A boiler is a closed metal container with a heating element. Its purpose is to produce steam or heat water by increasing the temperature inside the chamber so that it is higher than that of the environment. Boilers also increase the pressure so that it is greater than atmospheric.

The combination of a boiler and a superheater is known as a steam generator.

How do boilers work?

The basic principle of operation of the boilers consists of a chamber where combustion occurs with the help of combustion air. Then, through the use of a heat exchanger, the transfer of heat is performed and the water is heated.

Taking that into account, the term “boiler” is a remnant of the past when steam boilers boiled water to generate steam. Modern boilers generally heat water using natural gas, butane, or propane.

This hot water is distributed to each radiator through a network of pipes. This causes heat to be distributed more evenly throughout the room and provides a more homogeneous temperature throughout the building during the winter months.

What is the structure of a boiler?

The actual structure of a boiler will depend on the type; however, in a general way, we can describe the following parts:

  • Burner: used to burn the fuel.
  • Home: it houses the burner inside and its where the fuel is burned to generate the hot gases.
  • Heat exchange tubes: The heat from the gases is transferred to the water as they travel through these tubes. It also generates steam bubbles.
  • Liquid-vapor separator: it is necessary to separate the drops of liquid water from the hot gases before feeding them to the boiler.
  • Chimney: it is the escape route of the fumes and combustion gases.
  • Housing: contains the home and the heat exchange tube system.

Boiler classification

Several characteristics define the type of boiler:

A. Depending on the relative position between the fluid and the flue gases

1. With multiple smoke pipes – Pirotubular.

2. With multiple tubes of water pipes – Acuotubular.

B. Depending on the number of steps:

1. One step of gas travel.

2. Multi-step.

C. Depending on the energy needs of the process:

1. Hot water boilers.

2. Thermal fluid.

Advantages of gas boilers at home

Price: There are boilers with a variety of prices.

Speed, comfort, and space: for home use, the heating process can be quite fast. You can regulate the consumption and temperature using the built-in thermostat. Also, they do not usually take up much space.

Shelf life In general: this type of boiler lasts longer than other heaters.

Cleaning: Natural gas boilers, unlike some of the alternatives, do not pollute, unlike other means of heating that do emit waste.

 

A boiler is a crucial piece of equipment in most industrial, commercial facilities and power plants. Specifically, it is a closed pressure vessel that produces high or low-pressure steam or hot water for industrial or domestic use, and have a wide variety of uses. Consequently, there are several types of boilers serving every need. Here we present their classification so that you have a better idea of the kind of boiler that you need.

Classification of Boilers

Industrial Boilers

Fire Tube


They are the type of industrial boilers where heat and gases of combustion (from the furnace) pass through tubes that are enclosed on water. (1)

Water Tube


They are the type of industrial boilers where water passes through tubes while the hot combustion gas flows on the other side of the pipes. Water Tube boilers are more efficient and less dangerous than fire tube boilers. (2)

Fire Box

They are the traditional “locomotive” type of boiler. The “firebox” is the space where the heat originates, producing hot gases that pass through the tubes, heating the fluid. It is reliable but limited.

Packaged Type


The packaged type comes as a factory-assembled package with mountings, accessories, and control instruments installed on it. Either they can be of the fire tube or the water tube type. (4)

By the Type of Fuel Used by Boilers

Coal-fired


They generate thermal energy by burning pulverized coal. (21)

Oil-fired


They are used for application in low-pressure steam or hot water central heating system. (22)

Gas-fired


They, as its name indicates, are gas-fired by either natural gas or propane. (23)

Biomass


They are very similar to the conventional gas types, but instead of using gas (or oil) to produce the heat, they combust sustainably sourced wood pellets. (24)

Circulating Fluidized Bed (FBC Boiler)

CFB is a combustion technology that allows burning solid fuels in steam boilers. When air or gas passes through an inert bed of sand supported by a fine mesh, as the velocity of the air bubbles increases the bed particles, and the air attains a state of high turbulence and the bed assumes the appearance and exhibits the properties of a fluid, and hence its name. (5)

Pulverized Coal (PC Boiler)


Their use is commercial or industrial, and they generate thermal energy by burning pulverized coal or other combustible material. Specifically, compressed air blows the pulverized coal through a suitable nozzle where it burns. (6)

