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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 THE UNITED STATES, the word "furnace" is normally used if the reason is not to boil the fluid.) The heated or vaporized fluid exits the boiler for use in various procedures or heating system applications,[1 - [2 - including water heating, central heating system, boiler-based power generation, cooking food, and sanitation.

Materials
The pressure vessel of the boiler is usually manufactured from steel (or alloy steel), or of wrought iron historically. Stainless steel, especially of the austenitic types, is not used in wetted elements of boilers due to stress and corrosion corrosion breaking.[3 - However, ferritic stainless steel is often used in superheater sections that will not come in contact with boiling drinking water, and electrically heated stainless steel shell boilers are allowed under the Western european "Pressure Equipment Directive" for production 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 easier fabricated in smaller size boilers. Historically, copper was often used for fireboxes (especially for steam locomotives), because of its better formability and higher thermal conductivity; however, in more recent times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as steel) are used instead.

For much of the Victorian "age group of vapor", the only material used for boilermaking was the highest quality of wrought iron, with assembly by rivetting. This iron was often obtained from specialist ironworks, such as at Cleator Moor (UK), observed for the high quality of their rolled plate and its own 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 structure, which is quicker and requires less labour. It ought to be observed, however, that wrought iron boilers corrode much slower than their modern-day metal counterparts, and are less vunerable to localized stress-corrosion and pitting. This makes the durability of older wrought-iron boilers considerably superior to those of welded steel boilers.

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

Boiler efficiency
there are two solutions to gauge the boiler efficiency 1) direct method 2) indirect method

Immediate method -direct method of boiler efficiency test is more functional or more common

boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total vapor flow Hg= Enthalpy of saturated steam 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 pet coke (8200 kcal/KG)

indirect method -to gauge the boiler efficiency in indirect method, we are in need of a subsequent 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 gasoline in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified in to the following configurations:

Pot boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a fire heats a partially filled drinking water box from below. 18th century Haycock boilers produced and stored large quantities of very low-pressure vapor generally, often hardly above that of the atmosphere. These could burn off wood or frequently, coal. Efficiency was suprisingly low.
Flued boiler with a couple of large flues-an early forerunner or kind of fire-tube boiler.

Diagram of the fire-tube boiler
Fire-tube boiler: Here, water partially fills a boiler barrel with a small volume remaining above to accommodate the vapor (vapor space). This is the kind of boiler used in almost all steam locomotives. Heat source is inside a furnace or firebox that needs to be held completely surrounded by water in order to keep the heat range of the heating 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 surface which can be further increased by making the gases reverse direction through another parallel pipe or a bundle of multiple pipes (two-pass or come back flue boiler); alternatively the gases may be studied along the sides and then under the boiler through flues (3-move boiler). In case there is a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases go through a bundle of fire pipes inside the barrel which greatly escalates the heating surface in comparison to a single tube and further enhances heat transfer. Fire-tube boilers have a comparatively low rate of vapor production usually, but high steam storage capacity. Fire-tube boilers burn solid fuels mainly, but are easily flexible to the people of the liquid or gas variety.

Diagram of the water-tube boiler.
Water-tube boiler: In this type, pipes filled with drinking water are arranged in the furnace in a true quantity 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, such as a mono-tube boiler, drinking 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. Water pipe boilers can be made to exploit any warmth source and tend to be preferred in high-pressure applications because the high-pressure water/steam is included within small size pipes which can withstand the pressure with a thinner wall structure.
Flash boiler: A flash boiler is a specialized kind of water-tube boiler where pipes are close collectively and drinking water is pumped through them. A flash boiler differs from the type of mono-tube vapor generator where the pipe is permanently filled up with water. Super fast boiler, the pipe is kept so hot that the water give food to is quickly flashed into steam and superheated. Flash boilers had some use in automobiles in the 19th century and this use continued into the early 20th century. .

