BOILERS

WHAT IS IT? A closed vessel in which water or other fluid is heated for use in various processes or heating applications. Is the equipment for transferring heat energy to steam energy. Receives water and converts it into steam by absorbing the heat from the burning fuel.

Low steam or Low-pressure steam - steam of which the pressure is less than, equal to, or not greatly above, that of the atmosphere. Superheated steam - steam heated to a temperature higher than the boiling point corresponding to its pressure. It cannot exist in contact with water, nor contain water and resembles a perfect gas; -- called also surcharged steam, anhydrous steam, and steam gas. Wet Steam - steam which contains water held in suspension mechanically; -- called also misty steam.

Background: Construction of boilers is mainly in steel, stainless steel, and wrought iron. In live steam models, copper or brass is often used. Historically copper was often used for fireboxes (particularly for steam locomotives), because of its better thermal conductivity. The price of copper now makes this impractical. Cast iron is used for domestic water heaters. Although these are usually termed "boilers", their purpose is to produce hot water, not steam, and so they run at low pressure and try to avoid actual boiling. The brittleness of cast iron makes it impractical for steam pressure vessels. For much of the Victorian "age of steam", the only material for boilermaking was the highest grade of wrought iron. This iron was often obtained from specialist ironworks, such as Cleator Moor (UK), noted for the high quality of their rolled plate and its suitability for high reliability use in critical applications, such as high pressure boilers. 20th century practice moved towards steel and welding. The source of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Types of Steam High steam or High-pressure steam - steam of which the pressure greatly exceeds that of the atmosphere. Saturated steam - steam at the temperature of the boiling point which corresponds to its pressure; -sometimes also applied to wet steam. Fusible Plug a screw with a tapered hole in the center-smallest side inside the boiler. The hole is blocked with a metal of low melting point so steam is not released at normal working temperatures.

BASIC PARTS OF A BOILER

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Smokebox is an extension of the front end of the boiler barrel. The smokebox also contains the main steam pipes to the steam chests, blower, superheater header, tubes and exhaust for the Vacuum Ejector where fitted. Superheater Steam from the main steam pipe arrives at the saturated steam chamber of the superheater header and is fed into the superheater elements. Superheated steam arrives back at the superheated steam chamber of the superheater header and is fed into the steam pipe to the cylinders. Superheated steam is more expansive. Types of Superheater CONVECTION - TYPE SUPERHEATERS -the superheater tubes are protected from radiant heat by water screen tubes which absorb the intense radiant heat of the furnace. RADIANT TYPE SUPERHEATERS -the superheater tubes are not screened by water screen tubes but are exposed directly to the radiant heat of the furnace.

Dome The dome is positioned at the highest part of the boiler barrel where it forms a collector for steam above the surface of the water. Firedoor/Furnace It gives access for firing and can be adjusted to control the flow of secondary air. Brick Arch It protects the firebox tubeplate from the direct flame of the fire, radiates heat to prevent rapid fluctuation of the tubeplate temperature, and ensures thorough combustion of volatiles by lengthening their path from the fire to the tubeplate. Baffle Plate The baffle plate placed in the firehole is designed to direct the secondary air down towards the firebed in order to mix it thoroughly with the hot gases and flames.

BOILER ACCESSORIES:

Circulating Pump is designed to circulate water back to the boiler after it has expelled some of its heat.

Safety Valve used to relieve pressure and prevent possible explosion of a boiler. 2|Page

BOILER IN ACTION

through the walls of the tubes by thermal conduction, heating the water and ultimately creating steam. TYPES: Cornish boiler Lancashire boiler Scotch marine boiler Locomotive boiler Vertical Fire-Tube boiler Horizontal Return Tubular boiler

BASIC ENERGY PROCESSES

IGNITION Ignition temperature signals the readiness of the coals to be burned up and when the combustion process is established, it continues on burning up like a bonfire. COMBUSTION When coal and air is mixed together and heated to the ignition temperature, the oxygen in the air will combine with the carbon in the coal to form two gases, (CO2) and (CO). The goal is to increase the CO2 in order to obtain more heat from the coal. CO is strictly prohibited to obtain the complete processing of combustion.

WATER-TUBE BOILERS

CLASSIFICATION OF BOILERS
LOCATION OF FIRE AND WATER SPACES INTENDED SERVICE TYPE OF CIRCULATION ARRANGEMENT OF STEAM AND WATER SPACES NUMBER OF FURNACES BURNER LOCATION FURNACE PRESSURE OPERATING PRESSURE

a type of boiler in which water circulates in tubes heated externally by the fire. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In smaller boilers, additional generating tubes are separate in the furnace, while larger utility boilers rely on the water-filled tubes that make up the walls of the furnace to generate steam.

