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Jamesemuch JamesemuchOU ( boiler-repairs092@mail.ru ) aus JamesemuchDonnerstag, 18-01-18 00:05

A boiler is a closed vessel in which drinking water or other liquid is heated. The fluid will not boil. (In North America, the word "furnace" is normally used if the purpose is never to boil the liquid.) The heated or vaporized liquid exits the boiler for use in various heating or procedures applications,[1 - [2 - including drinking water heating, central heating system, boiler-based power era, food preparation, and sanitation.

Materials
The pressure vessel of the boiler is usually manufactured from steel (or alloy steel), or of wrought iron historically. Stainless steel, of the austenitic types especially, is not found in wetted elements of boilers due to corrosion and stress corrosion cracking.[3 - However, ferritic stainless steel is often used in superheater sections that won't be exposed to boiling water, and electrically heated stainless shell boilers are allowed under the Western "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 because it is easier fabricated in smaller size boilers. Historically, copper was often used for fireboxes (particularly for vapor locomotives), because of its better formability and higher thermal conductivity; however, in newer times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as steel) are used instead.

For a lot of the Victorian "age group of steam", the only material used for boilermaking was the best grade of wrought iron, with assembly by rivetting. This iron was from specialist ironworks, such as at Cleator Moor (UK), mentioned 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 transferred towards the utilization of metal instead, which is stronger and cheaper, with welded construction, which is quicker and requires less labour. It ought to be noted, however, that wrought iron boilers corrode significantly slower than their modern-day steel counterparts, and are less vunerable to localized pitting and stress-corrosion. This makes the longevity of old wrought-iron boilers significantly more advanced than those of welded steel boilers.

Cast iron may be used for the heating system vessel of domestic drinking water heaters. Although such heaters are usually termed "boilers" in a few countries, their purpose is usually to produce warm 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 vapor boilers.
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The foundation of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric vapor boilers use level of resistance- or immersion-type heating system elements. Nuclear fission is utilized as a heat source for producing steam also, either directly (BWR) or, generally, in specialised heat exchangers called "vapor generators" (PWR). Temperature recovery steam generators (HRSGs) use heat rejected from other processes such as gas turbine.

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

Immediate method -immediate approach to boiler efficiency test is more useful or even more common

boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam stream Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of give food to water in kcal/kg q= level 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 energy (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 fuel in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified in to the following configurations:

Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" in which a fire heats a partially filled water box from below. 18th century Haycock boilers generally produced and stored large volumes of very low-pressure steam, often barely above that of the atmosphere. These could burn off wood or frequently, coal. Efficiency was suprisingly low.
Flued boiler with one or two large flues-an early forerunner or kind of fire-tube boiler.

Diagram of the fire-tube boiler
Fire-tube boiler: Here, drinking water partially fills a boiler barrel with a little volume left above to accommodate the steam (vapor space). This is the type of boiler used in all steam locomotives nearly. Heat source is in the furnace or firebox that has to be held completely surrounded by the water in order to keep up the temperatures of the heating surface below the boiling point. The furnace can be situated at one end of a fire-tube which lengthens the path 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 lot of money of multiple pipes (two-pass or return flue boiler); on the other hand the gases may be studied along the edges and then beneath the boiler through flues (3-move boiler). In case there is a locomotive-type boiler, a boiler barrel stretches from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly escalates the heating surface in comparison to a single pipe and further boosts heat transfer. Fire-tube boilers will often have a comparatively low rate of vapor production, but high vapor storage capacity. Fire-tube boilers burn solid fuels mainly, but are readily adaptable to people of the gas or liquid variety.

Diagram of the water-tube boiler.
Water-tube boiler: In this type, tubes filled with water are arranged inside a furnace in a true variety of possible configurations. Water pipes connect large drums Often, the low ones containing water and the top ones water and steam; in other cases, such as a mono-tube boiler, water is circulated with a pump through a succession of coils. This type provides high vapor creation rates generally, but less storage capacity than the above mentioned. Water pipe boilers can be made to exploit any high temperature source and are generally preferred in high-pressure applications because the high-pressure water/steam is included within small diameter pipes which can withstand the pressure with a thinner wall.
Flash boiler: A flash boiler is a specialized kind of water-tube boiler where pipes are close jointly and water is pumped through them. A flash boiler differs from the kind of mono-tube steam generator where the tube is permanently filled with water. Super fast boiler, the pipe is kept so hot that the water give food to is quickly flashed into vapor and superheated. Flash boilers experienced 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 both above types have been mixed in the following manner: the firebox contains an assembly of water tubes, called thermic siphons. The gases pass through a typical 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. In a ensemble iron sectional boiler, sometimes called a "pork chop boiler" the water is included inside ensemble 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 such as the American Culture of Mechanical Designers (ASME) develop criteria and regulation codes. For instance, 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, security and design standards.[5 -

