a McDermott company

Water-Tube Package Boilers

P r o v i d e R e l i a b l e , E c o n o m i c a l S t e a m P r o d u c t i o n

Since 1867, Babcock &Wilcox has been design-

ing, manufacturing and installing the world’s

most reliable and efficient energy-generating

systems and environmental equipment. B&W

also services, repairs, upgrades and replaces

existing systems and associated equipment,

regardless of the original manufacturer. With

boiler installations operating in more than

85 countries, B&W has the experience and

flexibility to meet the ever-changing needs of

both the utility and industrial markets.

Water-Tube Package Boilers:Proven Design forEconomical Steam Production

To meet varying space, fuel, steamand economic conditions, B&W offers a complete line of auxiliaryequipment. A package boiler burnersystem is shown.

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Dependable performance in a wide variety of industries

B&W’s water-tube package boilercontinues this tradition of excellencewith more than 4,200 units in operation. Our established reputationfor reliability and proven performanceis continually enhanced by incorporat-ing the latest technological advance-ments into our design. B&W is dedicated to the water-tube packageboiler market, which is comprised ofindustrial and institutional marketssuch as:

➢Hospitals

➢Universities

➢Manufacturing and processing facilities

➢Utilities

➢Petrochemical

➢Pulp and paper

System components complement operationSpecifically designed to complementeach other in operation, B&W supplies

all the major components in the FMpackage boiler system:

➢Boiler

➢Burner

➢Controls

➢Fan

➢Heat traps

➢Sootblowers

➢Added options (feed pumps, deaerators, chemical feed systems)

Broad capacity rangeB&W water-tube package boilers are

available in a wide range of capacities:

➢Steam flow from 8,200 to 240,000pounds per hour (1 to 30 kg/sec)

➢Superheat temperatures up to 900°F (482°C)

➢Design pressures from 250 to 1050 psi (17 to 72 bar)

Support servicesIn addition to equipment supply,

B&W offers comprehensive support services, including:

➢Field service engineering

➢Inspection and maintenance services

➢Engineered upgrades–designed to last

➢Long-term service partnering programs

➢Training programs

➢Operating instructions

➢Spare parts manuals

➢Startup services

➢Sales assistance

Babcock &Wilcox: A single-source supplier ofinnovative energy solutions and total-scope services.

B&W’s engineering expertiseand complete project management skills help toensure that a project is rightthe first time and on timewithout additional costs.

The compact, efficient design of B&W’swater-tube package boilers allows foreconomical shipment via rail or truck.

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NOTES: 1.All package boilers are of

membrane construction.2.Because of the company’s

constant effort to improve design, equipment supplied

may differ slightly from that described above.

3.Package boiler capacities greater than 240,000 lb/hr are available in B&W’s high-capacity series.

METRIC CONVERSIONS:inches x 25.4 = mminches x 2.54 = cmfeet x 0.3048 = mlb/hr x 0.000126 = kg/sec

Water -Tube Package Boilers: Capacities toMeet the Most Demanding Requirements

* Steam capacities shown are saturated steam.Capacities shown will vary depending on conditions and limitations.

CapacityScale Boilers Range* Length Width Height Drum

1' = 1⁄16" (lb/hr) Size

FM 9-22 7' 7"26 8' 11"30 9' 11" 36" Steam34 8,200 11' 3" Drum39 to 12' 7" 10' 27⁄8" 12' 4"43 40,000 13' 11" 24" Lower48 15' 3" Drum52 16' 7"57 17' 11"

FM 10-52 16' 7"57 17' 11" 36" Steam61 35,000 19' 3" 10' 105⁄8" Drum66 to 20' 7" 13' 6"70 75,000 21' 11" 24" Lower79 24' 7" Drum

FM 101-88 27' 3" 11' 23⁄8"

FM 103-70 70,000 21' 33⁄16" 42" Steam

79 to 23' 113⁄16" 11' 9" 13' 93⁄4" Drum

88 100,000 26' 7 3⁄16" 24" Lower97 29' 11" Drum

FM 106-79 23 113⁄16" 48" Steam88 100,00 26' 73⁄16" 11' 9" 14' 3" Drum97 to 29' 33⁄16"

FM 117-88 155,000 26' 7 3⁄16" 11' 111⁄4" 15' 41⁄2" 24" Lower97 29' 33⁄16" Drum

FM 120-97 155,000 29' 33⁄16" 54" Steam

112 to 33' 73⁄16" 12' 53⁄8" 16' 101⁄2" Drum

124 240,000 37' 333⁄16" 24" LowerDrum

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Long-term reliabilityB&W maintains the same cornerstone

company values as we did in 1867 whenthe first B&W water-tube steam boilerwas patented. These values include acommitment to excellence, outstandingcustomer service, quality and continu-ous improvement, integrity, technologyleadership and a global outlook. Basedon these values, B&W builds equipmentthat is designed to last. In fact, many1950 vintage B&W package boilers arestill in use today.