LOCATION OF FIRE AND WATER SPACES

FIRE-TUBE BOILERS

a type of boiler in which hot gases from a fire pass through one or more tubes running through a sealed container of water. The heat of the gases is transferred 3|Page

INTENDED SERVICES
PROPULSION BOILERS used to provide steam for ships propulsion and for auxiliaries' services. AUXILIARY BOILERS installed in diesel-driven ships and in many steam- driven combatant ships. They supply the steam and hot water for galley, heating, and other hotel services and for other auxiliary requirements in port. vital

DOUBLE-FURNACE BOILERS

often called M-type boilers because the arrangement of the tubes is roughly M-shaped.

BURNER LOCATION
FRONT-FIRED BOILERS - burners are located at the front of the boiler. TOP-FIRED BOILERS - burners are on the top of the boilers.

TYPE OF CIRCULATION
NATURAL CIRCULATION BOILERS the circulation of water depends on the difference between the density of an ascending mixture of hot water and steam and a descending body of relatively cool and steam-free water. The difference in density occurs because the water expands as it is heated, and thus, becomes less dense. FORCED CIRCULATION BOILERS depend upon pumps, rather than upon natural differences in density, for the circulation of water within the boiler.

FURNACE PRESSURE
PRESSURE-FIRED or SUPERCHARGED BOILERS - these are pressurized-furnace boilers. These furnaces are maintained under a positive air pressure of about 65 psia (about 50 psig) when operated at full power. The air pressure in these boiler furnaces is maintained by special air compressors called superchargers.

OPERATING PRESSURE
400-PSI BOILERS - Header-type boilers and some older drum- type boilers are often called 400-PSI BOILERS. Their operating pressures range from about 435 psi to 700 psi. HIGH PRESSURE BOILERS- boiler that operates at a substantially higher pressure. 1200-PSI BOILERS- boilers that operate at about 1200 psi.

ARRANGEMENT OF STEAM AND WATER SPACES

DRUM-TYPE BOILERS have one or more water drums (and usually one or more water headers as well). Drum-type boilers are further classified according to the overall shape formed by the steam and water spaces-that is, by the tubes. M-type boilers D-type boilers HEADER-TYPE BOILERS have no water drum; instead, the tubes enter many headers which serve the same purpose as water drums.

HOW BOILERS WORK

NUMBER OF FURNACES
SINGLE-FURNACE BOILERS form a

often called D-type boilers because the tubes shape that looks like the letter D.

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 FIRST STAGE The first stage in the operation of a conventional boiler is the fuel supply to the burner. SECOND STAGE The fuel is mixed with air and ignited. THIRD STAGE The flame from the burner, and the resultant combustion gases escape into the boiler, transferring their heat to the water circulating through the heat exchanger within the boiler. FOURTH STAGE Boilers distribute heat from around the house using a wet system. FIFTH STAGE The gases of combustion escape from the boiler through the chimney or vent.

1. FURNACE DRAFT CONTROL SYSTEM

Utility and industrial boilers require some form of mechanical draft which is produced by combustion air fans. Balance draft boilers consist of forced draft (FD) and induced draft (ID). Forced Draft take suction from the atmosphere and forces air through the system. Induced Draft take suction from the boiler gas stream, discharging the flue gas to the stack.

The purpose of furnace control system is to maintain a constant pressure to maintain a constant furnace draft. Furnace DRAFT Control SYSTEM

APPLICATIONS OF BOILERS
1. Boilers are used mainly in power plant for generating high pressure steam to produce electricity. In power plant high pressure steam is expanded through nozzles to run steam turbine which generates electricity. 2. In cold countries hot water producing boilers are used for heating the buildings. 3. Boilers also find its application in textile industries for sizing and bleaching, and many other industries like sugar mills and chemical industries.

CONTROL SYSTEM
BOILER CONTROL SYSTEM FURNACE DRAFT CONTROL SYSTEM FEEDWATER CONTROL SYSTEM FUEL AIR CONTROL SYSTEM TEMPERATURE CONTROL SYSTEM ATTEMPERATION BURNER TILT POSITIONING FLUE GAS RECIRCULATION

2. FEEDWATER CONTROL SYSTEM

It equalize feedwater flow and steam flow while maintaining a stable water level in the steam drum. This system controls the steam flow from the superheater, feedwater flow from the economizer and the drum level. Q1: What will happen if the boiler exceeds on the drum level? A: Water carryover may damage the superheater or the turbines. Q2: What will happen if the drum level is low? A: It will lead to overheating that may damage the wall tubes. 5|Page

