CLASSIFICATIO

N
OF
BOILERS
1. RELATIVE POSITION OF WATER & HOT GASES
2. AXIS OF SHELL
3. FIRING POSITION – EXTERNAL & INTERNAL
4. METHOD OF WATER CIRCULATION
5. STATIONARY & MOBILE
6. PACKAGE & SITE ERECTED
7. Type of fuel fired
Package Boiler

1 Furnace tube.
2 Tubes (2nd pass).
3 Tubes (3rd pass).
4 Combustion chamber.
5 Front smoke box.
6 Rear outlet box.
7 Sight glass.
8 Safety valve.
9 Crown valve.
10 Feed check valve.
11 Level controls.
12 Manhole.
13 Spare.
14 Spare.
15 Feed pump.
16 Control panel.
17 Burner.
18 FD fan.
19 Fan inlet silencer.
 Packaged Smoke Tube Boilers
Salient Features
• Continuous supply of dry saturated steam
• Generation of steam at constant pressure
• Minimum site work: Lesser boiler house space
• Skid mounted, requires only a flat foundation
• Fast steaming
• Fully automatic, capable of adjusting steam generation to
varying loads

• Often left unattended for operations (wherever regulations

permit)

• Highly efficient, efficiencies range from 84-85% (GCV) depending

on the fuel

• Minimal operational costs

 FROM & AT RATING
OF BOILER
• WIDELY USED METHOD TO SPECIFY THE CAPACITY OF BOILER.

• F & A RATING GIVES THE MASS OF WATER BOILER IS CAPABLE O

CONVERTING INTO STEAM IF THE FEED WATER IS AT 100 DEG.C AN
STEAM IS GENERATED AT ATMOSPHERIC PRESSURE

• NET STEAM GENERATION @ OPT. PRESSURE

= (F X 540)/(Hf - Hs)
 BASIC CONSTRUCTIONAL
PARTS OF THE BOILER

• SHELL, FURNACE & COMBUSTION CHAMBER

• BURNER & BURNER MANAGEMENT SYSTEM

• MOUNTINGS & CONTROLS

• ACCESSORIES

• BOILER HOUSE EQUIPMENTS

 SHELL, FURNACE &
COMBUSTION CHAMBER

The furnace, when

concentric with the Y-axis of the
boiler and not with the X-axis, is
notified as the CONCENTRIC
FURNACE.
Here the furnace is placed at
the lower hemisphere of the
boiler below the X axis and about
the Y axis.
 ECCENTRIC
FURNACE

The furnace, when eccentric with

the Y axis and the X axis, is
notified as the ECCENTRIC
FURNACE. Here the furnace is
placed at the lower left hand side
of the boiler shell and is not
concentric with the X axis and Y
axis
Location of the furnace is at the
bottom most zone of boiler shell.
Water content between furnace top
and Normal Water Level (NWL) is
huge. This feature provides sinking
time more than stipulations. Furnace
being subjected to very high
temperature of flame, it is the most
sensitive part of boiler. It needs to be
always covered by water.
No chances of furnace failure
Furnace is located at one side
at a comparatively upper zone
in the shell. Lower water
content between furnace top &
NWL results in lower sinking
time.
Chances of failure of furnace
are more
 NWL NWL
FEED WATER
INLET FROM
PUMP

HEAT TRANSFER
DUE TO PROPER
ASSIMILATION OF
WATER

AGITATION
EFFECT AT
TUBE NEST

Water enters in boiler shell at two Furnace is located eccentric in

ends of shell through sparge holes. It the shell. Non symmetric water
gets evenly distributed about the currents do not yield proper water
vertical axis of boiler as shown distribution / circulation.
resulting in proper mixing.
Steam bubbles formed around the furnace break due to tube nest resulting in
agitation which helps heat transfer by convection.

