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A boiler is a closed vessel where water or other fluid is heated. The fluid will not always boil. (In North America, the term "furnace" is normally used if the reason is never to boil the liquid.) The warmed or vaporized fluid exits the boiler for use in various procedures or heating applications,[1 - [2 - including drinking water heating, central heating, boiler-based power generation, cooking food, and sanitation.
The pressure vessel of the boiler is usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel, of the austenitic types especially, is not used in wetted elements of boilers thanks to stress and corrosion corrosion breaking.[3 - However, ferritic stainless is often used in superheater sections that won't come in contact with boiling drinking water, and electrically heated stainless shell boilers are allowed under the European "Pressure Equipment Directive" for creation of steam for sterilizers and disinfectors.[4 -
https://en.wikipedia.org/wiki/Boiler - https://en.wikipedia.org/wiki/Boiler
In live steam models, copper or brass is often used because it is more fabricated in smaller size boilers easily. Historically, copper was often used for fireboxes (especially for steam locomotives), because of its better formability and higher thermal conductivity; however, in more recent times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as steel) are used instead.
For a lot of the Victorian "age group of vapor", the only material used for boilermaking was the best grade of wrought iron, with assembly by rivetting. This iron was from specialist ironworks, such as at Cleator Moor (UK), noted for the high quality of their rolled plate and its own suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice transferred towards the use of metal instead, which is stronger and cheaper, with welded construction, which is quicker and requires less labour. It should be noted, however, that wrought iron boilers corrode much slower than their modern-day metal counterparts, and are less vunerable to localized pitting and stress-corrosion. This makes the durability of old wrought-iron boilers far more advanced than those of welded steel boilers.
Cast iron may be used for the heating system vessel of local water heaters. Although such heaters are usually termed "boilers" in some countries, their purpose is to create warm water usually, not steam, and so they run at low pressure and try to avoid boiling. The brittleness of cast iron makes it impractical for high-pressure vapor boilers.
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The source of heating for a boiler is combustion of any of several fuels, such as wood, coal, oil, or gas. Electric steam boilers use level of resistance- or immersion-type heating elements. Nuclear fission is also used as a heat source for producing steam, either directly (BWR) or, in most cases, in specialised high temperature exchangers called "steam generators" (PWR). Heat recovery steam generators (HRSGs) use heat rejected from other processes such as gas turbine.
there are two methods to gauge the boiler efficiency 1) direct method 2) indirect method
Immediate method -direct method of boiler efficiency test is more usable or more common
boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total vapor movement Hg= Enthalpy of saturated vapor in k cal/kg Hf =Enthalpy of give food to drinking water in kcal/kg q= quantity of gas use in kg/hr GCV =gross calorific value in kcal/kg like pet coke (8200 kcal/KG)
indirect method -to gauge the boiler efficiency in indirect method, we need a subsequent parameter like
Ultimate analysis of gas (H2,S2,S,C moisture constraint, ash constraint)
percentage of O2 or CO2 at flue gas
flue gas temperature at outlet
ambient temperature in deg c and humidity of air in kg/kg
GCV of gas in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Boilers can be classified in to the following configurations:
Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" in which a open fire heats a partially filled water pot from below. 18th century Haycock boilers generally produced and stored large amounts of very low-pressure vapor, often barely above that of the atmosphere. These could burn wood or frequently, coal. Efficiency was suprisingly low.
Flued boiler with a couple of large flues-an early forerunner or kind of fire-tube boiler.
Diagram of a fire-tube boiler
Fire-tube boiler: Here, water partially fills a boiler barrel with a little volume remaining above to support the vapor (vapor space). This is the kind of boiler used in nearly all steam locomotives. Heat source is in the furnace or firebox that needs to be kept permanently surrounded by water in order to keep the temp of the heating system surface below the boiling point. The furnace can be situated at one end of the fire-tube which lengthens the path of the hot gases, thus augmenting the heating surface which can be further increased by causing the gases reverse direction through a second parallel tube or a lot of money of multiple pipes (two-pass or come back flue boiler); additionally the gases may be studied along the sides and then under the boiler through flues (3-pass boiler). In case there is a locomotive-type boiler, a boiler barrel expands from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly escalates the heating surface compared to a single tube and further boosts heat transfer. Fire-tube boilers usually have a comparatively low rate of vapor production, but high vapor storage capacity. Fire-tube boilers burn solid fuels mostly, but are easily adaptable to the people of the liquid or gas variety.