3. FUEL AIR CONTROL SYSTEM

One of the key components of the control is the ability of the fuel air control system to maintain sufficient air proportional to fuel to eliminate the possibility of a fuel rich condition that may lead to an explosion. But since it is not based on measurement fuel air ratio is not precise. It depends on other parameters and is affected by varying fuel characteristics, fuel temperature, pressure variations, atmospheric conditions, etc. 4. TEMPERATURE CONTROL SYSTEM

DISADVANTAGE OF WATERTUBE BOILERS They are, as a general rule, more difficult and expensive to build. ADVANTAGE OF FIRETUBE BOILERS Firetube boilers are easier and cheaper to build. DISADVANTAGE OF FIRETUBE BOILERS A firetube boiler is slow to raise steam, even in small sizes. holds great potential, in the large mass of stored energy, for a lethal explosion if not properly built and maintained.

Criteria for Selection

The primary benefit of constant steam temperature is improving the economy of conversion to mechanical energy and reduce the amount of moisture in the steam. a) ATTEMPERATION Controls the temperature of the steam by spraying water into the steam line to reduce the superheated steam to the desired temperature. It is normal to have the spray attemperation take place between the two superheater sections. b) BURNING TILT POSITIONING burner tilt is also used to control superheat during combustion process. Lowering the burners increases the furnace heat absorption and so less heat is absorbed by the superheat. Raising the burners decreases furnace draft absorption and so more heat is absorbed by the superheater. c) FLUE GAS RECIRCULATION provides a method for control of gas from the economizer outlet to the furnace by means of recirculating fans and ducts. This provides control of superheater steam temperature and tube protection. Of all the evaluation criteria the key factor is the fuel usage or boiler efficiency. Boiler efficiency, in the simplest terms, represents the difference between energy input and energy output. REMEMBER: Not all boilers are created equal. However, all boilers operate under the same fundamental thermodynamic principles. INDUSTRY-RECOGNIZED EFFICIENCY TEST STANDARDS The two most prominent industry-wide testing standards for boilers are ASME PTC 4 and BTS-2000. ASME PTC 4

As prescribed by the ASME Power Test Code, PTC 4, the fuel-to-steam efficiency of a boiler can be determined by two methods: the Input-Output Method, and the Heat Loss Method. 1. INPUT-OUTPUT METHOD.

ADVANTAGES AND DISADVANTAGES OF BOILERS

ADVANTAGE OF WATERTUBE BOILERS For a given surface area a watertube boiler will produce TWICE as much steam as a firetube boiler. The danger of explosion is greatly reduced due to the decreased quantity of water held and the small size of the pressure drum(s).

The Input-Output efficiency measurement method is based on the ratio of the output-to-input of the boiler. It is calculated by dividing the boiler output (in BTUs) by the boiler input (in BTUs) and multiplying by 100. 2. HEAT LOSS METHOD. The actual measurement method consists of subtracting from 100 % the total percentage of: A) stack, B) radiation, and C) convection losses. 6|Page

BTS-2000 STANDARD

Designed to facilitate laboratory testing and allows a fair comparison of boiler efficiency ratings under standard conditions. The standard BTS-2000 test conditions, for purposes of comparison, limit steam pressure to a maximum of 2 psig and steam quality to a minimum of 98 percent. Water tests require boiler inlet temperatures between 35 deg. F and 80 deg. F (75 deg. F and 85 deg. F for condensing boilers) and, for hot water boilers, outlet water temperatures between 178 and 182 deg. F. CONSIDERATIONS EFFICIENT BOILER WHEN CHOOSING THE MOST

1. PRESSURE VESSEL DESIGN.

Pressure vessel design is regulated by strict ASME code requirements. Water circulation (forced or natural), low stress design and accessibility are key criteria for proper pressure vessel design. 2.MAINTENANCE COSTS

Review your maintenance costs carefully. The old unit could be costing you money in various ways, including emergency maintenance,, major maintenance requirements (past and pending), difficult-to-find and expensive parts requirements, and overall vessel and burner problems. 3. REPEATABLE AIR/FUEL CONTROL

The efficiency of the boiler depends on the ability of the burner to provide the proper air-to-fuel mixture throughout the firing range, day in and day out, without the need for complex set-up or adjustments. 4.FUEL-TO-STEAM OR FUEL-TO-WATER EFFICIENCY

Fuel-to-steam or fuel-to-water efficiency is a measure of the overall efficiency of the boiler. For space heating boilers and in the BTS-2000 testing procedure, this type of efficiency is called thermal efficiency.

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