NATIONAL UNIVERSITY OF THE HIGHLANDS-PUNO

DIMENSIONS OF A WATER TUBE BOILER

Modern boilers provide most of the driving force in the

world and probably, the least known mechanical parts. The
boilers are a topic of engineering, tax laws, and regulations in
government dependencies.
In this type of unit, the combustion gases surround the tube banks.
and the water circulates through the interior of these tubes, which have a
vertical inclination, towards a container or vapor collector located at the point
higher than the boiler.

FRONTAL DESIGN OF THE BOILER

WIDTH OF THE ECONOMIZER:

To establish its dimension, the speed of the water is fixed, generally.
ranging from 1 to 2 m/s, with each step being a single row to maintain the
temperature homogeneity; the distance between the center of the tubes is set,
in such a way that based on the number of tubes the diameter of each one and the
spacing between them gives the width of the economizer, which corresponds
to the length of the boiler.

speed of water 1 - 2 m/s Fixed: 1.00 m/s

Water flow: 27000Kg/h
External diameter 0.75 in = 1.905 cm
Minimum thickness: 0.133in
BGW 10
Tube thickness 0.134in
Diameter of the tubes 1.2243cm
Allowable stress: 12995.38 psi
density of water = (density +
T7 960 Kg/m 3
ρ)/2
T8
Water flow: 3
30.21 m/h
Internal tube area 1177 cm 2
No. Tubes = Q/(v x A) 68.19 69 tubes
5.8 x Dext
= 5.8 x 1.905cm 11,049cm
Clare = Pitch–Dext 9,144 cm
Width del771,53cm
Water speed: 1.03 m/s

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 NATIONAL UNIVERSITY OF THE ALTIPLANO-PUNO

I think of the economizer = N 0 tubes × Dext + Clare × (N tubes

0 +

= 69 × 1,905 cm + 9,144 cm× 70 = 771.53 cm

LONGITUDINAL CALCULATION OF THE EVAPORATOR:

Once the length of the boiler is known, the frontal number can be calculated.
evaporator tubes, for the most convenient passage and adjusting the spacing between
tube center, so that both values are suitable.
The volumetric flow rate in the evaporator is higher than in the other two areas.
The maximum speed of steam and dry gases is given by the expression,
for steel pipes.

The maximum permitted speed of the value that passes through the evaporator is:

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LONGITUDINAL CALCULATION OF THE HEATER

The calculations are carried out in a manner similar to those of the evaporator:

v max vapor: 16.63 5.1 m/s

Pipe diameter (conventional):
ANSI 40
ExternalDiameter 6.0325cm
Minimum thickness: 0.133in
Tube thickness: 0.203 in
InternalDiameter 5,001 cm
2 2
Internal tube area = Pi x 5 / 4 cm 0.00196 m2

in pipes (steam) 3.96 m/s

No. Pipes: = Q/(v x A) 62.9 63 tubes
Pitch = 2.01 * Dext 12,125cm
Clare = Pich–Dext = 6.09cm

Length of the superheater: 769.99 cm

G (Kg/s*m^2) 218,159.67 v (m/s) 3,954

Transfer area required total length of each tube and number of tubes in
height for each changing table.

SUMMARY OF THE BOILER DIMENSIONS:

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SPECIFICATION OF THE WATER FEED PUMP TO THE

WATER TUBE BOILER
General purpose feed water pumps are divided into the
following types:
Reciprocating: they use a water cylinder and a piston directly.
mounted on a common axis of a steam cylinder directly coupled,
the type of discharge is pulsating.
Rotary: it is used to pump very viscous or pasty fluids.
Centrifuges: it has its main component in an envelope or casing.
a corona inside which a rotor spins, the fluid to be pumped is directed through
from the inlet pipe to the center of the pump, impeller, which directs the water
radially to through the steps of the wheel and this develops pressure by
convection of kinetic energy. It is the one commonly used in the
industry.
Multistage centrifugal pumps (see Figure 10) are used for pressures of
services not reachable by single-stage pumps, and they are found in
services such as water supply, fire equipment, food
of boilers and charge pumps for refineries and petrochemical industries.

