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A boiler is a closed vessel in which water or other liquid is heated. The liquid will not always boil. (In THE UNITED STATES, the word "furnace" is generally used if the reason is never to boil the liquid.) The warmed or vaporized fluid exits the boiler for use in a variety of heating system or procedures applications,[1 - [2 - including drinking water heating, central heating system, boiler-based power generation, cooking food, and sanitation.
Materials
The pressure vessel of a boiler is usually made of steel (or alloy steel), or of wrought iron historically. Stainless steel, of the austenitic types especially, is not found in wetted elements of boilers credited to corrosion and stress corrosion cracking.[3 - However, ferritic stainless is often found in superheater sections that won't be exposed to boiling water, and electrically heated stainless steel 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 since it is more easily fabricated in smaller size boilers. Historically, copper was often used for fireboxes (particularly for vapor locomotives), due to 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 metal) are used instead.
For much of the Victorian "age group of vapor", the only material used for boilermaking was the highest quality of wrought iron, with set up by rivetting. This iron was often 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 instead moved towards the use of metal, which is stronger and cheaper, with welded construction, which is quicker and requires less labour. It should be mentioned, however, that wrought iron boilers corrode far slower than their modern-day metal counterparts, and are less vunerable to localized pitting and stress-corrosion. This makes the longevity of older wrought-iron boilers considerably more advanced than those of welded steel boilers.
Cast iron may be used for the heating system vessel of home water heaters. Although such heaters are usually termed "boilers" in a few countries, their purpose is to create warm water usually, not steam, and they also run at low pressure and stay away from boiling. The brittleness of cast iron makes it impractical for high-pressure steam boilers.
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Energy
The source of heating for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric steam boilers use resistance- or immersion-type heating system elements. Nuclear fission is used as a heat source for producing steam also, either straight (BWR) or, generally, in specialised heat exchangers called "steam generators" (PWR). Warmth recovery vapor generators (HRSGs) use heat rejected from other procedures such as gas turbine.
Boiler efficiency
there are two solutions to gauge the boiler efficiency 1) direct method 2) indirect method
Direct method -direct approach to boiler efficiency test is more usable or even more common
boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam circulation Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of feed drinking water in kcal/kg q= quantity of energy 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 following parameter like
Ultimate analysis of energy (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 energy in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified in to the following configurations:
Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a fire heats a partially filled drinking water pot from below. 18th century Haycock boilers produced and stored large quantities of very low-pressure steam generally, barely above that of the atmosphere often. These could burn wood or frequently, coal. Efficiency was suprisingly low.
Flued boiler with a couple of large flues-an early type or forerunner of fire-tube boiler.
Diagram of a fire-tube boiler
Fire-tube boiler: Here, drinking water partially fills a boiler barrel with a little volume still left above to accommodate the vapor (steam space). This is the type of boiler used in almost all steam locomotives. The heat source is inside a furnace or firebox that needs to be held permanently surrounded by water in order to keep the heat of the heating surface below the boiling point. The furnace can be situated at one end of the fire-tube which lengthens the road of the hot gases, thus augmenting the heating system surface which can be further increased by causing the gases reverse direction through a second parallel pipe or a lot of money of multiple pipes (two-pass or come back flue boiler); alternatively the gases may be taken along the sides and then beneath the boiler through flues (3-move boiler). In case there is a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases go through a lot of money of fire tubes inside the barrel which greatly increases the heating system surface compared to a single tube and further increases 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 mainly, but are readily adaptable to people of the gas or liquid variety.
Diagram of a water-tube boiler.
Water-tube boiler: In this type, tubes filled up with water are arranged inside a furnace in a number of possible configurations. Often the drinking water tubes connect large drums, the lower ones formulated with water and top of the ones steam and water; in other instances, such as a mono-tube boiler, water is circulated with a pump through a succession of coils. This type generally gives high steam production rates, but less storage space capacity than the above. Water tube boilers can be made to exploit any warmth source and tend to be preferred in high-pressure applications because the high-pressure water/vapor is contained within small diameter pipes which can withstand the pressure with a thinner wall.
Flash boiler: A flash boiler is a specialized kind of water-tube boiler in which tubes are close collectively and water is pumped through them. A flash boiler differs from the type of mono-tube steam generator in which the tube is permanently filled up with water. Super fast boiler, the tube is held so hot that water feed is quickly flashed into steam and superheated. Flash boilers acquired some use in automobiles in the 19th century and this use continued into 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 mixed in the following manner: the firebox includes an set up of water pipes, called thermic siphons. The gases pass through a conventional firetube boiler then. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have met with little success in other countries.
Sectional boiler. Within a solid iron sectional boiler, sometimes called a "pork chop boiler" the water is included inside cast iron areas.[citation needed - These sections are assembled on site to generate the finished boiler.
Safety
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Culture of Mechanical Technical engineers (ASME) develop standards and regulation codes. For example, the ASME Boiler and Pressure Vessel Code is a standard providing an array of guidelines and directives to ensure compliance of the boilers and other pressure vessels with protection, design and security standards.[5 -
Historically, boilers were a way to obtain 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 poorly, leading to a violent eruption of the pressurized vapor. When water is changed into steam it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres per hour. As a result of this, steam is a great way of moving energy and warmth around a site from a central boiler house to where it is needed, but with no right boiler feed water treatment, a steam-raising herb will suffer from level development and corrosion. At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter vegetation and unreliable operation. At worst, it can lead to catastrophic reduction and failure of life. Collapsed or dislodged boiler pipes can also aerosol scalding-hot vapor and smoke from the air intake and firing chute, injuring the firemen who weight the coal into the open fire chamber. Extremely large boilers providing a huge selection of horsepower to use factories could demolish entire structures.[6 -
A boiler which has a loss of give food to water and it is permitted to boil dry out can be extremely dangerous. If nourish water is sent in to the vacant boiler then, the small cascade of incoming water instantly boils on connection with the superheated metallic shell and leads to a violent explosion that can't be managed even by basic safety vapor valves. Draining of the boiler can also happen if a leak occurs in the vapor supply lines that is bigger than the make-up water source could replace. The Hartford Loop was invented in 1919 by the Hartford Steam Boiler and Insurance Company as a method to assist in preventing this problem from taking place, and thereby reduce their insurance statements.[7 - [8 -
Superheated steam boiler
A superheated boiler on a steam locomotive.
Main article: Superheater
Most boilers produce vapor to be used at saturation heat; that is, saturated vapor. Superheated steam boilers vaporize water and then further heat the vapor in a superheater. This provides vapor at higher temperature, but can reduce the overall thermal efficiency of the vapor generating herb because the bigger steam temp takes a higher flue gas exhaust temperature.[citation needed - There are several ways to circumvent this problem, by giving an economizer that heats the give food to water typically, a combustion air heater in the hot flue gas exhaust route, or both. You can find benefits to superheated vapor that may, and often will, increase overall efficiency of both vapor generation and its utilization: benefits in input heat range to a turbine should outweigh any cost in additional boiler complication and expense. There could be useful restrictions in using wet steam also, as entrained condensation droplets will harm turbine blades.
Superheated steam presents unique safety concerns because, if any operational system component fails and allows steam to flee, the high pressure and temperature can cause serious, instantaneous harm to anyone in its path. Since the escaping steam will at first be completely superheated vapor, detection can be difficult, although the intense heat and sound from such a leak indicates its presence clearly.
Superheater operation is similar to that of the coils on an air conditioning unit, although for a different purpose. The vapor piping is directed through the flue gas path in the boiler furnace. The heat in this area is between 1 typically,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are radiant type; that is, they absorb heat by rays. Others are convection type, absorbing high temperature from a fluid. Some are a combination of the two types. Through either method, the extreme heat in the flue gas path will also high temperature the superheater steam piping and the vapor within. While the heat of the vapor in the superheater rises, the pressure of the steam will not and the pressure remains exactly like that of the boiler.[9 - Almost all steam superheater system designs remove droplets entrained in the steam to avoid harm to the turbine blading and associated piping.
