Boilers, Boiler Fittings and Steam Offtakes: Academic Manual AC/18/03

Boilers, Boiler Fittings and Steam
Offtakes
Academic Manual
AC/18/03
‘Open University’ project Boilers and Fittings AC/18/03 1

Boiler Types
• Agenda
• Introduction
• Lancashire Boiler
• Economic Boiler
• Package Boiler
• Limitations of Shell Boiler
• Water Tube Boiler
• Steam Generators

Centralised Steam Generation
• Choice of Fuel
• Thermal Efficiency
• Simplified Operation
• Reduced Capital Cost
• Flexibility

The Lancashire Boiler
Safety Water Manhole Steam Internal
Valve Level Stop Flues
Alarm Valve
Boiler
Feed
Coal Anti Priming

Blowdown Feed Pipe

Economic Boiler Two Pass, Dry Back
Steam
2nd pass (tubes)
1st pass (furnace tube(s))

Dry/Wet Back Boiler
Dry Back Reversal Wet Back Reversal

Chamber Chamber
2nd pass tubes 2nd pass tubes
1st pass 1st pass

(Furnace tube(s)) (Furnace tube(s))

Economic Boiler Three Pass, Wet
Back
Steam at 150 oC
3rd Pass (Tubes) 200 oC

350 oC
2nd Pass (Tubes)
400 oC
1600 oC 1st Pass (Furnace Tube(s))

Typical Heat Transfer Data for a 3
Pass Boiler

Package Boiler

Reverse Flame or Thimble Boiler
Steam
Chimney
Water Steam Space
Burner
Thimble Tubes Around Furnace

Furnace Furnace Back Wall

Hoop Stress
Pressure x Diameter
Hoop Stress 
2 x Thickness
Thickness Diameter

Boilermakers Rolls
Plate Movement A
B C
• Roll ‘A’ is adjusted downwards to reduce radius of

curvature.
• Rolls ‘B’ and ‘C’ are motorised to pull the plate
through the rolls.
• The rolls cannot curve the ends of the plate.

Boiler Shell
Flat
Fatigue Points

Heat Transfer
(t1  t2) x Constant

Heat Transfer Rate 
Thickness
t2 t1
Heat Flow
Thickness Diameter

Output Limitations
Road
27,000 kg/h
Transport

Comparison of Shell Boilers
Rated at 5,500 kg/h
Volumetric Steam Release

Boiler Type Fuel Length Diam Efficiency Heat Rate from Water
Release Surface
m m % kW/m3 kg/m2/s
Lancashire Coal 9 2.75 74 340 0.07
Economic Coal 6 3 76 730 0.12
Modern Oil 3.9 2.5 82 2330 0.2
Modern Gas 80 2600 0.2

Water Tube Boiler
Pendant Steam Drum
Superheater
Convection Bank
Gas Baffles
Economiser
Burners

Furnace or Radiant Section
Membrane Panel in Plan View
Insulation Material
Radiant Heat Radiant Heat
Boiler Tubes Fins

Furnace Flame

Convection Section
• Heat is given up by the

hot gases and Steam
Drum
transferred to the boiler
water by conduction
and convection
Hot Gases
Tubes
Water
Drum

Water Tube Boiler Classification
Reservoir drum position e.g. longitudinal or cross drum
Water circulation e.g. natural or forced
Number of drums e.g. two, three
Capacity e.g. 25,000 kg/h, 7 kg/s, 55,000 lb/h

Inclined Tube Boiler
Exhaust Gases
to Stack
Water
Heat

Longitudinal Drum Boiler
Cold Water Feed
Steam
Water
Waste
Gases
to Stack
Heat

Cross Drum Boiler
Steam
Heat Waste
Gases to
Stack

Bent Tube or Stirling Boiler
Feed Water in
Waste Gases
to Stack
Mud Drum
Heat

Three Drum Water Tube Boiler
Steam Steam
Drum
Rear Water
Drum
Front Water
Drum
Screen
Heat Water
Drum

Water Tube Boiler Configurations
‘D’ Type ‘A’ Type ‘O’ Type

Natural Circulation Water Tube Boiler
Steam
Boiler or
Steam Drum Water
Downcomer
Riser
Heat
Lower or
Mud Drum
Forced Circulation Water Tube Boiler
Economizer
Feed
Superheater
Steam &
Water
Drum
Evaporator Steam Outlet
Circulation
Pump
Exhaust Gases from Turbine

Exhaust gases from
Steam
Saturated Steam
Drum
Steam Scrubber
Steam
Feed Water
Water
Water Water mixed with

steam bubbles

Water Tube Boilers
• React rapidly to load changes.

• The water tube unit contains only a fraction of the water in
a shell boiler so the thermal inertia of the system is much
smaller. This also means that the steam storage is less so
its ability to react to short term peaks is reduced.
• It can be argued that water tube boilers are safer as tube
failure is not as catastrophic as in a shell boiler due to the
lower water content and hence less stored energy.
• Water tube boilers can be fired using any individual
conventional fuel, waste heat from process, they can
operate as multi-fuel units and may use fluid bed furnaces.

