FIRED

PRESSURE
VESSEL

BOILER
Learning Outcome

At the end of the lesson, learners should be able to:

1. Identify type of BOILER

2. Identify component for BOILER

2
Steam Boiler
• Is a closed fired pressure vessel, strongly constructed of steel.
• Partly filled with water and vaporized / converted into steam with
application of heat. The remaining space is called steam space.

• Heat transfer occurs from the combustion of fuel to the water.

• The correct air & fuel ratio are burned through burner to produce hot
gases or flue gases.
Steam Boiler
• Type of Boilers:

o Fire Tube Boiler

o Water Tube Boiler

• The fundamental difference between these
(Source: https://www.indiamart.com)

boiler types is which side of the boiler tubes

contain the combustion gases or the boiler
water/steam.

• Boiler function: to produce or generate steam

• Application of boiler: Run machinery (e.g.
compressor), Power generation (e.g. turbine),

Process/ manufacturing/ heating utilization

Steam Boiler
Steam Boiler Flow Diagram

(Source: https://www.ispatguru.com)
Steam Boiler
Steam Boiler Flow Diagram

38

(Source: https://www.electrical4u.com)
Steam Boiler
Steam Boiler Flow Diagram
Steam Boiler
Steam Boiler Flow Diagram
Steam Boiler
Steam Boiler Flow Diagram

Marine TypeWater TubeBoiler Schematic Fire Tube boiler Schematic

(Source: https://en.wikipedia.org) (Source: https://en.wikipedia.org)
Steam Boiler
Fire Tube Steam Boiler
• In firetube boilers, the combustion gases pass inside boiler tubes, and heat
is transferred to water on the shell side.

• Have front and back door.

• Heat transfer is from inside tube (hot gases) to outside (water).

• Burner is located outside & will supply combustion air, fuel & ignition.

(Source: http://www.hurstboiler.com)
 Steam Boiler
Fire Tube Steam Boiler
• The tubes sizes from 1¼" up to high as 3" diameter.
• These tubes are usually straight & relatively short in order for the hot gases
to have a low pressure lost in passing through them.

• The water surrounding the tubes is usually contained by a large diameter

cylindrical vessel (drum).

(Source: https://marinerspoint.in)
Steam Boiler
Fire Tube Steam Boiler
• Fire tube steam boiler classification:
Steam Boiler
Fire Tube Steam Boiler
1. Single Pass Fire Tube Steam Boiler
o Are the first generation of firetube boilers
where combustion is normally by solid fuel
such as coal and wood.

o These boilers were used extensively on

locomotives and have now been transferred
to industrial use.

o They consists of a water box chamber and a

one pass firetube where the heat transfer is (Source: http://www.naicranes.com)

by convection. 4
5
Steam Boiler
Fire Tube Steam Boiler
2. Dryback Fire Tube Steam Boiler
o These are the old type of boilers where the radiant heating surface
consists only of the furnace.

o The reversal chamber consists of refractory work.

o A lot of valuable heat is lost to the refractory at the reversal chamber.

(Source: https://www.boiler‐outlet.com)
 Steam Boiler
Fire Tube Steam Boiler
3. Wetback Fire Tube Steam Boiler
o Are newly designed boilers where radiant heating surface consists of
the furnace, the wrapper plate & the wetback rear plate.

o The wetback design reemploys a completely water cooled turn around

(gas reversal chamber) where the product of combustion leaves the
furnace & enters the second pass.

o This high temperature zone at the furnace exit is water cooled by the
wetback chamber & increases the proportion of radiant heating
surface. This lowers the gas temperature into the convectional tubes &
increases the overall fuel to steam efficiency.
 Steam Boiler
Fire Tube Steam Boiler
3. Wetback Fire Tube Steam Boiler
o It has been shown that the rear tube plate metal temperature is
significantly lower compared to the dryback. This results is longer life,
lower running cost & lower thermal stress.

o The wetback design also replaces the hot refractories and insulating
material.

(Source: https://www.spiraxsarco.com)
Steam Boiler
Fire Tube Steam Boiler
4. Multi-pass/Reverse Fire Tube Steam Boiler

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0

(Source: https://www.boilermech.com)
Steam Boiler
Fire Tube Steam Boiler
4. Multi-pass/Reverse Fire Tube Steam Boiler
o Are constructed such that the flame or hot gas after combustion is made to
reverse in the furnace.

o The radiant heating surface consists only of the furnace.

o The furnace is of a larger diameter as compared to the wetback chamber to
enable the flame to reverse.

o Only the pressure jet burner is applicable.

o The flame should be narrow and long and this would require very high fuel oil
pressure and correct nozzle size in order to produce this type of flame pattern.

o These boilers are normally two pass in nature.

Steam Boiler
Water Tube Steam Boiler
• Are the first generation of firetube boilers It
has the opposite condition, that is, water
passes through the inside & fire or hot gases
are on the outside tubes.

• Heat transfer from outside to inside tube.

