a McDermott company

Water-Tube
Package Boilers
Provide Reliable, Economical Steam Production
Water-Tube Package Boilers:
Proven Design for Economical
Steam Production
Since 1867, Babcock &Wilcox has been design-

ing, manufacturing and installing the world’s

most reliable and efficient energy-generating

systems and environmental equipment. B &W

To meet varying space, fuel, steam also services, repairs, upgrades and replaces
and economic conditions, B&W
offers a complete line of auxiliary
equipment. A package boiler burner existing systems and associated equipment,
system is shown.

regardless of the original manufacturer. With

boiler installations operating in more than

85 countries, B&W has the experience and

flexibility to meet the ever-changing needs of

both the utility and industrial markets.

2
Babcock &Wilcox: A single-source supplier of
innovative energy solutions and total-scope services.
Dependable performance in
a wide variety of industries
B&W’s water-tube package boiler
continues this tradition of excellence
with more than 4,200 units in
operation. Our established reputation
for reliability and proven performance
is continually enhanced by incorporat-
ing the latest technological advance-
ments into our design. B&W is
dedicated to the water-tube package
boiler market, which is comprised of
industrial and institutional markets
such as:
➢ Hospitals
➢ Universities
➢ Manufacturing and processing
facilities
➢ Utilities
➢ Petrochemical
➢ Pulp and paper
System components
complement operation
Specifically designed to complement
each other in operation, B &W supplies
B&W’s engineering expertise
and complete project
management skills help to
ensure that a project is right
the first time and on time
without additional costs.
all the major components in the FM ➢ Inspection and maintenance services
package boiler system: ➢ Engineered upgrades–
➢ Boiler designed to last
➢ Burner ➢ Long-term service partnering
programs
➢ Controls
➢ Fan ➢ Training programs
➢ Heat traps ➢Operating instructions
➢ Spare parts manuals
➢ Sootblowers
➢ Added options (feed pumps, ➢ Startup services
deaerators, chemical feed systems) ➢ Sales assistance
Broad capacity range
B&W water-tube package boilers are
available in a wide range of capacities:
➢ Steam flow from 8,200 to 240,000
pounds per hour (1 to 30 kg/sec)
➢ Superheat temperatures up to
900°F (482°C)
➢ Design pressures from 250 to
1050 psi (17 to 72 bar) The compact, efficient design of B&W’s
water-tube package boilers allows for
Support services economical shipment via rail or truck.
In addition to equipment supply,
B&W offers comprehensive support
services, including:
➢ Field service engineering
3
Water-Tube Package Boilers: Capacities to
Meet the Most Demanding Requirements

Capacity
Scale Boilers Range* Length Width Height Drum
1' = 1⁄ 16" (lb/hr) Size
FM 9-22 7' 7"
26 8' 11"
30 9' 11" 36" Steam
34 8,200 11' 3" Drum
39 to 12' 7" 10' 2 7⁄ 8" 12' 4"
43 40,000 13' 11" 24" Lower
48 15' 3" Drum
52 16' 7"
57 17' 11"

FM 10-52 16' 7"

57 17' 11" 36" Steam
61 35,000 19' 3" 10' 10 5⁄ 8" Drum
66 to 20' 7" 13' 6"
70 75,000 21' 11" 24" Lower
79 24' 7" Drum
FM 101-88 27' 3" 11' 2 3⁄ 8"

42" Steam
FM 103-70 70,000 21' 3 3⁄16"
Drum
79 to 23' 113⁄16" 11' 9" 13' 9 ⁄4"
3

88 100,000 26' 7 3⁄16"

24" Lower
97 29' 11"
Drum

FM 106-79 23 113⁄16" 48" Steam

88 100,00 26' 7 3⁄16" 11' 9" 14' 3" Drum
97 to 29' 33⁄16"
FM 117-88 155,000 26' 7 3⁄16" 11' 111⁄4" 15' 41⁄2" 24" Lower
97 29' 33⁄16" Drum

54" Steam
FM 120-97 155,000 29' 33⁄16"
Drum
112 to 33' 7 3⁄16" 12' 5 ⁄8"
3
16' 10 ⁄2"
1

124 240,000 37' 333⁄16"

24" Lower
Drum

NOTES:
1.All package boilers are of
membrane construction.
2.Because of the company’s
constant effort to improve
design, equipment supplied
may differ slightly from that
described above.
3.Package boiler capacities
greater than 240,000 lb/hr
are available in B&W’s
high-capacity series.
METRIC CONVERSIONS: * Steam capacities shown are saturated steam.
Capacities shown will vary depending on
inches x 25.4 = mm conditions and limitations.
inches x 2.54 = cm
feet x 0.3048 = m
lb/hr x 0.000126 = kg/sec

4
Water-Tube Package Boilers: B&W’s
Engineering Expertise Offers Many Benefits

Long-term reliability
B&W maintains the same cornerstone
company values as we did in 1867 when
the first B&W water-tube steam boiler
was patented. These values include a
commitment to excellence, outstanding
customer service, quality and continu-
ous improvement, integrity, technology
leadership and a global outlook. Based
on these values, B&W builds equipment
that is designed to last. In fact, many
1950 vintage B&W package boilers are
still in use today.

