BOILER CONSTRUCTION

Information Sheet Number 62B-203

INTRODUCTION

The D-type boiler has been installed in U.S. Navy ships since 1950.
Whether 600 psi or 1200 psi, D-type boiler construction is basically the
same with a few exceptions, such as number of fuel oil burners and overall
size and volume.

REFERENCES

(a) Boilers NSTM Chapter 221

(b) Fireman NAVEDTRA 10520 Series

(c) Boiler Technician 3&2 NAVEDTRA 10535B

(d) Principles of Naval Engineering 10788 H

(e) Boiler Operation and Maintenance Manual NAVSEA 0951-LP-022-

6010

INFORMATION

A. Main propulsion boilers provide steam to the main propulsion turbines and
auxiliary services in order to supply all shipboard steam systems in accordance
with demand. (refer to Figure 1). It is designated as a D-type boiler because of the
relative positions of the drums and side header which form the letter D. All D-
type boilers are designated as uncontrolled superheat boilers because all the steam
generated by the boiler must pass through the superheater. Superheater outlet
temperature is a result of the combustion gas flow in proportion to the total
amount of steam flow through all ranges (0 - 120%). The design characteristics
ensure that the temperature will stabilize at set point. The degree of superheat is
calculated by subtracting steam drum temperature from the actual reading on the
superheater outlet temperature gage. In this lesson we will examine the
components of the boiler and then we will bring everything together by describing
how water and steam is generated and circulated through the boiler. The flow path
of combustion gases through the boiler will also be discussed.
D TYPE BOILER

Figure 1
B. The economizer is a multi-pass heat exchanger located above the main generating
bank at the base of the exhaust stack, so that combustion gas will give up a lot of
its remaining heat to the incoming feedwater before passing out the stack (Refer
to Figure 2) The incoming feedwater absorbs about 100-200F sensible heat
from the exhaust gases. Fins are installed on the economizer tubes to increase the
heating surface area further, helping to increase efficiency.

ECONOMIZER

Figure 2

C. The steam drum is located at the top of the boiler to provide an upper reservoir for
the water covering the generating tube bank. Water is distributed from the steam
drum to the lower drums and headers by pipes called downcomers. Generated
steam is also collected and is separated from the water in the steam drum. Boilers
are also equipped with safety valves to relieve excessive pressure. The valves are
located on the steam drum and superheater outlet. They are designed to relieve
sufficient pressure to safely steam the boiler at 120% with boiler steam stop
valves closed (refer to Figure 3). These valves are discussed in detail in lesson
62B-206.
D. Air vents or air cocks are installed on top of the steam drum to expel air from
inside the steam drum during cold boiler light-off or when filling the boiler. The
air vents or air cocks are shut when the boiler starts generating steam.

SAFETY VALVE CONFIGURATION

Figure 3
E. The internal fittings in the steam drum help distribute the water evenly throughout
the drum, separate the generated steam from the water and remove moisture from
the steam before it leaves the boiler (refer to Figure 4).
1. Lower baffle plates or apron plates Separate the incoming feedwater and
generated steam and direct the steam to the separators.
2. Primary separators (cyclone separators) Separate most of the water from
the steam by giving it a cyclone or rotary motion so that the water particles
are expelled from the steam by the centrifugal forces. These separators are
vertically mounted in the steam drum so that the steam rises out the top
and the water falls back into the steam drum.
3. Secondary separators (chevron dryers) Remove additional moisture from
the steam by changing the direction of steam flow several times. The
steam passes on but the moisture cannot make the direction change with
the steam. These separators are mounted above the primary separators and
direct steam to the dry box which collects the steam at the top of the steam
drum, directing it to the steam outlet piping to the superheater.
4. Feedwater leaves the economizer and enters the boiler through the internal
feed pipe and becomes "boiler water." Perforations along the side of the
feed pipe allow water to be distributed evenly throughout the steam drum
(refer to Figure 4)

