Boiler Simulator

8/4/2019 Boiler Simulator

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iOffai ure ofe burner ~_.mbustionna ber

Maincombustion

chamber

A sirmpl·nedsection

through the boilershow ing the locatio

of the failure of theb urn er c om b us tio n

chamber.

Tubes



his gives

additionalngth. a

largerurtace area,and allows

for

i ~~~~~~~~~~~c=~~~~~

burnerusdon

hamberisorrugated. Burner combus tion

chamber Maiineemeuetlon

c ha mb e IF '



T he b urn er comb,ustlon cbarnbe,rfailed lo ng ltu dllnally alndcollap,sed

inward, &llong the tqp' of thechamb,leF"betw'e,en thlese P'OlilntS,.

Deformed ssctlon

Butner combustionchamber

Fracture'Ma:in

eombustlonchamber



lin e e Idf- --lbU I Iii1 0 1

ber cemousno -chamber



In normal ope atlon e burner com _snon chamber iscomptetejy surrounded y - erlll IHeat enerated in the

cham er i transf - rre [0 h - fer vi he -h~ m cr ' , "?- in



el isno co - . letely 0 I

unbe i



EVlentuai- - 1 1 -p-_ - _

h I er

eo

r

If the ituatio i _ allowed to coni i e in a very shorttime the me - reac e I e _ inlg p i ' _ t.becomes

seve el eak. n fin I 'co la se .





WhlYd Id tl3leelngln'eers 110'1react 'tOI I'o'wwater I , e v, e l lal,arDl5,?

-

2. W h'Y did ~.e bo,i_ 'er not auto mati ca i l ly 'shut ,do'wn on Ilow·llloww' i I_ le ' rle'vel ?

Pos'slb,le answers to the' st twoquestions tnclude :

I The, atarm and'sh,uf-dowlTIsystem'swer,e not workilnlg' I

The alar s were over tdden and / (JIi

,III



1 1 1 1?

I al__S

th r ' ,t ch -_

2 1 2 0 4



lev 1 01

Boiller s teamconnection

Controlldevlice

Fulchrum

Boner waterconnecticn

As the water level rl.l. Indthe ftoat wiUfollow, in tum

moving' the operating spindle upand down accordingly.

The movement of the spindle canbe used in a control device to,either open and close the feedwater supply valve, or operateel'ectrical contacts to start and

stop the feed pumps etc.

This is a simple and commonlyused method of water level

control.



el -

BloUersteamecnneetten

Boiler watercormection

W hen the noa!was opened for

in sp ecd on , th e lIo atfound sep arated from

co ntro l arm .

T his m eant that feedwater was not able to

enter the boiler · hencethe low water level and

s u b s e q u e n t c o m b u s t i o nchamber failure.



TI,e I vle~flo· t cl '_ er be -igi

opened for inspection.


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BoU ers



BoU,ers

Tlhere are many different types ,and makes ofboilers, witlil many different functions.

It 'wouldl be I,mpos'slblle for 'this pro'gram to cover allpcsslble boiler co'm,bination's thl,atexist, but co,ncentrates

on the most common typ1es and formats ..

Boil r tylpeclasslflc arion

The, module starts by ,class;iifying boilers in'to, differentgroups 'that are ealsUy fdentined.A vessel, depending

upon its 'tylpe and requlrements, c'ould have anyecmblnatton of these classified groups.

The module then Illustrates themore common boiler types.

The more common boiler types are discussed inmore detail in fo,Uowing separate mon les.



Steamshiip

I Curre1fdly(2002) th e m ost 'colmmlQ type of ship i,1 the motorsh llP, 'w h ere ' th e ,mailn pl~opuls;llon I , sby d l,ls ;e lenlg lne ..

Th e m ajorib ' o lf m eter sh ip,:salre fiiHe,dwith auxil11lia,ry'b 'o ile r's and' 'o rexh;a,uIs't g;asbo ilers. S om e I,ar'glle't ';ank,erswin be fifted with malin

b oilile r. to , su pp lly th eca,lrgo, pumlpin,g sys'tem,.

