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Actually, this would be classified as a hot-water boiler and there are significant safety hazards involved.
The "water box" worries me (which is about as far as I got in reading your description). Under normal circumstances, it would be designed in accordance with ASME codes. It is a pressure vessel that should be designed and stress analyzed by a qualified engineer. Rectangular pressure vessels have major stress risers at the edges. I doubt there are too many of us, if any, on this forum that would consider ourselves qualified to design your boiler. Those people mostly work for boiler manufacturers.
What design pressure were you thinking of? What hydrostatic test pressure were you thinking of? There are many other questions that I'm not competent to ask.
Your idea of using an automobile radiator cap for over-pressure protection is totally inadequate and suggests to me a dangerous lack of understanding.
I can't help wondering if this is possibly a joke.
Last edited by Mike Speed 30; 10-18-09 at 04:14 PM.
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