STEAM DRUM INTERNALS

 Figure 4

5. Since suspended solids may accumulate on the surface of the water in the
steam drum, there must be means of removing them. The surface blow
pipe is used to remove these light suspended solids from the surface of the
water and to reduce the total dissolved solid content of the boiler water.
Suspended solids usually consist of oil, salt contaminants, or excessive
treatment chemicals which can cause foaming on the water surface.
Dissolved solids usually consist of salt contaminants and treatment
chemicals that are in solution.
F. The D-type boiler uses the principle of accelerated natural circulation to circulate
water through the boiler. To enable this principle to work, relatively cool water
will naturally circulate through large diameter pipes to distribution points low in
the boiler. The downcomers are these large diameter pipes connecting the steam
drum with the water drum and lower headers to ensure proper circulation by
delivering water from the steam drum to the water drum and lower headers. The
downcomers are located between the inner and outer air casing to protect them
from the direct radiant heat of the furnace.
G. The water drum is located at the bottom of the boiler below the main generating
bank and acts as a lower reservoir of water for distribution to the main generating
bank. Also, this large drum serves as a collection point for solids (sludge) that
precipitate to the bottom that are removed by bottom blowdown.
H. The sidewall header is located along the furnace sidewall connecting sidewall
tubes from the furnace floor to the steam drum. It distributes water to the sidewall
tubes and provides another blowdown point for sludge removal. The sidewall
tubes are two inch tubes which protect the boiler sidewall refractory from the
direct heat of combustion and generate a small amount of steam.
I. The lower rearwall header is located along the furnace rearwall from the furnace
floor to the steam drum or upper header to provide a lower junction for rearwall
tubes. It distributes water to the rearwall tubes and provides yet another
blowdown point for removal of sludge. The rearwall tubes are two inch tubes
which protect the boiler rearwall refractory from the heat of combustion and
generate some steam.

NOTE: By using wall tubes, more of the heat in the furnace is absorbed by water
and less refractory material is required, thereby increasing boiler efficiency and
reducing the boiler weight.

J. The upper rearwall header is often called the "floating header" because of its free-
standing design. It is located along the rearwall of the furnace roof to provide an
upper junction for the rearwall tubes. It collects the steam generated in the
rearwall tubes and direct it to the steam drum through riser tubes.
K. Riser tubes are large tubes located above the furnace roof to provide a connection
between the upper rearwall header and the steam drum.
L. Superheater screenwall tubes help protect the superheater from direct radiant heat
of the furnace. The screen tubes consist of two to three staggered rows of two inch
tubes which are usually connected from the steam drum to the water drum. Some
boilers have a screenwall header installed parallel to the superheater along the
furnace floor as a lower connection and a blowdown point for sludge.
M. The steam passes through the superheater picking up sensible heat (about 300-
400 F) which increases the energy of the steam, allowing it to perform more
work. The superheater is composed of superheater headers which distribute steam
to the superheater tubes or elements and direct it from the inlet to outlet piping.
These headers and elements can be either vertically or horizontally mounted.
(Refer to Figure 5).

SUPERHEATER
 Figure 5

N. The bulk of the steam generated by the boiler is formed in the main generating
bank because it has the largest heating surface. This is a large group of one inch
tubes which run from the water drum to the steam drum and are located behind
the superheater.
O. Since these boilers are uncontrolled superheat and the plant is designed to use
lower temperature steam in many applications to help reduce construction and
maintenance costs, the steam needed for these services must pass through a
desuperheater. The desuperheater is a multi-pass tube bundle which is located in
the water drum in most boilers. There are several boilers which have the
desuperheater in the steam drum. As the superheated steam passes through the
tube bundle, it gives up heat to the boiler water in the water drum.
P. The boiler is protected from the high temperatures of combustion by the
refractory. Refractory lines the inside surface of the inner casing enclosing all of
the furnace area and extending to the outer row of generating tubes. There are
several different types of refractory which work together to protect the boiler.
1. Firebrick is a heavy casted refractory used as the outer layer of refractory
and is exposed to the direct flames of combustion. It has poor insulating
qualities, but it will withstand direct flame contact.
 2. Insulating brick is a lightweight casted refractory used between the
insulating block and firebrick. It has good insulating properties, but it will
not withstand direct contact with flame.
3. Insulating block is a pressed fiber material used next to the inner casing. It
has the highest insulating properties of the various refractory, but it will
not withstand direct contact with flame.
4. Burner tiles are preformed refractory used to form burner cones around
where the burner assembly protrudes into the furnace. Burner tiles are a
specially shaped, heavy casted refractory used next to the insulating brick
around the burner openings. They have poor insulating qualities, but they
will withstand direct flame contact.
5. High temperature castable refractory is used to fill in gaps in refractory or
where shaping is needed to cover irregular shaped items. It is used to patch
refractory or to smooth uneven areas between brickwork. It is packaged
dry and must be mixed with water prior to use, very much like cement or
plaster.
6. Baffle tiles are a specially shaped refractory made of silicon carbide for
use in some boilers to form baffles on superheater screen tubes. These
baffles direct the flow of combustion gases across the superheater to help
maintain the temperature within design parameters.
7. When the refractory is installed and stacked, it must be held in place.
Anchor bolts are used for preformed refractory. The anchor bolts are
connected to the inner casing to support and retain the refractories in
position.
8. Since the boiler expands and contracts with heating and cooling,
expansion joints are built into the refractory to allow for the thermal
expansion and contraction.
Q. Since the boiler expands and contracts as it heats up and cools down, sliding feet
are installed to allow the boiler to move easily. The feet are located below the
boiler, usually under the front end of the sidewall header and water drum. There is
a greased phosphor-bronze friction plate on which these feet will move. The
planned maintenance system (PMS) requires lubricating the sliding feet every
month. Some newer ships have permalube sliding feet which never require
lubrication. Failure of the sliding feet to move can cause cracks in the air casing
and can cause header handhole plug leaks. Movement indicators are installed on
the sliding feet which have to be checked prior to light off, during warm up, and
after the boiler is on line to ensure positive movement of the sliding feet. Each
time sliding feet are checked the results should be logged in the fireroom
operating log. (Refer to figure 6)

SLIDING FEET CONFIGURATION

 Figure 6

R. The boiler is enclosed by casings which provide an airtight boundary from the
boiler furnace up through to the stack area. The inner casing encloses the boiler
fireside area to the base of stack to provide an airtight lining between the
combustion air space and furnace to contain the products of combustion within
the boiler and support the refractory materials. The outer casing encloses the
entire boiler from the bilge to the stack to provide double encasement so the boiler
air pressure is not affected by the fireroom atmosphere. The combustion air flows
through this space between the inner and outer casing and is directed to the air
registers. The stack is located above the boiler economizer and extends to above
the superstructure to carry boiler combustion products safely away from the ship.
The inner stack or smoke pipe provides a path for combustion gases to the
atmosphere, the outer stack supports the inner stack and provides a space to
receive incoming combustion air to the boiler and protects personnel from the hot
inner stack surfaces.
S. The fireroom watch team must be able to monitor the exhaust gases to help
maintain a clear smoke free stack. Smoke indicators and periscopes are installed
to allow monitoring of the stack gases leaving the boiler. The smoke indicator is
an electro-mechanical device and the periscope is an optical device. All ships
have periscopes and many have electro-mechanical smoke indicators or stack gas
analyzers. These devices are located above the economizer at the base of the stack
so that combustion gases leaving the boiler must pass through its line of sight or
 the sensing element. From monitoring the stack gases, the combustion process can
be adjusted for maximum efficiency or a casualty situation can be detected (Refer
to Figure 7)

TYPICAL PERISCOPE CONFIGURATION

Figure 7

T. Maintaining proper boiler water level is one of the most critical aspects of boiler
operation. To be able to monitor this critical parameter water level indicators are
installed. There are two types, a direct reading gage glass mounted on the steam
drum and a remote water level indicator. The gage glass gives a direct
measurement of the steam drum water level. The remote water level indicator
gives an inferential indication of the steam drum water level.
1. The direct reading gage glass may be isolated or removed for maintenance
if necessary but, at least two remote water level indicators must be
installed and working. (Refer to Figure 8).

