Steam Boilers 101

A steam boiler is a pressurized vessel that transfers heat to water to produce steam for a variety of applications.

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This guide will provide a comprehensive and straightforward overview of what boilers do, how boilers function, and how to choose a safe, reliable and efficient steam boiler.

Table of contents

How Do Boilers Work?

Steam boilers produce pressurized steam power by heating water to its boiling point using a combustible fuel source.

How the water is heated depends on whether it is a firetube or watertube boiler. The primary differences between the two can be found in their names.

In a firetube boiler, the combustible fuel source is contained within a tube surrounded by a vessel filled with water. The tube gradually heats the water around it, eventually producing steam.

In a watertube boiler, the water is contained within multiple tubes, and heat from the combustible fuel source is applied to the outside of the tubes to produce steam.

The Anatomy of a Boiler System

• Pressure Vessel: A pressure vessel contains gases or liquids at high temperatures, usually under high pressure. In a boiler, the pressure vessel is constructed from a high-strength material, often steel.
• Burner: The burner provides heat to the boiler by combusting fuel and oxygen. Fuel sources include natural gas, low-pressure propane, No. 2 oil, coal and other fuels.
• Tubes: In watertube boilers, the metal tubes situated inside the boiler contain water and are externally heated. In firetube boilers, heated gas passes through one or more tubes, heating water surrounding the tubes.
• Economizer: An economizer is a heat exchange mechanism that transfers heat energy otherwise lost in exhaust gasses and uses that energy to heat the water entering the boiler. Consequently, less additional energy is required to heat the incoming water, making the boiler more efficient.
• Deaerator Tank: Deaerators are pressurized feedwater tanks that use pressure and heat to remove oxygen and other dissolved gases (notably, carbon dioxide) from the water fed into the boiler. Dissolved oxygen and carbon dioxide could otherwise cause serious corrosion to the boiler.
• Heat Exchanger: A heat exchanger transfers heat from one substance to another without those substances directly interacting. In a boiler, the hot gas&#; heat is transferred to the water via a heat exchanger.
• Control Panel: The control panel enables operators to control boiler settings such as temperature and pressure. Commercial and industrial boiler control panels include detailed analytics.
• Feedwater Tank: The feedwater tank is a collection tank that supplies the water used by the boiler to create steam. The feedwater tank is where the treated water is collected and then pumped into the boiler. Boiler chemicals that remove oxygen and protect the metals within the boiler are injected and mixed within the feedwater tank. Facilities with condensate return lines can collect condensate water from steam that drops below the boiler point and fed back into the system to recapture the treated water.
• Combustion System: The combustion system works by combining air and fuel then igniting the mixture to produce heat. Ensuring the correct balance of air to fuel is an important component of the boiler combustion system.
• Reverse Osmosis System: Reverse Osmosis works by using a high-pressure pump to increase the pressure on the raw water side of the RO and force the water across the semi-permeable RO membrane, leaving almost all (around 95% to 99%) of dissolved impurities behind in the reject stream.
• Chemical Monitoring Systems: The carefully controlled addition of chemicals can enhance a boiler&#;s operations. Chemical monitoring systems precisely monitor chemical levels and provide ongoing analysis.
• Fuel Types: Combusting fuel is the ultimate source of the boiler&#;s heat. Gas, oil, and coal are common sources of fuel. When coal is used, it is often crushed and heated to improve efficiency. Less commonly, biomass such as wood chips or other natural materials may be used.
• Water Treatment: Water used by the boilers needs to be treated before entering the boiler to prolong the life of the boiler. Water softeners and Reverse Osmosis systems help to prepare the water by removing dissolved solids like calcium and magnesium to reduce the potential for scale build-up within the boiler. Feedwater tanks are also a part of the water treatment as they use heat to reduce the number of dissolved gases within the water that can contribute to oxidation and corrosion within the boiler.

Firetube vs. Watertube Boilers

As mentioned earlier, the two main types of boilers you will find on the market today are firetube boilers and watertube boilers. Let&#;s dive deeper into how each type works.

