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[null,"ENERGY EFFICIENCY TOOLS FOR BOILER AND STEAM SYSTEMS"]
[null,"VER_03/180519"]
[null,"INTRODUCTION: This workbook consists of multiple tools that conduct Assessment of Compressed Air System, calculate Energy Performance of Compressors, and calculate Energy Saving Potentials in Compressed Air System"]
[null,"INTRODUCTION: This workbook consists of multiple tools that conduct Assessment of Boilers and Steam System, calculate Energy Performance and Efficiency of Boilers, and calculate Energy Saving Potentials in the System."]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white.\n2. Results of calculations will be displayed in Orange Cells.\n3. Examples of Data and Calculation are shown in each tool."]
[null,"SOURCES:"]
[null,"1. Spirax Sarco Limited; http://www.spiraxsarco.com/pages/home.aspx   \n2. Improving Steam Boiler Operating Efficiency , by Enercon.gov.pk   \n3. Energy Technology Handbook, McGraw Hill, 9-46   \n4. Saturated Steam Table by Pressure; http://www.tlv.com/global/TI/calculator/steam-table-pressure.html   \n5. https://www.engineersedge.com/thermodynamics/steam_tables.htm   \n6. Properties of Saturated Steam; http://www.engineeringtoolbox.com/saturated-steam-properties-d_457.html   \n7. Water Thermal Properties; http://www.engineeringtoolbox.com/water-thermal-properties-d_162.html   \n8. www.enggcyclopedia.com/2011/09/sample-problem-insulation-thickness-calculation-pipe/   \n9. www.engineeringtoolbox.com/fiberglas-insulation-k-values-d_1172.html   \n10. www.engineeringtoolbox.com/mineral-wool-insulation-k-values-d_815.html   \n11. \"INSULATION AND REFRACTORIES\"  by Bureau of Energy Efficiency India page 122-128, pdhonline.org/cources/m157/m157 content.pdf   \n12. http://www.infrared-thermography.com/material.htm   \n13. Estimating of cost steam lost through orifices(By Henry Manczyk, CPE, CEM); http://www.swagelokenergy.com/download/ECSLTOST.pdf  \n14. Bureau of energy efficiency India \n15. Enorcon Pakistan \n16.  APO Japan\n17. Excel add-in for Steam and Water Tables \"Water97_v13.xla\"  by Bernhard Spang"]
[null,"WHO WE ARE:"]
[null,"ESPIRE Consult provides consulting and training services in the fields of Resource Efficiency and Business Management in The Islamic Republic of Pakistan. Using internationally certified methodologies and systems, we provide end-to-end tailor made solutions to improve resource efficiencies resulting in cost reduction and operational excellence.\n\nFrom 2008 tiill 2016, ESPIRE operated as a partnership project between the Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH and business associations in Lahore and Karachi in Pakistan and was funded by the German Federal Ministry for Economic Cooperation and Development (BMZ) via Sequa gGmbH. The objective of ESPIRE project was to support industries in Pakistan to work economically more efficiently and ecologically more sustainable and start making energy conservation and cleaner production part of their work routine. Main project partners were; Pakistan Association of Automotive Parts and Accessories Manufacturers (PAAPAM), Pakistan Hosiery Manufacturers Association (PHMA), Pakistan Readymade Garments Manufacturers and Exporters Association (PRGMEA), Small and Medium Enterprises Development Authority (SMEDA), Towel Manufacturers Association of Pakistan (TMA).\n\nThis tool is developed under the Project ESPIRE and updated, maintained and distributed by ESPIRE Consult free of cost."]
[null,"DISCLAIMER:"]
[null,"The information, calculations and conclusions in this tool are based on the projects executed by the experts and consultant under Project ESPIRE by bfz gGmbH – International Division. Some sources (as mentioned above) were also consulted to validate the contents. The efficiency improvement measures proposed in this tool are tested and tried in many companies in Pakistan. However, implementation of these measures in any particular case should be based on real time data analysis by qualified engineers after judging financial viability. ESPIRE Consult, Bfz gGmbH – International Division and it's Project Partners in Pakistan accepts no liability whatsoever to any person, company or entity for any injury, loss or damage that may arise in connection with any misuse or reliance on the information.\n\nThe tool is provided as a freeware. Users may make copies and distribute the tool without making any changes."]
[null,"CONTACT:"]
[null,"Users may contact following for any clarification in this tool;"]
[null,"Muhammad Salman Butt\nExecutive Director\nEspire Consult, Pakistan\n0092 305 5552343\nsalman@espire.com.pk"]

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[]
[null,"CHECKLIST FOR HOT WATER & BOILER SYSTEM"]
[null,null,"ENERGY SAVING OPTIONS"]
[null,"LEVEL","PRODUCTION","RATING"]
[null,"-","Optimize boiler excess air, excess oxygen, and CO levels according to fuel type through boiler tuning based on Flue Gas Analysis [1% excess air reduction will increase 0.6% efficiency of combustion].","»"]
[null,"-","Insulate the Boiler surface completely and regularly monitor the surface temperatures to keep it close to Ambient Temperature.","»"]
[null,"-","Test Water Quality (feed water and Blow-down waste water) regularly to assess and maintain the efficiency of water treatment systems [Feed water and Blow-down TDS should be lesser than 100 ppm and 3500 ppm respectively].","»"]
[null,"-","Devise Blow-down cycle amounts and times based on water quality test to avoid the Blow-down loss.","»"]
[null,"-","Analyse the gap between the Generated and Demanded steam pressure and try to minimize it.","»"]
[null,"- -","Install automatic boiler Blow-down system.","»"]
[null,"- -","Separate fresh water from condensate water to avoid heat loss. Preheat fresh water before mixing with condensate water.","»"]
[null,"- -","Install stand-by feed water pump for contingency and to avoid any accidents.","»"]
[null,"- -","Keep stack temperature of Boiler as low as possible. Install a waste heat recovery system if the temperature of stack is more than 200°C.","»"]
[null,"- -","Install variable speed drives on Boiler Fans & Blowers.","»"]
[null,"- - -","Install waste heat recovery systems (exhaust air, blow-down) to preheat feed water or inlet air [20 degree Celsius rise in inlet air increases thermal efficiency by 1%].","»"]
[null,"- - -","Install micro modulation system with automatic excess air control and oxygen trimming.","»"]
[null,"- - -","Replace boiler if it is inefficient, over or under sized, and/or not fulfilling loading conditions. ","»"]
[null,null,"NETWORK","RATING"]
[null,"-","Regularly check steam distribution system for leakages and eliminate all steam leaks immediately.","»"]
[null,"-","Seal and insulate the Condensate tank completely to avoid heat loss.","»"]
[null,"-","Insulate all steam supply, condensate & feed water lines and fittings to avoid convection loss and keep the system pressure at optimum level.","»"]
[null,"-","Regularly monitor and maintain steam velocity and pressure drops within maximum allowable limits.","»"]
[null,"-","Avoid unnecessary Bends and Valves in the network.","»"]
[null,"-","Install all branch pipes upwards to avoid accumulation of condensate.","»"]
