1 Boilers Q. What is a boiler? Ans. Broadly speaking, a boiler is a device used for generating. (@) steama for power generation, process use or heat- ing purposes, and (b) hot water for heating purposes. However, according to the Indian Boiler Act, 1923, aboileris aclosed pressure vessel with capacity exceeding 22.75 litres ‘used for generating steam uader pressure. it inctudes al! the mountings fitted to such vessels which temain wholly or partly under Pressure when steam is shut-off, Q. Whar is the difference berween'a steam boiler and a steam generaior? Ans. Technically speaking, a steam boiler consists ‘only of the containing vessel ang convection heating surfaces, whereas a steam generator covers the whole ‘unit, encompassing waterwall tubes superbeaters, ait beaters and economizers. Q. How are boilers classified? Ans, Boilers are classified on the basis of: Mode of circulation of working fluid . Type of fuel Mode of firing Nature of heat source 5. Nature of working fluid Positjon of the fumace ‘Type of furnace Boiler size Materials of constuction ). Shape of tubes and their spatial position 11, Content of the tubes 12, Steam pressure 13. Specific purpose of utilization 14. General shape 15. Manufacturer's trade name Swern apaene 16. Special features. Q. What is circulation? ‘Ans. It is the motion of the working Nuid in the evaporating tubes. This motion is effected by bead or pressure differcace in the working Aluid between the downcomer and uptake (riser) tubes. ‘The circulation may be natural ot forced and the circulation circuit formed by the heated and unheated tubes may be a closed or open hydraulic system. A once-through boiler represents av open-hydraulic system (Fig. 1,3), While in natural (Fig. 1.1) and forced multiple circulation boilers (Fig. 1.2), the cit- culation circuit is a closed hydraulic system. In com- bined-virculation (Fig. 1.4) boilers, the plant operates on closed hydraulic system at the start-up and is switched over to an open hydraulic system after at- taining the specified load. Q. How are boilers classified on the basis of mode of circulation of working fluid? Ans. 1. Natural circulation boiler 2. Forced (ie., positive) circulation boiler QQ. What is natural circulation? Ans. The natural convection of water set up in the closed bydraulic system of heated and vnbeated tubes of the waterwall, Q. How is it accomplished? Ans. ‘The natural convection current is induced to water due to a difference in density resulting from difference in temperature. ‘The baffle separates out the heated riser from the unheated downcomer and therefore creates a temperature difference between the two tube systems,2. Boller Operation Engineering Superheated steam 5 2 Btw Header Feed pump Fig. 1.1 Natural circulation. It is a closed circuit in which the working fluid circulates by virtue of its density difference ‘Superheated steam ‘Steam drum _ Superheater Economizer Evaporator Pump for forced circulation Feed pump Fig. 1.2. Muttiple forced circulation. Itis a closed hydraulic system in which the working fluid is circu- lated by forced circulation pump ‘Superheated ‘steam Btw. y Economizer Evaporator Feed pump Fig. 1.3. Open-hydkaulc circuit. This system is adopted for once-through boilers Saturated water flows down the unheated in densities of saturated water in the downcomer and downcomer and receives heat in the riser whereupon the steam - water mixer in the riser brings about a part of it gets converted into steam, The difference natural circulation. (Fig. 1.5)Economizer Btw Feed pump Bollers 3 ‘Superheated steam Superheater Evaporator Fig. 1.4 Combined circulation. It operates on closed hydraulic system at low loads and open hydraulic system beyond specified load unheated downcomer fig. 1.8. Natural circulation mechanism Q. Whar is us limitation? Ans. It is applicable to all subcritical boilers, ie., all those which are operating at a pressure less than critical pressure. @. What is forced circulation? Ans, If the working fluid is forced through the boiler circuits by an external pump, the ensuing cir- culation is called positive or forced circulation, Q. What are the advantages of forced circulation over natural circulation? Ans. Steam generation rate is higher Greater capacity to meet load variation Quicker start-up