Boiler design & its Construction

Moiz . A . Shamsi

What is a Boiler ?
equipment in which steam is generated

Where is the generated steam used ?

generation of electric power process requirements heating requirements

How steam is produced ?

Water
Boiling temp

STEAM

Heat

Elementary Concepts
Boiling
Process of vapor generation that take place in whole mass of a liquid, bubbles forming inside the liquid and on the surface Boiling occurs at definite temp. & pressure.

Temp. & Pressure relationship T P (Charles Law) Heat Transfer

conduction convection radiation

Steam
saturated
steam produced in the presence of water with which it is in a state of equilibrium.

superheated
If additional heat is imparted to saturated steam without changing the pressure so that it has no water vapors.

Classification of Boilers
Boilers
Low Pressure Boilers P < 103 KPa H igh Pressure Boilers P > 103 Kpa

Water Tube Boiler

Fire Tube Boiler

Other Criteria
Basis
Firing Method Water Circulation

Types
Fired or Unfired Boilers Natural or Forced Circulation

Water Tube Boilers

When water is on the tube side of the boiler

Operation

Main Parts of Water Tube Boiler

Boiler Furnace Steam Drum Burner Risers & Down Comers Economizer Super heater Water Walls Furnace Draught System

Boiler Furnace
The section of Boiler where fuel is burned to generate heat. Heat is transferred to risers through radiation.

Steam Drum
Steam Drum is a high pressure vessel which serves as; a large reservoir for Boiler Feed Water center for water distribution steam purifier saturated steam collector & supplier to super heater

Burners
They are located in the vertical wall of the combustion chamber and burn fuel.

Risers & Down comers

Circulation in Boiler is directed into definite paths by arranging the tubes to form circuits for the circulation. The tubes are divided into 2 categories Down comers Risers Down comers located in cooler regions of furnace Risers located in the hottest zone of furnace. Water in risers is in 2 phase & hence less dense than that of down comers. Therefore, a positive circulation is produced due to density difference.

Economizer
Economizer is device which is used for heating the Boiler feed water by means of the exhaust gases. Economizer ; reduce losses of heat with the flue gases cut consumption of fuel improve the efficiency of the boiler installation

Super heater
It is used to superheat the saturated steam. saturated steam from the steam drum rises through demister pads and enters into a series of tubes which are located in the boiler furnace convection section First it passes through the primary super heater & then finally, the final super heater.

Water Wall Construction

A Boiler construction design in which water tubes are made a part of floor, roof & walls of the furnace. Water walls; Cool the flue gases in the furnace Protect lining Appreciably increase the steam generating capacity of unit without increasing its dimensions.

Furnace Draught System

It regulates the flow of air to and from the burner and provides enough amount of oxygen required for combustion. It also forces out combustion gases out of the furnace to the exhaust duct. A forced draft system uses a fan to force or push air through the furnace.

Safety Measures in Boiler Operation

Boiler drum low level Low fuel gas pressure Low combustion air flow BFW Quality

Boilers in ECPL
Utility -I SG-621, 631, 641 Utility - II SG-681 150 KPPH @ 900 oF, 910 psig 60 KPPH @ 700 oF, 615 psig

Heat Transfer is from hot to cold body

Heat Transfer modes

Effect of pressure on boiling point

Effect of heat on pressure & volume