[null,"- -","Divide network in areas/sections to facilitate measurement and maintenance; shut off when not in use.","»"]
[null,"- -","Install all steam pipes with a fall of 1% [1:100] in direction of steam flow towards steam traps. ","»"]
[null,"- -","Reduce the length of the network to avoid pressure drops at far points.","»"]
[null,"- -","Regularly monitor and maintain steam traps.","»"]
[null,"- -","Install pipe sizes appropriate to the flow and pressure requirements.","»"]
[null,"- - -","Design a proper condensate return system to maintain the condensate temperature and reduce evaporation loss. Also consider pressurizing the condensate return system.","»"]
[null,null,"USE","RATING"]
[null,"- -","Regularly check steam distribution system for leakages and eliminate all steam leaks immediately.","»"]
[null,"- - -","Seal and insulate the Condensate tank completely to avoid heat loss.","»"]
[null,"- - -","Insulate all steam supply, condensate & feed water lines and fittings to avoid convection loss and keep the system pressure at optimum level.","»"]
[null,"- - -","Regularly monitor and maintain steam velocity and pressure drops within maximum allowable limits.","»"]
[null,null,"MAINTENANCE","RATING"]
[null,"-","Monitor condensate temperatures regularly and keep it below saturated steam temperature (there should be no steam in the returned condensate).","»"]
[null,"-","Regularly check the steam traps and repair or replace the failed steam traps.","»"]
[null,"-","Regularly monitor pressure drops in the steam distribution system (Pressure drop of steam should be below 0.1 bar per 50m of transmission).","»"]
[null,"-","Inspect boiler for scaling [indicators of scaling could be rise in flue gas temperature, imbalance between water intake and steam production, reduction in steam production. Every 22°C increase in temperature reduces thermal efficiency by 1%].","»"]
[null,"- -","Maintain cleanliness of boiler through feed water treatment (Reverse Osmosis, Chemical Treatment) to avoid fouling and/or scaling.","»"]
[null,"- -","Physically inspect boiler for scaling at least once a year and remove any scaling.","»"]
[null,"- -","Remove soot as it increases the stack temperature and reduces efficiency [every 3mm soot increases fuel consumption by 2.5%].","»"]
[]
[null,"LEVEL OF DIFFICULTY:"]
[null,"-","No/Low Cost or Short Term Investment [Pay-back period < 6 months]"]
[null,"- -","Medium Term Investment  [Pay-back period < 18 months]"]
[null,"- - -","Long Term Investment or Needs Feasibility Study  [Pay-back period > 18 months]"]
[]
[null,"RATING OF IMPLEMENTATION STATUS:"]
[null,null,"Energy Saving Option has not been considered yet.",1]
[null,null,"Energy Saving Option is in the planning stage but not yet realized.",2]
[null,null,"Energy Saving Option is partially (not in all areas/ machines or not all the time) implemented/ realized. ",3]
[null,null,"Energy Saving Option has been mostly implemented/ realized.",4]
[null,null,"Energy Saving Option is fully realized. ",5]
[null,null,null,"»"]

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[]
[]
[null,null,"Fuel","Price Unit","GCV","Net Heating Value","Converted Fuel Price by Volume",null,null,"Fuel Consumption Unit","Fuel per Ton of Steam","Hourly Fuel Consumption"]
[null,null,null,null,null,null,"Example Column","Data Column"]
[null,null,"Natural Gas","[Rs/mmbtu]","[btu/ft²]","[kW/m³]",{"$f":"IF('2| Main Inputs'!C24=\"Natural Gas\", ('2| Main Inputs'!C26*'2| Main Inputs'!C28*35.31/1000000), \"-\")","v":"-"},{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\", ('2| Main Inputs'!E26*'2| Main Inputs'!E28*35.31/1000000), \"-\")","v":"-"},"[Rs/m³]","[Sm³/mo]","[Sm³/Ton]","[Sm³/hr]","[mmbtu/y]"]
[null,null,"HFO","[Rs/kg]","[kJ/kg]","[kW/kg]",{"$f":"IF('2| Main Inputs'!C24=\"HFO\",('2| Main Inputs'!C26*1.0551/('2| Main Inputs'!C28/1000000)), \"-\")","v":"-"},{"$f":"IF('2| Main Inputs'!E24=\"HFO\",('2| Main Inputs'!E26*1.0551/('2| Main Inputs'!E28/1000000)), \"-\")","v":"-"},"[Rs/mmbtu]","[kg/mo]","[kg/Ton]","[kg/hr]","[kg/y]"]
[null,null,"LPG",null,null,null,{"$f":"IF('2| Main Inputs'!C24=\"LPG\",('2| Main Inputs'!C26*1.0551/('2| Main Inputs'!C28/1000000)), \"-\")","v":"-"},{"$f":"IF('2| Main Inputs'!E24=\"LPG\",('2| Main Inputs'!E26*1.0551/('2| Main Inputs'!E28/1000000)), \"-\")","v":"-"},"[Rs/mmbtu]"]
[null,null,"Coal",null,null,null,{"$f":"IF('2| Main Inputs'!C24=\"Coal\",('2| Main Inputs'!C26*1.0551/('2| Main Inputs'!C28/1000000)), \"-\")","v":"-"},{"$f":"IF('2| Main Inputs'!E24=\"Coal\",('2| Main Inputs'!E26*1.0551/('2| Main Inputs'!E28/1000000)), \"-\")","v":{"$error":"#DIV/0!"}},"[Rs/mmbtu]"]
[]
[]
[]
[null,null,"Pressure Conversion"]
[null,null,"[bar g]",1]
[null,null,"[psi]",{"$f":"14.5037738007*D13","v":14.503773800699999}]
[]
[null,null,"mmbtu to kg","mmbtu","kg"]
[null,null,"HFO",1,{"$f":"D17*0.025219021687207*1000","v":25.219021687207}]
[null,null,"LPG",1,{"$f":"D18/0.047","v":21.276595744680851}]
[null,null,"Coal",1,{"$f":"D19/0.019","v":52.631578947368425}]

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[]
[null,"Water Enthalpy Table",null,null,null,null,"Saturated Steam Enthalpy Table"]
[null,"Temperature",null,"Pressure","Specific enthalpy of liquid water *",null,"Pressure",null,"Specific enthalpy of Saturated Steam as function of Pressure *"]
[null,"°C","°K","Bar","kj/kg",null,"Bar","psi","kj/kg"]
[null,0,{"$f":"_xll.CONVERTIR(B5,\"C\",\"K\")","v":273.14999999999998},1.01325,6.1011961912233389E-2,null,1,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G5","v":14.503773800699999},2674.9496408321465]
[null,1,{"$f":"_xll.CONVERTIR(B6,\"C\",\"K\")","v":274.14999999999998},1.01325,4.2787080737766559,null,2,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G6","v":29.007547601399999},2706.2413413742588]
[null,2,275.14999999999998,1.01325,8.4931308535231995,null,3,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G7","v":43.511321402099995},2724.8916665566517]
[null,3,276.14999999999998,1.01325,12.704552843894799,null,4,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G8","v":58.015095202799998},2738.0566229312817]
[null,4,277.14999999999998,1.01325,16.913221784309549,null,5,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G9","v":72.518869003500001},2748.1076146579694]
[null,5,278.14999999999998,1.01325,21.119362979809562,null,6,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G10","v":87.02264280419999},2756.1388895363325]
[null,6,279.14999999999998,1.01325,25.323181448848768,null,7,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G11","v":101.52641660489999},2762.7490827695106]
[null,7,280.14999999999998,1.01325,29.52486387039994,null,8,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G12","v":116.0301904056},2768.3024646637436]
[null,8,281.14999999999998,1.01325,33.724580348957701,null,9,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G13","v":130.5339642063},2773.0376230707607]
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[null,11,284.14999999999998,1.01325,46.313419112465141,null,12,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G16","v":174.04528560839998},2783.7691331052347]