REMOTE WATER LEVEL INDICATOR

 Figure 8

2. There are usually two remote water level indicators in the fireroom for
each boiler. They are located on the lower level and the BTOW/console
station. There is also a remote indicator located at the throttle station for
the engine served by that boiler.
3. There are high and low water alarms installed in the remote water level
indicators. They are set to alarm when the steam drum water level reaches
7 inches above normal or 6 below normal inches on most steam ships.
U. Because air casing fires sometimes occur in the boiler, a steam smothering system
is installed between the inner and outer casings. This piping comes from the 150
psi desuperheated steam system and is perforated to allow the steam to fill the
casing and smother the fire. The piping is located at the lower portion of the
casing under the furnace floor and/or brickpan. Steam can be admitted to the
furnance by filling the air casing and then opening the air registers. (Refer to
figure 9).

STEAM SMOTHERING CONFIGURATION

 Figure 9

V. Once the steam flowing through the superheater is what keeps it from
overheating, there must be a means of providing a flow prior to any steam
pressure forcing a flow. This means is called the superheater protection steam
system. The inlet is connected to the steam drum steam outlet piping and outlet is
connected to the desuperheater outlet piping. This arrangement provides steam
flow through the superheater during light-off and securing. It is also the entry
point for the steam used to provide a steam blanket lay-up. The steam bled off the
boiler to provide the flow is routed to the auxiliary exhaust system. When the
boiler is being secured, this system needs to be aligned to prevent over-
pressurization of the boiler because it is still generating steam. This system is
commonly called the superheater bleeder. (Refer to figure 10)

SUPERHEATER PROTECTION SYSTEM

 Figure 10

W. Fuel oil burners are located on the boiler front and extend into the furnace to
provide a means of firing the boiler. Depending on boiler design two to six
burners are installed in the boiler. (Refer to Figure 11).

BURNER ASSEMBLY
 Figure 11

1. The burners deliver fuel and air to the boiler furnace in the proper mixture
to obtain optimum combustion. The two main components of an oil burner
are the atomizer assembly and the air register assembly. The atomizer
divides the fuel oil into very fine particles, the air register admits
combustion air to the furnace and promotes mixing of the air and the fuel
oil spray.
2. The types of atomizers used on ships are straight mechanical, steam, and
vented plunger, as described below.
3. In straight mechanical atomization, all the oil pumped to the atomizer is
sprayed into the furnace. The firing rate of this type of burner is controlled
by varying the supply fuel oil pressure and changing sprayer plate sizes.
 4. In steam atomization, steam is used to help atomize the oil into minute
particles and to project a cone-shaped spray of atomized oil into the
furnace.
5. The vented plunger type atomizer is designed to permit a wide range of
operation using the straight mechanical pressure atomization principle
without the need to change sprayer plate sizes or use steam atomization. It
is found in 1200 psi boilers.
X. Because the combustion gases leave ash or soot deposits on the tube surfaces
which inhibit efficient heat transfer, the soot must be removed. Soot blowers use
steam to blow soot off of the tube surfaces. In addition to acting as an insulator,
this soot forms sulfuric acid when it becomes wet and eventually corrodes the
tube metal.
1. Boilers have varying numbers of soot blowers but, there are two basic
types, rotary and stationary. They use unreduced desuperheated steam as
the motive force which is reduced in the element by an orifice to 300 psi
for rotating units and approximately 150 psi for stationary units. Using
relatively hot steam at a reduced pressure minimizes moisture in the steam
which can lead to erosion or acid corrosion.
2. The rotary type of soot blower has multi-nozzle elements. The soot blower
head steam valve is actuated by a cam when the element is rotated. The
element can be turned by a crank, chain, or an air or electric motor. Steam
is admitted from the head into an element which incorporates uniformly
spaced nozzles/holes to evenly distribute steam along the area covered.
(Refer to figure 12)
 ROTARY SOOT BLOWER

Figure 12

3. The stationary type of soot blower usually has one or two rows of nozzles
directed to the area immediately near the drums of the boiler. Steam is
admitted for a short duration by a manually or power actuated stop valve.
 4. The soot blower element must be kept cool and clean during operation. To
accomplish this, a small amount of air is piped into the element through a
small air line. This air is called scavenging air and comes from the
combustion air that pressurizes the boiler air casing. This allows a small
amount of air to enter the soot blower element to keep it cool and clean.
There is a check valve installed in this line to prevent steam from entering
the air casing during soot blower operation.
5. The operation of soot blowers is called "blowing tubes." Tubes are blown
on the following minimum occasions:
a. After leaving port
b. Before entering port
c. After making heavy smoke
d. Once each week when steaming

NOTE: EOSS requires tubes to be blown prior to securing a boiler, if possible.