quality from cold Lower scaling problem due to high circulation velocity 5. More uniform heating of all parts reduces the danger of overheating and thermal stresses Smaller tube diameter and hence lighter tubes Greater freedom in arrangement of furnace, boiler component and tube layout 8. Operating temperature and pressure can be ‘made to deviate from the designed values. epee Q. What is circulation ratio? ‘Ans. tis the ratio of the mass flow rate of circulat- ing water (Gy, 1/A )to the rate of steam generation (G, 7h) kG /G, @Q. What is its value for natural circulation? Ans. Iusually ranges from 4 to 30. Whar is the value of circulation ratio for forced circulation? Ans, It ranges from 3 to 10. Q. What is the value of circulation ratio for once- through steam boilers? Ans. Unity.4 Boller Operation Engineering Water Btw pump~ Heat Flow Transition zone Steam ‘Superheater——4, [TeSys 4 Heat flow Fig. 1.6 Transformation of BFW to steam in once-through boiler Distribution header Economizer — Btw: Distribution header Fig. 1.7, Once-through circuit Bw pump Q Why? Ans. In such units, (Fig. t.6 and 1.7)the entire feed- ‘water is continuously converted to steam as it passes through the evaporating surfaces, i.c., Gu = Gy Q. Canonce-through boilers operate at subcritical as well as supercritical pressures? Ans. Yes. Q. Waar is the difference between a closed hydraulic system and an open hydraulic system? Ans. The former features a drum that acts both as a reservoir to provide working fluid circulation and separator to scparale water from stcam, while the latter has no drum and the working fluid passes through the evaporating tubes only once. Q. How canboiters be classified onthe basis oftube shape and position? =) ‘Superheater Evaporator \——+ Superheated steam ‘Ans. Depending on the form of tubular heating surface, boilers may be classified as 1. Straight ube boiler 2. Bent tube boiler. Depending on the inclination of tubular beating surface, boilers may be classified 48 1, Horizontal Boiler (Fig. 1.9) 2. Vertical Boiler (Fig. 1.8) 3, Inclined Boiler. Q. Whar is the difference between a horizonal boiler and a vertical boiler? Ans, The difference basically lies in the geometric position of the boilers. A horizontal boiler has its principal axis horizontal or slightly inclined white that of a vertical boiler is perpendicular to the horizontal plane. Q. What is a single tube boiler? Ans. A boiler having only one Gretube. (Comish or simple vertical boiler)Steam => nom a Fig. 1.8 Vertical boiler Blowdown Q. What is a multitube boiler? Ans. Boiler having two or more fire or watertubes. Q._ How can boilers be classified on the basis of use? Ans. This is done on the basis of the nature of service they perform. Customarily boilers are called (a) Stationary: these are iand based boilers. (b) mobile: these are mounted ot marine vessels, and steam locomotives. Q Whar is a stationary boiler? Ans. This boiler, as its name implies, is not required ~ to be transported frons one place to another. Q What are mobile boilers? Ans. Locomotive and marine boilers, which are moved from place to place, are mobile boilers, Btw in te L Ei, Fig. 1.9 Horizontal boiler Blowdown i Q._How may stationary boilers be classified fur- ther? Ans. They can be classified further depending on the specific service they meet: 1, Stationary boilers for central station (district) heating 2. Stationary boilers for process steam genera- tioa 3. Stationary boilers for power generation. Stationary boilers used for beating are often clas- sified asi 1. Residential boilers 2. Commercial boilers. Q. How can boilers be classified on the basis of furnace position? ‘Ans. Depending on the relative location of the fur- nace 10 the boiler, the boiler classification can be made by: 1, Externally fired furnace 2. Internally fired furnace. Q. What is the difference between externally fired and internally fired boilers?6 Boller Operation Engineering Flue Gas ‘Steam dome Fig. 1.10 (a) Locomotive boiler: Gas tlow circuit Ans. In the case of extemally fired boilers, the ‘combustion of fuel takes place in a chamber outside the boiler shell while in the case of internally fired boilers, the combustion chamber is provided inside the boiler shell. @Q. How canboilers be classified on the basis of tube contents? Ans. Depending on whether the flue gas or the water is in the tube side, the boiler can be classified as: 1, Firetube boiler 2. Watertube boiler. Q. Give some examples of firenibe boiters. Ans. 1, Locomotive boiler 2. Cochran boiler 3. Comish boiler. These have hot flue gas in the tube side and BFW in the shell side. Q. Cite some exampies of watertube boilers. 