent (mm) 50 50 63 75 100 125 150 200 250 300 350
Height (m) 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42 1.42
Diameter (m) .457 .457 .457 .457 .457 .457 .457 .457 .508 .609
13,636.4
Drain (mm) 75 75 75 75 75 75 75 75 75 62.5
Vent (mm) 50 50 63 75 100 125 150 200 250 300
Height (m) 1.422 1.422 1.422 1.422 1.422 1.422 1.422 1.422
Diameter (m) .355 .355 .355 .41 .41 .41 .41 .41
9,090.91
Drain (mm) 63 63 63 63 63 63 63 50
Vent (mm) 50 50 63 75 100 125 150 200
Height (m) .863 .863 .863 .863 .863 .863 .863
Diameter (m) .355 .355 .355 .355 .355 .355 .406
4,545.5
Drain (mm) 50 50 50 50 50 50 37.5
Vent (mm) 50 50 37.5 75 100 125 150
Height (m) .863 .863 .863 .863 .863 .863 .863
Diameter (m) .254 .254 .254 .254 .355 .355 .355
2,272.73
Drain (mm) 37.5 37.5 37.5 37.5 37.5 37.5 37.5
Vent (mm) 50 50 63 75 100 125 150
Height (m) .863 .863 .863 .863 .863
Diameter (m) .254 .254 .254 .254 .355
1,363.64
Drain (mm) 31.25 31.25 31.25 31.25 31.25
Vent (mm) 50 50 63 75 100
Taken from Penn Separator Corporation Chart B
 Table 11.4 Vent Line Size for Horizontal Flash Tank
Area Vent Pipe Size Area Vent Pipe Size
(m^2) (mm) (m^2) (mm)
Less than .30 20 3.36 – 4.37 100
.31 - .51 32 4.38 – 6.78 125
.52 - .69 38 6.79 – 9.76 150
.70 – 1.12 50 9.77 - 13 175
1.13 – 1.63 63 14 – 17.19 200
1.64 – 2.51 75 17.20 – 27.88 250
2.52 – 3.35 88 27.89 – 39 300

Fig. 11. 1 Blowdown tank (Taken from Penn Separator Corp.)

Fig. 11.2 Blow down tank schematic diagram (Taken from Spirax Sarco)
Fig. 11.3: Horizontal and vertical condensate flash vapor tank
Section 11: Design Problem - 11.1
A typical coal-fired water-tube boiler has a blown down mass flow rate of 7075 Kg/hr operates at 31 Bar.
Determine the following:
a. Draw the blow-down schematic diagram with labels
b. Blow-down tank design working pressure
c. Size the Blow-down tank line, tank sizes diameter vs lenght, water and vent pipe connections.
Solution:
a. Schematic diagram with labels

Fig. 11.2 Blow down tank schematic diagram (Taken from Spirax Sarco)

b. Blow-down Working pressure

From Table 11.1
Pb = 4.532* P1^.645485 = 4.532* 3100^.645485 = 812.66 KPa or 8.13 Bar and also use a pressure
reducing valve (PRV) downstream.
c. Blow-down tank line capacity, tank sizes, water and vent pipe connections.
1. Using Chart 11.1 given blow-down flow rate of B = 7075 Kg/hr or 1.97 Kg/s. Use the minimum
size Db = 20mm
2. From Table 11.2 with pressure range of 2757 – 3450 Bar and a 20mm blow down line, the
following blow-down tank specification:
a. Tank size : 500mm x 6 m
b. Vent size : 50mm
c. Water connections:
Inlet : 32mm
Outlet : 63mm
Section 11: Design Problem - 11.2:
Given the above selection of blow-down tank and if used to a “intermittent blow-down” not continuous.
Design a flash steam and make-up heat recovery systems for the blow-down system before this is dis-
posed off into the drainage system at 30C or less.

Determine the following:

a. Draw the design schematic diagram of the proposed steam and make-up water heat recovery
systems

Fig. 11.4 Proposed Schematic

Diagram (Taken from Spirax Sarco)

b. How much flash steam Wfs, Mfs (make-up water) and heat Qfd are recovered from the proposed
system
1. Steam properties:
Pb1 = 8.13 Bara blow-down working pressure computed in problem 11.1 & its hfb1 = 725 Kj/Kg
steam
Pb2 = 1.042 Bara heat exchanger working pressure by disposing steam at 31 C & its hfb2 = 420
Kj/Kg steam and its hbfg = 2250 Kj/Kg steam
Tw1 = 21 C entering treated make-up water temperature ( & its hfw1 = 88 Kj/Kg
2. Percent of steam recovered Wfs from flashing steam from 8.13 to 1.042 Bar inside the tank
% fs = ( hf at Pb1 – hf at Pb2 )/ hfg at Pb2, substituting the above values
% fs = ( 725 at Pb1 – 420 at Pb2 )/ 2250 at Pb2 = 13.6 %
Wfs = % fs/100 * B = .136*7075 Kg/hr = 962.2 Kg steam/hr
.2673 Kg/s
3. Amount of steam to disposed off into the drainage system
Wfd = amount of steam to be disposed
 = B – Wfs = 7075 – 962.2= 6113 Kg/hr, or in Kg/s =1.698 Kg/s
4. Amount of heat to be recovered
Qfd = Wfd* hfbe = 6113* 420 Kj/Kg = 2567460 Kj/hr
5. Amount of make-up water & heating to be recovered if Tw1 =11C and dtw =64 C
Qfd = M1*cpw*dtw computing for M1
M1 = Qfd/ (cpw*dtw) = 2567460/(4.19*64) = 9574.4 Kg/hr or Kg/s = 2.66 Kg/s @ 85C (=Tw2)
c. Size and Select the flash Tank
After the amount of flash steam rate has been computed from value of B=7075 Kg/hr, Size and select
the applicable vertical or horizontal flash tank.
1. Vertical Type
Using Table 11.3 given B and Wfs (the intersection of Wfs vs B in the table ) will determine the
following:
Height of vertical tank is 1.422m and its diameter is .41m and its vent size is vent size is 125mm
2. Horizontal Type

Using the following equation to compute for the cross section area of the tank
Aft = .4695* Wsf/ Pb2 = 4.335 m^2
where: Wsf = 962.2 Kg/hr and Pb2=104.2 KPaa
= .4695* 962.2/104.2
Length of a horizontal tank L/D = 4 D = 1.445m
Lft = Aft/ Dia. of the tank = 4.335/1.2 =3 m
Horizontal flash tank vent vent dia. = 100mm
Size of drain for both type of tanks is 63 mm
Section – 12 : Sizing and Selection of Condensate Receiving Tank
Steam contains two types of energy: latent and sensible. When steam is supplied to a process applica-
tion (heat exchanger, coil, tracer, etc.) the steam vapor releases the latent energy to the process fluid
and condenses to a liquid condensate. Instead of letting this valuable moisture simply evaporate, a
condensate receiver, also called a condensate tank, is required to captures it and sends it back to the
boiler room so it can be reused. A condensate receiver brings an incredible amount of savings to a
boiler system (note this is similar with Fig. 11.4):
a. With a condensate tank, the water temperature stays more consistent, which means lower heating
bills.
b. Since the steam is being recycled, less water is necessary to keep the boiler system functioning.
c. The water captured by a condensate receiver still contains some of the boiler water treatment, so
fewer chemicals need to be added.
d. A condensate receiver can also help prevent damage and corrosion to the equipment.
e. With an industrial condensate, you can ensure you are following the strict regulations regarding what
can be drained into your state’s sewer system, which means you won’t have to worry about non-
compliance fees.
f. Since condensate is pure—meaning there are no dissolved solids in it that you will find in regular
boiler water—your system will require less blow down.