Th e stearn sh ip w ill a lw,a y!sb,e fltte"dlw;ith ,8 m a in b oile r,to , meetth,e delm alnds o ,fth 'e Imailn propu,l,s: ii,on steam turbines.

S om e spec ial steam po ,werred$ h i I P " S , ~such as g,sa earners I(LNIGandILPG ) rnay be '"ttled with Ud'Ual fuel" main botlers, which can burn

etther h,eavy oll or the "boll off" gas from the carg'o.



Auxiliaryb o , U , e r

A "m aln" b O l n a ' r,c 'D lI1m only smpplil, es8 ; t i ' e ' amfo r ' 11 : 11 8mainIp r IPulsionlmacl lh i l r ; ' l ' e ry"SiIJICtila , sst,"amlturbinel ..

- -

,ole :: Seme t,alnk'81J'8 have ~"Inain·~boil,ellS ,ev,enl th,ough th,e,irmain pr,olpulsilon

lis a d lie s'e lellgilne ..lin 1 ,h islease 'Ie c lllr'g o P U lllp h llO s yM le mhas a v ery largedemall,d for ste,aun rle,quiring 1:be cal~llac.ity of ,a maln bo:ihu.

r- A, ' san AUXILI,AIRYboil'el[ ~

A n1 I I I I aux i l t a ry" ·

boiler commonly supplies steam forauxiliary machinery, such • room systemas engllneIhe 2Iltlinr~g.and domestic •services.

~- ,-,

.~~

A n , vboiler willihave additional tuncrlons. apart from its ma.n f"':I~c.;Jun.



L a scomplex

Lowerpressure

AUXILIARY boiler

Larger.

