ESET-212

Boiler and Auxiliaries

School of Engineering Technology & Applied Science

(SETAS)

Week: 6
Boiler Construction &
Calculations.

Centennial College - SDRE: ESET 212 Week 6 1

Watertube Boiler Construction:
 Watertube boilers have water passing through tubes that are
surrounded by the heat and gases of combustion.

 Watertube boilers can be single-drum or multidrum, straighttube

or bent-tube, and single-pass or multipass.

 Watertube boilers carry a smaller volume of water than firetube

boilers and can respond quickly to fluctuating steam loads.

 Watertube boilers which are externally fired do require refractory

material within the furnace area. Because of the spalling and
erosion of the refractory, waterwalls became necessary to reduce
maintenance costs.

 Waterwalls are constructed of closely spaced vertical or

horizontally placed tubes in the furnace walls.

Centennial College - SDRE: ESET 212 Week 6

2
Watertube Boiler Construction:
 Waterwalls increase capacity of
the pounds of steam generated
per hour.
 According to Section I, Power
Boilers, of the ASME code, the
minimum pounds of steam per
hour per square foot of
waterwall heating surface
generated is:

 hand-fired coal boilers-8 pounds/hour/square foot

 stoker-fired coal boilers-12 pounds/hour/square foot

 pulverized coal, fuel oil, or gas boilers-16 pounds/hour/square

foot

Centennial College - SDRE: ESET 212 Week 6

3
Watertube Boiler Construction:
 For pulverized coal

Centennial College - SDRE: ESET 212 Week 6

4
Boiler Operation Calculations:
Longitudinal Stress on Shell / Drum:

The Force is acting on Projected area ABCD

So, Total Force = P X ABCD
Resisting area = 2 X Length X Thickness

Centennial College - SDRE: ESET 212 Week 6

5
Boiler Operation Calculations:

D is the inner diameter.

Drum length does not affect the longitudinal seam
Centennial College - SDRE: ESET 212 Week 6
6
Boiler Operation Calculations::
 Circumferential Stress on Shell / Drum

Force acting on Area:

Centennial College - SDRE: ESET 212 Week 6

7
Resisting area:

Boiler Operation Calculations::

 Circumferential Stress on Shell / Drum

Resisting area:

D is the inner diameter.

Drum length does not affect the circumferential seam

Centennial College - SDRE: ESET 212 Week 6

8
Boiler Operation Calculations::

Problem:
What are the longitudinal and circumferential stresses on a
boiler with a steam pressure of 200 psi, a 40" outer diameter
1
drum that is 12' long, and a plate thickness of inch.
2

Centennial College - SDRE: ESET 212 Week 6

9
Boiler Operation Calculations:
Boiler Heating Surface:
Boiler heating surface is the part of the boiler that has fire and
gases of combustion on one side and water on the other.

In a firetube boiler, heat from gases of comblustion passes through

the tubes that are surrounded by water. Boiler heating surface is
found by using the following equation:

Heating surface of tubes = Circumference of tubes x Length of

tubes x Number of tubes
HStube = C X L X N
Circumferene =  X Diameter of tube
C= 3.1416 x D
Heating surface is measured in sq ft and the diameter of the tubes
is measured in ft.

Centennial College - SDRE: ESET 212 Week 6

10
Boiler Operation Calculations:
Boiler Heating Surface:

• For firetube boilers, use the inside diameter (ID) of the tube to determine
the circumference of the tube. The ID is determined by taking the outside
diameter (OD) minus two times the tube wall thickness.

• For watertube boilers, use the OD to determine the circumference of the

tube.

Centennial College - SDRE: ESET 212 Week 6

11
Boiler Operation Calculations:
Boiler Heating Surface:

Centennial College - SDRE: ESET 212 Week 6

12
Boiler Operation Calculations:
Boiler Heating Surface:

Centennial College - SDRE: ESET 212 Week 6

13
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:

• Boilers are rated in boiler horsepower (BHP), BHP is defined by

an equation using the factor of evaporation.

• 1 BHP is equal to the evaporation (generation) of 34.5 lb of water

per hour from and at 212oF as adopted by the ASME.

• This method of determining BHP is accurate at 212°F.

However, boilers do not operate with steam-water temperatures
of 212°F.

• A factor of evaporation is a correction factor used to compensate

for the difference between evaporation at 212°F and
evaporation at the corresponding temperature in the boiler.

Centennial College - SDRE: ESET 212 Week 6

14
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:
• By using the factor of evaporation, developed boiler horsepower
(DBHP) can be determined at any time. This allows BHP to be
measured precisely throughout the industry.

Centennial College - SDRE: ESET 212 Week 6

15
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:

Centennial College - SDRE: ESET 212 Week 6

16
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:

Centennial College - SDRE: ESET 212 Week 6

17
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:

Centennial College - SDRE: ESET 212 Week 6

18
Boiler Operation Calculations:
Boiler Horsepower and Factor of Evaporation:

Centennial College - SDRE: ESET 212 Week 6

19
Boiler Operation Calculations:

Boiler Horsepower and Factor of Evaporation:

Centennial College - SDRE: ESET 212 Week 6

20
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

21
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

22
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

23
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

24
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

25
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

26
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

27
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

28
Boiler Operation Calculations:
Maximum Allowable Working Pressure
All boilers are designed to have an MAWP and a bursting pressure,
which is usually five times greater than the MAWP. The factor of safety is
used to allow for fatigue, which is caused from age, corrosion, or other
factors. MAWP of a boiler is found by using the following equation:

Centennial College - SDRE: ESET 212 Week 6

29
Boiler Operation Calculations:

Centennial College - SDRE: ESET 212 Week 6

30
Steam and Water
Fittings and Accessories

Chapter: 3

Centennial College - SDRE: ESET 212 Week 6

31
STEAM FlTTINGS AND ACCESSORIES

 Steam fittings (trim) are attached to the boiler and are necessary
for its safe and efficient operation.

 Steam accessories are pieces of equipment not only directly

attached to the boiler and are also required for the operation of
the boiler.

 Steam fittings must be constructed in accordance with the ASME

code. The ASME code also specifies how these fittings are to be
attached to the boiler as determined by the temperatures and
pressures present in the boiler.

Centennial College - SDRE: ESET 212 Week 6

32
STEAM FlTTINGS AND ACCESSORIES
Safety Valves
 A safety valve is a valve used to release pressure and protect the
boiler from exceeding its MAWP and is the most important valve
on the boiler.

 If the MAWP is exceeded, a failure on the pressure side of the

boiler could occur.

 Safety valves must be located at the highest part of the steam

side of the boiler.

 They must be connected to the boiler shell according to ASME

code, with no intervening valves between the safety valve and the
boiler.

Centennial College - SDRE: ESET 212 Week 6

33
STEAM FlTTINGS AND ACCESSORIES
Safety Valves
 The only type of safety valve allowed is the spring-loaded pop-
type safety valve.
 Lever-type and deadweight safety valves can be easily tampered
with and are not permitted.
 The ASME code requires that every boiler have at least one
safety valve.
 Boilers with more than 500 sq ft of heating surface shall have two
or more safety valves.
 Safety valves over 3" in diameter for pressures over 15 psi shall
have a flanged or a weld-end inlet.
 Safety valve discharge piping must be installed and connected to
the safety valve, which allows proper discharge of steam, but
does not place strain on the safety valve.

Centennial College - SDRE: ESET 212 Week 6

34