4ns. Babcock and Wilcox boiler . Stirling boiler . La Mont boiler .. Yarrow boiler. BONE Steam outlet (b) Locomotive boiler : water circuiating 5 Flue gas —--+-—-) CHa (I SET eee header Fig. 1.11 Senson Boiler All these have BFW in the tube side and hot {gas in the shell side. Q. What are the comparative advantages and . advantages of firetube and watertube boilers?Boilers 7 2° Ans, Parameters Firetube boilers Watertube boilers 1. Rate of steam generation ‘Less rapid ‘More rapid 2, Suitaidity for power plants Unsuitable Suitable. All major power plants are based on these. 3. Operating steam pressure Limited to 25 kgf/cm? Can well exceed 125 kgficm? 4, Chances of explosion Less More 5. Risk of damage due to explosion Much more Much less 6, Water treatment Not very necessary as minor scaling Required as scaling will lead to ‘would not go far enough to cause tube-bursting, overheating and tube-bursting 7. Floor space requirement "Much Less 8. Cost and construction problem Higher Mach tess 9. Transportation Inconvenient due to large size of the Compsratively easier shell 10, Skill required for efficient Less More: operation Q. How many rypes of watertube boilers are there? Ans, Two. Straight tube and bent tube boilers. Q_ On what grounds are bent tube boilers more Savourable than straight tube boilers? Ans, 1, Bent tube boilers lend greater economy in fabrication and operation than straight tube boilers. These are due to use of welding, im- Proved quality steel, waterwall coustruction and new manufacturing techniques. 2, Bent tube boilers afford greater accessibility for inspection, cleaning and maintenance due to more spacious layout of tubes. 3. They have a higher steam generation rate that Straight tube boilers 4, They produce drier steam than straight tube boilers. What are she essential qualities ofa good boiler? Ans. 1, Itshould be capable of quick start-up 2. Should meet large load fluctuations 3, Occupy less floor space 4. Should afford easy maintenance and inspec- tion = 10. Should essentially possess the capacity of producing maximum steam with minimum fuel consumption . Light and simple in construction Various joints should be accessible for inspec- tion and should be away from direct flame impact Tubes should be sufficiently strong to resist wear and corrosion Mud and other deposits should not collect on heated plates The velocity of water and that of flue gas should be a minimum, Q_Whar basic factors will you consider in electing a boiler? Ans. PRI aweene Power required to be generated Operating pressure Fuel - quality and type Water availability and its quality Probable load factor Location of the power house or process plants Cost of operation and maintenance Cost of installation and erection Availability of floor space.8 Boller Operation Engineering Flue gas Air in Air out Economizer ‘Superheater Transition zone Separator! Evaporator « Distribution header Se Biw Blowdown Fig. 1.12. Suter Boiler tot eg Five gos m8 — sem anne Saga Bw ey nerd eS (ae St Aas Cupereater de I a te ae ae ae te I) Ca Seconamy 4 eee |] “T"eraporator= | ert Tt [Yransition zone Btw Fimary evaporator Circulation pump {calles eee Fig. 1.13 La Mont BoilerQ. How can boilers be classified on the basis of pressure? ‘Ans. According to the American Society of Mechanical Engineers’ “Boilers and Pressure Vessel Cole” known as ASME Boiler Code, boilers may be differentiated as 1, Low pressure boilers — operating steam pressure not exceeding 1.021 au” (103.427 N/m?) and operating pressures of hot water doiler not excceding 10.893 atm* (1.10 MN/tn?) and temperature 394°K". 