Construction of boilers is mainly insteel,stainless steel, andwrought iron.

In
live steammodels,copperorbrassis often used. Historically copper was often
used forfireboxes(particularly forsteam locomotives), because of its better
thermal conductivity. The price of copper now makes this impractical.

Cast ironis used for domestic water heaters. Although

these are usually termed "boilers", their purpose is to produce
hot water, not steam, and so they run at low pressure and try to
avoid actual boiling. The brittleness of cast iron makes it
impractical for steam pressure vessels.

For much of the Victorian "age of steam", the

only material for boilermaking was the highest grade
of wrought iron.This iron was often obtained from
specialist ironworks, such as Cleator Moor (UK), noted
for the high quality of their rolled plate and its
suitability for high reliability use in critical applications,
such as high pressure boilers. 20th century practice
moved towards steel and welding.

The source of heat for a boiler iscombustionof

any of severalfuels, such aswood,coal,oil, or
natural gas.

High steam, or
High-pressure steam

steam of which the

pressure greatly exceeds that of
the atmosphere.

Saturated steam,

steam at the temperature of the

boiling point which corresponds to its
pressure; -- sometimes also applied
to wet steam.

Low steam, or
Low-pressure steam

steam of which the

pressure is less than, equal to,
or not greatly above, that of the
atmosphere.

Superheated steam
steam heated to a temperature higher than the boiling point
corresponding to its pressure.It can not exist in contact with
water, nor contain water,and resembles a perfect gas; -called also surcharged steam, anhydrous steam, and steam
gas.

Wet steam
steam which contains water held in
suspension mechanically; -- called also misty
steam.

Fusible Plug

a screw with a

tapered hole in the

center-smallest side
inside the boiler.
The hole is

blocked with a
metal of low
melting point so
steam is not
released at normal
working
temperatures.

Smokebox
is an extension of
the front end of the
boiler barrel. The
smokebox also contains
the main steam pipes
to the steam chests,
blower, superheater
header, tubes and
exhaust for the Vacuum
Ejector where fitted.

Steam from the main steam pipe arrives at

the saturated steam chamber of the
superheater header and is fed into the
superheater elements. Superheated steam
arrives back at the superheated steam
chamber of the superheater header and is fed
into the steam pipe to the cylinders.
Superheated steam is more expansive.

Firedoor
Firehole doors vary from locomotive to locomotive. These give access for firing and can be adjusted to control the flow of secondary air.

DomE
The dome is positioned at the highest part
of the boiler barrel where it forms a collector
for steam above the surface of the water.

Firedoor/Furnace
It gives access for firing
and can be adjusted to
control the flow of
secondary air.

Brick Arch

It protects the firebox tubeplate from the

direct flame of the fire, radiates heat to
prevent rapid fluctuation of the tubeplate
temperature, and ensures thorough
combustion of volatiles by lengthening
their path from the fire to the tubeplate.

Baffle Plate
The baffle plate placed in the
firehole is designed to direct the
secondary air down towards the firebed in
order to mix it thoroughly with the hot

Circulating Pump
is designed to circulate water
back to the boiler after it has
expelled some of its heat.

Safety Valve

used to relieve pressure and prevent

possibleexplosion of a boiler

LOCATION OF FIRE AND WATER

SPACES
INTENDED SERVICE
TYPE OF CIRCULATION
ARRANGEMENT OF STEAM AND
WATER SPACES
NUMBER OF FURNACES
BURNER LOCATION
FURNACE PRESSURE
OPERATING PRESSURE

 FIRE-TUBE BOILERS

a type ofboilerin which

hot gases from a fire pass
through one or more
tubes running through a
sealed container of water.
Theheatof the gases is
transferred through the
walls of the tubes
bythermal conduction,
heating the water and
ultimately
creatingsteam.

TYPES:

Cornish boiler
Lancashire
boiler
Scotch marine
boiler
Locomotive
boiler
Vertical FireTube boiler
Horizontal

WATER-TUBE BOILERS

a type ofboilerin which water circulates

in tubes heated externally by the fire.
Fuel is burned inside thefurnace,
creating hot gas which heats water in
the steam-generating tubes. In smaller
boilers, additional generating tubes are
separate in the furnace, while larger
utility boilers rely on the water-filled
tubes that make up the walls of the
furnace to generatesteam.

INTENDED SERVICES
PROPULSION BOILERS

used to provide steam for ships propulsion

and
for vital auxiliaries' services.
AUXILIARY BOILERS

installed in diesel-driven ships and in many

steam- driven combatant ships. They
supply the steam and hot water for galley,
heating, and other hotel
services and
for other auxiliary requirements in
port.