[null,12,285.14999999999998,1.01325,50.506694310477748,null,13,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G17","v":188.54905940909998},2786.4933612440836]
[null,13,286.14999999999998,1.01325,54.698656493351109,null,14,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G18","v":203.05283320979999},2788.8930140073867]
[null,14,287.14999999999998,1.01325,58.889405121951157,null,15,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G19","v":217.55660701049999},2791.010536295325]
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[null,20,293.14999999999998,1.01325,84.0130581525964,null,21,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G25","v":304.57924981470001},2799.3594202549652]
[null,21,294.14999999999998,1.01325,88.197509537878886,null,22,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G26","v":319.08302361540001},2800.2026882465839]
[null,22,295.14999999999998,1.01325,92.381310478867732,null,23,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G27","v":333.58679741610001},2800.9248286083694]
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[null,45,318.14999999999998,1.01325,188.51736971233049,null,46,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G50","v":667.17359483220002},2797.307805072785]
[null,46,319.14999999999998,1.01325,192.69619174452671,null,47,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G51","v":681.67736863289997},2796.5851420408685]
[null,47,320.14999999999998,1.01325,196.87513751687976,null,48,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G52","v":696.18114243359992},2795.8301269346061]
[null,48,321.14999999999998,1.01325,201.05422952459659,null,49,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G53","v":710.68491623429998},2795.0437825574509]
[null,49,322.14999999999998,1.01325,205.23349008914786,null,50,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G54","v":725.18869003499992},2794.2270660450631]
[null,50,323.14999999999998,1.01325,209.41294137698313,null,51,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G55","v":739.69246383569998},2793.3808738181665]
[null,51,324.14999999999998,1.01325,213.5926054159907,null,52,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G56","v":754.19623763639993},2792.5060460703012]
[null,52,325.14999999999998,1.01325,217.77250410997235,null,53,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G57","v":768.70001143709999},2791.6033708433815]
[null,53,326.14999999999998,1.01325,221.95265925136925,null,54,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G58","v":783.20378523779993},2790.6735877368519]
[null,54,327.14999999999998,1.01325,226.13309253242724,null,55,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G59","v":797.70755903849999},2789.717391290329]
[null,55,328.15,1.01325,230.31382555501989,null,56,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G60","v":812.21133283919994},2788.7354340744964]
[null,56,329.15,1.01325,234.49487983926738,null,57,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G61","v":826.7151066399},2787.7283295209413]
[null,57,330.15,1.01325,238.67627683113466,null,58,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G62","v":841.21888044059995},2786.6966545172354]
[null,58,331.15,1.01325,242.85803790911419,null,59,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G63","v":855.72265424130001},2785.6409517910588]
[null,59,332.15,1.01325,247.04018439014627,null,60,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G64","v":870.22642804199995},2784.5617321037048]
[null,60,333.15,1.01325,251.22273753486482,null,61,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G65","v":884.73020184270001},2783.4594762712145]
[null,61,334.15,1.01325,255.4057185522783,null,62,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G66","v":899.23397564339996},2782.3346370292211]
[null,62,335.15,1.01325,259.58914860397556,null,63,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G67","v":913.73774944410002},2781.1876407555201]
[null,63,336.15,1.01325,263.77304880792212,null,64,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G68","v":928.24152324479996},2780.0188890630266]
[null,64,337.15,1.01325,267.95744024193363,null,65,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G69","v":942.74529704549991},2778.8287602742389]
[null,65,{"$f":"_xll.CONVERTIR(B70,\"C\",\"K\")","v":338.15},1.01325,272.14234394688185,null,66,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G70","v":957.24907084619997},2777.6176107870051]
[null,66,339.15,1.01325,276.32778092968306,null,67,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G71","v":971.75284464689992},2776.3857763404658]
[null,67,340.15,1.01325,280.51377216612457,null,68,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G72","v":986.25661844759998},2775.1335731890813]
[null,68,341.15,1.01325,284.70033860357665,null,69,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G73","v":1000.7603922482999},2773.8612991915033]
[null,69,342.15,1.01325,288.88750116361149,null,70,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G74","v":1015.264166049},2772.5692348209341]
[null,70,343.15,1.01325,293.07528074458349,null,71,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G75","v":1029.7679398497},2771.2576441022647]
[null,71,344.15,1.01325,297.2636982241844,null,72,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G76","v":1044.2717136504},2769.9267754812822]
[null,72,345.15,1.01325,301.45277446200964,null,73,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G77","v":1058.7754874510999},2768.5768626303025]
[null,73,346.15,1.01325,305.64253030214451,null,74,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G78","v":1073.2792612517999},2767.2081251946415]
[null,74,347.15,1.01325,309.83298657580673,null,75,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G79","v":1087.7830350525001},2765.8207694834073]
[null,75,348.15,1.01325,314.02416410404442,null,76,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G80","v":1102.2868088532},2764.414989108082]
[null,76,349.15,1.01325,318.21608370051905,null,77,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G81","v":1116.7905826538999},2762.9909655721071]
[null,77,350.15,1.01325,322.40876617437198,null,78,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G82","v":1131.2943564545999},2761.5488688142309]
[null,78,351.15,1.01325,326.60223233318948,null,79,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G83","v":1145.7981302553001},2760.0888577082364]
[null,79,352.15,1.01325,330.79650298608078,null,80,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G84","v":1160.301904056},2758.6110805215576]
[null,80,353.15,1.01325,334.99159894686136,null,81,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G85","v":1174.8056778567},2757.1156753348673]
[null,81,354.15,1.01325,339.18754103735915,null,82,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G86","v":1189.3094516573999},2755.6027704250309]
[null,82,355.15,1.01325,343.38435009084424,null,83,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G87","v":1203.8132254580999},2754.072484612986]
[null,83,356.15,1.01325,347.58204695557856,null,84,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G88","v":1218.3169992588},2752.5249275788401]
[null,84,357.15,1.01325,351.78065249849891,null,85,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G89","v":1232.8207730595},2750.9602001456014]
