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Steam Consumption Calculation for 500 Bed Madina Hospital

1.0

Steam Consumption for Domestic Hot Water Storage Calorifier


As per the Approved Sanitary Fixture Data (Data Sheet attached for reference), the Hot water
consumption can be calculated using the ASHRAE Tables for Hot Water Demand as detailed
below:
Sanitary Fixture

Qty.

Shower Tray
Wash Basin
Janitor Sink
Bathtub
Scrub Sink
Kitchen Sink
Lavatory (Wash Basin)
Dish Washer
Washing Machine

452
1226
34
48
51
196
45
2
5
(Assumed)

Demand rate per


Fixture
GPH
75
6
20
20
20
20
6
150
400

Total Demand Rate


GPH

Total Demand

33900
7356
680
960
1020
3920
270
300
2000

50,406 GPH

As per ASHRAE consider a Demand Factor of 0.25 for a Hospital Application


Therefore the Most Probable Hot Water Demand is 50,406 x 0.25= 12602GPH ~47704 LPH
Storage Capacity Factor is 0.6
Therefore the Storage Capacity of the Calorifier is 12600 x 0.6=7560 Gallons (29100 Liters)
Based on the above results we can select 3 Off Duty Storage Calorifiers with a storage
capacity of 10000 Liters to give a total of 30000 Liters of Hot Water Storage which is very
close to the above calculation based on ASHRAE.
STORAGE CALORIFIER SELECTION:
4 Off (3 Duty & 1 Standby) Copper Lined Storage Calorifier ( As per attached Technical
Submittal Approval ) each having 10000 Liters of Storage Capacity with a Flow Rate of 15900
L/Hr
We assume a temperature rise from 100 C to 600 C for domestic heating purpose
The Heating Capacity required is = 15900 x 4.186 x 50 / 3600 = 925 KW
Steam supply @ 6 bar(g) before the Control Valve will have a specific enthalpy of 2066 KJ/Kg
Therefore the Steam Consumption in Kgs/Hr would be = 925 x 3600 / 2066 = 1610 Kgs/Hr
Steam Consumption for 3 Duty storage calorifiers would be = 4830 Kgs/Hr

2.0

Steam Consumption for AHU Hot Water Heat Exchanger


As per the AHU Heating Load Schedule, HEs Duty (Heating Load=2692 MBH) is 790 KW
Hot Water Temperature inlet and outlet can be considered as 71.10 C and 82.20 C.

Steam required for the Heat Exchanger is = 790x 3600 / 2066

= 1377 Kgs/Hr

SELECTION OF HEAT EXCHANGERS:


We will select 2Off (1Duty & 1 Standby) Packaged Plate Heat Exchanger each having a
duty of 800 KW heating 17.22 lit/sec of Water for AHU from 71.1 to 82.2 Deg C.
Steam required for the 1 Duty Heat Exchangers will be =800x 3600 / 2066=1394 Kgs/Hr

3.0

Humidification
As per the AHU Humidification Schedule the Steam required for Humidification is 980 Kg/Hr
Steam required for humidification

4.0

980 Kgs/Hr

C.S.S.D
Due to non-availability of Equipment data, we will base our steam calculation on another 500
Bed MOH Hospital, the steam consumption can be considered as 600 Kg/Hr
Steam required for Sterilization =

5.0

600 Kgs/Hr

Laundry
Assumptions for the Laundry Equipment based on 500 Bed MOH Hospital:
Steam
Equipment
Qty
Consumption

Total Steam
Load

Washer Extractor

50 Kg/Hr

150 Kg/Hr

Tumbler Dryers

75 Kg/Hr

300 Kg/Hr

Flat Work Ironer

255 Kg/Hr

255 Kg/Hr

Ironing Board

20 Kg/Hr

40 Kg/Hr

Presses

25 Kg/Hr

100 Kg/Hr

Dry Cleaning Machine

80 Kg/Hr

160 Kg/Hr

Total Steam Demand

1005 Kgs/Hr

Steam required for Laundry is =

1005 Kgs/Hr

Calculation of Simultaneous Steam Consumption:


Case 1 Night Time:
Probable maximum consumption of steam during night time with the reduction in requirements
from Laundry, CSSD and domestic hot water production:
Domestic Hot Water Consumption
AHU Heating
Humidification
CSSD
Laundry

4830 x 30%
=
1450 Kg/Hr.
1394 x100%
=
1394 Kg/Hr.
980 x 100%
=
980 Kg/Hr.
600 x 30%
=
180 Kg/Hr.
1005 x 30%
=
302 Kg/Hr.
-----------------------------------------------Total Steam Demand 4306 Kg/Hr

Case 2 Day Time:


Probable maximum consumption of steam during day time with the reduction in requirements
from AHU Heating and Humidification:
Domestic Hot Water Consumption
AHU Heating
Humidification
CSSD
Laundry

4830 x 100%
=
4830 Kg/Hr.
1394 x 30%
=
418 Kg/Hr.
980 x 30%
=
294Kg/Hr.
600 x 100%
=
600 Kg/Hr.
1005 x 100%
=
1005 Kg/Hr.
-----------------------------------------------Total Steam Demand 7147 Kg/Hr

Considering the maximum of the above two cases, the Max. Steam demand is 7147 Kg/Hr
Consider 10% Losses due to Feed Water Re-heating and Blowdown 715 Kg/Hr
Hence Total Steam required shall be 7147 + 715 = 7862 Kg/Hr

SELECTION DATA
As per attached Technical Submittal Approval
Quantity: 3 Each (2 Duty and 1 Standby)
Boiler Capacity Selected 4000 Kgs/Hr F&A 100 Deg C.
Boiler Type: Conventional 3 Pass Wet Back Type
Boiler Working Pressure: 10.3 Bar(g)
Fuel Type: Diesel Oil
Electrical Rating: 380 V / 3 Ph / 60 Hz.

Equipment Specifications:

1. Boiler:
As per attached Technical Submittal Approval
Selection Criteria:
The detail selection procedure is provided in the steam consumption calculations.
Boilers Selected:
Qty: 3 Off (2 Duty and 1 Standby)
Model: Cochran Wee-Chieftain Packaged Steam Boiler
Capacity: 4000 Kg/Hr F&A 100 Deg C @ 10.3 bar(g)
Overall Dimensions: Approx. 4896 long x 2690 wide x 3251 high (Dimensions in mm)
Boiler Specifications
The boilers should be Horizontal Three Pass Wet Back Conventional Type and shall be
designed and constructed to BS2790 latest revision.
Model: Cochran Wee-Chieftain
The boilers will be rated at 4000 kg/hr F&A 100 0C.
Working Pressure: 10.3 bar(g)
Electrical supply: 380 V / 3 Ph / 60 Hz; Control Circuit: 220 V / 1 Ph / 60 Hz.
Fuel: Diesel Oil
Accessories:
The boiler package shall consist of:

Pressure vessel (Shell)


Suitably sized Burner with all necessary controls and Control Panel,
Valves and fittings required as per relevant standards,
Water Level Controls Self Monitoring Probe Type Level Controls for Pump Control
and Independent Level Control for First and Second Low Level Alarms and Lock Out.
Vertical Multi-Stage Feedwater pump wired to the control panel,
Automatic TDS Control System,
Sample Cooler System,
Automatic Timed Bottom Blowdown System
Rear Heat Shield,
Flue Gas Temperature Indicator,

2. Feed Water Tank:


As per attached Technical Submittal Approval
Selection Criteria:
Feed Water tank provides a reserve of water to cover the interruption of supply to the feed
pumps. Traditional practice is to have a feed water tank with sufficient capacity to allow one
hours steaming at maximum boiler evaporation.
As we have only 2 Duty boilers with each boiler providing 100% of total rated capacity during
peak load.
Feed Tank Capacity Selected:
Capacity: 8000 Liters
Approximate Dimensions: 2000 mm x 2000 mm x 2000m ( H x W x L)
Tank Specifications:
The tank will be fabricated in Saudi Arabia using Spirax Sarco design drawing and will be
constructed from 304 St. St. sheets of 5mm thickness and Size 2.0m x 2.0m x 2.0m complete
with 50mm Mineral Wool Insulation and Aluminum Cladding.
Accessories:
Spirax Sarco De-Aerator Head suitable sized as per attached sheet (Type DH)
Spirax Sarco Type RFS Re-circulating Feed Water Spray System
Spirax Sarco Steam Injection System comprising of Temperature Control Valve,
Sensor Pocket, Steam Injector and Vacuum Breaker.
Spirax Sarco Water Level Controls (LP10-4) complete with LC1350 Controller
Spirax Sarco Water Level Gauge
Spirax Sarco Dial Thermometer
Spirax Sarco Cold Water Make Up Valve (WV1)
Vent Head (Type VH)

