[boiler [steam generator] description and application]
Student name: Srwd Safin
Class: stage two group-c
Course title: Thermodynamic lab
Department: chemical & petrochemical engineering
College of Engineering Salahaddin University-Erbil
AcademicYear
2024-2025
table of content:
Introduction:…………………………………………………………………………………
Procedure:……………………………………………………………………………………
Types of boilers:…………………………………………………………………………..
Heat sources:………………………………………………………………………………
Steam Application:……………………………………………………………………..
Simulator with controls and fault boiler generation:…………………..
Types of level controle (switches):………………………………………………..
Apparatuse:………………………………………………………………………………..
Discussion:…………………………………………………………………………………
Conclusion:………………………………………………………………………………..
Reference:…………………………………………………………………………………
Introduction
A boiler is an enclosed vessel that provides a means for combustion and transfers
heat to water until it becomes hot water or steam. The hot water or steam under
pressure is then usable for transferring the heat to a process. Water is useful and
cheap medium for transferring heat to a process. When water is boiled into steam
its volume increases about 1,600 times, producing a force that is almost as
explosive as gunpowder. This causes the boiler to be extremely dangerous
equipment and should be treated carefully. Liquid when heated up to the
gaseousstate thisprocess is called evaporation. The heating surface is any
part of the boiler; hot gases of combustion are on one side and water on the
other. Any part of the boiler metal that actually contributes to making steam is
heating surface. The amount of heating surface of a boiler is expressed in square
meters. The larger the heating surface a boiler has, the more efficient it
becomes. The boiler system is consisting of a feed water system, a steam system
& a fuel system.
Procedure
There are two general types of boilers (fire tube) and (water tube). Boilers are
also classified as (high pressure) or (low-pressure) and (steam boiler) or (hot
water boiler). Boilers that operate higher than 15 psig are called (high pressure)
boilers and vice versa. Hot water boilers that have temperatures above 250°
Fahrenheit or pressures higher than 160 psig are called (high temperature hot
water boilers). Hot water boilers that have temperatures not exceeding 250°
Fahrenheit or pressures not exceeding 160 psig are called (low temperature hot
water boiler's).
Types of boiler
a) Fire tube Boilers:
In firetube boilers, combustion gases pass through the inside of the tubes
with water surrounding the outside of the tubes. The heat is conducted through
the walls of tube from the hot gases through the surrounding water.
Advantages of Fire Tube Boilers:
1. It is quite compact in construction.
2. Fluctuation of steam demand can be met easily.
3. It is also quite cheap.
Disadvantages of Fire Tube Boilers:
1. As the water required for operation of the boiler is quite large, it requires long
time for rising steam at desired pressure.
2. As the water and steam are in same vessel the very high pressure of steam is
not possible.
3. The steam received from fire tube boiler is not very dry.
b) Water tube Boilers:
In a water-tube boiler the water is inside the tubes and combustion gases pass
around the outside of the tubes. A water-tube design is the exact opposite of a
fire-tube. Here, the water flows through the tubes and is encased in a furnace in
which the burner fires.
Advantages of Water Tube Boilers:
1. Larger heating surface can be achieved by using more numbers of water tubes.
2. Due to convectional flow, movement of water is much faster than that of fire
tube boiler, hence rate of heat transfer is high which results into higher efficiency.
3. Very high pressure in order of 140 kg/cm2 can be obtained smoothly.
Disadvantages of Water Tube Boilers:
1. The main disadvantage of water tube boiler is that it is not compact in
construction.
2. Its cost is not cheap.
Figure 1/ schematic diagram of water tube boiler and fire tube boiler.
Heat sources
Heat sources such as burners, solar energy, and nuclear reactors vary in the way
they generate heat:
1. Burner: A burner typically uses the combustion of fuels like natural gas, oil, or
wood to produce heat. Burners are widely used in homes, industries, and power
plants for heating purposes.
2. Solar Energy: Solar energy harnesses the power of the sun to generate heat.
Solar thermal systems use sunlight to heat a fluid, which can then be used for
space heating, water heating, or generating electricity through a steam turbine.
3. Nuclear Reactor: In a nuclear reactor, the heat is produced through nuclear
fission, where the nucleus of atoms (usually uranium or plutonium) is split,
releasing a large amount of energy. This heat is used to produce steam that drives
turbines to generate electricity.
Steam Application
Steam has a wide range of applications across various industries due to its ability
to transfer large amounts of energy. Here's a breakdown of its uses in power
generation and industrial applications:
1. Power Generation:
Steam is the driving force behind many power plants, particularly in the following
ways:
Thermal Power Plants: Steam is generated by heating water using coal, natural
gas, oil, or nuclear reactions. This steam drives turbines, which convert thermal
energy into mechanical energy, and subsequently into electrical energy.
Combined Cycle Power Plants: These plants use both gas and steam turbines. The
gas turbine produces electricity, and the waste heat is used to generate steam,
which powers a secondary turbine, increasing overall efficiency.
Geothermal Power Plants: Steam from geothermal sources is harnessed directly
to drive turbines.
2. Industrial Applications:
Steam is used in various industrial processes that require heating, cleaning, and
mechanical work. Specific industries include:
Steam Cleaning:
Used for cleaning and sterilization in industries like pharmaceuticals, hospitals,
and heavy equipment.
Effective for removing dirt, grease, and contaminants from surfaces.
Food Factories:
Used in food processing for cooking, drying, and sterilizing food products.
Steam is often used for pasteurization, blanching, and other thermal processes
that require precise temperature control.
Textile Factories:
Steam is used in dyeing, drying, and finishing fabrics. The textile industry relies on
steam to provide consistent heat for processes like setting fibers and treating
materials.
Chemical Factories:
Steam plays a vital role in various chemical processes such as distillation, heating,
and polymerization.
It's used for cleaning equipment, temperature control, and producing chemicals
that require heat for reactions.
Steam's versatility, safety, and efficiency make it an essential utility in these
sectors, enhancing productivity and ensuring consistent quality.
Simulator with controls and fault boiler generation
Overpressure: The simulator would detect a fault if the pressure exceeds a safety
threshold, possibly due to valve failure or insufficient [Link] Water Level: If
the water level drops below a certain point, the simulator triggers an alarm and
possibly shuts down the boiler to prevent [Link] Instability.
Types of level controle (switches)
1- capacitive level control:
A capacitive level sensor is an electronic device that measures the height of a fluid
surface. The sensor consists of a conductive plate, which is mounted on a
movable arm.
2- Magnetic level control;
These types of level switches detect the level of a liquid by sensing the level of the
magnet within the float & transmit the data back toward the control system. This
switch includes buoyancy, electronics & magnetostriction to measure liquid
levels.
3- Optical level control:
These switches simply use the reflection concept within a prism & it is utilized for
high pressure & temperature applications.
Apparatuse
The experiment devise designed for us a working model simulating all the factors
governing the use, the operating, maintenance and repair of a steam generating
system.
For example:
⮚ A mixed gas/oil burner;
⮚ Three different types of level controls;
⮚ Modulation and safety pressure switches;
⮚ Failure generating panels;
⮚ Synoptic panels with connectors and indicator lamps;
⮚ Electrical fault-finding circuit.
The boiler body is made of transparent material to enable the
students to observe the behavior of the hydraulic phenomena
taking place inside the boiler and that of the various controls.
The electrical control and management board, with the synoptic
panel and the failure generator at the front, is fixed to the
structure of the boiler.
The Device Component
View of the system
1. Electrical control panel
2. Water tank with 100 l. capacity
3. Combined gas/oil burner
4. Mechanical type level control
5. Pressure control manometer
6. Safety valve
7. Max./min. level probe
8. 3-probe electronic level control
9. Magnetic type level control
10. Bunching steam tank
11. Reed contact type level control
❖ IG General switch
❖ F1-5 Fuses
❖ TP 1-8 Connectors for electric tests
❖ Min. level (TP6/7) / Minimum level in the boiler
❖ Pressure (TP7/8) / Pressure in the boiler
❖ Min. level (TP3/4) / Minimum level in the supply tank
❖ Max. level (TP4/5) / Max. level in the boiler
❖ Water feed pump
❖ Relief valve
❖ Steam outlet
❖ P Manometer
❖ S1 Burner selector
❖ Flame failure reset
❖ Flame failure
❖ Gas burner / Gas burner synoptic panel
❖ Oil burner / Oil burner synoptic panel
1. Pedal operated pump for boiler pressure simulation
2. Water recirculation pump
3. Pressure accumulator
4. Working pressure switch
5. Maximum pressure with manual reset pressure switch
6. Working thermostat
7. Gas minimum pressure switch
8. Water recirculation valve
9. Discharge valve
10. Gas feed solenoid valve
` Fault simulation panel
This is located to the right of the electric panel and it accommodates twenty
switches, each of them having a different function, which produce different
operating anomalies by opening or short circuiting the electric nodes.
The effects of the anomalies change depending on the type of burner used
(whether gas or oil fuelled). The table lists the different switches and their specific
functions.
DISCUSSION
In this experiment we learnt how to use different types of boiler and working
principle of each part of the boiler.
And I am going to discuss the steps of working :
A steam generator is basically a heat exchanger. A heat source warms a pool of
liquid water to above boiling temperature. Steam vapor collects in the space at
the top. Steam vapor may go through a moisture separator and then leave the
steam generator to do work or to heat a building. Liquid water is returned to the
steam generator to maintain a consistent liquid level. The steam generator must
be built to withstand the operating pressure of the steam.
conclusion
After doing this study we have learnt the working principal, major components &
otherregarding instruments of Boiler.
reference
[Link]
[Link]
Experiment_Name_Study_of_Boiler_Objectives
[Link]
mechanical-engineering-design-analysis/experiment-no-5/6173290
[Link]
[Link]