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A boiler is a closed vessel where water or other liquid is heated. The fluid does not boil. (In THE UNITED STATES, the term "furnace" is generally used if the purpose is not to boil the fluid.) The warmed or vaporized liquid exits the boiler for use in various heating or procedures applications,[1 - [2 - including water heating, central heating system, boiler-based power generation, cooking, and sanitation.

Materials The pressure vessel of the boiler is usually manufactured from steel (or alloy steel), or historically of wrought iron. Stainless steel, especially of the austenitic types, is not found in wetted elements of boilers credited to corrosion and stress corrosion cracking.[3 - However, ferritic stainless steel is often found in superheater sections that will not come in contact with boiling water, and electrically heated stainless shell boilers are allowed under the Western 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 easier fabricated in smaller size boilers. Historically, copper was often used for fireboxes (particularly for steam locomotives), due to 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 metal) are used instead.

For much of the Victorian "age group of steam", the only materials used for boilermaking was the best quality of wrought iron, with set up by rivetting. This iron was from specialist ironworks, such as at Cleator Moor (UK), noted for the high quality of their rolled plate and its suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice relocated towards the use of steel instead, which is stronger and cheaper, with welded construction, which is quicker and requires less labour. It should be observed, however, that wrought iron boilers corrode far slower than their modern-day steel counterparts, and are less vunerable to localized pitting and stress-corrosion. This makes the durability of old wrought-iron boilers far superior to those of welded metal boilers.

Cast iron might be utilized for the heating vessel of local drinking water heaters. Although such heaters are usually termed "boilers" in some countries, their purpose is to produce warm water usually, not steam, and they also run at low pressure and stay away from boiling. The brittleness of cast iron helps it be impractical for high-pressure steam boilers. Boiler Repairs Deptford, SE8, Boiler Breakdown Emergency Service http://boiler-repairs-deptford.co.uk - More info! Energy The foundation of heating for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric steam boilers use level of resistance- or immersion-type heating elements. Nuclear fission is utilized as a heat source for generating steam also, either directly (BWR) or, generally, in specialised temperature exchangers called "steam generators" (PWR). High temperature recovery steam 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 -direct approach to boiler efficiency test is more useful or even more common

boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam movement Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of feed water in kcal/kg q= quantity of energy 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 gas (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 gasoline 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" in which a fireplace heats a partially filled water pot from below. 18th century Haycock boilers generally produced and stored large volumes of very low-pressure vapor, often hardly above that of the atmosphere. These could burn wood or frequently, coal. Efficiency was very low. Flued boiler with one or two large flues-an early type or forerunner of fire-tube boiler.

Diagram of a fire-tube boiler Fire-tube boiler: Here, water partially fills a boiler barrel with a small volume remaining above to accommodate the steam (steam space). This is the type of boiler used in all steam locomotives nearly. Heat source is in the furnace or firebox that needs to be kept completely surrounded by the water in order to keep up the heat range of the heating system surface below the boiling point. The furnace can be situated at one end of the fire-tube which lengthens the road of the hot gases, thus augmenting the heating surface which may be further increased by making the gases invert direction through another parallel pipe or a lot of money of multiple tubes (two-pass or return flue boiler); additionally the gases may be studied along the sides 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 go through a lot of money of fire pipes inside the barrel which greatly escalates the heating system surface compared to a single tube and further increases heat transfer. Fire-tube boilers have a comparatively low rate of steam creation usually, but high steam storage capacity. Fire-tube boilers mainly burn solid fuels, but are readily adaptable to the people of the gas or liquid variety.

Diagram of a water-tube boiler. Water-tube boiler: In this kind, tubes filled with drinking water are arranged in the furnace in a genuine quantity of possible configurations. Usually the water pipes connect large drums, the low ones containing water and the upper ones water and steam; in other instances, such as a mono-tube boiler, water is circulated with a pump through a succession of coils. This kind generally provides high steam production rates, but less storage capacity than the above. Water tube boilers can be made to exploit any warmth source and are generally preferred in high-pressure applications since the high-pressure drinking water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall structure. Flash boiler: A flash boiler is a specialized kind of water-tube boiler where pipes are close together and water is pumped through them. A flash boiler differs from the type of mono-tube vapor generator in which the pipe is permanently filled up with water. In a flash boiler, the pipe is held so hot that the water give food to is quickly flashed into steam and superheated. Flash boilers got some use in automobiles in the 19th century which use continued into 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 next manner: the firebox includes an assembly of water tubes, called thermic siphons. The gases then pass through a conventional firetube boiler. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have fulfilled with little success in other countries. Sectional boiler. In a solid iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside cast iron sections.[citation needed - These sections are assembled on site to generate 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 instance, the ASME Boiler and Pressure Vessel Code is a typical providing an array of guidelines and directives to ensure compliance of the boilers and other pressure vessels with basic safety, security and design standards.[5 -

Historically, boilers were a way to obtain many serious injuries and property destruction as a consequence to poorly understood engineering principles. Thin and brittle metal shells can rupture, while badly welded or riveted seams could start, resulting in a violent eruption of the pressurized vapor. When water is converted to steam it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres per hour. As a result of this, vapor is a great way of moving energy and high temperature around a niche site from a central boiler house to where it is needed, but with no right boiler give food to water treatment, a steam-raising flower are affected from scale corrosion and formation. At best, this boosts energy costs and can result in poor quality steam, reduced efficiency, shorter vegetation and unreliable procedure. At worst, it can lead to catastrophic loss and failing of life. Collapsed or dislodged boiler pipes can also spray scalding-hot vapor and smoke out of the air intake and firing chute, injuring the firemen who weight the coal in to the fireplace chamber. Extremely large boilers providing a huge selection of horsepower to use factories could demolish entire buildings.[6 -