Historically, boilers were a source of many serious injuries and property destruction as a consequence to badly understood engineering principles. Thin and brittle metallic shells can rupture, while badly welded or riveted seams could open up, resulting in a violent eruption of the pressurized vapor. When drinking water is converted to steam it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres each hour. Because of this, steam is a superb way of moving energy and warmth around a site from a central boiler house to where it is needed, but with no right boiler feed water treatment, a steam-raising vegetable will suffer from size development and corrosion. At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter plant life and unreliable operation. At worst, it can lead to catastrophic loss and failure of life. Collapsed or dislodged boiler pipes can also spray scalding-hot steam and smoke out of 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 operate factories could demolish entire structures.[6 -

A boiler which has a loss of feed water and it is permitted to boil dry out can be hugely dangerous. If supply drinking water is sent into the empty boiler then, the small cascade of incoming water instantly boils on connection with the superheated metal shell and leads to a violent explosion that cannot be controlled even by security vapor valves. Draining of the boiler can also happen if a leak occurs in the vapor supply lines that is bigger than the make-up drinking water source could replace. The Hartford Loop was developed in 1919 by the Hartford Vapor Boiler and Insurance Company as a strategy to help prevent this problem from happening, 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 utilized at saturation temperatures; that is, saturated vapor. Superheated vapor boilers vaporize the water and then further heat the vapor in a superheater. This provides steam at higher temperature, but can reduce the overall thermal efficiency of the steam generating herb because the bigger steam temperature takes a higher flue gas exhaust temp.[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 heater in the hot flue gas exhaust path, or both. You can find advantages to superheated vapor that may, and often will, increase overall efficiency of both steam generation and its utilization: benefits in input heat to a turbine should outweigh any cost in additional boiler problem and expense. There could be practical restrictions in using moist steam 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 flee, the temperature and pressure can cause serious, instantaneous harm to anyone in its path. Since the escaping steam will at first be completely superheated vapor, detection can be difficult, although the intense 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 path in the boiler furnace. The temperature in this field is normally between 1,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are radiant type; that is, they absorb warmth by rays. Others are convection type, absorbing temperature 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 range of the vapor in the superheater rises, the pressure of the steam will 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 prevent damage to the turbine blading and associated piping.

Supercritical steam generator

Boiler for a power seed.
Main article: Supercritical steam generator
Supercritical steam generators are generally used for the production of energy. 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 no era of vapor bubbles within the water, because the pressure is above the critical pressure point of which vapor bubbles can form. As the liquid expands through the turbine stages, its thermodynamic condition drops below the critical point as it does work turning the turbine which turns the electrical generator that power is eventually extracted. The fluid at that time may be considered a mixture of vapor and liquid droplets as it passes into the condenser. This results in somewhat less gasoline use and therefore less greenhouse gas production. The word "boiler" should not be used for a supercritical pressure vapor generator, as no "boiling" occurs in this product.
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Accessories
Boiler fittings and accessories
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 upper limit of steam pressure, the operating pressuretrol, which settings when the boiler fires to keep pressure, as well as for boilers equipped with a modulating burner, a modulating pressuretrol which settings the quantity of fire.
Protection valve: It can be used to alleviate pressure and prevent possible explosion of the boiler.
Water level signals: They show the operator the amount of fluid in the boiler, known as a view cup also, water gauge or drinking water column.
Bottom level blowdown valves: They offer a way for removing solid particulates that condense and rest on underneath of a boiler. As the name indicates, this valve is usually located on underneath of the boiler, and is occasionally opened up to use the pressure in the boiler to push these particulates out.
Continuous blowdown valve: This allows a small quantity of water to flee 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 vapor - a condition known as priming. Blowdown is also often used to monitor the chemistry of the boiler water.
Trycock: a type of valve that is often use to manually check a liquid level in a tank. Most found on a water boiler commonly.
Flash container: High-pressure blowdown enters this vessel where in fact the vapor can 'flash' safely and become found in a low-pressure system or be vented to atmosphere as the ambient pressure blowdown flows to drain.
Automatic blowdown/continuous heat recovery system: This technique allows the boiler to blowdown only when makeup water is moving to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the make-up water. No flash container is normally needed as the blowdown discharged is close to the heat of the make-up water.
Hand holes: They are metal plates installed in openings in "header" to permit for inspections & installation of pipes and inspection of internal surfaces.
Vapor drum internals, a series of display screen, scrubber & cans (cyclone separators).
Low-water cutoff: It really is a mechanical means (usually a float switch) that is used to turn off the burner or shut down fuel to the boiler to avoid it from working once the 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 line: It provides a way for removing foam or other lightweight non-condensible chemicals that have a tendency to float on top of water inside the boiler.
Circulating pump: It is made to circulate drinking water back again 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 range. This may be fitted to the side of the boiler, just below the water level, or to the top of the boiler.[10 -
Top give food to: Within this design for feedwater injection, the water is fed to the very best of the boiler. This may reduce boiler exhaustion caused by thermal stress. By spraying the feedwater over a series of trays the water is quickly warmed and this can reduce limescale.
Desuperheater tubes or bundles: Some pipes or bundles of tubes in the water drum or the vapor drum made to cool superheated steam, in order to provide auxiliary equipment that does not need, or may be damaged by, dry out vapor.
Chemical substance 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 utilized on multiple boiler installations.
Combustion accessories
Gasoline oil system:fuel oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure measure attachment:
Name plate:
Registration plate:

 

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