Fig. 12.1 Simplified Diagram - A Basic Steam Generation Cycle

Applicable Equations
a. Thermo-physical properties steam/condensate using steam table as follow:
1. Entering condensate temperature 125C
SVw = m^3/Kg
Denw = 1/SVw Kg/ m^3
hf1 = saturated liquid enthalpy @TC1 Kj/Kg
SVg1 = saturated specific volume @ TC1 m^3/Kg
Deng1= 1/SVg1 = 1/.77 Kg/ m^3
2. Leaving the tank condensate temperature TC2
hf2 = saturated liquid enthalpy @ TC2 Kj/Kg
hfg2 = latent heat @ TC2 Kj/Kg
b. Vapor or steam % flash, mass and volume of flash steam also its maximum flash vapor velocity
1. Percent flashing from C = 40,000 Kg/hr and flash quantity from C
%fc = (hf1 – hf2)/hfg2 %
Mg = %fc * C /100 Kg/hr
Vg = Mg* SVg1 m^3/hr
2. Maximum velocity of flash vapor in the flash tank (Vgm) and
Vgm = Ks*( (Denw – Deng)/Deng ).50 assuming 10 microns droplets m/s
where: Souders – Brown factor Ks = .018 m/s using Chart 12.1 (see next page)
Vgm = m^3/hr
3. Condensate volumetric flow rate
Vw = C*SVw m^3/hr
c. Size the condensate receiving tank (CRT) and Vent, Inlet and Outlet connections
1. Condensate tank cross-sectional area (Act), diameter (Dct) and tank length L
a. Act = Vg/3600 / Vgm m^2
Act/.20
when the vessel is full vapor occupy 15 – 25% of the cross
sectional area. For design purposes a value of 20% is used
and the total cross sectional is Act/.20 and computing for
the diameter therefore,
b. Dct = 4* Act/(.20* 3.1416)^.50 m
c. L = assuming L/D, therefore, 3*Dct m
2. Vent line, Inlet and Outlet condensate connections
a. Acv = Vg/3600 / Vf m^2
.50
Dcv = (4*Acv/π) m
b. Water inlet and outlet connections (the same size)
Aco = Vw /3600 /Vc m^2
.50
Dco = (4*Aco/π) m
where:
Act = condensate tank cross-sectional area (m2)
Acv = condensate tank vent line cross-sectional area (m2)
Aco = condensate tank outlet water line cross-sectional area (m2)
Ks = .018 m/s Souders – Brown constant from chart 12.1 (source PetroSkill by John
M Campbell)
Dct = condensate tank diameter (m)
Dcv = condensate tank vent line diameter (m)
Dco = condensate tank outlet water line diameter (m)
Denx = (x=w, condensate water density) or (x= g flash vapor density) (Kg/m3)
hfg = flash vapor latent heat (KJ/Kg) due to TC2
Mg = flash vapor mass flow rate (Kg/s or Kg/Hr)
SVw = specific volume of condensate water (m3/Kg)
SVg = specific volume of flash vapor (m3/Kg)
TC1 = inlet condensate temperature (°C) and TC2 = outlet condensate temperature (°C)
Vc = condensate water outlet velocity from condensate tank (m/s)
Vf = 50 m/s vent line sizing m/s ( flash vapor velocity at the time of generation from
condensate
Vgm = velocity of flash vapor of condensate tank (m/s)
Section 12: Design Problem 12. 1 - Sizing of Condensate Receiving Tank (CRT)
In an industrial plant, a plant engineer is required to size a condensate receiving tank (CRT) with the
following given data and the proposed system diagram below:
Condensate inlet temperature (TC1) = 125 °C
Condensate outlet temperature (TC2) = 123°C
Condensate outlet velocity (Vc) = .01 m/s
Flash vapor velocity in vent line (Vf) = 50 m/s
Determine the following:
a. Draw the proposed system diagram
b. Steam thermo-physical properties for TC1 and TC2
c. Maximum velocity of flash vapor of condensate receiver tank (Vgm)
d. Condensate water volumetric flow rate (Qw)
e. Flash vapor mass flow rate (Mg) and its volumetric flow rate (Qg)
f. Size the condensate receiving tank :
1. Condensate tank cross-sectional area (Act) and diameter (Dct)
2. Vent line cross-sectional area (Acv) and diameter (Dcv)
3. Outlet water line cross-sectional area (Aco) and diameter (Dco)
Solution:
a. See below the proposed system diagram:
b. Thermo-physical properties steam/condensate using steam table as follow:
1. Entering condensate temperature 125C
SVw = = .001065 m3/Kg
Denw = 1/SVw = 1/.001065 = 939 Kg/ m3
hf1 = saturated liquid enthalpy @125C = 525 Kj/Kg
SVg1 = saturated specific volume @125C = .77 m3/Kg
Deng1= 1/SVg1 = 1/.77 = 1.3 Kg/ m3
2. Leaving the tank condensate temperature 122C
hf2 = saturated liquid enthalpy @ 122C = 513 Kj/Kg
hfg2 = latent heat @ 122C = 2196 Kj/Kg
c. Vapor or steam % flash, mass and volume of flash steam also its maximum flash vapor velocity
1. Percent flashing from C = 40,000 Kg/hr and flash quantity from C
%fc = (hf1 – hf2)/hfg2 = (525 – 513)/2196 = .0055 or .55%
Mg = %fc * C = 40,000* .0055 = 220 Kg/hr
Vg = Mg* SVg1 = 220*.77 = 169.4 m^3/hr
2. Maximum velocity of flash vapor in the flash tank (Vgm) and
Vgm = Ks*( (Denw – Deng)/Deng ).50 assuming 10 microns droplets
where: Souders – Brown factor Ks = .018 m/s using Chart 12.1 (see next page)
Vgm = .018*( (939 – 1.3)/1.3 ).50 = .48 m/s
 Chart 12.1 (w/out mist pad or eliminator)