Heavier

Moreco,rnplex

Hi'gher 'pressure

rNt: The n.any tube hanks are not shown

~~~S_c_a_le_c_o_11_11_)a_ri_s_I_'~~~~~~~~~~~~~. - i l l f i l e I ' l a i l }b o i l e r a b o v e .



There a~e many IUlnctl,onsthat a Ilolle r Imus tprovide th e p rim aryfunction of' C,OUIIiSI is t,o SUplPIy st.am r O l rvariou~ service

requiilremeftts :ab,o,uf'the ves,s,el,.lihes,sm,ayinc:ludesteam 'for:

M'ain P, f,opuls ion turD ,ines.

Turbo.alrterlnators for ge'neratlnge'le'c11tIc,a'lpower ..

Turbine driven Icar'go pumps on a I Iqm' id i,c;argo,tanker.

Auxiliary steam turbine driven pumpa inthe eng'ilne room.

Tank heating.

Fresh water g,enerators.

nglne roem 'system heaters, such as fuelo nhe.t,ers"s,elparato'r he:,aters e t l e . .

E'Aglinre roem machinery "warmingthli,ough U heaters.

'Hot water for dlomes,tic "hotel" services,such as showers, laundry,~,washilng etc.

A,ccom'mo,dat'io,n heating and a i i rconditioningl.





AuxUil81ry ,"='

boiler

F. Q I ! 1 U I I U Ito cla .aitY a by 1 8 stlam flow,st.am low Is often quoted In aboiler specillcation.

A,typical mailinbeller has a rnaxlmum

steam flow o ,f50 tlo nlne 's per h o ur, at40 balrpressure.

AUXliLIARY be,iler steam flow

A typ,ical ll auxiUaryb,orlilelr h,8'S amaximumsteam fl'D'W lo f6 tonnes per hour, at B bar

pressure.

1 1 0J

....12. .. ..

2- - 14I '\

e 16tOl1nes!h

G -i-,1 04 _ , 1 2

'2 .,-. 14- I '\

n 1 1 6b a r

Boillers may b ,e cla•• llied by their metho 'd



W'atertube:s

F' i l retubes

I"

y , yof beat transf1!1 wilhin their tub,.s.

,_ . 'WATER,TIUIB,ES "" ' I I

This a rra ng 1 e lm e n t is :I C : Q 1 m m o n l yals ,s ;o 'Ci ,8 , t,e,dwithmaln boners t b u , t: m o t ' 'inevery ease,

" ".. .

--- -

F'IRETUBE,S

. This arranqement is, commonly ,8ss,o"ciated w'ith

aux liUalry betters.but not in levery case.

The difference between each me'thod isiUustrated on the next display ...,.



WA TE R TU llE

Tulbl'

~





111.s. are IlowprlIIS,SUll'!e b,o,illers"generatin'g steam ataib,out7 barto 191Ibar..Theilr h,.'at 8 Qurcela hllg'h

p,rll:s.sLlre steam, Inio rm lailly " alm ] a 'm alnb1 o,U er ..

'Thley wlQuldnlot bit fitted with sup1

eri1e:aters" ·thewetsteam ~ge'ln lelraledIbe'ln!gused Irolraux:I,Uluy'sY'st'lems,

sueh aa h,eaters ,I,nd dOlm,esticslllrviel,'s.

There alre alt'l'rnrative fue,ls availlabl'l to fire or h eat a b ollef.

Thes',efuels are used but they are not Vlel)' common, and areoften associated with spe'ci,alliised vesse, '1 typ,es.

- -

'GAS FIRIEDI IBIOIILERS

These boilers can burnE:mHIER fuefolU or IgIIS. 'They are l often

found on llquld gas c,arrying vesaels I(LNG and L .P 'IG ) .The gascomes from this "bolloff" from the cargo tanks, _--'TI1Ies,e-hollers are somtimes ,eaUed-udual tuel" boilers.

- - - -- . : _-"_ -

Boil off

Dual fuel

continued ....



When thle''price, of fuel '0 i l lres ,y ry ,quickly"' there' wereseve !ra l e !x lperi mentail IC 'doa l l i i l l i ' edboiler's bunt fOl'rs,hips.

u'slng Wh;811 i lk,no'wrnas a 1"'fIu'ldlsedbed u..

_UCL,E~R

Nuclear IPowered , boilers never found favour lnthe commercial 'wor1ldbecause of p u . b U l cfear of

s"afety and envlronmental Issues.

Neither of the above types w in be covered in detail. as thereare very few of them in use on merchant vessels.



Main oilfired

This Ib"o i i I11e l rmay be CI'u'otedas blein~glwith O~w'll~h 'Q"uta s:lUlper'heatelr'•

No rm ailly th ey A RE.e!dw'lth suplerheater.s.

uxiliary ollfired - -

Thls bejler mlay b ile q u o telld l a s b 'e iln gwith or with ,0 u t, a superheater ..

NormlaUyt h l e ' yare N O T'fltt,e d w ith su perheate'rs.

Both types are basically th,. aame, except for physical size, workpressure and steam 1 f t - o w,the maln boiler b,eing larger in all cases

Both type's cain be' either water tube orfire tu be c on stru cn on .

EXHAUST GAS BOILI!RSI



bollir may b. quoted .. being with or

This type's normally an auxiliary boiler of fir. tube ~''''I~

Both of the above typ,es are commonlyfound on diesel main propulsion plants, to

utilise the ene,rlgy from the main dieselengilne exhaust gases., ;op tJ l""c~d ....

-,+ I eXHAUST GAS~__.,;_ ------'

This, boller Imay be queted as b'eing w'ith or witho,ut a superheater.

This type is nOlrmallly 'an auxinary boiler lo ffire tube construction.



So,m l' woulldlln,o,Cc - ~Ithe 'steam~st••• '&J,llneJator'a Utrull·'•boileli" ,8:8' they gle!nelrateite',.lm~ from steam.

Thleilliheiat seuree Is: 1 f t!g,bp,ressure steam, A,Q from amalilnboU.r, rath ier rflan'ff-D'mla ,'combustiloln c h a 1 m l b e r , .

Hot wa'terg e'n l.ra to r

Som'e' woul,dnot can the hot wat,e 'rg,enleratolr a " true" boiler, as theyonly raise th i,ete mpe ra tu re o fwatelr t'OIjust bellowbo'iiUngpoint

This tvlpe ,ofboiler ls 'foUllndon vessels t'OI'supply' domestic hot watersystems, and m ,a'c h iinery sy stem pre-heaters,



'Th e m :ain I,team ' geneliating tube,sIii, in a velrt11calplene,

T he m ain steam generaltingl tubeslle lin a h o riz ,o n t,a lplane

Both types can be either water t 'l!Jbe orfire tube construction.



Heat

energy

Feed pumip

- - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - -, W ,tin

-- -- ----- This diagram illustrates the basic steam plantsystem, The boiler component can be isol

shown on the r ext d:Sp~'J~' · ..I 'WorkI energy,



The heat sOUlre., fUelmav,be i:

Residual fuel oU

Engine exhaust gas

steam

Nuclear

_ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-- -

Ge1neratedsteam ,out

The steam may be :

Wet steam

S,uperheated steam



Symbo, lfOlra :s,inlgl,eburner fo r as i m i a nboiler,.,

,~

Combustionchamber

The "heist Bource lll device on an oilfired boU.lr ill

c,.Ue!d' aB'URNER.m ep len dlng U lp lD ndesilgn'J therem.y 1beftom 1 to -4bumiersl iftltld.

..._."'.are several symbols which may be usedfor bum.ra, typically •• shown below:

' S , y m b , o lfo r 4 ,bUlllners:'folr a I,llr'gleboiler.

A nern ,a tiv e s'y m'b ol fo r 4burners fO lrII largle boiler.

The burner lill,sd,e silgnedto mh ( tihe fuel elland air tOllgeth,elr,and burn thle' fuelllin a

ICOIMB,US,TIIONCH,A,MBE:R.



Tubas are groupedtoglether .. Th,e

groups O lr tl:;l,b,e'sareknown as TUBE

BANKS.

The different tube stackswill be placed in seriesacross the flow of the

combustion gases,

according to thetem perature of the heat

tra ns fe r re qu ire d.

The'tulb'l bank will Y'sry by :

The number of the tubes:

'T h e dia Lm eter o f'th e tu be s

L,owtemperature

g,as

Hightemperature

g a s

Tubebank2

T'ulbebanlk 3:

'Tubebank '11



'S,at-tvvallves

Gaugeglass,

Feed cheekv a l ' v l e 'S

· "" ' -1Com b us ' t l ionchamber

F ir e b ric kw o rk

'This c:ampll.tes th e,compllone'ntde'scrlptlon

thils time.

YOIIU c 'an e lear th e screand re~runthils display,

m ove onto the nextdlsplay.



Stlearml

spaceIGauge glass

1:]V'

FD air fan

---_

B , u r , n l l e ~ r

