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Firetube Boiler Design,
Construction & Engineering
Presented by Steve Connor
July 29, 2015
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What We Are Covering Today
2
Engineering &
SummaryConstruction
The BurnerDryback vs
Wetback
Brief on FT boiler
evolution
Major FT
components
Advancing
Firetube
Boiler
Design
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Boiler Evolution
3
Steam Locomotives
NOTE:
These firetube boilers could weigh up to 200,000lbs and reach speeds of 100mph
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Boiler Evolution
4
Steam Locomotive Cut-A-Way
Furnace
Convection tubes
Steam dome
Tube sheet
Stack
Water line
NOTE:
These boilers were an integral part in leading the way in the industrial
revolution starting in the 1860’s.
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Boiler Evolution
5
Titanic Titanic Boiler Room
NOTE:
The Titanic was powered by 29 firetube boilers that contained 159furnaces which were fired with 825 tons of coal per day.
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Titanic’s Steam Engines
6
• Discovered 13,000 feet deep
• 2.5 miles down…
4 Cycle Steam Engines
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Scotch Marine Boiler With
Single or Multiple Furnaces
7
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Firebox Boiler
8
Locomotive
convection
Furnace
Furnace
Convection section
Firebox
Steam drum Stack
NOTE:
The Firebox boiler is only for low pressure steam and hot water.
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Major Components
9
Pressure vesselBurner Controls
Stack
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Single Package
10
A Standard For Firetube Construction Was Created
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Typical Industries Served
11
• Refinery & Petro-Chemical
• Universities/Colleges/Schools
• Government buildings
• Hospitals
• Hotels and Conference Centers
• Chemical/Pharmaceutical
• Automotive
• Food & Beverage
• Textiles
• Corrugated container
• Pulp & paper
• Building supplies
• Ethanol & Bio-Diesel
• Aerospace & Military
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Construction
12
Integral
Gun
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Construction
• Starts with flat plate
• Shell openings are cut in
13
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Construction
Shell is rolled into form
14
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Construction
• Seams are welded; longitudinal & circumferential
• X-Rayed and witnessed
• Tube sheets cut and drilled
15
Shell welding
Tube sheet cutting/drilling
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Tube Sheets Installed
• First tacked
• Full penetration weld; Down hand position
16
Tack weld Full penetration weld
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Boiler Fittings Are Installed
• Outlet & return connections
• Safety valve connection(s)
• Vent connection
• Surface blow-off connection
• Feed water connection
• Bottom blowdown connections
• Water level control connections
• Stay braces for high pressure
17
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Furnace Fabrication & Install
18
Fabrication Install
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After all pressure
vessel welding is
completed the entire
assembly is stress
relieved @ 1100 deg. F.
Stress Relieving
19
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Burner & Trim Prepared
Burner components affixedTrim assembled
Gas train
Feed water piping
Integral burner
20
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Tubes Fabricated
21
Roll Stock
Rolling & Welding
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Tubes Banded and Ready For Install
22
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Tube Install
23
• Rolled and Welded
• Rolled and Beaded
• Rolled and Flared
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24
Rolled and
Beaded Tube
Tube End
Cooling
Tube End
Cooling
Rolled and
Flared Tube
Tube End
Cooling
Rolled and
Welded Tube
Tube Attachment
24
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25
• 1 1/2 times the maximum
allowable working pressure
Hydrostatic Testing
25
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Boiler Construction
• Insulation & lagging
• Throat & liner installation
• Front & rear door hanging
• Burner installation
• Final assembly & trim
• Test fire
26
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Final Painting & Shipping
27
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Horizontal Firetube Boilers
28
The Dryback
Refractory Filled Door
1
2
3
4
Baffles
Tubesheet
Two (2) Tubesheets
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Three (3)Tubesheets
Water Leg
1
2
3
Horizontal Firetube Boiler
29
The Wetback
• Three
Tubesheets
• Difficult access,
2nd
pass
Rear access plug
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Size & Pressure Ranges
30
• 100 – 2500 HP
• Design pressures to 350#
• Wetback design used
above 800 - 900 HP
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The Burner
31
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Firetube Burner Types
32
IntegralGun
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33
Integral burner Gun burner
Wind box
Blower/fan
Burner Ass’y
Air inlet
Blast tube
Diffuser
Burner Types
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Types of Firing
34
• High-low-Off
• Modulating
• Turndown: 4:1 or 10:1
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Fuels
35
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Maximize Combustion Control
36
Single Point Parallel Positioning
Fuel Air FGR
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Emission Reduction
37
Flue Gas Recirculation
Integral burnerGun burner
FGR
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Efficiency
38
Range based on boiler capacity,
Fuel, Firing rate and Operating
Pressure/Temperature:
81 – 87%
NOTE: FGR may impact turndown,
Reducing efficiency.
