BOILER

Boiler is a closed fired pressure vessel for Generating Steam Hot Pressurized Water Vaporizing Fluid

THE BOILER

PARTS

Boiler has two types of components

Mountings & Accessories

MOUNTINGS
Mountings are the components that are required to operate the boiler regularly and to examine the process and conditions to operate in a proper way safely Essential part of boiler

Mountings include Safety Valve Check Valve Pressure Gauge Temperature Gauge Level Glass

SAFTY VALVE

It releases the extra steam generated so that bursting is safe

CHECK VALVE

Check valve controls the one dimensional flow and let not allow fluid to be back on same side

PRESSURE GAUGE

Indicates the pressure so easy to check the presser of steam and if some wrong to designate and see the real problem to resolve

TEMPARATRE GAUGE

Indicates temperature may e a outlet or if more are there at different stages like flue gas and furnace

LEVEL GLASS

It Indicates the level of water in steam drum so that if the level is fluctuating it should e controlled

ACCESSORIES
Accessories improves the efficiency of boiler by value addition via processing the steam or may be the heat going to be lose Auxiliary to Boiler

These include Super Heater Air Pre-Heater Economizer Feed Pump

SUPER HEATER

Super Heats steam for process at outlet of steam drum to dry it at certain temperature

AIR PREHEATER

Heats air before entering to make air fuel mixture to achieve temperature as soon Exhaust gases are used for heating urpose

ECONOMIZER

Preheats water before entering to the drum Exhaust gases are used for heating

FEED PUPM
Feeds water at a pressure to steam drum more than seam drum Used for forces circulation

BOILER CLASSIFICATION

Boiler are classified according to some criteria like

Material Pressure Tube Contents

MATERIAL
Cast Iron Boiler
Theses are castled and are solid pieces Were used long ago

Steel Boilers
These are made by steel sheet rolling, welding and riveting These days mostly in use

PRESSURE
On Base of pressure we can classify Low Pressure 25 Kg/cm2 Medium Pressure 40 High Pressure 100 Sub Critical 140 Super critical 170

TUBE CONTENTS
The classification on base of tube contents is as below Fire Tube Water Tube

Fire Tube

The water is in drum and flue gases in tubes

Water tube

The water in tubes and flue gases on outside of tubes

DRY & WET BACK

This is sub classification of Fire tube boiler on the bases of reversing chamber type

DRY BACK

The reversing chamber is dry (insulated)

WET BACK

Reversing chamber side is water in drum that makes it more heat transfer rate for higher efficiency

BOILER DESIGN
o o

When boiler is designed it consist of two portion Thermal design Mechanical design

THERMAL DESIGN
In thermal design we have the input data as steam fuel composition, outlet temperature, feed temperatures, pressure, evaporation rate, load consideration Here we assume some parameters and stat our calculations By using iteration we calculate some parameters as BOT

In thermal balance we see that our assumed parameters fulfill the condition or not here we have 2-3 % error to avoid he calculation confliction Then we see furnace and each pass separately to calculate their temperatures and other parameters

MECHANICAL DESIGN
Here on base of our desired shape of boiler using SME code we calculate for the stresses and thickness of all components like furnace Shell Tubes Stay rods

ASME
American Society of Mechanical Engineers founded in 1880 Responsible for coding and standardizing about boilers and pressure vessels

STAMPING

For manufacturers they should have facility to fabricate the boiler according to the ASME code to fulfill the international standard

STAMPS
Power Boiler Miniature boilers Electrical boilers Boiler assembly Welded Piping Safety valve

BOILER APPLICATIONS

Boiler are used in almost all types of industry

HEATING

For central heating of buildings where open firing is dangerous

ENGINE DRIVING

Steam is used to drive engines as in MERINES Also to drive reciprocating machines

PWER GERATION

Boilers are widely used for power generation at power stations

PROCESS INDUSTRY

In process industry for many purposes

Washing Purification Concentration Process Activation

EVAPORATION
Boiler is used to evaporate some fluid for process where that have to be injected in vapor form Like NH3 in fertilizer plant is injected in vapor form so the fluid used in boiler will be NH3

BOILER CLEANING
When boilers work for a long time then it need cleaning because with time the deposition of insoluble contents are there to decrease efficiency of boiler So scheduled cleaning is performed

WTB CLEANING
In water tube boilers the smoke that is on fire side. That deposition is to be removed for proper functioning There is a nozzle provided on fire side there the steam under pressure is fired over the outside of tubes that washes that fumes

MECHANICAL CLEANING

Fouling is the deposition of insoluble contents of water that are here in tubes and drums that causes the reduction of heat transfer so that is cleaned by mechanical means of scraping or vibrations

CHEMICAL CLEANING

The deposits are acidic in nature so the asdic solution is added to the water and filled boiler then heating to a certain time the depositions are solved in water then that water is removed and after washing the boiler it is again ready for use

FIRETUEB BOILER CLEANING

Small fire tube boiler does not need cleaning but if the cleaning is desired then it is washed to use again

BOILER PROBLEMS

Problems in boiler can be Thermal

or
Operational

DESIGN PROBELMS
When the boiler is to design we have some problems like Thermal Balance Sulpher Contents Efficiency Achievement Air Leakage

THERMAL BALANCE
For thermal iteration procedure we assume a temperature ad then we define the thermal properties to calculate the temperature again to get exact value of temperature Ideally these are equal but in real we can have 2-3 % error allowance to avoid from too much complicated calcualtions

SULPHER CONTENTS
The presence of Sulpher in fuel which after burning causes SO3 during combustion. With reaction of water to this it will result corrosive H2SO4 BOT is taken higher than Due Point of Sulpher

OPERATIONAL PROBLEMS

When boiler is working there so many problems are to face and they must be immediately to resolve or made safe before the boiler is let to start

Operational problems are Inefficient Combustion Back Firing Process Dynamics Explosion Adjustment of Air Fuel ratio Power failure & Shut Down

INEFFICEINT COMBUSTION
Non homogeneous mixture of fuel due to mechanical parts or Non availably of fuel contents in combustion zone causes inefficient combustion So proper equipment is to be used

BACK FIRING
Continuous running of boiler some times causes the low velocity of flue gases than the combustion flam that results in travel of flam to the chimney and firing sounds can be heard Explosion door is provided that efficiently breaks that pressuedriffrence

PROCESS DYNAMICS

Process variables like Level, Pressure, Temperature fluctuate during its operation so the associated problems occurs and they should have be controlled

Level Pressure Blow Down Water Quality Power failure Shut Down