TYPE OF CIRCULATION
NATURAL CIRCULATION BOILERS

the circulation of water depends on the

difference between the density of an
ascending mixture of hot water and steam
and a descending body of relatively cool and
steam-free water. The difference in density
occurs because the water expands as it is
heated, and thus, becomes less dense.
FORCED CIRCULATION BOILERS
depend upon pumps, rather than upon natural
differences in density, for the circulation of
water
within the boiler.

ARRANGEMENT OF
STEAM AND WATER
SPACES
DRUM-TYPE BOILERS

have one or more water drums (and usually one

or
more water headers as well). Drum-type
boilers are
further classified according to the
overall shape formed
by the steam and water spaces-that is, by the tubes.
M-type boilers
D-type boilers
HEADER-TYPE BOILERS
have no water drum; instead, the tubes enter many
headers which serve the same purpose as water drums.

NUMBER OF FURNACES
SINGLE-FURNACE BOILERS

often called D-type boilers because the

tubes
form a shape that looks like the
letter D.
DOUBLE-FURNACE BOILERS

often called M-type boilers because the

arrangement of the tubes is roughly Mshaped.

BURNER LOCATION
FRONT-FIRED BOILERS

burners are located at the front of

the
boiler.
TOP-FIRED BOILERS

burners are on the top of the boilers.

FURNACE PRESSURE
PRESSURE-FIRED
or SUPERCHARGED BOILERS
these are pressurized-furnace boilers.
These furnaces are maintained under a
positive air pressure of about 65 psia
(about 50 psig) when operated at full
power. The air pressure in these boiler
furnaces is maintained by special air
compressors called superchargers.

OPERATING PRESSURE
400-PSI BOILERS

Header-type boilers and some older drumtype boilers

are often called 400-PSI
BOILERS. Their operating pressures range
from about 435 psi to 700 psi.
HIGH PRESSURE BOILERS
boiler that operates at a substantially higher
pressure.
1200-PSI BOILERS
boilers that operate at about 1200 psi.

FIRST STAGE
The first stage in the operation of a conventional boiler
is the fuel supply to the burner.
SECOND STAGE
The fuel is mixed with air and ignited.
THIRD STAGE
The flame from the burner, and the resultant
combustion
gases escape
into the boiler,
transferring their heat to the water circulating through
the heat exchanger within
the
boiler.
FOURTH STAGE
Boilers distribute heat from around the house using a
wet system.
FIFTH STAGE
The gases of combustion escape from the boiler
through
the chimney or vent.

1. Boilers are used mainly in power plant for

generating high pressure steam to produce

electricity. In power plant high pressure
steam is expanded through nozzles to run
steam turbine which generates electricity.
2. In cold countries hot water producing boilers
are used for heating the buildings.
3. Boilers also find its application in textile
industries for sizing and bleaching, and
many other industries like sugar mills and
chemical industries.

BOILER CONTROL SYSTEM

FURNACE DRAFT CONTROL SYSTEM
FEEDWATER CONTROL SYSTEM
FUEL AIR CONTROL SYSTEM
TEMPERATURE CONTROL SYSTEM
ATTEMPERATION
BURNER TILT POSITIONING
FLUE GAS RECIRCULATION

BOILER CONTROL SYSTEM

1. FURNACE DRAFT CONTROL SYSTEM
Utility and industrial boilers require some
form of mechanical draft which is produced by
combustion air fans. Balance draft boilers consist
of forced draft (FD) and induced draft (ID).
Forced Draft take suction from the
atmosphere and forces air through the system.
Induced Draft take suction from the boiler gas
stream, discharging the flue gas to the stack.
The purpose of furnace control system is to

maintain a constant pressure to maintain a

constant furnace draft.

Furnace Control
Furnace

ESP 1 ESP 2

ID.Fan
M

Primary Secondary

Recur Gas Fan

BOILER CONTROL SYSTEM

2. FEEDWATER CONTROL SYSTEM

It equalize feedwater flow and steam flow while

maintaining a stable water level in the steam drum.

This system controls the steam flow from the

superheater, feedwater flow from the economizer and
the drum level.
Q1: What will happen if the boiler exceeds on the drum
level?
A: Water carryover may damage the superheater or the
turbines.
Q2: What will happen if the drum level is low?
A: It will lead to overheating that may damage the wall
tubes.

BOILER CONTROL SYSTEM

3. FUEL AIR CONTROL SYSTEM
One of the key components of the control is

the ability of the fuel air control system to

maintain sufficient air proportional to fuel to
eliminate the possibility of a fuel rich
condition that may lead to an explosion.

But since it is not based on measurement fuel

air ratio is not precise. It depends on other

parameters and is affected by varying fuel
characteristics, fuel temperature, pressure
variations, atmospheric conditions, etc.

BOILER CONTROL SYSTEM

4. TEMPERATURE CONTROL SYSTEM
The primary benefit of constant steam temperature is improving
the economy of conversion to mechanical energy and reduce the
amount of moisture in the steam.
a) ATTEMPERATION
Controls the temperature of the steam by spraying water into the
steam line to reduce the superheated steam to the desired
temperature. It is normal to have the spray attemperation take
place between the two superheater sections.