2. Power boilers — all boilers with operating pressure and temperature exceeding those of LP boilers stated above 3. Miniature boilers — include all fired pres- sure vessel haying the following parameters (a) ID of shell + 406.4 mm” (b) Gross volume (casiog and insulation in- cluded) + 0.14158 nr (©) Water heating surface + 1.858 m2* (@) Allowable working pressure > 6.8 atm (689.7 N/m"), (Nore + refers to converted unit) Q. How can classification of boilers be effected on the basis of materials of construction? Ans. According to ASME Boiler Code Material ‘Specifications (a) Low Pressure Heating Boilers can be con- structed of vast ison or steel (b) Miniature Boilers may be constructed of cop- per, stainless steel, etc. ‘c) Power Boilers are constructed of special steels. Q. How are boilers classified on the basis of size? Ans. Based on theit size ancl rating, the Steel Boiler Institute (USA) has classified boilers into three categories; Category (I): These are commercial boilers. ‘Twenty two sizes have been standardized. Their, ‘Heating surface = 11.98 — 331.756 m** Gross beat output = (45333 ~ 1260) keal/s?* = (10827 ~ 300) ki/s* These are residential boilers. Category (II): Seventeen sizes. Bolles 9 Heating Surface = 1.486-27.313 m™* Gross beat output = upto 126 kcal/s (30 ki/s)” Category (II): Oil fired boilers. Fourteen sizes. Gross heat output range is of'up to 30 ki/s” For low-pressure cast-iron heating boilers, the In- stitute of Boiler and Radiator Manufacturers (USA), standardized cast-iron boilers into 33 sizes. Their steam generation rate is upto 3143.44 kg/h”. (Note * refers to converted unit) Q_ How may boilers be classified on the basis of Siring? Ans. 1. Fired boifers in which supplied heat comes from the combustion of fuel. 2. Non-fired boilers receive heat other than that produced by the burning of fuel. @ How can classification of boilers be done depending on the heat source? ‘Ans, Depending o the nature of heat source, boilers can be classified into 1, Fuel fired boiler—these derive their heat energy by combustion of fuel which may be solid, liquid or gaseous. 2. Waste heat boilers—recover beat from the hot waste gases of other chemical reactions. 3. Electrical powered bollers—generate steam by the application of electrical energy. 4, Nuclear powered bollers—utilize the energy of controlled thermonuclear fission reactions to generate steam. Q_ How can boilers be designated on the basis of the nature of fuel used? Ans, 1, Coal fired (a) Pulverized coal fired (b) Stoker fired (©) Hand fired 2, Gas fired 3. Oil fired 4. Wood fired 5. Bagasse fired (Fluidized bed bagasse fired furnace for boilers have recently been developed).10 Boller Operation Engineering Blowaown cireutation pump Fig. 1.14 Loeffler Boiler Q. How canboiters be described in terms of the type of furnace? Ans. 1. Dutch oven boiler 2. Open boiler 3. Scotch boiler 4, Screened boiler 5. Twin boiler. Q. How is the general shape factor harnessed 10 classify a boiler? Ans. Depending on their shapes and design fea- tures, boilers can be classified as follows: (A) Watertube boilers 1. Horizontal straight tube: (a) boxed header type (b)_ sectional header type 2. Bent tube boilers (2) mono-drum type (b) bidrum type , (©) ridrum type {d) quadridrum type. (B) Firetube boilers (a)_ short fire box type (b) compact (©) vertical tube type (a) horizontal type (€) locomotive (1) Scotch type. Q. How can ihe boiler type be indicated by the manufacturer's trade name? Ans, Many a manufacturer applies his trade name to the particular type of boiler he designs, e.g. Benson boiler 1. La Mont boiler |. Sulzer boiler Velox boiler . Loeffler boiler Babcock boiler |. Wilcox boiler Yarrow boiler Manning boiler Thomycraft boiler Seoenaueene 1 If the drum is parallel 10 the tubes, it is called ©. Somerimes special features of boilers are used Jongitudinal drum type boiler; if across the tubes, it is called a cross-drum type. to classify them. How is this done?Ans. Depending upon the placement and firing ‘operation of burners, boilers may be classified as: differential fired type tangential fired type. Similarly there is the anthratube boiler, which is a completely self-contained anthracite burning unit. Different variations exist, such as tube-in-tube boiler, top-fired boiler, and so on. There are also: dual circulation boiler, boiler with gas recirculation pressurized and supercharged boilers. ‘Q._ How are boilers generally categorized? Ans types 1, Steel boilers: (a) Firetube type (b) Watertube type (©) “Shell type Cast-iron boilers Special design boilers Nuclear powered boilers, Watertube boilers may be