Powermaster

T. (+52) 55 5393 5711 / 5700 / 5770 / 8449

CONTACT
en_US
en_US es_MX

Design and Evaluation

ㅤ

design and evaluation

ㅤ

types, design, evaluation, reliability, ease of use, maintenance and service.

Types of Boilers

There are two types of industrial boiler designs:

• Fire Tube: In fire tube boilers, hot combustion gases flow through tubes and heat the water that surrounds them
• Water Tube: In water tube boilers, water flows through tubes and is heated by the flame and combustion gases that surrounds it.

The large majority of industrial steam boilers are fire tube boilers.

Calderas Powermaster manufactures fire tube boilers, which have been the mainstay of the industrial steam boiler generation, to a maximum capacity of 1500 boiler horse power (BHP ) and a maximum operating pressure of 300 lbs/in² (PSI).

If a larger boiler size is required, it is convenient, when possible, to divide the boiler capacity requirement into two or more fire tube boilers. Barring that, a water tube boiler would be necessary. A water tube boiler would also be required to achieve a higher maximum operating pressure. Calderas Powermaster does not manufacture water tube boilers.

 Boilers use an incredible amount of pressure to generate an equally impressive amount of energy. A deficiency of strength in any part of the boiler caused by poor materials, inferior workmanship, or a failure of the safety controls or other critical components of the boiler to function properly can cause tremendous damage. Because of this, understanding the safety features of your boiler is critical.

Powermaster boilers are designed to be among the safest in the market. From the quality and thickness of the materials, to the safety controls and devices, Powermaster always exceeds the standard safety requirements in order to guarantee a top-tier boiler in terms of both performance and security:

• 11 gauge flux tubes are 100% thicker than the ASME requirement , thus guaranteeing a longer useful life.
• Horizontal boiler's 80-1500hp tube sheets are 30% thicker than the ASME requirement , thus guaranteeing a longer useful life.
• Control measures exceed the minimum requirement to such a degree that there will always be a redundant control to regulate the water level or working pressure, thus greatly reducing the possibility of an accident.
• Safety features also exceed the minimum requirements with combustion gas relief valves at the exit of the second pass coming standard on most horizontal boilers, thus mitigating any type of explosion or potential accident.

In the US, boilers are designed and manufactured in strict accordance with the Boiler and Pressure Vessel Code (the “Code”) set forth by the American Society of Mechanical Engineers (“ASME” or “the Society”); only then can the boilers be embossed with the corresponding ASME stamp. The ASME Code is a product of the compilation of all the Society´s engineering knowledge base gathered over the years. The goal of the Code is simple: to protect boiler users, by demanding minimum quality, design, calculation, and manufacturing requirements, and thus ensuring that the end user receives a safe and reliable boiler with a long useful life.

The requirements regarding materials are much stricter, demanding greater thicknesses, than both the European and Asian codes. Because of this, it is very common, especially in more developed countries where they do not manufacture their own boilers, to require imported boilers to bear the ASME stamp.

The first boilers smoke tubes were manufactured in the early 19th century, they used very large amounts of refractory, they burned coal and engaged in the transfer of heat in a fairly efficient. As a result of this, it is required surfaces of heat transfer of 10 ft2 for BHP to be able to comply with the generation of steam required. In the decade of the 1960s, manufacturers of boilers, smoke tubes have been greatly improved their designs, and technologies. Burning usually liquid or gaseous fuels that are allowed to have a higher heat transfer and lower emissions to the atmosphere. The criterion of the design of these boilers has evolved, requiring only surfaces of heat transfer 5 ft2 by BHP for boilers reliable and good efficiency, but are manufactured boilers smoke tubes of a maximum of 700 BHP. With the technological advances of the 20th century and the development of the engineering, experience and technical scans, the design criterion of tube boilers smoke has continued to evolve. Today the majority of manufacturers in the world, succeed in designing boilers of more power using less heat transfer surface sometimes as low as 3 ft2 by BHP, while maintaining the reliability and safety standards.

The criteria which govern the design of the boiler manufacturing of smoke tubes currently, not norman 5 ft2/BHP, giving it greater interest in the manufacture of this type of boiler:

• Efficiency of operation.
• Low levels of pollutant emissions.
• Compliance with the codes of manufacturing (ASME for north America).
• Compliance with the requirements of the National Board of Boiler and Pressure Vessel Inspectors.
• Ease of maintenance.
• Long life and reliability.


