Boiler & Water Heater Types and their Differences · the various types of packaged boilers and...
Transcript of Boiler & Water Heater Types and their Differences · the various types of packaged boilers and...
Boiler &
Water Heater
Types and their
Differences
10/04/2016 - MJL
5930 Bandini Blvd.
Los Angeles, CA., 90040
Phone: 323-727-9800
Fax: 323-722-2848
www.parkerboiler.com
Welcome To TechForum 2016
New Orleans, LA
Overview
• A discussion of basic definitions and
the various types of packaged
boilers and water heaters commonly
found in use today
• Advantages and disadvantages of
each type
For the Record
Definition of a Boiler • A device for generating steam or hot
water
• Designed to transmit heat from an
external combustion source to a fluid
contained in the boiler
• Contained/controlled combustion
• Boiler HP = output of 33,482 BTU/Hr.
• Boiler HP = 34.5 lbs/hr evaporation of
water
• Low pressure or High pressure
TYPES OF BOILERS
• Thrust of our discussion will
focus on most commonly
encountered boilers - below
8,000,000 btuh
- commonly referred to as “Package
Boilers”
TYPES OF BOILERS
NOT IN THIS DISCUSSION
Field erected
built in place at job site
– Usually < 20,000,000 btu/h
typical of power generation plants or
very large industrial application or
a central plant
Water Tube
Boiler
Flexible or
Bent Water
Tube Type
Boilers
Flexible Water Tube
• Water inside tubes
• Fire surrounds or outside of tubes
• Serpentine Bent Tubes
• Same Pressed In, Some Welded
WATER TUBE TYPES
ADVANTAGES –
FLEXIBLE WATER TUBE
TYPE • Quick heat up time
• Most designs handle Thermal Shock well
• Small water volume
• Small Footprint – Easy to repair
– Wide water flow ranges for Hot Water
DISADVANTAGES –
FLEXIBLE WATER TUBE
TYPE
• Can scale slightly sooner in
steam service (open systems)
• Steam must be sized for
instantaneous loads
Typical Types – Flex Tube
Flex Water Tube Boilers
• Parker Boiler www.parkerboiler.com
• Babcock & Wilcox www.babcock.com
• Bryan Steam www.bryanboilers.com
• English Boiler www.englishboiler.com
• Nebraska Boiler www.neboiler.com
• Unilux Boiler Works UBW www.uniluxboilers.com
(Owned by Easco)
• Universal Boiler Works www.universalboiler.com
(Now owned by Precision Boiler)
Straight Tube
Water Tube
Type Boilers
Still a Water Tube Type where tubes have water inside, fire on outside.
Tubes are straight, rolled into heads.
Straight Water Tube
ADVANTAGES –
STRAIGHT TUBE TYPE
• Quick Heat Up
• Small Water Volume
• Low Cost
• Easy to Clean
DISADVANTAGES –
STRAIGHT TUBE TYPE •Can scale slightly sooner in steam service
•Many bolts to remove to do internal
•Not able to withstand true thermal shock
•Steam units Carry Over 40-125 PSI
Typical Types – Straight Tube
Straight Water Tube Boilers
•Ajax/Ace http://aboilerinc.com (Out of
business Nov 2015)
•Allied Boilers www.alliedboilers.com
•Rite Engineering www.riteboiler.com
Copper Fin Boilers
(also water tube)
Copper Fin
ADVANTAGES
• Low cost
• Small foot print
• Good for potable water or space
heating
DISADVANTAGES –
COPPER FIN
• Lighter duty construction
• Scales slightly easier at higher
temperatures
tubes won’t last running over 140 deg F
• Thinner .065 wall can corrode out
quicker in condensing environment
• Limited size
Typical Types Copper Finned Tube Boilers
• Ace Boiler www.aboiler.com
• Camus Hydronics Ltd. www.camus-hydronics.com
• Hamilton Engineering (Made by Lochinvar) www.hamiltonengineering.com
• Laars (used to be Teledyne) www.laars.com
• Lochinvar www.lochinvar.com
• Patterson-Kelly www.patkelco.com/home.shtm
• Raypak www.raypak.com
• RBI Water Heaters www.rbiwaterheaters.com
• Thermal Hydronics Supply LTD www.thermalhydronics.com (Make copies of parts for all copper tube boilers)
• Thermal Solutions www.thermalsolutions.com/left.htm
• Toyotomi www.toyotomiusa.com
• Weben Jarco www.weben-jarco.com
Fire Tube Type
Boilers
FIRE TUBE TYPE
• FIRE IN TUBES
• WATER IN VESSEL SURROUNDING
TUBES
• STEAM TO 300 PSI
• HOT WATER TO 150PSI
• MULTI FUEL
Fire Tube Type
Fire Tube Type
FIRE TUBE TYPE
• CLEAVER
BROOKS
FIRE TUBE TYPE –
ADVANTAGES
• CAN HANDLE LARGE INSTANEOUS DRAWS WELL
• POTENTIAL FOR GOOD EFFICIENCY
• NOT PARTICULARLY PRONE TO SCALING