Source: Campbell, J.M., Gas Conditioning and Processing, Volume 2: The Equipment Modules, 9th Edition, 2nd
Printing, Editors Hubbard, R. and Snow–McGregor, K., Campbell

3. Condensate volumetric flow rate

Vw = C*SVw =40,000* .001065 = 42.6 m^3/hr
d. Size the condensate receiving tank (CRT) and Vent, Inlet and Outlet connections
1. Condensate tank cross-sectional area (Act), diameter (Dct) and tank length L
a. Act = Vg/3600 / Vgm = 169.4 /3600 / .48 = .098 m2
Act/.20 = .49 m2
when the vessel is full vapor occupy 15 – 25% of the cross
sectional area. For design purposes a value of 20% is used
and the total cross sectional is Act/.20 and computing for
the diameter therefore,
b. Dct = (4* .49/3.1416)^.50 = .789 m (say 800 mm)
c. L = assuming L/D, therefore, 3*Dct = .49* 3 = 1.47m (say 1.5m)
2. Vent line, Inlet and Outlet condensate connections
a. Acv = Vg/3600 / Vf = 169.4 /3600 /5 = .00094 m^2
Dcv = (4*Acv/π).50 = (4*.00094 /π).50 = .0346 m (say 38mm)
b. Water inlet and outlet connections (the same size)
Aco = Vw /3600 /Vc =.012/.5 = .0.024 m2
Dco = (4*Aco/π).50 = (4*.044/π).50 = .174 m (say 150 mm)
Section – 13 : Sizing and Selection of Steam Accumulator

Figure 13.1 Load profile

Figure 13.2 P-h diagram

Figure 13. 3 Accumulator with nozzles ( Taken from Spirax Sarco)

 Figure 13.4 Accumulator schematic diagram (Taken from Spirax Sarco)

Formulas:
Weight of steam per m3 (Wg)
Wg = Denw*[(hf – hc)/ (hgb – hc)]
Note: Denw = density of outlet feed water at T (°C)
hh = enthalpy of outlet feed water at T (°C)
hc = enthalpy of inlet feed water at T (°C)
hgb = enthalpy of saturated steam at T (°C)
Volume (V) and total volume (Vt) of the accumulator tank
V = (Ws*ts)/Wg
Vt = V/(SA_Eff*FV_Coef)
Note: SA_Eff = steam accumulator efficiency between .98 and .99, use .98
FV_Coef = water filling volume coefficient, .90
Select for type vessel head
Note: If internal pressure of accumulator is 1030 KPaa or less, select a torispherical head
else select a 2:1 ellipsoidal head
Sizing the accumulator: Accumulator diameter (Da)
D = { Vt/[ (2*fhv ) + (π* (L/D)/4) ] }1/3
Accumulator surface area (SAa)
SAa = .711*D*L
Maximum discharge of accumulator (Wa)
Wa = 3*P1*SAa
Pressure Vessel Design :
a. Design pressure (Pd)
Pd = 1.1 * P1 or Bar
Pd = P1 + 25*6.89/100 Bar
whichever is larger of the above, will be used as the design value for Pd, also if P1<10.3 Bar use
torispherical head else use 2:1 ellipsoidal head
b. Maximum acceptable working temperature = 370 C
c. Material:
Shell SA – 516 Gr 70, allowable stress Sa (16,600 psi) = 114374 KPa
Head SA – 181 class 70, allowable stress Sa (16,600 psi)= 114374 KPa
d. Weld Efficiency = .85
Volumetric flow rate per nozzle
Q_NZ = [ ( (no. of holes)*π*D*h2 ) /4]*Vg

Steam flow rate per nozzle (ENZ)

ENZ = Q_NZ*Deng
Computing for number of nozzles (NNZ)
NNZ = Ws/ENZ
Section 13: Design Problem 13 -1:
Size and select the steam accumulator (acting as thermal energy storage) to supply steam at peak load
of a coal fired water-tube boiler generating steam 113,636.4 kg/hr operating at 31 Bar with peak steam
demand duration of 30 mins ( .5 hr).
Given data:
1. Boiler
Saturated steam rate (Ws) = 113,636.4 kg/hr
Operating pressure (P1) = 31 Bar (Saturated)
Saturated temperature at 15 Bar (Tb) = 197.69 °C
2. Economizer
Inlet feed water temperature (Twe1) = 38 °C
Outlet feed water temperature (Twe2) = 186 °C (121)
3. Accumulator
Internal pressure (P2) = .10 x P1 = .10 x 31 Bar = 3.1 Bar
4. Material = Carbon steel
Allowable stress (Sa) = 485 x 106 Pa
(based on ASME Code)
Determine the following:
a. Draw the load profile and process diagram for the application of the accumulator
b. Weight of steam released per m3 (Wg)
c. Volume (V) and total volume (Vt) of the accumulator tank
d. Select a type vessel head
e. Select the geometrical factor for the volume of the head (fhv)
f. Design pressure (Pd)
g. Size the steam accumulator:
1. diameter (Da)
2. length (La)
3. surface area (SAa)
4. head thickness (tH)
5. shell thickness (tks)
h. Maximum discharge rate of accumulator (Wa)
Solution:

a.
 Fig. 13.4 - Accumulator (Taken from Spirax Sarco)
3
b. Weight of steam per m (Wg)
Wg = Denw x [(hf – hc)/(hgb – hc)]
Note: Denw = density of outlet feed water at 186 °C
Denw = 881.05 kg/m^3 (from steam table at 186 °C)
Computing for the following enthalpies:
hh = enthalpy of outlet feed water at 186 °C
= 791.86 Kj/Kg
hc = enthalpy of inlet feed water at 38 °C
= 156.83 Kj/Kg
hgb = enthalpy of saturated steam at 197.69 °C
= 2,885.32 Kj/Kg
For checking purposes, use steam table 1 and steam table 2
hh = enthalpy of outlet feed water at 186 °C = 791.86 Kj/Kg
hc = enthalpy of inlet feed water at 38 °C = 159.22 Kj/Kg
hgb = enthalpy of saturated steam at 31 Bar = 1016.9 Kj/Kg
Wg = 881.05 kg/m^3* [ (791.86 – 156.83)/ (2885.32 – 156.83) ] = 205.05 Kg/m3
Alternate solution,
Wg = 881.05*[(791.86 – 159.22)/ (2791.7 – 159.22)] = 211.73 Kg/m3
c. Volume (V) and total volume (Vt) of the accumulator tank
V = (Ws*ts)/ Wg = (113636.4*.5)/205.05 = 277.09 m3
Alternate solution,
V = (113636.4*.5)/211.73 = 268.35 m3
 Vt = V/(SA_Eff* FV_Coef)
Note: SA_Eff = steam accumulator efficiency between .98 and .99, use .98
FV_Coef = water filling volume coefficient, .90
Vt = 277.09/(.98* .90) = 314.16 m3
Alternate solution,
Vt = 268.35/(.98* .90) = 304.25 m3
d. Select for type vessel head
Note: If internal pressure of accumulator is 10.3 Bar or less, select a torispherical head
else select a 2:1 ellipsoidal head
Since the internal pressure of accumulator is 31 Bar, use ellipsoidal head . Selecting for geometrical
factor for the volume of the head, fhv
Use fhv = .1309 for torispherical head
e. Size the steam accumulator:
1. Accumulator diameter (Da)
D = { Vt/ [ (2* fhv) + (π* (L/D)/ 4) ] } .333
Note: L/D = (6 + 2.5)/2 = 4.25
D = { 314.16/ [(2* .0778) + (π*(4.25)/4) ] } .333 = 4.47 m
Alternate solution,
D = { 304.25/ [(2*.0778) + (π*(4.25)/4) ] } .333 = 4.43 m
2. Accumulator length (La)
L/D = 4.25
L = 4.25*(D) = 4.25*4.43 = 18.83 m
3. Accumulator surface area (SAa)
SAa = .711*D*L = .711*4.3*18.83 = 59.31 m2
4. Maximum discharge of accumulator (Wa)
Wa = 3*P1*SAa = 3 *3100 *59.31 = 551,583 Kg/hr
f. Pressure Vessel Design :
1. Design Specification
Design pressure (Pd)
a. Pd = 1.1 * P1 = 34.1 Bar and
Pd = P1 + 25*6.89/100 = 31 + 25*6.89/100 Bar = 33 Bar
use whichever is larger as the design value for Pd = 3410 KPa
and also use 2:1 ellipsoidal head w/ R = D/2 = 2.235 m
b. Maximum acceptable working temperature = 370 C
c. Material:
Shell SA – 516 Gr 70, allowable stress Sa (16,600 psi) = 114374 KPa
Head SA – 181 class 70, allowable stress Sa (16,600 psi) = 114374 KPa
d. Weld Efficiency = .85
2. Shell thickness (tkS)
tkS = Pd* R/( Sa * ε – .6* Pd)
Note: ε = .85 weld efficiency for 2:1 ellipsoidal head
tkS = 3410*2.235/ (114374*.85 – 1.2* 3410) = .080 m (80mm)
3. Head thickness (tH)
tH = Pd*R/[2*ε*(Sa) – .20*Pd]
Note: ε = .85 weld efficiency for 2:1 ellipsoidal head
tH = 3410*2.235/[2*(.85)*114374 – .20*(3410)] = .039 m ( 39.4 mm)
Section 13: Design Problem 13. 2:
Using the same steam accumulator above problem, select and design the needed number of nozzles and
number of holes per nozzle to be used during charging mode of the steam accumulator. Assuming 50
m/s for safety steam velocity for the nozzle. Determine the following:
a. Size and number of holes per nozzle.
b. Volumetric flow rate (QNZ) and steam flow rate (ENZ) per nozzle.
c. Number of nozzles to serve the 113636.4 Kg/hr steam flow rate (NNZ).
Solution:
a. In designing steam accumulator, it is normally a design norm to assume the following:
1. Dh, size of hole is 6.35 mm or .00635 m (1/4 of an inch) or base from safe steam velocity
of 50m/s.
2. Using initially, a -12 hole per nozzle
b. Volumetric flow rate per nozzle (QNZ)
Q_NZ = [ ( (no. of holes)*π*Dh2)/ 4 ]*Vs
Q_NZ = [( (12)*π*(.00635)2)/4 ]*50 = .019 m3/s
Note: Computing for Density of steam (Dens) at Tsat of 197.69 °C
SVg = (1/16)*exp [9.3239 – .041055*(1.8*T + 32) + .000071159*(1.8*T + 32)2
– .00000005703*(1.8*T + 32)3]
SVg = (1/16)*exp [9.3239 - .041055*(1.8*(197.69) + 32) + .000071159*(1.8*(197.69) + 32)2
– .00000005703*(1.8*(197.69) + 32)3] = .1360 m3/kg
Deng = 1/SVg = 1/.1360 = 7.35 kg/m3
Steam flow rate per nozzle (ENZ)
ENZ = Q_NZ x Deng = .019 x 7.35 = .14 Kg/s
c. Computing for number of nozzles (NNZ)
NNZ = Ws/ENZ = 113636.4/.14*3,600 = 225.46 say 226 nozzles
Section – 14 : Sizing and Selection of Vertical Vapor – Liquid Separator

Vertical Gas Liquid Separator:

Variables:
Denw - density of liquid
Deng - density of vapor
VL - volumetric liquid flow rate
VV - volumetric vapor flow rate
Mw - sat. liquid mass flow rate
Mg - sat. vapor mass flow rate
Mv - maximum vapor velocity
kv - velocity factor, (.03045 m/s - with no mist eliminator) or (.107 m/s - with a mist eliminator)
As - cross sectional Area
LL - liquid level height
ts - surge time, (3 ≤ ts ≤ 5min)
LT - separator height
LT/D - height to diameter of separator tank ratio
Generic Procedure for Sizing Vertical Gas - Liquid Separator
1. Select a Souders - Brown velocity factor, Ks .
2. Calculate the maximum gas velocity Mv, ( Mv = Ks*( (Denw - Deng)/ Deng).50 )
3. Calculate the separator tank cross sectional area AS, As = ( (π*D²)/ 4)
4. Calculate the separator tank Diameter, D
5. Round off the diameter D in .152m increments, starting at .762m. If diameter D is less than
.762m, use standard pipe
6. Select a liquid phase surge time, ts
7. Calculate the liquid level height, (LL = (VL)* ts/A) – where the minimum value of LL is .610m
8. Calculate the total separator height, (LT = LL + 1.5*D + 1.5) or 2.59m whichever is larger - Round off
L in .0762 m increments, for example, 1.524, 1.6002, 1.6764, 1.752 m, etc.
9. If L/D < 3.0; then calculate L so that L/D > 3.0 by letting L/D = 3.2
If L/D > 5 use a horizontal separator.
10. Pressure Vessel Design :
a. Design pressure (Pd)
Pd = 1.1 * P1 or Bar
Pd = P1 + 25*6.89/100 Bar
whichever is larger of the above, will be used as the design value for Pd, also if P1<10.3 Bar use
torispherical head else use 2:1 ellipsoidal head
b. Maximum acceptable working temperature = 370 C
c. Material:
Shell SA – 516 Gr 70, allowable stress Sa (16,600 psi) = 114374 KPa
Head SA – 181 class 70, allowable stress Sa (16,600 psi)= 114374 KPa
d. Weld Efficiency = .85

