BOILERS

PREPARED BY:- MASOOD-UR-REHMAN

TECHNICAL TRAINING CENTER

COURSE INTENTIONS
THIS COURSE HAS BEEN PREPARED TO INTRODUCE THE MECHANICAL MAINTENANCE PERSONNEL, INVOLVED IN MAINTENANCE OF BOILERS, ABOUT THE BOILER BASICS, CONSTRUCTION AND THEIR WORKING SPECIAL CONSIDERATION HAS BEEN GIVEN TO B-605 AND B-601/B-602

COURSE OUTLINES
INTRODUCTION TO BOILERS TERMINOLOGIES USED MAIN COMPONENTS AUXILIARY BOILER B-605 WASTE HEAT BOILER B-601/B-602 AUXILIARY BOILER B-4601 FIRE TUBE BOILERS BOILER MAINTENANCE HISTORY WATER TREATMENT TECHNIQUES

INTRODUCTION TO BOILERS

WHAT IS A BOILER ?

THE BOILER IS A CLOSED HIGH PRESSURE VESSEL IN WHICH HEAT CHANGES WATER INTO STEAM. BOILERS ARE WIDELY USED IN INDUSTRY FOR PRODUCTION OF HOT WATER AND STEAM

WHY WE USE WATER IN A BOILER ?

THE REASON BEING: WATER IS A CHEAP MEDIUM AVAILABLE EVERYWHERE BOILS AT RELATIVELY LOW TEMPERATURE NON-TOXIC, HAZARDOUS OR COMBUSTIBLE ON BOILING IT VOLUME INCREASES ABOUT 1600 TIMES

CLASSIFICATION OF BOILERS
THERE ARE TWO MAJOR CLASSIFICATION OF BOILERS

FIRE TUBE BOILERS WATER TUBE BOILERS

FIRE TUBE BOILERS

WHEN BOILER WATER IS ON THE SHELL SIDE OF THE BOILER IT IS CALLED FIRE TUBE BOILER

ADVANTAGES OF FIRE TUBE BOILER

LOW INITIAL COST FUEL EFFICIENT EASIER TO OPERATE PACKAGED DESIGN

DISADVANTAGES
LOW CAPACITY LOW INITIAL COST LOW PRESSURE UNITS AND TEMPERATURE

LIMITATIONS
HIGH PRESSURES ARE DANGEROUS POOR CIRCULATION TUBE LEAKAGES AT HIGH TEMPERATURES

WATER TUBE BOILERS

WHEN BOILER WATER IS ON THE TUBE SIDE OF THE BOILER IT IS CALLED WATER TUBE BOILER

TYPICAL WATER TUBE BOILER

ADVANTAGES OF WATER TUBE BOILER

HIGH CAPACITY HIGH PRESSURES AND TEMPERATURES GOOD EFFICIENCY

DISADVANTAGES
HIGH INITIAL COST OPERATIONAL DIFFICULTIES HIGH MAINTENANCE COSTS

OTHER CLASSIFICATION CRITERIA

PRESSURE HIGH, MEDIUM AND LOW PRESSURE BOILERS FIRED OR UNFIRED BOILERS COAL, OIL OR GAS NATURAL OR FORCED CIRCULATION NATURAL, INDUCED OR FORCED DRAUGHT

FIRING METHOD FUEL USED

WATER CIRCULATION

FURNACE TYPE

BASIC TERMINOLOGIES
CONDUCTION CONVECTION RADIATION THERMO-SIPHON BOILER CAPACITY HEATING SURFACE BOILER BLOW DOWN DE-AERATION CONVECTION SECTION

CONDUCTION
A METHOD OF HEAT TRANSFER IN WHICH HEAT IS TRANSFERRED FROM ONE POINT TO ANOTHER WITHOUT ACTUAL MOVEMENT OF MOLECULES

CONVECTION
CONVECTION IS THE MODE OF HEAT TRANSFER IN WHICH HEAT IS TRANSFERRED FROM ONE LOCATION TO THE OTHER THROUGH MOVEMENT OF MOLECULES