Firetube Boilers

As the name implies, in firetube boilers, a flame passes through an enclosed tube. The flame heats the ambient gas. That heat is transferred through the tube walls, heating the water contained in the vessel to the point that steam is produced.

Firetube boilers have a lot of history. After all, they powered some of the world&#;s first steam locomotives. Due to the immense stored pressure and inherent inefficiencies, more industrial processes are turning to watertube boilers for greater safety and efficiency.

Watertube Boilers

In watertube boilers, a furnace heats the gas which circulates tubes containing water. The heat is transferred through the tube walls, heating the water inside the tubes until steam is produced. Watertube boilers are typically capable of generating considerably more pressure than firetube boilers.

As watertube boilers do not enclose large volumes of water, their inherent risk is less than firetube boilers. Watertube boilers are also much more efficient, making them a preferred choice for intensive industrial processes.

Common Boiler Applications

Steam boilers are used for a wide variety of residential, commercial, and industrial applications.

Boilers intended for residential and commercial use typically have the lowest capacities. They are suitable for use in smaller-scale buildings and facilities that do not require a large amount of steam power.

Industrial boilers can handle a wide array of industrial processes that require greater horsepower. You can find industrial boilers in various settings, including hospitals, university campuses, chemical plants, breweries, food processing facilities, and manufacturing factories. In automotive production plants, steam is used for vulcanizing rubber for tires and other applications.

In food manufacturing and brewing, innumerable processes require steam, both in direct food production and sterilizing equipment and containers. High-temperature steam is also used to ensure food safety through pasteurization.

Boilers vs. Hot Water Heaters vs. Furnaces

Boilers, hot water heaters, and furnaces all produce heat, but they vary in their design and function. Let&#;s uncover the differences:

• Boilers heat water in a pressurized container to create steam. Many facilities will set a steam pressure, that has a direct correlation to steam temperature which can be adjusted for a wide range of commercial and industrial applications. When used domestically for central heating, the steam can be efficiently distributed to radiators to heat the house. Boilers vary in complexity and design, depending on their specific purpose.
• Compared to boilers, hot water heaters are more basic. Their single function is to heat water. Commonly, water is stored in a tank and heated with heating rods. Alternatively, instant water heaters rapidly warm water without the need for a storage tank.
• Rather than heating water, furnaces heat air that circulates through a home or building. Fuel burns to warm a heat exchanger, which heats the air before it distributes through a series of vents. The furnace temperature is controlled with a thermostat.

Boiler Efficiency

The efficiency of a boiler will directly affect the cost of running the boiler over its lifetime.

Boiler efficiency improves by optimizing the way boilers are used. Ultimately, however, the design of the boiler system determines much of the efficiency outcomes.

Functionally, boilers can be thought of as heat exchanging mechanisms. A boiler generates heat and ultimately transfers that heat to water &#; the less heat energy that is lost throughout the process, the more efficient the boiler.

Fuel-to-Steam Efficiency vs. In-Service Efficiency

The two industry standards for measuring efficiency are fuel-to-steam efficiency and in-service efficiency. Fuel-to-steam efficiency, also known as Annual Fuel Utilization Efficiency (AFUE), measures combustion efficiency. That is, what percentage of energy is converted to steam. A limitation of fuel-to-steam efficiency is that it only gives you a measurement of efficiency when the boiler runs at full capacity. Practically speaking, most boilers do not constantly run at full capacity. That&#;s why it&#;s important to consider in-service efficiency, which refers to the boiler&#;s total efficiency in its everyday function.

Boiler Turndown Ratios

Another important measure of operational efficiency is the boiler turndown ratio. Boilers with a high turndown ratio provide flexibility with the ability to produce lower amounts of steam than the maximum output. This allows facilities to deviate from the maximum steam output and conserve resources by turning down the boiler output to efficiently match the facility&#;s steam supply demands.

NOx Ratings

NOx is a blanket term for a group of nitrogen oxides responsible for smog and air pollution (nitric oxide and nitrogen dioxide). Any form of combustion is likely to produce NOx emissions. As boilers combust fuel to produce heat, NOx is produced. NOx emissions are regulated because they can harm human health and damage the environment.