Waste Heat Recovery


It is an energy recovery heat exchanger that recovers heat from hot streams with potential high-energy content. In particular, hot fuel gases from a diesel generator or steam from cooling towers or even wastewater from different cooling processes such as in steel cooling. (7)

Nuclear Steam Generators


Nuclear Steam generators are heat exchangers that are used to convert water into steam from heat produced in a nuclear reactor core. Specifically, pressurized water reactors (PWR) use them in between the primary and secondary coolant loops. Then, his primary coolant is pumped through the reactor core, where it absorbs heat from the fuel rods. (8)

By the Steam Pressure of Boilers

Low-Pressure


They are of the steam or hot water types that have a maximum pressure of 15 pounds per square inch for steam and a maximum of 160 pounds per square inch for hot water. (9)

High-Pressure


A high-pressure is a boiler that generates steam or other vapor at a pressure of more than 15 PSIG or heats water to a temperature higher than 250°F and pressure greater than 160 PSIG for use external to itself. (10)

By the Boilers’ Steam Uses

Process Boilers.


They produce a heated or vaporized fluid for use in various processes or heating applications. For instance, water heating, central heating, boiler-based power generation (11)

Utility Boilers


It is a combustion unit of more than 25 megawatts that serves a generator that produces electricity for sale and fires fossil fuel. (12)

Marine Boilers


They are usually of the two-drum water-tube type with water-cooled furnaces. Likewise, heat recovery equipment of the economizer or air-heater type. The majority of ships are fitted with two units, although some large passenger ships may have three or more. (13)

By their Portability

Stationary and Portable boilers.

By the Furnace Position

Externally Fired Boilers


It has the combustion chamber outside of the shell. This type of furnaces are not surrounded by water but by brickwork (14)

Internally Fired Boilers


It is one whose furnace is wholly or partly surrounded by water. (14)

By the Axis of the Shell

Vertical (Cochran)


It is a vertical drum axis, natural circulation, natural draft, low pressure, multi-tubular, solid fuel fired, fire tube boiler with an internally fired furnace. (15)

Horizontal (Cornish, Lancashire)


Lancashire is a simple horizontal boiler which belongs to the shell and tube class. While Cornish is much like the Lancashire boiler, it is a fire-tube type of boiler that its hot gases flow in tubes and water surround these tubes in shell. (16)

By the Number of Tubes in the Boiler

Single-tube Boilers


It is a type of boiler in which hot gases pass from a fire through one tube running through a sealed container of water. (17)

Multi-tube Boilers


It is a type of boiler in which hot gases pass from a fire through many tubes running through a sealed container of water. (18)

According to the Circulation of Water and Steam in the Boiler

Natural Circulation Boilers


Inside them, the heating of water sets up convection currents that make the water flow. Consequently, as the temperature of the water in the boiler increases, the difference in density makes the water circulate. (19)

Forced Circulation Boilers


It is one where a pump circulates water inside the boiler. Notwithstanding, it differs from a natural circulation type, which relies on current density to circulate water inside the boiler. Furthermore, in some forced circulation boilers, the water flows at a speed of twenty times the rate of evaporation. (20)

Conclusion

Independently of the type of boiler that you need, our steam team has over 100 years of combined experience and is prepared to serve you! We provide solutions for all of your industrial boiler rental and boiler sales needs for all market segments, request a quote today here.

Sources: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24

A boiler is an engineering machine or device designed to generate steam. In particular, this steam is produced through a constant pressure heat transfer, in which the fluid, initially in a liquid state, is heated and its phase changes.

What type of steam does an industrial boiler produce?

The main objective of an industrial boiler is steam generation. Specifically, using a heat transfer at constant pressure to generate steam. Thus, the fluid, which is initially in a liquid state, heats up and becomes saturated steam.

Saturated steam can have different applications such as sterilization, fluid heating, or electricity generation.

Use of boilers

Steam has a wide variety of applications, boiler-created steam, which is usually water steam, is used for the following purposes:

Sterilization (staining): it was common to find pots in hospitals, which generated steam to sterilize medical instruments. Also, it is useful for the sterilization of cutlery in dining rooms with industrial capacity.

To heat other fluids, such as in the oil industry. For instance, heating heavy substances with steam can improve their fluidity.