[null,85,358.15,1.01325,355.98018760902085,null,86,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G90","v":1247.3245468601999},2749.3783945332975]
[null,86,359.15,1.01325,360.18067320298013,null,87,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G91","v":1261.8283206608999},2747.7795945852636]
[null,87,360.15,1.01325,364.3821302266939,null,88,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G92","v":1276.3320944616},2746.1638759677776]
[null,88,361.15,1.01325,368.58457966115384,null,89,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G93","v":1290.8358682623},2744.5313063447961]
[null,89,362.15,1.01325,372.78804252634654,null,90,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G94","v":1305.3396420629999},2742.881945529055]
[null,90,363.15,1.01325,376.99253988569728,null,91,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G95","v":1319.8434158636999},2741.2158456109223]
[null,91,364.15,1.01325,381.19809285063428,null,92,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G96","v":1334.3471896644},2739.5330510663312]
[null,92,365.15,1.01325,385.40472258528223,null,93,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G97","v":1348.8509634651},2737.8335988451568]
[null,93,366.15,1.01325,389.61245031126197,null,94,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G98","v":1363.3547372657999},2736.1175184410918]
[null,94,367.15,1.01325,393.82129731261784,null,95,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G99","v":1377.8585110664999},2734.3848319444919]
[null,95,368.15,1.01325,398.03128494085792,null,96,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G100","v":1392.3622848671998},2732.6355540791892]
[null,96,369.15,1.01325,402.24243462009105,null,97,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G101","v":1406.8660586679},2730.869692224469]
[null,97,370.15,1.01325,406.45476785229465,null,98,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G102","v":1421.3698324686},2729.0872464235504]
[null,98,371.15,1.01325,410.66830622266855,null,99,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G103","v":1435.8736062692999},2727.2882093793023]
[null,99,372.15,1.01325,414.88307140510153,null,100,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G104","v":1450.3773800699998},2725.4725664387411]
[null,100,373.15,1.01325,2675.5848534065949,null,101,{"$f":"'Dropdown & Conversions'!$D$14*'Steam and Water tables'!G105","v":1464.8811538707},2723.6402955669237]
[]
[null,"* Enthalpy is calculated using Excel add-in for Steam and Water Tables \"Water97_v13.xla\"  by Bernhard Spang"]

{"sheet":"2| Main Inputs","index":4,"n_rows":42,"n_cols":8,"rows_kept":42,"cut":false,"hidden":false,"merged":[[1,1,1,7],[40,1,40,7],[41,1,41,7],[32,7,33,7],[2,1,2,7],[16,7,17,7],[21,7,24,7]]}
[]
[null,"BOILER PARAMETER INPUTS"]
[null,"ISSUE: Calculating basic parameters of Boilers is time-taking and difficult at times. \n\nWHAT WE DO HERE: Enter basic parameters of boilers, Calculate Boiler Capacity, Steam Enthalpy and Water Enthalpy."]
[null,null,"Example",null,"Steam Production by Boiler"]
[null,null,5.82,null,null,"[Ton/h]",">","From steam flow meter"]
[null,null,null,null,"Surface area of Boiler "]
[null,null,4810,null,null,"[ft²]",">","From boiler Manual if steam flow meter is not installed"]
[null,null,null,null,"Total Energy Generated from Surface Area"]
[null,null,4468.634,null,{"$f":"E7*0.092903*10","v":0},"[kWth]",">","1 m² Surface area = 10 kW"]
[null,null,null,null,"Steam Pressure"]
[null,null,7.5,null,null,"[bar g]",">","From pressure gauge at Boiler output. Select Unit from Dropdown Menu"]
[null,null,null,null,"Steam Temperature"]
[null,null,168,null,null,"[°C]",">"]
[null,null,null,null,"Specific Enthalpy of Steam at Required Pressure [Saturated Vapour]"]
[null,null,2762.75,null,{"$f":"VLOOKUP(E11,'Steam and Water tables'!$G$5:$I$105,3,TRUE)","v":{"$error":"#N/A"}},"[KJ/Kg]",">","Automatically calculated for entered pressure of Saturated Steam"]
[null,null,null,null,"Calculated Steam Production by Boiler"]
[null,null,5.82,null,{"$f":"IF(E5>0,E5,E9/(E15/3600*1000))","v":{"$error":"#N/A"}},"[Ton/h]",">","Used for Calculations"]
[null,null,null,null,"Fuel Type"]
[null,null,"Coal",null,"Natural Gas",null,">","Select fuel from option menu"]
[null,null,null,null,"HFO",null,">","Default Selection is Natural gas"]
[null,null,null,null,"LPG",null,">","All Values in Example column are for Natural Gas"]
[null,null,null,null,"Coal",null,">","If your fuel is not listed here, please select the fuel with closest similarity in properties from this list."]
[null,null,null,null,4]
[null,null,null,null,{"$f":"IF(E23=1, \"Natural Gas\", IF(E23=2, \"HFO\", IF(E23=3, \"LPG\", IF(E23=4, \"Coal\", \"No Fuel Selected\"))))","v":"Coal"},null,">"]
[null,null,null,null,"Fuel Price"]
[null,null,16.5,null,null,{"$f":"IF(E24=\"Natural Gas\", 'Dropdown & Conversions'!D5,'Dropdown & Conversions'!D6)","v":"[Rs/kg]"},">","Values in Example are for Natural Gas"]
[null,null,null,null,"Gross Calorific Value"]
[null,null,25104,null,null,{"$f":"IF(E24=\"Natural Gas\",'Dropdown & Conversions'!E5,'Dropdown & Conversions'!E6)","v":"[kJ/kg]"},">","kJ/kg = kCal/kg x 4.184; See Utility Bill or Data Sheet or Test Report"]
[null,null,null,null,"Net Heating Value"]
[null,null,6.97,null,{"$f":"IF(E24=\"Natural Gas\",((E28*0.9)*1.0551*35.31/3600),IF(E24=\"HFO\",(E28*0.9)/3600,E28/3600))","v":0},{"$f":"IF(E24=\"Natural Gas\", 'Dropdown & Conversions'!F5,'Dropdown & Conversions'!F6)","v":"[kW/kg]"}]
[]
[null,null,null,null,"Monthly Fuel Consumption"]
[null,null,457223,null,null,{"$f":"IF(E24=\"Natural Gas\",'Dropdown & Conversions'!J5,'Dropdown & Conversions'!J6)","v":"[kg/mo]"},">","Calculate monthly average from Utility Bill or Purchase Bill"]
[null,null,null,null,"Annual Operation Hours"]
[null,null,8640,null,null,"[hr/y]",">","24h/7d =8,760 hours; 24h/5d =6,240 hours; h/5d = 2,080 hours"]
[null,null,null,null,"Temperature of Feed Water"]
[null,null,120,null,null,"[°C]",">","Final Temperature of feed water entering into the boiler"]
[null,null,null,null,"Enthalpy of Water at Mentioned Temperature"]
[null,null,502.44,null,{"$f":"4.187*$E$37","v":0},"[KJ/Kg]",">","=Specific Heat of Water [4.187 kJ/kg°C] x Temperature of Feed Water [°C]"]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company,s boiler that are highlighted in white \n2. Enthalpy of steam and water against working pressure and temperature are automatically calculated \n3. Find the value of enthalpy of water against feed water temperature from water property table\n4. Select Fuel Type. All corresponding units will change automatically\n5. The tool uses the cell \"Steam Production by Boiler\" by default. If you dont have the steam flow meter installed, then enter the value in \"Surface Area of Boiler\" to calculate the steam production.\n"]

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[]
[null,"BOILER COST AND EFFICIENCY CALCULATIONS "]
[null,"ISSUE: Steam produced is vary expensive form of energy. Efficiency of Boiler is important indicator of its performance.It directly effects the fuel consumption and cost. \n\nWHAT WE DO HERE: Calculate Overall Boiler Efficiency."]