Fast load response

B&W’s 2 1⁄ 2" tubes are spaced 1" apart.
This provides a larger volume of water
in our furnace walls and contributes
to a faster load response. In addition,
our uniquely designed drum internals
can handle varying loads without This photograph contrasts the differences between B&W’s 2 1⁄2" tubes spaced
circulation disruptions or carryover. 1" apart (tube panel in background), and competitors’ 2” tubes spaced 2" apart
Connections for lower drum heating (tube section in foreground). As shown, B&W’s 2 1⁄2" tubes on 3 1⁄2" centers increase
coils also are standard. the overall water-cooled tube furnace surface and reduce the membrane area
between the tubes. This helps to prevent membrane thermal cracking and
Low O&M costs
contributes to a faster load response.
The B&W package boiler drives main-
tenance to a minimum with:
➢ No reliance on refractory seals
➢ Positive circulation, 100%
water-cooled rear wall
➢ Bricks on floor for long-term
protection
➢ A fully drainable and 100%
convection superheater
➢ Galvanized, primed and enamel-
painted exterior lagging
➢ Hinged drum manways for better
waterside access

Controlled emissions
B&W has its own staff of combustion
design engineers and works with outside
burner suppliers to meet your stringent
requirements. Our furnace has more
water-cooled surface, thereby helping to
meet today’s tough NOx limits. B&W’s water-tube package boilers offer more water-cooled surface, which in turn
helps to meet today’s stringent emissions regulations.
5
Water-Tube Package Boilers: Unique Features
and Rugged Construction Enhance Operation
Superheater
(optional) Boiler Sidewall
Boiler Screen Division Wall
Furnace
Furnace Sidewall
B&W’s water-cooled package boilers are designed for
reliable, efficient operation in a wide variety of industries.
Proven “D”-type construction,
which has separate boiler and furnace
sections, creates proper geometry
of the burning chamber. As a result,
combustion efficiency is increased and
the following benefits are added:
➀ Furnace wall water cooling includes
not only the side walls, roof and floor,
but the high-duty rear wall as well–
eliminating refractory and its attendant
maintenance. This unique boiler
feature locates total water cooling
where it can contribute most to keeping
maintenance costs down, and each
rear wall tube is a single flow path
between drums to assure proper
circulation and cooling.
➁ Gas-tight setting membrane pro-
vides the gas-tight setting absolutely
necessary on all package boilers. This
construction eliminates dew-point
sulfur corrosion and outages caused
by gas leaks. B&W’s membrane panels
6
To Stack or
Economize
Windbox
use large diameter tubes and small
membrane spacing, which provides the
best combination of heat transfer
efficiency and maintenance accessibility.
Scalloped seal plates (illustrated in
2-A) on the membrane design also
provide a continuous gas-tight seal
between the tube membrane and
drums. Where inner- cased construction
is used, a 10-gauge plate is welded to
the tie bars, instead of directly to the
pressure parts (shown in 2-B). To
maintain casing above the dew point
temperature, the plate is formed
around the tie bar to ensure close
plate-to-tube contact.
➂ Rugged steel-base frame supports
the entire boiler, and allows jacking
and skidding of the boiler. A concrete
slab with no special saddle, supports
or piers is all that is needed for the
package boiler. To ease installation
and relocation, B&W’s frame has
built-in lifting lugs and jacking pads.
➃ Outer steel lagging is galvanized,
primed and painted, making it weather-
tight for outdoor installations. The
12-gauge roof casing also provides a
surface strong enough to walk on.
➄ Drum internals provide high steam
purity and ensure positive circulation.
There are two primary steam separators
to choose from – a baffle-type for 3 ppm
solids or an optional cyclone-type for
1 ppm solids. Both designs incorporate
corrugated-type secondary scrubbers.
Dry pipe steam separation also is
available for 1⁄2% moisture steam.
➅ Water wash troughs and drains are
standard on every new package boiler.
➆ Grooved tube seats with polished
tube ends provide maximum protection
during initial handling and transporta-
tion, as well as against leakage through-
out the unit’s life. B&W’s tube seats
provide more holding power and
seal integrity.
➇ Sootblowers are properly located
for effective convection bank cleaning.
Sootblower bearings, wallbox(es) and
tube openings are standard on all
package boilers, regardless of fuels
fired. An additional B&W boiler
feature is that the alternating front-
to-rear bank spacing allows removal
of any tube if necessary (illustrated
in 8-A).
➈ Front wall fire brick is designed for
expansion and protection of the front
corner seals, and the front wall tile is
anchored by a floating alloy retainer.
To protect the corner seals, the front
wall of the membrane unit is set inside
furnace “D” tubes (illustrated in 9-A).
➉ Thermal sleeve connections for
lower drum heating coils are standard.
Heating coils can reduce the time from
light-off to full load by several hours.
1 2 2-A A

OD=
21⁄2"

A
Membrane Scalloped
Bar Seal Plate

31⁄2"
Furnace Rear
Wall Tubes 1
⁄4" Thick A-A
Membrane

2-B 3 4

12-Gauge Roof Casing

Tie Bar

Plate
Casting Base Frame FM-9, 10, 101

5 6 7
Drum Internals, Type "B"

Lower Drum

Drum Internals, Type "C"

Wash Water Drains Grooved Tube Seat

8 8-A 9 Brick Holder

Tubes Can Be Removed
Generating 4 ⁄8"
1

Bank Sootblower
Tubes 3" 3"
Elements

Generating Bank Front Wall Tile Front Plate

9-A Windbox 10 Lower

Drum

Thermal Sleeve
Connections
Furnace
Furnace Burner Wall "D" Tubes

7
Water-Tube Package Boilers: Efficient Separation
and Positive Circulation Assure Dependability

Steam Outlet
Type “B” Internals

Secondary
Diffuser Baffle Steam Scrubber

B&W designs and manufactures all our

own drum internals, including cyclone
steam separators.

Even when load changes are wide or frequent

enough to affect water level in the drum, positive
circulation is assured with B &W drum internals.
As hot furnace flue gas crosses the first row of
Adequate slope is designed on all heat-absorbing surfaces, and tubes in the boiler bank, a considerable amount
all downcomers are located in the cooler zone of the convection of steam is generated. This quantity is substantially
bank for proper circulation. Each tube is completely drainable. greater on higher-capacity units for essentially
the same drum length, imposing a tremendous
Steam Outlet burden on drum internals.
Type “C” Internals B&W separation equipment is specifically
designed to effectively handle this rapid, intense
Secondary generation of steam. Diffuser baffles direct
Cyclone Separator Steam Scrubber
portions of the steam to less turbulent zones of
the drum, making use of the entire length of
scrubbing elements to remove unwanted
moisture droplets.

Superheater tube failures eliminated

When superheaters or special processes require
it, steam with less than one ppm solids can be
obtained. Turbine blades are kept cleaner, and
costly superheater tube failures are eliminated. An
equally important feature designed into B&W’s
drum internals is the supply of bubble-free solid
water back to the downcomer circuits for positive
circulation. The drum internals’ design also
allows free end flow to minimize turbulence and
end-to-end level fluctuation.

8
Water-Tube Package Boilers: Complemented
by a Complete Line of Auxiliary Equipment

Economizers, superheaters, burners

and controls are available from B&W
for package boilers in accordance with
operating and economic design con-
siderations. Additional accessory
equipment, including a forced draft
fan and drive, a junction piece, flues
and ducts, stacks, feedwater pumps,
deaerator, and an oil pump and
heater set can be ordered to simplify
planning and engineering.
To meet your required steam conditions,
a superheater unit can be added to
B&W package boilers. B&W also offers
pre-engineered arrangements
of extended surface or bare-
tube economizers.

Economizers
increase efficiency
Economizers are available for
increased efficiency. Pre-engineered
arrangements of extended surface
or bare-tube economizers are offered
to meet varying fuel, space and
economic considerations.

Fully drainable superheaters

Proven, dependable and fully drain-
able superheaters – especially designed
for package boilers – also are an avail-
able accessory. The vertical-tube design
provides positive bottom support and
excellent expansion characteristics.
Multi-pass steam flow ensures high
steam velocities and good distribution
of fluid throughout, effectively cooling
each tube. Because it is positioned out
of the full radiant heat zone, it has a
convective-radiant temperature char-
acteristic for a relatively constant
superheater steam temperature over
the load range. For further conve-
nience, the steam outlet is located
near floor level. To protect the thicker
wall drums in the superheater area,
refractory drum protection is provided.

Refractory drum
protection safe-
For oil-fired applications, sootblowers
guards the thicker
are a typical feature. The sootblower
wall drums in the
supply and superheater outlet
superheater area.
connection are pictured to the left.

9
 Water-Tube Package Boilers:
Total-Scope Supply and Services
B&W’s extensive, worldwide experi-
ence allows us the flexibility to easily
meet diverse project requirements –
anything from a knock-down boiler to
an entire steam island. We can pack-
age your boiler system with properly
sized, quality auxiliaries to match your
needs and our standards of excellence.
Typical project scope
Although every project is unique in
scope, a typical project includes:
➢ FD fan and drive
➢ Burners and fuel trains
➢ Deaerator and feedwater pump set
➢ Burner management system
➢ Combustion controls – jackshaft
to DCS
➢ Economizer
➢ Stack
➢ Platforms
Stringent quality
control standards
At B&W, quality assurance is integral
to our design, engineering and manu-
facturing processes. To ensure all codes
and specifications are met, B&W uses
stringent quality control procedures
and sophisticated testing apparatus.
Rigid standards have been established
for our material suppliers as well.
B&W’s commitment to quality is
evident by our:
➢ Advanced technology –B&W builds
quality into its products during every
process and stage
➢ Strength in size and capacity – facili-
ties, manpower and global presence
provide you with a complete range
of fabricating processes
➢ Outstanding responsiveness –B &W is
equipped and structured to meet
your delivery needs and requirements
10
Manufacturing and
safety excellence
B&W’s package boilers are designed,
engineered and manufactured at our
West Point, Mississippi, U.S.A. facility –
one of seven B&W manufacturing
plants located worldwide. This plant
is ISO-9001 registered, ASME code
approved, and is in compliance with
AWS code requirements. B&W’s West
Point plant also maintains an outstand-
ing safety record and has been awarded
the OSHA Star Status in the Voluntary
Protection Program. Manufacturing
and safety excellence are a continuous
goal for B&W.
Worldwide, responsive service
and manufacturing support
B&W’s network of domestic and
international sales representatives and
field service engineers assures you of a
prompt response – whether servicing
and upgrading your existing system
or specifying new equipment. We can
provide services ranging from routine
inspections and controls tuning to
capacity increase engineering studies,
low emissions conversions or new
digital control systems.
B&W’s package boilers are being
To meet the needs of the global
market, we also design, engineer fabricated at our West Point,
and manufacture package boilers in Mississippi, U.S.A., manufacturing
accordance with all B&W standards at facility. This plant is ISO-9001
six international operations. These
operations are Thermax B&W in Pune, certified, ASME code approved, and
India, B&W BC in Beijing, Peoples possesses an outstanding safety record,
Republic of China, PT BWI in Batam, receiving OSHA Star Status in the
Indonesia, B&W Gamma in Ankara, Voluntary Protection Program.
Turkey, B&W Egypt in Cairo, Egypt,
and B&W Mexicana in Mexico City,
Mexico. These facilities are ASME for package boilers and auxiliary
code approved and participate in equipment. From engineering and
The McDermott Safety Program. manufacturing to start-up and opera-
tion, B&W knows how to make it all
Reliable single-source work together for maximum operating
supplier efficiency and dependability, and
B&W’s proven expertise in boilers, keeps you in compliance with today’s
burners and controls makes us a environmental regulations.
reliable and responsive single source
Through innovative
energy solutions and
total-scope services,
B&W is dedicated to
powering the world
in an environmentally
safe, efficient and
economical manner.

11
a McDermott company

For more information, or a complete listing of

our sales and service offices worldwide, call
1-800-BABCOCK (222-2625) in North America.
Outside North America, call (330) 753-4511
or fax (330) 860-1886 (Barberton, Ohio, USA). Or
access our Web site at http://www.babcock.com.

Canada:
Cambridge, Ontario
Edmonton, Alberta
Halifax (Dartmouth), Nova Scotia
Montreal, Quebec
Saint John, New Brunswick
Vancouver (Richmond), British Columbia
Czech Republic: Prague In all the world, there is only
Egypt: Cairo one Babcock & Wilcox. Others
England: London
may copy our name, but none
India: Pune
Indonesia: Jakarta can duplicate the engineering
Mexico: Mexico City excellence and advanced
People’s Republic of China: Beijing
Poland: Warsaw technologies developed by the
Russia: Moscow original Babcock & Wilcox.
Taiwan: Taipei
Turkey: Ankara
United States of America:
Akron (Wadsworth), Ohio
Atlanta, Georgia
Charlotte, North Carolina
Cherry Hill, New Jersey
Chicago (Downers Grove), Illinois
Cincinnati, Ohio
Denver (Sheridan), Colorado
Houston, Texas
Kansas City, Missouri
San Francisco (Vacaville), California

Powering the World Through

Teamwork and Innovation SM

The information contained herein is provided for general information

purposes only and is not intended or to be construed as a warranty, an
offer, or any representation of contractual or other legal responsibility.

© The Babcock & Wilcox Company. All rights reserved.

Powering the World Through Teamwork and Innovation
is a service mark of The Babcock & Wilcox Company.

E101-3155 5MAP6I