A boiler that has a loss of feed water and it is permitted to boil dry out can be extremely dangerous. If give food to water is then sent into the bare boiler, the small cascade of inbound drinking water instantly boils on contact with the superheated metallic shell and leads to a violent explosion that cannot be controlled even by safety steam valves. Draining of the boiler can also happen if a leak occurs in the steam supply lines that is larger than the make-up drinking water supply could replace. The Hartford Loop was developed in 1919 by the Hartford Steam Boiler and Insurance Company as a method to help prevent this problem from occurring, 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 heat; that is, saturated vapor. Superheated steam boilers vaporize water and further heating the steam in a superheater then. This provides steam at higher temp, but can decrease the overall thermal efficiency of the vapor generating place because the bigger steam temperature takes a higher flue gas exhaust heat range.[citation needed - There are many ways to circumvent this problem, typically by providing an economizer that heats the give food to drinking water, a combustion air heating unit in the hot flue gas exhaust path, or both. You will find advantages to superheated vapor that may, and often will, increase overall efficiency of both steam generation and its own utilization: benefits in input heat to a turbine should outweigh any cost in additional boiler complication and expense. There could be useful limitations in using wet vapor 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 escape, 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 extreme heat and sound from such a leak clearly indicates its presence.

Superheater operation is similar to that of the coils on an fresh 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 normally between 1,300 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 warmth from a liquid. Some are a combination 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 steam in the superheater rises, the pressure of the steam will not and the pressure remains exactly like that of the boiler.[9 - Virtually all steam superheater system designs remove droplets entrained in the steam to avoid harm to the turbine blading and associated piping.

Supercritical steam generator

Boiler for a power place. Main article: Supercritical steam generator Supercritical steam generators are generally used for the production of energy. They operate at supercritical pressure. In contrast 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 to occur; the fluid is neither water nor gas but a super-critical liquid. There is absolutely no generation of steam bubbles within the water, because the pressure is above the critical pressure point of which vapor bubbles can form. 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 power generator from which power is eventually extracted. The fluid at that time may be considered a mix of steam and liquid droplets as it passes into the condenser. This results in somewhat less gas use and therefore less greenhouse gas creation. The word "boiler" should not be used for a supercritical pressure steam generator, as no "boiling" occurs in this device. Boiler Repairs Deptford, SE8, Boiler Breakdown Emergency Service http://boiler-repairs-deptford.co.uk - Show more!.. Accessories Boiler fittings and accessories Pressuretrols to regulate the steam pressure in the boiler. Boilers generally have 2 or 3 3 pressuretrols: a manual-reset pressuretrol, which functions as a basic safety by setting the upper limit of steam pressure, the working pressuretrol, which handles when the boiler fires to maintain pressure, and for boilers outfitted with a modulating burner, a modulating pressuretrol which settings the quantity of fire. Safety valve: It is used to relieve pressure and stop possible explosion of the boiler. Water level indications: They show the operator the level of fluid in the boiler, also called a sight cup, water measure or drinking water column. Bottom level blowdown valves: They provide a way for removing solid particulates that condense and rest on underneath of the boiler. As the name indicates, this valve is usually located directly on the bottom of the boiler, and is sometimes opened up to use the pressure in the boiler to push these particulates out. Constant blowdown valve: This enables a small quantity of water to flee continuously. Its purpose is to avoid water in the boiler becoming saturated with dissolved salts. Saturation would lead to foaming and cause water droplets to be carried over with the vapor - a condition 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 tank. Most commonly entirely on a water boiler. Flash container: High-pressure blowdown enters this vessel where the steam can 'flash' safely and become used 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 system allows the boiler to blowdown only once makeup water is flowing to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the make-up water. No flash tank is generally needed as the blowdown discharged is near to the temperature of the makeup water. Hand openings: These are steel plates installed in openings in "header" to allow for inspections & installation of tubes and inspection of internal surfaces. Steam 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 utilized to turn off the burner or shut off energy to the boiler to avoid it from running once the drinking water runs below a certain point. If a boiler is "dry-fired" (burned without drinking water in it) it can cause rupture or catastrophic failure. Surface blowdown collection: It offers a means for removing foam or other lightweight non-condensible substances that tend to float together with the water inside the boiler. Circulating pump: It really is made to circulate drinking water back to the boiler after they have expelled a few of its heat. Feedwater check valve or clack valve: A non-return stop valve in the feedwater collection. This may be suited to the comparative aspect of the boiler, below water level just, or to the very best of the boiler.[10 - Top give food to: Within this design for feedwater injection, water is fed to the very best of the boiler. This can reduce boiler fatigue triggered by thermal stress. By spraying the feedwater over some trays the water is quickly heated and this can reduce limescale. Desuperheater tubes or bundles: Some tubes or bundles of tubes in water drum or the vapor drum made to cool superheated steam, in order to supply 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 steam stop valve: Steam traps: Main steam stop/check valve: It can be used on multiple boiler installations. Combustion accessories Energy 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 dish: Registration plate: