Types of Boiler Safety and its Importance .

 Basic about Boiler : 

Boiler explosion history tells that an industrial boiler is a potential bomb and   have chance to  explode without precaution

Cause : 

Main Possible Causes of Industrial Boiler Explosions

Few common cause for boiler explosion such as.
 
 1. Failure of the boiler safety .

2. Reckless management is the main cause of every accident . 

Type of Boiler Safety 

 1.Low or high water level alarm.

2.Too low water level alarm and shut down.

3.Water level indicators.

4.High pressure cut off switch .

5.High and Low pressure cut off.

6.Fusible Plug .

7.Photocell

8.Boiler Mabrey

9.Safety Valve 

Details on safety 

 Water Safety 

Water Indicators : Water indicator show the boiler drum water level or it should be always 70% of total boiler capacity.

Boiler Mobrey : 

Boiler Mobrey is very useful safety in boiler . It work with two or three safety of boiler .

1. Low water alarm .
2. Very very low water alarm and cut off (it command to stop the boiler operation .)
3. Maintained the boiler drum level water and interlock with boiler feed pump.     

Boiler 

Boiler Pressure Switch 

Pressure Switch working with two method .

1. 1^st Cut off the boiler when it reach the setting pressure .
2. 2^nd it command to modulation and start the modulation in low fire .
3. 3nd  if the boiler pressure reach the tripping point of pressure switch than pressure switch command to boiler for stop fire .

                                Pressure switch is also very important safety for boiler 

             

Boiler Fusible Plug 

When the water level goes below the fusible plug, the lead present inside the Plug gets melted because of super-heated steam and now the water from the boiler shell comes out and wets the flue gases and even disrupts the combustion thereby protecting the Steam Boiler from any mishap that may have happened otherwise.

क फ्यूज़िबल प्लग एक सुरक्षा वाल्व के रूप में कार्य करता है जब खतरनाक तापमान, बजाय खतरनाक दबाव, एक बंद बर्तन में पहुंच जाते हैं। ... भाप के दबाव को कम करने के लिए प्लग के माध्यम से छेद बहुत छोटा है और पानी की थोड़ी मात्रा, यदि कोई हो, जो इससे गुजरती है, तो आग बुझाने में कोई बड़ा प्रभाव होने की उम्मीद नहीं है।

Watch full on below link 📺📺📺📹

https://youtu.be/Md9VWfdZ_1I

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     Difference Between Boiler Accessories and Boiler Mounting 

BOILER MOUNTINGS

These are the components generally mounted on the surface of the boiler to have safety during operation. These are the essential parts of the boiler, without which the boiler operation is not possible. The following are the important mountings of the boiler:

मॉउंटिंग के बिना बायलर का कोई भी ऑपरेशन हो पाना संभव नहीं है इसीलिए माउंटिंग को बायलर के  सतह पर लगाया जाता है। मॉउंटिंगस, बायलर का एक महत्त्वपूर्ण पार्ट है

BOILER ACCESSORIES

These are those devices which are installed with a boiler and its neighboring area to increase the efficiency of the boiler. These are not the essential part of the boiler and thus without installing these devices, the boiler operation can be accomplished though at a lower efficiency.

बायलर की कार्यक्षमता (Efficiency) बढाने के लिए जिन यन्त्र (Device) को बायलर के साथ इंस्टॉल किया जाता है, उन्हें Accessories कहते हैं। यह यन्त्र (Device) माउंटिंग के अपेक्षा कम महत्वपूर्ण होते है। एक्सेसरीज के बिना भी हम बायलर को चला सकते हैं लेकिन एक्सेसरीज के साथ वाले बायलर की अपेक्षा बिना एक्सेसरीज वाले बायलर कम कार्यक्षमता (Efficiency) पर कार्य करेंगे।

 

                                                             Types of Boiler Mounting :

1.       Stop  Valve

2.       Water  Level Gauge

3.       Main Feed Water  Valve

4.       Blow Down Pipe

5.       Blow Down Valve

6.       Water Level Gauge 

7.       Valves

8.       Pressure Gauge

9.       Air Vent Valve

10.   Safety Valve

 

Boiler Accessories : 

• Injector

• Pressure reducing valve

• Economizer

• Air pre heater

• Super heater

• Steam drier or separator

• Steam trap

•   On line steam monitoring system

  Watch full Video on You tube : 📺

              https://youtu.be/XiElSGOhaoI    

How to Calculate Boiler Efficiency

 

Calculation formula :

This method calculates boiler efficiency by using the basic efficiency formula-

η=(Energy output)/(Energy input) X 100

In order to calculate boiler efficiency by this method, we divide the total energy output of a boiler by total energy input given to the boiler, multiplied by hundred.

Calculation of direct efficiency-

E= [Q (Hg-hf)/q*GCV]*100

Where,

Q= Quantity of steam generated (kg/hr)

Hg= Enthalpy of steam (Kcal/kg)

hf= Enthalpy of water (kcal/kg)

q= Quantity of fuel

GCV= Gross calorific value of the fuel

Enthalpy : Heat Content of system at constant pressure

                  H : U + PV 

U : Internal Energy ( E) ,  P : External Pressure , V : Volume 

GCV : The amount of heat energy produced on complete combustion of 1 kg of fuel

Example : 1

Total Steam Generate : 30000 kg

Total fuel Consumption : 2000 ltr ( HSD ) High Speed Diesel

E= [Q (Hg-hf)/q*GCV]*100                        

Q : 30000 kg            Steam Pressure : 8 kg/cm2

q  :  2000 ltr             Feed Water Temperature : 60 degree

1> Enthalpy of steam on 8 kg/cm2 : 661 Kcal/Kg

2> Enthalpy of Water at 60 degree :  60 Kcal/ kg

3> GCV Value of fuel ( HSD )            :   10800 Kcal/kg

Step : 1  Hg : 661 , hf : 60     > 661-60 = 601

   =  (30000( 661-60)/ 2000 x  10800)X100

  =   ( 30000( 601)/21600000) x 100

  =   (18030000/ 21600000) X 100

  =    83.4 %

Example : 2

Total Steam Generate : 30000 kg

Total fuel Consumption : 3500 kg Coal

E= [Q (Hg-hf)/q*GCV]*100                        

Q : 30000 kg            Steam Pressure : 8 kg/cm2

q  :  3500 kg           Feed Water Temperature : 60 degree

1> Enthalpy of steam on 8 kg/cm2 : 661 Kcal/Kg

2> Enthalpy of Water at 60 degree :  60 Kcal/ kg

3> GCV Value of fuel ( coal )            :   5800 Kcal/kg

Step : 1  Hg : 661 , hf : 60     > 661-60 = 601

   =  (30000( 661-60)/ 3500 x  5800)X100

  =   ( 30000( 601)/20300000) x 100

  =   (18030000/ 20300000) X 100

  =    88.81 % 

                                                Steam Enthalpy Chart 

                                                                 Enthalpy of Water Chart on Temperature based

 

GCV Value of fuel  

HSD : Gross calorific value of Diesel or HSD is 10800 Kcal/kg

Coal :  Gross calorific value coal is  5800 Kcal/kg  

also watch  full video 📺

What is Steam Traps and Types

 Steam Traps : 

A steam trap is an mechanical device  that holds the steam and  allow the condenses to flow out .

Types of Steam Traps : 

1. Thermodynamic Steam Trap Valve
2. Thermostatic Steam Trap Valve
3. Float Steam Trap Valve
4. Inverted Bucket Steam Trap Valve

 Why Steam Traps Used : 

We know that Steam generate from water at a particular temperature . When steam flow in pipes its temperature decrease and start to convert in water again or when heating a vessel steam convert into condensate or water .   

Property of Steam : 

Steam is an invisible gas created by adding heat energy to water. It is liquid water changed to its gaseous state at particular pressure and temperature or easily convert again in water when temp decrease .

What is Steam Condensate : When the temperature of steam decrease than steam start to convert in water molecules .  

Design of Trap Valve  

 Parts of Steam Trap Valve : 

1. Insulation Cap 

2. Cover 

3. Disc

4. Body 

5. Strainer 

6. Strainer Plug 

7. Blow down valve (optional ) 

Working of Steam Trap Valve : 

At star-up, air will enter the steam trap and will be discharged out through the bleed hole. 2. As condensate enters the trap, it forms a water seal inside the body. The weight of the bucket keeps the valve off its seat and so condensate can flow around the bottom of the bucket and out of the trap

Watch full Video on Working of Steam Trap Valve :

What is Steam Trap and Working 📺

How to calculate Steam Load and Steam Consumption

 Steam Load Calculation 

            In general steam heating is used to

•       change a product or fluid temperature

•       maintain a product or fluid temperature

                                               

                                                 Formula for Steam Consumption in Heating Vessel 

                                                               Q = m c△ t

•       Q =  Quantity of heat or  energy ( unit : kj )

•       m =  mass of liquid ( Unit : kg or Litre )

•       c= Specific heat ( Unit : kj/kg )

•       △ t = change in temp

 Example : 

     5000 kg water heat from temp 20 to 80 degree at 3 kg steam pressure . Calculate steam consumption . 

•       Use formula Q = m c △ t

 •       m        = 5000 kg

•       C    = 4.19 kj/kg  ( Standard )

•       △ t    = ( 80-20) = 60 degree

 •       C ( Specific heat) : quantity of heat required to raise the temperature of one gram of a substance by one Celsius degree

 •       m        = 5000 kg

•       C   = 4.19 kj/kg  ( Standard )

•       △ t    = ( 80-20) = 60 degree

•       Q = 5000 X 4.19x 60

•           = 1257000 kj

 •       Convert kj to kg

•       Divide by Latent heat of steam

 •       Amount of  heat required to convert 1 kg of liquid to vapour or steam  

 •       Latent heat of steam at 3 kg is 2163.22

        Q = 5000 X 4.19x 60

           = 1257000 kj

       Latent Heat of Steam = 2163.22  kj/kg

      = 1257000/2163.22

       =  581.07 kg 

                     

 Thanks 

Watch full video on Steam consumption calculation