JOB QUALIFYING PROGRAMME SKILL BLOCK NO.

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TITLE SKILLS BLOCK UNIT NO DEPARTMENT

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Boilers 3 1 Production, Engineering & Services

ICI PAKISTAN LIMITED POLYESTER WORKS

Name Written By: Mazhar-ul-Haque Khan Reviewed By: S. R. Ahmed / A. R. Vine

Signature

Date

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Approved By:

List of Revisions made to this training unit to-date

Sr. No. Para # Page # Description of Revisions Details Prepared By Revised By Approved By Date

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Table of Contents
1. INTRODUCTION....................................................................................................................................................4 2. BOILER TYPES......................................................................................................................................................4 2.1. FIRE TUBE BOILERS.................................................................................................................................................4 2.1.1. DESIGN...............................................................................................................................................................4 2.1.2. OPERATION..........................................................................................................................................................4 2.2. WATER TUBE BOILERS............................................................................................................................................5 2.2.1. DESIGN...............................................................................................................................................................5 2.2.2. OPERATION..........................................................................................................................................................5 3. PRINCIPLES OF OPERATION............................................................................................................................6 3.1. STEAM PRODUCTION & COMBUSTION.........................................................................................................................6 3.1.1. REQUIREMENTS FOR STEAM PRODUCTION.................................................................................................................6 3.1.2. REQUIREMENTS FOR COMBUSTION............................................................................................................................6 3.2. BASIC BOILER OPERATING PRINCIPLES.......................................................................................................................6 3.2.1. BASIC BOILER DESIGN............................................................................................................................................6 3.2.2. LIMITATIONS........................................................................................................................................................7 3.2.3. ADDITIONS TO THE BASIC BOILER...........................................................................................................................7 4. HEAT TRANSFER..................................................................................................................................................8 4.1. HEAT TRANSFER IN BOILER......................................................................................................................................8 4.1.1. RADIATION..........................................................................................................................................................8 4.1.2. CONVECTION........................................................................................................................................................9 4.1.3. CONDUCTION.......................................................................................................................................................9 4.2. HEAT TRANSFER PROBLEMS......................................................................................................................................9 4.2.1. SCALE.................................................................................................................................................................9 4.2.2. INSUFFICIENT FEED WATER...................................................................................................................................9 4.2.3. SOOT................................................................................................................................................................10 4.2.4. IMPROPER WARM-UP...........................................................................................................................................10

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1.

INTRODUCTION

Industrial plants rely on steam for heating and other processes and boilers are commonly used to provide this steam. The function of a boiler is to produce steam. Steam is produced by heating water to its boiling point. When water reaches its boiling point, it changes from a liquid to a vapor. This vapor is known as steam.

2.

BOILER TYPES
Fire Tube Boilers Water Tube Boilers

Most boilers can be grouped into two categories:

2.1.

Fire Tube Boilers

In general fire tube boilers use tubes to transport combustion gases

2.1.1. Design
Basically fire tube boilers rout hot combustion gases through metal tubes that run through a shell filled with water. Fire tube boilers very in design, but most operate under similar principles. In a typical fire tube boiler, horizontal fie tubes route combustion gases through the boiler. There is also an outlet for the combustion gases, a feed water line, and a steam outlet line.

2.1.2. Operation
During operation, water enters through the feed water line. The water level is maintained above the fire tubes to protect the tubes from overheating. Fuel and air enter the combustion area. The burning fuel transfers heat to the water in the shell.

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The hot gases flow through the fire tubes and additional heat is transferred to the water surrounding them. Each time gases are routed through the shell is called a pass. For Example, If the gases pass through two times, the boiler is a two-pass boiler. The combustion gases flow out of the boiler through the combustion gas out let. As the water in the boiler is heated, some of it turns to steam. This steam / water mixture is lighter than the cooler water in the boiler, so it tents to rise. Steam collects above the water level and then flows through the steam out let and into the plant. The feed water, which is cooler and heavier than the steam / water mixture flows to the bottom of the boiler. It is heated by heat from the combustion area, and the cycle continues.

2.2.

Water Tube Boilers

Water tube boiler is used tubes to transport water and steam.

2.2.1. Design
Generally speaking water tube boiler use tubes to rout water and steam through the boiler. Combustion gases flow past the outside surfaces of the tubes. Water tube boiler may vary in design, but most of them operate in basically the same way. In one type of boiler design the boiler consists of the series of water tubes and two drums. The drums distribute water to the tubes. The water tubes connect the drums and form of wall around the combustion area of the boiler, where heat is generated.

2.2.2. Operation
Water is fed into the upper drum through a feed water inlet line. The water tubes and the lower drum are completely filled with water. The upper drum is filled only to a certain level to provide space for steam to collect. For this reason the upper drum is often called the steam drum. As fuel is burned in the combustion area, heat is transferred to the adjacent water tubes. The combustion gases then flow out of the boiler.

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Water circulates from the upper drum, through the tubes called down comers, to the lower drum. The lower drum is often referred as the mud drum. From the lower drum, the water is distributed to the water tubes surrounding the combustion area. As the water in the tubes is heated, a steam / water mixture is produced. The steam / water mixture enters the upper drum. This steam is then separated from the water and routed through the steam out let and into the plant. ______________

3.
3.1.

