Jameshek A boiler is a closed vessel in which water or other liquid is heated. The fluid does not boil. (In North America, the word "furnace" is normally used if the purpose is not to boil the fluid.) The warmed or vaporized liquid exits the boiler for use in various procedures or heating applications,[1 - [2 - including water heating, central heating system, boiler-based power era, cooking food, and sanitation.

Materials
The pressure vessel of the boiler is usually manufactured from steel (or alloy steel), or historically of wrought iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of boilers due to corrosion and stress corrosion cracking.[3 - However, ferritic stainless is often found in superheater sections that won't be exposed to boiling water, and electrically heated stainless shell boilers are allowed under the Western "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 more fabricated in smaller size boilers easily. Historically, copper was often used for fireboxes (particularly for steam locomotives), due to its better formability and higher thermal conductivity; however, in newer 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 materials used for boilermaking was the highest grade of wrought iron, with assembly by rivetting. This iron was extracted from specialist ironworks, such as at Cleator Moor (UK), observed for the high quality of their rolled plate and its suitability for high-reliability use in critical applications, such as high-pressure boilers. In the 20th century, design practice instead transferred towards the utilization of steel, which is stronger and cheaper, with welded construction, which is quicker and requires less labour. It ought to be observed, however, that wrought iron boilers corrode significantly 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 significantly superior to those of welded metal boilers.

Cast iron might be utilized for the heating vessel of local water heaters. Although such heaters are usually termed "boilers" in a few countries, their purpose is to create warm water usually, not steam, and so they run at low pressure and stay away from boiling. The brittleness of cast iron helps it be impractical for high-pressure vapor 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 gas. Electric steam boilers use level of resistance- or immersion-type heating system elements. Nuclear fission can be used as a heat source for producing steam also, either straight (BWR) or, generally, in specialised warmth exchangers called "steam generators" (PWR). Temperature recovery vapor generators (HRSGs) use the heat rejected from other procedures such as gas turbine.

Boiler efficiency
there are two methods to measure the boiler efficiency 1) direct method 2) indirect method

Direct method -immediate method of boiler efficiency test is more useful or even more common

boiler efficiency =Q*((Hg-Hf)/q)*(GCV *100 ) Q =Total steam movement Hg= Enthalpy of saturated steam in k cal/kg Hf =Enthalpy of feed drinking water in kcal/kg q= level of energy use in kg/hr GCV =gross calorific value in kcal/kg like family pet coke (8200 kcal/KG)

indirect method -to gauge the boiler efficiency in indirect method, we are in need of a following parameter like

Ultimate analysis of gasoline (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 energy in kcal/kg
ash percentage in combustible fuel
GCV of ash in kcal/kg
Configurations
Boilers can be classified in to the following configurations:

Container boiler or Haycock boiler/Haystack boiler: a primitive "kettle" where a fireplace heats a partially filled water container from below. 18th century Haycock boilers produced and stored large volumes of very low-pressure vapor generally, hardly above that of the atmosphere often. These could burn wood or most often, coal. Efficiency was suprisingly low.
Flued boiler with one or two large flues-an early type or forerunner of fire-tube boiler.

Diagram of the fire-tube boiler
Fire-tube boiler: Here, water partially fills a boiler barrel with a little volume left above to accommodate the vapor (steam space). This is the kind of boiler used in all steam locomotives nearly. Heat source is in the furnace or firebox that has to be held permanently surrounded by water in order to keep the heat of the heating system surface below the boiling point. The furnace can be situated at one end of a fire-tube which lengthens the road of the hot gases, thus augmenting the heating system surface which may be further increased by causing the gases invert direction through another parallel pipe or a bundle of multiple tubes (two-pass or return flue boiler); on the other hand the gases may be taken along the edges and then under the boiler through flues (3-pass boiler). In case there is 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 increases the heating system surface in comparison to a single tube and further improves heat transfer. Fire-tube boilers have a comparatively low rate of steam production usually, but high vapor storage capacity. Fire-tube boilers mostly burn off solid fuels, but are readily adjustable to those of the liquid or gas variety.