Supercritical steam generator
Boiler for a power vegetable.
Main article: Supercritical steam generator
Supercritical steam generators are frequently used for the production of electric power. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical steam 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 liquid nor gas but a super-critical fluid neither. There is no generation of steam bubbles within the water, because the pressure is above the critical pressure point at which steam bubbles can develop. As the fluid expands through the turbine stages, its thermodynamic condition drops below the critical point as it does work turning the turbine which changes the power generator that power is eventually extracted. The fluid at that time may be considered a mixture of steam and liquid droplets as it goes by into the condenser. This results in slightly less fuel 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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Accessories
Boiler accessories and fittings
Pressuretrols to control the steam pressure in the boiler. Boilers generally have two or three 3 pressuretrols: a manual-reset pressuretrol, which functions as a safety by setting the upper limit of vapor pressure, the operating pressuretrol, which handles when the boiler fires to maintain pressure, and for boilers outfitted with a modulating burner, a modulating pressuretrol which handles the amount of fire.
Protection valve: It can be used to relieve pressure and prevent possible explosion of the boiler.
Water level indications: They show the operator the level of liquid in the boiler, known as a sight glass also, water measure or water column.
Bottom level blowdown valves: They offer a way for removing solid particulates that condense and rest on underneath of a boiler. As the name suggests, this valve is situated straight on underneath of the boiler usually, and is sometimes opened to use the pressure in the boiler to press these particulates out.
Constant blowdown valve: This allows a small quantity of water to escape continuously. Its purpose is to avoid the water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause drinking water droplets to be transported over with the steam - an ailment known as priming. Blowdown is often used to monitor the chemistry of the boiler drinking water also.
Trycock: a kind of valve that is often use to manually check a liquid level in a container. Most commonly found on a drinking water boiler.
Flash container: High-pressure blowdown enters this vessel where in fact the vapor can 'flash' safely and become used in a low-pressure system or be vented to atmosphere as the ambient pressure blowdown flows to drain.
Automatic blowdown/continuous heat recovery system: This technique allows the boiler to blowdown only once make-up water is flowing to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the makeup water. No flash container is generally needed as the blowdown discharged is close to the heat range of the make-up water.
Hand openings: They are steel plates installed in openings in "header" to allow for inspections & installing pipes and inspection of inner surfaces.
Vapor drum internals, some display screen, scrubber & cans (cyclone separators).
Low-water cutoff: It really is a mechanical means (usually a float switch) that is used to turn from the burner or shut down energy to the boiler to avoid it from running once the drinking water runs below a certain point. If a boiler is "dry-fired" (burnt without water in it) it can cause rupture or catastrophic failing.
Surface blowdown range: It provides a means for removing foam or other light-weight non-condensible chemicals that tend to float together with water inside the boiler.
Circulating pump: It really is designed to circulate water back to the boiler after they have expelled some of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater series. This can be suited to the relative part of the boiler, below water level just, or to the very best of the boiler.[10 -
Top give food to: Within this design for feedwater injection, water is fed to the top of the boiler. This may reduce boiler fatigue triggered by thermal stress. By spraying the feedwater over some trays the water is quickly warmed and this can reduce limescale.
Desuperheater pipes or bundles: A series of tubes or bundles of tubes in water drum or the vapor drum made to cool superheated vapor, in order to supply auxiliary equipment that does not need, or may be damaged by, dry vapor.
Chemical injection line: A connection to add chemicals for controlling feedwater pH.
Steam accessories
Main steam stop valve:
Steam traps:
Main steam stop/check valve: It is used on multiple boiler installations.
Combustion accessories
Energy oil system:energy oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure measure attachment:
Name dish:
Registration plate: -
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