[null,null,null,null,"Steam Cost"]
[null,null,"Example",null,"Quantity of Fuel used per Ton of steam"]
[null,null,{"$f":"'2| Main Inputs'!C33/('2| Main Inputs'!C17*('2| Main Inputs'!C35/12))","v":109.11201794578082},null,{"$f":"'2| Main Inputs'!E33/('2| Main Inputs'!E17*('2| Main Inputs'!E35/12))","v":{"$error":"#N/A"}},{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\",'Dropdown & Conversions'!K5,'Dropdown & Conversions'!K6)","v":"[kg/Ton]"},">","The unit automatically changes based on fuel selected."]
[null,null,null,null,"Hourly fuel consumption "]
[null,null,{"$f":"C6*'2| Main Inputs'!C17","v":635.03194444444443},null,{"$f":"E6*'2| Main Inputs'!E17","v":{"$error":"#N/A"}},{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\",'Dropdown & Conversions'!L5,'Dropdown & Conversions'!L6)","v":"[kg/hr]"},">","Sm3 of gas, KG of oil or LPG /coal"]
[null,null,null,null,"Cost of production per hour "]
[null,null,34148,null,{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\",E8*'Dropdown & Conversions'!$H$5,IF('2| Main Inputs'!E24=\"HFO\",E8*'2| Main Inputs'!E26,IF('2| Main Inputs'!E24=\"LPG\",E8*'2| Main Inputs'!E26,IF('2| Main Inputs'!E24=\"Coal\",E8*'2| Main Inputs'!E26,\"select fuel in Main Inputs\"))))","v":{"$error":"#N/A"}},"[Rs/ Hr]",">","(Without maintenance and Overheads) "]
[null,null,null,null,"Cost of steam (Only fuel cost)"]
[null,null,2277,null,{"$f":"E10/'2| Main Inputs'!E17","v":{"$error":"#N/A"}},"[Rs/Ton]",">","(Without maintenance and Overheads) "]
[null,null,null,null,"Cost of steam (Only fuel cost)"]
[null,null,274553049.76999998,null,{"$f":"E10*'2| Main Inputs'!E35","v":{"$error":"#N/A"}},"[Rs/y]",">","(Without maintenance and Overheads) "]
[null,null,null,null,"Boiler Efficiency"]
[null,null,"Example",null,"Energy input to boiler "]
[null,null,13858,null,{"$f":"E8*'2| Main Inputs'!E30","v":{"$error":"#N/A"}},"[KW/hr]",">","= Hourly Fuel Consumption x Net heating Value of Fuel"]
[null,null,null,null,"Net energy required to produce steam "]
[null,null,2624,null,{"$f":"'2| Main Inputs'!E15-'2| Main Inputs'!E39","v":{"$error":"#N/A"}},"[KW/Ton]",">","= Specific Enthalpy of Steam - Enthalpy of Feed Water"]
[null,null,null,null,"Net energy required to produce Hourly steam "]
[null,null,10935,null,{"$f":" E19*'2| Main Inputs'!E17*1000/3600","v":{"$error":"#N/A"}},"[KW/h]",">","= Net Energy Required per Ton x Hourly Steam Production"]
[null,null,null,null,"Overall Efficiency of Boiler (ƞ)",null,null,"=Quantity of steam generated per hour[T/h] x (enthalpy of steam at working pressure[kCal/kg]-Enthalpy of Feed water[kCal/kg]) / Quantity of Fuel used per hour[kgs/h] / GCV  x 1000"]
[null,null,0.78910000000000002,null,{"$f":"+E21/E17","v":{"$error":"#N/A"}},"[%]",">"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. This sheet does not require any inputs."]

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[]
[null,"CALCULATING COMBUSTION EFFICIENCY OF BOILER"]
[null,"ISSUE: Steam is expensive form of energy used in different process and also to produce electricity, To produced steam at optimum cost, Boiler should run at optimum efficiency by reducing the excess air supplied for combustion.  \n\nWHAT WE DO HERE: Calculate the Stoichiometric Excess Air, Loss Factors, and Combustion Efficiency of the boiler."]
[null,null,"Example",null,"Fuel Heating Value (Btu/lb)"]
[null,null,10815,null,{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\", ('2| Main Inputs'!E28*35.3/0.78*0.45), ('2| Main Inputs'!E28/1.0551)/2.2)","v":0},"[btu/lb]",">","Depends upon fuel selection"]
[null,null,null,null,"%age of Flue gas Oxygen\n (Stack analysis (by volume, dry))"]
[null,null,0.09,null,null,"[%]",">","%age of oxygen using oxygen sensor or stack analyzer\n[Ideal Oxygen % is 2~3% for Natural Gas and LPG, 3.41% for HFO, 15~25% for Coal]"]
[null,null,null,null,"Stoichiometric Excess air % "]
[null,null,0.43730000000000002,null,{"$f":"+E7*100/(20.9-E7)","v":0},"[%]",">","= % Oxygen ÷ (20.9 - % Oxygen) "]
[null,null,null,null,"Hydrogen content in fuel % "]
[null,null,5.0000000000000001E-3,null,null,"[%]",">","%age of Hydrogen in fuel. Moisture x 0.1119"]
[null,null,null,null,"Sulphur content in Fuel % "]
[null,null,4.4999999999999997E-3,null,null,"[%]",">","%age of Sulphur. See Safety Data Sheet of fule or contact supplier."]