Multistage Centrifugal Pump

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OPERATION OF WATER-TUBE BOILERS

HIGH PRESSURE TUBES

FUNDAMENTAL OPERATIONS:
CONTROL OF FEED WATER.
SAFETY CONSIDERATIONS.
OPERATIONS FOR STARTUP.
Preparations for the start.
DISTRIBUTION OF THE HEATING SURFACE.
HEAT RECOVERY EQUIPMENT.
THE OVERHEATER.
SAVER.
AIR HEATER.
OPERATION TECHNIQUES FOR MAXIMUM EFFICIENCY

BOILER OPERATION OPERATIONAL CHARACTERISTICS OF THE

COMPONENTS OF A BOILER
The ash from the fuel possibly has the greatest significance on the
operational characteristics of the boiler downstream of the home, the
the arrangement of heat transfer surfaces implies a balance between
the differences in temperature, space, pressure drops, and loss of draft. The
the final disposal of these surfaces must comply with the requirements of
operation, and with the management of ash deposition, corrosion, and erosion.

OPERATING CHARACTERISTICS OF THE COMPONENTS

Water-tube boilers The operation of steam production equipment varies
depending on the type of system, the fuel it uses, and its application.
FUNDAMENTAL OPERATIONS
Even if the equipment is of the latest technology, the basic principles of operation
they remain the same. To have proper control of the operation of a
It is necessary to know the factors that determine its state. These
factors are mainly: Fuel flows, air, water, steam, pressures,
temperatures.
SAFE COMBUSTION
Before of to light the unit no must news waste of
flammable in his interior. If must remover this material
to avoid the equipment from turning on. A proper relationship must be maintained.
air/fuel to prevent the formation of gas pockets that may
cause an explosion.

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FEEDWATER CONTROL
Its goal is to equalize the feed water flow with the steam flow.
maintaining a stable level in the steam drum during low, high, or
with rapid changes, taking as a reference the steam production and the level of
drum.
Combustion should never be established until proper cooling.
GENERAL SECURITY CONSIDERATIONS
The failure of pressure vessels is a major concern. The ASME in its
Section VIII of the code describes the design, construction, and inspection of tanks and
pressure vessels.
The control of emissions also receives considerable attention.
Production of (CO2), (CO), (SOx), and (NOx) must be considered.
Ventilated spaces with sufficient oxygen for the staff.
Good lighting is important for a safe work environment.
INITIAL STARTUP OPERATIONS
Operator requirements:
Be equipped to understand the responsibility taken to ensure the
safety of all personnel involved and that of the team.
Be prepared for all situations that may arise.
Having a complete knowledge of all the components, design,
functions and limitations.
Preparations for the start
The procedure varies according to the design of the boiler; however, certain
steps are necessary for all boilers. The steps can be classified
how:
Inspection
Cleaning
Hydrostatic test
Pre-calibration of instruments and controls
Preparation of auxiliary equipment
Chemical cleaning
Line steam cleaning (blow)
Safety valve tests

INSPECTION:

The inspection of the boiler and auxiliary equipment serves to

two purposes:

Familiarize the operator with the equipment.

Check the conditions of the equipment.

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CLEANING:

Any foreign material that accumulates during transport must be removed.

storage, assembly or repair. Dirt in the water can restrict the
circulation or covering the drainage lines. Remove fuel waste. The
Combustible material can ignite and burn at an uncontrollable rate and cause
considerable damage. The fuel lines should be cleaned, especially the
of oil and gas lines, to prevent later damage to the valves and
the clogging of the burner components.

HYDROSTATIC TEST

The test consists of increasing the boiler pressure to 1.5 times the pressure.
of design and is maintained for a sufficient time to detect possible leaks.
It takes place in the steam water circuit of the boiler and includes: the steam drum,
sludge drum, the collectors and the pipes that connect the drums.

PROCEDURE

Check that the boiler is completely empty, that the drains and vents
the boiler and the superheater should be open. Install blinds on all lines
that enter or exit the boiler and in the flanges of the safety valves. Fill
the superheater with condensate or cold water to protect it from corrosion and
Depots. Fill the boiler with cold water, through the extraction line,
keeping the steam drum vent open to evacuate the air. Let it
the kettle should be vented for 15 minutes or until the water stream is continuous.
Close the steam drum vent. Observe the pressure reading on the manometer.
to know what the pressure of the feeding system is, close the supply of
water.

Press the boiler by connecting the auxiliary pump designed to the extraction line.
for the hydrostatic test, up to achieving the test pressure. (1.5 times the
design pressure). Check if the pressure indicator maintains the pressure of
test. If this does not happen, check the clamps, collectors, drum hatches.
vapor, indoor piping of the home.
If after 1 hour, the test pressure holds, the Department of
Equipment Inspection (GIE) checks the state of the boiler and gives the green light.
Clear the boiler by draining the sludge drum and have the blinds removed.
installed for the test.

