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|A boiler is a closed vessel where drinking water or other liquid is heated. The fluid does not necessarily boil. (In THE UNITED STATES, the term "furnace" is generally used if the purpose is not to boil the liquid.) The heated or vaporized liquid exits the boiler for use in various heating or procedures applications,[1 - [2 - including water heating, central heating system, boiler-based power generation, cooking food, and sanitation.
The pressure vessel of the boiler is usually manufactured from steel (or alloy steel), or of wrought iron historically. Stainless steel, especially of the austenitic types, is not used in wetted parts of boilers credited to corrosion and stress corrosion breaking.[3 - However, ferritic stainless is often found in superheater sections that won't come in contact with boiling water, and electrically heated stainless steel shell boilers are allowed under the Western 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 steam 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 steam", the only material used for boilermaking was the highest quality of wrought iron, with set up by rivetting. This iron was obtained from specialist ironworks, such as at Cleator Moor (UK), noted for the high quality of their rolled plate and its suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice instead shifted towards the use of steel, which is more powerful and cheaper, with welded building, which is quicker and requires less labour. It ought to be observed, however, that wrought iron boilers corrode far slower than their modern-day metal counterparts, and are less susceptible to localized stress-corrosion and pitting. This makes the longevity of older wrought-iron boilers considerably superior to those of welded metal boilers.
Cast iron might be used for the heating vessel of domestic drinking water heaters. Although such heaters are usually termed "boilers" in some countries, their purpose is to produce hot water usually, not steam, and they also run at low pressure and stay away from boiling. The brittleness of cast iron helps it be impractical for high-pressure vapor boilers.
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The source of heating for a boiler is combustion of some of several fuels, such as wood, coal, oil, or gas. Electric vapor boilers use resistance- or immersion-type heating elements. Nuclear fission can be used as a heat source for generating steam also, either directly (BWR) or, in most cases, in specialised heat exchangers called "steam generators" (PWR). Temperature recovery vapor generators (HRSGs) use heat rejected from other procedures such as gas turbine.
there are two solutions to gauge the boiler efficiency 1) direct method 2) indirect method
Immediate 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 movement Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of give food to 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 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" where a fireplace heats a partially filled water box from below. 18th century Haycock boilers generally produced and stored large quantities of very low-pressure steam, often hardly above that of the atmosphere. These could burn off wood or most often, 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 remaining above to accommodate the steam (vapor space). This is the kind of boiler used in almost all steam locomotives. Heat source is in the furnace or firebox that needs to be held permanently surrounded by water in order to maintain the temperature 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 may be further increased by making the gases invert direction through a second parallel tube or a bundle of multiple tubes (two-pass or return 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 extends from the firebox and the hot gases go through a bundle of fire pipes inside the barrel which greatly increases the heating surface in comparison to a single tube and further enhances heat transfer. Fire-tube boilers usually have a comparatively low rate of vapor creation, but high steam storage capacity. Fire-tube boilers burn off solid fuels mostly, but are readily adaptable to people of the gas or water variety.
Diagram of a water-tube boiler.
Water-tube boiler: In this type, tubes filled with water are arranged in the furnace in a number of possible configurations. Often the drinking water tubes connect large drums, the lower ones containing water and top of the ones water and steam; in other situations, such as a mono-tube boiler, drinking water is circulated with a pump through a succession of coils. This kind generally gives high steam production rates, but less storage space capacity than the above. Water tube boilers can be designed to exploit any high temperature source and are generally preferred in high-pressure applications because the high-pressure drinking water/vapor is included within small diameter pipes which can withstand the pressure with a thinner wall structure.
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 vapor generator where 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 had some use in automobiles in the 19th century which 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 both above types have been combined in the next manner: the firebox includes an set up of water pipes, called thermic siphons. The gases then pass through a conventional firetube boiler. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have fulfilled with little success in other countries.
Sectional boiler. Inside a solid iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside ensemble iron sections.[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 specifications and regulation codes. 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 safety, security and design standards.[5 -
Historically, boilers were a source of many serious injuries and property destruction due to poorly understood engineering principles. Thin and brittle steel shells can rupture, while poorly welded or riveted seams could open up, resulting in a violent eruption of the pressurized steam. When water is converted to steam it expands to over 1,000 times its original quantity and moves down steam pipes at over 100 kilometres each hour. As a result of this, steam is a great way of moving energy and heat 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 vegetable will suffer from scale formation and corrosion. At best, this boosts energy costs and can lead to poor quality vapor, reduced efficiency, shorter plant life and unreliable operation. At worst, it can lead to catastrophic failure and loss of life. Collapsed or dislodged boiler tubes can also aerosol scalding-hot vapor and smoke from the air intake and firing chute, injuring the firemen who fill the coal into the fire chamber. Extremely large boilers providing a huge selection of horsepower to operate factories could demolish entire structures.[6 -
A boiler which has a loss of feed drinking water and it is permitted to boil dry can be extremely dangerous. If give food to drinking water is then sent into the unfilled boiler, the tiny cascade of inbound drinking water instantly boils on contact with the superheated steel shell and leads to a violent explosion that cannot be managed even by security steam valves. Draining of the boiler can also happen if a leak occurs in the vapor supply lines that is larger than the make-up water supply could replace. The Hartford Loop was invented in 1919 by the Hartford Steam Boiler and INSURANCE PROVIDER as a strategy to help prevent this problem from taking place, and therefore reduce their insurance statements.[7 - [8 -
Superheated steam boiler
A superheated boiler on the steam locomotive.
Main article: Superheater
Most boilers produce vapor to be utilized at saturation temp; that is, saturated vapor. Superheated vapor boilers vaporize the water and then further temperature the vapor in a superheater. This provides vapor at much higher temperature, but can reduce the overall thermal efficiency of the steam generating flower because the higher vapor heat range requires a higher flue gas exhaust heat range.[citation needed - There are many ways to circumvent this problem, by giving an economizer that heats the give food to drinking water typically, a combustion air heating unit in the hot flue gas exhaust path, or both. You will find advantages to superheated vapor that may, and often will, increase overall efficiency of both steam generation and its own utilization: benefits in input temperature to a turbine should outweigh any cost in additional boiler complication and expense. There may be practical restrictions in using wet vapor also, as entrained condensation droplets will harm turbine blades.
Superheated steam presents unique safety concerns because, if any system component fails and allows steam to escape, the ruthless and temperature can cause serious, instantaneous injury to anyone in its path. Since the escaping steam will be completely superheated vapor, detection can be difficult, although the extreme heat and sound from such a leak indicates its existence clearly.
Superheater procedure is similar to that of the coils on an air conditioning unit, although for a different purpose. The steam piping is directed through the flue gas route in the boiler furnace. The heat in this area is normally between 1,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are glowing type; that is, they absorb temperature by rays. Others are convection type, absorbing high temperature from a liquid. Some are a combination of both types. Through either method, the extreme heat in the flue gas path will heat the superheater steam piping and the steam within also. While the heat range of the steam in the superheater rises, the pressure of the steam does 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 prevent damage to the turbine blading and associated piping.
Supercritical steam generator
Boiler for a charged power seed.
Main article: Supercritical steam generator
Supercritical steam generators are used for the production of electric power 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 liquid nor gas but a super-critical fluid neither. There is absolutely no generation of vapor bubbles within water, because the pressure is above the critical pressure point of which vapor bubbles can develop. As the fluid expands through the turbine levels, its thermodynamic state drops below the critical point as it can work turning the turbine which changes the electrical generator from which power is eventually extracted. The fluid at that point may be a mixture of vapor and liquid droplets as it goes by in to the condenser. This leads to less fuel use and for that reason less greenhouse gas production slightly. The term "boiler" should not be used for a supercritical pressure vapor generator, as no "boiling" occurs in this device.
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Boiler accessories and fittings
Pressuretrols to regulate the steam pressure in the boiler. Boilers generally have two or three 3 pressuretrols: a manual-reset pressuretrol, which functions as a protection by setting the top limit of steam pressure, the operating pressuretrol, which handles when the boiler fires to keep up pressure, and for boilers equipped with a modulating burner, a modulating pressuretrol which handles the quantity of fire.
Protection valve: It is used to relieve pressure and stop possible explosion of a boiler.
Water level signals: They show the operator the level of liquid in the boiler, known as a sight glass also, water gauge or water column.
Bottom blowdown valves: They provide a way for removing solid particulates that condense and lay on the bottom of a boiler. As the name implies, this valve is usually located on underneath of the boiler, and is occasionally opened to use the pressure in the boiler to drive these particulates out.
Continuous blowdown valve: This enables a small quantity of water to flee continuously. Its purpose is to avoid the water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause water droplets to be carried over with the vapor - a disorder 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 water level in a tank. Most found on a water boiler commonly.
Flash container: High-pressure blowdown enters this vessel where in fact the steam can 'flash' safely and become used in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown flows to drain.
Automatic blowdown/continuous heat recovery system: This system allows the boiler to blowdown only once 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 heat of the make-up water.
Hand holes: These are metal plates installed in openings in "header" to permit for inspections & installing pipes and inspection of inner surfaces.
Vapor drum internals, some 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 off energy to the boiler to avoid it from running once the drinking water moves below a certain point. If a boiler is "dry-fired" (burnt without drinking water in it) it can cause rupture or catastrophic failure.
Surface blowdown collection: It provides a means for removing foam or other lightweight non-condensible substances that have a tendency to float on top of water inside the boiler.
Circulating pump: It is designed to circulate water back again to the boiler after it has expelled some of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater collection. This can be installed to the medial side of the boiler, below water level just, or to the very best of the boiler.[10 -
Top feed: In this design for feedwater injection, the water is fed to the very best of the boiler. This can reduce boiler exhaustion caused by thermal stress. By spraying the feedwater over some trays the water is quickly heated and this can reduce limescale.
Desuperheater pipes or bundles: A series of tubes or bundles of pipes in the water drum or the steam drum made to cool superheated vapor, in order to provide auxiliary equipment that does not need, or may be damaged by, dry out steam.
Chemical 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.
Energy oil system:gas oil heaters
Other essential items
Inspectors test pressure measure attachment:
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