900 BED HOSPITAL

PSYCHIATRIC & ADDICTION

HOSPITAL PROJECT

SUBMITTED BY

TIG-TESCO INTERNATIONAL LTD

P.O. BOX. #647, DAMMAM – 31421
TEL. # 03-833-8600, FAX. # 03-833-8487
 Steam Consumption Calculation for
900 Bed Dammam Addiction & Psychiatric Hospital

1.0 Steam Consumption for Domestic Hot Water Storage Calorifier

As per the data of number of Sanitary Fixtures attached, the Hot water consumption can be
calculated using the ASHRAE Tables for Hot Water Demand as detailed below:
Sanitary Fixture Qty. Demand rate per Total Demand Rate
Fixture GPH

Shower 309 75 23175

Bath tub 33 20 660
Lavatory (Wash Basin) 1117 6 6702
Kitchen Sink 132 20 2640
Janitor Sink 103 20 2060
Dish Washer (Assumed) 4 150 600
Washing Machine (Assumed) 8 150 1200

Total Demand 37037 GPH

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

Therefore the Most Probable Hot Water Demand is 37,037 x 0.25 = 9260 GPH ~ 9260 GPH
Storage Capacity Factor is 0.6

Therefore the Storage Capacity of the Calorifier is=9260 x 0.6 = 5555 Gallons ~ 5600 Gallons

Let us consider the Hot Water Storage Calorifier (Item # 1) 2000 Gallons Storage
Capacity as specified in the Project BOQ. Based on this we can select 3 Calorifiers on
duty (3 x 2000 Gallons = 6000 Gallons).

SELECTION:

(3 Duty & 1 Standby) Copper Lined Storage Calorifier each having 2000 Gallons Storage
Capacity with a Flow Rate of 3250 GPH

We assume a temperature rise from 100 C to 600 C for domestic heating purpose

The Heating Capacity required is = 3250 x 3.786 x 4.186 x 50 / 3600 = 720 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 = 720 x 3600 / 2066 = 1250 Kgs/Hr

Steam Consumption for 3 Duty storage calorifier’s would be = 3750 Kgs/Hr

2.0 Steam Consumption for AHU Hot Water Heat Exchanger
As per the AHU Heating Load Schedule the hot water required is 1472 GPM (112 L/S)

Hot Water Temperature inlet and outlet can be considered as 71.10 C and 82.20 C.

Therefore HE’s Duty can be calculated as – 112 x 4.186 x 11.1 – 5200 KW

Steam required for the Heat Exchanger is = 5200 x 3600 / 2066 = 9000 Kgs/Hr

SELECTION OF HEAT EXCHANGERS:

As the capacity specified in the Project BOQ is very low i.e. 998 KW each, we have to
select 5 Heat Exchangers on Duty. This will take lot of space, pipe work and steam
accessories, we suggest to consider 3 off 1750 KW Heat Exchanger on Duty to get 5200
KW (112 L/S) of Hot Water.

4 Off (3 Duty & 1 Standby) Non-Storage Packaged Plate Heat Exchanger each having a
duty of 1750 KW heating 37.33 lit/sec of Water for AHU from 71.1 to 82.2 Deg C.

Steam required for the Heat Exchanger is = 1750 x 3 x 3600 / 2066 = 9150 Kgs/Hr

3.0 Humidification
There is no steam required for humidification in AHU as per the tender and approved AHU

Steam required for the steam humidifier is = 0 Kgs/Hr

4.0 C.S.S.D
As this is a Psychiatric and Addiction Hospital and no major Operating Theators in the
Hospital, there will be very less amount of Sterilizers and Washers in the CSSD:

Steam Total Steam

Equipment Qty
Consumption Load
Steam Sterilizers 2 130 Kg/Hr 260 Kg/Hr
Washer Disinfector 1 540 Kg/Hr 540 Kg/Hr
Total Steam Demand 800 Kgs/Hr

Steam required for CSSD = 800 Kgs/Hr

5.0 Laundry
Due to non availability of Equipment data, we will assume the steam demand for Laundry area
as per list below:

Steam Total Steam

Equipment Qty
Consumption Load

Washer Extractor 6 75 Kgs/Hr 450 Kgs/Hr

Tumbler Dryers 4 100 Kgs/Hr 400 Kgs/Hr

Flat Work Ironer 1 400 Kgs/Hr 400 Kgs/Hr

Presses 4 15 Kgs/Hr 60 Kgs/Hr

High Spin Washer 3 100 Kgs/Hr 300 Kgs/Hr

Dry Cleaning Machine 2 125 Kgs/Hr 250 Kgs/Hr

Total Steam Demand 1860 Kgs/Hr

Steam required for Laundry =1860 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 3750 x 30% = 1130 Kg/Hr.

