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A boiler is a closed vessel in which drinking water or other fluid is heated. The fluid will not boil. (In North America, the term "furnace" is generally used if the reason is not to boil the fluid.) The warmed or vaporized fluid exits the boiler for use in a variety of procedures or heating system applications,[1 - [2 - including water heating, central heating, boiler-based power generation, food preparation, and sanitation.

Materials
The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of boilers credited to corrosion and stress corrosion breaking.[3 - However, ferritic stainless steel is often used in superheater sections that will not come in contact with boiling water, and electrically heated stainless steel shell boilers are allowed under the European "Pressure Equipment Directive" for creation of steam for sterilizers and disinfectors.[4 -
https://en.wikipedia.org/wiki/Boiler - https://en.wikipedia.org/wiki/Boiler
In live steam models, copper or brass is often used since it is more fabricated in smaller size boilers easily. Historically, copper was often used for fireboxes (especially for steam locomotives), due to its better formability and higher thermal conductivity; however, in newer times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as metal) are used instead.

For a lot of the Victorian "age group of vapor", the only materials used for boilermaking was the best quality of wrought iron, with assembly by rivetting. This iron was extracted from specialist ironworks, such as at Cleator Moor (UK), mentioned for the high quality of their rolled plate and its suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice shifted towards the use of steel instead, which is more powerful and cheaper, with welded construction, which is quicker and requires less labour. It should be noted, however, that wrought iron boilers corrode much slower than their modern-day steel counterparts, and are less susceptible to localized pitting and stress-corrosion. This makes the longevity of older wrought-iron boilers considerably more advanced than those of welded steel boilers.

Cast iron might be utilized for the heating vessel of local water heaters. Although such heaters are usually termed "boilers" in some countries, their purpose is usually to produce hot water, not steam, and they also run at low pressure and stay away from boiling. The brittleness of cast iron makes it impractical for high-pressure vapor boilers.
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Energy
The foundation of heating for a boiler is combustion of some of several fuels, such as wood, coal, oil, or natural gas. Electric vapor boilers use level of resistance- or immersion-type heating elements. Nuclear fission is used as a heat source for generating steam also, either directly (BWR) or, generally, in specialised high temperature exchangers called "steam generators" (PWR). Temperature recovery vapor generators (HRSGs) use heat rejected from other processes such as gas turbine.

Boiler efficiency
there are two methods to measure the boiler efficiency 1) direct method 2) indirect method

Immediate method -immediate method of boiler efficiency test is more usable or even more common

boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam circulation Hg= Enthalpy of saturated vapor in k cal/kg Hf =Enthalpy of give food to water in kcal/kg q= level of gasoline use in kg/hr GCV =gross calorific value in kcal/kg like family pet coke (8200 kcal/KG)

indirect method -to gauge the boiler efficiency in indirect method, we need a following parameter like

Ultimate analysis of gas (H2,S2,S,C moisture constraint, ash constraint)
percentage of O2 or CO2 at flue gas
flue gas temperature at outlet
ambient temperature in deg c and humidity of air in kg/kg
GCV of gas in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified into the following configurations:

Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a open fire heats a partially filled water container from below. 18th century Haycock boilers produced and stored large amounts of very low-pressure vapor generally, hardly above that of the atmosphere often. These could burn wood or most often, coal. Efficiency was very low.
Flued boiler with one or two large flues-an early forerunner or kind of fire-tube boiler.

Diagram of a fire-tube boiler
Fire-tube boiler: Here, water partially fills a boiler barrel with a small volume left above to accommodate the vapor (steam space). This is the type of boiler used in nearly all steam locomotives. The heat source is inside a furnace or firebox that has to be held permanently surrounded by water in order to maintain the heat range of the heating system surface below the boiling point. The furnace can be situated at one end of the fire-tube which lengthens the road of the hot gases, thus augmenting the heating system surface which can be further increased by causing the gases reverse direction through a second parallel tube or a bundle of multiple pipes (two-pass or come back flue boiler); additionally the gases may be taken along the sides and then under the boiler through flues (3-move boiler). In case of a locomotive-type boiler, a boiler barrel expands from the firebox and the hot gases go through a bundle of fire pipes inside the barrel which greatly increases the heating system surface in comparison to a single tube and further improves heat transfer. Fire-tube boilers have a comparatively low rate of steam production usually, but high vapor storage capacity. Fire-tube boilers burn solid fuels mostly, but are readily adaptable to those of the gas or liquid variety.

Diagram of a water-tube boiler.
Water-tube boiler: In this type, tubes filled with drinking water are arranged inside a furnace in a genuine number of possible configurations. Often the drinking water tubes connect large drums, the low ones containing water and the upper ones water and steam; in other situations, like a mono-tube boiler, water is circulated with a pump through a succession of coils. This kind generally provides high steam production rates, but less storage capacity than the above mentioned. Water pipe boilers can be designed to exploit any high temperature source and tend to be preferred in high-pressure applications since the high-pressure drinking water/vapor is contained within small size pipes which can withstand the pressure with a thinner wall.
Flash boiler: A flash boiler is a specialized kind of water-tube boiler in which tubes are close collectively and water is pumped through them. A flash boiler differs from the kind of mono-tube vapor generator where the tube is permanently filled with water. In a flash boiler, the pipe is kept so hot that the water give food to is quickly flashed into steam and superheated. Flash boilers experienced some use in automobiles in the 19th century and this use continued in to the early 20th century. .

1950s design vapor locomotive boiler, from a Victorian Railways J class
Fire-tube boiler with Water-tube firebox. Sometimes both above types have been mixed in the following manner: the firebox contains an assembly of water pipes, called thermic siphons. The gases go through a conventional firetube boiler then. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have fulfilled with little success in other countries.
Sectional boiler. Inside a ensemble iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside solid iron areas.[citation needed - These sections are assembled on site to produce the finished boiler.
Safety
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Society of Mechanical Technicians (ASME) develop standards and regulation codes. For example, the ASME Boiler and Pressure Vessel Code is a standard providing an array of guidelines and directives to ensure compliance of the boilers and other pressure vessels with protection, security and design standards.[5 -

Historically, boilers were a source of many serious injuries and property destruction due to badly understood engineering principles. Thin and brittle metal shells can rupture, while welded or riveted seams could start poorly, leading to a violent eruption of the pressurized vapor. When water is converted to vapor it expands to over 1,000 times its original volume and travels down vapor pipes at over 100 kilometres per hour. Because of this, steam is a great way of moving energy and high temperature around a niche site from a central boiler house to where it is needed, but with no right boiler feed water treatment, a steam-raising herb are affected from size development and corrosion. At best, this raises energy costs and can result in poor quality steam, reduced efficiency, shorter plant life and unreliable operation. At worst, it can lead to catastrophic reduction and failure of life. Collapsed or dislodged boiler pipes can also aerosol scalding-hot vapor and smoke out of the air intake and firing chute, injuring the firemen who insert the coal in to the fireplace chamber. Extremely large boilers providing a huge selection of horsepower to use factories could demolish entire structures.[6 -

A boiler that has a loss of give food to drinking water and it is permitted to boil dry out can be extremely dangerous. If supply drinking water is sent into the clear boiler then, the small cascade of incoming water instantly boils on contact with the superheated metal shell and leads to a violent explosion that can't be controlled even by protection steam valves. Draining of the boiler can also happen if a leak occurs in the steam supply lines that is larger than the make-up drinking water supply could replace. The Hartford Loop was developed in 1919 by the Hartford Steam Boiler and INSURANCE PROVIDER as a method to help prevent this problem from happening, and therefore reduce their insurance claims.[7 - [8 -

Superheated steam boiler

A superheated boiler on a steam locomotive.
Main article: Superheater
Most boilers produce steam to be utilized at saturation temperatures; that is, saturated vapor. Superheated steam boilers vaporize water and further heating the steam in a superheater then. This provides steam at much higher temperatures, but can reduce the overall thermal efficiency of the steam generating place because the bigger vapor temp requires a higher flue gas exhaust temp.[citation needed - There are several ways to circumvent this problem, typically by providing an economizer that heats the feed drinking water, a combustion air heater in the hot flue gas exhaust route, or both. There are benefits to superheated vapor that may, and will often, increase overall efficiency of both steam generation and its utilization: benefits in input heat to a turbine should outweigh any cost in additional boiler problem and expense. There may be practical limitations in using wet steam also, as entrained condensation droplets will harm turbine blades.

Superheated steam presents unique safety concerns because, if any system component fails and allows steam to flee, the ruthless and temperature can cause serious, instantaneous injury to anyone in its path. Since the escaping steam will be completely superheated vapor, detection can be difficult, although the intense heat and sound from such a leak indicates its existence clearly.

