Beruflich Dokumente
Kultur Dokumente
Asit Patel
ANP Energy Consulting Services
Learning objectives
1
Lets look at what the Merriam-Webster
dictionary says the BOILER IS…
What is a boiler?
2
Boiler Classifications
• Low Pressure:
• Section IV of ASME Code (Heating Boiler)
• Steam: Up to 15 PSIG
• Water: Up to 160 PSIG and or 250°F
• High Pressure:
• Section I (Power Boiler) of ASME Code
• Steam: Above 15 PSIG
• Water: Above 160 PSIG and or 250°F
5
Non-
• Mid Efficiency (85-90%) Condensing
3
Defining Boiler Efficiency
4
Boiler Capacity
Units of Measurement
What is a BTU?
5
Types of Boilers
Types of Boilers
12
6
Types of Boilers
Boiler Types
Cast Iron Sectional
14
7
Boiler Types
Cast Iron Boilers
• Advantages • Disadvantages
• Modular Design • Low Pressure Only
15
Types of Boilers
8
Boiler Type
Steel Firetube Scotch
Two Pass – Dryback
Boiler Type
Steel Firetube Scotch - Four Pass - Wetback
18
9
Boiler Type
Steel Firetube Scotch - Wetback
• Design Principles
• Rear turnaround is totally surrounded by
water
Boiler Type
Steel Firetube Scotch - Dryback
• Design Principles
• Rear turnaround is a refractory wall
20
10
Boiler Type –
Steel Firetube Scotch - Dryback
21
Boiler Type
Steel Firetube Scotch
• Advantages • Disadvantages
• Wide range of sizes • Operating weight
• Both high and low • Requires more floor
pressure space
• Higher Efficiency • Space required for
• Easy to clean tube removal &
• No mud legs cleaning
• Longevity • Refractory
Maintenance (dryback
• No refractory floor design only)
• No rear door refractory
(3-Pass & 4-Pass
Wetback Only)
22
11
Types of Boilers
Boiler Type
Steel - Firebox
24
12
Boiler Type
Steel - Firebox
• Advantages • Disadvantages
• Wide range of sizes • Low Pressure ONLY
• Compact (for places • Operating weight
where Scotch will not • Refractory
fit) maintenance costs
• Easy to clean • Space required for
• Longevity tube removal &
cleaning (but not as
much as Scotch)
25
Boiler Type
Modified Firebox (fits through 36” door)
26
13
Types of Boilers
Boiler Type
Flexible Watertube
28
14
Boiler Type
Flexible Watertube
• Advantages • Disadvantages
• Lower Cost • Low Pressure
• Lower operating Application ONLY
weight • Water treatment more
• Long life expectancy critical (difficult to
(40 Years) clean)
• Wide range of sizes
• Knockdown capability
• Minimum space
required for tube
removal & cleaning
• Tubes easily replaced 29
Boiler Type
Steel - Watertube
• D Type
• S Type
• A Type
• O Type
30
15
Boiler Type
Steel Watertube
31
Boiler Type
Steel - Watertube
• Advantages • Disadvantages
• High Pressure up to • Steam Only
900 psig • Process Only
• Fast Steaming
• Low Water Content
• Quick Response to
Load Demands
32
16
Types of Boilers
Boiler Type
Copper Fin Tube – Horizontal Lay-out
34
17
Boiler Type
Copper Fin Tube – Vertical Lay-out
35
Boiler Type
Copper Fin Tube
• Advantages • Disadvantages
• Medium efficiency • Gas only
• Low initial cost • Water only
• Low Mass • Special vent
• Low operating weight requirements
• Small footprint
• Lower stand-by losses
36
18
Types of Boilers
Boiler Type
High Efficiency – Condensing Boilers
38
19
True Operating Efficiency of
Condensing Boiler
Boiler Type
High Efficiency – Condensing Boilers
• Advantages • Disadvantages
• Highest Efficiency • Water only
• Can be used in low • Gas only
RWT systems
• Special venting
• Various types
• Costly???
• Condensate will not
harm properly
designed boiler
• Standard features &
Controls
• Smaller Venting
40
20
TYPES OF BOILERS
Atmospheric - Gas
Types of Boilers
• Knockdown
• Boiler (vessel) only
• Packaged
• Boiler and burner
• May be the same manufacturer or may be two
different manufacturers
• Mostly two different manufacturers
• Integral unit
• Boiler and burner is one unit
• Most condensing boilers 42
21
Criteria for boiler selection
• Application
• Heating/Process
• Steam/Hot Water
• High Pressure/Low Pressure
• Fuel availability and venting options
• Space availability
• Budget
• Efficiency
43
22
From operating perspective..
45
23
Part-Load Efficiency Curves of
Non-condensing High Mass boiler
Typical high
mass boilers
have low part-
load efficiency.
Another concern
is flue gas
condensation.
47
24
So What Makes Condensing Boiler
Efficient?
• Condensation of water vapor.
• Extraction of latent heat that is otherwise
going up the chimney in form of water
vapor.
49
• HC + O2 Carbon
• Good, “complete” combustion Monoxide
• CO2 + H20(vapor) + heat hazard
25
Energy Improvement Opportunities
Associated with Boilers/burners
• Maximize combustion efficiency
• Minimize excess air
FEMP
O&M
Manual
Ver. 3
P. 9.17
52
26
Opportunity in field
Lowering of excess
air results in lower
exhaust gas
temperature and
higher efficiency
53
54
27
Heating System Efficiency
55
56
28
Optimization Opportunity
(Minimize stand-by losses)
57
Thank You
58
29
Q&A
59
30