further subdivided into: 1, Horizontal straight tube type 2. Bent tube type: (a) Natural circulation type (b) Forced circulation type. Q. What are the inherent advantages of horizontal straight lube boilers ifthe tube sizes are small? They may be categorized imto 4 (four) general BeP Ans. 1, Tube replacement is easier 2. Draught (draft) loss is low 3. Better cnd-to-end. visibility through tubes before and after cleaning 4, Greater accessibility 0 all components for inspection and cleaning 5. Low head room, Q. However, smaller straight tube horizontal boilers are associated with certain disadvantages. What are they? Ans 1. Access to internal components uses more ume and labour. Inadequacy in design adds to the tievance of the operators Bollers 11 2. Because of relatively low circulation rates and poor circulatory distribution, the steam generation rate is sharply impaired 3. If steaming rate is raised, the separation of steam from water in the steam drum becomes inadequate because a limited surface area is available for disengagement. Q. Briefly describe the horizontal straight tube boiler. Ans. These boilers are made up of banks of straight tubes laid out in a staggered arrangement at an angle Sto 15° to the horizontal, which are expanded into headers at the ends, The tubes are 75-100 mm in diameter with length not exceeding 600 cm. Smaller diameter tubes are selected when greater tube spacing is required to mect steam demand at higher pressure. Providing flat surfaces for these tube connections, the header may be a box or sectional type connected to the drum by means of circulation tubes — downtakes and uptakes. The drum may be of the longitudinal or cross type. These boilers may be oil, gas, coal, bagasse or wood fired. Pulverized coal firing can also be incor- porated. ‘When the boiteris fired, steam and water rise along the inclined tubes to the front headers and then pass to the drum through circulation tubes (uptakes). The water then circulates down through downtakes to the rear header and finally to the tubes to complete the cycle. Qs Why are the tubes, in horizontal straight tube boilers, inclined at an angle of 5 ~ 15°to the horizon- ta? Ans. To ensure better circulation. Q. Briefly describe a bent tube boiler. Ans These are muliidrum watertube boilers fitted with two, three or four drums, and usually having one lower drum called mud drum that serves as a blow- down for removal of sludge and concentrations of salts, The remaining drums placed at the top of the boiler are called steam and water drums, The tubes may be inclined or vertical, arranged in banks, or forming waterwalls backed with furnace wall refractories,12 Boller Operation Engineering a Wont i Fire Blowdown fig.1.15A Inclined bent-tube boiler Baffles are placed in the gas path to ensure even heating of watertubes. The drums are protected from the radiant heat of fire. The mode of steam-water circufation is as shown in Fig. 1.15. The boilers lend themsc!ves to a wide range of fuel burning. They can be fired with oil, gas, coal, bagasse or wood. For higher capacity of steam generation (451/h) pulverized cval or crushed coal (eyclone fur- nace) firing is adoptd. Bent tube boilers ave high steam generation rate and are quick to respond to fluctuating loads. Q. What are the aavantages of bent tube boilers over straight tube boilers? Ans. 1, Steaming rate is higher 2. Deliver more drier steam 3. More responsive to load fluctuations: 4, Lend greater economy in fabrication and operation 5. Afford greater accessibility for inspection, cleaning and ma:ntenance 6. Greater design flexibility as the tubes enter the «drum radially 7. The bent tubes aliow free expansion and con- traction 8, Boiler capacity can be increased without in- creasing the drum diameters, Steam outlet Blowdown Fig. 1.158 Vertical bent-tube boiler Q Why do bent tube boilers have a quicker response 10 load fluctuation? Ans, They have very good evaporating flexibility because of the relatively small water volume for the. steam generating capacity. Q. When are vertical tubes preferred 10 inclined tubes in designing bent tube boilers? Ans. This is given primary desig consideration when bent tube boilers are fired with coal having Jow-melting ash or particularly abrasive ash. Q. What isa waste heat