Chapter 6

Learning Outcome

Acquire sufficient knowledge of boiler system Able to identify types of boiler and its application.

What is a Boiler?
A boiler

is an enclosed vessel in which water is heated and circulated, either as hot water, steam, or superheated steam
- heating, powering, and/or producing electricity.

Purpose

Fuel/ air mixtures are normally introduced into the furnace (combustion) by using burners, where the flames are formed.
The resulting hot gases travel through a series of heat exchangers, where heat is transferred to the water flowing though them. The combustion gases are finally released to the atmosphere via the stack of exhaust section of the boiler.

Types of Boilers
Back boiler Conventional boiler Combination boiler Combination storage boiler Condensing boiler System boiler Fire tube boiler Water tube boiler

Back Boiler

Back Boiler
Fitted

to a residential heating stove or open fireplace

provide both room heat and domestic hot water or central heating. compact boiler fitted at the back of an open fireplace hearth.

To

Small,

 Hot

water output at the top of the chamber and a cold water feed at the bottom.
circuit - use gravity feed circuit to the hot water cylinder, with a vent or overflow to prevent excess pressure build up.

Water

 Despite

its compact size, a back boiler is more than capable of fulfilling all heating and hot water needs. boilers are reliable, and allow homeowners to run hot water from several taps at once without loss of pressure.

Back

Conventional Boiler

Can have two water tanks in the loft, a large 'cold water storage tank' and a small 'feed and expansion tank'. The 'cold water storage tank' draws water from the cold water mains to refill. Fuel is burned and the hot gases produced are passed through a heat exchanger where much of their heat is transferred to water, thus raising the water's temperature.

Water from the storage tank feeds cold water down to the cylinder . Condensing central heating boiler heats the cylinder - release gallons of hot water to taps throughout the house. A pump circulate hot water via the pipes to the radiators.

Conventional Boiler

Combination (Combi) Boiler

A combi

boiler provides heating and hot water directly from the boiler.

Combi Boiler

A high-efficiency water heater and a central heating boiler, combined (hence the name) within one compact unit.
No separate hot water cylinder is required, offering space saving within the property.

Other Benefits

Significant savings on hot water costs delivered through the taps or shower at mains pressure - without the need for a pump.
Save money on installation time and costs, since no tank in the roof space means less pipe work and a shorter installation time.

Disadvantages
A combi

boiler will only really be able manage one shower or bath at a time.
combi boilers hot water flow rate will be lower than some other boiler.

The

Combination Storage Boiler

By

adding a storage tank to a combi, the problems of flow rate reduction are overcome. Now, a couple of taps can be used. (over conventional boiler) Hot water never runs out. Doesn't need time to recover before you can use it again.

Advantage

Condensing Boiler
Is a water heater in which a high efficiency (typically greater than 90%) It is achieved by using the waste heat in the flue gases to pre-heat the cold water entering the boiler. They may be fuelled by gas or oil Called condensing boilers because the water vapour produced during combustion is condensed into water, which leaves the system via a drain.

Disadvantages
Less reliable Requiring professional installation and regular service Condensate produced on the combustion side of the heat exchanger may corrode an aluminum heat exchanger and shorten the boiler's life.

System Boiler

Like conventional boilers, a system boiler can provide central heating and hot water from a cylinder if required.
The key difference with a system boiler is that all the major components are built in to the boiler. For example the pump, normally installed remote from the boiler, is built in; so is the expansion vessel, which replaces the feed/expansion tank often installed in the loft. The safety valve, the automatic air vent are also included.

 With

these components built in installation time is reduced significantly, fewer materials are required, costs are reduced and servicing is simplified.
A system boiler, just like a regular (conventional) boiler works on the principle of stored hot water.

Different from a conventional boiler

Many of the major individual components of the heating and hot water system are built into a system boiler installation is quicker, neater, easier and more efficient.