~~~W,ater· .:I, . . • , p * c ~ ' ' .

Combustion Generatlnqchamber tubes

T h e exh au st g,8se. are , .away up to the funnel

thr'otlgh a'n exhaus, t 'plpeor t r u n k , i n rg .

IFeed,', IC , h ,eckvalves



'the DIIVE'RTE:RVALV

Gaug'lgllass W

W h eln, 'steam i:srequirede diverter valve is m av

over :10 that th ,e ,exh augas l,! pass thl~'olughtheboner 'g ienarating tubes.

'T he v alv'e can bepositii'one,d in any

intermediate pcsltlon tecontrol the ga:sflow.

Divertervalve

~- - - - -_Exh,8ust

, Q I8 'S inlet: Main dieselengin,e



FDfan . .Burner'

,

!Exhau:s't 'giiS i ,n: , let

in dieselengine

Stopped I

T he C 'O M B US TIO N'CMAMBER.

T1he combu,s l1orn ch'ambeli

h I , I II ln e dw f t t: ' lfI,reb'rlc'kwo'rk.



FDfan . .

Exhaus,tg l a , s~nlilet

Malin dleselengine

2,8..,AT SEA, O N BY PAS S.

The divIner ¥:alvi.wouldbe in the byp,;ass p1osltlon.

T he b urn erunit w'ould be'shut dow n, ne steam Is

generated.

T he arran g,e m en t w o uldbe' as sh own linthe'

dJagralm.



FDfan . .