[null,null,null,null,"% Carbon monoxide in exhaust gases "]
[null,null,5.9999999999999995E-4,null,null,"[%]",">","%age of CO using stack analyzer = CO ppm ÷ 10,000"]
[null,null,null,null,"Combustion air temperature at Inlet of burner"]
[null,null,80,null,null,"[°C]",">","Temperature of air when entered for combustions"]
[null,null,null,null,"Exhaust gas stack temperature"]
[null,null,328,null,null,"[°C]",">","Exhaust gas/Flue gas temperature"]
[null,null,null,null,"Stack Temp Rise"]
[null,null,446,null,{"$f":"CONVERT(E19,\"C\",\"F\")-CONVERT(E17,\"C\",\"F\")","v":0},"[°F]",">","Differenceof temperature of gases at inlet and outlet in [°F] to use in calculations"]
[null,null,null,null,"Calculated % of Carbon dioxide in Flue gas"]
[null,null,0.1132,null,{"$f":"(11.368-(0.556*E7))/100","v":0.11368},"[%]",">","=11.368-(0.556 x Oxygen%)"]
[null,null,null,null,"Dry Flue gas (mass flow)"]
[null,null,14.81,null,{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\",(((11*E23+8*E7+7*(100-E7-E23))*0.72)/(3*E23))/100,(((44*E23+32*E7+28*(100-E7-E23)+28*E15)/(12*(E23+E15)))*((0.72+(12*E13/32))))/100)","v":14.787925123152709},"[kg/kg of fuel]",">","Depends upon fuel selection"]
[null,null,null,null,"Calculated Combustion efficiency "]
[null,null,0.81850000000000001,null,{"$f":"(100-((E21)*(((0.66/(20.9-E7))+0.009))))/100","v":1},"[%]",">","calculated with  100  % fuel burning "]
[null,null,null,null,"Calculated excess air in the Analysis"]
[null,null,0.3412,null,{"$f":"((100*E7)/(0.2682*(100-E7-E23)-E7))","v":0},"[%]",">","% excess air in the exhaust gas analysis "]
[null,null,null,null,"Dry Flue gas loss due to stack temp and combustion air temp"]
[null,null,1696.18,null,{"$f":"+(E25*(E29/100)+E25+1)*0.24*(E21)","v":0},"[btu/lb]",">","Loss due to excess oxygen and excess stack temperature",{"$f":"0.05/(11.36+0.05)*10160*0.75","v":33.391761612620513}]
[null,null,null,null,"Energy loss due to presence of Hydrogen n Fuel "]
[null,null,0.54,null,{"$f":"9*(E11/100)*((1055+0.467*E21)*100/E5)*100","v":{"$error":"#DIV/0!"}},"[btu/lb]",">","Loss due to excess hydrogen contents in fuel. Contact supplier for improvement"]
[null,null,null,null,"Energy loss due to presence of C0 % in Stack gas  "]
[null,null,42.85,null,{"$f":"((E15)/(E23+E15)*10160*0.75)","v":0},"[btu/lb]",">","Loss due to CO in stack (incomplete combustion)"]
[null,null,null,null,"Energy loss due to presence of Moisture in Fuel "]
[null,null,60.21,null,{"$f":"9*(E11/100)*(1089+(0.46*(E21)))*100","v":0},"[btu/lb]",">","Excess moisture in fuel results in heat loss in combustion. More effective in case of solid fuel"]
[null,null,null,null,"Net Combustion Efficiency "]
[null,null,0.83360000000000001,null,{"$f":"+(1-(E37+E31+E33+E35)/E5)","v":{"$error":"#DIV/0!"}},"[%]",">","= 1- (sum of all losses ÷ Fuel Heating Value)"]
[]
[]
[null,"OVERALL EFFICIENCY CLASSIFICATION:"]
[null,null,null,null,"EFFICIENCY","OPTIMIZATION GUIDELINES"]
[null,null,null,null,0.85,"System is runnning well. Continuously monitor energy performance"]
[null,null,null,null,0.83,"Automate Boiler Controls, Improve Fuel Properties(GCV*, Sulphur, Moisture)"]
[null,null,null,null,0.8,"Adjust Air:Fuel ratio, Check Insulations, Inspect Steam Traps and PRVs*"]
[null,null,null,null,0.77,"Pre-Heat Air and/or Feed Water, Conduct Boiler Maintenance"]
[null,null,null,null,0.75,"Consult Expert; Boiler is Over Designed or Needs Replacement"]
[null,null,null,null,"*","GCV = Gross Calorific Value"]
[null,null,null,null,"**","PRV = Pressure Reducing Valve"]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white \n2. Find current combustion efficiency by using graph agaisnt %age of flue gas oxygen at line of Stack Temperature rise in [°F] \n3. Find Proposed combustion efficiency by using graph agaisnt %age of proposed oxygen at line of Stack Temperature rise [°F]\n"]

{"sheet":"5| Steam Leakage Calculation","index":7,"n_rows":19,"n_cols":8,"rows_kept":19,"cut":false,"hidden":false,"merged":[[1,1,1,7],[2,1,2,7],[18,1,18,7],[17,1,17,7]]}
[]
[null,"STEAM LEAKAGE COST CALCULATION BY USING SIZE OF ORIFICE"]
[null,"ISSUE: A considerable amount of steam is wasted through leaks in the steam distribution system and equipments. This wastage of energy can be saved through proper leakage management program.\n\nWHAT WE DO HERE: Calculate the cost of steam leakge through orifices of different sizes."]
[null,null,"Example",null,"Approximate diameter of orifice"]
[null,null,3.125E-2,null,null,"[In]",">","Enter orifice dia from which steam leaks"]
[null,null,null,null,"Line Pressure"]
[null,null,4,null,null,"[bar g]",">","Pressure in the line where leakage is detected"]
[null,null,null,null,"Amount of steam loss per hour"]
[null,null,1.72,null,{"$f":"+(24.24*((E7*'Dropdown & Conversions'!$D$14)+14.7)*(E5^2))","v":0},"[lb/h]",">","[=24.24 x (gauge pressure in psi + atm pressure in psi) x (Orifice Dia)²"]
[null,null,null,null,"Amount of steam loss per hour"]
[null,null,7.8099031045997323E-4,null,{"$f":"E9/2204","v":0},"[Ton/yr]",">","Amount of steam loss per hour[lb/h] / 2204"]
[null,null,null,null,"Amount of steam loss per year"]
[null,null,6.3,null,{"$f":"E11*'2| Main Inputs'!E35","v":0},"[Ton/yr]",">","Amount of steam loss per hour[T/h] x Annual operation Hours"]
[null,null,null,null,"Cost of steam loss per year"]
[null,null,14295,null,{"$f":"E13*'3| Boiler Cost & Efficiency'!E12","v":{"$error":"#N/A"}},"[Rs/y]",">","Amount of steam loss per year[T/y] x Average steam cost per ton[Rs/T]"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white"]

{"sheet":"6| Insulation Thickness + Cost","index":8,"n_rows":76,"n_cols":8,"rows_kept":76,"cut":false,"hidden":false,"merged":[[75,1,75,7],[51,7,52,7],[74,1,74,7],[2,1,2,7],[6,7,7,7],[16,7,17,7],[18,7,19,7],[1,1,1,7],[49,4,49,5],[43,4,43,5],[44,7,45,7],[45,4,45,5],[34,4,34,5],[9,4,9,5],[11,4,11,5],[4,4,4,5],[15,4,15,5]]}
[]
[null,"CALCULATE REQUIRED INSULATION THICKNESS & COST"]
[null,"ISSUE: Considerable energy loss occurs due to heat loss in distribution system (Piping without insulation).\n\nWHAT WE DO HERE: Calculate required insulation thickness and energy saving potential."]