Diagram of a water-tube boiler.
Water-tube boiler: In this type, tubes filled up with water are arranged in the furnace in a number of possible configurations. The water tubes connect large drums Often, the low ones containing water and the top ones water and steam; in other cases, such as a mono-tube boiler, drinking water is circulated by a pump through a succession of coils. This kind provides high vapor creation rates generally, but less storage space capacity than the above. Water tube boilers can be designed to exploit any heat source and tend to be preferred in high-pressure applications since the high-pressure drinking water/steam is contained within small size pipes which can withstand the pressure with a thinner wall structure.
Flash boiler: A flash boiler is a specialized type of water-tube boiler where pipes are close collectively and drinking water is pumped through them. A flash boiler differs from the kind of mono-tube steam generator where the pipe is permanently filled up with water. In a flash boiler, the pipe is kept so hot that the water feed is quickly flashed into vapor and superheated. Flash boilers got some use in cars in the 19th century and this use continued in to the early 20th century. .
1950s design vapor locomotive boiler, from a Victorian Railways J class
Fire-tube boiler with Water-tube firebox. Sometimes the two above types have been combined in the next manner: the firebox consists of an set up of water tubes, called thermic siphons. The gases pass through a typical firetube boiler then. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have fulfilled with little success in other countries.
Sectional boiler. In a cast iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside ensemble iron areas.[citation needed - These sections are assembled on site to make the finished boiler.
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Society of Mechanical Technicians (ASME) develop standards and regulation rules. For instance, the ASME Boiler and Pressure Vessel Code is a typical providing a wide range of rules and directives to ensure compliance of the boilers and other pressure vessels with basic safety, security and design standards.[5 -
Historically, boilers were a source of many serious injuries and property destruction due to badly understood engineering principles. Thin and brittle metallic shells can rupture, while welded or riveted seams could start badly, resulting in a violent eruption of the pressurized vapor. When water is converted to steam it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres each hour. Because of this, vapor is a great way of moving energy and temperature around a niche site from a central boiler house to where it is necessary, but without the right boiler feed water treatment, a steam-raising plant will suffer from level corrosion and formation. At best, this boosts energy costs and can lead to poor quality steam, reduced efficiency, shorter vegetation and unreliable operation. At worst, it can result in catastrophic reduction and failure of life. Collapsed or dislodged boiler pipes can also squirt scalding-hot steam and smoke out of the air intake and firing chute, injuring the firemen who insert the coal into the open fire chamber. Extremely large boilers providing hundreds of horsepower to operate factories could demolish entire buildings.[6 -
A boiler that has a loss of feed water and it is permitted to boil dry out can be extremely dangerous. If nourish water is sent into the vacant boiler then, the small cascade of incoming water instantly boils on contact with the superheated metallic shell and leads to a violent explosion that cannot be controlled even by security steam valves. Draining of the boiler can also happen if a leak occurs in the steam source lines that is bigger than the make-up water source could replace. The Hartford Loop was invented in 1919 by the Hartford Vapor Boiler and Insurance Company as a method to assist in preventing this condition from occurring, and therefore reduce their insurance claims.[7 - [8 -
Superheated steam boiler
A superheated boiler on the steam locomotive.
Main article: Superheater
Most boilers produce vapor to be used at saturation heat; that is, saturated vapor. Superheated steam boilers vaporize the water and additional heat the steam in a superheater then. This provides vapor at much higher temp, but can decrease the overall thermal efficiency of the steam generating flower because the higher steam temperatures requires a higher flue gas exhaust temp.[citation needed - There are many ways to circumvent this problem, typically by giving an economizer that heats the feed drinking water, a combustion air heating unit in the hot flue gas exhaust route, or both. A couple of advantages to superheated steam that may, and often will, increase overall efficiency of both steam generation and its own utilization: increases in input temperature to a turbine should outweigh any cost in additional boiler problem and expense. There may also be useful restrictions in using damp steam, as entrained condensation droplets will damage turbine blades.
Superheated steam presents unique safety concerns because, if any system component fails and allows steam to escape, the high pressure and temperature can cause serious, instantaneous injury to anyone in its path. Since the escaping steam will at first be completely superheated vapor, detection can be difficult, although the extreme heat and sound from such a leak indicates its existence clearly.