PRINCIPLES OF OPERATION
Steam Production & Combustion

3.1.1. Requirements for Steam Production

The two requirements for steam production are water and heat. To generate the heat needed for steam production, boilers rely on the process of combustion. In other words, a boiler burns fuel to provide the required heat.

3.1.2. Requirements for combustion

In simple terms there are four requirements for combustion. If any of the four requirements is missing combustion will not occur: Fuel Air Heat & Chemical Reaction For fuel, more boilers burn oil natural gas or coal. Air contains the oxygen that is needed for combustion. Heat is required to raise the temperature of the fuel / air mixture to a point at which a chemical reaction or ignition takes place.

3.2.

Basic Boiler Operating Principles

3.2.1. Basic boiler design

Boilers are designed to allow the requirements for steam production and the requirements for combustion to come together. The way that this is done can be shown using a simplified boiler that consists of a container, or shell with water in it.

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The water is one of the acquirements for steam. The boiler also has a pipe to provide a continuous supply of fuel to the combustion area, that is, the area beneath the shell. Heat from a flame satisfies the second requirement for steam production. As the shell heats up, heat is transferred from the shell to the water and the water boils, producing steam.

3.2.2. Limitations
A boiler modeled on the preceding examples will not work for industrial applications. One reason is that the shell is open to the atmosphere so there is no way to collect the steam. In addition, as the water boils to steam, there is no way to replenish it. Without water, the shell could overheat and be damaged.

3.2.3. Additions to the Basic Boiler

To make the example boiler more suitable for industrial applications, the shell is covered to prevent steam from escaping. A steam outlet line is added to collect the steam and route it to where it can be used. A feed water line is added to provide a continuous supply of water to replace the water that is changed to steam.

With these additions, the boiler can heat water, produce steam and route the steam out of the shell to where it can be used. However, this design is still not as efficient as it could be, because much of the heat in the combustion area is escapes to the atmosphere. This heat is wasted, because it does not go toward the production of steam.

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Adding an insulated casing minimizes the heat loss. A fan is added to supply air for combustion, and an outlet is added to remove combustion gases.

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4.

HEAT TRANSFER

Heat transfer is a natural process that occurs anytime there is a difference in Temperature. Heat naturally transfers from a hotter object to a colder object.

4.1.

Heat Transfer in Boiler

Radiation convection and convection are all involved in transferring heat from burning fuel to the water in a boiler. Heat transfer in a boiler can be explained using of water tube boiler. The example boiler has a series of tubes and two drums, which distribute water to the tubes. The tubes form a wall around the combustion area, where the heat is generated.

4.1.1. Radiation
When fuel burns in a boiler, radiant energy in the form of electromagnetic waves is produced. These waves travel through the combustion area. The waves in a direct line

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of sight with the tubes make contact with the outer tube surfaces, and the tubes absorb heat. This is heat transfer by radiation.

4.1.2. Convection
The burning fuel also produces combustion gases. As these hot gases pass through the boiler, they transfer heat to the tubes, as well. This is convection heat transfer. Convection heat transfer also occurs as the warmer water mixes with cooler water. When enough heat has been transferred raise the water temperature to the boiling point, steam is produced.

4.1.3. Conduction
As the outer surfaces of the tubes absorb heat, convection heat transfer occurs. Heat is transferred from the outer surface to the cooler inner surface. Then, heat is transferred from the inner surface to the water flowing through the tube.

4.2.

Heat Transfer Problems

When a boiler is working properly the heat produced by the burning fuel will be readily transferred to the water in the tubes. However there are problems that can interfere with heat transfer.

4.2.1. Scale
One problem is a condition called scale. Scale is the buildup of solid impurities on boiler components that contain water. The boiler's feed water supply may contain impurities. These impurities can coat the surfaces of boiler components, insulate them, and restrict their ability to transfer heat. If the surfaces can not transfer heat to water, tubes can overheat and rupture.

4.2.2. Insufficient Feed Water

A heat transfer problem could also occur if the feed water supply if were to stop for any reason. Without a continuous supply of feed water, the boiler could boil dry. With no water to remove the heat, the tube metal would rapidly overheat and severe damage could result. Industrial boilers are equipped with controlled systems work to prevent this problem.

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4.2.3. Soot
In boilers that burn coal or oil, another problem that can affect heat transfer is the buildup of soot. Soot is created by ash and unburned fuel particles in the combustion gases. Soot buildup insulates the tube surfaces, preventing good heat transfer. When this occurs, the amount of heat transferred to the water decreases. As a result, heat is wasted. It is escapes with the gases routed out of the boiler, reducing boiler efficiency.

4.2.4. Improper Warm-up

Another heat transfer problem is improper boiler warm-up. This may occur if the boiler is not started up correctly. Water tubes other metal parts expand when they are heated. If the boiler has not been operated for a while and then is rapidly heated, its metal parts may expand at different rates, causing some parts to bend or break. To protect the boiler, heat must be applied gradually to ensure that all the metal component expand at the same rate.

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