Boilers are an essential part of thermoelectric power plants. In fact, they create steam which rises and moves a turbine that generates electricity.

Boilers are industrial installations that vaporize water for various applications in many industries. Specifically, they produce steam by applying the heat of a solid, liquid or gaseous fuel.

Objectives:


Boilers or steam generators purpose is to:

  • Generate hot water for heating and general use, or
  • Generate steam for power plants, industrial processes, or heat.

Operation and Applications of Industrial Boilers


Boilers are vessels that work under pressure using constant heat transfer, in which the liquid heats and changes state.

Industrial boilers have a great variety of applications in many industries that depend on them to deliver their products or services. For instance, hospitals, oil companies, restaurants, laundries, textiles, etc.

The water used in hot water and steam boilers needs a recalcification treatment typically to preserve the life of the boiler.

Every boiler has one or more drain pipes, which connects to the tanks’ lowest point. They are used to purge and extract the sludge.

The discharge of the purge pipes will be arranged in such a way that there is no danger of accidents for the personnel. Thus, it is emptied to the sewer through an intermediate retention pond or purge tank.

The conditions retention ponds must-haves are:

a) It will be easily accessible for inspection and sludge removal.
b) To prevent steam leaks, adjusted inspection covers or doors will be used.
c) The pond will be provided with a metal ventilation tube, which is connected to the room’s exterior.
d) The diameter of the exhaust pipe must be greater than the width of the purge tube.
e) It must have a valve in the lower part that allows personnel to drain all the water from the boiler.

For ideal performance, industrial boilers need to use proper fuel. In particular, these are characterized by a high calorific value, a specific degree of humidity, and a percentage of volatile materials and ashes.

It is necessary to analyze the fuels that we are going to use in each device. In particular, the chemical analysis is what allows us to distinguish the elements that are part of the fuel.

It’s also important to remember that air-fuel mixtures should be accurate, otherwise, it can damage the industrial boiler, and serious accidents can occur. It is necessary to take all the required precautions before handling industrial machinery and its fuel.

Boiler installation

Important factors to account in the installation of a boiler:

-Adequate illumination is imperative Noy only to ensure proper installation, but also to avoid accidents.

-Its location: usually, it will be located in the basement of the building, with good lighting, and adequate ventilation. Also, enough space for the operator to perform the maintenance work comfortably.

-Manufacturer specifications: adhere to them at all times.

-Protection devices: necessary for safe operation.

-Qualified staff: To ensure proper installation and maintenance you should hire only qualified and certified personnel.

-Another aspect to consider is that proper installation can significantly reduce the most common problems in boilers. For example, scale, corrosion, and deposits. Furthermore, among other pressing issues, these elements can affect the thermal performance, or cause the boiler control component reading to fail.

How to provide preventive maintenance to a boiler?

Check:

  • Water level, combustion.
  • Pressure/temperature feed water.
  • Flue gas temperature.
  • Fuel oil pressure and temperature.
  • Gas pressure.
  • Atomization air pressure.
  • Supply and return water temperatures.
  • Replacement water consumption.
  • Vapor pressure.
  • Adequate fuel valve closure.
  • Air and fuel connections.
  • Indicator lights and alarm.
  • Limiting and operating controls.
  • Security controls and connections.
  • Filtration, noise, vibrations, abnormal conditions, etc.

-Inspect the inside surface of the container

Clean:

  • chimney sweeping of fire pipes
  • Water chamber inspection

If you are looking to install an industrial boiler in your facility we recommend that you hire a specialized company. It can offer installation and maintenance for peace of mind.

Knowing how an industrial boiler works is very important because they are machines widely used in many industrial processes. Boilers are equipment for steam generation. They are thermal instruments that have the purpose of converting water into steam by burning fuel.

The steam, which is produced by a generator, advances at high pressure through pipes. Industrial boilers heat water and generate vapor, using two prevalent methods: the smoke pipe and the water pipe.

At the beginning of the industrial revolution, when industrial boilers became popular, those with heat pipes were the most popular.

The hot gases of the fire, made with coal or wood, passed through pipes to heat the water in the tank, generating steam for use in industrial processes.

This type of boiler is considered hazardous because the tank is fully pressurized. For instance, if the tank explodes, the explosion can cost several lives or severely injure people nearby.