1950s design steam locomotive boiler, from a Victorian Railways J class
Fire-tube boiler with Water-tube firebox. Sometimes the two above types have been combined in the next manner: the firebox contains an set up of water pipes, called thermic siphons. The gases pass through a typical firetube boiler then. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have met with little success far away.
Sectional boiler. Inside a cast iron sectional boiler, sometimes called a "pork chop boiler" the water is included inside cast iron sections.[citation needed - These sections are assembled on site to create the finished boiler.
Safety
See also: Boiler explosion
To define and secure boilers safely, some professional specialized organizations like the American Society of Mechanical Designers (ASME) develop specifications and regulation codes. For example, the ASME Boiler and Pressure Vessel Code is a typical providing an array of guidelines and directives to ensure compliance of the boilers and other pressure vessels with safety, security and design standards.[5 -

Historically, boilers were a way to obtain many serious injuries and property destruction as a consequence to badly understood engineering principles. Thin and brittle metallic shells can rupture, while welded or riveted seams could start badly, leading to a violent eruption of the pressurized vapor. When drinking water is changed into vapor it expands to over 1,000 times its original quantity and travels down steam pipes at over 100 kilometres per hour. As a result of this, steam is a superb way of moving energy and high temperature around a site from a central boiler house to where it is necessary, but without the right boiler give food to water treatment, a steam-raising plant will suffer from range corrosion and formation. At best, this boosts energy costs and can result in poor quality steam, reduced efficiency, shorter vegetation and unreliable procedure. At worst, it can lead to catastrophic failure and lack of life. Collapsed or dislodged boiler tubes can also aerosol scalding-hot vapor and smoke out of the air intake and firing chute, injuring the firemen who weight the coal into the open fire chamber. Extremely large boilers providing hundreds of horsepower to use factories can potentially demolish entire buildings.[6 -

A boiler which has a loss of give food to drinking water and is permitted to boil dry out can be hugely dangerous. If feed drinking water is sent into the unfilled boiler then, the small cascade of incoming drinking water instantly boils on contact with the superheated metallic shell and leads to a violent explosion that cannot be controlled even by security vapor valves. Draining of the boiler can also happen if a leak occurs in the vapor supply lines that is bigger than the make-up drinking water supply could replace. The Hartford Loop was developed in 1919 by the Hartford Vapor Boiler and Insurance Company as a strategy to help prevent this problem from taking place, 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 used at saturation temperature; that is, saturated vapor. Superheated steam boilers vaporize water and further heat the steam in a superheater then. This provides steam at much higher heat range, but can reduce the overall thermal efficiency of the vapor generating flower because the bigger steam temperature requires a higher flue gas exhaust heat range.[citation needed - There are many ways to circumvent this issue, by giving an economizer that heats the feed drinking water typically, a combustion air heater in the hot flue gas exhaust route, or both. You will find advantages to superheated vapor that may, and often will, increase overall efficiency of both vapor generation and its own utilization: benefits in input heat range to a turbine should outweigh any cost in additional boiler problem and expense. There can also be practical limitations in using moist vapor, as entrained condensation droplets will harm turbine blades.

Superheated steam presents unique safety concerns because, if any system component fails and allows steam to escape, the high temperature and pressure can cause serious, instantaneous harm to anyone in its path. Since the escaping steam will be completely superheated vapor, detection can be difficult, although the extreme heat and sound from such a leak obviously indicates its presence.

Superheater procedure is similar to that of the coils on an fresh air conditioning unit, although for a different purpose. The steam piping is directed through the flue gas path in the boiler furnace. The temperature in this field is between 1 typically,300 and 1,600 °C (2,372 and 2,912 °F). Some superheaters are glowing type; that is, they absorb temperature by radiation. Others are convection type, absorbing warmth from a fluid. Some are a mixture of both types. Through either method, the extreme heat in the flue gas path will also high temperature the superheater vapor piping and the vapor within. While the temp of the vapor in the superheater rises, the pressure of the steam does not and the pressure remains the same as that of the boiler.[9 - Almost all steam superheater system designs remove droplets entrained in the steam to prevent harm to the turbine blading and associated piping.