AHU Heating 9150 x 100% = 9150 Kg/Hr.
Humidification 0 x 100% = 0 Kg/Hr.
CSSD 800 x 30% = 240 Kg/Hr.
Laundry 1860 x 30% = 560 Kg/Hr.
------------------------------------------------
Total Steam Demand 11,080 Kg/Hr

Case – 2 Day 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 3750 x 100% = 3750 Kg/Hr.

AHU Heating 9150 x 30% = 2750 Kg/Hr.
Humidification 0 x 30% = 0 Kg/Hr.
CSSD 800 x 100% = 800 Kg/Hr.
Laundry 1860 x 100% = 1860 Kg/Hr.
------------------------------------------------
Total Steam Demand 9,160 Kg/Hr
Considering the maximum of the above two cases, the Max. Steam demand is 11,080 Kg/Hr

Consider 15% Losses due to Feed Water Re-heating and Blowdown – 1660 Kg/Hr

Hence Total Steam required shall be 11,080 + 1660 = 12,740 Kg/Hr

As per BOQ there are 3 Off 2000 Kg/Hr Boilers specified with 2 Duty & 1 Standby, the 2
Qty duty boilers will generate about 4000 Kg/Hr Steam which is very less than the
calculated steam demand of 12,740 Kg/Hr and hence we suggest to select the capacity of
boilers as per the above calculation.

SELECTION DATA

OPTION - 1

Quantity: 4 Each (3 Duty + 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.

OPTION - 2

Quantity: 3 Each (2 Duty + 1 Standby)

Boiler Capacity Selected 6000 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:

(Option – 1)

Selection Criteria:

The detail selection procedure is provided in the steam consumption calculations.

Boilers Selected:

Qty: 4 Off (3 Duty + 1 Standby)

Model: Cochran Wee-Chieftain Packaged Steam Boiler
Capacity: 4000 Kg/Hr F&A 100 Deg C @ 10.3 bar(g)

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 Modulating 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,
 Rear Heat Shield,
 Flue Gas Temperature Indicator,
 Flue Gas CO2 / O2 Analyzer with Recorder and
 Boiler Lead Lag Controls.
(Option – 2)
Selection Criteria:

The detail selection procedure is provided in the steam consumption calculations.

Boilers Selected:

Qty: 3 Off (2 Duty + 1 Standby)

Model: Cochran Thermax Packaged Steam Boiler
Capacity: 6000 Kg/Hr F&A 100 Deg C @ 10.3 bar(g)

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 Thermax Packaged Steam Boiler

The boilers will be rated at 6000 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 Modulating 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,
 Rear Heat Shield,
 Flue Gas Temperature Indicator,
 Flue Gas CO2 / O2 Analyzer with Recorder and
 Boiler Lead Lag Controls.
2. Feed Water Tank:
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
hour’s steaming at maximum boiler evaporation.

As we have 3 Duty boilers with each boiler providing 4000 kgs/Hr of steam at 100% load, the
total Feed Water required for 1 Hour of continuous operation is about 12000 Liters.

Feed Tank Capacity Selected:

Capacity: 12000 Liters

Approximate Dimensions: 3.0m x 2.0m x 2.0m (L x W x H)

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 4mm thickness and Size 3.0m x 2.0m x 2.0m complete
with 100mm 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 LC1300 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:

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:

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 (CSSD & Laundry - Max. 2500
Kg/Hr) which amounts to 1500 Liters/Hr of condensate return (As only 30% of condensate
will return from Sterilizers and 70% will return from Laundry).