Economiser
Feed Water
Tank Chimney
Feed Water Line Economiser

Feed Water Line
Feed Water Line

Boiler

Superheater
Superheated Saturated Steam Stack

Steam
Superheater
Pendant
Heat Water Tube Boiler

Steam Generator
Burner Steam Outlet
Water Combustion Chamber

1 st Pass, Downward
Finned Convection
2 nd Pass, Upward

Coil Boiler
Q kg/h Dry Saturated

Steam to Plant
Flame
Boiler Coil
10% water with impurities

to waste/recycle
Q kg/h + 10%

Boiler Fittings
There are a number of attachments and fitting on a boiler.

The objectives of these fittings include:
> Operation.
> Safety.
> Efficiency.
> Compliance with laws, regulations and guidance notes.

Boiler Name Plate
Serial Number 32217
Model Number Lincoln Mk II
Output 3,000 kg/h
Design Pressure 19 bar
Max. Working Pressure 18 bar
Hydraulic Test Pressure 28.5 bar
Date of Test 26/03/91
Design Standard BS 2790 (1989)
Class 1
Inspection Authority British Engine
Manufactured by Babcock Robey

‘From and At’ Rating of a Boiler
Graphically 120
100
80
Feed Water 15 bar
Temperature oC 60 10 bar
5 bar
40 0 bar
20
0
80 85 90 95 100 105 110
% of From and At Rating
‘From and At’ Rating of a Boiler
By Calculation
Spec. Enthalpy of Evaporation at Atmos. Press.

Factor =
Spec. Enthalpy of Spec. Enthalpy of
Steam at Op. - Water at Feedwater
Press. Temp.

Boiler Output - kW Rating
Example:
A 10 bar boiler with a rating of 3000 kW and a feed water
temperature 50 oC
The boiler will evaporate
3000 kW x 3600(seconds in an hour)
2572.2 kJ/kg *
= 4198 kg/h
*(heat required to raise feed water to saturation
temperature, and then to change state)

Boiler Horse Power (BoHP)
1 Boiler Horse Power = The energy to evaporate

34.5 lb of water at 212 oF.
Example:
A 500 BoHP boiler will evaporate:
500 x 34.5 = 17,250 lb/h of

steam

Maximum Continuous Rating
• This is numerically the same as the ‘from and at’

rating, but may be based on customers
requirements.

Safety Valves
• Two safety valves are required on

boilers rated at over 3,400 kg/h.
• They must be set at the boiler
maximum working pressure.
• They must be vented to atmosphere.
• The vent must be drained.

Burner Control
Boiler Rating
Under 500 kg/h 500 to 2,000 kg/h 2,000 to 5,500 kg/h Over 5,500 kg/h
High/Low/Off
High/Low/Off
On/Off Control or Modulation Control
Control
Modulation Control
Pressure Jet Pressure Jet Pressure Jet or Pressure Jet or

Burner Burner Rotary Cup Burner Rotary Cup Burner

Burner Types
Burner Type Turndown Ratio
Pressure Jet 3 to 1
Rotary Cup 4 to 1
Gas 5 to 1

Stop or Crown Valve
Rising Hand Wheel Indicator
Material - Cast Steel

Pressure Gauges
Red mark shows Purple mark shows

normal working maximum working
pressure pressure

Feed Check Valve Installation
Feed Tank
Head
Stop Valve
Feed Check Valve
Feed Pump

Level Gauge Glass
Steam Space
Nominal Water
Level
• Two required on boilers

rated over 145 kg/h
• All handles should point
downwards in the
running condition

Level Control Chambers
Level Control Probe
Level Control Chamber
Boiler
Sequencing Purge Valve

Sequencing Purge Valve
Position 2
Blow Through Position 1
Water Normal Working
Position 3
Blow Position 2
Through Blow Through
Chamber Water
Position 1 Position 3
Normal Working Blow Through
Chamber
Drain Connection
Bottom Blowdown Valve
Steam Boiler
Blowdown Vessel

Air Vent and Vacuum Breaker

Steam Header Design
To Plant
1 2 3 4
Boilers

Pressure Drop Equation
k Q2 L
P 
D5
Where
P = pressure difference between points.
Q = mass flow of the steam
L = the length of pipe
D = pipe bore
k = constant incorporating the
acceleration due to gravity,
friction factor & steam density.

To Examine the Effect Quantitatively
Let
d = 0.14 m
D = 0.30 m,
l = L = 8.0 m
q1 = 10,800 kg/h steam
The previous formulae give the following figures:
q1 = 10,800 kg/h
q2 = 10,926 kg/h, an increase of 1.2% over q1
and for a fifth boiler it would be
q5 = 14,328 kg/h, an increase of 33%

Objectives for a Steam Header
• To equalise pressure drop to within 0.1 bar

• This will:
> Minimise carry over.
> Prevent overload and lock out of boilers.

