PACKAGED BOILER

PACKAGED BOILER
 The packaged boiler is so called because it comes
with a complete package. Once delivered to site, it
requires only the steam, water pipe work, fuel
supply and electrical connections to be made for it
to become operational.
 Package boilers are generally of shell type with
fire tube design so as to achieve high heat transfer
rates by both radiation and convection.
Features of packaged boiler are:
 Small combustion space and high heat release
resulting in faster evaporation.
 Large number of small diameter tubes leading to
good convective heat transfer.
 Forced or induced draft systems resulting in good
combustion efficiency.
 Number of passes resulting in better overall heat
transfer.
 Higher thermal efficiency levels compared with
boilers.
INTERNAL ARRANGEMENT
Package boilers are commonly
called water or fire tube Boilers.

The package boiler is usually a two

or three-pass fire-tube boiler with an
internal furnace tube. Internal layout of a three-pass
fire-tube boiler
These boilers can be rated up to
500,000 lb/hr.
Water tube boilers use convection heating, which draws the heat from the
fire source, and passes against the generating tubes of the boiler, causing
water inside those tubes to boil off into steam.

Fire tube boiler arrangement utilizes conduction heating which transfers

heat from physical contact.
Fire tube boilers are not commonly used due to their method of
conduction heating because pipes in direct contact with fire and cold water
could damage the pipes.

Generating tubes filled with water are in direct contact with the heat
source inside the boiler, causing damage to the pipes as well as scaling.

These boilers however are great with steam production due to the large
volume inside the boiler and the surface area of the steam output.

In order for these boilers to operate properly, they require a long warm-up
process, and are prone to thermal shock of the boiler.

The wall membrane of the boiler are dual welded, (welded on either side
of the wall membrane) to provide extra reinforcement for high loads
TYPES OF PACKAGE BOILERS

A-type, D-type and O-type are all water

tube package boilers.
D-type Package Boiler

The D-type boiler has a water

drum, steam drum, and generating
tubes.
Water flows into the steam drum,
flows down the downcomers and
into the water drum.

Water is then sent from the water drum through the generating tubes,
where the fire is located around causing water molecules to boil off into
steam.
Steam rises up more generating tubes and finally back into the steam
drum where the dry pipe is located then into the plant.
This configuration shaped the package boiler into a D-shape, hence the
name D-type package boiler.
These boilers are mostly used for plants that allow greater clearances.
A-type Package Boiler

The A-type package boiler has two

water drums and one steam drum
compared to the D-type package
boiler.
Water boils off in the water drums
shared by a common header, then sent
up the generating tubes, into the steam
drum and up the dry pipe.
Just like the D-type package boiler, fire heats the tubes surroundings
causing the tubes to increase in temperature thus boiling off water
molecules to steam.
A-type package boilers were designed to improve package boiler
reliability and reduce tube replacements.
A-type package boilers are smaller than D-type therefore will fit
smaller plants, but does not have the same power output as D-type
package boilers.
O-type Package Boiler

The O-type boilers are a little simpler

compared to D-type and A-type.
They consist of one water drum and one
steam drum.
Generating tubes are lined up from either sides
of the steam and water drums.

When water boils due to convection heating, steam rises up through

the tubes and into the steam drum.
This is a symmetrical design for restrictive plant layouts. O-type
boilers are mainly used for their fast steam production and reduced
maintenance cost.
Advantages
 Compact design capable to fit tight engineering spaces
 Utilizes forced or induced draft system to provide
greater efficiency and better air flow
 Many tube passes which provide greater heat transfer.
 High thermal wear levels.
 Inexpensive maintenance.
 Ease of installation.
 Less costly than water tube boiler erected on site of same
capacity.
 Less man power is required.
Disadvantages
 Complex Construction
 High initial cost of package boiler
 Difficult to clean tubes within boiler
 Combustion chamber, door opened for tube cleaning
 Not suitable for very large amount of steam production