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The Engineering Behind the Design
39
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Established in 1880
40
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Commissioned Jan.
1863
Boiler repaired a few
days before the
explosion.
Events like this lead
to safety regulations;
stringent codes…
The Sultana Boiler Explosion Kills 1238 in April 27, 1865
Safety Becoming a Key Issue
41
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Steam Locomotive Explosions…..Devastating
Safety Becoming a Key Issue
42
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ASME Code
(American Society of Mechanical Engineering)
Section I
High pressure - Steam boilers above 15 psi.
Hot water boilers above 160 psi (hydrostatic pressure)
and/or 2500 F outlet temperature
Section IV
Low pressure - Steam boilers less than 15 psi. Hot
water boilers less than 160 psi and/or 250 F. outlet
temperature
43
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Steam Nozzle Sizing & Velocity
44
Steam nozzle
Steam header valve
Water Surface
• Surface velocity: 10’/sec.
• Nozzle: 5000’/min.
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Radiant & Convective Heat Transfer
45
Radiant Furnace Convection heat transfer
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Furnace Emissivity & Heat Release
Radiant
BTU/Ft3
Stefan’s Law M = T4
Greater temperature difference by the power of 4!
46
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Burner and Furnace Matching
47
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Engineering Analysis
Plain Furnace Corrugated Furnace
No difference in efficiency, durability or life expectancy
48
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Heating Surface
Radiant
Convective
• Reynolds number:
. Relation of viscous to inertia forces
. Velocity = square root of temperature
• Heat Transfer Coefficient:
. Proportionality between heat flow & Delta T
49
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Convective Heat Transfer
50
Extended Surface TubesPlain Tubes
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Convective Heat Transfer
Typical Boiler Tube
51
Boundary layer
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Extended Tube Surface
52
No Boundary layer
INCREASED
INERTIA FORCES
=
INCREASED HEAT
TRANSFER
Spiral tubes
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Reducing Weight and Footprint
53
• 30% less weight
• 15% less floor space
• Reduced fan motor horsepower
• Same or better efficiency, durability and life
Optimum furnaceImprove convection heat transfer
2 pass
NOTE:
These are attractive features to
architects designing new boiler
rooms when faced with
budget restraints.
Typical:
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Designing Boilers in the 21st
Century
54
Is boiler R&D like it was in the past?
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Computation Fluid Dynamics &
Finite Element Analysis
55
CFD Modeling
FEA Proving
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Structural Verification
56
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Metal Stresses
57
Tensile Strength
Metal Deformation
Tube Sheets
Tubes & Ligaments
Furnace
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Summary
• The firetube boiler is a versatile package suitable for a
plethora of applications including heating and process
• Typical size range is 100 – 2500 HP
• Pressures to 350#
• Construction follows ASME code Sections I & IV and includes
close 3rd
party inspections
• There are both dryback & wetback horizontal firetubes with
each having advantages and disadvantages
• The fuel firing capability of these boilers is extensive
including bio-fuels.
• The boiler is getting smaller in size and weight without
compromising efficiency, durability and life span.
• The engineering is complex, but present day advancements
in computer technology has accelerated and improved the
process
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David Brick
Firetube Product Manager
414-577-2736
cleaverbrooks.com