Fig. 14.1 : T-s diagram of a single-flash geothermal/industrial plant

Table 14.1 API 12 J Recommended range of Ks –values for Vertical and Horizontal separators

Source : American Petroleum Institute, 12 J, Specification for Oil and Gas Separators, 8th Edition, October, 2008.
with mist eliminator

Chart 12.1 Souders – Brown Velocity Factor

(w/out the application of mist pad or eliminator)

Source: Campbell, J.M., Gas Conditioning and Processing, Volume 2: The Equipment Modules, 9th Edition, 2nd
Printing, Editors Hubbard, R. and Snow–McGregor, K., Campbell
 Figure 14.2 : Ellipsoidal and torispherical vessel heads

Table 14.2: Wall thickness Rounding Increments for Pressure Vessels

Wall Thickness, mm (in) Rounding Increment, mm (in)
≤25.4 (1) .794 (1/32)
>25.4≤50.8 (>1 ≤ 2) 1.59 (1/16)
>50.8≤76 (>2 ≤ 3) 3.18 (1/8)
>76 (>3) 6.35(1/4)
Note: Because alloy steels and nonferrous metals are more costly than
carbon steel, the rounding increment should be smaller than the above.

Table 14.3: Minimum vessel thickness for pressure vessels

Minimum Vessel Thickness for Pressure Vessels
Metal Service Minimum thickness, mm (in)
Carbon and low alloy steels Noncorrosive 2.38 (3/32)
High alloy steels and
Noncorrosive 1.59 (1/16)
nonferrous metals
High alloy steels and
Corrosive 2.38 (3/32)
nonferrous metals
Section 13: Design Problem - 13.1
Calculate the length and diameter of a gas liquid separate 5.68 m3/min of vapor from .189 m3/min
of a liquid.
Given:
Vapor Density - - - - - - 21.98 Kg/m3
Liquid Density - - - - - - 499 Kg/m3
Design pressure - - - - - 3.45 Barg
Design Temperature - - 93 C
Material - - - - - - - - - - -
Shell SA – 516 Gr 70, allowable stress Sa (16,600 psi) = 114374 KPa
Head SA – 181 Class 70, allowable stress Sa (16,600 psi) = 114374 KPa
Weld Efficiency - - - - - - 85% or .85
Solution:
Sizing for Vertical Gas Liquid Separators
Ks = .107 m/s ( with a mist eliminator will be used)
For Max. Vapor Velocity, Mv
Mv = Kv*(Denw – Deng/Deng).50 = .107*(499 – 21.98/21.98).50 = .497m/s
For cross-sectional area of the separator, As
As = VV/ Mv
As = (5.68m3) /(.497*60) = .191m2
For Separator Diameter, D
D = (4*A/π).50 = (4*.191/π).50 = .493 m
Use standard pipe because the diameter is below .762m. From the Chemical Eng’g Handbook.
Select a .254 m pipe, which has an inside diameter of .495m, an inside cross-sectional area of .193m2
For the height of the liquid,
ts = 4min (ave. surge time)
LL = (VL)*ts / A
LL = .189 m3/min*(4min) / 1*(.193 m2) = .393m
The minimum liquid level is .610m
LT = LL + 1.5*D+1.5
= 2 + 1.5*(.495) + 1.5 = 1.81m
Round off the length in .0762 m intervals. Therefore, L= 1.8288 m, but the minimum length is 1.83 m.
L/D = 1.83/.495 = 3.7
For torispherical head, tH
Material:
Sa = Su/ Factor of safety
= 5000/2.5
= 4800 psi (33072 KPa) with ε = .80 – Weld efficiency
Pd = 345 KPag
D = .495 m
th = 1.104*(Pd)*D/(2*ε*(Sa) – 1.2*Pd)
= 1.104*(345)*(.495)/2*(.80)*(33094.84) – 1.2*(345) = .0036m (3.59mm)
For shell thickness, tks
tks = Pd*D/2*ε*(Sa) – 1.2*Pd
= 345*(.495)/2*(.70)*(33,094.84) – 1.2*(345) = .0073m (3.72mm)
Section 13: Design Problem - 13.2
An engineer in an industrial plant is required to size a vertical vapor-liquid separator to separate a
mixture of steam and water given the following data:
Mass flow rate of vapor steam (Mg) = 20,000 Kg/hr
Mass flow rate of liquid water (Mw) = 10,000 Kg/hr
Design pressure (Pd) = 2,100 KPag (saturated)
Design temperature (T) = 214.90 °C (saturated)
Material = Carbon steel with yield strength (Su) of 34,450 KPa
= factor of safety of 2.5
Determine the following:
a. Select appropriate velocity factor (Ks) and surge time (ts)
b. Density of liquid water and vapor steam (Denwand Deng)
c. Maximum vapor velocity (Mv)
d. Volumetric flow rate of liquid (VL) and vapor (VV)
e. Size the vertical gas-liquid separator:
1. Tank cross-sectional area (As)
2. Tank diameter (D)
3. Separator height (H)
4. Height to diameter of separator tank ratio (LT/D)
5. Allowable stress (Sa)
6. Head thickness (th)
7. Shell thickness (tks)
f. Liquid level height (LLH)

