Steam Generation Systems

 Boiler Classifications/Types/Evolution
 Boiler Boiler Design Water/Steam
Circuit
 Natural/Forced Circulation
 Tube Design and Construction
 ASME Code Calculations
 Auxiliaries (Attemporators)
 Fuel/Air/Flue Gas Circuit
 Combustion
 Auxiliaries (Fans, Air Preheaters)
 Boiler Classifications
 Industrial – small package-type
boilers used in apartment houses,
commercial buildings or industry.
Steam capacity of 50,000 pph with
pressures up to 300 psia.
 Marine – larger package-type or
field erected boilers servicing ships.
Higher pressures (up to 900psia)
and temperatures (up to 1000
degF)
 Boiler Classifications cont.
Power – usually field erected. Produce
several million pph of steam at pressures up
to 5500 psia and 1100 degF
HRSG – Heat Recovery Steam Generators.
Installed on the back end of a combustion gas
turbine and used to recover heat and
produce steam.
Industrial Boiler

Source:Victory Energy
Marine Boiler

Source:HistoricNavalShipsAssociation
Power Boiler

Source: B&W
Once Thru (Universal Pressure) Steam Generator

Source: Babcock & Wilcox

HRSG

Source:Victory Energy
 Boiler Types
 Electric – small boilers heated via
resistance coils. Pressures up to 15psig.
 Fire Tube – small industrial, package-
type boilers that direct flue gas through
tubes that are surrounded by water.
 Water Tube – larger boilers that are
constructed with drums and headers
with tubes connected to them with flue
gas flowing external to tubes in a
furnace.
Electric Boilers

Source:Sussman Boilers
Fire Tube Boiler

Source:Ciciboilers
Fire Tube Boiler
Water Tube Boiler
Hero’s Aelopile 200 BC
Waggon Boiler 1769
Early Steam Drum Designs
Boiler Explosions
 Babcock & Wilcox
Horizontal Inclined Tube Type

Source: B&W
Stirling Boiler
Multiple Drum Boiler
Radiant Boiler
Power Boiler

Source: B&W
Once Thru (Universal Pressure) Steam Generator

Source: Babcock & Wilcox

HRSG

Source:Victory Energy
 Steam Generation Systems
Boiler
Classifications/Types/Evolution
Boiler Boiler Design
Water/Steam Circuit

Tube Design and Construction

ASME Code Calculations
Auxiliaries (Attemporators)
Fuel/Air/Flue Gas Circuit
Feedwater Circuit
 Economizer
 The purpose of an economizer is to recover waste
heat from the flue gas exiting the boiler and to
utilize that heat to preheat the feedwater to the
boiler thereby increasing boiler efficiency
Economizer

Source: Babcock & Wilcox

Finned Economizer Tubes

Source: www.honghengti.com
Waterwall Circuit
Natural Circulation

Source: Spirax
 Forced Circulation

Boiler Circulation Pump (BCP)

Orifices
✕
 Circulation Ratio

Circulation Ratio (CR) = Total circulation

flow rate divided by the steam
generation rate.

Usually, CR = 4.0 to 5.0 for conventional

boilers and up to 20.0 for HRSGs
Steam Drum Internals

Source: Thermopedia
Cyclone and Demister

Source: Babcock & Wilcox

Superheater Circuit
Reheater Circuit
 Steam Generation Systems
Boiler
Classifications/Types/Evolution
Boiler Boiler Design
Water/Steam Circuit
Natural/Forced Circulation

ASME Code Calculations

Auxiliaries (Attemporators)
Fuel/Air/Flue Gas Circuit
Tube and Tile Wall Construction
Waterwall Circuit
Tangent Tube Construction

Source:BrightHubEngineering
Studded Tube Construction
Membrane Tube Construction
 Steam Generation Systems
Boiler
Classifications/Types/Evolution
Boiler Boiler Design
Water/Steam Circuit
Natural/Forced Circulation
Tube Design and Construction

Auxiliaries (Attemporators)
Fuel/Air/Flue Gas Circuit
 ASME Code
Conceived in 1911 because of the 1905
Grover Shoe Factory explosion that resulted
in 58 fatalities, 117 injured, and levelled the
factory
First issued in 1914 as a standard for
designing boiler components
Presently the Boiler & Pressure Vessel Code
has 28 books
 Boiler Tube Design
Pipe Tube
Pipe wall measured by “schedule” Tube wall measured by “gauge”

Source: TheEngineeringToolBox
Boiler Tube Design Cont.

Source: WorldwideMetric
Minimum Wall Thickness

t = min. design wall

thickness
P = max. allow. working
press.
D = tube outside
diameter
S = max. allow. stress
value at metal design
temperature
Tube Roller or Expander
Maximum Allowable Working Pressure
ASME Code Maximum Allowable
Stress Values
Calculations

Do examples
Tube Metal Profile During DNB

Source: Combustion Engineering

Tube Temperature Profile

Source: Combustion Engineering

Tube Temp Profile – Plan View

Source: Combustion Engineering

Heat Flux Profile in Furnace

Source: Babcock & Wilcox

Heat Absorption Component vs. Surface
Area

Sources: Combustion Engineering, E.Ecock

Schematic Plan Arrangement of
Convection Tubes

Source:B&W
Parallel vs. Counterflow Tubes

Source:B&W
Steam Temperature Characteristics of
Radiant and Convection Superheaters
Superheater Coils

Source: Indiamart
Superheater Pendant Design Schematic

Source: ConEdison
Gas Touch Length Diagram