• MULTIPLE FUEL CHOICES
FIRE TUBE TYPE -
DISADVANTAGES • LARGE VOLUME OF WATER TO HEAT UP FROM A
COLD START
• STRAIGHT TUBES EXPAND --CAN LEAK IF BOILER IS CYCLED FROM COLD OR IS THERMALLY SHOCKED
• IF HEAVY SCALING OCCURS, EXPENSIVE OR IMPOSSIBLE TO REPAIR
• LARGE VOLUME OF WATER AT ELEVATED TEMPERATURE AND PRESSURE
• WEIGHT
• SIZE
Typical Types Fire Tube Boilers
• Boilersmith LTD (Canada) www.boilersmith.com
• Burnham www.burnham.com
• Cleaver-Brooks www.cleaver-brooks.com
• Dixon Boiler www.dixonboiler.com (out of business) - running w/ Porter Boiler
• Easco Boiler Corp. www.easco.com
• Hurst Boiler www.hurstboiler.com
• Lattner Boiler www.lattner.com
• Kewanee Boiler Works www.kewaneeboiler.com/ (out of business - now Burham)
• Saskatoon Boiler www.saskatoon.com
• Sellers Boiler www.sellersengineering.com
• Superior Boiler Works www.superiorboiler.com
• Triad Boiler Systems Inc www.triadboiler.com
• York Shipley (Div. of AE SysTech, LLC) www.aesystech.com
Cast Iron
Sectionals
CAST IRON SECTIONAL
Cast Iron Sectional
CAST IRON SECTIONAL
TYPE
•Assembled of pancake-like sections
•Cast iron material
•Factory or Field assembled
•Rope gasket seals between sections
•Draw rods hold sections together
ADVANTAGES –
CAST IRON TYPE
• Tend to last a long time in most
applications
• Can operate with little water
treatment
• Can operate with some scale
buildup
• Cast iron is brittle
• Susceptible to Thermal Shock – Severe Damage and Cracked Sections
• Leaks between sections
• Limited Pressure and Temperature – 15 PSI Steam
– 75 PSI Hot Water
– ASME Section IV only
• Lots of Labor if not Packaged
DISADVANTAGES –
CAST IRON TYPE
Typical Types
Cast Iron Boilers
• Burnham www.burnham.com (now owners of Kewanee and Bryan)
• Buderus www.buderus.com
• Crown Boiler Company www.crownboiler.com
• De Dietrich Boilers http://macna-dedietrich.com
• Peerless Heater Company (Boilers) www.peerlessboilers.com
• H.B. Smith Cast Iron Boilers www.smithboiler.com
• Hydrotherm www.hydrotherm.com
• Weil-Mclain www.weil-mclain.com
• Viessmann www.viessmann.com
Vertical
Tubeless
Vertical Tubeless
Vertical Tubeless
• Fire surrounds water and/or water &
steam similar to tea kettle concept.
• Atmospheric or Forced Draft.
• Very popular for steam in small dry
cleaners.
ADVANTAGES - TUBELESS
•Less forgiving for scaling
•Small actual foot print
DISADVANTAGES
- TUBELESS
• Cost to repair 80% or more of new cost
• Long heat up time
• Cannot handle thermal shock well
• Actual listed clearance for combustibles &
access is 36” or greater – tosses out small
footprint advantage concept
Typical Types
Vertical Tubeless Boilers
• Columbia Boiler www.columbiaboiler.com
• Fulton Boiler www.fulton.com
• Hurst Boiler www.hurstboiler.com
• Lattner Boiler www.lattner.com
Vertical Boiler – Tube Type
• Thermo Steam www.thermosteam.com
Forced Steam
Generators or
Hot Water
Generators
Generators
Water in small tube
pumped through coil or
vessel.
Fire on outside.
ADVANTAGES
• Fast Heat Up
• Small Footprint Per BTU
DISADVANTAGES
• Very Loud, Large Feed & Blower Motor
• Some units have 25HP Motors – Heavy Parasitic Energy Costs
• Water Treatment Must Be Perfect. Scale Very Easily – Very Costly To Repair
Typical Types
Forced Steam Generators
• Clayton Boiler www.claytonindustries.com
• Miura www.miuraboiler.com
• Vapor Power International www.vaporpower.com
DISADVANTAGES
• Cannot Use In Closed Loop Even though some are marketing this
way (PH Increases)
• Some Units, Efficiency Drops To
55% In Re-circulation Mode
BONUS SECTION –
BOILERS USED IN
GALVANIZING
APPLICATIONS
• Besides capturing the waste heat
off furnace, boilers best method
for heading pickling and acid
tanks
• Danger is, what happens when coil fails
and when pressure is lower (system off
) than boiler, where does this acid end
up?
BONUS SECTION –
BOILERS USED IN
GALVANIZING
APPLICATIONS
• Helpful warning
• tools?
BONUS SECTION –
BOILERS USED IN
GALVANIZING
APPLICATIONS
• Continuously monitor
• TDS and wire to alarm
• Or isolation valves
BONUS SECTION –
BOILERS USED IN
GALVANIZING
APPLICATIONS
Parker T3600 skid
built for AZZ Galv-
• St. Louis, MO
• TDS and wired to
alarm