Superheater operation is similar to that of the coils on an fresh air conditioning unit, although for a different purpose. The vapor piping is directed through the flue gas route in the boiler furnace. The temperature in this field is normally between 1,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are glowing type; that is, they absorb warmth by rays. Others are convection type, absorbing warmth from a liquid. Some are a mixture of both types. Through either method, the extreme high temperature in the flue gas route will also warmth the superheater vapor piping and the steam within. While the temp of the vapor in the superheater rises, the pressure of the vapor will not and the pressure remains the same as that of the boiler.[9 - Virtually all steam superheater system designs remove droplets entrained in the steam to avoid damage to the turbine blading and associated piping.
Supercritical steam generator
Boiler for a charged power herb.
Main article: Supercritical steam generator
Supercritical steam generators are used for the production of energy frequently. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical vapor generator operates at such a higher pressure (over 3,200 psi or 22 MPa) that the physical turbulence that characterizes boiling ceases that occurs; the fluid is neither water nor gas but a super-critical fluid. There is absolutely no generation of steam bubbles within water, because the pressure is above the critical pressure point at which vapor bubbles can form. As the liquid expands through the turbine phases, its thermodynamic condition drops below the critical point as it can work turning the turbine which converts the electrical generator from which power is ultimately extracted. The liquid at that point may be a mixture of steam and liquid droplets as it passes in to the condenser. This results in slightly less gasoline use and for that reason less greenhouse gas production. The word "boiler" shouldn't be used for a supercritical pressure steam generator, as no "boiling" occurs in this device.
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Boiler accessories and fittings
Pressuretrols to control the vapor pressure in the boiler. Boilers generally have 2 or 3 3 pressuretrols: a manual-reset pressuretrol, which functions as a protection by setting the upper limit of steam pressure, the operating pressuretrol, which controls when the boiler fires to keep up pressure, as well as for boilers outfitted with a modulating burner, a modulating pressuretrol which handles the quantity of fire.
Basic safety valve: It can be used to relieve pressure and stop possible explosion of the boiler.
Water level signals: They show the operator the level of fluid in the boiler, known as a sight glass also, water gauge or water column.
Bottom blowdown valves: They offer a way for removing solid particulates that condense and rest on the bottom of the boiler. As the name indicates, this valve is usually located directly on the bottom of the boiler, and is sometimes opened to use the pressure in the boiler to push these particulates out.
Constant blowdown valve: This allows a small level of water to escape continuously. Its purpose is to avoid water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause water droplets to be transported over with the steam - a condition known as priming. Blowdown is often used to monitor the chemistry of the boiler drinking water also.
Trycock: a type of valve that is often use to manually check a liquid level in a container. Most entirely on a drinking water boiler commonly.
Flash tank: High-pressure blowdown enters this vessel where in fact the steam can 'flash' safely and be used in a low-pressure system or be vented to atmosphere as the ambient pressure blowdown flows to drain.
Automatic blowdown/constant heat recovery system: This system allows the boiler to blowdown only when make-up water is flowing to the boiler, thereby transferring the utmost amount of heat possible from the blowdown to the makeup water. No flash tank is generally needed as the blowdown discharged is close to the temperatures of the make-up water.
Hand holes: These are steel plates installed in openings in "header" to permit for inspections & installing tubes and inspection of inner surfaces.
Vapor drum internals, a series of display, scrubber & cans (cyclone separators).
Low-water cutoff: It really is a mechanical means (usually a float change) that is used to turn off the burner or shut off fuel to the boiler to prevent it from working once the water goes below a certain point. If a boiler is "dry-fired" (burned without water in it) it can cause rupture or catastrophic failure.
Surface blowdown collection: It provides a way for removing foam or other lightweight non-condensible substances that tend to float on top of the water inside the boiler.
Circulating pump: It really is designed to circulate drinking water back again to the boiler after they have expelled a few of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater series. This may be installed to the side of the boiler, just below water level, or to the top of the boiler.[10 -
Top give food to: With this design for feedwater injection, water is fed to the very best of the boiler. This can reduce boiler fatigue caused by thermal stress. By spraying the feedwater over a series of trays the water is quickly warmed which can reduce limescale.
Desuperheater tubes or bundles: Some pipes or bundles of tubes in water drum or the steam drum designed to cool superheated vapor, in order to supply auxiliary equipment that does not need, or may be damaged by, dry vapor.
Chemical substance injection line: A connection to add chemicals for controlling feedwater pH.
Main vapor stop valve:
Main steam stop/check valve: It is utilized on multiple boiler installations.
Gas oil system:energy oil heaters
Other essential items
Inspectors test pressure gauge attachment:
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