We will size the Packaged Condensate Pump Unit based on the 2000 Kg/Hr Flow and 20m
head and as per attached Sizing chart we select Spirax Sarco Packaged Pump Unit

Condensate Pump Unit Capacity Selected:

2000 Liters/Hr @ a head of 20m

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

Selection Criteria: (Type # 1 Storage Calorifier from BOQ)

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 7500

Overall Dimensions: 3700 mm High x 1680 mm diameter

Capacity: 7500 Liters

Duty: 12,300 Lit/Hr (720 KW)
Secondary Water: 10 to 60 deg C.

6. Heat Exchangers (for AHU):

Selection Criteria: (Type # 2 Heat Exchanger from BOQ)

The detail selection procedure is provided in the steam consumption calculations.

Heat Exchangers Selected:

Qty: 4 Off ( 3 Duty + 1 Standby)

Model: Spirax Sarco EASIHEAT PACKAGED PHE System

Overall Dimensions: (As per attached Drawing)

Capacity: 1750 KW
Duty: 37.33 Lit/Sec.
 List of Manufacturers / Products submitted by Tig-Tesco for the Boiler Room:

 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

 Fabrication in Saudi Arabia : Feed Water Tank (Stainless Steel)



 

 
 
 
 
 
 
 
 

 



 
   
 

   




 
 

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Examples

  Determine the required water heater size for a 300-student womenÕs dormitory for the following crite-
ria:
a. Storage system with minimum recovery rate.
b. Storage system with recovery rate of 2.5 gph per student.
c. With the additional requirement for a cafeteria to serve a maximum of 300 meals per hour for minimum recov-
ery rate, combined with item a ; and for a recovery rate of 1.0 gph per maximum meals per hour, combined with
item b .
Solution :
a . The minimum recovery rate from Figure 15 for womenÕs dormitories is 1.1 gph per student or 330 gph total.
At this rate, storage required is 12 gal per student or 3600 gal total. On a 70% net usable basis, the necessary
tank size is 3600/0.7 = 5150 gal.
b. The same curve shows 5 gal storage per student at 2.5 gph recovery, or 300 x 5 = 1500 gal storage with
recovery of 300 x 2.5 = 750 gph. The tank size will be 1500/0.7 = 2150 gal.
c. The requirements for a cafeteria can be determined from Figure 19 and added to those for the dormitory. For
the case of minimum recovery rate, the cafeteria (Type A) requires 300 x 0.45 = 135 gph recovery rate and 300 x
7/0.7 = 3000 gal of additional storage. The entire building then requires 330 + 135 = 465 gph recovery and 5150 +
3000 = 8150 gal of storage.
With 1 gph recovery at the maximum hourly meal output, the recovery required is 300 gph, with 300 x 2.0/0.7 =
860 gal of additional storage. Combining this with item b, the entire building requires 750 + 300 = 1050 gph
recovery and 2150 + 860 = 3010 gal of storage.
Note : Recovery capacities shown are for heating water only. Additional capacity must be added to offset the
system heat losses.
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 Plumbing Hot Water Fixtures for Dammam Psychiatric and Addiction Hospital ( For 900 Beds )
Co Location Shower Bath Tub Lavatory Kitchen Sink Janitor Sink

1 Main Building 240 30 870 90 90

2 Villa (10 Villa) 30 1 157 14 4
3 Emergency 30 2 35 18 0
4 Recreation (1 & S) 0 0 16 4 4
5 Occupational Therapy 8 0 24 0 4
6 Ware House 0 0 0 1 0
7 Mosque 1 0 2 2 1
8 Administration 0 0 11 3 0
9 Guard House 0 0 2 0 0

Total 309 33 1117 132 103

 Heating Load for AHU's (900 Bed Option)
Hot Water Flow
Total Flow Rate
Sl. # Location AHU No. Qty. Rate
GPM
GPM

1 Villa AHU 1 30 21 630

AHU 2 30 18 540
2 Hospital AHU 1 2 35.3 71
AHU 2 1 15.25 15
AHU 3 1 16.42 16
AHU 4 1 5.66 6
AHU 5 1 5.77 6
AHU 6 1 14.55 15
AHU 7 2 6.36 13
AHU 8 1 3.11 3
AHU 9 1 13.45 13
AHU 10 1 4.03 4
3 Emergency AHU 1 4 10.12 40
AHU 2 1 11.31 11
4 Administration AHU 1 1.5 10.49 16
5 Recreation AHU 1 4 11.6 46
6 Occupational Therapy AHU 1 4 6.7 27