Miura boilers produce less NOx by reducing the flame temperature. As the temperature rises so does NOx creation.

The Most Efficient Boilers

Traditional firetube boilers can take a long time to heat up and begin generating steam &#; all while consuming large amounts of fuel in the process. In contrast to firetube boilers, watertube boilers are more efficient because the reduced water content means there is less wasted energy used to heat the system when beginning operation.

For greater efficiency, consider a modular boiler system. Instead of a single massive boiler, modular boilers systems are a group of small boilers that work together to meet your steam demands precisely.

Essentially, each boiler in the modular boilers system operates independently. The independent boilers integrate into a single system, with a single master controller switching them ON or OFF as needed to meet demand. All modules may operate simultaneously, or individual modules can be shut down and quickly restarted as needed. This means you&#;re only producing steam when you need it.

At Miura America, we specialize in modular water tube boiler systems. There are several advantages of using a Miura boiler system:

• Each module starts up in less than five minutes, making the system more flexible and heat efficient.
• Smaller modular boiler units take up less floor space.
• You can rotate the use of individual units to reduce wear and tear.
• Operators can turn off individual boilers when not needed to save fuel.
• If one unit stops working, the rest continue to function. There&#;s less chance of downtime.
• The system is completely scalable. You can add more units as needed.

Boiler Safety

In the early days of steam power, boilers were volatile and not always securely constructed. Boiler explosions were commonplace, resulting in injury and even death.

Today, boiler design follows rigorous safety guidelines overseeing both the production and use of boilers. Let&#;s explore a brief history of boiler safety and identify the safest boiler option currently available.

Boiler Safety Through the Decades

Most early boiler explosions were caused by a breakdown in the parts of the pressure vessel, either through corrosion or poor build quality.

A turning point in the regulation of boilers came about in the wake of the Grover Shoe Factory disaster in . A boiler located at the RB Grover shoe factory in Brockton, Massachusetts exploded, causing widespread injury and loss of life.

There were no reliable boiler operation guidelines in the decades preceding the disaster, and industrial safety inspections were uncommon. As a result, thousands of boiler explosions had occurred.

Following a successful campaign by the American Society of Mechanical Engineers (ASME) to persuade industrialists of the need for regulation, Massachusetts passed a law regulating boiler use in . Those state laws would eventually inform a national safety code.

The ASME&#;s first Boiler and Pressure Vessel Code was published in . Today, the ASME has issued 28 books, covering a comprehensive range of operational issues, running into tens of thousands of pages.

The safest modern boilers virtually eliminate the possibility of catastrophic failure, creating a much safer work environment.

So, What&#;s the Safest Boiler on the Market?

Modern boilers are robustly built, with additional features to prevent corrosion and damage that might cause safety issues. Effective monitoring and robust safety measures are essential to ensure ongoing safety, particularly for commercial and industrial applications.

In terms of boiler design, the safest type of boiler is a watertube boiler because it is designed to operate with less water volume than a firetube boiler. Additionally, should a watertube boiler fail, that failure would be contained within the tubes rather than exploding outward like a firetube boiler failure.

Boilers should also be designed to minimize the chance of thermal shock or even eliminate it. Thermal shock occurs when cold water enters a boiler and reacts with the extremely hot water already in the boiler. The ensuing rapid contraction and expansion of components could lead to catastrophic failure. Some measures can be taken to reduce the likelihood of thermal shock (such as reducing daily operating cycles). Still, ideally, a boiler should be designed to prevent thermal shock from occurring under any conditions.

Boiler Maintenance & Monitoring

Effectively monitoring and maintaining boilers before any problems arise will help ensure your facility stays safe and productive.

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Chemical Water Treatment

Chemical water treatments are used to reduce dissolved oxygen within the water or treat metal surfaces to prevent degradation. Using these treatments allows facilities to control pH, prevent scale, reduce corrosive ions, and ensure the boiler&#;s reliable function.

