aizvane Pages - Shell Bators 1% | [Rosge your sake ann at any tine ba # youd, ouray lane se hnsorle on aunt, Nore armas cr bafound our Pracyigy nn nena YAN can Spirax aco come ce © won Hose ‘Steam Engineering Ttorials » The Bole House Shell Boilers ‘overview of the diferent types of shel bollr with layouts, heat and steam 250 considerations plus pressure and output limitations. re ube’ or smoke tbe bolls because he products of combustion pags tcugh the bole utes, which in Lam Yanafer hea! othe surourding blr wale ‘Several sien! combinations cube layut are used in shall oles, valving the numberof passes the heat ram he baller fumace wll useilly make before boing discharged Fiques 3.210 and 32.18 show a ypicl twe-pass salle contgwation. Figuie 2.2.18 shows a dy back blr whore the Mot gases are reversed bya reractory Fined chamber onthe cuter ping ofthe alle Dy back Seam p08 Wiser. ‘ed pas es Contstin gs: We Wat tk reel ter Seam ace ‘ed pas tes Contin pss: We Fig. 3241 Shall boler- Wot and ary back coniuatons Figue 3.2.19 shows a more eet method of oversing he hol aases tough a wel back baler coxiguration. The revere chambers contained ential waa the Bole. This allows fora grester het tester tes, as well 9s allwing the baler water to be heated tthe pot where the het fom the ‘umece ll be resiest- onthe end ofthe chamber wal Its inportat tomate hal the combustion gases should be cooled o atleast 420°C fr pain sel bers and 470°C or alloy steel bles before enter the reversal chamber. Temperatures in excess of hs wil cause overheating and caching ofthe tube end plates. The ble designer wil have ‘aken th ito consideration, andi isan imgertant pint if tarot ols ae being corscered Lancaster si biqutous and wore the predecessors ofthe sopitcated ang high elfen holes used loa liar Fibs developod the Lancashire bol in 844 rom Trvithic’ single flee Camis bol. Athough enya fw ae stlln operation they were ‘The Lancashieboleecorvised alge steel shall usually between 5-91 long tvaugh which passed two lrgetore fumace tubes called us. Pat ofeach ‘Wyo was corugated to aks up th expansion whon the belor became hs, arto proventcolapse uncer presse. A funace was instaled a he entrance to ‘each fe, al he ort end ofthe ble: Typically, the frnace would be wanged fo bun coal, being eter manually or aomataly stoked. hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspx waizvane Pages - Shell Balers “The hot gaseous prosues of combustion pass om the furnace trough the large-bore conugate es. Heal om the ho ue gases was transfered no the ator surounding hose thus “The Boller was ina brickwork song which was aranged to duct he hat gases emarging from tho fues dowrwares and benoath ths blr, trantatng Peat ttvough th bltom ofthe blr shal, and secondly back along te sides of the bol bor oxing trough the stack, ‘Thess two sid ducts met th back of he boar and fe nto the chin. ‘Ths passes wore an llonp! to exe! the maximum amount of energy fom the hol prot gases bear hay ware assed a atmoepho, Later he effe-ency was improved by tne ation a an economist The gas steam aftr he thie pass, passed trough the eccnaiser int the chimney. Tre ‘sconomiser hated the fedwator and esis in an improvement in thermal fone. (One ofthe asaavantages of he Lancashire bale was thal repeated heating ne colng of he bol, wth the resultant expansion and convaction tat occured, Upset he brckwerksating and ducting, This resulted in ho inflaton ofa which upset tne fumace aught. These bolts would now be very expensive Lo produce, due tothe lage amounts of mae used andthe labour requed to ale the brick sting ‘at Star Siley neve Marl pay stp rr es we ‘iam ewe aren onion Co ad Fig. 9.22 sneashie voter Capac ‘Snail tae Dimensions EEmbIy x 2m aan Tig x maar ‘put 100197 ‘st0 gh Presure Tpie beg wie T2berg Table 22.1 ‘Size range of Lancashire bolls ‘The lage size and water capecty af these bolls had