HVAC 01 Boiler

Heat, Ventilation &
Air Conditioning (HVAC)

Introduction of Boilers
Department of Maritime Studies Hochschule Wismar

Prof. Dr.-Ing. Michael Rachow
E-Mail: michael.rachow@hs-wismar.de
www.hs-wismar.de
Dept. of Marine Engineering ITS

Sutopo Purwono Fitri, Ph.D.
Email: sutopopf@its.ac.id
www.its.ac.id
PM 24 Heat Ventilation and Air Condition 04/2012
Boilers 2
I. Boiler II. Heat Exchanger III. Fuels
IV. Combustion V. Firing System VI. Combustion Air

Calculation Supplying
VII. Feed Water VIII. Water Steam IX. Condensate

Circulation Management
X. Legal Regulations XI. Safety Equipment XII. Boiler Damage
XII. Thermal Oil XIV. Boiler Operation

Boilers 3
Module Schedule
Summer term:
Steam technology
o 2 CH Lecture (CH = course hours)
o 1 CH Exercise
o 1 CH Laboratory
Winter term:
Refrigeration-, Air conditioning technology
o 1 CH Lecture
o 1 CH Exercise
o 1 CH Laboratory
Prerequisite for Examination: Laboratory slip
Module Examination: Exam 180 minutes (9 ECST)
Boilers 4
Lecture Concept
Module Steam-, Ventilation-, Air Conditioning Technology
Topic overview Steam technology
0 Introduction
1. Steam pressure generation systems
2. Heat exchangers
3. Firing systems and combustion
4. Supply sytems of boilers
5. The water-steam-circuit
6. Condensate management
7. Safety-, regulation- and warning systems of boilers
8. Comissioning and decomissioning of boilers
9. Boiler damages
Boilers 5
References
Mayr F.: Kesselbetriebstechnik, Verlag Dr. Ingo Resch

GmbH, 12. Edition 2009
Effenberger, Helmut; Dampferzeuger; Deutscher Verlag
fr Grundstoffindustrie; 1989; 374 S.
Repetitorium Dampferzeuger; Energie & Management
Verlagsgesellschaft mbH; 1996;227 S.
Brandt, Fritz; Wrmebertragung in Dampferzeuger und
Wrmeaustauschern; VULKAN; 1995; 307 S.
Steinmller; Taschenbuch Dampferzeugertechnik; Vulkan
1999; 278 S.
Boilers 6
Key Aspects
Introduction history
General basics for boilers
Supply systems
Classification of boilers
Physical operating principle
natural circulation boiler
forced circulation boiler
once-through boiler
Boilers 7
Historical Development
History of steam-use goes back to 1st century

1712 first operational steam machine by Thomas
Newcomen =0,5%
1769 James Watts steam engine was patented =3%
First steam turbine by Carl Gustav Patrik de Laval-1883
acting on action principle, almost at once (1884) reaktion
turbine Charles Parsons
Utilization of steam was essential precondition for
industrialization
Boilers 8
Historical Development
Steam today
Steam as heat transfer medium Heating- and process
steam
Steam power plant with unit outputs up to 1300 MWel
Steam generation by:

combustion of fossile fuels
nuclear fission
geothermal energy
sun energy
waste heat (chemical processes, production processes .)
Boilers 9
History of steam in power plant technology
Striving for increase of efficiency leads inevitable to:

pS 250 bar 300 350 bar,
S 550C 600 - 750C
changed boiler constructions
new boiler steels (creep-resistent steel with high load cycle number)
Today reached efficiency of power plants at ca. 50 %
Efficiency can drop in futere ( Exhaust-after treatment plants)
Boilers 10
Charakteristic Boiler
Classical boilers are heat transmitter, which have on the

one hand exhaust gas- and radiant heat as source of
energy and on the other hand water or rather steam as
process medium.
Exhaust gas and water or rather steam are divided by a

solid barrier
Boilers 11
Supply systems of boilers
For the continuous operation important supply systems are:

boiler feeding water system including water treatment
fuel supply system
combustion air supply system
combustion support systems (e.g. ash drain)
regulation- and control systems
safety systems
Boilers 12
Demands on Boilers
High operating safety

Simple operation
Quick adjustment on changing loads
Small required space
Low weight
Low noise development
Additional for ship boilers:
save operation at rolling and pitching of the ship
adequate cooling of heated surfaces at extreme trim-

and stern positions
Boilers 13
Classification of Boilers to Physical Active Principle
Boiler
Natural Forced Forced

Circulation Circulation Once-through
Boiler Boiler Boiler
Boilers 14
Construction Nature Circulation Boiler in Principle
Body of Boiler
Boilers 15
Feedwater
Economizer
Boilers 16
Steam Drum
Boilers 17
Downpipe
Boilers 18
Mud Drum
Boilers 19
Rising Pipes
(Heating Tubes)
Boilers 20
Superheater
Boilers 21
Formation of Nature Circulation

Boilers 22

Steam Drum
Water in boiling
condition
Boilers 23
Downpipes
As much as possible
Boiling condition
Boilers 24
Mud drum
As much as possible
Boiling condition
Boilers 25

Heating tubes
mixed
mixed
Boilers 26
Operation Pressure p (simplified view)
p * g *h
h
Boilers 27
Operation Pressure p
p * g *h
( down rise ) * g * h
h
Boilers 28
p * g *h
down
h
Boilers 29
p * g *h
down
Rise x * (1 x) * h
Boilers 30
p * g *h
down
Rise x * (1 x) * h
p {[ x * (1 x) * ]}* g * h
Boilers 31
p * g *h
p {[ x * (1 x) * ]}* g * h
h
Boilers 32
p * g *h
p {[ x * (1 x) * ]}* g * h
p {[ x * x * ]}* g * h h
Boilers 33
p * g *h
p {[ x * (1 x) * ]}* g * h
p {[ x * x * ]}* g * h h
p { x * x * }* g * h
Boilers 34
p * g *h
p {[ x * (1 x) * ]}* g * h
p {[ x * x * ]}* g * h h
p { x * x * }* g * h
p x * ( )* g * h
Boilers 35
p * g *h
p {[ x * (1 x) * ]}* g * h
p {[ x * x * ]}* g * h h
p { x * x * }* g * h
p x * ( )* g * h
p xrise * ( )* g * h
Boilers 36
pSteam 8bar
h
Boilers 37
p xRise * ( )* g * h
pSteam 8bar
896,86 kg m 3
4,162 kg m 3 h
Boilers 38
pSteam 8bar
896,86 kg m 3
4,162 kg m 3 h
x 0,15
Boilers 39
pSteam 8bar
896,86 kg m 3
4,162 kg m 3 h
x 0,15
kg m
p 0,15 * (896,86 4,162) 3 * 9,81 2 * 3m
m s
Boilers 40
pSteam 8bar
896,86 kg m 3
4,162 kg m 3
x 0,15 h
kg m
p 0,15 * (896,86 4,162) 3
* 9,81 2
* 3m
m s
N
p 3940,82 2 p 3940,82 Pa
m
Boilers 41
pSteam 8bar
896,86 kg m 3
4,162 kg m 3
x 0,15 h
kg m
p 0,15 * (896,86 4,162) 3 * 9,81 2 * 3m
m s
N
p 3940,82 2 p 3940,82 Pa
m
p 0,00394MPa p 0,0394bar
Boilers 42
pSteam 8bar
896,86 kg m 3
4,162 kg m 3
x 0,15 h
kg m
p 0,15 * (896,86 4,162) 3 * 9,81 2 * 3m
m s
p 0,00394MPa
p 0,394mWaterColumn
Boilers 43
Nature Circulation in Different Boiler Type

Air preheater
Large Water Drum Boiler Superheater
Water Tube Boiler

Boilers 44
Charakteristics Nature Circulation

Low operation pressure, depending on steam content
starting up on low load (p=f(p H2O)
after start of evaporation firing capacity can be rised
low heating surfaces load

Boilers 45
Charakteristics Nature Circulation

after start of evaporation firing capacity can be

increased
Downpipes and heating tubes are to be filled always with

water
downpipes and heating tubes enter the steam drum
under the min. water level
Boilers 46
Characteristics Nature Circulation

after start of evaporation firing capacity can be increased
Downpipes and heating tubes are to be filled always with water

down-pipes and heating tubes enter the steam drum under
the min. water level
Cooling of heat exchanging surfaces decreases with rising
steam content
low heat surface load
max. steam content in heating tubes at x=15

Boilers 47
Embodiments of Nature Circulation Boilers
Air layer
Insulation
Water tube boiler

Boilers 48
Water Tube Boiler

Boilers 49
Steam Drum
Laboratory boiler House 5

Lower Drum
Boilers 50
Flue Boiler
Boilers 51
Smoke Tube Boiler
Vertical
smoke tube
boiler
Horizontal smoke tube

boiler as exhaust gas
boiler
Boilers 52
Flue Tube-Smoke Tube Boiler
Flue tube and smoke tube on Flue tube and smoke tube on
top of each other positioned after another positioned
(two-passed with reversing (three-passed with reversing
chambers) chambers)
Boilers 53
Flue Tube Smoke Tube Boiler (two passed with reversing

chambers)
Boilers 54
Reversing Chamber of a Flue Tube Smoke Tube

Boiler
Boilers 55
Water Tube Boiler
Inclined-tube boiler Vertical tube boiler Edge tube boiler

Boilers 56
Construction Forced Circulation Boiler in principle
Feed water entry
Feed water economizer
Superheater
Characteristics:
Circulation pump sustains
circulation flow in all load
Hot steam exit
points of the boiler
Evaporator
Water from the feeding drum
feeds the circulation pump
Evaporator can be postioned
user-defined
Circulation pump
Boilers 57
Characteristics Forced Circulation Boiler
Operating pressure is sustained by circulating pump

starting up on medium load
after warming up firing capacity can be increased
high heating surfaces load possible

Boilers 58

Starting up on medium load
After warming up firing capacity can be increased
High heating surfaces load possible
Water has to run towards the circualting pump
Minimum total suction height to avoid cavitation
Steam drum is to be filled with water sufficiently

Boilers 59

Starting up on medium load
After warming up firing capacity can be increased
High heating surfaces load possible
Water has to run towards the circualting pump
minimum total suction height to avoid cavitation
steam drum is to be filled with water sufficiently
Cooling of heat transmission surfaces decreases with

rising steam content
high circulating water quantities
max. steam content in heating tubes at x= 0,3 - 0,35

Boilers 60
Operation Forced Circulation Boiler
Problem:
Tube lenghts in parallel vaporizer tubes are different
different flow resistances
different circulating quantities
different cooling of tubes

(Influence to steam content and surface temperatures)
Boilers 61
Operation Forced Circulation Boiler
Problem:
Tube lenghts in parallel vaporizer tubes are different
Different flow resistances
Different circulating quantities
Different cooling of tubes

(Influence to steam content and surface temperatures)
Solution:
Matching of flow conditions
installation of dominating flow resistances
increasing pump power

Boilers 62
La-Mont-Boiler (Forced-Circulation-Boiler)
Throttle insert
Boilers 63
Throttle Insert La-Mont-Boiler
Characteristic
curve of
Sub system I
ptotal
circualting pump
Sub system II
Operating point
Pressure drop
Curve of
complete
Picture: Throttle Insert in distribution
circulating
collector of a forced circulation boiler system
a) Vaporizer tube
b) Throttle insert
Mass flow
c) Distribution collector
d) End cap
e) Throttle mounting
f) Pressure spring
Boilers 64
Construction Once-Through-Boiler in principle

Feed water entry
From Feed water economizer
Feed water pump
Evaporator
Characteristics:
Feed water pump forces
water/steam through the boiler
Superheater
Feed water evaporates in one
Hot steam exit pass through
No storage capability
Pre-Evaporator High requirements on boiler
feed water
Boilers 65
Characeristics Once-Through-Boiler
Feeding pressure is generated by feed water pump

high feed water pump power
spare pumps are essential for boiler cooling during in

case of pump failure
very high heating surfaces load possible
Boilers 66

spare pumps essential for boiler cooling in case of

pump failure
Feed water evaporates in one pass through
accompanying substances remain in evaporator
high requirements on purity of feeding water

Boilers 67

spare pumps essential for boiler cooling in case of

pump failure
Feed water evaporates in one pass through
accompanying substances remain in evaporator
high requirements on purity of feeding water
No storage capability
high inertia of boiler (limited control dynamics)

Boilers 68
Benson Boiler
Benson boiler as exhaust

gas boiler of a 50 MW gas
turbine
Boilers 69
Benson Boiler with Partly Forced Circulation
1 Pipes for starting up

2 Flow direction for starting up
3 Flow direction for operation
Distributor
Collector
A1) Starting up pump; B1) Starting up cooler; A2) Operation Feeding- and
Circulating Pump; B2) Operation Cooler; C) Steam Collector; D) Feed Water
Heater; E), F) Radiation Evaporator; G) Contact Evaporator; H) Superheater
Boilers 70
800 MW Power
Plant Boiler
Boilers 71
???

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Heat, Ventilation &

Air Conditioning (HVAC)

Department of Maritime Studies Hochschule Wismar

Dept. of Marine Engineering ITS

I. Boiler II. Heat Exchanger III. Fuels

IV. Combustion V. Firing System VI. Combustion Air

VII. Feed Water VIII. Water Steam IX. Condensate

X. Legal Regulations XI. Safety Equipment XII. Boiler Damage

XII. Thermal Oil XIV. Boiler Operation

Mayr F.: Kesselbetriebstechnik, Verlag Dr. Ingo Resch

History of steam-use goes back to 1st century

Steam power plant with unit outputs up to 1300 MWel

Steam generation by:

History of steam in power plant technology

Striving for increase of efficiency leads inevitable to:

Classical boilers are heat transmitter, which have on the

Exhaust gas and water or rather steam are divided by a

Supply systems of boilers

For the continuous operation important supply systems are:

High operating safety

Quick adjustment on changing loads

Small required space

Low noise development

Additional for ship boilers:

save operation at rolling and pitching of the ship

adequate cooling of heated surfaces at extreme trim-

Classification of Boilers to Physical Active Principle

Natural Forced Forced

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Construction Nature Circulation Boiler in Principle

Formation of Nature Circulation

Formation of Nature Circulation

Formation of Nature Circulation

Formation of Nature Circulation

Formation of Nature Circulation

Operation Pressure p (simplified view)

Nature Circulation in Different Boiler Type

Large Water Drum Boiler Superheater

Water Tube Boiler

Charakteristics Nature Circulation

after start of evaporation firing capacity can be rised

low heating surfaces load

Charakteristics Nature Circulation

after start of evaporation firing capacity can be

Downpipes and heating tubes are to be filled always with

Characteristics Nature Circulation

after start of evaporation firing capacity can be increased

low heating surfaces load

Downpipes and heating tubes are to be filled always with water

max. steam content in heating tubes at x=15

Embodiments of Nature Circulation Boilers

Water tube boiler

Water Tube Boiler

Laboratory boiler House 5

Smoke Tube Boiler

Horizontal smoke tube

Flue Tube-Smoke Tube Boiler

Flue Tube Smoke Tube Boiler (two passed with reversing

Reversing Chamber of a Flue Tube Smoke Tube