What you should consider before a boiler installation

Before installing boilers, you must ask yourself a series of questions that will help you make the acquisition much more efficient.

Types of boilers according to their fuel

You should choose a boiler that uses a fuel that’s widely available and affordable near the area where you live.

Gas boilers:

They can be of two types:

Natural gas: It is the one that emits less gas from all types of fuel. You need to pass the relevant controls and proper ventilation.

Butane gas: Usually used wherever there’s very little need for heating.

Oil or diesel boilers

They need to store the gas in their tank. Oil or diesel boilers can be by accumulation or snapshots.

Types of boilers according to their typology

-Atmospheric. They are the ones that use the cabin air where they are for combustion. They are illegal in many countries.

– Stakes: They are called watertight because combustion takes place in a sealed chamber.

If you need more information, contact us.

If your boiler shows signs of not working well, remember that when choosing a boiler company to service the boiler of your building, you should make sure to consider a few key things.

The repair or replacement of the boiler in a commercial or industrial environment requires extensive knowledge and experience, here’s a guide of questions you should ask yourself when embarking in this journey.

How long has the boiler company been in business?

The longer a boiler company has been in business, the more likely it is that they have experience in finding and repairing problems such as those experienced by your company.

Another advantage of a company with a long time in business is financial stability; established companies are less likely to fail in the middle of the repair and more likely to repair their service if something went wrong.

Do they have experience in your industry?

If you run a specific type of factory, don’t expect a boiler company that works primarily in office buildings to have experience in your boiler applications. Choose a company that has experience in your industry.

Does the boiler company guarantee parts and service?

Select a boiler company that gives you a guarantee for the work done. If an arrangement does not correct your problem, a part and labor warranty could offer you protection so that you will not be charged for the same repair.

Is a pre-start inspection included in the deal?

Let’s say a fan in your boiler needs to be replaced, and the boiler service company repairs it. Make sure they restart the computer and perform a pre-start inspection.

Doing so allows the seller to make sure no other repairs or maintenance are present, but if they do, your provider can fix it before leaving. It makes your business run more efficiently by reducing equipment downtime.

Can they provide proof of license, insurance, and certification?

Even if a company does not need a specific consent to operate in its state, the city in which it is based will likely grant one.

The license is essential, as the threat of loss of permit significantly contributes to enforcing your agreement with the provider.

Insurance is always necessary to protect your company against the additional risk of property damage or injury to your employees or visitors.

When a service or your technician is certified in the repair and installation of boilers, you know that you are hiring a company with the updated skills and equipment necessary to provide quality work.

What are their safety procedures?

At work, safety is also a constant concern. Does your candidate company have a safety plan? How often do they train staff on this? How many days of work do they have without a workplace injury? Will they follow the boiler safety plan of your installation?

Are they a representative of the manufacturer?

Is the company the manufacturer’s representative of its boiler brand? If so, this could be an indication that their technicians are kept up to date on the brand’s product line.

What is the cost of an annual service contract?

Do not confuse the price with the cost. A cheaper provider can save you money in the short term, but it will cost you more in the long run due to a below-average service. Choose a company with a reputation free of complaints about poor quality services.

Boiler company references

Ask and verify their references. Make sure they are from companies in your industry with boiler needs similar to yours. Verify the performance, professionalism, and customer service of the candidate company. Less than stellar criticisms in any of these categories strongly suggest that you continue your search.

Asking these questions will help you make sure you find the right boiler service company for your building or installation and will save you many long-term headaches.

If your boiler room ever needs to be shut down, installing a portable boiler room is the most efficient way to solve your water heating needs. Make sure you know how to quickly acquire a portable boiler rental so that you are prepared for any eventuality.

Portable boiler rooms usually come in containers and can be transported to your facility within hours. They are prewired and configured so that they can be up and running in no time at all.

Be ready for an emergency with a portable boiler rental

Unplanned shutdowns can be dangerous, so having a contingency plan to solve that emergency is critical.

Even if you already have a boiler room in your facility, having the number of a portable boiler supplier can be a lifesaver in the case of an emergency shutdown.

Portable boiler rooms should include everything they need to work: pumps, controls, valves, etc. It’s a self-contained system. It is usually delivered in an insulated container to protect it from the elements. They have external connectors for easy installation.