BOILER CONTROL SYSTEM

4. TEMPERATURE CONTROL SYSTEM
b) BURNING TILT POSITIONING
burner tilt is also used to control superheat during
combustion process. Lowering the burners increases the
furnace heat absorption and so less heat is absorbed by
the superheat. Raising the burners decreases furnace
draft absorption and so more heat is absorbed by the
superheater.
c) FLUE GAS RECIRCULATION
provides a method for control of gas from the economizer
outlet to the furnace by means of recirculating fans and
ducts. This provides control of superheater steam
temperature and tube protection.

Advantages and
Disadvantages of Boilers

ADVANTAGE OF
WATERTUBE
BOILERS
For

a given surface
area
a
watertube
boiler will produce
TWICE as much steam
as a firetube boiler.
The
danger
of
explosion is greatly
reduced due to the
decreased quantity of
water held and the
small
size
of
the
pressure drum(s).

DISADVANTAGE OF WATER
TUBE BOILERS
They are, as a

general rule, more

difficult and
expensive to build.

Advantages and
disadvantages of boilers
ADVANTAGE OF
FIRETUBE BOILERS
Firetube boilers

are easier and

cheaper to build.

DISADVANTAGE OF
FIRETUBE BOILERS
A firetube boiler is

slow to raise
steam, even in
small sizes.
holds great
potential, in the
large mass of
stored energy, for
a lethal explosion
if not properly built
and maintained.

Criteria for
Selection

Criteria for selection

Of all the evaluation criteria the key
factor is the fuel usage or boiler efficiency.
Boiler efficiency, in the simplest terms,
represents the difference between energy
input and energy output.
REMEMBER:
Not all boilers are created equal.
However, all boilers operate under the same
fundamental thermodynamic principles.

Criteria for selection

INDUSTRY-RECOGNIZED
EFFICIENCY TEST STANDARDS

INDUSTRY-RECOGNIZED EFFICIENCY
TEST STANDARDS
The two most prominent
industry-wide testing standards for
boilers are ASME PTC 4 and BTS-2000.
ASME PTC 4

As prescribed by the ASME

Power Test Code, PTC 4, the fuel-tosteam efficiency of a boiler can be
determined by two methods: the InputOutput Method, and the Heat Loss
Method.

INDUSTRY-RECOGNIZED EFFICIENCY TEST

STANDARDS

1. INPUT-OUTPUT METHOD.
The Input-Output efficiency measurement
method is based on the ratio of the outputto-input of the boiler. It is calculated by
dividing the boiler output (in BTUs) by the
boiler input (in BTUs) and multiplying by 100.
2. HEAT LOSS METHOD.
The actual measurement method consists of
subtracting from 100 % the total percentage
of: A) stack, B) radiation, and C) convection
losses.

INDUSTRY-RECOGNIZED EFFICIENCY
TEST STANDARDS
BTS-2000 STANDARD

Designed to facilitate laboratory testing and

allows a fair comparison of boiler efficiency
ratings under standard conditions. The standard
BTS-2000 test conditions, for purposes of
comparison, limit steam pressure to a maximum
of 2 psig and steam quality to a minimum of 98
percent. Water tests require boiler inlet
temperatures between 35 deg. F and 80 deg. F
(75 deg. F and 85 deg. F for condensing boilers)
and, for hot water boilers, outlet water
temperatures between 178 and 182 deg. F.

Criteria for selection

CONSIDERATIONS WHEN CHOOSING
THE MOST EFFICIENT BOILER

CONSIDERATIONS WHEN CHOOSING

THE MOST EFFICIENT BOILER
1. PRESSURE VESSEL DESIGN.

Pressure vessel design is regulated by strict

ASME code requirements. Water circulation
(forced or natural), low stress design and
accessibility are key criteria for proper
pressure vessel design.
2.MAINTENANCE COSTS
Review your maintenance costs carefully. The old
unit could be costing you money in various ways,
including emergency maintenance,, major
maintenance requirements (past and pending),
difficult-to-find and expensive parts requirements,
and overall vessel and burner problems.

CONSIDERATIONS WHEN CHOOSING

THE MOST EFFICIENT BOILER
3. REPEATABLE AIR/FUEL CONTROL

The efficiency of the boiler depends on the ability of

the burner to provide the proper air-to-fuel mixture
throughout the firing range, day in and day out,
without the need for complex set-up or adjustments.
4.FUEL-TO-STEAM OR FUEL-TO-WATER

EFFICIENCY
Fuel-to-steam or fuel-to-water efficiency is a measure
of the overall efficiency of the boiler. For space
heating boilers and in the BTS-2000 testing
procedure, this type of efficiency is called thermal
efficiency.