BOILERS

Eng. W.M. SATHYAJITH KANDEGAMA

MARCH 2010
THIS IS A BOILER
ENERGY SOURCE
ADDING ENERGY TO BOILER
AFTER ADDING THE ENERGY
ADDING THE ENERGY FURTHER
STEAM GRNERATION
ADDING HEAT ENERGY
INTRODUCING MAIN STEAM
VALVE
INTRODUCING SAFETY VALVE

V-10
INTRODUCING OF PRESSURE
GAUGE

V-32

I-13

V-31
INTRODUCING FEED WATER PUMP

V-9

I-12

V-4

E-1
INTRODUCING FEED WATER STOP
VALVE

V-7

I-11

V-8
V-6

E-2
INTRODUCING OF NON RETURN
VALVE

V-12

I-10

V-14
V-13
V-11

E-3
INTRODUCING OF WATER LEVEL
CONTROLL
V-16

I-9

P-1

V-18
V-17
V-15

E-4
DECIDING THE NORMAL WATER
LEVEL
V-20

I-8

P-2

V-22
V-21
V-19

E-5
INTRODUCING WATER LEVEL
GLASS
V-24

I-7

P-3

V-26
V-25
V-23

E-6

I-2 I-3
INTRODUCING OF WATER LEVEL
LOW AND EXTRA LOW
CONTROLLERS
V-28

I-6

P-4

V-30
V-29
V-27

E-7

I-4 I-5
INTRODUCING OF BLOW DOWN
VALVE
V-35

I-16

P-6

V-37
V-36
V-34

E-9

I-14 I-15

P-7

V-38
INTRODUCING OF BURNER
CONTROLL PRESSURE SWITCH
I-21

V-40

I-20
I-19

P-8

V-42
V-41
V-39

E-10

I-17 I-18

P-9

V-43
BOILER WITH BASIC
INSTRUMENTS
P-13

V-45

PC H/L PI

P-14

V-46 I-28 I-22

V-47

E-12

P-11

P-12

V-48

E-11
BOILER CLASSIFICATION
BOILERS ARE CLASSIFIED BY,

• THE DESIGN
• NO. OF PASSES OF THE FLUE GAS
• TYPES OF FUEL USED
• LOCATION AND WAY OF FABRICATION
• CONDITION OF STEAM
CLASSIFICATION BY DESIGN
• FIRE TUBE
• WATER TUBE
• COMBINATION
• TUBELESS

CLASSIFICATION BY NO. OF PASSES

• SINGLE PASS
• TWO PASS
• THREE PASS
• FOUR PASS
CLASSIFICATION BY FUEL
• LIQUID FUEL • NUCLEAR
• GAS • WASTE HEAT
• SOLID • ELECTRIC
• MULTI FUEL

CLASSIFICATION BY LOCATION & METHOD OF

FABRICATION
• PACKAGE
• IN SITE
• HORIZONTAL
• VERTICAL
CLASSIFICATION BY CONDITION OF STEAM
• SATURATED STEAM
• SUPER HEATED STEAM
• HOT WATER
CONVENTIONAL THREE PASS BOILER
REVERSE FLAME 3 PASS BOILER
REVERSE FLAME 3 PASS BOILER-FRONT VIEW
 BOILER ACCESSORIES
• BLOW DOWN VALVE
• WATER LEVEL CONTROL
• WATER LEVEL GAUGE GLASSES
• FEED WATER PUMP
• PRESSURE CONTROLS
• PRESSURE GAUGES
• VALVES
• MAIN STOP VALVES
• CONTROL PANEL
• BURNER
• ECONOMISER
• WATER SOFTENER
Bottom Blow-Down Valve

•A bottom blow-down is
provided to discharge
sediments at the bottom of the
boiler
•This valve must be operated
regularly
•It is a quick opening valve
with specially fitted locking
guard which prevents removal
of the box-key unless the valve
is closed.
Blowdown Valve
Water Level Controls
•Two independent water level
controls are provided each
with different functions.
•One serves as a water level
control unit which maintains
the water level inside the
boiler as well as a 1st low
water alarm and cut-off.
•The other serves as a 2nd low
water alarm and lockout.An
extra High water alarm can be
provided on this unit.
Magnetic
Switch
Mobrey Chamber
Modulating Water Level Controllers
• Consists of a flange
modulating valve with twin
solenoid valve assembly,
and an electronic control
box.

Features :
- Inherently stable
- Easily adjusted for
individual operating
requirements
- Instant reversion to hand
control in emergency
Water Level Gauge Glasses
•Attached to the boiler by
independent stand pipes are two
water level gauges.
•It shows the true water level
inside the boiler
•The gauge glasses and seal rings
are consumable items and needs
to be replaced regularly.
Gauge Cock
Set
Gauge Cock
Boiler Feedwater Pump
•A boiler feedwater pump is
provided to supply make-up
water into the boiler.
•The pump operates at a high
head to overcome the pressure
resistance in the boiler.
•The pump is a vertical multi-
stage centrifugal type which is
normally mounted on the boiler
skid.
•Suction conditions of the pump is
very important to avoid cavitation
Pressure Controllers
•Two independent pressure
controllers are provided to
maintain the boiler pressure
within the safe working
level.
•One serves as a burner
on/off, high/low, or
modulating control unit
which controls the firing
level within the boiler.
•The other serves as a High
pressure cut-off in case of
excessive pressure.
The Boiler Pressure Gauge

•A Pressure Gauge is provided

to indicate the working
pressure in the boiler.
•The Pressure Gauge is of the
Bourdon Tube Industrial Type
and comes complete with a
steel syphon and a cock. The
syphon protects the gauge
from overheating.
The Safety Valve

•A Double Port High Lift

Safety Valve is provided to
relieve the boiler of excessive
pressure.
•This Valve will only come into
operation if the pressure
controls fail.
•The Valve is set to lift just
above the working pressure of
the boiler with one port set to
operate earlier than the second
port.
Safety
Valve
The Main Stop Valve

•A Boiler Main Steam Stop

Valve is provided to isolate the
boiler from the process.
•The valve seat is spring loaded
which also serves as a check
valve and prevents back flow
of steam into the boiler.
Main Stop Valve
The Boiler Control Panel

•The Control Panel contains

the motor contactors, the
fuses, indicating lamps,
operating switches, alarms,
and the main isolator switch.
•Operating switches fitted
are Burner on/off, Burner
low/auto, Feed Pump hand/
off/auto, 2nd low water reset
and mute, and Burner
lockout reset and mute.
The Water Softener

•A water softener is a simply a

vessel containing resins for ion
exchange whose main purpose
is to soften the water.
•Soluble bicarbonates of
calcium and magnesium break
downs to insoluble carbonates
when heated up contributing to
scale formation
•The resins convert calcium
and magnesium salts to a more
desirable form of sodium salts.
The Water Softener (Continued)

•When the resins becomes

saturated with calcium and
magnesium ions it has to be
regenerated with brine (NaCl)
solution.
•The four cycles of operation of
a water softener are Service,
Backwash, Regeneration, and
Rinsing.
•A softener is generally termed
as a Cation exchanger since it
allows exchange of positive
ions.
The Deaerator

•The Deaerator is an
equipment used for
removing dissolved
gases, specially oxygen,
that can cause corrosion
in the boiler system
•The principle of
deaeration is simply
heating up the water to a
temperature, normally
105°C, wherein the gases
are liberated.
The Deaerator’s PRV Station
 The Economizer.

An economiser is used to pre-heat boiler

feedwater using
the heat in the flue gases, thus providing the
boiler with
heated water
Features :
• Compact design, specially design to suit
existing boiler house
• Low flue gas & water side pressure drop
• Low maintenance costs
• Saving of 4%-6% of burner heat input depending
on boiler exit flue gas temperature
 The Economiser
(Continued)
Operational
Benefits :
Easier
Steaming Longer Boiler Increased
- by using Life Steaming
heated - reduces Capacity
“racking - can be used to
feedwater,t increase the
he stresses”caus steam
boiler reacts ed production
more readily by cold water above
to entering the previous
peak loads. hot maximum
boiler, thus outputs.
protecting the
The Chemical Dosing Unit

•The Chemical Dosing Unit injects

chemicals directly into the Boiler
water.
•It normally consists of a positive
displacement piston pump and a
chemical mixing tank.
•The rate of injection can be adjusted
trough the pump.
•Chemicals are injected for pH
control, corrosion inhibition, and scale
formation control.
System Schematic
VARIABLE SPEED DRIVE
VALVE PROVING WITH
HIGH/ LOW GAS PRESSURE
GAS
I.D.
GAS
PRESS.
SENSOR

LOAD
OIL SENSOR FLUE

OIL
PRESS. FUEL
SENSOR SERVO

E.G.A.

F.D. AIR
AIR PRESS. U.V
SERVO SENSOR

BOILER
STANDARD
SELF CHECK
& IR

VARIABLE SPEED DRIVE

0-10V OR 4-20mA

0-10V OR 4-20mA
OUTSIDE AIR
TEMP. DETECTOR
Range

Mk6 MM Mini Mk6 MM Mini Mk5 MM

MM fuel-air ratio control ü ü ü
3 parameter trim ü ü ü
Precise boiler load control ü ü ü
Burner management ü ü
UV Flame safeguard ü
Gas, oil & air pressure supervision ü
Remote monitoring and control ü ü ü
IR upload/ download ü ü ü
User display ¼ VGA 20x4 line 20x2 line
Servo motors
• Large and small
servos
– From 1.2 to 15 Nm
– From 0.89 to 11 ft.lbs

• Industrial servos
– From 98 to 400 Nm
– From 72 to 295 ft.lbs
Boiler load detectors
• Water
Temperature
Sensor
– 0 to 400°C
– 0 to 752 o F
• Steam Pressure
Sensor
– 0 to 64 Kpa
– 0 to 435 PSI
Fuel valves
Oil valves
• Material
– Mild steel nickel plate body
– Bronze bobbin
– Stainless steel bobbins for
special applications
• Formats
– Metering
– Spill-back/bypass

• Custom made oil valves

available upon request
Gas valves
• Material
– Mild steel, Nickel plated
drive shaft and stainless
steel disc as standard
• Fitting
– Screwed 0.5 to 3” NPT/BSP
– Flanged 2 to 6” 150lb/PN16

• Custom made gas valves

available upon request
Gas
proving
System

Valve proving sequence

Stage 1: Vent valve normally open or normally

closed.
 Valve proving sequence

Stage 2: Vent valve open to ambient pressure, zero

pressure between all valves.
 Valve proving sequence

Stage 3: Vent valve closed, test first safety shut off valve
(10 secs).
 Valve proving sequence

Stage 4: First safety shut off valve open, line pressure test.
 Valve proving sequence

Stage 5: Test second safety shut off valve and vent valve
(10 secs).
OIL BURNER - NOL125