Solution:
a. Selecting for velocity factor (Kv) and surge time (ts)
Use Kv = .107 m/s with mist eliminator
ts = 240 sec (4 mins)
b. Computing for density of liquid water (Denw) using equation
Denw = 1004.061 – .056555*(1.8*T + 32) - .00077*(1.8*T + 32)2
= 1004.061 – .056555*[1.8*(214.9) + 32] – .00077*[1.8*(214.9) + 32]2 = 845.31 Kg/m3
Computing for specific volume (SVs) and density of vapor steam (Deng) using equation
SVg = (1/16)*exp[9.3239 – .041055*(1.8*T + 32) + .000071159*(1.8*T + 32)2
– .00000005703*(1.8*T + 32)3]
= (1/16)*exp[9.3239 – .041055*(1.8*(214.9) + 32) + .000071159*(1.8*(214.9) + 32)2
– .00000005703*(1.8*(214.9) + 32)3]
= .095 m3/kg
Deng = 1/SVg = 1/.095 = 10.53 Kg/m 3
c. Computing for maximum vapor velocity, Mv
Mv = Ks* ((Denw - Deng)/Deng).50
Mv = .107*((845.31–10.53)/10.53).50 =.95 m/s
d. Computing for volumetric flow rate of vapor and liquid, VV and VL
VV = Mg/(3600*Deng) = 20,000/(3600*10.53) = .53 m3/s
VL = Mw/(3600*Denw) = 10,000/(3600*845.31) = .0033 m3/s
e. Size the vertical gas-liquid separator:
1. Tank cross-sectional area (As)
As = VV/Mv = .53/.95 = .558 m2
2. Tank diameter (D)
D = (4*As/π).50 = (4* .558/π).50= .843 m
3. Separator height (LT)
H = LLH + 1.5*D + 1.5 = [(VL)*(ts)/As]+ 1.5*D + 1.5
= [(.0033)*(240)/.558] + 1.5*(.843) + 1.5 = 4.18 m
4. Height to diameter of separator tank ratio (LT/D)
H/D = 4.18/.843 = 4.9 SAY 5
5. Allowable stress (Sa)
Sa = Su/Factor of safety =34,450/2.5 = 13,780KPaa
6. Head thickness (tH)
tH = 1.104*(Pd)*(D)/2*ε*(Sa) – 1.2*Pd
Note: use ε = .80 - weld efficiency
tH = 1.104*(2100)*(.843)/2*.80*(13,780) – 1.2*(2100) = .10 m (100 mm)
7. Shell thickness (tks)
tks = Pd*(D)/2*ε*(Sa)-1.2*Pd
Note: use ε = .70 - weld efficiency
tks = (2100)*(.843)/2* .70*(13,780)-1.2*(2100) = .11 m (110 mm)
f. Liquid level height (LLH)
LLH = (VL)*(ts)/As = (.0033)*(240)/.558 = 1.42 m
Section – 14 : Sizing and Selection of Horizontal Vapor – Liquid Separator

Fig. 14.1

Fig. 14.2

Horizontal Gas Liquid Separator

Variables:
VL - Volumetric liquid flow rate
VV - Volumetric vapor flow rate
Mw - sat. liquid mass flow rate
Mg - sat. vapor mass flow rate
Mv - Max. gas velocity
Kv - Velocity factor, (.0305 m/s - with no mist eliminator)
(.107 m/s - with a mist eliminator)
As - separator tank cross sectional Area
L - length of the separator tank ,
ts - surge or residence time (7.5 ≤ tS ≤ 10mins)
D - separator tank diameter
Generic Procedure for Sizing Horizontal Gas – Liquid
1. Select velocity factor, kv
2. Calculate the maximum vapor velocity, Mv, ( Mv = (1.25)*Kv (Denw - Deng/ Deng).50 )
3. Calculate the cross sectional area, As , (As = π* D2/ 4)
4. Calculate the Length L, (L = (VL)*ts / (.5)*As)
5. Calculate D using D = (4*A/ π).50. Round off Length L in (.762m) intervals (for example, in meter
1.524, 1.6002, 1.6764, 1.752, etc.
6. If L/D < 3.0, then recalculate L so that L/D > 3.0 by setting L/D = 3.2.
If L/D > 5.0, then recalculate D so that L/D < 5.0 by setting L/D = 4.8
7. Pressure Vessel Design :
a. Design pressure (Pd)
Pd = 1.1 * P1 or Bar
Pd = P1 + 25*6.89/100 Bar
whichever is larger of the above, will be used as the design value for Pd, also if P1<10.3 Bar use
torispherical head else use 2:1 ellipsoidal head
b. Maximum acceptable working temperature = 370 C
c. Material:
Shell SA – 516 Gr 70, allowable stress Sa (16,600 psi) = 114374 KPa
Head SA – 181 class 70, allowable stress Sa (16,600 psi)= 114374 KPa
d. Weld Efficiency = .85

Figure 1: T-s diagram of a single flash geothermal/industrial plant

 Figure 2: Ellipsoidal and torispherical vessel heads

Table 1: Wall thickness Rounding Increments for Pressure Vessels

Wall Thickness, mm (in) Rounding Increment, mm (in)
≤25.4 (1) .794 (1/32)
>25.4≤50.8 (>1 ≤ 2) 1.59 (1/16)
>50.8≤76 (>2 ≤ 3) 3.18 (1/8)
>76 (>3) 6.35(1/4)
Note: Because alloy steels and nonferrous metals are more costly than
carbon steel, the rounding increment should be smaller than the above

Table 2: Minimum vessel thickness for pressure vessels

Minimum Vessel Thickness for Pressure Vessels
Metal Service Minimum thickness, mm (in)
Carbon and low alloy steels Noncorrosive 2.38 (3/32)
High alloy steels and
Noncorrosive 1.59 (1/16)
nonferrous metals
High alloy steels and
Corrosive 2.38 (3/32)
nonferrous metals
Section 14: Design Problem - 14.1
Calculate the length and diameter of a gas liquid separate 5.68 m3/min of vapor from .189m3/min
of a liquid.
Given:
Vapor Density = 21.98 kg/m3
Liquid Density = 499 kg/m3
Design pressure = 3.45barg
Design Temperature = 93°C
Material = Carbon steel
kv = .107 m/s - (with a mist eliminator will be used)
For Max. Vapor Velocity, Mv
Mv = Kv*( Denw – Deng/Deng).50
Mv = 1.25*.107(499-21.98/21.98).50 = .623 m/s
Area of the separator, A
A = VV/ Mv = (5.68/.623*(60s/min))
A = .305m2
For Separator Diameter, D
D = (4*A/π).50
D = (4*.305m2/π).50 = .623 m
The minimum vapor-phase height is .838. Because the liquid level is at the middle of the separator, the
minimum D = 1.68m.
For cross-sectional area, As
As = π*D2/4
As = π*(1.68)2/4 = 2.21 m2
Now for a separator that is half filled with liquid
LT = (VL)*ts/ .5*A
LT = .189 m3/min*(8.75min) /(2.21 m2)*(.5) = 1.50m
This clearly is not satisfactory. The L/D ratio should be in the range of 3.0<L/D<5.0. If we select 3.2, then
LT = 3.2*(1.68 m) = 5.38
Round off the length to 5.41m. This separator is larger than the vertical separator.
Let us try to reduce the size of the horizontal separator. If we move the mist eliminator to outside of the
separator shell, the diameter will be reduced. From the calculation of separator diameter, D < .623 m.
Because D<.762m we can use pipe. From the mechanical engineering handbook, select a

.76m pipe Schedule SI pipe, which has an inside diameter of .743m. An inside cross- sectional area of
.4335 m2 and a wall thickness of .00953 m. The allowable pressure for carbon steel at 93°C and 18.3 barg
which is above the design pressure of 3.5 barg.

L = (VL)*ts/ .5A
L = .189 m3/min*(8.75min) / 1*(4.45 m2)*(.5) = .743

Round off the length to 2.06m. The effect of increasing the separator length is to increase the surge time
above the original 8.75 min.
The vertical separator is .494m in diameter and 2.59m long. At this point, it appears that the vertical
separator is the best choice because of its smaller diameter and wall thickness. Also, locating the mist
eliminator outside of the separator shell will add to the cost of the horizontal separator.
Section 14: Design Problem - 14.2
An engineer in an industrial plant is required to size a horizontal vapor-liquid separator to separate a
mixture of steam and water with the following data:
Mass flow rate of vapor steam (Mg) = 20,000 Kg/hr
Mass flow rate of liquid water (Mw) = 10,000 Kg/hr
Design pressure (Pd) = 2,100 KPag (saturated)
Design temperature (T) = 214.90 °C (saturated)
Material = Carbon steel with yield strength (Su) of 34,450 KPaa
factor of safety = 2.5
Table 1: Height to diameter of horizontal separator tank ratio

Operating Pressure, bar (KPa) Height: Diameter (H/D)

0 – 20 (0 – 2000) 3
20 – 35 (2000 –3500) 4
35 above (3500 above) 5

Determine the following:

a. Select appropriate velocity factor (Kv)
b. Density of liquid water and vapor steam (Denw and Deng)
c. Maximum vapor velocity (Mv)
d. Volumetric flow rate of liquid (VL) and vapor (VV)
e. Size the horizontal gas-liquid separator:
1. Surface area (SA)
2. Tank diameter (D)
3. Cross-sectional area (As)
4. Height to diameter of separator tank ratio (H/D)
5. Surge time (ts) and separator tank height (H)
f. Allowable stress (Sa)
g. Head thickness (th)
h. Shell thickness (tks)
Solution:
a. Selecting for velocity factor, Kv
Kv = .107 m/s with mist eliminator
b. Density of liquid water (Denw)
Denw = 1004.061 – .056555*(1.8*T + 32) – .00077*(1.8*T + 32)2
Denw = 1004.061 – .056555*[1.8*(214.9) + 32] – .00077*[1.8*(214.9) + 32]2 = 845.31 Kg/m3
Specific volume (SVs) and density of vapor steam (Deng)
SVg = (1/16)*exp[9.3239 – .041055*(1.8*T + 32) + .000071159*(1.8*T + 32)2
– .00000005703*(1.8*T + 32)3]
 SVg = (1/16)*exp[9.3239 – .041055*(1.8*(214.9) + 32) + .000071159*(1.8*(214.9) + 32)2
– .00000005703(1.8*(214.9) + 32)3] = .095 m3/kg
Deng = 1/SVg = 1/.095 = 10.53 Kg/m3
c. Maximum vapor velocity, Mv
Mv = 1.25*Kv ((Denw – Deng)/Deng).50
Mv = 1.25*(.107) ((845.31 – 10.53)/10.53).50 = 1.19 m/s
d. Volumetric flow rate of vapor and liquid (VV and VL)
VV = Mg/ (3600*Deng) = 20,000/ (3600*10.53) = .53 m3/s
VL = Mw/ (3600*Denw) = 10,000 /(3600*845.31) = .0033 m3/s
e. Size the horizontal gas-liquid separator:
1. Surface area (SA)
SA = VV/ Mv = .53/1.19 = .445 m2
2. Tank diameter (D)
D = (4*SA/ π).50 = (4* .445/π).50 = .753 m
Use minimum standard diameter 1.68 m
3. Cross-sectional area (As)
As = π*D2/ 4 = π*(1.68)2/ 4 = 2.22 m2
4. Height to diameter of separator tank ratio (H/D)
Using Table 1 above, H/D = 4
5. Surge time (ts) and separator tank height (H)
ts = use 240 sec (4 mins.)
H = (VL)*ts/.5*As = (.0033)*(240)/.5*(2.22) = .714 m
This clearly is not satisfactory. The H/D ratio should be in the range of 3.0<L/D<5.0.
If we select 3.2,
H/D = 3.2
H = 3.2*D =3.2*(1.68) = 5.38 m
Alternative solution,
If we selectH/D = 4 from Table 1,
H = 4*(1.68m) = 6.72 m
6. Allowable stress (Sa)
Sa = Su/ Factor of safety = 34,450/2.5 = 13,780 KPaa
7. Head thickness (tH)
tH = 1.104*(Pd)*(D)/2*ε*(Sa) – 1.2*Pd
Note: use ε = .80 – weld efficiency
tH = 1.104*(2100)*(1.68)/2* .80*(13,780) – 1.2*(2100) = .20 m (200mm)
8. Shell thickness (tks)
tks = Pd*(D)/2*ε*(Sa) – 1.2*Pd
Note: use ε = .70 – weld efficiency
tks = (2100)*(1.68)/2* .70*(13,780) – 1.2*(2100) = .21 m (210 mm)
STEAM BALANCE

FIGURE 1: STEAM BALANCE SCHEMATIC DIAGRAM

Sample Problem 1: From the given diagram below with its pressures and temperatures, the following
enthalpies (from Mollier chart) to be used in the mass and energy balance are
as follow:

FIGURE 1: SAMPLE PROBLEM SCHEMATIC DIAGRAM

Determine the following:

a. Establish the seven (7) basic mass & energy equations. Furhtermore, also establish the 1 – 13
equations with three (3) unknowns (B, C & D) due the outcome of the 7 basic mass & energy
equations.
b. Given item a, compute for steam masses B, C & D through matrix analysis. Furthermore, compute
for the other steam masses A, E & G.
c. What are the pressure drops using top-down analysis?
Solution:
a. Establishing the 7 basic mass and energy equations
1. Seven equations derived from Figure 1:
a. Mass balance at Turbine 1
A=B+C Eq. 1
b. Energy balance at Turbine 1
14,920 = B/18.3 + C/4.88
Simplifying by multiplying the above equation by 18.3 and 4.88
(18.3)*(4.88)*(14,920) = (B/18.3 + C/4.88)*(18.3)*(4.88)
1,332,415.7 = 4.88*B + 18.3*C
4.88*B + 18.3*C = 1,332,415.7 Eq. 2
c. Mass balance at header B and D (42 Bar)
B = 13,636.4 + D + 45,454.5 + 45,454.5
B = D + 104,545.4 Eq. 3
d. Mass balance at header E (4.5 Bar)
G + D + 13,636.4 = E and computing for G
G = E – D – 13,636.4 Eq. 4
e. Energy balance at boundary wxyz
D*(3,425) + 13,636.4*(3,425) + G*(505) = E*2,800 Eq. 5
f. Mass balance at boundary 1234
E + C + 90,909.1 = A + G Eq. 6
g. Energy balance at boundary 1234
E*(2,800) + (C + 90,909.1)*(158) = (A + G)*(505) Eq. 7
Where: A, B, C, D, E and Gare variables shown in the above diagram in Kg/Hr
2. Substitute Equation 4 to Equation 6 and simplify to get Eq. 8
G = E – D – 13,636.4
E + C + 90,909.1 = A + G
E + C + 90,909.1 = A + E – D –13,636.4
A – C – D = 104,545.5Equation 8
3. Substitute Equation 1 to Equation 8and simplify to obtain Eq. 9
A=B+C
A – C – D = 104,545.5
B + C – C – D = 104,545.5
B – D = 104,545.5Equation 9
4. Substitute Equation 4 to Equation 7 and simplify to have Eq. 10
G = E – D – 13,636.4
E*(2,800) + (C + 90,909.1)*(158) = (A + G)*(505)
 E*(2,800) + (C + 90,909.1)*(158) = (A + E – D – 13,636.4)*(505)
2,800*E + 158*C + 14,363,637.8 = 505*A + 505*E – 505*D – 6,886,382
505*A + 505*E – 505*D – 2,800*E – 158*C = 14,363,637.8 + 6,886,382
505*A – 158*C – 505*D – 2,295*E = 21,250,020 Eq. 10
5. Substitute Equation 1 to Equation 10and simplify to obtain Equation 11 and compute for E.
A=B+C
505*A – 158*C – 505*D – 2,295*E = 21,250,020
505*(B + C) – 158*C – 505*D – 2,295*E = 21,250,020
505*B + 505*C – 158*C – 505*D – 2,295*E = 21,250,020
505*B + 347*C – 505*D – 2,295*E = 21,250,020
2,295*E = 505*B + 347*C – 505*D – 21,250,020
E = (505*B + 347*C – 505*D – 21,250,020)/2,295 Eq. 11
6. Substitute Equation 4 to Equation 5 and simplify to get Equation 12.
G = E – D – 13,636.4
D*(3,425) + 13,636.4*(3,425) + G*(505) = E*2,800
D*(3,425) + 13,636.4*(3,425) + (E – D – 13,636.4)*(505) = E*2,800
3,425*D + 46,704,670 + 505*E – 505*D – 6,886,382 = 2,800*E
2,800*E – 3,425*D – 505*E + 505*D = 46,704,670 – 6,886,382
2,295*E – 2,920*D = 39,818,288 p[[[[ Eq. 12
7. Substitute Equation 11 into Equation 12and simplify to obtain Equation 13.
E = (505*B + 347*C – 505*D – 21,250,020)/2,295
2,295*E – 2,920*D = 39,818,288
2,295*(505*B + 347*C – 505*D – 21,250,020)/2,295) – 2,920*D = 39,818,288
505*B + 347*C – 505*D – 21,250,020 – 2,920*D = 39,818,288
505*B + 347*C – 505*D – 2,920*D = 39,818,288 + 21,250,020
505*B + 347*C – 3,425*D = 61,068,308 Eq. 13
b. Select Equations 2, 9 and 13.
Step 1: 4.88*B + 18.3*C = 1,332,415.7
B – D = 104,545.5
505*B + 347*C – 3,425*D = 61,068,308
Arrange the above three equations in tabulate form.
B C D Sum or Difference
4.88 18.3 0 1,332,415.7
1 0 -1 104,545.5
505 347 -3,425 61,068,308
Step 2: Form Determinant matrix A (as numerator)
18.3 0 1,332,415.7 18.3 0
0 -1 104,545.5 0 -1
347 -3,425 61,068,308 347 -3,425

Step 3: Form Determinant matrix B (as denominator)

4.88 18.3 0 4.88 18.3

1 0 -1 1 0
505 347 -3,425 505 347

Step 4:
18.3 0 1,332,415.7 18.3 0
0 -1 104,545.5 0 -1 Numerator
347 -3,425 61,068,308 347 -3,425
B = ___________________________________________
4.88 18.3 0 4.88 18.3
1 0 -1 1 0 Denominator
505 347 -3,425 505 347

Step 5: Perform the determinant matrices by cross multiply the numbers diagonally.
18.3 0 1,332,415.7 18.3 0
0 -1 104,545.5 0 -1 Numerator
347 -3,425 61,068,308 347 -3,425
B = _______________________________________________________
4.88 18.3 0 4.88 18.3
1 0 -1 1 0 Denominator
505 347 -3,425 505 347

Step 6: Compute for steam mass B using matrix analysis

B = +(18.3)*(-1)*(61,068,308) – (347)*(-1)*(1,332,415.7) – (- 3,425)*(104,545.5)*(18.3)
+(18.3)*(-1)*(505) – (347)*(-1)*(4.88) – (- 3,425)*(1)*(18.3)

B= - 1,117,550,036 + 462,348,247.9 + 6,552,650,576

- 9,241.5 + 1,693.36 + 62,677.5

B = 5,897,448,788B = 106,974.7 Kg/Hr

55,129.4
After solving for steam mass B solve for the other steam masses,
Solving for D
B = D + 104,545.4
D = B – 104,545.4= 106,974.7 – 104,545.4D = 2,429.3 Kg/Hr
Solving for C
4.88*B + 18.3*C = 1,332,415.7
C = (1,332,415.7 – 5*B)/18.3
C = (1,332,415.7 – 5*(106,974.7))/18.3C = 44,283.01 Kg/Hr
Solving for A
A = B + C = 106,974.7 + 44,283.01A= 151,257.7 Kg/Hr
Solving for E
E = (505*B + 347*C – 505*D – 21,250,020)/2,292
E = (505*(106,974.7) + 347*(44,283.01) – 505*(2,429.3) – 21,250,020)/2,292
E = 20,440.8 Kg/Hr
Solving for G
G = E – D –13,636.4
G = 20,440.8 – 2,429.3 – 13,636.4 = 4,375.1 Kg/Hr

Alternate solution: Using TK Program without resulting to matrix analysis

Step 1: Input the thirteen (13) equations in the Rule sheet.
Step 2: Proceed to Variable sheet.
Avail of unique TK iteration capability by entering initial values of .10 for both A & B
For A, right click
“Status”, right click and select “Display Subsheet”, enter .10 under “First Guess” and do
the same thing for B.
Step 3: Click “Solve” icon.
Step 4: You will get the same values for A, B, C, D, E and G.

c. Using top-down analysis for the pressure drops;

1. Pressure drop across the two steam turbines (∆P1)
∆P1 = Pa – Pb = 104 – 42 = 62 Bar
2. Pressure drop across thesteam turbine 2 vs. the deaerator (∆P2)
∆P2 = Pb – Pd = 42 – 4.5 = 37.5 Bar
3. Pressure drop inside the deaerator (∆P3)
∆P3 = Pd – Pf = 4.5 – 2 = 2.5 Bar