Diagram of a water-tube boiler.
Water-tube boiler: In this type, tubes filled with water are arranged inside a furnace in a genuine quantity of possible configurations. Water tubes connect large drums Often, the low ones filled with drinking water and the top ones steam and water; in other cases, like a mono-tube boiler, water is circulated with a pump through a succession of coils. This type generally gives high steam creation rates, but less storage space capacity than the above. Water pipe boilers can be designed to exploit any warmth source and are generally preferred in high-pressure applications because the high-pressure water/steam is contained within small diameter 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 jointly and drinking water is pumped through them. A flash boiler differs from the kind of mono-tube vapor generator in which the pipe is permanently filled up with water. Super fast boiler, the tube is held so hot that water feed is quickly flashed into vapor and superheated. Flash boilers had some use in automobiles in the 19th century and this use continued in to the early 20th century. .

1950s design vapor 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 assembly of water pipes, called thermic siphons. The gases go through a conventional firetube boiler then. Water-tube fireboxes were installed in many Hungarian locomotives,[citation needed - but have fulfilled with little success far away.
Sectional boiler. Inside a cast iron sectional boiler, sometimes called a "pork chop boiler" the water is contained inside solid iron sections.[citation needed - These sections are assembled on site to produce 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 requirements and regulation rules. For example, the ASME Boiler and Pressure Vessel Code is a standard providing a wide range of rules and directives to ensure compliance of the boilers and other pressure vessels with security, design and security standards.[5 -

Historically, boilers were a source of many serious injuries and property destruction due to badly understood engineering principles. Thin and brittle metallic shells can rupture, while badly welded or riveted seams could open up, resulting in a violent eruption of the pressurized vapor. When drinking water is changed into vapor it expands to over 1,000 times its original travels and volume down steam pipes at over 100 kilometres per hour. As a result of this, vapor is a superb way of moving energy and heat around a site from a central boiler house to where it is needed, but without the right boiler give food to water treatment, a steam-raising vegetable are affected from range formation and corrosion. At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter vegetation and unreliable procedure. At worst, it can result in catastrophic loss and failing of life. Collapsed or dislodged boiler pipes can also spray 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 operate factories can potentially demolish entire structures.[6 -

A boiler that has a loss of give food to drinking water and it is permitted to boil dry out can be extremely dangerous. If supply water is then sent in to the bare boiler, the tiny cascade of inbound drinking water instantly boils on connection 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 steam supply lines that is bigger than the make-up drinking water source could replace. The Hartford Loop was invented in 1919 by the Hartford Vapor Boiler and INSURANCE PROVIDER as a method to help prevent this condition from happening, and thereby reduce their insurance claims.[7 - [8 -

Superheated steam boiler

A superheated boiler on the steam locomotive.
Main article: Superheater
Most boilers produce steam to be utilized at saturation heat range; that is, saturated steam. Superheated steam boilers vaporize the water and further heat the steam in a superheater then. This provides vapor at higher temp, but can decrease the overall thermal efficiency of the steam generating seed because the bigger vapor temperatures requires a higher flue gas exhaust temperatures.[citation needed - There are several ways to circumvent this issue, typically by providing an economizer that heats the give food to water, a combustion air heater in the hot flue gas exhaust path, or both. You can find benefits to superheated vapor that may, and will often, increase overall efficiency of both steam generation and its own utilization: gains in input temp to a turbine should outweigh any cost in additional boiler complication and expense. There can also be useful restrictions in using moist vapor, as entrained condensation droplets will damage turbine blades.

Superheated steam presents unique safety concerns because, if any operational system component fails and allows steam to escape, the high pressure and temperature can cause serious, instantaneous injury 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 indicates its existence clearly.