a rumber 2 signleart advantages: + Sudden large steam demands, such 28 pitindng engne beng stared, coud easly be tleated because the resuting reduction in ole pressure released cools amount of lash steam fom the Boer water held salvation temperate bean aon, + The large volume of water rt hat rough thes ring ate migh vary widely, the ae of change af the water a a atively sow faadvater valve to malta the des water lve +The lo level alan was simply a float hat cescended itn ne water level, ad opened a pot oa roaches, + The lege water surface area nein othe steaming rate moat hat he rte a whieh steam was releases ram the surface oxgressd i toms of kg per aquare metre) wa kw sm whlle when a predctomined Lal was ‘This ow volt moat tha, oven with watr containing high concertos of Total Dissolved Sols (TDS), thre was plenty of apport othe tears and wate paces to separate andl dy steam to be supplied othe plan ‘As conte systems, tei, and manufacturing tecriques have become more sophisticated lable and cot eective, te design of blr plant has changes Economie sae (wo-pas, ty beck) ‘The twepass economic bole was nly about ral the sizeof an equivalent Lancashire boiler and ithad a higher thermal fcency. had etna ter shal containing two lage-orecoagated umace fuss acting asthe main cortbuaton chambers. The otf gases passed cu ofthe two func fae a the back ofthe bol into brickwork sting (ty cack) and were detected though a numoer of small-bars tubes aranged above the lagebore fumace Tues. ‘These smal bors tubes presenoda large heating surface to tho water The fo gases passe out ofthe boil a infront ad nto a induced draught fn, hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspxaizvane Pages - Shell Balers Fig. 323 Economie baler (w0-p988, ey back) apaeiy ‘Seah ‘ar Dimensions Tinto x 1dr —| Tmo 4 m daar ‘apt Too igh 15000807 Pressure Tp oa woe Tere 1 ‘e922 Econamic bal (hee pass, wat back) Afar. Jopment of he ecanamic baler was te reson of tree-ss vit back baler whic isa standard configuration n use toca, (see Figure 2.2.4, Steam a 150 a ose Fig. 624 Econo bllorhoo-pass, wot back) ‘This dosion has evalved ae material and manufacturing technology has advanced thinner mea bes were inveduced allowing mo tubes o be acommadate, the heat arsfrrtes to be Improved, and he bllrsthamselves te became mote compact “Typical host ransfer data fora throo-pass, wot back, economic baler shown in Table 3.2.3, ‘Bien of abe Teper operon of tal at wana Tapas Tie 1600 oe nd pss ‘am ore 25 ed poss ea 3607 ic Table 32:2 Heat transfer details of modem tives pass, wet back, economic bole Packaged baer In the early 18605, tho UK Minty of Fuslané Powor sponsored coarch int inroving baller pln. The outcome of his research was the packaged ole, 5 onthe thee-pass economic wet back ole, Mail, hase bolo were designe fo uke ol athor han os “Te packaged boris so cals because comes asa complete package wth bums, lvl carts, feedpump and al necessary alr itings and mourtigs. (Once delved ta sitet rogues ony the star, water, and clown pipework, fel suey and loreal cannoetion to be made for ito become oparaiona Development has also had a santicant elect onthe pysial sizeof bolls fora ivan output + Manufacurre ware to make th bolle aa aml a poeslalsto save on mstarle anc hance keep ther peauctcompative, + ficincy aded by making the baler ak smal a it pact ne smal te baler and tne lass its siface ara, th oss haat s lost othe “To some extent the universal auareneas ofthe need forneultio, anh high pero of modem insulating material, reduces his issue, hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspxaizvane Pages - Shell Bators space sv lb for other pu F9.925 Modem packagoa bate + Boless wen male aemensions (forthe same stear ete) er tobe lowe In eaptal cost Table 324 cemenstaias tis, and alee fact, ‘Sean Wotumatie | elease Boer Fast | tong | Diameter | ciency | heet rate