Total Heating Water Flow Rate (GPM) 1,472

Steam tables
Specific Enthalpy Specific
Pressure Temperature Volume
Water (hf) Evaporation (hfg ) Steam (hg ) Steam
o
bar kPa C kJ/kg kJ/kg kJ/kg m3/kg
absolute
0.30 30.0 69.10 289.23 2336.1 2625.3 5.229
0.50 50.0 81.33 340.49 2305.4 2645.9 3.240
0.75 75.0 91.78 384.39 2278.6 2663.0 2.217
0.95 95.0 98.20 411.43 2261.8 2673.2 1.777
gauge
0 0 100.00 419.04 2257.0 2676.0 1.673
0.10 10.0 102.66 430.2 2250.2 2680.2 1.533
0.20 20.0 105.10 440.8 2243.4 2684.2 1.414
0.30 30.0 107.39 450.4 2237.2 2687.6 1.312
0.40 40.0 109.55 459.7 2231.3 2691.0 1.225
0.50 50.0 111.61 468.3 2225.6 2693.9 1.149
0.60 60.0 113.56 476.4 2220.4 2696.8 1.083
0.70 70.0 115.40 484.1 2215.4 2699.5 1.024
0.80 80.0 117.14 491.6 2210.5 2702.1 0.971
0.90 90.0 118.80 498.9 2205.6 2704.5 0.923
1.00 100.0 120.42 505.6 2201.1 2706.7 0.881
1.10 110.0 121.96 512.2 2197.0 2709.2 0.841
1.20 120.0 123.46 518.7 2192.8 2711.5 0.806
1.30 130.0 124.90 524.6 2188.7 2713.3 0.773
1.40 140.0 126.28 530.5 2184.8 2715.3 0.743
1.50 150.0 127.62 536.1 2181.0 2717.1 0.714
1.60 160.0 128.89 541.6 2177.3 2718.9 0.689
1.70 170.0 130.13 547.1 2173.7 2720.8 0.665
1.80 180.0 131.37 552.3 2170.1 2722.4 0.643
1.90 190.0 132.54 557.3 2166.7 2724.0 0.622
2.00 200.0 133.69 562.2 2163.3 2725.5 0.603
2.20 220.0 135.88 571.7 2156.9 2728.6 0.568
2.40 240.0 138.01 580.7 2150.7 2731.4 0.536
2.60 260.0 140.00 589.2 2144.7 2733.9 0.509
2.80 280.0 141.92 597.4 2139.0 2736.4 0.483
3.00 300.0 143.75 605.3 2133.4 2738.7 0.461
3.20 320.0 145.46 612.9 2128.1 2741.0 0.440
3.40 340.0 147.20 620.0 2122.9 2742.9 0.422
3.60 360.0 148.84 627.1 2117.8 2744.9 0.405
3.80 380.0 150.44 634.0 2112.9 2746.9 0.389
4.00 400.0 151.96 640.7 2108.1 2748.8 0.374
4.50 450.0 155.55 656.3 2096.7 2753.0 0.342
5.00 500.0 158.92 670.9 2086.0 2756.9 0.315
5.50 550.0 162.08 684.6 2075.7 2760.3 0.292
6.00 600.0 165.04 697.5 2066.0 2763.5 0.272
6.50 650.0 167.83 709.7 2056.8 2766.5 0.255
7.00 700.0 170.50 721.4 2047.7 2769.1 0.240
7.50 750.0 173.02 732.5 2039.2 2771.7 0.227
8.00 800.0 175.43 743.1 2030.9 2774.0 0.215
8.50 850.0 177.75 753.3 2022.9 2776.2 0.204
9.00 900.0 179.97 763.0 2015.1 2778.1 0.194
9.50 950.0 182.10 772.5 2007.5 2780.0 0.185
10.00 1000.0 184.13 781.6 2000.1 2781.7 0.177
10.50 1050.0 186.05 790.1 1993.0 2783.3 0.171
11.00 1100.0 188.02 798.8 1986.0 2784.8 0.163

EDB/1 1.01