Water Softeners

Water softeners remove hard metals (notably calcium and magnesium) from the water used in the boiler. Hard water can cause scale build-up and can damage boiler components over time.

Controllers and Monitoring Systems

Modern boiler controllers include sophisticated diagnostics to help users identify potential issues before they become serious problems. Comprehensive monitoring systems can provide analytics on everything from current steam pressure to water hardness.

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Introduction

This article provides a detailed look at.

Read further to answer questions like:

• What is a steam boiler?
• Types of steam boilers
• How steam boilers are made
• Uses for steam boilers
• And much more&#;

Chapter One - What is a Steam Boiler?

A steam boiler is a steam producing heating system. It creates energy by heating water to get steam. It is a heat exchanger that makes steam for outside usage and has a combustion chamber and water container. The several varieties of steam boilers include those that are very small and those that are large for more demanding jobs.

A steam boiler burns fuel to heat water. The combination of heat and water produces steam. There are three forms of heat used to generate steam: radiation, convection, and conduction.

Chapter Two - Types of Steam Boilers

Steam boilers are defined by their construction, portability, tube type, fuel type, and the pressure they produce. When boilers were initially introduced, they were as efficient as modern boilers but were dangerous since there were few control mechanisms. The size, fuel, and dimensions of a boiler change in accordance with the job it is designed to perform and the industry in which it is used. The types of fuel include electricity, wood, natural gas, coal, and fossil fuels. The difference between the fuels is their cost, eco-friendliness, and efficiency. As the demand for electricity and power generation has increased, alternative fuels have been developed, including biomass and refuse or trash.

Steam Boilers Boiler Types

Hot Water Boilers

Hot water boilers are tanks that transfer heat to water that is circulated for heating purposes. They are made of stainless steel, cast iron, aluminum, and steel and are capable of withstanding increased temperature and pressure.

The types of hot water boilers are defined by their tube systems, which can be fire or water. Fire tube hot water boilers have tubes immersed in water; heat moves through the tubes and heats the water around them. Water tube boilers have water inside the tubes that circulates as the tubes are heated.

Electric Boilers

Electric boilers use electric elements to generate heat; it is a faster and more efficient heating method. It is an eco-friendly, cleaner system since it does not necessitate the burning of a fuel. Electric boilers are longer lasting, require less cleaning, and are maintenance free. The one factor that has to be controlled with electric boilers though is the buildup of scaling in the water reservoir.

Gas Boilers

Gas steam boilers are powered by natural gas or propane and are more efficient than standard boilers. The fuel for a gas boiler is piped into the boiler from an outside source that is connected directly to the boiler. The distribution of heat using a gas steam boiler depends on its configuration. Gas steam boilers can be used for industrial purposes and low pressure applications.

Low Pressure Boilers

Low pressure steam boilers transfer heat at pressures between 10 and 15 psi with a temperature of 300°F (149°C). This type of boiler is used where there is little need for rapid temperature change, where a consistent temperature is required. The popularity of low pressure steam boilers is due to the speed at which they deliver steam; they can do so much faster than high pressure steam boilers.

High Pressure Boilers

High pressure steam boilers create excessive pressure to power equipment and machinery. The force and power of a high pressure steam boiler is produced by a pump that forces the steam at high pressure into the circulation system. To be classified as a high pressure steam boiler, a boiler must be able to produce pressure between 15 psi and 800 psi at temperatures that exceed 250°F (121°C).

For safety and efficiency, high pressure steam boilers are regularly monitored for the pressure they produce and their temperature. The high pressure loads of high pressure steam boilers are classified as batch or continuous, with batch used for short term demand and continuous used for long term demand.

Oil Boilers

Oil steam boilers operate on the same principles as gas boilers; oil is ignited in the combustion chamber instead of gas. The burning oil heats the exchanger that heats the water. Oil steam boilers can reach an efficiency of over 90%. Though they are more expensive than gas steam boilers, they tend to have twice the lifespan of a gas boiler.

One concern with oil boilers is the need for an oil tank inside or outside that has to be refilled regularly to provide a constant supply of fuel.