Fast load responseB&W’s 21⁄2" tubes are spaced 1" apart.

This provides a larger volume of waterin our furnace walls and contributes to a faster load response. In addition,our uniquely designed drum internalscan handle varying loads without circulation disruptions or carryover.Connections for lower drum heatingcoils also are standard.

Low O&M costsThe B&W package boiler drives main-

tenance to a minimum with:

➢No reliance on refractory seals

➢Positive circulation, 100% water-cooled rear wall

➢Bricks on floor for long-term protection

➢A fully drainable and 100% convection superheater

➢Galvanized, primed and enamel-painted exterior lagging

➢Hinged drum manways for betterwaterside access

Controlled emissionsB&W has its own staff of combustion

design engineers and works with outsideburner suppliers to meet your stringentrequirements. Our furnace has morewater-cooled surface, thereby helping tomeet today’s tough NOx limits.

Water -Tube Package Boilers: B&W’s Engineering Expertise Offers Many Benefits

B&W’s water-tube package boilers offer more water-cooled surface, which in turnhelps to meet today’s stringent emissions regulations.

This photograph contrasts the differences between B&W’s 21⁄2" tubes spaced 1" apart (tube panel in background), and competitors’ 2” tubes spaced 2" apart(tube section in foreground). As shown, B&W’s 21⁄2" tubes on 31⁄2" centers increasethe overall water-cooled tube furnace surface and reduce the membrane areabetween the tubes. This helps to prevent membrane thermal cracking and contributes to a faster load response.

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Proven “D”-type construction, which has separate boiler and furnacesections, creates proper geometry of the burning chamber. As a result, combustion efficiency is increased andthe following benefits are added:

➀ Furnace wall water cooling includesnot only the side walls, roof and floor,but the high-duty rear wall as well–eliminating refractory and its attendantmaintenance. This unique boiler feature locates total water coolingwhere it can contribute most to keepingmaintenance costs down, and eachrear wall tube is a single flow pathbetween drums to assure proper circulation and cooling.

➁ Gas-tight setting membrane pro-vides the gas-tight setting absolutelynecessary on all package boilers. Thisconstruction eliminates dew-point sulfur corrosion and outages caused by gas leaks. B&W’s membrane panels

use large diameter tubes and smallmembrane spacing, which provides thebest combination of heat transfer efficiency and maintenance accessibility.Scalloped seal plates (illustrated in 2-A) on the membrane design alsoprovide a continuous gas-tight sealbetween the tube membrane anddrums. Where inner- cased constructionis used, a 10-gauge plate is welded tothe tie bars, instead of directly to thepressure parts (shown in 2-B). Tomaintain casing above the dew pointtemperature, the plate is formedaround the tie bar to ensure closeplate-to-tube contact.

➂ Rugged steel-base frame supportsthe entire boiler, and allows jackingand skidding of the boiler. A concreteslab with no special saddle, supports or piers is all that is needed for thepackage boiler. To ease installationand relocation, B&W’s frame has built-in lifting lugs and jacking pads.

➃ Outer steel lagging is galvanized,primed and painted, making it weather-tight for outdoor installations. The 12-gauge roof casing also provides asurface strong enough to walk on.

➄ Drum internals provide high steampurity and ensure positive circulation.There are two primary steam separatorsto choose from – a baffle-type for 3 ppmsolids or an optional cyclone-type for 1 ppm solids. Both designs incorporatecorrugated-type secondary scrubbers.Dry pipe steam separation also is available for 1⁄2% moisture steam.

➅ Water wash troughs and drains arestandard on every new package boiler.

➆ Grooved tube seats with polishedtube ends provide maximum protectionduring initial handling and transporta-tion, as well as against leakage through-out the unit’s life. B&W’s tube seatsprovide more holding power and seal integrity.

➇ Sootblowers are properly locatedfor effective convection bank cleaning.Sootblower bearings, wallbox(es) andtube openings are standard on allpackage boilers, regardless of fuelsfired. An additional B&W boiler feature is that the alternating front-to-rear bank spacing allows removal of any tube if necessary (illustrated in 8-A).

➈ Front wall fire brick is designed forexpansion and protection of the frontcorner seals, and the front wall tile isanchored by a floating alloy retainer.To protect the corner seals, the frontwall of the membrane unit is set insidefurnace “D” tubes (illustrated in 9-A).