Calderas Powermasterunder the leadership of Ing. Herman B. E., Notholt, has developed its designs of boilers with the advancing technologies while maintaining the highest standards of safety and reliability to their customers. All boilers of the series SWB, WB-A2-3P and WB-A2-4P, have a surface area of heat transfer 5 piés2 by BHP up to 600 BHP. In larger capacities, the excess heat transfer surface results in a deterioration of the efficiency and performance of the boiler, so that out of 700 BHP onwards it gradually reduces the heat transfer surface to maintain the guaranteed efficiencies higher of the market.

All the designs Calderas Powermaster guarantee a long service life, reliability and safety in its operation, but pay particular attention and emphasis to efficiency.

As previously described, in fire tube boilers, water surrounds tubes containing combustion gases. If the tubes, from the outside, become encrusted with scale, the heat transfer will be reduced, resulting in a less efficient boiler and increasing the exit temperature of the combustion gases. Nevertheless, this type of scaling is easily removed, and if done correctly the boiler can be returned to its original working order without critical repercussions.

In water tube boilers, not only does scaling of the tubes from within reduce the heat transfer (and therefore efficiency) of the boiler and increase the exit temperature of the combustion gases that surround the water-containing tubes, but it also diminishes the flow of water required inside the tubes. This, in turn, causes damage to the tubes and may even burn them out completely.

For this reason, water tube boilers require an incredibly precise water treatment system – one that cannot fail. The requirements, therefore, for the reliable operation of a water tube boiler demand stricter and more costly controls, such as the 100% elimination of dissolved oxygen via a pressurized deaerator (a device used for the removal of oxygen and other dissolved gases from the feedwater of steam boilers). This is completely unnecessary in a fire tube boiler for which a simple, non-pressurized atmospheric deaerator or even a system that provides for a high percentage of returned condensates, is sufficient

Water tube boilers also require an exact control of salts, a buildup of which can considerably reduce the efficiency of the boiler. To do this, continuous surface blowdowns are required. Once again, such a measure is not normally required for the fire tube boiler, making it a simpler, and more reliable and economical option.

One of the most relevant factors in selecting a boiler is evaluating its useful life.

The useful life of a fire tube boiler meeting the following criteria can easily reach 20 years:

• Designed and manufactured in strict accordance with the ASME Code, and if possible, bearing the ASME stamp

• Heat transfer surface area of 5 ft²/BHP

• Acceptable fatigue and flame release coefficients



Water tube boiler meeting the following criteria may similarly achieve a useful life of 20 years:

• Designed and manufactured in strict accordance with the ASME Code, and if possible, bearing the ASME stamp

• Built as a two dome construction with natural circulation and a large furnace

• Heat transfer surface area of 5 ft²/BHP

• Acceptable fatigue and flame release

coefficients • Supported by an excellent (and generally very costly) water treatment system

Boilers not meeting the above-mentioned criteria will have a significantly shorter expected useful life.



Understanding the factors that contribute to the optimal performance and safe operation of your boiler is critical. From confirming the quality of the materials and craftsmanship of the boiler to understanding key elements of boiler design and the particular maintenance requirements of the various types of boilers, the more knowledge you have, the better able you will be to select the ideal boiler to meet your specific operational goals.

Calderas Powermaster is dedicated to ensuring our clients receive the information they need to make the right decision concerning their boiler needs. For more information about the topics addressed above or to speak with a qualified Calderas Powermaster team member about your particular boiler requirements, please contact us directly.

The Method of Assessment:

Knowing the heat transfer area (next to fire) of the household (in m2) and by knowing the volume of the home of the flame (in m3), we can calculate the coefficient of heat exhaustion Kcal/hm2) and the coefficient of the release of the flame in the home (Kcal/hm3).

Among smaller these ratios, the lower the fatigue of the material at the time, the higher will be the distribution of heat absorption or heat transfer and hence, the greater will be the life of the boiler. The greater reliability of operation as its efficiency natural and we will have more possibilities of obtaining emissions ecological to the atmosphere.