Superheater operation is similar to that of the coils on an air conditioning unit, although for a different purpose. The vapor piping is directed through the flue gas route in the boiler furnace. The temperature in this field is normally between 1,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are glowing type; that is, they absorb high temperature by radiation. Others are convection type, absorbing temperature from a fluid. Some are a mixture of the two types. Through either method, the extreme heat in the flue gas route will also heat the superheater vapor piping and the steam within. While the heat range of the vapor in the superheater goes up, the pressure of the steam will not and the pressure remains exactly like that of the boiler.[9 - Virtually all steam superheater system designs remove droplets entrained in the steam to avoid damage to the turbine blading and associated piping.

Supercritical steam generator

Boiler for a charged power herb.
Main article: Supercritical steam generator
Supercritical steam generators are used for the production of energy frequently. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical steam generator operates at such a higher pressure (over 3,200 psi or 22 MPa) that the physical turbulence that characterizes boiling ceases to occur; the liquid is neither liquid nor gas but a super-critical liquid. There is absolutely no generation of steam bubbles within the water, because the pressure is above the critical pressure point at which vapor bubbles can form. As the fluid expands through the turbine levels, its thermodynamic condition drops below the critical point as it does work turning the turbine which changes the electrical generator that power is eventually extracted. The fluid at that point may be a mixture of vapor and liquid droplets as it goes by in to the condenser. This results in slightly less gasoline use and therefore less greenhouse gas creation. The term "boiler" shouldn't be used for a supercritical pressure vapor generator, as no "boiling" occurs in this device.
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Accessories
Boiler fittings and accessories
Pressuretrols to regulate the vapor pressure in the boiler. Boilers generally have 2 or 3 3 pressuretrols: a manual-reset pressuretrol, which functions as a safety by setting the upper limit of steam pressure, the working pressuretrol, which settings when the boiler fires to keep pressure, and for boilers equipped with a modulating burner, a modulating pressuretrol which settings the amount of fire.
Protection valve: It is utilized to alleviate pressure and prevent possible explosion of a boiler.
Water level indications: They show the operator the amount of liquid in the boiler, known as a sight cup also, water measure or water column.
Bottom blowdown valves: They provide a way for removing solid particulates that condense and lie on underneath of the boiler. As the name suggests, this valve is located straight on underneath of the boiler usually, and is sometimes opened to use the pressure in the boiler to drive these particulates out.
Continuous blowdown valve: This allows a small level of water to escape continuously. Its purpose is to prevent the water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause water droplets to be carried over with the steam - a condition known as priming. Blowdown is often used to monitor the chemistry of the boiler water also.
Trycock: a type of valve that is often use to manually check a liquid level in a container. Most found on a drinking water boiler commonly.
Flash tank: High-pressure blowdown enters this vessel where the steam can 'flash' safely and be found in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown flows to drain.
Automatic blowdown/constant heat recovery system: This technique allows the boiler to blowdown only once make-up water is moving to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the makeup water. No flash container is normally needed as the blowdown discharged is close to the temp of the make-up water.
Hand openings: They may be steel plates installed in openings in "header" to allow for inspections & installing tubes and inspection of inner surfaces.
Steam drum internals, some display screen, scrubber & cans (cyclone separators).
Low-water cutoff: It is a mechanical means (usually a float change) that is utilized to turn from the burner or shut off energy to the boiler to prevent it from jogging once the drinking water moves below a certain point. If a boiler is "dry-fired" (burnt without water in it) it can cause rupture or catastrophic failure.
Surface blowdown line: It provides a means for removing foam or other light-weight non-condensible substances that have a tendency to float on top of water inside the boiler.
Circulating pump: It really is designed to circulate water back again to the boiler after they have expelled a few of its heat.
Feedwater check valve or clack valve: A non-return stop valve in the feedwater collection. This can be suited to the relative aspect of the boiler, below water level just, or to the very best of the boiler.[10 -
Top feed: Within this design for feedwater injection, water is fed to the very best of the boiler. This may reduce boiler exhaustion caused by thermal stress. By spraying the feedwater over some trays water is quickly heated and this can reduce limescale.
Desuperheater pipes or bundles: Some tubes or bundles of pipes in water drum or the steam drum designed to cool superheated vapor, in order to supply auxiliary equipment that will not need, or may be damaged by, dry vapor.
Chemical injection line: A connection to add chemicals for controlling feedwater pH.
Steam accessories
Main vapor stop valve:
Steam traps:
Main steam stop/check valve: It can be used on multiple boiler installations.
Combustion accessories
Fuel oil system:gasoline oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure gauge attachment:
Name plate:
Registration dish:

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