➉ Thermal sleeve connections forlower drum heating coils are standard.Heating coils can reduce the time fromlight-off to full load by several hours.

Water -Tube Package Boilers: Unique Featuresand Rugged Construction Enhance Operation

B&W’s water-cooled package boilers are designed for reliable, efficient operation in a wide variety of industries.

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Superheater(optional) Boiler Sidewall

To Stack orEconomize

Boiler Screen Division Wall

Furnace

Windbox

Furnace Sidewall

Furnace RearWall Tubes

OD=21⁄2"

31⁄2"1⁄4" Thick

Membrane

41⁄8"

3" 3"

MembraneBar

Scalloped Seal Plate

PlateCasting

Drum Internals, Type "B"

Drum Internals, Type "C"

GeneratingBank Tubes

SootblowerElements

Windbox

Furnace Burner WallFurnace

"D" Tubes

LowerDrum

Thermal SleeveConnections

Tie Bar

Base Frame FM-9, 10, 101

Lower Drum

Wash Water Drains

Generating Bank

Tubes Can Be RemovedBrick Holder

Grooved Tube Seat

Front Wall Tile Front Plate

12-Gauge Roof Casing

A-A

A

A

1

2-B

5

8

9-A 10

8-A 9

6 7

3 4

2 2-A

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Even when load changes are wide or frequentenough to affect water level in the drum, positivecirculation is assured with B&W drum internals.As hot furnace flue gas crosses the first row oftubes in the boiler bank, a considerable amountof steam is generated. This quantity is substantiallygreater on higher-capacity units for essentially the same drum length, imposing a tremendousburden on drum internals.

B&W separation equipment is specificallydesigned to effectively handle this rapid, intensegeneration of steam. Diffuser baffles direct portions of the steam to less turbulent zones ofthe drum, making use of the entire length ofscrubbing elements to remove unwanted moisture droplets.

Superheater tube failures eliminatedWhen superheaters or special processes require

it, steam with less than one ppm solids can beobtained. Turbine blades are kept cleaner, andcostly superheater tube failures are eliminated. Anequally important feature designed into B&W’sdrum internals is the supply of bubble-free solidwater back to the downcomer circuits for positivecirculation. The drum internals’ design alsoallows free end flow to minimize turbulence andend-to-end level fluctuation.

Water -Tube Package Boilers: Efficient Separationand Positive Circulation Assure Dependability

Adequate slope is designed on all heat-absorbing surfaces, andall downcomers are located in the cooler zone of the convectionbank for proper circulation. Each tube is completely drainable.

B&W designs and manufactures all ourown drum internals, including cyclonesteam separators.

Type “B” Internals

Type “C” Internals

Diffuser Baffle

Steam Outlet

Secondary Steam Scrubber

Cyclone Separator

Steam Outlet

Secondary Steam Scrubber

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Economizers, superheaters, burnersand controls are available from B&Wfor package boilers in accordance withoperating and economic design con-siderations. Additional accessoryequipment, including a forced draftfan and drive, a junction piece, fluesand ducts, stacks, feedwater pumps,deaerator, and an oil pump and heater set can be ordered to simplifyplanning and engineering.

Economizers increase efficiency

Economizers are available forincreased efficiency. Pre-engineeredarrangements of extended surface or bare-tube economizers are offeredto meet varying fuel, space and economic considerations.

Fully drainable superheatersProven, dependable and fully drain-

able superheaters – especially designedfor package boilers – also are an avail-able accessory. The vertical-tube designprovides positive bottom support andexcellent expansion characteristics.Multi-pass steam flow ensures highsteam velocities and good distributionof fluid throughout, effectively coolingeach tube. Because it is positioned outof the full radiant heat zone, it has aconvective-radiant temperature char-acteristic for a relatively constantsuperheater steam temperature overthe load range. For further conve-nience, the steam outlet is locatednear floor level. To protect the thickerwall drums in the superheater area,refractory drum protection is provided.

Water -Tube Package Boilers: Complementedby a Complete Line of Auxiliary Equipment

To meet your required steam conditions,a superheater unit can be added toB&W package boilers. B&W also offerspre-engineered arrangements of extended surface or bare-tube economizers.

For oil-fired applications, sootblowersare a typical feature. The sootblowersupply and superheater outlet connection are pictured to the left.

Refractory drum protection safe-guards the thickerwall drums in thesuperheater area.

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B&W’s extensive, worldwide experi-ence allows us the flexibility to easilymeet diverse project requirements –anything from a knock-down boiler toan entire steam island. We can pack-age your boiler system with properlysized, quality auxiliaries to match yourneeds and our standards of excellence.