[]
[null,null,null,null,"Heat Loss through Uninsulated Pipes"]
[null,null,"Example",null,"Dia of pipe"]
[null,null,16,null,null,"[In]",">","Enter dia of pipe containing fluid"]
[null,null,null,null,"Uninsulated Pipe Length"]
[null,null,20,null,null,"[ft]",">","Enter length of uninsulated pipe "]
[null,null,null,null,"Surface area of pipe"]
[null,null,83.73,null,{"$f":"(2*3.14*E9/2/12*E7)","v":0},"[ft²]",">","Surface area of pipe "]
[null,null,null,null,"Surface Temp (Ts)"]
[null,null,101,null,null,"[°C]",">","Temperature of pipe"]
[null,null,null,null,"Ambient Temp (Ta)"]
[null,null,35,null,null,"[°C]",">","Ambiant temperature where pipe is installed"]
[null,null,null,null,"Convection Losses "]
[null,null,14921,null,{"$f":"(E13-E15)*1.8*1.5*E11","v":0},"[btu/hr]",">","(Surface Temp [°C]-Ambient Temp [°C]) x 1.8 x Surface area of pipe x Co-efficient of convection[1.5 btu/ft²/hr/˚F] "]
[null,null,null,null,"Emisivity ξ"]
[null,null,0.4,null,null,"-",">","Range from 0.1 - 1.0 for different  material  (0.4 for dull colour steel pipes)\ncheck emisivity value at http://www.infrared-thermography.com/material.htm"]
[null,null,null,null,"Ts⁴ "]
[null,null,{"$f":"(C13*1.8+492)^4","v":206121847561.47354},null,{"$f":"(E13*1.8+492)^4","v":58594980096},"[R⁴]",">","(Surface temperature x 1.8 + 492)⁴ "]
[null,null,null,null,"Ta⁴ "]
[null,null,{"$f":"(C15*1.8+492)^4","v":94879400625},null,{"$f":"(E15*1.8+492)^4","v":58594980096},"[R⁴]",">","(Ambiant temperature x 1.8 + 492)⁴ "]
[null,null,null,null,"Radiation Losses"]
[null,null,6386,null,{"$f":"E11*0.000000001714*(E21-E23)*E19","v":0},"[btu/hr]",">","(Ts⁴ -Ta⁴) x Stefen boltzman[1.714E-09 btu/ft²/hr/R⁴] x Emisivity x Surface area of pipe"]
[]
[null,null,null,null,"Total Heat Loss"]
[null,null,21307,null,{"$f":"E25+E17","v":0},"[btu/hr]",">","Radiation loss + Convection Loss"]
[null,null,null,null,"Energy loss per year"]
[null,null,171.31,null,{"$f":"IF('2| Main Inputs'!E$24=\"Natural Gas\",('2| Main Inputs'!E$35*E28)/1000000,IF('2| Main Inputs'!E$24=\"HFO\",(('2| Main Inputs'!E$35*E28)/1000000)*'Dropdown & Conversions'!$E$17,IF('2| Main Inputs'!E$24=\"LPG\",(('2| Main Inputs'!E$35*E28)/1000000)*'Dropdown & Conversions'!$E$18,(('2| Main Inputs'!E$35*E28)/1000000)*'Dropdown & Conversions'!$E$19)))","v":0},{"$f":"IF('2| Main Inputs'!E24=\"Natural Gas\", 'Dropdown & Conversions'!M5,'Dropdown & Conversions'!M6)","v":"[kg/y]"},">","Total heat loss x annaul operation hours /10⁶"]
[null,null,null,null,"Cost of energy lost per year"]
[null,null,111353,null,{"$f":"E30*'2| Main Inputs'!E$26","v":0},"[Rs/y]",">","Energy loss per year x Fuel Price"]
[]
[]
[null,null,null,null,"Economic Insulation Thickness"]
[null,null,"Example",null,"Steam Temperature"]
[null,null,356,null,{"$f":"_xll.CONVERTIR('2| Main Inputs'!E13,\"C\", \"F\")","v":{"$error":"#NAME?"}},"[°F]",">","Temperature in [°F] Converted from \"Basic Inputs\" will be used to find the value of thermal conductivity and Heat loss per length"]
[null,null,null,null,"Maximum allowable surface Temperature after insulation "]
[null,null,50,null,null,"[°C]",">","Surface temperature of pipe after insulation"]
[null,null,null,null,"Thermal conductivity of insualting material"]
[null,null,0.04,null,null,"[W/K/m]",">","Different materials have different thermal conductivity at different temperatures. Find value against temperature in graph "]
[null,null,null,null,"Max. Allowable Heat loss per unit length of insulated pipe"]
[null,null,80,null,null,"[W/m]",">","Enter maximum allowable heat loss per meter or use default value of 80 Watt/m"]
[null,null,null,null,"Calculated Diameter of pipe with Insulation"]
[null,null,24.1,null,{"$f":"(EXP(2*22/7*E41*('2| Main Inputs'!E13-E39)/E43)*'6| Insulation Thickness + Cost'!E7)","v":{"$error":"#DIV/0!"}},"[In]",">","EXP{2 x π x Thermal conductivity of insualting material[Watt/K/m] x (Fluid Temperature[°C] -Maximum  allowable surface Temperature after insulation[in] [°C])/Heat loss per unit length of insulated pipe} x Diameter of beared pipe carrying fluid[In]"]
[null,null,null,null,"Required Insulation thickness(t) "]
[null,null,4,null,{"$f":"(E45-'6| Insulation Thickness + Cost'!E7)/2","v":{"$error":"#DIV/0!"}},"[In]",">","(Diameter of insulated pipe carrying fluid[in]-Diameter of beared pipe carrying fluid[In])/2"]
[]
[]
[null,null,null,null,"Insulation Cost and Payback"]
[null,null,"Example",null,"Mean Diameter of Pipe after Insulation"]
[null,null,20,null,{"$f":"E47+'6| Insulation Thickness + Cost'!E7","v":{"$error":"#DIV/0!"}},"[In]",">","Diameter of pipe after insulation"]
[null,null,null,null,"Area of Insulation Material Required"]
[null,null,104.9,null,{"$f":"_xll.CONVERTIR((2*PI()*E52/2),\"in\",\"ft\")*'6| Insulation Thickness + Cost'!E9","v":{"$error":"#NAME?"}},"[ft²]",">","Required Area of Insulation Sheet"]
[null,null,null,null,"Price of Insulation Material"]
[null,null,150,null,null,"[Rs/ft²]",">","Price of insulation material as quoted by vendors"]
[null,null,null,null,"Area of Insulation Jacket Required"]
[null,null,126.1,null,{"$f":"_xll.CONVERTIR((2*PI()*E45/2),\"in\",\"ft\")*'6| Insulation Thickness + Cost'!E9","v":{"$error":"#NAME?"}},"[ft²]",">","Required Area of Insulation Jacket Cover"]
[null,null,null,null,"Price of Insulation Jacket Material"]
[null,null,300,null,null,"[Rs/ft²]",">","Price of insulation jacket material as quoted by vendors"]
[null,null,null,null,"Labour Rate"]
[null,null,20,null,null,"[Rs/ft²]",">","Prevailing Labour rate for insulation works"]
[null,null,null,null,"Cost of Insulation Material"]
[null,null,15737.3,null,{"$f":"E56*E54","v":{"$error":"#NAME?"}},"[Rs]",">","=Area of Insulation x Price of insulation"]
[null,null,null,null,"Cost of Insulation Jacket"]
[null,null,37816.400000000001,null,{"$f":"E60*E58","v":{"$error":"#NAME?"}},"[Rs]",">","=Area of Jacket x Price of Jacket"]
[null,null,null,null,"Labour Cost"]
[null,null,400,null,{"$f":"E62*'6| Insulation Thickness + Cost'!E9","v":0},"[Rs]",">","=Length of Uninsulated Pipe x Labour Rate"]
[null,null,null,null,"Total Insulation Cost"]
[null,null,53953.68,null,{"$f":"E64+E66+E68","v":{"$error":"#NAME?"}},"[Rs]",">","= sum of costs of insulation material, jacket and labour"]
[null,null,null,null,"Payback Period"]
[null,null,5.8,null,{"$f":"E70*12/E32","v":{"$error":"#NAME?"}},"[mo]"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white \n2. Find the Thermal Conductivity of insulation material against Fluid temperature from Graphs\n\n"]

{"sheet":"7| Condensate Recovery","index":9,"n_rows":33,"n_cols":8,"rows_kept":33,"cut":false,"hidden":false,"merged":[[1,1,1,7],[2,1,2,7],[31,1,31,7],[32,1,32,7]]}
[]
[null,"COST SAVING THROUGH CONDENSATE RECOVERY "]
[null,"ISSUE: Condensate contains valuable energy in it. It must be recovered to maximize boiler efficiency. Moreover it also reduced the water and water treatment costs as well. \n\nWHAT WE DO HERE: Calculate the  energy saving by condensate recovery."]
