Watertube and Tubular

Heating Boilers
Learning Outcome
When you complete this module you will be able to:
Describe the types of watertube and tubular boilers used in heating systems.

Learning Objectives
Here is what you will be able to do when you complete each objective:
1. Describe the construction of watertube heating boilers.
2. Describe the construction of copper-tubular heating boilers.

1
BLRS 6015

INTRODUCTION
Industrial type watertube boilers are seldom selected for low-pressure heating
plants except for large building complexes. The main reasons are the high cost of
this type of boiler as compared with the cast-iron or steel firetube boiler, and the
need for closer supervision, especially with regard to water treatment.
Specially designed watertube boilers are used for low-pressure heating
applications. They are usually supplied as packaged units. A few types will be
discussed in this module.

WATERTUBE HEATING BOILERS

Watertube Boiler with Serpentine-Shaped Tubes
A popular type of watertube boiler is illustrated in Fig. 1. It consists essentially of
a lower and upper header connected by a large number of copper or steel
serpentine-shaped tubes attached to the headers with threaded connections.

BF_1_0_3.jpg
P

Figure 1
Low-Pressure Watertube Boiler
2
BLRS 6015

The combustion chamber of this boiler is below the tubes and is equipped with
atmospheric gas burners. The entire unit is enclosed by an insulated casing.
The lower part of the tubes is exposed to the radiant heat of the fire. The
combustion gases travel upwards to the flue between the tubes and give up their
heat by convection. Even though the gas travel is relatively short, heat transfer is
efficient due to the arrangement of the tubes which causes turbulent and intensive
scrubbing of the gases around the tubes.
Advantages of this boiler design are the flexibility of the serpentine-shaped tubes
which eliminates expansion and contraction stresses, and the ease of replacement
of a defective tube since no welding or expanding is needed.
The boiler shown in Fig. 1 is a hot water heating boiler.
Bent-Tube Watertube Boiler
Another type of packaged watertube boiler that has become increasingly popular
is illustrated in Fig. 2 and Fig. 3. This boiler is actually a special version of the
industrial "O" type packaged watertube boiler.

BF_1_0_4.jpg
P

Figure 2
Watertube Boiler with Membrane Waterwalls
(Cleaver-Brooks)

3
BLRS 6015

Fig. 2 shows the basic boiler, the pressure part, before being enclosed. It consists
of a large upper drum, a small lower drum and a number of bent watertubes which
connect the upper and lower drums.
The tubes are arranged in such a way as to form the furnace enclosure, thus, the
furnace walls are formed by water-filled tubes and, therefore, are called
waterwalls. The tubes in these walls are spaced apart but connected to each
other by steel plating welded to the tubes so that gastight walls (membrane
waterwalls) are formed. Two such walls are used in each side of the boiler, the
inner walls form the furnace enclosure, the outer walls passageways for the flue
gases. Front and rear of the boiler are closed by single waterwalls.
BF_1_0_5.jpg
P

Large amounts of radiant heat from the fire are absorbed by the furnace walls.
This heat is carried off by the rapidly circulating water in the tubes. The
combustion gases, after leaving the furnace, travel between the inner and outer
membrane walls on their way to the stack, giving up their heat to the walls by
convection.
The boiler is enclosed by an insulated steel casing. It is either oil or gas fired and
equipped with a forced draft fan.
Fig. 3 shows an illustration of the boiler complete with casing, firing equipment,
fittings and controls. This boiler can be used as a steam or hot water boiler for
low as well as high-pressure service depending on its design pressure rating.
A tubular boiler is in principle a watertube boiler. However, it is not equipped
with drums or headers. Instead of having a large number of tubes, it has one or
more continuous coils of copper or steel tubing, the number depending on the
capacity of the boiler. A pump forces water through the coil which is exposed to
the hot products of combustion.
The tubular boiler was originally only used in hot water systems. When used as a
steam boiler, the hardness forming salts (present in most waters) concentrated in
the boiler and formed scale on the inside of the tubing resulting in restriction of
the waterflow and overheating of the tube material. However, this problem has
now been overcome, and the tubular steam boiler is gaining popularity rapidly.

4
BLRS 6015

BF_1_0_1.jpg
P

Figure 3
Watertube Boiler
(Cleaver-Brooks)
Packaged watertube boilers usually follow one of the three main structural
configurations shown in Figs. 4, 5, and 6.
The "A" type, Fig. 4, has two small lower drums or headers. The upper drum is
larger to permit separation of water and steam. Most steam production occurs in
center furnace-wall tubes entering the drum.

Figure 4
A Type Packaged Boiler

5
BLRS 6015

The "D" type allows much flexibility of design since the combustion chamber
volume can be easily varied. The more active steaming tubes become risers and
enter the drum near the water line. The boiler is fired between the outer "D" tubes
either at the end or at the side, the tubes being bent to allow the burner entry.
Superheaters and economizers can be added to the "D" type radiant or convection
zone with relative ease.