RADIATION
A METHOD OF HEAT TRANSFER THAT DOES NOT REQUIRE ANY MEDIUM OR MOLECULES FOR HEAT TRANSFER

THERMO-SIPHON
THE FLOW OF WATER (OR ANY LIQUID) FROM A LOWER ELEVATION TO A HIGHER ELEVATION DUE TO DIFFERENCE IN TEMPERATURE AT TWO LOCATIONS

BOILER CAPACITY
IS THE QUANTITY OF STEAM PRODUCED PER HOUR AND IT SHOWS IT SIZE. IT IS ALSO THE QUANTITY OF WATER EVAPORATED IN ONE HOUR. IT IS REPRESENTED IN TONNES PER HOUR

HEATING SURFACE AREA

REFERS TO THE TOTAL AREA EXPOSED TO HOT COMBUSTION GASES

CONVECTION SECTION
IS THE SECTION OF THE BOILER WHERE HEAT IS TRANSFERRED TO THE MEDIUM THRU CONVECTION

BLOW DOWN
IS THE DRAINAGE OF WATER FROM A BOILER TO REDUCE THE LEVEL OF IMPURITIES AND REPLACING IT WITH BETTER QUALITY WATER

DE-AERATION
DE-AERATION IS THE REMOVAL OF DISSOLVED GASES ESPECIALLY OXYGEN FROM THE DEMIN. WATER. THESE GASES (ESPECIALLY OXYGEN) CAUSE CORROSION INSIDE THE BOILERS AT HIGH TEMPERATURES

MAIN PARTS OF A BOILER

BOILER FURNACE BURNERS STEAM DRUM BOILER BANK TUBES SUPERHEATER ECONOMIZER FURNACE DRAUGHT SYSTEM

BOILER FURNACE
THE SECTION OF THE BOILER WHERE FUEL IS BURNED TO GENERATE HEAT. HEAT IS TRANSFERRED TO MEDIUM THRU RADIATION IN THIS SECTION

BURNERS
THEY ARE LOCATED IN THE VERTICAL WALL OF THE COMBUSTION CHAMBER AND BURN FUEL. BURNERS ARE DESIGNED FOR EFFICIENT BURNING OF THE FUEL AND MAINTAIN HIGH EFFICIENCY.

STEAM DRUM
STEAM DRUM IS A HIGH PRESSURE VESSEL WHICH SERVES MANY FUNCTIONS IN A BOILER SUCH AS A LARGE RESERVOIR FOR BOILER FEED WATER, CENTER FOR WATER DISTRIBUTION AND SATURATED STEAM COLLECTING AND SUPPLY TO SUPERHEATER.

BOILER BANK TUBES

THIS IS A BUNCH OF TUBES CONNECTED TO STEAM DRUM (AND LOWER DRUM) AND FALLS IN THE CONVECTION ZONE OF THE BOILER. THE WATER PARTIALLY EVAPORATES IN THE BOILER BANK TUBES. IT CONTAINS RISERS AND DOWN-COMERS.

SUPERHEATER
SATURATED STEAM FROM THE STEAM DRUM RISES THRU DEMISTER PADS AND ENTERS INTO A SERIES OF TUBES WHICH ARE LOCATED IN THE BOILER FURNACE RADIANT SECTION OR IN CONVECTION SECTION BEFORE ENTERING BOILER SECTION.

ECONOMIZER
ECONOMIZER IS A STEEL TUBE BANK PLACED AT THE OUTLET OF THE BOILER SECTION IN THE WAY OF FLUE GASES BEFORE THEY EXIT.

FURNACE DRAUGHT SYSTEM

IT REGULATES THE FLOW OF AIR TO AND FROM THE BURNER AND PROVIDES ENOUGH AMOUNT OF OXYGEN REQUIRED FOR COMBUSTION IT ALSO FORCES OUT COMBUSTION GASES OUT OF THE FURNACE TO THE EXHAUST DUCT. A FORCED DRAFT SYSTEM USES A FAN TO FORCE (OR PUSH) AIR THROUGH THE FURNACE AN INDUCED DRAFT SYSTEM USES A FAN TO DRAW (OR PULL) AIR THROUGH THE FURNACE. BALANCED DRAFT SYSTEM IS SOMETIMES USED WHICH UTILIZES BOTH FORCED AND INDUCED DRAFT FANS.