Superheater operation 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 route in the boiler furnace. The heat 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 liquid. Some are a combination of the two types. Through either method, the extreme heat in the flue gas route will also heat the superheater vapor piping and the steam within. While the heat range of the steam in the superheater increases, the pressure of the steam does not and the pressure remains exactly like 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 place.
Main article: Supercritical steam generator
Supercritical steam generators are used for the production of electric power frequently. They operate at supercritical pressure. As opposed to a "subcritical boiler", a supercritical steam generator operates at such a higher pressure (over 3,200 psi or 22 MPa) that the physical turbulence that characterizes boiling ceases to occur; the fluid is liquid nor gas but a super-critical fluid neither. There is no generation of steam bubbles within the water, because the pressure is above the critical pressure point at which vapor bubbles can develop. As the fluid expands through the turbine levels, its thermodynamic state drops below the critical point as it can work turning the turbine which converts the power generator that power is ultimately extracted. The fluid at that time may be considered a mix of steam and liquid droplets as it goes by into the condenser. This leads to less fuel use and for that reason less greenhouse gas production slightly. The term "boiler" should not be used for a supercritical pressure steam generator, as no "boiling" occurs in this product.
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Accessories
Boiler fittings and accessories
Pressuretrols to regulate the vapor pressure in the boiler. Boilers generally have two or three 3 pressuretrols: a manual-reset pressuretrol, which functions as a basic safety by setting the top 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 controls the amount of fire.
Basic safety valve: It can be used to alleviate pressure and prevent possible explosion of the boiler.
Water level indicators: They show the operator the amount of fluid in the boiler, also known as a sight glass, water measure or water column.
Bottom level blowdown valves: They offer a way for removing solid particulates that condense and lay on underneath of a boiler. As the name implies, this valve is located directly on the bottom of the boiler usually, and is sometimes opened up to use the pressure in the boiler to force these particulates out.
Continuous blowdown valve: This enables a small level of water to escape continuously. Its purpose is to avoid water in the boiler becoming saturated with dissolved salts. Saturation would business lead to foaming and cause water droplets to be transported over with the vapor - an ailment known as priming. Blowdown is often used to monitor the chemistry of the boiler drinking water also.
Trycock: a kind of valve that is often use to manually check a water level in a container. Most found on a drinking water boiler commonly.
Flash container: High-pressure blowdown enters this vessel where in fact the vapor can 'flash' safely and become used in a low-pressure system or be vented to atmosphere while the ambient pressure blowdown moves to drain.
Automatic blowdown/constant heat recovery system: This system allows the boiler to blowdown only once make-up water is moving to the boiler, thereby transferring the utmost amount of heat possible from the blowdown to the make-up water. No flash tank is normally needed as the blowdown discharged is near to the temperature of the make-up water.
Hand holes: These are steel plates installed in openings in "header" to permit for inspections & installation of tubes and inspection of internal surfaces.
Steam drum internals, a series of screen, scrubber & cans (cyclone separators).
Low-water cutoff: It really is a mechanical means (usually a float switch) that is used to turn off the burner or shut down energy to the boiler to prevent it from jogging once the drinking water goes below a certain point. If a boiler is "dry-fired" (burnt without water in it) it can cause rupture or catastrophic failing.
Surface blowdown line: It offers a way for removing foam or other lightweight non-condensible chemicals that have a tendency to float together with 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 range. This may be suited to the relative part of the boiler, below the water level just, or to the very best of the boiler.[10 -
Top feed: With this design for feedwater injection, water is fed to the very best of the boiler. This can reduce boiler fatigue triggered by thermal stress. By spraying the feedwater over some trays the water is quickly heated which can reduce limescale.
Desuperheater tubes or bundles: A series of pipes or bundles of tubes in the water drum or the vapor drum made to cool superheated steam, in order to supply auxiliary equipment that does not need, or may be damaged by, dry out steam.
Chemical substance injection line: A link with add chemicals for controlling feedwater pH.
Steam accessories
Main vapor stop valve:
Steam traps:
Main steam stop/check valve: It is utilized 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 gauge attachment:
Name dish:
Registration dish: