Technical Data Section 2

Chimney Sizing

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Contents
Basis General recommendation chimneys Flues Metal flues Brick or concrete flues Ancillary equipment for chimneys and flues Rapid selection table (see also page 5) Outlet cones Multi boiler installations Maximum chimney heights Specific chimney calculations Calculation Procedure Chimney height in metres above boiler flue exit Maximum positive pressure All pressure jet models Draught stabilisers Gas fired pressurised combustion boilers operating with a fan dilution system Rapid selection table Height for balanced draught at boiler flue outlet K Factors for flue fittings Graph 1 Resistance of chimneys & flues at 205oC (smooth internal finishes e.g. metal) Graph 2 Flue gas velocity pressure at 205oC

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Hoval Ltd. Northgate, Newark, Notts. NG24 1JN.

Tel: (01636) 672711

Fax: (01636) 673532

e-mail: BoilerSales@hoval.co.uk

web: www.hoval.co.uk

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. KAI To ensure the free flow of waste gases, flues should be free from sharp turns or bends to the point of entry of the flue to the chimney. Wherever possible the flue should enter at an angle of 135o, or more, to the vertical, terminating in an easy bend in an upward direction. To avoid turbulence and excessive heat loss, the chimney should be filled in below the lowest flue entry, though it may be desirable to provide a small well below the intersection to accommodate an inspection door. Where more than one boiler or furnace connects to a chimney, a separate flue to the base of the stack is preferable to a common flue. Where a common flue is used, entries from individual boilers or furnaces should be inclined in the direction of gas travel and staggered. In cases where two or more flues are coupled by a common breeching before entering the chimney, the breeching should be designed to maintain a constant gas velocity by differential duct sizing. Sudden expansions and contractions of flue should be avoided by the use of tapered transition pieces and all bends should be of the maximum practicable radius. The use of sharp bends or elbows must be avoided, particularly where forced draught fans are used. AJ=  B KAI should be either castiron, mild steel or stainless steel. Such chimneys should be well insulated to prevent condensation. Where flues enter brickwork or concrete, a mild steel sleeve ring should first be built in, with a clearance around the entering flue to allow for caulking with heat resistant material. The connection should not project beyond the internal face of the chimney. *HE?  H ? ?HAJA B KAI should be lined with suitable insulating bricks and should be adequately supported to avoid movement due to expansion, fracture or distortion. ) ?E =H O AGKEF A J B H ?DE AOI = @ B KAI Gas-tight cleaning doors of adequate size should be provided at bends in the flue, at the end of horizontal flues and at the base of the chimney. Pressure relief doors in addition to that on the boiler smoke box may be required in certain circumstances such as long horizontal sections of flue. Full guidance on this may be obtained from Building Inspectors and the Fire Service. 4=FE@ IA A?JE  J=> A F=CA # This relates the boiler rating to the chimney size, and gives heights for the buoyancy of a chimney to overcome the resistance of the three flue systems described, to give a neutral condition at the boiler outlet. A higher chimney would give a negative pressure - a lower one would give a positive pressure. Where excess fan pressure is available, lower chimneys can be accepted, providing that the loss of buoyancy does not exceed the excess pressure available. For each metre reduction in chimney height, the approximate loss of buoyancy is 4 N/m2. Also shown in the table is the gas velocity at the base of the chimney. With insulated chimneys, loss of temperature will be between 0.5oC and 1oC per metre so entry velocity is approximately equal to discharge velocity. KJ AJ ? AI If a higher efflux velocity is needed a reduction cone can be fitted. Velocity and area are directly proportional. So the area of discharge at the cone exit = Area of chimney x velocity in chimney Required velocity To overcome the resistance of the cone, extra chimney height is needed - unless this small extra resistance can be dealt with by the burner fan.
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Most Hoval boilers have pressurised combustion chambers. All pressure losses through burner and boiler are met by the burner fan, and normal efficient operation does not depend on the chimney draught. Where site conditions demand extended flue systems, sizing data is needed. A simple approach is outlined below. *=IEI All charts, graphs and tables are based on the following: Gross C.V.of oil 45.5 MJ/kg Gross C.V. of natural gas 38.5 MJ/m3 Excess air 25% CO2 oil firing 12% CO2 gas firing 9.5% Flue gas temperature 205oC Flue gas quantity: 0.0671m3/s per 100 kW rating

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All chimneys should be as slender as strength considerations permit. Embellishments such as elaborately designed copings at the chimney exit should be avoided. Considerable care is necessary where chimneys for oil burning installations are to be used in conjunction with appliances burning other fuels or with incinerators. Flanged joints in steel chimneys should be tested to ensure they are gas-tight before they are covered with insulation or cladding. Chimneys constructed of common red building brick or concrete should always be lined internally. The lining may be gunned solid insulating refractory, or acid-resisting brick depending upon requirements and temperature conditions. Metal liner inserts may also be used with this type of chimney. The advice of specialist firms should be sought before a decision is taken on the most suitable type of lining.

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Hoval Ltd. Northgate, Newark, Notts. NG24 1JN.

Tel: (01636) 672711

Fax: (01636) 673532

e-mail: BoilerSales@hoval.co.uk

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I += ?K =JE The procedure is to calculate the resistance of the flue system connections, considering only the most distant boiler, and add this to the discharge resistance. With the sum total of the system resistance established, divide this by the nett chimney buoyancy per metre to obtain the required chimney height in metres. 2H ?A@KHA 1. Prepare diagram of flue system. Mark gas quantities in m3/s 2 Sectional area in m Velocity in m/s Select velocities in chimney between 4.5 and 12 m/s. On multi-boiler installations a velocity of 6m/s is suggested. (Common flue area = sum of boiler flue outlet areas or more). 2. Add up the resistances of the flue run components and include discharge resistance. 3. Add on the flue pipe resistance, which equals the pipe length x resistance /m (from graph 1). 4. Establish nett chimney buoyancy from 5N/m2 per metre. (the flue gas buoyancy at 230oC) +DE AO DAECDJ E  AJHAI = > LA > E AH B KA A NEJ ANEJ Total sum of flue resistances Nett buoyancy per metre Resistance in N/m2 Buoyancy per metre in N/m2 J A JA By using nett buoyancy, the chimney resistance is already taken into account and must not, therefore, be added to the total of resistances. If the resultant chimney is too high, consider the following: - Improve layout of the flue system (easy bend, swept junctions etc.) - Increasing area of flue connections. - Increasing chimney area. - Crediting the sum of resistances with the excess burner fan power available (see maximum positive pressures list). Providing the total of the fan pressure plus the chimney buoyancy exceeds the total resistances, the system design will work satisfactorily. However, a high positive pressure in the boiler flue requires extra care to ensure that the complete chimney is gas tight with good joint sealing.
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Where two or more boilers connect to one chimney or to a simple header, the rapid selection table opposite can be used by adding together the boiler ratings. In such cases an efflux velocity of 5m/s should apply with one boiler firing. The flue header should have a cross section area equal to the sum of the boiler outlet areas. =NE K  ?DE AO DAECDJI

Maximum positive pressure at the boiler outlet allowable with standard burners. )  FHAIIKHA AJ 20kW 175kW 325kW 625kW 1500kW @A I

150kW = zero 300kW = 25N/m2 600kW = 30N/m2 1450kW = 60N/m2 6000kW = 90N/m2

On very high chimneys consider whether (a) cooling of gases is not too great and whether (b) natural draught variations will significantly affect combustion and justify modulating dampers. 5FA?EBE? ?DE AO ?= ?K =JE I

If the chimney design requires a higher positive pressure, consult Hoval Technical Department which may be able to recommend a burner with higher fan pressure. ,H=KCDJ IJ=>E EIAHI On high efficiency forced draught burners, the presence of a draught stabiliser of the swinging flap type is undesirable for the following reasons: 1. It admits cold air which may result in the gases reaching dew point before they leave the chimney. 2. The gas volume is increased and chimney capacity thereby lowered. 3. On occasions positive pressure conditions may arise at the base of the stack. Generally, draught stabilisers are not necessary for efficient boiler operation and should not be fitted, except when a fan dilution system is to be used and where the draught from a tall chimney is greater than the boiler resistance leading to negative pressure in the combustion chamber. /=I BEHA@ FHAIIKHEIA@ ? >KI JE  > E AHI FAH=JE C MEJD = B=  @E KJE  IOIJA The dilution fan should be sized to the formula given on page 6 of data section 1. Air for dilution is drawn independently into the dilution header from outside the boiler house. The diluted exhaust gases should be discharged from the same side of the boiler house as the air inlet to ensure wind pressures are balanced. To avoid excess suction from the dilution fan acting on the boiler flue gas outlet, a draught stabiliser should be fitted in the vertical flue from the boiler to the dilution header. Boiler house ventilation and combustion air requirements should be as listed in Tables 1a & 1b Pages 3 & 4 of Data section 1.
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The object in chimney design calculations is to make sure the resistance of the flue system does not exceed the power available. Discounting spare power from the burner fan, it follows that: Chimney Chimney = Buoyancy Resistance

Therefore: Chimney height in metres =

The resistance arises from five components: 1) Burner head. 2) Boiler. 3) Flue run to chimney. 4) Chimney. 5) Discharge from chimney outlet. 1) and 2) are amply covered by the burner fan. 3) For this resistance, add together the resistance of bends, junctions and flue pipe. 4) For chimney resistance see graph 1. 5) Discharge. Use velocity pressure from graph 2 multiplied by appropriate K. factor as listed opposite.

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Hoval Ltd. Northgate, Newark, Notts. NG24 1JN.

e-mail: BoilerSales@hoval.co.uk

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Type A 90o Bend Easy Sweep

Type B 135o Bend 45o Junction 4 metres connecting pipe

Type C As B with the addition of 2 x 90o Bends - Easy sweep Does not allow for extra horizontal runs.

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Model Number & nominal output (kW) Chimney / Flue i/d (mm) Chimney height above boiler flue outlet (m) Type A Type B Type C Flue gas velocity (m/s)

125 150 225 300 375 300 400 450 500 600 600 700 750 950 1000 1200 1300 1450 1400 1500

175 200 200 200 200 225 225 250 250 250 275 300 250 250 250 250 400 450 400 450

3.0 2.5 5.0 10.0 28.0 5.0 9.5 4.5 8.5 17.0 8.5 9.5 3.5 5.0 7.0 10.5 5.0 4.0 10.5 6.5

5.0 4.2 8.5 17.0 45.5 7.5 15.0 7.5 13.5 26.5 13.5 14.0 6.0 7.5 10.0 15.0 7.0 6.0 14.5 9.0

6.5 12.0 11.5 23.0 10.0 21.0 10.0 18.5 36.0 18.5 19.0 8.5 10.0 13.5 21.0 10.0 8.0 20.5 13.0

3.56 3.46 5.19 7.36 9.21 5.47 7.3 6.98 7.39 8.87 7.33 7.18 5.52 6.99 7.53 9.03 7.50 6.78 8.07 6.83

JA 1.Figures suitable for smooth bore steel flue pipes and chimneys which are well insulated over full length.

2.Chimney buoyancy taken as 5 N/m2 per metre.

] ^ . =?J H IB HB KABEJJE CI Resistance of fitting = K x Velocity Pressure (See Graph 2 overleaf). ^. .=?J HIB

12 1 12 1 12 1 123 12 123 12 1 123 12 1 123 123 1 12

90o bend

90o bend (easy)

135o bend (easy)

branch (at 45o)

discharge

taper discharge

K = 1.2 K = 0.4 K = 0.3 K = 0.5 K = 1.0 K = 1.1 JA  ] ^ B=?J HI The factors given are in common use and equal those advocated by various Design authorities. However, each factor can only relate to a specific configuration and some attempt should be made by the designer to sense the true situation and adjust the K figure accordingly.
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chimney entry at 90o K=1.2 at 60o K=0.7 at 45o K=0.5

Note, if base of chimney is left open double above values.
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Hoval Ltd. Northgate, Newark, Notts. NG24 1JN.

Tel: (01636) 672711

Fax: (01636) 673532

e-mail: BoilerSales@hoval.co.uk

web: www.hoval.co.uk

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Chimney Inside Diameter (mm)

1 0 0
Per Metre 100 0 .0 0 0.0
0 .5 0 0.5 1 .0 0 1.0 1 .5 0 1.5 2 .0 0 2.0
6m/s 3m/s

2 0 0
200

3 0 0
300

4 0 0
400

5 0 0
500

6 0 0
600

7 0 0
700

8 0 0
800

4m/s

Chimney Pressure Drop N/m

5m/s

Graph 1 for Steel

JA P at tg = V1.742 x 64 x 273+230 D1.266 273+tg

2 .5 0 2.5 3 .0 0 3.0 3 .5 0 3.5

8m/s 7m/s

)(

4 .0 0 4.0 4 .5 0 4.5
/H=FD . KA C=I LA
16

Where: V = Flue gas velocity (m/s) D = Flue diameter (mm) tg = Flue gas temperature (oC)

9m/s 10m/s 12m/s

?EJO FHAIIKHA =J # + JA 1. Calculations based on flue gas temperature of 205oC 2. Resistance = K x Velocity pressure

Flue Gas Velocity Pressure m/s

14 12 10 8 6 4 2 0 0 10 20 30 40 50 60 70 80

Graph 2

P = 175 x V2 273+tg Where: V = Flue gas velocity tg = Flue gas temperature 3.

Velocity Pressure in N/m2

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Hoval Ltd. Northgate, Newark, Notts. NG24 1JN.

Tel: (01636) 672711

Fax: (01636) 673532

e-mail: BoilerSales@hoval.co.uk

web: www.hoval.co.uk

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