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Boiler design & its

Construction

Moiz . A . Shamsi
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R What is a Boiler ?
equipment in which steam is generated

R Where is the generated steam used ?

generation of electric power
process requirements
heating requirements
R How steam is produced ?
Boiling
Water STEAM
temp

Heat
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Elementary Concepts
R Boiling
Process of vapor generation that take place in whole mass of a liquid,
bubbles forming inside the liquid and
on the surface
Boiling occurs at definite temp. & pressure.

R Temp. & Pressure relationship

T P (Charles Law)
R Heat Transfer
conduction
convection
radiation
R Steam
saturated
steam produced in the presence of water with which it is in a
state of equilibrium.
superheated
If additional heat is imparted to saturated steam without
changing the pressure so that it has no water vapors.
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Classification of Boilers
Boilers

Low Pressure Boilers H igh Pressure Boilers

P < 103 KPa P > 103 Kpa

Water Tube Boiler Fire Tube Boiler

Other Criteria
Basis Types

O Firing Method Fired or Unfired Boilers

O Water Circulation Natural or Forced Circulation

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Water Tube Boilers

When water is on the tube side of the boiler

Operation
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Main Parts of Water Tube Boiler

R Boiler Furnace
R Steam Drum
R Burner
R Risers & Down Comers
R Economizer
R Super heater
R Water Walls
R Furnace Draught System
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R Boiler Furnace
The section of Boiler where fuel is burned to generate heat. Heat is
transferred to risers through radiation.
R Steam Drum
Steam Drum is a high pressure vessel which serves as;
a large reservoir for Boiler Feed Water

center for water distribution

steam purifier

saturated steam collector & supplier to super heater

R Burners
They are located in the vertical wall of the combustion chamber and
burn fuel.
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R Risers & Down comers
Circulation in Boiler is directed
into definite paths by arranging
the tubes to form circuits for the
circulation. The tubes are
divided into 2 categories
Down comers
Risers

ODown comers located in cooler

regions of furnace
ORisers located in the hottest
zone of furnace.
OWater in risers is in 2 phase &
hence less dense than that of
down comers. Therefore, a
positive circulation is produced
due to density difference.
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R Economizer
Economizer is device which is used for heating the Boiler feed water
by means of the exhaust gases. Economizer ;
reduce losses of heat with the flue gases

cut consumption of fuel

improve the efficiency of the boiler installation
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R Super heater
It is used to superheat the
saturated steam.
saturated steam from the
steam drum rises through
demister pads and enters
into a series of tubes which
are located in the boiler
furnace convection section
First it passes through the
primary super heater & then
finally, the final super heater.
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R Water Wall Construction

A Boiler construction design in which water tubes are made
a part of floor, roof & walls of the furnace. Water walls;
Cool the flue gases in the furnace

Protect lining
Appreciably increase the steam generating capacity of unit
without increasing its dimensions.
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R Furnace Draught System

It regulates the flow of air to
and from the burner and
provides enough amount of
oxygen required for
combustion. It also forces out
combustion gases out of the
furnace to the exhaust duct.

A forced draft system uses a

fan to force or push air through
the furnace.
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Safety Measures in Boiler

Operation
R Boiler drum low level
R Low fuel gas pressure
R Low combustion air flow
R BFW Quality

Boilers in ECPL
R Utility -I
SG-621, 631, 641 60 KPPH @ 700 oF, 615 psig
R Utility - II
SG-681 150 KPPH @ 900 oF, 910 psig
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Heat Transfer is
from hot to cold
body

Heat Transfer
modes
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Effect of pressure
on boiling point

Effect of heat on
pressure & volume