Water Tube Boilers

Water tube boilers pass water through the tubes of the boiler. Fire created in the combustion chamber burns around the outside of the tubes and heats the tubes, thus heating the water. This boiler design produces high pressure steam by way of the tangential pressure in the tubes, known as hoop stress; it is pressure applied to the circumference of the tubes and is like the stress applied to the bands of a wood barrel as it is filled.

There are different types of water tube boilers that have been used since the development of the first boiler but have gradually changed over the centuries.

La Mont Boilers, Benson Boilers, and Loeffler Boilers

La Mont, Benson, and Loeffler steam boilers use forced circulation and draught fans to produce large quantities of steam at high efficiency. Small diameter, closely spaced tubes have water forced through them by a centrifugal pump. The efficiency of a La Mont, Benson, and Loeffler is due to the economizer that preheats the water using the flue or pipes gases from the combustion chamber.

Fire Tube Boilers

In a fire tube steam boiler, the tubes on the boiler are heated, and the water circulates around the tubes. The heat inside the tubes is produced by gases heated by coal or oil, and it is transferred by thermal conduction to the water to create steam. Fire tube steam boilers produce low pressure steam. There are three main types of fire tube steam boilers: Cochran, locomotive, and Lancashire.

A fire tube steam boiler can be fitted with an economizer to enhance its efficiency and heat recovery system.

Shell Boilers

Shell boilers have their heat transfer surfaces enclosed in a shell that is usually made of steel. Several combinations of tube layouts are used; tube layout determines the number of passes heat makes before being discharged. Shell boilers, also known as flue boilers, have a long water tank configuration with fire tubes. The heat from the furnace or combustion chamber passes through these fire tubes to heat the water.

The earliest form of this type of boiler was the Cornish boiler, which consisted of a long cylinder with a single large flue or pipe that contained the heat or fire. It was replaced by the Lancashire steam boiler, which had two flues for the fire.

Shell steam boilers, also known as shell and tube boilers, are the simplest form of boiler that produce steam efficiently and economically.

Methods Used to Heat a Boiler

A steam boiler absorbs heat that is released from combustion. The heat is transferred either by radiation, convection, or conduction. The percentage of heat that is transferred is dependent upon the type of steam, fuel, and transfer surface.

Radiation

Radiation is energy that is transmitted by all elements and bodies. It is the continuous interchange of energy between surfaces using electromagnetic waves. In the case of a steam boiler, the tubes in the boiler absorb radiant heat from the flame produced in the combustion chamber. The heat from radiation heating depends on the rate at which the electromagnetic waves are absorbed.

Convection

Convection is the transfer of heat within a liquid or gas when the liquid or gas is heated. As the liquid or gas is heated, it mixes with the cooler liquid or gas and heats the cooler liquid or gas. In a steam boiler, the convection process occurs when the fluid in the boiler is heated and becomes lighter and less dense. Heavier, cooler fluids or air move in as the lighter heated fluid or gas moves out. The replacement of hot fluids with cold fluids begins the process all over again.

Conduction

Conduction is a physical contact process where heat is transferred from one surface to another by contact. Heat in a metal moves through the metal to heat what it has touched. Conduction in a steam boiler takes place as the outer part of the tubing is heated, and the heat passes through to the inner part and to the cool water in the tube.

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Chapter Three - How Steam Boilers Are Made

A steam boiler heats water much like a teapot, only on a larger and more complex scale. Though not every steam boiler is the same, there are basic elements that are common to all steam boilers: burner, combustion chamber, heat exchanger, expansion tank, steam temperature control, safety relief valve, and low water cutoff.

The designs and types of steam boilers widely vary depending on their construction and purpose.

List of Made Steam Boilers

Burner

The purpose of the burner is to inject fuel and air into the combustion area. The fuels, such as oil, gas, or pulverized coal, have to mix easily with air. Dampers are used to regulate the amount of air that enters the burner. An impeller circulates the air evenly around the burner. Pipes referred to as spuds inject the fuel into the boiler and are ignited by an igniter.

Combustion Chamber

The combustion chamber contains the reaction of the fuel with air and uses it to create the heat to produce steam. To enhance the efficiency of the combustion chamber, it needs to be adequately insulated to avoid loss of heat through radiation. The combustion chamber has tubes containing water and steam that pass through the open box with the burner and controls. Efficient combustion is an essential part of boiler operations. The heat produced in the combustion chamber is absorbed on the surface of the boiler at the top of the combustion chamber.

The heat exchanger allows heat to be exchanged between fluids without allowing the substances to mix. A heat exchanger contains a long coiled pipe that is immersed in the fluid to be heated. Gas or a heated liquid passes through the pipe and heats the water around it. Heat exchangers are made of a variety of materials with stainless steel being the best material since it does not corrode or rust.

Expansion Tank

The expansion tank helps to maintain the pressure in a boiler by providing a place for water to expand, absorb the pressure, and regulate the pressure. The tank has a diaphragm that is divided into two sections with one portion accepting water from the boiler and the other side being controlled by an air valve to alleviate pressure. The air valve pushes against the water in the other section until normal pressure is reached.

Steam Temperature Control

Steam temperature control prevents thermal stress; precise control of steam temperature is important. The control of pressure and temperature is necessary to keep fuel costs down. Steam temperature is normally controlled by spraying water on the first and second stage superheater. This is done using an attemperator or desuperheater.

Other methods to control steam temperature are through the use of flue gas circulation, flue gas bypass, or the tilting angle at which the burners fire the furnace. The simplest method for controlling steam temperature is to monitor the temperature of the steam as it exits the boiler and change the position of the spray water valve.

Safety Relief Valve

The pressure relief valve is the most important safety measure for steam boiler use. It ensures that the build up of pressure in a steam boiler will be relieved; this assists in avoiding a catastrophic disaster. The pressure relief valve opens when the pressure reaches a critical level and closes when the pressure returns to normal.

Low Water Cutoff

A low water cutoff turns off the burner or shuts off fuel to a steam boiler when the water level drops below a set point. A dry fired boiler can rupture or suffer significant failure. Low water cutoffs are another safety feature built into a steam boiler to help avoid damage and harm to the boiler. They are a normal part of boiler construction and are installed in steam boilers and hydronic devices to shut down the boiler in the case of the loss of water.

Chapter Four - Uses for Steam Boilers

The traditional function of steam boilers is to serve as central heating for homes, offices, businesses, hospitals, and other facilities. Regardless of where they are used, all boilers have the same basic functions and mechanisms that work as a contained heat generating combustion process.

There are a variety of fuels used to generate the heat in a boiler to ignite the burner. The created heat moves through the system using pumps and heat exchangers. In order to specialize the function of a steam boiler, additional control mechanisms are added.

Steam Boilers Uses

Aquariums

Aquariums use steam boilers to power their operations. The many tanks required to operate an aquarium have to have the water temperature and water conditions carefully regulated to protect the wide varieties of species that are on display. Gas powered steam boilers are used with heat exchangers to regulate fresh and saltwater tanks as well as provide water currents and surges to create ocean like environments.

Food and Beverage

Pasteurization requires products be heated at set temperatures to eliminate pathogens. If the temperature is not precisely controlled, the taste of the final product can be damaged. Brewers and distillers use low pressure steam heat to produce consistent batches at a low cost. Dairy producers use steam boilers for cleaning and sanitization.

Laboratories

Labs on college campuses use exhaust air when experimenting and testing. To replenish the exhausted air, experimenters bring in outside air that can be cold, so they require heating. Since laboratories are large and spacious, an extensive amount of heat is required to heat them. In order to meet the need, universities and colleges use low pressure steam boilers.

Skyscrapers

The heating of multi-story skyscrapers requires a high powered energy production system that is capable of withstanding constant use. The massive size of skyscrapers necessitates the use of multiple boilers to heat them efficiently and effectively. Steam boilers used to heat skyscrapers can weigh up to 165 tons and consume liters of fuel per hour; this is enough to heat private residences.

