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THE AUTHOR
is an Assistant Professor of Marine Engineering and Naval Architec-
ture at the Faculty of Engineering, Alexandria University. He graduated
with a Bachelor of Science degree from Cairo University in 1943. A
Master of Science degree in Naval Architecture and Marine Engineer-
ing was received in 1941 from the University of Michigan, U.S.A. F m
Kings College, University of Durham, U.K., he received a Doctor of
Philosophy degree in Naval Architecture in 1959.
.
SCOTCH eoiLt~
HLAOER TYPE
MULT !-DRUM
MARINE BOILER TYPES
DRUM T Y P E
TWO-DRUM
CONTROLLED
CIRCULATION
SUPERCHARGED
SEPARATELY flRCD
BAHGAT
*
DlSTRl BUT1 M G
SUPERHEAT ER
COMPLCTE WATCR
such way the boilers could be set on the
engine room lower level. It also allows for
almost uniform expansion of all pressure
HEADER T Y P t COOLEO FURNACE
parts since the furnace has nearly cubic
Figure 1. configuration.
SepamteZy Fired Superheater Boilers: In a
more quickly in starting. This calls for smaller tube way to control the steam temperature for
diameters, higher furnace ratings as well as greater large steam outputs it is usually simple and
application of water cooled furnace. more economical to use two-furnace type
Many varieties of water tube boilers have been boilers incorporating one main and one
developed to meet the advancement in turbine pro- auxiliary furnaces. These boilers may be
pulsion machinery requiring higher pressures, either of the single or double uptake types.
greater evaporation capacity and increased effi- Controlled Circulution Boilers: For more ad-
ciency. These types can generally be set under the vanced high steam conditions; positive or forced
following categories: - circulation inside the tubes offers important ad-
Sectional Header Boilers: These are also known vantages; namely limited space and compactness
as the cross-drum boilers with their straight tubes together with relatively light weight [23.
being ideal for mass production. Their limitation Supercharged Boilers: Another alternative for the
as regards space and weight, however, has been advanced steam conditions is the pressure-fired
demonstrated in a previous paper [ll. boilers known previously as the Velox or Sural
Bent Tube Boilers: These, in turn, cover a wide boilers employing the natural circulation prin-
range of designs which are based essentially on ciple. In this type, however, a supercharger is set
the natural circulation principle. to replace the forced draft blowers 13, 4, 51.
The Muttidrum Express Type: This being the The main advantages of this system being in the
early type of bent tube boilers of which the reduction in both space and weight, economy of
three-drum, A-type or Admiralty boilers have operation, simplified construction as well as reduc-
been fully explained in the literature. tion in maintenance. Some disadvantages are, how-
The T w o Drum Type: This is the type most ever, encountered mainly that because of the use
suited for merchant ships of both normal and of a gas turbine, distillate fuel has to be used; be-
high powers. These can be classified, in turn, sides since an integral unit construction is adopted
into: any flaws in its construction becomes exceedingly
(a) Horizontal Superheater Type: difficult to correct.
This is known generally as the D type
boiler with its superheater, of the continuous
loop type, fitted horizontally between rows REQUIREMENTS FOR FURNACE DESIGN
of bent tube screen tubes and the main tube In order to start the furnace deaign calculations
bank. and to allow the determination of the boiler firing
(b) Vertical Superheater Type: rates; the following items must be known or esti-
This has been developed in a way to have mated. The firing rates, however, allow the prelimi-
easy access to the superheater for both in- nary estimate of the furnace size as well as its heat
spection and cleaning as well as to avoid the release and absorption rates.
horizontal slag collecting surfaces which re-
sult in damage caused by slag deposits. This Steam Conditions
design also makes use of clean lanes for In a paper by D. C. MacMillan and M. L. Ireland
effective soot blower action as well as the re- [61, it was concluded that steam conditions of 450
duction of the bulky superheater support. psi and 750F would be normally selected for mer-
Moreover, vertical superheater boilers may chant ship installations of about 6000 SHP. Steam
be either of the conditions of 600 psi and 850F would normally be
Distributing Header Type: selected for higher powers. The use of %O0F super-
By the use of a separate header fitted heat temperature hardly appears to be worth the
to the lower end of the screen tubes the risk.