3. Blowdown Vessel:
As per attached Technical Submittal Approval

Selection Criteria:
The Selection of a blowdown vessel depends on the flowrate and the proportion of flash steam
released.
The following factors affect the selection:

The Boiler Pressure


The Blowdown Line Size
The Length of the Blowdown line between the boiler and the blowdown vessel.

Blowdown Vessel Selected:


Spirax Sarco Blowdown Vessel Type: BDV60/4

Vessel Specifications:
The Vessel is designed, constructed and tested by Spirax Sarco to BS 5500 Category 3 with
Independent Third Party Verification and Inspection.
Accessories:
Spirax Sarco Blowdown Vessel System is supplied complete with all necessary manifolds,
valves and check valves required on the Bottom Blowdown connection and the TDS
Blowdown Connection from the three boilers. A cooling water system is provided to be
installed on the BDV for proper cooling of the boiler blow down water before being dumped to
the drain.

4. Condensate Recovery Unit:


As per attached Technical Submittal Approval

a. Main Hospital (Humidifiers, CSSD & Laundry)


Selection Criteria:
Condensate return from all the steam consumers from the main hospital can be calculated
based on the maximum steam demand inside the hospital (Humidifiers, CSSD & Laundry Max. 2600 Kg/Hr) which amounts to 1550 Liters/Hr of condensate return (As only 30% of
condensate will return from Humidifiers, 90% from Sterilizers and 70% return from
Laundry).
We will size the Packaged Condensate Pump Unit based on the 1550 Kg/Hr Flow and 20m
head and as per attached Sizing chart we select Spirax Sarco DN50 x DN50 MFP14
Packaged Pump Unit
Condensate Pump Unit Capacity Selected:
1550 Liters/Hr @ a head of 20m
Model Selected: Spirax Sarco DN50 X DN50 MFP14 PPU

5. Storage Calorifier: (Domestic / Kitchen / Laundry Hot Water)


Selection Criteria:
The detail selection procedure is provided in the steam consumption calculations.
Storage Calorifiers Selected:
Qty: 4 Off (3 Duty + 1 Standby)
Model: Rycroft Copper Lined Storage Calorifiers MCZE 10000 (2640 Gallons)
Overall Dimensions: 4600 mm High x 1680 mm diameter
Capacity: 10000 Likters (2640 USG)
Duty: 15900 Lit/Hr (925 KW)
Secondary Water: 10 to 60 deg C.

6. Heat Exchangers (for AHU):


Selection Criteria:
The detail selection procedure is provided in the steam consumption calculations.
Heat Exchangers Selected:
Qty: 2 Off ( 1Duty + 1 Standby)
Model: Horizontal Mild Steel Shell and Tube Heat Exchanger
Capacity: 800 KW
Duty: 17.22 Lit/Sec.

List of Manufacturers submitted for the complete Boiler Package

BIB Cochran Boiler UK : Boilers Package


Rycroft Ltd. UK

: Storage Calorifiers

Spirax Sarco Ltd. UK


: Feed Tank Accessories (Including Level Controls,
Recirculating Feed Water System, Steam Injection System etc.), Blowdown Vessel and all
related accessories, Automatic TDS Control System, Sample Cooler, Header Isolating Valves,
Condensate Recovery Unit, All steam and Condensate accessories like Valves, Strainers,
Separators, Steam Traps, Air Vents, Pressure Reducing Valves, Check Valves, Temperature
Control Valves & High Limit Control Valves and EASIHEAT PACKAGED PHE
Local Fabrication - KSA

: Feed Water Tank St. St. material as per Spirax Sarco Design.

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