Most should be able to work with natural gas, #2 oil, or propane. You only need to supply the fuel, water, and electricity for the controls.

Electrical boilers aren’t a good fit for portable boiler rooms. They would take too much energy to power from a generator in case of a power outage.

There are many different sizes, from 20′ containers and up. You can get one with the exact output required for your facility.

Don’t wait until your boiler room is down to look for a rental company. Find one that can get one to you as soon as possible. Have a contingency in place. You might hope for the best, but it is wiser to prepare for the worst.

If you want to get a quote for a portable boiler rental today, don’t hesitate to contact us. We are more than happy to help.

Rental boilers are machines or engineering devices designed to generate steam through a constant pressure heat transfer so that the fluid in a liquid state is heated and changes to saturated steam.

Steam boilers are designed so that their transportation is easy, and the installation is quick. Steam boilers up to 6000 kg/h come preassembled in individual containers and need no specialized equipment for installation.

Boilers must have necessary accessories and services, to ensure a safe installation and rapid commissioning, from the design of their perfect 3D solution to logistics, installation, and dismantling.

Steam is a vital tool for food and beverage processes (Petro) chemicals and paper. If you have a temporary need for steam due to planned maintenance, an increase in production, or unexpected interruptions, you must have a reliable, safe, and compliant solution.

How does the maintenance of Rental Boilers work?

A rental agreement always includes standard maintenance, so you don’t have to worry about hidden costs. That means that our technicians are responsible for on-site maintenance, saving you time and effort.

The technician assigned to your application is also available during your rental agreement to solve problems and for special projects.

Rental boilers are designed for a maximum operating time of 72 hours without supervision. Most of the companies that provide this service have service technicians available 24 hours a day, seven days a week.

How should the boiler room rental be?

According to each case, you must choose the right place and accessories for the boiler, fully adapted to your needs.

Whether it is a simple hose, a combustion heater, or even a feed water tank, there must be a place with everything that is needed for the temporary installation of steam boilers.

We can also provide a full range of services, including design plans, 3D scanning, logistics, installation, wiring, commissioning, and training.

The boiler room contains a series of equipment responsible for transforming a fossil fuel (natural gas, propane gas, C diesel, coal, biomass) into thermal energy (HEAT) through a combustion process.

Types of boilers

Depending on the risk of internal condensation, they can be:

  • Standard
  • Low temperature
  • Condensing boilers: the ones with the highest performance, obtaining more heat with less fuel consumption.

Commercial boilers have plenty of advantages. They can operate continuously for prolonged periods. In addition to this, they are more efficient than their residential counterparts, which means they are more environmentally friendly. Being more efficient translates into savings that help your bottom line stay in the black. Here some of its benefits:

Commercial boilers save energy with power fractionation

The high cost and continuous increase in fuel prices have forced energy audits and actions. This has lead to improvements and reforms in industrial facilities, aimed at reducing energy costs. For example, most industries with commercial boilers have installed economizers in the gas outlet. Others have optimized steam distribution and consumption networks.

Many companies have committed to the power fractionation technique. It consists of the installation of several smaller boilers, instead of a larger unit.

This technique allows the boilers to always work in their optimal working range. Additionally, it facilitates greater temperature control and a reduction of the space needed for the boiler room, which brings significant savings.

Advantages of annual maintenance of commercial boilers

When carried out, the yearly inspection of industrial boilers verifies that the devices that work inside the installation are safe and suitable for use.

Upon inspection, it can then be determined whether the commercial boiler is burning correctly with the correct operating pressure.

A proper intervention can help identify potential failures or problems that may need immediate attention.

In many countries, annual maintenance is mandatory. Which will keep your installation within the legal parameters in case of an accident; otherwise, your insurance will refuse to pay.

An annual check may be necessary to maintain the manufacturer’s warranty in your commercial boiler

Performing boiler maintenance will ensure that your furnace and the heating system remains safe to use to verify that your boiler works with the correct operating pressure. That means it will only spend the energy or gas it needs, without wasting money and ensuring that its performance is adequate.

Annual maintenance extends the life of the commercial boiler

When performing the combustion analysis, you need to make sure that the boiler does not emit toxic byproducts such as carbon monoxide. Carbon monoxide at high concentrations can cause serious accidents.