the rest of the boiler parts and thus optimization height; while for bent tube boilers, they are cus-
could be easily effected. tomarily arranged in clusters so as to reduce the
furnace size. The minimum burner clearances were,
Operation and Service Conditions however, given in reference C11 and in this respect
Not only the furnace dimensions but also the type it should be noted that the proximity of the oil
and number of burners as well as the radiant heat burner to the screen tubes affects to a great extent
surface could be decided upon by consideration of the final steam temperatures. Nevertheless, the
the service condition. The operating conditions en- furnace dimensions must be selected in such a way
countered during the ships service also influences as to allow as nearly a uniform gas flow as possible
directly the boiler and its furnace dimensions. entering the screen tubes. Previous experience on
Moreover, the load pattern and its variation as well similar boilers would help greatly in this respect
as the ships trade route schedule affects the choice thus securing nearly uniform gas temperatures.
of the optimum boiler design. It has to be noted in
this respect that most marine boilers are adapted Amount of Furnace Waterwalls
to wide variations in the load pattern. The furnace dimensions are usually selected to
Furthermore, the availability of the operating provide the maximum amount of water wall heating
personnel in what affects both boiler maintenance surface which in turn renders an appropriate fur-
and repair is not to be underestimated. nace heat release and heat absorption rates.
On drum type boilers the supply tubes to the
Space and Weight Limitations furnace waterwalls take water either from the
Space and weight restrictions are extremely im- steam drum or receive water from the water drum
portant on most ships and they are influenced still directly or through the distributing header. The
by the type of boiler used. furnace roof is usually formed by the side wall
On sectional header boilers, for example, maxi- tubes which discharge directly into the steam drum;
mum efficiency is obtained with maximum height while the furnace rear wall tubes generally termi-
and length together with minimum width; while nate in headers connected to the steam drum. On
from maximum weight considerations this is ar- some boilers especially of the higher evaporation
rived at by high, long and narrow boilers. rates front wall tubes can be used.
On the other hand, for drum type boilers from
Circulation in Furnace Waterwalls
maximum efficiency and minimum weight points of
view maximum furnace height together with mini- In the design of the furnace waterwalls satisfac-
mum furnace depth coupled with maximum num- tory water-steam ratio in the wall tubes must be
ber of tube rows are required. Height restriction on provided in order to relieve the generated steam.
a particular design, therefore, may result in in- This is usually in the order of 15 to 20 at the over-
creased boiler weight as well as furnace floor space all rates of operation of merchant ship boilers: while
hence increased boiler cost. It thus follows that a on naval designs the range is between 5 and 10 in
compromise must be made for any particular design. a way to reduce boiler size and weight.
In analysing the boiler circulation, however, the
Burner Arrangements and Gns Flow U-tube analogy is usually adopted as base for the
Since the marine boiler furnace is actually built circulation calculations from which it can be de-
around it4 burners; it is thus essential that the duced that when the heat is applied at the lower
number and type of burner must first be deter- portions of the tube maximum circulation effect is
mined. obtained. This is the case with the distributing
Each burner type has its own operating charac- header type boiler in which the burners are located
teristics and the boiler furnace must be so designed at the lower part of the furnace. In this type of
as to suit those characteristics. The use of wide- boiler, as mentioned previously, the furnace di-
angle oil sprays shortens the flame and concentrates mensions could be set at the optimum values since
the products of combustion at the boiler front and the furnace is set independent of both the lower
thus reduces the steam temperature; while the use drum as well as the main tube bank.
of the narrow-angle oiI sprays directs the flame
towards the rear of the fumace reducing the gas FURNACE RATES A N D GAS TEMPERATURES
flow into the gas cavity in wont of the superheater
thus increasing the steam temperature. Once the preliminary furnace size and contour
One of the well known burner types is the return are decided upon taking due account of the various
flow type using wide range firing to meet changing factors treated previously; it is then possible to
load imposed by the ships operation. The burner estimate both the furnace heat release and absorp-
overload capacity, however, usually ranges to about tion rates as well as the furnace exit gas tempera-
1,500 and 2,500 pounds of fuel oil per hour. ture
Burner arrangements are also affected by the type In a previous paper 113 the merits of the differ-
of boiler. The burners in sectional header boilers are ent furnace ratings were discussed; three of which
usually arranged in line in a way to limit the boiler are of particular value in furnace design namely;
the heat release rate (H.R.R.), the heat absorption for various heat absorbing rates is given for both
rate (H.A.R.) and the liberation per cu. ft. of fur- the steam condition of 450 psi, 750F and 600 psi,
nace volume. Need is required, a priori, of the radi- 85O0F; while on (Figure 5) the same relation is
ant heat absorbing surface area (R.H.A.) which has shown at various furnace exit gas temperatures for
been previously defined in the same paper and the same steam conditions with feed water tempera-
which is largely determined by the furnace water ture of 250OF. Moreover, (Figure 6) gives the rela-
walls and the screen tubes within the furnace di- tion between the furnace exit gas temperature and
mensions. the boiler evaporation rating at various radiant heat
The furnace heat release rate, however, is pri- surface area.
marily determined by the burners firing rate as Finally, the liberation in BTU released per cu.
well as the radiant. heat absorbing surface. This ft. of furnace volume can be readily calculated after
should be so selected as to result in good combus- the furnace dimensions have been settled on.
tion conditions as well as minimum boiler size. The
heat absorption rating, on the other hand, is for all
practical considerations a function of the heat re-
lease rating as mentioned in reference 181.