[null,null,"Example",null,"Quantity of condensate water recovered per hour "]
[null,null,8500,null,null,"[kg/h]",">","Condensate water recovered in one hour"]
[null,null,null,null,"% condensate water "]
[null,null,0.56669999999999998,null,{"$f":"(E5/1000)/'2| Main Inputs'!E17","v":{"$error":"#N/A"}},"[%]",">","% of condensate recovered against total water consumption"]
[null,null,null,null,"% make-up water "]
[null,null,{"$f":"1-C7","v":0.43330000000000002},null,{"$f":"1-E7","v":{"$error":"#N/A"}},"[%]",">","% of condensate recovered against total water consumption"]
[null,null,null,null,"Temperature of Condensate water "]
[null,null,95,null,null,"[°C]",">","Temperature at which condensate water is recovered"]
[null,null,null,null,"Temperature of makeup water"]
[null,null,33,null,null,"[°C]",">","Ambiant temperature of make up water"]
[null,null,null,null,"Estimated Temperature of Feed water"]
[null,null,68,null,{"$f":"SUM(E11*E7+E13*E9)/(E7+E9)","v":{"$error":"#N/A"}},"[°C]",">","Temperature of feed water after mixing condensate and makeup water"]
[null,null,null,null,"Enthalpy of Feed water"]
[null,null,285,null,{"$f":"VLOOKUP(E15,'Steam and Water tables'!$B$5:$E$105,4,TRUE)","v":{"$error":"#N/A"}},"[KJ/Kg]",">","Automatically calculated for entered temperature of makeup water (upto 100 °C)"]
[null,null,null,null,"Raw water cost"]
[null,null,10,null,null,"[Rs/T]",">","The price of raw water per Ton"]
[null,null,null,null,"Water treatment cost"]
[null,null,30,null,null,"[Rs/T]",">","Total water treatment cost like chemical, filteration, descaling etc"]
[null,null,null,null,"Energy Saving per year"]
[null,null,2169,null,{"$f":"+(E17/1.0551)*1000*'2| Main Inputs'!E35/1000000","v":{"$error":"#N/A"}},"[mmbtu/y]",">","Quantity of condensate water recovered per hour [kg/h] x Water specific heat[kJ/kg/°C] x (Temperature of Condensate water [°C] -Temperature of makeup water [°C]) x 0.9478/1000000"]
[null,null,null,null,"Fuel cost Saving per year"]
[null,null,1410144.981084534,null,{"$f":"IF('2| Main Inputs'!E$24=\"Natural Gas\",('2| Main Inputs'!E$26*E$23),IF('2| Main Inputs'!E$24=\"HFO\",E23*'Dropdown & Conversions'!H6,IF('2| Main Inputs'!E$24=\"LPG\",E23*'Dropdown & Conversions'!H7,E23*'Dropdown & Conversions'!H8)))","v":{"$error":"#N/A"}},"[Rs/y]",">","Cost of fuel saved in a year"]
[null,null,null,null,"Water Cost saving per year"]
[null,null,2733600,null,{"$f":"((E21+E19)*E5*'2| Main Inputs'!E35)/1000","v":0},"[Rs/y]",">","Cost of water saved in a year"]
[null,null,null,null,"Total Cost Saving"]
[null,null,4143744.981084534,null,{"$f":"E25+E27","v":{"$error":"#N/A"}},"[Rs/y]",">","Total saving per year"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white"]

{"sheet":"8| Economizer","index":10,"n_rows":27,"n_cols":8,"rows_kept":27,"cut":false,"hidden":false,"merged":[[26,1,26,7],[9,4,9,5],[7,4,7,5],[2,1,2,7],[3,4,3,5],[19,4,19,5],[21,4,21,5],[25,1,25,7],[16,7,17,7],[18,7,19,7]]}
[]
[null,"POTENTIAL SAVING BY INSTALLING ECONOMIZER"]
[null,"ISSUE: Steam is expensive form of energy used in different process . To produced steam at optimum cost, economizer has important role to recover waste heat from stack and increases the efficiency of Boiler, and thus cuts cost of boiler's operation.\n\nWHAT WE DO HERE: Calculate the potential energy saving by installation of economizer. "]
[null,null,"Example",null,"%age of Flue gas Oxygen by Stack analysis (by volume, dry) "]
[null,null,0.02,null,null,"[%]",">","Enter data from \"4| Combustion Efficiency\" if same"]
[null,null,null,null,"Combustion air temperature at Inlet"]
[null,null,40,null,null,"[°C]",">","Enter data from \"4| Combustion Efficiency\" if same"]
[null,null,null,null,"Current Exhaust gas stack temperature"]
[null,null,250,null,null,"[°C]",">","Enter data from \"4| Combustion Efficiency\" if same"]
[null,null,null,null,"Proposed Exhaust gas stack temperature"]
[null,null,200,null,null,"[°C]",">","Target Exhaust gas/Flu gas temperature"]
[null,null,null,null,"Current stack Temerature rise"]
[null,null,378,null,{"$f":"CONVERT(E9,\"C\",\"F\")-CONVERT(E7,\"C\",\"F\")","v":0},"[°F]",">","Current Difference of temperature of gases at inlet and outlet"]
[null,null,null,null,"Proposed stack temerature rise"]
[null,null,288,null,{"$f":"CONVERT(E11,\"C\",\"F\")-CONVERT(E7,\"C\",\"F\")","v":0},"[°F]",">","Proposed Difference of temperature of gases at inlet and outlet"]
[null,null,null,null,"Current combustion efficiency"]
[null,null,77.959999999999994,null,null,"[%]",">","Find the current combustion effeciency using sheet \"4| Combustion Efficiency\" at Current Exhaust Temperature"]
[null,null,null,null,"Proposed Combustion efficiency"]
[null,null,80.27,null,null,"[%]",">","Find the Proposed combustion effeciency using sheet \"4| Combustion Efficiency\" at Proposed Exhaust Temperature"]
[null,null,null,null,"% fuel saving"]
[null,null,2.9000000000000001E-2,null,{"$f":"((E19-E17)/E19)","v":{"$error":"#DIV/0!"}},"[%]",">","(Proposed combustion efficiency-Current combustion efficiency)/Current combustion efficiency"]
[null,null,null,null,"Fuel Saving per year"]
[null,null,7901053,null,{"$f":"E21*'3| Boiler Cost & Efficiency'!E14","v":{"$error":"#DIV/0!"}},"[Rs/y]",">","%age Fuel saving x Cost of current Fuel consumption per year"]
[]
[]
[null,"HOW TO USE:"]
[null,"1. Insert data from your company in cells that are highlighted in white"]