Instrumentation and Controls

Every boiler must have at least two measuring instruments: a meter

of vapor pressure and a water level indicator. pressure levels, flow
of steam and temperature must be within the design limits. Therefore, the
equipment should not be operated until we are sure that these instruments are
they are properly calibrated.

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 NATIONAL UNIVERSITY OF THE HIGHLANDS - PUNO

AUXILIARY EQUIPMENT

The auxiliary team must also be prepared for the operation.

This equipment includes:

Fans
Water feed pumps
Economizers
Chimney sweepers
Drainage system
Superheater

Chemical cleaning

The impurities present in the water can cause the boiler tubes to fail.
they can lead to solid drag in the steam.
the use of high-quality water for the hydrostatic test.
The solvents used for acid cleaning are varied. Among them are the
hydrochloric acid and phosphoric acid. The usual process is to fill the boiler up to
that the solution overflows through the vent (the acid is added from the outside to the
caldera).

STEAM BLOWING

The steam line should be blown out to clean it of any dissolved deposits.
the strange material before being coupled to the turbine. There are several methods to
the blowing of the steam pipe, but blowing with steam has proven to be the
most effective means to eliminate dissolved matter.
It is used for cleaning ash deposits on surfaces of
heat transfer.

SAFETY VALVES

Safety valves are essential for the safe operation of any

pressure vessel, which allows for the proper release of excess pressure
during abnormal operating conditions.

They must be kept calibrated. It must be verified that their closing and opening
it is within an established range. Procedure for adjusting the valves
of security.

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PROCEDURE

Wait for the operating pressure condition to be achieved. Make sure that the valve
Edward is closed and the vent of the superheater is open. Place the clip or
muffling the valve, leaving the highest pressure firing valve free. Increase
gradually the pressure in the boiler by turning on one of the burners located
at the bottom of the burner box.
Manually discharge each valve to remove foreign materials, this discharge must
last for no more than 10 seconds.
Control the water level at 50%. To adjust the shot, loosen the lock nut and turn.
the adjustment nut to decrease the spring pressure. When the adjustment nut is turned
to the right, the tension on the spring increases and the firing pressure rises.
Allow the pressure to drop to an operating level and proceed to remove the clamp.
to the next valve in descending order.
Repeat the procedure given in points 3, 4, and 5. Once the test is completed, the
boiler is in condition to be put online.

DISTRIBUTION OF THE HEATING SURFACE

As the function of a boiler is to convert water into steam when it is given

supplies heat, the amount of heating surface and the way it is
distributed affects the efficiency and capacity. When the gases leave the
boiler absorption section, still contains a large amount of heat
that if it were not recovered it would be one of the greatest losses in unity.

That heat can be recovered with the help of economizers and heaters.
of air which translates into an increase in the efficiency of the unit. Equipment of
heat recovery It is a device that offers an absorption surface of
heat by which the temperature of the steam is raised above its
saturation point.

Although the gain in total efficiency varies according to pressure, it

Calculate that this may be around 3% for every 100°F of excess.
heating.

THE OVERHEATER

Overheating protection:

The temperature of the combustion gas entering the section of the

overheater must be controlled for limit the temperature
from the superheater up to 900F (482C) for carbon steel pipes and
950 to 1000F (510 to 538C) for pipes of alloy. The two requirements
Previous for the steam flow through each superheater tube are:

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1) Elimination total del water of each tube.

A total steam flow equal to or greater than approximately 10% of the flow.
of nominal steam.

The water is removed from the steam superheaters simply by opening the header.
from the drains and ventilation grilles

THE OVERHEATER

Probably the oldest method to recover heat from gases from the
caldera. It involves passing the gases through an exchanger called
economizer for reheating the feed water. The economizer heats
the feed water, resulting in an increase of nearly 1% in efficiency
from the boiler.

SAVER:

Protection of the economizer; The economizers are located in areas of

relatively low temperatures. However, some economizers generate
vapor during the pressure increase period.

It not only makes controlling the water vapor level in the drum difficult;
it also causes water hammer.

This difficulty is overcome if continuous feed water is supplied to

remove the steam from the economizer. The final heat recovery takes place in the
air heater. This point is the lowest limit in operation.
The use of air heaters in units that consume common fuels
like coal, gas, oil, and under similar conditions at home, it produces a
increase in its efficiency close to 2.5% for every 100°F that is decreased
temperature of gases.

Viewed from the air side, this means a gain of 2% for every 100°F that is
increase the air temperature.

AIR HEATER

Water/Steam circulation
The overheating of the boiler tubes is limited by the flow of water in the
interior of the tubes. The natural circulation of the flow in the boiler occurs due to the
gravity force that acts on liquids of different densities. The
the flow circulation begins when the density of the water in the tubes
heating is lower than in the down tubes. This flow increases to
As the steam production rate increases. In some
types of boilers with forced circulation depend on a pump
circulation to help this flow.
Forced circulation boilers depend on the water pump.
nutrition to produce the necessary flow circulation.

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THE PURGE

Considerable attention has been paid to the prevention of furnace explosions.

especially in units that burn fuel in suspension. Most
explosions in the boilers occur during startup periods
and low load. There is always the possibility of gas accumulation
flammables or combustibles dust in any part of the unit, it should not be
try to ignite the burners until the unit has been completely
purged.

OPERATION TECHNIQUES FOR MAXIMUM EFFICIENCY

Fuel consumption is an important cost in the operation of

a boiler. It is important to minimize fuel consumption and maximize
steam production.

The factors that affect the efficiency of the boiler are:

Fuel quality.
Sulfur and chloride content in coal.
Ash content.

2. Type of fuel.
Pulverized fuel. (coal.)
Natural gas.
3. Combustion Conditions.
Excess air.
Length of the flame.
Air/fuel turbulence at the burner outlet.
Turbulence at home.
Temperatures.
Air distribution.
Types of walls in the home.
4. Design
Location, type, and spacing of the elements of the superheater,
air heater and the economizer.
Height of the home and exhaust gas temperature.
5. Costs
Loss of efficiency.
Steam gas leaks.
Heat dissipation by radiation and convection in walls and lines.
Chemical treatment.
Condensate recovery.
Water quality.
Although the efficiency of a boiler is primarily the result of its
design, the operator can significantly maintain or improve the
efficiency through the control of the factors that affect the losses of
boiler heat.

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The factors that can be controlled by the operator are:

LOST IN THE CHIMNEY

PRESSURES AND TEMPERATURE

EMISSION CONTROL PRESSURES AND TEMPERATURE

For steam systems that produce electrical energy, the temperature of

vapor has a significant impact on turbine efficiency.
modern controls can usually maintain this temperature
within 10F (6C) of the design settings.

Every 50F (28C) in the reduction of steam temperature reduces the

efficiency of the cycle at approximately 1% efficiency in the unit
To maintain optimal efficiency and minimal use of ammonia the
The combustion system has been improved to generate the highest levels.
low possible nitrogen oxide (NOx) emissions.

EMISSION CONTROL

A modern distributed control system (DCS) is installed to

offer much more information, analysis, and assistance to the staff of
operation in the optimization of the steam generator.

As a result, NOx can be reduced during periods

selected and heat losses are also minimized.

COMBUSTION OPTIMIZATION KEY OPERATIONS

Burner adjustments The air and fuel are combined and

they release heat in the burners. To maintain an even distribution
of the heat flow across the oven, the air and the
fuels must be supplied evenly to all the
burners. While the individual settings of the burners affect
a particular burner will also affect the
adjacent burners.

Most boilers have multiple burners in the paths.

of parallel flow at the front and/or on the back walls of the oven.
The burners must be similar in design and must fit the ...
same way to optimize the distribution of airflow. The adjustment for
In general, turbulence and flow rates can vary in the
burners. The increase in turbulence enhances the air-fuel mixture.
combustible. It also increases the intensity of combustion, provides
a faster release of heat, reduces the amount of carbon without
burn (UBC), allows operation with less air in
excess, and increases the efficiency of the boiler.

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However, the increase in NOx emissions, the increase

of scoring and greater energy consumption of the fan can also
increase. Burner systems that are intended for
NOx reduction is typically in the early stages of
combustion and are generally operated with less than the theoretical air for the
complete combustion.
The remaining air necessary to complete the combustion process is
introduce separately, above the area of the main burner. The flow
hot air (OFA) is typically varying as a function
of load, based on parametric tests carried out during the commissioning
march. Although it is normally satisfying to ensure a
complete combustion and compliance with emissions, any change
in the type of fuel, the quality of fuel preparation, or the
fuel/air transport systems will require monitoring
meticulous performance of the OFA system. More dynamic schemes
advanced control methods are available, depending on the feedback in
the measurement of the combustion process in the upper zones of the furnace.
Adjustment of the air vents

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EQUIPMENT

SAFETY VALVES:
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a vulnerable
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important about a boiler, and it can be the last line of defense against
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NATIONAL UNIVERSITY OF ALTIPLANO-PUNO

Thermal driving force

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