The hot water is pumped from the system boiler through the heating system to the radiators and hot water cylinder, resulting in a fast response and more economical.
The system boiler removes the need for a feed and expansion cistern (basin) because it includes an expansion vessel

Firetube Boiler
Water

partially fills a boiler barrel with a small volume left above to accommodate the steam.
in nearly all steam locomotives.

Used

The

heat source is inside a furnace or firebox that has to be kept permanently surrounded by the water in order to maintain the temperature of the heating surface just below boiling point.

 In

the case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot gases pass through a bundle of fire tubes inside the barrel which greatly increase the heating surface compared to a single tube and further improve heat transfer.

Fire-tube

boilers usually have a comparatively low rate of steam production, but high steam storage capacity.

Diagram of a fire-tube boiler

Watertube Boiler
Water

tubes are arranged inside a furnace in a number of configurations: water tubes connect large drums, the lower ones containing water and the upper ones, steam and water in other cases (monotube boiler), water is circulated by a pump through a coils

 This

type generally gives high steam production rates, but less storage capacity than the above. tube boilers can be designed to exploit any heat source and are generally preferred in high pressure applications since the high pressure water/steam is contained within small diameter pipes which can withstand the pressure with a thinner wall.

Water

Watertube Boiler

Boiler 13 Essential Fittings

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Below are the boiler essential fittings; Safety Valves Water Gauges Steam Pressure Gauges Blow Down Valve or Cock Feed Pumps Main Steam Stop Valve Feed Check Valve Inspector's Test Pressure Gauge Attachment Fuse Plug Low Water Alarm Low Water Fuel Cut-Out Manufacturer's Name Plate Registration Plate

http://boilersafe.blogspot.com/2012/02/boiler-13-essential-fittings.html

13 Boiler Essential Fitting (Factory and Machinery Act 1967)

1.

Two or more safety valves, at least one of which shall be of the direct spring-loaded type (for steam boiler having a large heating surface);
Two water gauges (for higher evaporative capacity); A steam pressure gauge;

2.

3.

4. 5.

A blown down valve or cock; Two feed pumps or alternatively one feed pump and one injector (for any steam boiler having a large heating surface) or any steam boiler fitted with automatic controls which "fail to safety" may be fitted with one feed pump; A main steam stop valve; A feed check valve;

6. 7.

8.

An inspector's test pressure gauge attachment;

A fusible plug in each furnace or combustion chamber: provided that any steam boiler fired with liquid or gaseous fuel shall not be required to have a fusible plug; A low-water alarm; A low-water fuel cut-out where such steam boiler is fired with liquid or gaseous fuel; The manufacturer's or maker's name plate; and A registration plate.

9.

10. 11.

12.

13.

Boiler inspection and maintenance

Regular

maintenance program is very important, an annual cleaning is often the best method of to prevent system failure and increase fuel savings should follow manufacturer recommendations. basic elements that should be part of any annual cleaning program.
Inspect and clean the fireside. A dirty fireside (such as one

Some

with deposits of soot and non-combustible material) will lead to loss of efficiency.

 Inspect and clean the waterside. This inspection should not

begin until the boiler has cooled to 120F. Allowing the water to cool will limit the possibility of scalding.
Check the refractory. Boiler failures are often caused by

cracking or erosion in the refractory. Patch as necessary following manufacturer recommendations.

Burner inspection. Open the burner and inspect the

components. All parts should move freely without making contact with other parts. Clean all components to like-new condition.
Detach controls and inspect them for both mechanical and

electrical operation. Reinstall and double check them before restarting boiler.

 Check the fluid levels on hydraulic valves and repair any

signs of leakage.
Adequate fresh air supply should be maintained. Check

filters, and clean or replace them as needed.

Check boiler feed pumps, and replace or recondition if

necessary.
Empty and wash out condensate receivers, and make an

internal inspection. If necessary, overhaul and check for proper operation.

Check electrical connections on starters and relays for

tightness.