Exhaustgas Inlet

Mainldiiesell.~engine

2b'.AT SEA, 'S TE AM O N.

Th el div 8lrt.r valve would,ello,.eorr'lhe bypas,s.

The ,'xhaust ga's pa'ssisthro1ugh the' Igeneratl1ng

'tube's" Ii ,ai ls l l lnlgi:steam.

The larrangement W IQ l u ldbe as sh own Itn th e

di"agnlm.



CombUistionchamber

Bur,nelrs

The 'Ic'onomiserheate"xcn:ang'er isusedfer

.,...•• , ...eating the bloller'"edw,ate'r.

The' e 'c ,o,nomiser utilisesw aste h ,.at fr,o im th e

exhaustgas.



S,af.ty val"••

Th e air 'hlater i:s norm,.11y

the laat h e,atexcha'n,gerInthe exhaust trunkllng.

It pre -hea ts 'thec,o'mbll.lsti,ona , l r,i,ncreasl'ng

combusnon 'efficiency.

Combustionchamber

Burners

Lower !i

header' Brick work





- -

Rle'sidual fuel o n- -

:Generat:edsteam lout

---------------- ~--e-~



-- --~--

Can be installed im "wasted'·space. such as the funne,l

housing.

More di,mlCulltaccess flo 'l i 'maintenance. because of

height.

(;;\1\oJ

@.

IM .· . , - .' . · .· .\QJ

Low headroom r,equired.

lealnlnOI ' I ·be lnstalled i:nfunnel,requires v8.lu,ableengline room

space,

@

®

A~ccess fO F maintenance iseasier. because of low he'ight.





- H - '; ; -;;"-"1-- -,' .,

,tat" "I::. • r _ • _ .. . ~ -

'~l1ergy' ','I_ '. t - • •

. . - - .

design Is the ...... iIIIIIir, '"4I!

area for heat transfer

~ Smoke box. From theexhaust g ,8 ' sto the steam In

the steam space.

~ Combustion chamber. Fromthe combustion gas to thewater in the water space.



Tube diam eter - 5 0 m m T h eplain tub

There would bstay tube •

There w ould be 198tubes in total.

N o te th at not ev ery

tUibe is shown.

Approlx. every third tubeis a stay tube.

o Stay tubeo Plain tube





S,1'8ytube

S'tay tube

P la in tub e



V~,e- acro,ss the---l.- __ .__..... ~.,_LU ...J_t:;_IU' .I· _ 3 't_ e _----------~~--~-===~~~~~~

I elded Stay tube 2 0 0 4



• {JIll hHHIIJU IIIlI' -

Spill return"'pply 1 nk

Iglnher s ys te m fu el s up p

-50-=

0-

1 1 00 ( .





· :S t.eam drum

-_ - --

Wate'r drum

Riselr anddlowncomler

tubes b,etwe,ensteam a nd w ater

drums

Babcock Wilcox Type



A D VA N TA G E S

i TIn,eprimary high pressure boiler. 'ela,d wateris'not clrculated (as s'te'.llm) to a,ny

ccnsumere,

-Ie p'lrimlaryhig'h p1re':ss:ureboiller sy'sJtem hasvery smalll feed water loss dUle to leaks in

s team p ilant con su mersy:s;tems,.

Boiler fe ed w 'a .t,e r, q ! u , a U l ymust be high, 'thisneeds expensive ,chemical ' treatments.

Ch,emica'i costs are reduced.

Nlo danqer olf pr'ilmlary'boller wate'r systembeing contaminated by ,o nleaks (from oil

h I, atersatc ).

DISADV'-Nl' AGI!'S

MOireequipment, more maintens_nce.

-

- ----------~- - - - --

.Alr''vent



he boiler could have up to3 burners, each with lts

own turnace, feedinlg inrtolndlvidual combustion

chambers.

I 2 x 'safety valvesI

'St·e,am stenva1lves

.The boiler shape is that of ,8

. large diameter cylinder,lyin'g on itssilde.

.,. linked togethlerd o p rating In p.r.a ll I.



Boiler Simulator

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