Comprehesive Boiler Manual Jan 2019

Table of Contents
Preface: Boiler Design ............................................................................................................................................................. 8
1) Primitive Boilers ........................................................................................................................................................... 8
2) Fire Tube ....................................................................................................................................................................... 9
i. Multi-Pass ........................................................................................................................................................... 9
ii. Dryback vs. Wetback ........................................................................................................................................ 10
iii. Tube Connections: Roll and Bead ..................................................................................................................... 12
iv. Stays ................................................................................................................................................................. 13
3) Water Tube ................................................................................................................................................................. 14
i. Types of water tube boilers .............................................................................................................................. 14
ii. Tube Connections: Roll and Flare ..................................................................................................................... 20
iii. Downcomer ...................................................................................................................................................... 21
iv. Superheater ...................................................................................................................................................... 22
v. Steam Scrubber: Baffles/Dry Pipe ..................................................................................................................... 23
vi. Mud Drum continuous heater .......................................................................................................................... 23
4) Water Cum Smoke Tube (Water and Fire Tube) ......................................................................................................... 25
5) Cast Iron Sectional ...................................................................................................................................................... 26
6) Closed Loop Boilers (Hot Water Circulation) .............................................................................................................. 27
Aquastat ................................................................................................................................................................ 27
Air Removal ........................................................................................................................................................... 28
Water Expansion Control ...................................................................................................................................... 29
Exterior Circulation Pumps .................................................................................................................................... 30
Closed Loop Corrosion Control ............................................................................................................................. 30
PEX tubing ............................................................................................................................................................. 31
Antifreeze .............................................................................................................................................................. 32
Condensing Boiler ................................................................................................................................................. 35
7) Co-Generation ............................................................................................................................................................ 37
a. Electricity ........................................................................................................................................................... 37
b. Turbo Generator ............................................................................................................................................... 38
c. Steam Turbine ................................................................................................................................................... 39
d. Condenser ......................................................................................................................................................... 40
e. Non-Condensing Turbines ................................................................................................................................. 41
f. Combined Cycle ................................................................................................................................................. 42
A) Boiler Start Up, Operation and Shutdown ........................................................................................................................ 43
1) Ideal Gas Law: PV=nRT ............................................................................................................................................... 43
i. Heat Pump ........................................................................................................................................................ 45
ii. Dehumidifier ..................................................................................................................................................... 46
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