Ideal Boiler Header Layout 4 Boilers

Ideal Boiler Header Layout 6 Boilers
1 2 3 4 5 6

Steam Off -Takes
Should ensure that:

• Dry steam is exported to the plant
• Warm up is controlled
• One boiler cannot pressurise another
• Steam can be distribution to the plant

Water Carry Over
Crown Valve Separator
Steam to plant
Drain to waste or blowdown vessel
Water in a steam system means:

• Water hammer
• Reduced plant performance
• Contamination
Warm Up
The plant warm up rate must be controlled to avoid:

• Water hammer
• Thermal shock
• Priming

Warm Up Using a
Control Valve
Control Valve Controller
Crown Valve

Warm Up Using a
Control Valve in a
By-Pass Control Valve Controller
Crown Valve
Line Size
Stop Valve

Non Return Valves
Disc Type Non

Return Valve
• Must be fitted if two or more boilers are fitted to a common

header.
• This is to ensure that one boiler cannot pressurise another,
particularly if one boiler is off line for maintenance.

Steam Distribution Header
Steam in From Boiler(s)
Steam
Out to
Plant
Air Vent
Steam Distribution Header
Steam Trap Set

What Happens When the Boiler Pressure
Drops?
Pressure Flash Steam

bar g kg
10 0
9 46
8 72
7 101
6 132
5 168
4 210
3 262
2 300

Volume Increases as Pressure drops
Increase in
Pressure
Specific Volume
bar g %
10 0
9 11
8 23
7 38
6 56
5 81
4 114
3 164
2 251

Specific Volume of Steam
1.8
1.6
1.4
1.2
Specific
Volume 1
(m3/kg) 0.8
0.6
0.4
0.2
0
0 1 2 3 4 5 6 7 8 9 10
Pressure (bar)

Boilers, Boiler Fittings and Steam Offtakes: Academic Manual AC/18/03

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Boilers, Boiler Fittings and Steam Offtakes: Academic Manual AC/18/03

Uploaded by

Copyright:

Available Formats

Boilers, Boiler Fittings and Steam

‘Open University’ project Boilers and Fittings AC/18/03 1

‘Open University’ project Boilers and Fittings AC/18/03 2

‘Open University’ project Boilers and Fittings AC/18/03 3

Coal Anti Priming

‘Open University’ project Boilers and Fittings AC/18/03 4

2nd pass (tubes)

1st pass (furnace tube(s))

‘Open University’ project Boilers and Fittings AC/18/03 5

Dry Back Reversal Wet Back Reversal

2nd pass tubes 2nd pass tubes

1st pass 1st pass

‘Open University’ project Boilers and Fittings AC/18/03 6

3rd Pass (Tubes) 200 oC

‘Open University’ project Boilers and Fittings AC/18/03 7

‘Open University’ project Boilers and Fittings AC/18/03 8

‘Open University’ project Boilers and Fittings AC/18/03 9

Water Steam Space

Thimble Tubes Around Furnace

‘Open University’ project Boilers and Fittings AC/18/03 10

‘Open University’ project Boilers and Fittings AC/18/03 11

• Roll ‘A’ is adjusted downwards to reduce radius of

‘Open University’ project Boilers and Fittings AC/18/03 12

‘Open University’ project Boilers and Fittings AC/18/03 13

(t1  t2) x Constant

‘Open University’ project Boilers and Fittings AC/18/03 14

‘Open University’ project Boilers and Fittings AC/18/03 15

Volumetric Steam Release

‘Open University’ project Boilers and Fittings AC/18/03 16

‘Open University’ project Boilers and Fittings AC/18/03 17

Membrane Panel in Plan View

Radiant Heat Radiant Heat

Boiler Tubes Fins

‘Open University’ project Boilers and Fittings AC/18/03 18

• Heat is given up by the

‘Open University’ project Boilers and Fittings AC/18/03 19

Reservoir drum position e.g. longitudinal or cross drum

Water circulation e.g. natural or forced

Number of drums e.g. two, three

Capacity e.g. 25,000 kg/h, 7 kg/s, 55,000 lb/h

‘Open University’ project Boilers and Fittings AC/18/03 20

‘Open University’ project Boilers and Fittings AC/18/03 21

Cold Water Feed

‘Open University’ project Boilers and Fittings AC/18/03 22

‘Open University’ project Boilers and Fittings AC/18/03 23

‘Open University’ project Boilers and Fittings AC/18/03 24

‘Open University’ project Boilers and Fittings AC/18/03 25

‘D’ Type ‘A’ Type ‘O’ Type

‘Open University’ project Boilers and Fittings AC/18/03 26

Evaporator Steam Outlet

Exhaust Gases from Turbine

Water Water mixed with

‘Open University’ project Boilers and Fittings AC/18/03 29

• React rapidly to load changes.

‘Open University’ project Boilers and Fittings AC/18/03 30

Feed Water Line Economiser

Feed Water Line

‘Open University’ project Boilers and Fittings AC/18/03 31

Superheated Saturated Steam Stack

Heat Water Tube Boiler

‘Open University’ project Boilers and Fittings AC/18/03 32

Burner Steam Outlet

Water Combustion Chamber