Moreover, the furnace exit gas temperature is
determined by the heat remaining in the exit gases
leaving the furnace or in other words the radiant
heat not absorbed by the furnace and the relation
is derived from test data. This has been the topic
of a previous paper by the author CBI. A mean line
has been considered in that paper and the results
are reproduced on (Figure 3) giving the relation
between both the heat release and heat absorption
rates on a base of furnace exit gas temperatures for
boilers working with 15 per cent excess air.
Figure 5.
130 450
15% EXCESS NPIUCAN LINE1
120 *L ,
420
I.380
L
I-
c
9 340
3
ZJOO
0
P a0
x
=
- .- - - r.220
I
iao
rUQNACE G4S TEWCRLTURL F
so uo
2300 Lux) rn 2800 2?00 zm ZSW
Figure 3. Figure 6.
11
'I
. . . .
0
. . . .
1 E \IrPoRC.rlon! L B p l ~ 1 0 0 0
9 20 30 u1 5Q 60 70 M 90
Figure 9.
8 120
, I20
110 -_. . . . , . , . .
.,./
. 0
. ~ 110
5
BAHCAT MARINE BOILER FURNACE DIMENSION
First Step of 90,000 BTU per sq. ft. RHA per hour with a
A straight line relationship between the furnace straight line relationship being considered for the
width and the evaporation rate is considered in this intermediate values.
treatment; while fixing both the furnace breadth As for the lower evaporation value for the 450
as well as the distance between drum center lines, psi steam condition; the heat absorption rating was
(fixed here at 12 ft.-6 in. for the 450 psi steam con- left to be computed from the calculations in the
dition and 14 ft.-6 in. for the 600 psi steam con- following manner.
dition) so that the standardized boilers only differ On Figure 3 point A is fixed with the assump-
in the furnace width or else the length of the steam tion of an absorption rating of 75,000 BTU/sq.
ft. RHA/hr.; while point B is fixed with the adap-
drum adopted to suit each evaporation. Minimum
tion of a minimum furnace width of 6 ft.-3 in. A
furnace widths (taken 6 ft.-3 in. for 450 psi and straight line relationship between point A and B
6 ft.-6 in. for 600 psi steam conditions) were con-
would consequently render a straight line relation-
sidered for the lower evaporation rates of 25,000
ship of furnace width (Figure 14) as well as fur-
lb. per hour and 50,000 lb. per hour respectively.
nace volume (Figure 12) versus evaporation rating.
This in turn would render a straight line relation-
ship between the RHA as well as the furnace vol- In such manner the anticipated heat absorption
ume and the evaporation rating as shown on Fig- rating for other evaporation rates a t the 450 psi
ure 11 and Figure 12 respectively for each Of steam condition could be computed as shown on
the two steam conditions selected. Figure 13,
160
120
280
!40
. . . . . . . , . .
200 EVhBDRATIOY $ W H R XlDOO I !OO
20 30 40 50 so 70 80 YO Figure 13.
Figure 11.
12 12
lloo ,
1 . . .
l1 I
Figure 14.
Third Step:
Second Step: Once the relation between the RHA as well as
A heat absorption rating is next selected arbi- the furnace volume and the evaporation rating is
trarily for both the chosen higher evaporation value established for the standardized boilers, both the
of the 450 psi steam condition (60,000 pounds per heat release rating in BTU per sq. ft. RHA per hour
hour) as well as the evaporation rate for the 600 as well as the heat liberation in BTU per cubic foot
psi condition (50,000 lb. per hour); namely 75,000 furnace volume per hour could be calculated for
BTU per Square foot RHA per hour (Figure 13). both steam conditions a t various evaporation ratings
The selected higher evaporation value for the 600 as drawn on both Figure 15 and Figure 16 re-
psi steam condition (90,000 lb. per hour) was also spectively at the boiler full load condition.
fixed at an arbitrary value of heat absorption rating The furnace exit gas temperature can next be