The use of water and steam for skyscrapers is a very practical and effective method for providing heat since it is easy to transport and readily available.

Brewing

Beer is brewed in large kettles, and steam boilers are used to heat and sanitize the kettles. Once the brewing cycle is finished, the kettles have to be completely sanitized and cleaned to ensure the removal of any contaminants. The first consideration in the design of a brewery is the type of boiler that will be used to keep the kettles clean and operating.

The spent grain from the brewing process can be repurposed to serve as fuel for steam boilers. It is an ecologically sound and a cost saving concept.

Power Generation

One of the functions of a steam boiler is to power turbines to produce electricity. A very powerful and large boiler can generate as much as 225,000 pounds of steam per hour at 900 psi. A boiler system of that size can generate 20 megawatts of electricity. With technological upgrades and innovations, steam boilers can be designed to save on energy while producing it.

Lumber Kilns

Low pressure steam boilers are used in the lumber industry for kilns used to dry specialty lumber products. Hardwoods used for making furniture and cedar planks used for cooking require drying in a kiln. A low pressure steam boiler allows producers to perform the drying process safely and effectively to increase the quality of wood products. Since low pressure steam heat is manageable and exceptionally consistent, it is ideal for this type of drying process.

Chapter Five - Steam Boiler Regulations and Standards

As with all industrial equipment, the production and use of steam boilers are guided by codes, regulations, and standards that have been published by regulating agencies, voluntary organizations, and the United States government. The most widely accepted boiler and pressure codes are published by the American Society of Mechanical Engineers (ASME) in its boiler and pressure vessel code guide.

The codes most pertinent to boilers were published in and are organized into different sections:

• Section I Power Boilers This applies to high pressure boilers.
• Section II Materials Covers all acceptable metals for boiler use.
• Section IV Heating Boilers This applies to low pressure boilers.
• Section V Nondestructive Examination This section covers the inspection and certification of boilers and pressure producing equipment.
• Section VI Covers Boiler Care and Operation
• Section VII Guidelines for the Care of Power Producing boilers

• Section VIII Guidelines for Pressure Vessels of which there are three types:

  1. Fired and unfired pressure vessels operating in excess of 15 psig
  2. Rules for the design of pressure vessels
  3. Rules for high-pressure vessels.
• Section IX Welding and Brazing Qualifications

The ASME has other codes and standards for boiler systems; these include the B31 series of piping and the CSD series of controls and safety equipment.

Occupational Safety and Health Administration (OSHA)

The main concern for OSHA is worker safety. Steam boilers have been identified as potentially dangerous and unsafe devices that can only be operated by trained, experienced, and authorized workers. OSHA requires frequent and regular inspection of boilers to check for leakage, proper combustion, and operational safety devices and gauges.

Older steam boilers that have been insulated with asbestos coatings, wraps, or lagging should be inspected for leaks, damage, flaking, or deterioration. Any damaged materials should be removed and replaced.

American Boiler Manufacturers Association (ABMA)

The ABMA was founded in and is the longest operating trade association in the United States. The original purpose of the association was to deal with the many safety issues that were prevalent at the turn of the century. Due to the ABMA, several safety measures have been implemented for steam boilers, and they have advanced their use into the 21st Century.

The mission of the modern ABMA is to lead and unite the boiler industry by providing education, awareness, and a commitment to solving steam boiler issues and problems. The ABMA represents manufacturers in all facets of the industry from heavy duty steam boilers for power plants to those for the utility sector. Any device that produces steam and hot water is covered by the ABMA.

Conclusion

• A steam boiler is a steam producing heating system; it produces energy by heating water to create steam.
• A steam boiler burns fuel to heat water. The combination of heat and water produces steam.
• Steam boilers are defined by their construction, portability, types of tubes, types of fuel, and the pressure they produce.
• A steam boiler absorbs heat that is released from combustion. The three ways that the heat is transferred are radiation, convection, and conduction.
• The designs and types of steam boilers widely vary depending on their construction and purpose.

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