BOILERS

PREPARED BY:- MASOOD-UR-REHMAN

TECHNICAL TRAINING CENTER

COURSE INTENTIONS
THIS COURSE
INTRODUCE
MAINTENANCE
MAINTENANCE
BOILER BASICS,
WORKING

HAS BEEN PREPARED TO

THE
MECHANICAL
PERSONNEL, INVOLVED IN
OF BOILERS, ABOUT THE
CONSTRUCTION AND THEIR

SPECIAL CONSIDERATION HAS BEEN GIVEN

TO B-605 AND B-601/B-602

COURSE OUTLINES
INTRODUCTION TO BOILERS
TERMINOLOGIES USED
MAIN COMPONENTS
AUXILIARY BOILER B-605
WASTE HEAT BOILER B-601/B-602
AUXILIARY BOILER B-4601
FIRE TUBE BOILERS
BOILER MAINTENANCE HISTORY
WATER TREATMENT TECHNIQUES

INTRODUCTION TO
BOILERS

WHAT IS A BOILER ?

THE BOILER IS A CLOSED HIGH

PRESSURE
VESSEL IN WHICH HEAT CHANGES WATER INTO
STEAM.
BOILERS ARE WIDELY USED IN INDUSTRY FOR
PRODUCTION OF HOT WATER AND STEAM

WHY WE USE WATER IN A BOILER ?

THE REASON BEING:
WATER IS A CHEAP MEDIUM
AVAILABLE EVERYWHERE
BOILS AT RELATIVELY LOW TEMPERATURE
NON-TOXIC, HAZARDOUS OR COMBUSTIBLE
ON BOILING IT VOLUME INCREASES ABOUT
1600 TIMES

CLASSIFICATION OF BOILERS
THERE ARE TWO MAJOR CLASSIFICATION OF
BOILERS

FIRE TUBE BOILERS

WATER TUBE BOILERS

FIRE TUBE BOILERS

WHEN BOILER WATER IS ON THE SHELL SIDE
OF THE BOILER IT IS CALLED FIRE TUBE
BOILER

ADVANTAGES OF FIRE TUBE BOILER

LOW INITIAL COST
FUEL EFFICIENT
EASIER TO OPERATE
PACKAGED DESIGN

DISADVANTAGES
LOW CAPACITY
LOW INITIAL COST
LOW PRESSURE
UNITS

AND

TEMPERATURE

LIMITATIONS
HIGH PRESSURES ARE DANGEROUS
POOR CIRCULATION
TUBE LEAKAGES AT HIGH TEMPERATURES

WATER TUBE BOILERS

WHEN BOILER WATER IS ON THE TUBE SIDE
OF THE BOILER IT IS CALLED WATER TUBE
BOILER

TYPICAL WATER TUBE BOILER

ADVANTAGES OF WATER TUBE BOILER

HIGH CAPACITY
HIGH PRESSURES AND TEMPERATURES
GOOD EFFICIENCY

DISADVANTAGES
HIGH INITIAL COST
OPERATIONAL DIFFICULTIES
HIGH MAINTENANCE COSTS

OTHER CLASSIFICATION CRITERIA

PRESSURE

FIRING METHOD

HIGH, MEDIUM AND

LOW PRESSURE BOILERS

FUEL USED

WATER CIRCULATION

FURNACE TYPE

FIRED OR UNFIRED BOILERS

COAL, OIL OR GAS
NATURAL OR FORCED
CIRCULATION
NATURAL, INDUCED OR
FORCED DRAUGHT

BASIC TERMINOLOGIES
CONDUCTION
CONVECTION
RADIATION
THERMO-SIPHON
BOILER CAPACITY
HEATING SURFACE
BOILER BLOW DOWN
DE-AERATION
CONVECTION SECTION

CONDUCTION
A METHOD OF HEAT TRANSFER IN WHICH
HEAT IS TRANSFERRED FROM ONE POINT TO
ANOTHER WITHOUT ACTUAL MOVEMENT OF
MOLECULES

CONVECTION
CONVECTION IS THE MODE OF HEAT
TRANSFER IN WHICH HEAT IS TRANSFERRED
FROM ONE LOCATION TO THE OTHER
THROUGH MOVEMENT OF MOLECULES

