BOILERS

Espiritu,Christopher James
Managuit, John Jeruel
Querubin, Russel John
 Topics:
• Introduction
• Definition of terms
• Boiler
• Purpose of Boiler
• Types of Boiler
• Cost and Energy
• General Requirements
• Diagnostic Tools
• Energy Savings and Economics
• Boiler Loading Energy Savings and
Economics Example
• Boiler Tube Cleaning Energy Savings
and Economics Example
 Introduction
Boilers are fuel-burning appliances that produce either hot water or steam that
gets circulated through piping for heating or process uses.

Boiler systems are major financial investments, yet the methods for protecting
these investments vary widely. Proper maintenance and operation of boilers
systems is important with regard to efficiency and reliability. Without this
attention, boilers can be very dangerous.
 Definition of terms
Air registers — devices that control the flow of air to the burners to maintain the
correct fuel-to-air ratio and to reduce smoke, soot, or NOx (nitrogen oxide) and
CO (carbon monoxide) formation.

Blowdown — the process of taking water out of a boiler to reduce the concentration
level of impurities. There are two types of blowdown, continuous and intermittent.

Burners — devices that introduce, distribute, mix, and burn a fuel (e.g., natural
gas, fuel oil, or coal) for heat.

Coagulation — a method for concentrating and removing suspended solids in boiler

feedwater by adding chemicals to the water, which causes the impurities to cling
together.
 Definition of terms
Condensate — condensed steam, which often is recycled back to the boiler.

Damper — a movable plate that regulates the flow of air or flue gases in boilers.

Deaeration — removal of air or other gases from boiler feedwater by increasing

the temperature using steam and stripping out the gases.

Demineralization — a process that uses ion exchange to remove mineral salts;

also known as deionization. The water produced is referred to as deionized water.

Desuperheated steam — superheated steam from which some heat has been
removed by the reintroduction of water. It is used in processes that cannot tolerate the
higher steam temperatures.
 Definition of terms
Desuperheater — a system that controls the temperature of steam leaving a boiler
by using water injection through a control valve.

Downcomers — tubes that transfer water from the steam drum to the mud drum.

Draft fan — a fan used to control draft in a boiler.

Economizer — the section of a boiler used to preheat feedwater before it enters

the main boiler system.

Filtration — the process of removing particles from water or some other fluid by
passing it through porous media.
 Definition of terms
Firebox — the area of a boiler where the burners are located and where radiant
heat transfer occurs.

Fire tube boiler — a device that passes hot combustion gases through the tubes to
heat water on the shell side.

Igniter — a device (similar to a spark plug) that automatically ignites the

flammable air and fuel mixture at the tip of the burner.

Impeller — a fixed, vaned device that causes the air/fuel mixture to swirl above
the burner; different from an impeller in a turbine or pump.

Knockout pots — devices designed to remove liquids and condensate from the
fuel gas before it is sent to the burners.
 Definition of terms
Mud drum — the lower drum in a boiler; also called the water drum; serves as a
settling point for solids in the boiler feedwater.

Pilot — an initiating device used to ignite the burner fuel.

Premix burner — a device that mixes fuel gas with air before either enters the burner
tip.

Radiant tubes — tubes containing boiler feedwater that are heated by radiant heat
from the burners and boiled to form steam that is returned to the steam drum.

Raw gas burner — a burner in which gas has not been premixed with air.
 Definition of terms
Refractory lining — a bricklike form of insulation used to reflect heat back into
the box and protect the structural steel in the boiler.

Reverse osmosis — method for processing water by forcing it through a membrane

through which salts and impurities cannot pass (purified bottled water is produced
this way.

Riser tubes — tubes that allow water or steam from the lower drum to move to
the upper drum.

Saturated steam — steam in equilibrium with water (e.g., steam that holds all of the
moisture it can without condensation occurring).

Softening — the treatment of water that removes dissolved mineral salts such as
calcium and magnesium, known as hardness in boiler feedwater.
 Definition of terms

Spiders — devices with a spiderlike shape that are used to inject fuel into a boiler.

Spuds — devices used to inject fuel into a boiler.

Stack — an opening at the top of the boiler that is used to remove flue gas.

Steam drum — the top drum of a boiler where all of the generated steam is
collected before entering the distribution system.

Steam trap — a device used to remove condensate or liquid from steam systems.
 Definition of terms

Superheated steam — steam that has been heated to a very high temperature so
that a majority of the moisture content has been removed (also called dry steam).

Superheater — tubes located near the boiler outlet that increase (superheat) the
temperature of the steam.

Waste heat boiler — a device that uses waste heat from a process to produce steam.
boiler
Boiler is defined as a closed vessel in which steam is produced from
water by the combustion of fuel. They are also called Steam
Generators. Generally steam is produced in boilers by the
interaction of hot flue gases coming out from the fuel mainly coal
or coke and water flowing through pipes. In boilers chemical
energy of stored the fuel is converted into heat energy and this
heat energy is absorbed by water to and converts to steam.
 purpose of a boilers
1
Power
generation
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 3
heater Chemical
In cold countries hot water industries
producing boilers are used Boilers also find its
for heating the buildings. application in textile
industries for sizing and
bleaching, and many other
industries like sugar mills and
chemical industries.
Types of boilers
Firetube
Boiler
Fire Tube Boilers are used widely in small and
medium-sized industries. They are factory-made
and come with pumps and control systems, all
set to start operations as soon as connected to a
fuel and water supply. They are often called the
packaged boilers. These kinds of boilers are
befitting for low to medium pressure steam
requirements. Here, the combustion gases flow
outside the water pipes.
Types of boilers
watertube Boiler
The Water Tube Boiler is multifaceted. They are
significantly different from the fire tube boilers.
The two types differ in the ways they function.
Water Tube boilers are usually used in large
manufacturing factories where there is a need
for high-pressure requirement. There is a
circulation of water between the mud and the
steam drum, ensuring more control over the
circulation by density differences.
Types of boilers
Electric boiler
The most popular boiler type. It is incredibly
efficient and environment friendly as it does not
require any kind of fossil fuel and hence leaves
a smaller carbon footprint. The best part is
unlike other boilers; there are no exhaust fumes.
Rural users use them widely as the installation
cost is lower, less noisy and requires less space
than the others as well.
Types of boilers
Condensing
Boiler
Condensing boilers are different and work
differently. They use natural gases and two heat
exchangers, making it the most efficient boiler.
They extract heat from the exhaust or waste
gases. This helps in reducing the wastage. They
are capable of achieving 98% thermal efficiency
and are now replacing other boilers for central
heating.
Types of boilers
Oil Boiler
The efficiency of oil-fired boilers is usually
86% while oil condensing boilers are 90% or
more efficient. The fuel used here is not natural
gas but oil. The oil is ignited in the combustion
chamber, and then the heat exchanger heats the
cold water. It is usually used in the household to
get warm water in showers, taps or radiators.
Types of boilers
Natural Gas
Boiler
Natural Gas Boilers, as the name suggests, use
natural gas as its fuel. A temperature gauge
regulates it, and a thermoelectric device is used
to reduce fuel wastage. The gas lights up the
pilot which heats the coils in the boiler. Rural
areas use propane gas most of the time.
 Cost and
Energy/Water
Efficiency
Efficiency, Safety, and Life of the
Equipment

It is impossible to change the efficiency

without changing the safety of the
operation and the resultant life of the
equipment, which in turn affects
maintenance cost. An example to illustrate
this relation between efficiency, safety,
and life of the equipment is shown in
Figure 9.2.5.
Efficiency, Safety, and Life of the
Equipment

This fouling will result in an increase in stack

temperature, thus decreasing the
efficiency of the boiler. A metal failure
will also change the life of the boiler,
since fouling material will allow corrosion
to occur, leading to increased maintenance
cost and decreased equipment reliability
and safety.
General Requirements for a Safe and Efficient
Boiler Room
1. Keep the boiler room clean and clear of all unnecessary items. The
boiler room should not be considered an all-purpose storage area. The
burner requires proper air circulation in order to prevent incomplete fuel
combustion. Use boiler operating log sheets, maintenance records, and
the production of carbon monoxide. The boiler room is for the boiler!

2. Ensure that all personnel who operate or maintain the boiler room are
properly trained on all equipment, controls, safety devices, and up-to-
date operating procedures.
General Requirements for a Safe and Efficient
Boiler Room
3. Before start-up, ensure that the boiler room is free of all potentially
dangerous situations, like flammable materials, mechanical, or physical
damage to the boiler or related equipment. Clear intakes and exhaust
vents; check for deterioration and possible leaks.

4. Ensure a thorough inspection by a properly qualified inspector.

5. After any extensive repair or new installation of equipment, make

sure a qualified boiler inspector re-inspects
the entire system.
General Requirements for a Safe and Efficient
Boiler Room
6. Monitor all new equipment closely until safety and efficiency are
demonstrated.

7. Use boiler operating log sheets, maintenance records, and

manufacturer’s recommendations to establish a
preventive maintenance schedule based on operating conditions, past
maintenance, repair, and replacement
that were performed on the equipment.

8. Establish a checklist for proper startup and shutdown of boilers and

all related equipment according to
manufacturer’s recommendations.
General Requirements for a Safe and Efficient
Boiler Room
9. Observe equipment extensively before allowing an automating
operation system to be used with minimal
supervision.

10. Establish a periodic preventive maintenance and safety program that

follows manufacturer’s recommendations.
 Maintenance of Boilers
● A boiler efficiency improvement program must include two aspects:
(1) action to bring the boiler to peak efficiency and
(2) action to maintain the efficiency at the maximum level. Good maintenance and
efficiency start with having a working knowledge of the components associated with the
boiler, keeping records, etc., and end with cleaning heat transfer surfaces, adjusting the air-
to-fuel ratio, etc
Operation and Maintenance – Persistence
● Boiler operators should record the results of the boiler water-chemistry tests daily. The
waterchemistry tests should be recorded and benchmarked to determine the necessary
treatment.
● Boiler operators should complete daily records of the de-aerator’s operation to ensure
continuous and proper operation.
● Boiler operators should take daily logs of stack temperature for trending purposes as
this is a highly diagnostic indication of boiler heat-transfer-surface condition. An
increasing stack temperature can be indicative of reduced heat transfer.
● The fire side of the boiler should be cleaned once a year, and is usually mandated by
local emission regulatory committee.
● The Boiler Operations and Maintenance Checklist, sample boiler maintenance log, and
water quality test report form are provided at the end of this section for review and
consideration.
 Diagnostic tools
Combustion analyzer – A combustion analyzer samples, analyzes, and reports
the combustion efficiency of most types of combustion equipment including
boilers, furnaces, and water heaters. When properly maintained and calibrated,
these devices provide an accurate measure of combustion efficiency from which
efficiency corrections can be made. Combustion analyzers come in a variety of
styles from portable units to dedicated units.

Thermography – An infrared thermometer or camera allows for an accurate, non-

contact assessment of temperature. Applications for boilers include insulation
assessments on boilers, steam, and condensate-return piping. Other applications
include motor/bearing temperature assessments on feedwater pumps and draft
fan systems. More information on thermography can be found in Chapter 6.
 Energy Savings and Economics
Estimated Annual Energy Savings
 Energy Savings and Economics
Estimated Annual Cost Savings. The annual cost savings, which
could be realized by eliminating or reducing cycling losses, can
be estimated as follows:

Annual Cost Savings = Annual Energy Savings × FC

where: FC = fuel cost, $/MMBtu

 Boiler Loading Energy Savings and Economics
Example
Example Synopsis: A boiler’s high-pressure set point was increased to
reduce the cycling losses of a given boiler. Before the change was
implemented, the boiler cycled on and off 5 times per hour, during low-load
conditions. With the new set point, the boiler only cycles on and off 2 times
per hour. The boiler operates at this low load condition for approximately
2,500 hours per year and has a firing rate at this reduced loading of 20%.
The rated fuel consumption at full load is 10 MMBtu/hr, with an efficiency
of 82%. The average fuel cost for the boiler is $9.00/MMBtu.
Boiler Loading Energy Savings and Economics
Example

$ 3652/Year
Boiler Loading Energy Savings and Economics
Example
 Combustion Efficiency Energy Savings and
Economics
Estimated Annual Energy Savings. The annual energy savings,
which could be realized by improving combustion efficiency, can
be estimated as follows:

where
EFF1 = current combustion efficiency, %
EFF2 = tuned combustion efficiency, %
AFC = annual fuel consumption, MMBtu/yr
 Combustion Efficiency Energy Savings and
Economics
Estimated Annual Cost Savings. The annual cost savings, which
could be realized by improving combustion efficiency, can be
estimated as follows:

where FC = fuel cost, $/MMBtu

 Combustion Efficiency Energy Savings and
Economics Example
Example Synopsis: A boiler has an annual fuel consumption of 5,000
MMBtu/yr. A combustion efficiency test reveals an excess air ratio of
28.1%, an excess oxygen ratio of 5%, a flue gas temperature of 400°F, and a
79.5% combustion efficiency. The boiler manufacturer’s specification sheets
indicate that the boiler can safely operate at a 9.5% excess air ratio, which
would reduce the flue gas temperature to 300°F and increase the combustion
efficiency to 83.1%. The average fuel cost for the boiler is $9.00/MMBtu.
Combustion Efficiency Energy Savings and
Economics Example

P
$1949/year
 Estimated Annual Energy Savings
The annual energy savings, which could be realized by removing
scale from the water side of the boiler, can be estimated as
follows:
 Estimated Annual Energy Savings
where
BL = current boiler load or firing rate, %/100
RFC = rated fuel consumption at full load, MMBtu/hr
EFF = boiler efficiency, %/100
EL1 = current energy loss due to scale buildup, %
EL2 = tuned energy loss with out scale buildup, %
H = hours the boiler operates at the given cycling rate, hours
 Estimated Annual Cost Savings
The annual cost savings, which could be realized by removing scale
from the water side of the boiler, can be estimated as follows:
 Boiler Tube Cleaning Energy Savings and
Economics Example
Example Synopsis: After visually inspecting the water side of a water tube
boiler, normal scale 3/64 inch thick was found on the inner surface of the
tubes resulting in an estimated 3% efficiency penalty (see Figure 9.2.14).
On-site O&M personnel are going to manually remove the scale. The boiler
currently operates 4,000 hrs per year, at an average firing rate of 50%, with a
boiler efficiency of 82% and a rated fuel consumption at full load of 10
MMBtu/hr. The average fuel cost for the boiler is $9.00/MMBtu.
Boiler Tube Cleaning Energy Savings and
Economics Example

$3,394/year