tor. ‘ype | om | oH release | wate Surface wim | “ain Taacaatre | Coat | a0] 295 —| 7a 0 ‘oor Feonomie | Coa | 60 | 300_| 76 730 ox Packaged | os | 39 | 250 | a2 700 20 Paciaged | Gos | 38 | 25000 7600, ‘70 Table 324 Comparison of $000 kg/h oilers Volurtic hot leas Win") “This actors ealulates ty ving the total het input by tha vlume ef water inthe baler footie eats the quanty of etean released under maximum toad tothe amount of water in tn baller. The wer this number, the greater he aint of reserve anergy nthe bale, ‘Note thatthe Tau fora modem baller tlatve toa Lanceshie bole, s larger bya factor of almost eight, rceating aveducton in stored energy by a sina amount. This means tata reduced amcunt of store energy is aval in madem bole. This development ras been made possible by conto systems whieh respond uikly and it appropriate actions to safegian ne bolerandto salsty demars ‘teary lease rate kam) forwate paticles to separate rom Ihe star and produce dy steam, [Note the modem bot’ gure larger by a factor of almost ves, Ts means that ie fas opportanty forthe sopratin af steam and water crops, This s made much worse by water wih a high TDS level, and accurate cotol's essential foresee and he pro [A tes of mpl increasing fad, the bal wil experience a rediton of pressv', which nim, means that the dens of the steam f reduced, ard oven higher stam release ats wl occur and pogrssivly wate: steam is expoted Hom the Role Fourpass boos Fourpass unts are potty the most ermal ficient, but ful type and oparting codons may prevent their use, Whon his typeof units fred at low tr oan fal blow the these can leat sss cracks or fase win the Bole stuctre, Far inasa reasons, fourpase bles are oman with heavy fue lo oa, the heat transfer rm the eorbuton gates can be vor large, As aru the ext ve gs tempo acid don port, causing comation ofthe ues and ckmiey ar possibly af the bor Ast. The fou-pass Bol un i especialy age lose swings sudenly unusual hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspxaizvane Pages - Shell Bators Revers lame I tnme toler This sa varaton on conventional bole design. The combustion chambers in the frm ofa himbl, and the buner fires down the centre. The fame doues back onset thin the combustion chembarto com tothe rent f th Bol, Smoke oes auound ha thiol an pes the tie Gases tothe ea of te boiler an the chine. ibe arava flame baler Pressure ard oulplmtations of shel ype bors ‘The srosses that may be imzosed on the bolr a ited by naonl standards. Maximum stress wil accu rcurd the crcumforerce of cylinder. This is calla hoop’ or currant sires, The vale ofthis slrss canbe calculated ving Equation 3.2.1 PD o= 2x Equation 32.1 this thcker plates harder and may nse sss rloving wth plate tekness over 32 mm. (One ofthe proses in manufactaring 2 bole sin roling the plat forthe shell Bolemakers’ ls, as shown in Figures 3.2.7 and 3.2.8, canrol curve the ens of ha pate a wi ance, sve a at + Ralls B and ¢ are motorised pull the oate trough th als + The lle cannot curve te ance ofthe oat Fig. 827 ‘nen the potas are welds together andthe baller is pressurised, the shall il assume aerculeeross section. When ine baller taken one, th plates wl rover tatne'ae rolled’ shape. Tie cyolng can cause aque cracks 1 aocur ome distance away fom the shall wes Ite @ cause for oancem to bile Inspector wro wl perodcaly atk forall the belle laging fo be removed an then se a template to determine the accuracy of the dole shall cuatro fat \/ Fat pons Fig. 3.28 Possitle fatigue pots ona baler shel (Obviously. this problem sof more concer on bole that experince ale of eyelng. such as boing shutdown every right and then refed every maming Prose ination Heat varsfr trough the furace lubes is by conduction. ts ala that tick plate does nol conduct neat as quickly atin plat. Thicker ples ao alo to “This sof parila imporance in te furnace tubes whers the ame tomperatze may 80 up to 1 800°C, anda balance must be stuck between: hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspxaizvo016 Pages - Shell Balers + Athickor pa, which hs the stata strong to withstand the for gonaratd by peessur inthe eile “+ Athinne plate, wtih has th ait te rnetara moreauicly. “The equation tat connec plate thickness to structural strength s Equation 2.2.4 _ PD 2H caution 2.4 Euaon 32.1 shows tha ab he plate chnass outs ass, he sess create forthe same ole pressure ‘The equation tat connec pate thicknass te heal ranefor fs Cauation 25.1 Q= wt % comms se Cui 28 how cj he teary asia ih gt oe eh a= 20 x“ kAAT oe er trosemons2 cea PD _ kAAT Q p= 20kAAT QD Forte same bolero; Ki and ae constant and, a AT 8 eeclyprpariona te Pi eanbe eis ta Pax Q caatina22 For any one vote, the net transter ae is nre556a, the maximum alowsdle baer pressure Is reduced. | compromise is reached wth fuace tube wal thickness of bebween 18 mm and 20 mm, This translates to practical reese lnk for shal bors of round 27 bat Fig. 828 et tranefe fromthe fumaoe tube (ouput umtation ‘Shall balers aw manufactured as packages units wih al he ancitary equpment fed ino positon. tr manufactur, tne packages Beller mast be vanspored to tte and re ergest bol whieh ean be ranspovted by rod in tne UX has an tpt of around 27 000 Kah. 7 mu-boler installations are used Howaver tis nas the advantage of providing bettor secu of supply ans improved I mor thar 27 900 kgs raquo ant endow, hitpihnuwspiraxsarco com Resources Pages/Sleam-Enginooring Ttrialshe-oiler-hauselshall-bolers aspxaizvane Pages - Shell Bators Fig. 32.10 Fad transportation summary Too’ hl ficient nd espensive eel bo os the result of more han 150 years of development i + Bole and bumer design, + Matera! scence. + Bote: manutacuing ectniaues, To guarantee ts success + Krow the conor, envionment and demand characteristics ofthe part, and accurately soe thesecondton fo the bollr mandacturs, + Provide a baller house yout and nataltion that promotes od eperaton ard maintenance “+ Select the control systems tat allow the boler to operate safely and ficiently + Select the conto systems that il suppor the bole insuplyng cry steam to the plant atthe requred pressures) and flowrate. + ldontty the fuel tbe used an, i necessary, where ané how the fuel reserves tobe safely stowed, Advantages of shell bollers: + The ete plant may be purchased a a complete package oly needing seowing to base foundations, ané connecting to wae, eect, tel and x" systems before commissioning. This means tat installtion costs + This package aangerent also means that tie simple orloeato a packaged shell bol + shal boiler conisins a sustantal amount of wale al satraon temesature, ard hence has a substantial amount of stores energy which cn be calod pan to cope wth short te, rapid appled lads ‘This can also bea disadvantage in tha when the energy ine lord water used, il may take some Ue befor the reserve is built up again + The consnicton ofa shell ollie goeraly sai forwars, wich man tha maiconanee s simple + Shallbaiosoftan have one fumsce tubo and bumes. This maans tha contol ystan ae fity simple. + Attcugh shall bailar may bs designed a bl to operate upto 27 bar, th mony operate a 17 ba or lees, This rlaivaly lw pase rmsans that he associated acily equipment is easly avaiable at campttive pices Disadvantages of shell boilers “+The package pneiple means that speroximatly 27000 kg nis the max mum ouput of shel bole. more steam required then several bots ead ob connect together + Tho laga camstroyindars used in hs constuction of shell balers toch limit thi operating prassurs to apprximataly 27 bar. highor pressures are mondo, than a watee-ube bor rue, Copyright © 2016 lovastors Spirax Sarco Limited Pewsey Paley EXPERTISE [SOLUTIONS [SUSTAINABILITY Toms of Use To 4 0) 1242 21961 Fax: #44 (0) 1242 572842 -housalshel-bolers aspx ca