Y. Since the boiler water chemistry control systems, Chelant or Coordinated

Phosphate, both settle sludge to help maintain water purity, there must exist a
means to remove this sludge. The bottom blowdown system is used to remove
sludge from the water drum and the lower headers. The surface blowdown system
is used to remove suspended particles in the water and provide a means of
changing out the water in the boiler to lower the conductivity and dissolved
substances. Both systems share a common piping arrangement with an overboard
guarding valve and overboard discharge valve. (Refer to figure 13)

SURFACE/BOTTOM
BLOWDOWN
PIPING

Figure 13

1. Surface blowdowns are conducted on a steaming boiler as needed to

maintain boiler water within the proper chemical control limits. The
Chelant system also uses an occasional scum blow to maintain limits.
 2. A boiler is bottom blown only when it is secured. Never bottom blow a
steaming boiler since this could cause a loss of natural circulation and
boiler damage. Boilers shall be secured and bottom blown every 360
steaming hours if the Chelant treatment system is installed or every 168 if
the Coordinated Phosphate (COPHOS) system is in use. There are many
conditions that require a boiler to be bottom blown. For a complete listing
refer to NSTM 221 or 220 volume II.

A. Knowing the water/steam flow through the boiler is critical to understanding the
interrelationships of the boiler components. A summary follows:
1. The flow begins when feedwater enters the economizer inlet header and
flows through the economizer tubes to the outlet header picking up
approximately 100-200 F of sensible heat to about 350F.
2. Feedwater leaving the economizer enters the steam drum via the internal
feed pipe. The feed pipe distributes the water evenly along the length of
the steam drum.
3. Boiler water then flows over the baffle plates to the ends of the drum
where the cooler more dense water flows down through the downcomers
to the water drum and lower headers.
4. Water in the water drum and lower headers is distributed to the various
generating tubes to replace the water being generated into steam.
5. As water rises through the tubes, it is exposed to the combustion gases
through the tube walls increasing the water temp which decrease it's
density, allowing it to continue the flow upward.
6. Continuing upward, a portion of the water changes to steam and enters the
steam drum under the baffle plates. The water-steam mixture is guided to
the primary separators which separate the excess water from the steam by
centrifugal motion. Separated water falls back to the steam drum above the
baffle plates.
7. Steam exits the primary separator and enters the secondary separators
where the rapid changes in direction of flow causes it to give up more
moisture. Moisture removed drains back to the steam drum above the
baffle plates.
8. All accumulated steam is directed to the dry box. The quality of saturated
steam leaving the steam drum is designed to be 99.75% moisture free.
9. Steam flows through the saturated steam line to the superheater inlet
header. It makes four passes through the superheater increasing steam
temperature 300-400 F to approximately 850 F and then exits through
the outlet header.
10. Superheated steam leaves the outlet header and a portion is routed to the
desuperheater inlet based upon system demand. All remaining steam goes
through the main steam stop to the main steam system to provide
superheated steam to the main engine turbines, ship's service turbine
generators (SSTG), and on some ships, the main feed pumps (MFP).
11. The steam that passes through the desuperheater which is submerged in
the water drum, gives up superheat to the surrounding water. Steam
 leaving the desuperheater passes through the auxiliary steam stop to
provide steam to all auxiliary system demands.
12. A summary of the combustion gas flow follows:
a. Combustion gases flow from the furnace through the screenwall
tubes, superheater tubes, main generating bank, and economizer.
The hot combustion gases then pass through the inner stack and
finally exit the stack to the atmosphere. (Refer to figure 1)