Steam Generating Unit 3.

Performing certain processes in sugar

mills, chemical and textile industries
-is an integrated, assembly of several
(Manufacturing Plants)
essential components, the function of which
is to produce steam at predetermined
pressure and temperature
Boiler Properties
-used for power generation, commercial and
Safety: The boiler should be safe under
industrial application
operating conditions.
*Hydrostatic Testing – a test to determine
Boiler the condition of boilers by filling the vessel
with liquid (usually water) up to its
-is a closed vessel in which the water under
maximum capacity which may help see
pressure is transferred into steam by the
visual leak detection. Pressure tightness can
application of heat
be tested by shutting the supply valve and
-pressure vessel observing pressure loss.
Accessibility: Various parts of the boiler
should be accessible for repair and
Function of Boilers maintenance.
-transfer the heat to water in the efficient Capacity: Should be capable of supplying
manner steam according to the requirements.
Working: Efficiency: Should be able to absorb a
Chemical energy converts into heat energy maximum amount of heat produced due to
by combustion process which is absorbed by burning of fuel in the furnace.
the boiler. Others: Simple construction, initial and
Quality: maintenance cost should be low, no joints
exposed to flames, capable of quick starting
A boiler must be designed to absorb the and loading
maximum amount of heat released in the
process of combustion.
Simple Representation of Boiler

Boiler steam is used for: YUNG MAY ARROW ARROW SA

BOILER
1. Mechanical work by expanding it in
steam engine or steam turbine (Power
Plants) Types of Boilers
2. Heating of residential and industrial 1. Fire tube
buildings. (Commercial/Industrial Plants)
-flue gas passes through the tubes and the
water stay inside the shell
-small capacity (up to 25 tons/hr and 17.5 According to the position of the furnace
kg/cm²)
1. Internally Fired – the furnace is
-advantage: low capital cost and fuel inside the drum.
efficiency (82%) 2. Externally Fired – furnace is
separated from the drum.
2. Water tube
-the water passes through the tubes and the
flue gas stay inside the shell  First Pass – where the fire is
 Second Pass – low fire
-steam range 5.5 to 130 tons/hr
 Third Pass – heat vapor (upper
-advantage: used in high-capacity steam portion of boiler)
boilers; disadvantage: high capital cost and
needs efficient control system
3. Package *Waterwall - series of tubes welded together
tangentially or with membrane bar between
-a boiler that had been fabricated and them to form the walls of the boiler’s
available as a complete package. The entire combustion chamber
pressure parts have been assembled in the
workshop and ready to be sent to the field or According to the position of principle axis
site where the power plant is located. 1. Vertical
-it comes as a complete package that’s why 2. Horizontal
it is called package boiler 3. Inclined

-it is generally shell type with fire tube

design According to application
-large number of small diameter tubes 1. Stationary
leading to good heat transfer 2. Mobile
-high thermal efficiency compared to other
types
According to circulating water
1. Natural circulation
*Breaching – process of filtering/cleaning 2. Forced circulation
smoke

According to steam pressure

Classification of Boiler according to flow
1. Low
1. Fire tube 2. Medium
2. Water tube 3. High
Basic Components of Boiler 6. Steam Space – entire upper space of
boiler and tubes which is not occupied by
1. Shell – it consists of one or more steel
water. (Up to 30%)
plates made into cylindrical shape and
welded or riveted together. The ends of the *Air vent – air exits. Uses ball valve.
shell are closed by flat or curved plates
*Main valve – biggest vent. Uses globe
called “boiler heads”. Curved or
valve.
hemispherical shaped ends are also called
“dished ends”. 7. Heating surface – a surface of boiler tubes
or plates, that is exposed to flue gases on
2. Foundation and wall – it is constructed of
one side and water on the other side. Heat
bricks and refractories. The wall of the
energy transfer into water takes place
boiler and combustion chamber may also be
through the heating surfaces.
made of bricks. This wall restricts heat to
the boiler and forms flue gas passage. Also, 8. Feed pump – a pump used to pump feed
walls provide support to drums and tubes. water into a steam boiler. (Companies use 2
feed pumps – operating and backup)
*Furnace pressure should be negative
9. Economizer – this uses waste heat to pass
*Backfire – positive furnace pressure
to the chimney to pre-heat feed water. This
3. Tubes – these are narrow pipes that also increases the efficiency of the steam
connect boiler heads. Tubes act as a passage generating system of the boiler.
in Fire Tube boilers and water or steam in
10. Super heater – a device used to convert
Water Tube boilers where evaporation and
saturated steam or wet steam into dry steam.
steam generation take place in these tubes.
Reduction of moisture increases the internal
4. Baffle Plates – these are steel plates that energy of the steam and then thermal
block off the direct exit of flue gases to the efficiency.
chimney. Baffles make flue gas paths longer
11. Deaerator – a deaerator is a device that
and zigzag around heating surfaces and
us widely used for the removal of air and
make boiler more efficient. This also
other dissolved gases from the feedwater to
supports tube banks.
steam generating boilers.
5. Grate – a grate consists of cast iron bars
12. Furnace – “fire box”. The primary part
on which solid fuel such as coal or wood is
of the boiler where the chemical energy
burnt. The air passes through the gaps
available in the fuel is converted into
between the bars and sustains the
thermal energy by combustion process.
combustion process of fuel. Ashes fall
Designed for efficient and complete
through the gate.
combustion.
Conveyors:
 Traveling Grate – used for fire that
Major factor of efficient combustion
burns slowly. Uses slag.
 Reciprocating Grate – used for fire  time of fuel inside the furnace
that burns fast.  temperature inside the furnace
  mixing of coal and air 6. Fusible Plug – if the water level in the
boiler falls below the predetermined level,
*Another important feature of the the boiler shell and tubes will be overheated.
construction of the furnace is to reduce the
air infiltration 7. Blow-off Cock / Blowdown valve – the
water supplied to the boiler always contain
impurities like mud, sand, and salt due to
Types of Furnaces heating, these are deposited at the bottom of
the boiler, they must be removed using a
1. Dry bottom furnace blow-off cock.
2. Slag type or wet bottom type furnace
3. Oil fired furnace *Surface blowdown
*Bottom blowdown

13. Boiler Drum – the secondary part of the

boiler where the water absorbs the heat and Heat Loss in Boiler
is converted into steam, that steam is sent to
the turbine after reheating by the super 1. Heat loss due to un-burnt Carbon
heater.
-This loss can be reduced by using of proper
grinded fuel
Main Parts of Boiler 2. Heat loss due to flue gasses
1. Pressure Gauge – indicates the pressure of -This heat can be minimized by completely
the steam in the boiler. utilizing the heat of flue gases.
2. Water Level Indicator – indicates the 3. Heat loss due to moisture in the fuel
water level in the boiler.
-For minimizing this loss, we must use dry
3. Safety Valve – prevents the increase of fuel as possible
steam pressure boiler above its design
4. Heat loss due to surface radiation
pressure
-This heat loss can be minimized by proper
4. Steam Stop Valve – (6-8 inches diameter)
maintenance of the furnace
regulates the flow of steam supply outside.
The steam from the boiler first enters an
antpriming pipe where most of the water
Boiler Fuels
particles associated with steam are removed.
1. Solid Fuels – wood, palm shell, coconut
5. Feed Check Valve – high-pressure feed
shell, rice husks, bagas, corn cob, coal,
water is supplied to the boiler through this
briquette
valve. This valve opens towards the boiler
and feeds the water to the boiler. 2. Oil Fuels – diesel, bunker, gasoline, low
sulfur heavy stock (LSHS)
3. Gas Fuels – natural gas, propane gas, 9. Actual specific evaporation or boiler
liquid petroleum gas economy
4. Nuclear Fuels – Uranium is the most 10. Boiler Efficiency
widely used fuel in nuclear power plants for
nuclear fission. Nuclear power plants use a
certain type of uranium—U-235—as fuel Kayo na po bahala sa mga formula😊
because its atoms are easily split apart.
Although uranium is about 100 times more
common than silver, U-235 is relatively rare
at just over 0.7% of natural uranium.

When designing a boiler consideration is

given to
 cost of fuel
 availability of fuel
 efficiency of fuel
 burning characteristics if fuel

Boiler Efficiency
 Boiler horsepower is the amount if
energy
 Latent Heat of Vaporization

Method of rating a boiler

1. Heat supplied
2. Rated boiler horsepower
3. Developed boiler horsepower
4. Percent rating
5. Factor of evaporation
6. Equivalent Evaporation
7. ASME evaporation unit
8. Specific factor of evaporation