Livre d'or - Page 31/207

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A boiler is a closed vessel in which water or other fluid is heated. The fluid does not boil. (In THE UNITED STATES, the word "furnace" is generally used if the reason is not to boil the fluid.) The heated or vaporized fluid exits the boiler for use in a variety of processes or heating system applications,[1 - [2 - including drinking water heating, central heating, boiler-based power era, cooking, and sanitation.

Materials
The pressure vessel of the boiler is usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel, of the austenitic types especially, is not found in wetted parts of boilers thanks to stress and corrosion corrosion cracking.[3 - However, ferritic stainless is often found in superheater sections that will not come in contact with boiling water, and electrically heated stainless steel shell boilers are allowed under the European "Pressure Equipment Directive" for production 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 because it is more fabricated in smaller size boilers easily. Historically, copper was often used for fireboxes (particularly for steam locomotives), because of 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 steel) are used instead.

For much of the Victorian "age group of vapor", the only material used for boilermaking was the highest grade of wrought iron, with assembly by rivetting. This iron was often obtained from specialist ironworks, such as at Cleator Moor (UK), observed 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 transferred towards the use of metal, which is stronger and cheaper, with welded structure, which is quicker and requires less labour. It should be observed, however, that wrought iron boilers corrode much slower than their modern-day metal counterparts, and are less susceptible to localized pitting and stress-corrosion. This makes the longevity of old wrought-iron boilers far more advanced than those of welded steel boilers.

Cast iron might be utilized for the heating system vessel of local water heaters. Although such heaters are usually termed "boilers" in a few countries, their purpose will be to produce hot water, not steam, and so they run at low pressure and stay away from boiling. The brittleness of cast iron helps it be 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 gas. Electric vapor boilers use resistance- or immersion-type heating elements. Nuclear fission is utilized as a heat source for producing steam also, either directly (BWR) or, in most cases, in specialised heat exchangers called "vapor generators" (PWR). Heat recovery vapor generators (HRSGs) use the heat rejected from other processes such as gas turbine.

Boiler efficiency
there are two solutions to gauge the boiler efficiency 1) direct method 2) indirect method

Direct method -immediate approach to boiler efficiency test is more functional 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 give food to water in kcal/kg q= quantity of fuel use in kg/hr GCV =gross calorific value in kcal/kg like pet coke (8200 kcal/KG)

indirect method -to measure the boiler efficiency in indirect method, we are in need of a subsequent parameter like

Ultimate analysis of fuel (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
Configurations
Boilers can be classified into the following configurations:

Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a open fire heats a partially filled water box from below. 18th century Haycock boilers produced and stored large amounts of very low-pressure steam generally, hardly above that of the atmosphere often. These could burn wood or frequently, coal. Efficiency was very low.
Flued boiler with a couple of large flues-an early type or forerunner of fire-tube boiler.

Diagram of the fire-tube boiler
Fire-tube boiler: Here, water partially fills a boiler barrel with a little volume remaining above to support the steam (vapor space). This is the type of boiler used in all steam locomotives nearly. The heat source is inside a furnace or firebox that needs to be kept completely surrounded by the water in order to keep the temp of the heating surface below the boiling point. The furnace can be situated at one end of a fire-tube which lengthens the road of the hot gases, thus augmenting the heating surface which may be further increased by causing the gases invert direction through another parallel tube or a bundle of multiple pipes (two-pass or come back flue boiler); alternatively the gases may be studied along the sides and then beneath the boiler through flues (3-pass boiler). In case of a locomotive-type boiler, a boiler barrel stretches from the firebox and the hot gases pass through a lot of money of fire tubes inside the barrel which greatly escalates the heating surface in comparison to a single pipe and further enhances heat transfer. Fire-tube boilers will often have a comparatively low rate of vapor production, but high vapor storage capacity. Fire-tube boilers mainly burn off solid fuels, but are readily flexible to people of the liquid or gas variety.

Diagram of the water-tube boiler.
Water-tube boiler: In this kind, pipes filled up with water are arranged inside a furnace in a true variety of possible configurations. Water pipes connect large drums Often, the lower ones made up of water and the upper ones steam and drinking water; in other situations, like a mono-tube boiler, water is circulated by a pump through a succession of coils. This kind gives high vapor creation rates generally, but less storage capacity than the above mentioned. Water tube boilers can be made to exploit any temperature source and are generally preferred in high-pressure applications because the high-pressure 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 type of water-tube boiler in which pipes are close jointly and drinking water is pumped through them. A flash boiler differs from the type of mono-tube vapor generator where the pipe is permanently filled with water. In a flash boiler, the pipe is kept so hot that water feed is quickly flashed into steam and superheated. Flash boilers got some use in automobiles in the 19th century and this use continued in to the early 20th century. .

1950s design steam 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 next manner: the firebox contains an assembly of water tubes, 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 fulfilled with little success in other countries.
Sectional boiler. Inside a solid iron sectional boiler, sometimes called a "pork chop boiler" water is included inside solid iron sections.[citation needed - These areas are assembled on site to make the finished boiler.
Safety
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Society of Mechanical Technical engineers (ASME) develop specifications and regulation rules. For example, the ASME Boiler and Pressure Vessel Code is a standard providing a wide range of rules and directives to ensure compliance of the boilers and other pressure vessels with basic safety, design and security standards.[5 -