RADIATION
A METHOD OF HEAT TRANSFER THAT DOES
NOT REQUIRE ANY MEDIUM OR MOLECULES
FOR HEAT TRANSFER

THERMO-SIPHON
THE FLOW OF WATER (OR ANY LIQUID) FROM
A LOWER ELEVATION TO A HIGHER ELEVATION
DUE TO DIFFERENCE IN TEMPERATURE AT
TWO LOCATIONS

BOILER CAPACITY
IS THE QUANTITY OF STEAM PRODUCED PER
HOUR AND IT SHOWS IT SIZE. IT IS ALSO THE
QUANTITY OF WATER EVAPORATED IN ONE
HOUR. IT IS REPRESENTED IN TONNES PER
HOUR

HEATING SURFACE AREA

REFERS TO THE TOTAL AREA EXPOSED TO HOT
COMBUSTION GASES

CONVECTION SECTION
IS THE SECTION OF THE BOILER WHERE HEAT
IS TRANSFERRED TO THE MEDIUM THRU
CONVECTION

BLOW DOWN
IS THE DRAINAGE OF WATER FROM A BOILER
TO REDUCE THE LEVEL OF IMPURITIES AND
REPLACING IT WITH BETTER QUALITY WATER

DE-AERATION
DE-AERATION IS THE REMOVAL OF DISSOLVED
GASES ESPECIALLY OXYGEN FROM THE
DEMIN. WATER. THESE GASES (ESPECIALLY
OXYGEN) CAUSE CORROSION INSIDE THE
BOILERS AT HIGH TEMPERATURES

MAIN PARTS OF A BOILER

BOILER FURNACE
BURNERS
STEAM DRUM
BOILER BANK TUBES
SUPERHEATER
ECONOMIZER
FURNACE DRAUGHT SYSTEM

BOILER FURNACE
THE SECTION OF THE BOILER WHERE
FUEL IS BURNED TO GENERATE HEAT.
HEAT IS TRANSFERRED TO MEDIUM
THRU RADIATION IN THIS SECTION

BURNERS
THEY ARE LOCATED IN THE VERTICAL
WALL OF THE COMBUSTION CHAMBER
AND BURN FUEL.
BURNERS ARE DESIGNED FOR EFFICIENT
BURNING OF THE FUEL AND MAINTAIN
HIGH EFFICIENCY.

STEAM DRUM
STEAM DRUM IS A HIGH PRESSURE
VESSEL
WHICH
SERVES
MANY
FUNCTIONS IN A BOILER SUCH AS A
LARGE RESERVOIR FOR BOILER FEED
WATER,
CENTER
FOR
WATER
DISTRIBUTION AND SATURATED STEAM
COLLECTING
AND
SUPPLY
TO
SUPERHEATER.

BOILER BANK TUBES

THIS IS A BUNCH OF TUBES CONNECTED
TO STEAM DRUM (AND LOWER DRUM)
AND FALLS IN THE CONVECTION ZONE
OF THE BOILER.
THE WATER PARTIALLY EVAPORATES IN
THE BOILER BANK TUBES. IT CONTAINS
RISERS AND DOWN-COMERS.

SUPERHEATER
SATURATED STEAM FROM THE STEAM
DRUM RISES THRU DEMISTER PADS AND
ENTERS INTO A SERIES OF TUBES WHICH
ARE LOCATED IN THE BOILER FURNACE
RADIANT SECTION OR IN CONVECTION
SECTION BEFORE ENTERING BOILER
SECTION.

ECONOMIZER
ECONOMIZER IS A STEEL TUBE BANK
PLACED AT THE OUTLET OF THE BOILER
SECTION IN THE WAY OF FLUE GASES
BEFORE THEY EXIT.

FURNACE DRAUGHT SYSTEM

IT REGULATES THE FLOW OF AIR TO AND FROM
THE BURNER AND PROVIDES ENOUGH
AMOUNT OF OXYGEN REQUIRED FOR
COMBUSTION
IT
ALSO
FORCES
OUT
COMBUSTION GASES OUT OF THE FURNACE TO
THE EXHAUST DUCT.
A FORCED DRAFT SYSTEM USES A FAN TO
FORCE (OR PUSH) AIR THROUGH THE FURNACE
AN INDUCED DRAFT SYSTEM USES A FAN TO
DRAW (OR PULL) AIR THROUGH THE FURNACE.
BALANCED DRAFT SYSTEM IS SOMETIMES
USED WHICH UTILIZES BOTH FORCED AND
INDUCED DRAFT FANS.