Typical project scopeAlthough every project is unique in

scope, a typical project includes:

➢FD fan and drive

➢Burners and fuel trains

➢Deaerator and feedwater pump set

➢Burner management system

➢Combustion controls – jackshaft to DCS

➢Economizer

➢Stack

➢Platforms

Stringent quality control standards

At B&W, quality assurance is integralto our design, engineering and manu-facturing processes. To ensure all codesand specifications are met, B&W usesstringent quality control proceduresand sophisticated testing apparatus.Rigid standards have been establishedfor our material suppliers as well.

B&W’s commitment to quality is evident by our:

➢Advanced technology –B&W buildsquality into its products during everyprocess and stage

➢Strength in size and capacity – facili-ties, manpower and global presenceprovide you with a complete rangeof fabricating processes

➢Outstanding responsiveness –B&W isequipped and structured to meetyour delivery needs and requirements

B&W’s package boilers are being fabricated at our West Point,Mississippi, U.S.A., manufacturingfacility. This plant is ISO-9001 certified, ASME code approved, andpossesses an outstanding safety record,receiving OSHA Star Status in theVoluntary Protection Program.

Manufacturing and safety excellence

B&W’s package boilers are designed,engineered and manufactured at ourWest Point, Mississippi, U.S.A. facility –one of seven B&W manufacturingplants located worldwide. This plant is ISO-9001 registered, ASME codeapproved, and is in compliance withAWS code requirements. B&W’s WestPoint plant also maintains an outstand-ing safety record and has been awardedthe OSHA Star Status in the VoluntaryProtection Program. Manufacturingand safety excellence are a continuousgoal for B&W.

Worldwide, responsive serviceand manufacturing support

B&W’s network of domestic andinternational sales representatives andfield service engineers assures you of aprompt response – whether servicingand upgrading your existing system or specifying new equipment. We can provide services ranging from routineinspections and controls tuning tocapacity increase engineering studies,low emissions conversions or new digital control systems.

To meet the needs of the globalmarket, we also design, engineer and manufacture package boilers inaccordance with all B&W standards atsix international operations. Theseoperations are Thermax B&W in Pune,India, B&W BC in Beijing, PeoplesRepublic of China, PT BWI in Batam,Indonesia, B&W Gamma in Ankara,Turkey, B&W Egypt in Cairo, Egypt,and B&W Mexicana in Mexico City,Mexico. These facilities are ASMEcode approved and participate in The McDermott Safety Program.

Reliable single-source supplier

B&W’s proven expertise in boilers,burners and controls makes us a reliable and responsive single source

Water -Tube Package Boilers: Total-Scope Supply and Services

for package boilers and auxiliaryequipment. From engineering andmanufacturing to start-up and opera-tion, B&W knows how to make it allwork together for maximum operatingefficiency and dependability, andkeeps you in compliance with today’senvironmental regulations.

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Through innovativeenergy solutions andtotal-scope services,B&W is dedicated to powering the worldin an environmentallysafe, efficient andeconomical manner.

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a McDermott company

In all the world, there is onlyone Babcock & Wilcox. Othersmay copy our name, but nonecan duplicate the engineeringexcellence and advanced technologies developed by theoriginal Babcock & Wilcox.

For more information, or a complete listing of our sales and service offices worldwide, call 1-800-BABCOCK (222-2625) in North America. Outside North America, call (330) 753-4511 or fax (330) 860-1886 (Barberton, Ohio, USA). Oraccess our Web site at http://www.babcock.com.

Canada:Cambridge, OntarioEdmonton, AlbertaHalifax (Dartmouth), Nova ScotiaMontreal, QuebecSaint John, New BrunswickVancouver (Richmond), British Columbia

Czech Republic: PragueEgypt: CairoEngland: London India: PuneIndonesia: JakartaMexico: Mexico CityPeople’s Republic of China: BeijingPoland: WarsawRussia: MoscowTaiwan: TaipeiTurkey: AnkaraUnited States of America:

Akron (Wadsworth), OhioAtlanta, GeorgiaCharlotte, North CarolinaCherry Hill, New JerseyChicago (Downers Grove), IllinoisCincinnati, OhioDenver (Sheridan), ColoradoHouston, TexasKansas City, MissouriSan Francisco (Vacaville), California

Powering the World Through Teamwork and InnovationSM

The information contained herein is provided for general informationpurposes only and is not intended or to be construed as a warranty, anoffer, or any representation of contractual or other legal responsibility.

© The Babcock & Wilcox Company. All rights reserved.

Powering the World Through Teamwork and Innovationis a service mark of The Babcock & Wilcox Company.

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