boiler? Ans. it is a special purpose boiler designed to generate steam by {a)_ removing the generated heat, as called for, by the chemical processes involving exothermic reactions viz, the partial gasification of fuel oil; synthesis of ammonia N, + 3H; —» 2NH, + 22 kcal) ; oxidation of sulphur dioxide ta trioxide (280, + 0, + 2S05 + 45 kcal) ; conversion of ammonia to nitric oxide (4NH, +50, 9 4NO + 6H0 + 305 keal) (b) recovering heat that is (i) evolved ay ae integral part of the process and would otherwise go waste, such as {rom an open-bearth fumace (ii) a by-product of chemical process, e.g.. black liquor recovery(ii) made avaitable by burning wastes, €.8., wood scraps, Q._ Does it serve any purpose in addition eo produc~ ing useful steam? Ans. 1, Itreduces air and water pottution 2, Tt lowers the flue gas temperature, reducing ‘the maintenance of flues, fans, and stacks. Q How may waste heat boilers be classified? Ans. They can be classified as: 1. Watertube boiler 2. Gastube boiler 3. Bent tube boiler 4, Positive circulation boiler 5. Supercharged boiler 6. Three-drum-low-head boiler 7. Waterwall bidrum type boiler, Q. Where are these generally employed? Ans. Waste Heat Boiler Type Application 1, Watertube For clean or dust laden flue gas 2. Gastube For relatively clean flue gases : 3. Bent tube Handles heavily dust laden gases 4, Positive circulation For clean, low temperature gases, Gas turbine exhaust Suitable for light dust loadings For gases with suspended sticky particles, S. Supercharged 6, Three-drum-low-head boil 7, Waterwall bidrum type Q. What should be the design considerations in the selection of a waste heat boiler? Ans, 1, Heat load and temperature of the gases avail- able for waste heat recovery for steam genera- tion 2. Chemical nature and corrosiveness of the gases 3. Available draught (draft) Boilers 13, 4, Dust load and its nature in the gases 5. Whether the gases are under pressure or suc- tion Available space 7. Requirement for a start-up furnace, gas preheating emergency use or added capacity, etc, 8. Location for the outlet in the case of flue gases, Incase of lower gas temperature what madifica- tions should be made in designing a waste neat boiler? Ans. This drawback is offset by (a) providing high gas velocity () reducing the diameter of the heat exchanger tubes (©) increasing the number of such mbes 6 in crease the magnitude of convective heat trans- fer, Q. What is the usual mass flowrate in the WHB {Waste Heat Boiler) of flue gases being discharged 10 the atmosphere after waste heat recovery? Ans. 29000-39 000 ke/tt mr, Q. Insome cases a large quanium of dust particles is found laden in the waste gases available for steam generation. Whar problems are associated with dust load? Ans, Dust laden waste gases, if they contain abrasive dust particles, may cause severe damage 10 boiler tubes by erosion. Therefore, waste gases loaded with such particles require low gas velocities and that decreases the heat (rasfer rate in the WHB. If the gases contain sticky or tacky particles they will deposit on heat transfer tubes, impair the heat exchange process and reduce the efficiency of the WH, Q._ How canthe dust load in waste gases be contrat led? Ans. By (a) installing dust collectors (8). preventing by-passing of tubes with baffles (©) providing abrupt change in the direction of {2a flow path to settle dust14 Boller Operation Engineering (¢) minimizing bridging between tubes by ade- quate spacing. Q. What is a gasube WHB? Ans. Such boilers are shell- and -tube type boilers with hot gases flowing in the tube-side and BFW in. the sheti-side, They are usually single pass in arrangement and absorb only convection heat from the hot gases. They have a high weight-to-heat output ratio. They are usually found in applications for gas pressure 27-35 atm. and temperature up to 1255°K (982°C). ‘The extemal surface of the boiler is hot insulated. The boiler tubes are of smaller diameter and more closely spaced than direct-fired waste heat boilers. Soot blowers with nozzles directed towards the tube ends are used to clean the deposits, Gastube boilers are used in the case of gases with light dust loadings, for obvious reasons, Q. How many types of gastube WHBs are there? Ans, Two types : Horizontal and Vertical. Q. Horizonal gastube waste heat boilers are set at an angie of 15° 10 the horizontat, Why? Ans. This is1o (a) ensure steam collection at the high point (b) allow suspended solids in the water to settle down by gravity to the lowest point (©) enhance circulation. Q._ In which case is a vertical gastube WHB preferred to its horizontal counterpart? Ans, It is preferred when it is a prime necessity to save floor space. Q. Avertical gastube WHB with shell diameter 2.5 ‘mis rarely found. What is the cause of such a limita- tion? ‘Ans. This is due to limitations inherent in tanspor- tation and drum attachments. Q. Why are wateriube boilers most frequently used ‘for waste heat recovery? Ans. i. They can work successfully at higher pres- sures 2. Since water is circulated in the tube-side which can be readily cleaned, watertube WHB3 are not so susceptible to Gamage from poor feedwater quality 3. Better capacity 10 withstand the shock due (© fluctuation of gas temperature 4, ‘The furnace wall can be adequately cooled by applying water- wall tubes, This imparts long life to the refractory lined WHE intesios wall 5. The slagging and erosion problems can be minimized by varying the tube size and spac- ing 6. Dust particles may be recovered 7. Lends itself toa more economic arrangement, Q. What are the primary considerations in design- ing a watertube WHB? Ans. ‘The design considerations should primarily focus on two major problems. These are: (a) problems due to sticky dust particles (b) problems duc to heavy dust loadings The cooling and subsequent elimination of sticky particles is necessary before their entry into the con- vection shaft of the WHB, otherwise they will deposit ‘on the external surfaces of watestubes and impair the heat transfer characteristics Hot gases heavily laden with dust particles may entail erosion problems for tubes as well as reduced beat transfer due to surface deposition of dust par- ticles on watertubes. Q. What are the reasons that led 10 the application of bent tube boilers for waste heat recovery? Ans. 1. These boilers can tolerate beavy dus! load- ings. The vertical tubes collect less dust 2. Greater flexibility in tube size, spacing and arrangement 3. Tube damage problem is minimized by more positive circulation 4, Allows pendant superheater installation 5. Less space is required for tube removal.Se Q. Whar is te chiefadvamage of aposiuive circuta- tion waste heat boiler? Aas, ‘The unitis nore compact aud tight asextreme- Jy small diameter tubes (30-49 mm are used, which ‘can be arranged without regard to natural circulation requitements. QName one such boiler. Ads, Positive circulation La Mont Waste Heat Boiler. What are the applications of waste heat boilers? Ans. Waste heal boiler finds its application in: 1, Steel ealits — use all types of smali boilers: (@) horizontal ang vertical gasmbe WHE QO) borizomal straight tubulas WHE do) Bent waterube type boilers, Waste heat boilers are fitted to openstearth, forge and continuous heating furnaces. Coke oven and blast fumace gases being beavily ‘dust laden need special handting in the burner. 2 Cement kilns—-need 2 WHE that must be specially designed to handle extremely dust Jaden gas. Hoppersare provided under the boiler and ecéuomizer 1 remove dust continucusty. Asmuch as 20-40 101s of cement dust issecovered per day from a single kiln, ‘Two-drom ang three-drum WHRs are particutarly used, These are fitted with economizers, superbeaters and soot blowers. 3. Oreroaster—A typical WHB forzecovering ‘waste heat frown ofe roasters is a three-crum, Jow-bead boiler fitted with hoppers under the sections of gas path 10 collect gas-bome ore particles as they settle wher the gases makes fow-velocity tums around the bates. 