Historically, boilers were a way to obtain many serious injuries and property destruction due to poorly understood engineering principles. Thin and brittle metal shells can rupture, while welded or riveted seams could start badly, resulting in a violent eruption of the pressurized steam. When drinking water is converted to vapor it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres each hour. Because of this, vapor is a great way of moving energy and high temperature around a site from a central boiler house to where it is necessary, but without the right boiler give food to water treatment, a steam-raising plant will suffer from size formation and corrosion. At best, this boosts energy costs and can result in poor quality steam, reduced efficiency, shorter plant life and unreliable procedure. At worst, it can result in catastrophic failure and loss of life. Collapsed or dislodged boiler pipes can also squirt scalding-hot vapor and smoke from the air intake and firing chute, injuring the firemen who weight the coal in to the fire chamber. Extremely large boilers providing a huge selection of horsepower to use factories can potentially demolish entire structures.[6 -

A boiler that has a loss of feed water and it is permitted to boil dry can be hugely dangerous. If nourish water is then sent in to the clear boiler, the small cascade of incoming water instantly boils on contact with the superheated metallic shell and leads to a violent explosion that cannot be controlled even by basic safety steam valves. Draining of the boiler can also happen if a leak occurs in the vapor source lines that is bigger than the make-up drinking water source could replace. The Hartford Loop was created in 1919 by the Hartford Steam Boiler and INSURANCE PROVIDER as a method to help prevent this condition from taking place, and thus reduce their insurance claims.[7 - [8 -

Superheated steam boiler

A superheated boiler on the steam locomotive.
Main article: Superheater
Most boilers produce steam to be used at saturation heat; that is, saturated steam. Superheated steam boilers vaporize water and additional heat up the steam in a superheater then. This provides vapor at higher heat, but can reduce the overall thermal efficiency of the steam generating place because the bigger steam temperatures requires a higher flue gas exhaust heat range.[citation needed - There are several ways to circumvent this problem, typically by providing an economizer that heats the give food to drinking water, 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: gains in input heat range to a turbine should outweigh any cost in additional boiler complication and expense. There can also be useful limitations in using damp vapor, 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 escape, the high temperature and pressure can cause serious, instantaneous harm to anyone in its path. Since the escaping steam will initially be completely superheated vapor, detection can be difficult, although the extreme heat and sound from such a leak indicates its existence 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 route 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 glowing type; that is, they absorb high temperature by rays. Others are convection type, absorbing heat from a fluid. Some are a mixture of the two 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 of the vapor in the superheater increases, the pressure of the steam does not and the pressure remains the same as that of the boiler.[9 - Almost all steam superheater system designs remove droplets entrained in the steam to avoid damage to the turbine blading and associated piping.

Supercritical steam generator

Boiler for a charged power vegetable.
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 turns the electrical generator that power is ultimately extracted. The fluid at that point may be considered a mix of steam and liquid droplets as it goes by into the condenser. This leads to less fuel use and therefore less greenhouse gas production slightly. The term "boiler" should not be used for a supercritical pressure steam generator, as no "boiling" occurs in this product.
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Accessories
Boiler fittings and accessories
Pressuretrols to control the vapor pressure in the boiler. Boilers generally have two or three 3 pressuretrols: a manual-reset pressuretrol, which functions as a protection by setting top of the limit of steam pressure, the operating pressuretrol, which handles when the boiler fires to keep up pressure, as well as for boilers equipped with a modulating burner, a modulating pressuretrol which handles the quantity of fire.
Basic safety valve: It is used to alleviate pressure and prevent possible explosion of the boiler.
Water level signals: They show the operator the level of fluid in the boiler, also called a view cup, water gauge or drinking water column.
Bottom blowdown valves: They provide a means for removing solid particulates that condense and lie on underneath of the boiler. As the name suggests, this valve is usually located on underneath of the boiler, and is occasionally opened up to use the pressure in the boiler to force these particulates out.
Continuous blowdown valve: This allows a small level of water to escape continuously. Its purpose is to avoid water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause water droplets to be transported over with the steam - an ailment known as priming. Blowdown is also often used to monitor the chemistry of the boiler water.
Trycock: a kind of valve that is often use to manually check a liquid level in a container. Most commonly found on a water boiler.
Flash tank: High-pressure blowdown enters this vessel where the steam can 'flash' safely and be found in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown moves to drain.
Automatic blowdown/constant heat recovery system: This technique allows the boiler to blowdown only once make-up water is moving to the boiler, thereby transferring the utmost amount of heat possible from the blowdown to the make-up water. No flash container is generally needed as the blowdown discharged is close to the heat range of the makeup water.
Hand openings: They are metal plates installed in openings in "header" to permit for inspections & installation of tubes 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 fuel to the boiler to avoid it from jogging once the drinking water moves below a certain point. If a boiler is "dry-fired" (burnt without water in it) it can cause rupture or catastrophic failing.
Surface blowdown series: It provides a means for removing foam or other lightweight non-condensible chemicals that tend to float on top of water inside the boiler.
Circulating pump: It really is made to circulate drinking 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 line. This may be installed to the side of the boiler, below water level just, or to the very best of the boiler.[10 -
Top give food to: With this design for feedwater injection, the water is fed to the top of the boiler. This may reduce boiler fatigue triggered by thermal stress. By spraying the feedwater over a series of trays the water is quickly heated which can reduce limescale.
Desuperheater tubes or bundles: Some tubes or bundles of pipes in the water drum or the steam drum designed to cool superheated steam, in order to provide auxiliary equipment that will not need, or may be damaged by, dry steam.
Chemical injection line: A link with add chemicals for controlling feedwater pH.
Steam accessories
Main vapor stop valve:
Steam traps:
Main vapor stop/check valve: It is used on multiple boiler installations.
Combustion accessories
Fuel oil system:gas oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure gauge attachment:
Name dish:
Registration plate:

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