Figure 5
D Type Packaged Boiler
The "O" type, Fig 6, is also a compact steamer. Transportation limits the height
of the furnace, so for equal capacity, a longer boiler is often required. Floors of
"D" and "O" types are generally tile-covered.
The "O" type has a symmetrical design but exposes the least tube surface to
radiant heat.

Figure 6
O Type Packaged Boiler
Manufacturers tend to standardize package boiler designs with regard to the
outside dimensions of width and height and to vary the length according to the
required boiler output rating. This is largely dictated by the size limitations
imposed on rail or road transportation.

6
BLRS 6015

The Copper-Tubular Boiler

A very popular boiler, extensively used in residential and commercial hot water
heating systems and for domestic hot water supply, is the copper-tubular boiler of
which a cut-away view is shown in Fig. 7.
The heating surface of this boiler consists of one continuous, small diameter
copper tube. Copper is used because it resists corrosion and it has a much faster
heat transfer rate than cast iron or steel.

BF_1_0_2.jpg
G

Figure 7
Copper-Tubular Boiler
(A. O. Smith)
The heating surface is divided into three parts:
1.

The lower section consisting of a tightly wound coil which surrounds the
combustion chamber. The coil absorbs the radiant heat of the fire and
transfers it to the water.

2.

An intermediate section made up of several layers of loosely wound spirals

allowing the hot gases to flow freely around the tubing after they leave the
furnace.

3.

The upper section consisting of a fin-and-tube type heat exchanger. Fins

are crimped or bonded on the tubes increasing the heating surface so more
heat is absorbed from the hot gases rising from the furnace on their way to
the chimney.
7

BLRS 6015

The boiler is either gas or oil fired, with the burner placed in the lower part of the
furnace section.
In smaller heating systems a single, copper-tubular boiler is used. In larger
heating systems, instead of using one single, large capacity boiler, many designers
prefer to use several smaller units in parallel.
The Packaged Tubular Steam Boiler
Fig. 8 shows a basic diagram of a tubular boiler used for steam generation. The
boiler is supplied as a packaged unit and is equipped with its own feedwater pump
and a steam separator. The units are available for high as well as low-pressure
applications.
The heating surface consists of one continuous steel tube forming a waterwall of
tightly wound coils around the furnace in the lower section and several layers of
loosely wound spirals in the upper section.
The tubing in the waterwall is protected by steel sheathing against the erosive
action of the flames.
Water circulates at high velocity through the boiler tubing from the top
downwards while the hot gases travel upwards. In this way, no cold water is
pumped into the hottest section of the boiler, excessive stresses are prevented, and
longer life is assured.
The boiler can be fired by oil or gas. A blower, driven by the same motor driving
the feedwater pump, supplies the combustion air.
The operation of the unit is as follows:
Make-up water and returned condensate enter the feedwater inlet (A) and flow to
the feedwater pump heads (B). The water is then pumped through the mixing
chamber (C) to the heating coil (D). In the single pass heating coil (D) the water
is heated to equivalent steam temperature by the combustion gases flowing
upward through the coil assembly. The steam-water mixture is then passed into
the thermostat tube (E) and counterflows back across the combustion chamber (F)
to the accumulator (G). Here steam and water are centrifugally separated by the
separating nozzle (H).
Steam is discharged through the steam discharge valve (M). The water is drawn
from the accumulator (G) by the recirculating pump heads (J) and pumped to the
mixing chamber (C) where it blends with the feedwater. Excess water in the
accumulator is returned to the condensate tank through a steam trap (K). A liquid
flow control (L) is incorporated to prevent burner operation in case of a low water
condition. Automatic half-fire modulation is provided to reduce on-off cycling
during periods of light steam demand.
Softened water is used as feedwater to prevent scale forming. Since any salt
carried into the boiler with the feedwater stays behind and would concentrate in
the boiler water, an automatic blow-down is provided which drains sufficient
water off the accumulator to keep the concentration within safe limits.
8
BLRS 6015

BF1_fig8.gif

Figure 8
Packaged-Type Tubular Steam Boiler
(Clayton Mfg. Co.)

9
BLRS 6015

Advantages of the Low-Pressure Watertube and Tubular Type Boilers

1. Compact. Considerably smaller and lighter than firetube boilers of equal
capacity.
2. No special foundation required.
3. Very short warm-up period required.
4. Bent or coil tube design avoids thermal stress and distortion.
5. Rapid response to fluctuating loads.
6. Supplied as packaged units completely equipped with firing equipment,
automatic controls, and safety devices.
7. Safer than firetube boilers in the case of tube failure since the boilers contain
very little water and no disastrous explosion could occur.
8. Maintenance cost low. Boiler has a minimum of refractory.

The main disadvantages of watertube and tubular heating boilers when compared
to firetube heating boilers are the higher first cost of most of the watertube and
tubular types and their need for closely monitored water treatment.

10
BLRS 6015