Water circulation around furnace is
good resulting in quick replacement
of vacuum left by steam formation
resulting in effective heat transfer.
Heat release rate in furnace can
be higher resulting in compact
boiler.
Film of steam
formed due to
improper
movement of
water affecting
poor heat
transfer
Water circulation around furnace
is not as good as that in
symmetric furnace design. Thus
chances of steam film formation
around furnace are much more.
This results in poor heat transfer.
Heat release rate are required
to be kept lower resulting in
bulkier boiler.
 NWL
NWL
FREE BOARD
DISTANCE

Lower free board distance

Higher free board distance helps
resulting into poor steam quality
to improve quality of steam &
& chances of water carryover
reduce water carryover
along with steam are more.
Cylindrical plain furnaces ensures Due to corrugations in the furnace air
streamlined air pattern which flow is highly fluctuating and
gives steady flame geometry. changing. This causes flame
impingement and inefficient heat
transfer.
Plain furnace will avoid Chances of accumulation of water
accumulation of water sediments sediments between the
resulting into effective heat corrugations will result into
transfer. ineffective heat transfer and may
result into failure of furnace
Easy for cleaning from both Difficult for cleaning
water & smoke side.
 BURNER
TYPES OF BURNERS

•
…..
1) BASED ON MODE OF ATOMISATION
THE
PRESSURE JET
• HEART
ROTARYOF THE
CUP
BOILER!!!!!
2) TYPE OF MODULATION
• HIGH / LOW
• 3 STAGE MODULATION
• STEPLESS MODULATION
3) BASED ON FUEL FIRED
• GAS FIRED
• OIL FIRED
• DUAL FIRED
4)BASED ON CONSTRUCTION
• MONOBLOCK
• DUAL BLOCK
Essential Features of a Good
Burner
è High combustion efficiency
è Part load performance
è Easy change over of fuels in case of dual fuel firing
è Ease of mounting
è Robust and compact design
è Noiseless operation
è Easy accessibility to all parts for inspection and maintenance
è Reliable components for continuos service
è Easy adjustment of air / fuel ratio
è Suitability of components for specific fuel characteristics
è Low power consumption and preheating of air
è Provision for various safety interlocks
ON- OFF
BURNER
3 STAGE
BURNER
 STEPLESS
MODULATION
BURNER
 CONTROLS

a. Oil temperature indicator 1 no. Local cum panel mounted to indicate oil
temperature
b. Pressure switch 2/3 nos. For firing positions of burner
c. Photo resistant cell 1 no. Flame failure and audio visual alarm
d. Temperature controller 1 no. To control oil temperatures in burner
heater before nozzle with audio visual
alarm and burner trip
e. Sequence controller 1 no. To control sequence of firing, pre -
purging etc.
f. Modulating mechanism 1 no. Stepped / Three stage modulation
g. Low oil pressure switch 1 no. To trip burner with audio visual alarm
h. Level controller 2 nos. To regulate feed water pump operation
and trip burner in case of very low level
with audio visual alarm.
 SAFETY
INTERLOCKS

Unsafe condition Instrument Action

High water level Level controller No. 1 Feed water pump trip.
Low water level Level controller No. 1 Alarm & Burner Shut down
Extra low water level Level Controller No. 2 (Overriding Alarm & lock-out
controller)
Flame failure Photocell Alarm & burner trip
Boiler high pressure Safety valves Lift & discharge
 BASIC
CALCULATIONS
FUEL CONSUMPTION
Fc = {(Boiler Capacity F & A 100 Deg.C) * 540}/(NCV * Eff-NCV)
OR
Fc = {(Steam Generated) * (Hs – Hfw)}/(NCV * Eff-NCV)
Hs – Enthalpy of Steam at Rated Pressure
Hfw – Enthalpy of Feed Water
Hw – Enthalpy of Water at Saturated Pressure
DF – Dryness Fraction

Fc = {(SG*DF*(Hs – Hfw))+(SG*(1-DF)* (Hw – Hfw)}/(NCV * Eff-NCV)

Calculation of Chimney Height (H)

H = 14 * (Q)^0.3

Q – Total Sulphur in Flue Gases

Q = 2*(Sulphur in Fuel)*(Fuel Consumption)