• The modern water tube package boiler has
the ability to develop more boiler horse
power, rapid circulation & to produce steam
at high pressure in a compact design. (Source: http://www.daviddarling.info)
Steam Boiler
Water Tube Steam Boiler
• Water tube steam boiler classification:
Steam Boiler
Water Tube Steam Boiler
1. Type D Water Tube Steam Boiler
o The most common type.
o Has a water drum, steam drum and generating
tubes.

o 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
(Source: https://www.indiamart.com)
back into the steam drum where the dry pipe is
located then into the plant.
Steam Boiler
Water Tube Steam Boiler
2. Type O Water Tube Steam Boiler
o Boiler has two drums, one water drum [#3] and
one steam drum [#2].

o Combustion Chamber [#1] is in the middle

surrounded by downcomers and generating tubes.

o Downcomer - outside tube & Riser - inside tube.

o When water boils due to convection heating,
steam rises up through the tubes and into the
steam drum. (Source: https://en.wikipedia.org)
Steam Boiler
Water Tube Steam Boiler
3. Type A Water Tube Steam Boiler
o Has two water drums and one steam drum
compared to the D-type package boiler.
o 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.
o 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.

o Smaller than D-type therefore will fit smaller

plants. (Source: http://jkmpsp.blogspot.com)
55
Boiler Component

Water Side Requirement from FMA 1967

1. Economizer 15. 13 Essential Fitting
2. Feed Water Regulator i. Two Safety Valve
3. Steam Drum ii. Two Water Gauge
4. Tube iii. Pressure Gauge
5. Mud Drum iv. Blow Down Valve
6. Blow Down Chamber v.Main Stop Valve vi.
--------------------------------------------------- Fusible Plug
Flue Gas Side vii. Feed Check Valve
7. Draft Fan viii. Low Water Fuel Cut Out
8. Ash pit ix. Low Water Alarm
9. Explosion door x.Inspector Test Attachment xi.
10. Soot Blower xii. Name Plate
11. Combustion Chamber Two Feed Pump
12. Burner xiii. Registration Plate
13. Baffle 5
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14. Stack
Steam Boiler
Boiler Essential Fitting
• Based on Factories And Machinery (Steam Boiler And Unfired Pressure
Vessel) Regulations, 1970, every boiler shall be provided with 13 essential
variables:
Boiler Component

Typical Boiler Downstream and Upstream

(https://www.kepco.co.jp)
 Boiler Component

Locations for Each Boiler Component

(https://boilersinfo.com)
Boiler Component
Economizer
• Before entering the steam drum, the feed
water passes through the economizer
where heat is recovered from the flue
gases leaving the boiler

• May be arranged for counter or parallel

flow with the flue gases flowing either up
Economizer Location
(https://www.steamautomobile.com) and down

• Temperature of the feed water is increased

and in some cases steam is generate

Economizer
(https://hangzhouhangheng.en.alibaba.com)
 Boiler Component
Feedwater Regulator
• Control feedwater into steam drum. • The outlet steam mass-
flow is measured and
the inlet feedwater
mass-flow is adjusted
to the very same
amount. The level
transmitter is merely
used to tune up the
system so the water
level lies within the
limits.
Feedwater Regulator Location
(http://steamesteem.com)
Boiler Component
Steam Drum
• Provide space for steam-water separation
o Separate saturated steam from
steam-water received from riser
before send to steam header.

o Water without steam can be supply

into downcomer

• Provided with continuous blowdown

Main Component in Steam Drum

(https://www.babcock.com)

Steam Drum Internal View

(https://boilersinfo.com)
Boiler Component
Steam Drum

6
3
Water‐Steam Separation
(https://www.youtube.com)
Boiler Component
Tubes
• Downcomer: Channel water from steam
drum to the mud drum

• Riser: Channel water from mud drum to the

steam drum. During the flow, water heated
and change into steam.

• Superheater: Channel saturated steam

from steam drum to the header. During the
Tubes Location
(http://lejpt.academicdirect.org)
flow, saturated steam heat-up into
superheated steam

Tubes Bend for Boiler

(https://www.amobgroup.com)
Boiler Component
Mud Drum
• Located at the bottom of water tube boiler
• Provided with blowdown valve for the
intermittent blowdown operation since it
susceptible to deposit

Mud Drum (Internal)

(https://www.pinterest.com)

Mud Drum (External)

(https://www.tei.co.uk)
 Boiler Component
Blowdown Chamber
• Located at distance from boiler
• Designed to received continuous blowdown
and intermittent blowdown.

Typical Blowdown Chamber

(https://docplayer.net)
Boiler Component
Draft Fan
• Draft in boiler is to ensure the hot air flow
meet the operation need.

• Type of draft are natural draft, induce draft,

force draft and balance draft.

Draft Fan Location

(https://rakhman.net)
Typical Draft Fan
(https://www.indiamart.com)
Boiler Component
Burner
• Commonly used when source of fuel from
fluid or gas

• Have an ignited point

• Install in combustion chamber

Burner Component
(https://www.powermag.com)

Burner Operation
(https://www.babcock.com)
Boiler Component
Burner

9
Burner Operation
(https://www.youtube.com)
Boiler Component
Combustion Chamber
• Furnace area

• Where combustion occurred

• Fuel burning at this area before blower
used to flow the hot flow gaseous

Combustion Chamber
(https://www.mawera.co.uk)
Boiler Component
Baffle
• Compartment plate inside the furnace to guide the flow of the hot gaseous

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1

(https://www.mecholic.com)
Boiler Component
Ash Pit
• The area where ash can be collected without enter the furnace

(https://in.pinterest.com)
Boiler Component
Explosion Door
• These door function during small explosion occurred inside furnace

• Its prevent the failure of the refractory

(https://www.indiamart.com)
Boiler Component
Soot Blower
• Used to spray or to clean the ash which

cover the outside tube

• Located at generating tubes

• Small amount of steam used

• Install either in manual or automation

• Can set the time

(http://human‐style.blogspot.com)

(https://beingmechanical.wordpress.com)
Boiler Component
Soot Blower

7
5
Soot Blower Operation
(https://www.youtube.com)
Boiler Component
Stack
• Also called chimney

• Create natural draft

• The high the stack the high pressure draft
out

• Build of carbon steel or stainless steel

Stack
(https://dissolve.com)