Supercritical steam generator

Boiler for a charged power plant.
Main article: Supercritical steam generator
Supercritical steam generators are generally used for the production of energy. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical steam generator operates at such a high pressure (over 3,200 psi or 22 MPa) that the physical turbulence that characterizes boiling ceases that occurs; the fluid is liquid nor gas but a super-critical fluid neither. There is absolutely no era of steam bubbles within water, because the pressure is above the critical pressure point of which steam bubbles can form. As the fluid expands through the turbine stages, its thermodynamic condition drops below the critical point as it does work turning the turbine which turns the electrical generator from which power is eventually extracted. The liquid at that point may be considered a mixture of steam and liquid droplets as it passes in to the condenser. This leads to somewhat less fuel use and therefore less greenhouse gas creation. The term "boiler" should not be used for a supercritical pressure vapor generator, as no "boiling" occurs in this product.
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Accessories
Boiler fittings and accessories
Pressuretrols to regulate the steam pressure in the boiler. Boilers generally have 2 or 3 3 pressuretrols: a manual-reset pressuretrol, which functions as a security by setting top of the limit of vapor pressure, the working pressuretrol, which settings when the boiler fires to keep pressure, as well as for boilers equipped with a modulating burner, a modulating pressuretrol which settings the amount of fire.
Safety valve: It is utilized to relieve pressure and stop possible explosion of a boiler.
Water level signals: They show the operator the level of liquid in the boiler, also known as a sight glass, water gauge or drinking water column.
Bottom blowdown valves: They provide a way for removing solid particulates that condense and rest on the bottom of the boiler. As the name indicates, this valve is usually located on the bottom of the boiler, and is sometimes opened to use the pressure in the boiler to push these particulates out.
Constant blowdown valve: This enables a small level of water to flee continuously. Its purpose is to prevent 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 also often used to monitor the chemistry of the boiler drinking water.
Trycock: a kind of valve that is often use to manually check a water level in a container. Most commonly found on a drinking water boiler.
Flash tank: High-pressure blowdown enters this vessel where in fact the vapor can 'flash' safely and become 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 system allows the boiler to blowdown only when make-up water is flowing to the boiler, thereby transferring the maximum amount of heat possible from the blowdown to the make-up water. No flash container is generally needed as the blowdown discharged is near to the temp of the make-up water.
Hand openings: They may be steel plates installed in openings in "header" to permit for inspections & installing tubes and inspection of inner surfaces.
Vapor drum internals, some display screen, scrubber & cans (cyclone separators).
Low-water cutoff: It really is a mechanical means (usually a float switch) that is used to turn from the burner or shut down gas to the boiler to avoid it from running once the drinking water runs below a certain point. If a boiler is "dry-fired" (burnt without drinking water in it) it can cause rupture or catastrophic failure.
Surface blowdown collection: It provides a way for removing foam or other lightweight non-condensible substances that tend to float on top of the water inside the boiler.
Circulating pump: It is made 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 series. This can be suited to the comparative side of the boiler, below water level just, or to the very best of the boiler.[10 -
Top feed: In 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 a series of trays water is quickly warmed and this can reduce limescale.
Desuperheater pipes or bundles: Some pipes or bundles of pipes in water drum or the vapor drum designed to cool superheated steam, in order to provide auxiliary equipment that does not need, or may be damaged by, dry out vapor.
Chemical injection line: A connection to add chemicals for controlling feedwater pH.
Steam accessories
Main vapor stop valve:
Steam traps:
Main vapor stop/check valve: It is used on multiple boiler installations.
Combustion accessories
Fuel oil system:gas oil heaters
Gas system:
Coal system:
Soot blower
Other essential items
Pressure gauges:
Feed pumps:
Fusible plug:
Inspectors test pressure measure attachment:
Name plate:
Registration plate:

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