4, Lead and Zine setters These need a kind of WAB that is capable of handing 2 gas whose temperature is gs high as 1450-1480"K_ and whichis laden with sotidsin a semimolten of sticky form, Usually a vertical watertube ‘WHB js used, which must coo! the gas down to 1000-1030" K in the radiant chamber to condense out tbe metal (Zn, Pb) vapour from, Wee hat gas before its ontry Wo supecieater amd convection shaft. Bollers 15 5. Paper making-uses « WHB 1 (a) generate process steam by burning the waste liquor (b) recover the salt cake 40) efiminate syeam pollution. The waste liquor is debydrated to produce char which is bumt in 2 large heap in a reducing atmos- phere in the recovery funace. The furnace tempesa- ture is as high as 1500-1530" K. Gas velocities are kept tow to avoid fouling of the heat absorbing sur- faces which comprise waterwall tubes taid af the reftactory lined boiler furnace, The Aue gases after passing theough the economizer go dirough ibe evaporator to concentrate the black liquor. Q. How are marine botlers classified? Ans, 1. Sectionat header boiler—either horizontat aight tube type or the sectional express type 2, Drum type—these. are bent tbe doilers haying a double furiace of simple furnace 3. Positive circulation boiler 4, Thermonuclcar steam generator Q. How are marine botlers typified? Ans, Depending upon the specific usuage of steam they produce, the marine voilers are divided into: 1. Main boilers — used for ship propulsion 2, Auxiliary boilers —used for running the ausiiary systems abroad the ship. QL Whar are these aitxiliary systems? Ans. 2. Tusbogenerators for electric power genera- ‘ton 2 Water distffation 3, Fuet oit heating 4. Space heating 5. Cooking 6. BFW turbines Whar factors must b¢ considered in designing a marine buiter? Ans, 1. The boiler must be compact it size and mini- MUM ity weigh!16 Boller Operation Engineering a Maximus operating efficiency to be imparted by ensuring (a) proper combustion and its control (b) efficient heat recovery (© adequate insulation (@) higher operating steam pressure and temperature, Special design features must be effected to (a) outweigh the effect of ships's rolling, pitching and vibration on steam genera- tion (b) eliminate gas leakage in the fireroom (©) minimize heat loss to the fireroom Opetation reliability is to be attained by (@) correct designing and construction of boiler (b) proper installation of boiler unit, super- heater and auxiliaries Simplicity in desiga and operation Complete accessibility to boiler internals for inspection, cleaning and repairing must be ensured to minimize outage time Flexible enough to maintain constant steam temperature and pressure over a wide range of steam loads This necessitates: (a) large steam dram (b) large ratio of heat generating to contained water volume. Fuel and its efficient utifization. Pulverized coal is seldom used because of space limitation. Almost all oceanliners use oil fired boilers as {a) oi} burns more cleanly than coal (b) oil leaves no ash (©) ool needs 55% of the storage capacity needed for coal (G) oil burning devices require less space. Q. What is called an ‘M’ boiler? Ans, Because of its shape, the double-fumace- single-uptake unit is referred to as an “M’ boiler. Itis, fitted with a separately fired superheater and extended surface economizer. QQ What is the range of steam generation capacity of the ‘M’ boiler? Ans. 45 to 135th, QQ What are the advantages of an “M’ boiler? Ans. 1 2. 3 4 5. 6. Close control over superheater temperature ensures greater efficiency Generation of steam at almost any desired temperature and pressure condition can be effected at any load condition by varying the rate of combustion in the twin furnaces Desuperheater is not required Requires less maintenauce Ensures good fuel economy at bigh efficiency under norma) conditions Compact. Less floor space is required. Q What are its main drawbacks? Ans. bere Unequal distribution of heating surta Unbalanced combustion characteristics ‘Complicated in operation in earlier design tis difficult to light off the superheater fire due to high furnace pressure and this becomes Particularly dangerous when the boiler load is considerable. . Since the saturated auxiliary steam is taken directly from the steam dmum, under condi- tions of low evaporation rate the superheater may receive insufficient steam, causing su- perhater starvation. Q Whar is a ‘D' boiler? Ans. boiler It is a single-furace, single-uptake marine aving two drums, The water-cooled furnace is shaped in the form of aD" and hence its name, Q. What are the advantages of a ‘D’ boiler over an “M' boiler? Ans, J pees More compact and light for a given steam output More reliable in operation Higher steam generation efficiency More economical at normal load Operation is more simplified. Maintenance is much less and outage time is low