The importance of maintaining the boiler in good condition is evident, as should be the importance of hiring qualified boiler maintenance and repair services.

It is a profitable investment

Although it is necessary to make a high investment, industrial biomass boilers and the storage system are more efficient than traditional fuel boilers. The low operating cost compensates for the initial investment.

Like all industrial equipment, steam boilers require periodic maintenance and inspections to ensure their correct, safe, and efficient operation.

However, boilers are machines that compromise the continuity of production in many industries. This means that shutting them down can come at a high price, not only because of the maintenance cost but also on lost production.

It is for this reason that we establish an annual maintenance plan in which we perform important inspection tasks to detect most breakdowns preemptively.

What is the maintenance plan for a steam boiler?

    • Internal inspection of the pressure body, plates, household, and tubular beam to control the formation of incrustations or corrosion of building materials.
    • Hydro-washing of sludge deposited at the bottom of the body if it exists. This is important for optimal operation.
    • Change inspection door gaskets, always install new gasket materials and check cover seats. This will avoid many accidents within the company.
    • Measurement of plate thicknesses, and cylindrical body by ultrasound, we also record these values. It may be necessary to recalculate the maximum working pressure if these thicknesses are reduced over time.

Important aspects for your steam boilers

    • Disassembly of security elements. In the case of electromagnetic level controls, check floats, bottles, verify play in mechanisms, check the integrity of the mercury ampoules and check that the insulation of the cables is not damaged.

For the electrodes, the task is cleaning parts that are in contact with water, alignment check, caulking, and seals.

    • Hydraulic test of the work pressure equipment. Performed in order to verify that there are no leaks before and after maintenance (inspection of door seals, flanges, threads, etc.). After that, the container must remain pressurized for at least 15 minutes.
    • Verification of opening of safety valves at a regulated pressure. If possible, remove them for stamping on a test bench.
    • Inspection of refractory status in a burner or dry bottoms. Fill cracks if there are any or replace damaged parts with the appropriate materials.
    • Verification of the internal state of the burner and its cleanliness. Check the condition of cables and connection cards.
    • Start-up of the equipment where the operation of the control and safety elements will be checked.
    • Gas analysis and combustion regulation. Through this process, the percentage of the following gases will be determined: O2, CO2, and CO.

Also, the temperature of the gases in the chimney, and the thermal efficiency of the boiler will be measured.

    • Preparation of a technical report with the results obtained in the measurement of combustion efficiency and the general condition of the equipment, maintaining a history.

The steps for maintaining a steam boiler are quite specific, so you should entrust it to skilled professionals. In conclusion, if you need this type of service or any other related to preventive maintenance in your facilities, let us help you.

For an industrial boiler to work at 100% performance, you must not only take into account a proper installation. But it is also essential to have a maintenance service that guarantees its performance over time. Throughout this post, we will tell you all the advantages of hiring a professional team for the maintenance of your boiler.

-Mandatory

The law establishes that annual periodic reviews must be carried out. The maintenance contract with your installation company must include all annual reports and even some repair costs. It is also necessary to perform an annual boiler cleaning.

-An efficiently run boiler saves you money

If your boiler has passed all the checks correctly, it will be at the highest possible performance. An efficient boiler means a lower power bill at the end of the month.

-An industrial boiler improves the security of your company

Hiring a maintenance service will ensure that leaks are detected on time, without exposing your company’s personnel to any risk.

Many industrial boiler maintenance companies offer a maintenance contract with emergency service with 24-hour coverage, every day of the week with professionals who will repair any breakdown in the shortest possible time to avoid delays.

-Reduce repair costs of industrial boilers

Hiring the maintenance service of your boiler with a professional company will mean savings for your company since usually, the service includes mandatory periodic reviews and some of the repair costs. If you need to carry out a preventive or urgent repair, you will probably only have to pay for the parts that need replacing.

-Warranty:

When you hire a maintenance service with a professional boiler company, the company will guarantee the effectiveness of the work. Also, the company will respond to any eventuality that occurs later. That is why it is essential to hire a professional company.

These are some of the advantages of having a maintenance service take care of your industrial boilers, so do not hesitate to ask us if you need more information.

Source: Superior Boiler