Design and Fabrication of Pressing Steam Boiler
Design and Fabrication of Pressing Steam Boiler
Design and Fabrication of Pressing Steam Boiler
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Abstract— A boiler is a device used to create steam by applying heat energy to water. Changes in
investment costs, increases in scale, demands placed on energy efficiency and environmental
requirements are the main factors directing Development of the recovery boiler. This has
resulted in use of higher steam Parameters of ironing and food production .Wood fired boiler
equipment is common in the lumber processing industry. Many facilities will use wood waste
boilers as an integral part of the production process. Steam or hot water is generated for lumber
drying and process requirements. Wood burning boilers however, normally create considerable
ash and soot build-up in the fire tubes, resulting in inefficient heat transfer and a loss of steam
pressure. Most wood fired boilers require manual tube brushing. This means shutting down the
boiler for hours while mill personnel brush the ash build-up from the fire tubes. The trade-off
for not continually cleaning the fire tubes is excessive fuel usage, loss of energy and boiler
inefficiency. The fluid does not necessarily boil. (The term "furnace" is normally used if the purpose is not
actually to boil the fluid.) Boiler is an apparatus use to produce steam.
Keywords— Pressure gauge, Safety valve, Steam outlet valve, Exhaust valve, Multipurpose iron
box, Drain valve, Teflon tube
I. INTRODUCTION
A boiler is an enclosed vessel in which water is heated and circulated, either as hot water or
steam, to produce a source for either heat or power. A central heating plant may have one or more
boilers that use gas, oil, or coal as fuel. The steam generated is used to heat buildings, provide hot
water, and provide steam for cleaning, sterilizing , cooking, and laundering operations. Small
package boilers also provide steam and hot water for small buildings. A careful study of this
course can help you acquire useful knowledge of steam generation, types of boilers pertinent to
boiler operations, various fittings commonly found on boilers, and so on. The primary objective of
this chapter is to lay the foundation for you to develop skill in the operation, maintenance, and repair
of boilers.
A boiler is an enclosed vessel that provides a means for combustion and transfers heat to water
until it becomes hot water or steam. The hot water or steam under pressure is then usable for
transferring the heat to a process. Water is useful and cheap medium for transferring heat to a
process. When water is boiled into steam its volume increases about 1,600 times, producing a force
that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous
equipment and should be treated carefully. Liquid when heated up to the gaseous state this process.
The heating surface is any part of the boiler; hot gases of combustion are on one side and water
on the other. Any part of the boiler metal that actually contributes to making steam is heating
surface. The amount of heating surface of a boiler is expressed in square meters. The larger the
heating surface a boiler has, the more efficient it becomes.
the feed water before it reaches the boiler. Boilers have several strengths that have made them a
common feature of buildings. They have a long life, can achieve efficiencies up to 95% or greater,
provide an effective method of heating a building, and in the case of steam systems, require little or
no pumping energy. However, fuel costs can be considerable, regular maintenance is required, and if
maintenance is delayed, repair can be costly. Guidance for the construction, operation, and
maintenance of boilers is provided primarily by the ASME (American Society of Mechanical
Engineers), which produces the following resources:
Rules for construction of heating boilers,
Boiler and Pressure Vessel Code,
Section IV-2007
Recommended rules for the care and operation of heating boilers, Boiler and Pressure Vessel
Code, Section VII-2007 Boilers are often one of the largest energy users in a building. For every
year a boiler system goes unattended, boiler costs can increase approximately 10%
3. Finish Pressing:
Adds the final shape to seams and garments
4. Buck Presses:
Used by manufacturers of slacks, skirts, and jackets and most of the dry cleaning plants A lower
buck and a complementary moveable head with a linkage system, buck padding, steam and
vacuum systems, frame and table, gauges and manual/automatic controls for steams, vacuum,
heat and pressure May be used for in-process pressing and finish pressing.
5. Iron Pressing:
Manual molding operation with pressure and heat application with a flat contact surface
Consists of an iron, power line, bed buck, and an iron support system Irons vary in weight and
plate dimensions and characteristics depending on the type of pressing operation, fabric, area to
be pressed and quality specifications of the operation Mostly used for under-pressing and are
more versatile and mobile and are most common in our daily life.
7. Form Pressing:
Used for final pressing or for renovating garments in dry cleaning plants Formed in approximate
shapes as the finished garment Designed to reduce the positioning and repositioning time Just
smooth garment fabric but does not set creases.
1. Tube content: (i) Fire tube boiler and (ii) water tube boiler
As it indicated from the name, the fire tube boiler consists of numbers of tubes through which
hot gasses are passed. These hot gas tubes are immersed into water, in a closed vessel. Actually in
fire tube boiler one closed vessel or shell contains water, through which hot tubes are passed. These
fire tubes or hot gas tubes heated up the water and convert the water into steam and the steam
remains in same vessel. As the water and steam both are in same vessel a fire tube boiler cannot
produce steam at very high pressure. Generally it can produce maximum 17.5 kg/cm 2 and with a
capacity of 9 Metric Ton of steam per hour.
There are different types of fire tube boiler likewise, external furnace and internal furnace fire
tube boiler. External furnace boiler can be again categorized into three different types- 1) Horizontal
Return Tubular Boiler. 2) Short Fire Box Boiler. 3) Compact Boiler. Again, internal furnace fire tube
boiler has also two main categories such as horizontal tubular and vertical tubular fire tube boiler.
Normally horizontal return fire tube boiler is used in thermal power plant of low capacity. It consists
of a horizontal drum into which there are numbers of horizontal tubes. These tubes are submerged in
water. The fuel (normally coal) burnt below these horizontal drum and the combustible gasses move
to the rear from where they enter into fire tubes and travel towards the front into the smoke box.
During this travel of gasses in tubes, they transfer their heat into the water and steam bubbles come
up. As steam is produced, the pressure of the boiler developed, in that closed vessel.
A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot.
This is the basic definition of water tube boiler. Actually this boiler is just opposite of fire tube boiler
where hot gasses are passed through tubes which are surrounded by water.
Horizontal Straight Tube Boiler again can be sub - divided into two different types,
Bent Tube Boiler also can be sub divided into four different types,
is a good resource describing a preventive maintenance plan and also explaining the importance of
such a plan.
III. METHODOLOGY
Steam boiler or simply a boiler is basically a closed vessel into which water is heated until
the water is converted into steam at required pressure. This is most basic definition of boiler.
Direct method:
Direct method of boiler efficiency test is more usable or more common boiler efficiency =Q*(Hg-
Hf)/q*GCV *100 Q =Total steam flow, Hg= Enthalpy of saturated steam in k cal/kg, Hf =Enthalpy
of feed water in kcal/kg, q= quantity of fuel use in kg/hr, GCV =gross calorific value in Kcal/kg
,like pet coke (8200 KCAL/KG).
Indirect method:
To measure the boiler efficiency in indirect method we need a following parameter like
TANK CONNECTIONS
The heater is supplied with separate cold water and hot water connections. A connection is
provided for mounting a combination safety temperature and pressure relief valve. An overflow line
should be utilized from the relief valve outlet to a floor drain. See drawing for locations and sizes.
HEATING COIL
The water heater is supplied with a high quality factory installed 2, 4, or 6-pass U-tube
heating coil constructed from 20-gauge ¾-inch O.D. single wall copper tubing designed for a
maximum working pressure of 150 psi. The tubing is installed in a heavy-duty fabricated steel head
with threaded NPT connections. Each assembly is fastened to a corresponding tank flange using a
gasket and hex head steel bolts and nuts. Specialized heating coil construction may be included.
These options include, Double wall tubing with a leak detection port, or special materials (stainless
steel, 90/10 copper-nickel, other) for the tubes and/or head. See drawing for complete details.
CONTROL VALVE
A fully modulating temperature regulator (also referred to as a control valve) should be
installed to regulate the flow of boiler water through the heating coil. No quick opening or snap-
acting valve should be used as these can cause surges in pressure or thermal shock to the coil. If the
unit is furnished with a pilot operated or self contained control valve, no external source of power is
required for the valve. The operating controls are factory selected sized, piped, and tested to ensure
reliable operation, but can be shipped loose for in the field installation by others up on request. The
following is an overview of the various boiler water control systems available.
In the garment industry, equipment for handling fabrics with damp heat to iron surfaces, fold
edges, iron out seams, shape flat parts, and raise the pile during the manufacture of clothing. Ironing
and pressing equipment shapes the semi finished garment by bringing the fabric fibers into a highly
elastic state and then deforming and setting them. This is done by the simultaneous action of
moisture, heat, and pressure on the fabric. Different types of fabric require specific combinations of
moisture, pressure per surface unit, temperature, and duration of the process.
Ironing and pressing equipment includes irons, presses, steamers, steam-air dummies,
assembling and shaping equipment, and auxiliary equipment. There is equipment that operates in
sequence (irons, steamers), in sequence and in parallel fashion (presses, assembling and shaping
equipment), and in parallel fashion (steam-air dummies). Ironing and pressing equipment can be
operated manually or by a pedal; it can also be powered by pneumatic, hydraulic, or belt drive from
electric motors. Presses with capacities up to 50 MN (500 kilogram-force) are considered light, up to
250 MN (2,500 kilogram-force) as medium, and above 250 MN as heavy. Presses are manufactured
with electric, steam, and oil heating equipment. Auxiliary equipment includes various attachments,
forms, and moisteners.
The most common but least productive ironing and pressing device is the iron, which is
suitable for performing a large number of operations in processing with heat and moisture. More
refined and more productive but less widespread are ironing presses, which permit a considerable
degree of mechanization and some automation of processing with heat and moisture. Fabrics are
steamed in order to eliminate sheen (luster), which develops when ironing and pressing equipment is
used. Steaming is done either on specially designed ironing presses that combine pressing and
steaming or on steaming equipment. In steam presses the steam is delivered to the article through an
upper ironing cushion. The working part of steaming equipment is a brush with a nozzle mounted on
a flexible, steam-resistant sleeve joined to a steam line or individual steam generator.
Work on steam-air dummies is highly efficient. A steam-air dummy consists of a metal frame
on a firm rotating base, with padding in the shape of the finished product placed on the frame.
Special equipment employing steam and hot air under
Pressure is used to shape the product placed on the dummy. Steam-air dummies are used to
form dresses, suits, coats, underwear, and certain other products. Sequential and parallel ironing and
pressing equipment includes highly productive machinery and equipment for unit processing and the
assembly of parts with thermoplastic glues to ensure high quality and stable production.
Extensive use is made of control and measuring equipment such as mechanical, oil, and
electronic time relays; bimetallic, fluid, and semiconductor thermo regulators; pressure gauges; and
moisture gauges. This equipment maintains the regimens of moisture and heat treatment within the
limits recommended for a particular type of fabric. Presses with electrically heated ironing surfaces
(cushions) are wide-spread, but the use of steam or of fluids that create a more even heat when mixed
with hot air offers better long-range prospects as heat conductors.
Textile industry is suffering from energy crisis specially Gas, Low pressure and high demand
among residence in winter causes complete breakdown. So, it’s high requirement to shift on alternate
energy resources e.g. Coal. Country is very rich with its coal reserves and it can serve for quite long.
In this post we will discuss possible energy alternates for textile industry, Economical aspect
(Costing), Merits and demerits involved. Major focus is on costing to evaluate efficiency of different
energy resources. Industry utilizes different kind of boilers with varying pressure and of different
capacities as per unit requirement.
Let’s assume a boiler working at pressure 5Bar and producing steam of Two Tons per hour.
Efficiency of this boiler is approx. 80%.
What would be cost of producing 2Tons of steam per hour on Natural Gas, Coal and Furnace
Oil?
Our solution to this scenario is a simple formula which says:
Omitting Specific Gravity of fuels to simplify and Shifting variables of formula from here to
there and vice versa. So, that Final shape becomes.
Qf = Qs X hf
GCV X n
It includes with thermal efficiency, combustion efficiency & fuel to steam efficiency. Steam
boiler efficiency depends upon the size of boiler used. A typical efficiency of steam boiler is 80% to
88%. Actually there are some losses occur like incomplete combustion, radiating loss occurs from
steam boiler surrounding wall, defective combustion gas etc. Hence, efficiency of steam boiler gives
this result.
BOILER
A boiler is a closed vessel in which water or other fluid is heated. The fluid does not
necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating
applications including water heating, central heating, boiler-based power generation, cooking, and
sanitation.
PRESSURE GAUGE
Many techniques have been developed for the measurement of pressure and vacuum.
Instruments used to measure pressure are called pressure gauges or vacuum gauges. A manometer is
an instrument that uses a column of liquid to measure pressure, although the term is often used
nowadays to mean any pressure measuring instrument. A vacuum gauge is used to measure the
pressure in a vacuum which is further divided into two subcategories, high and low vacuum and
sometimes ultra-high vacuum. The applicable pressure range of many of the techniques used to
measure vacuums has an overlap. Hence, by combining several different types of gauge, it is
possible to measure system pressure continuously from10 m bar down to 10−11mbar.
SAFETY VALVE
A safety valve is a valve mechanism which automatically releases a substance from a boiler,
pressure vessel, or other system, when the pressure or temperature exceeds preset limits. It is one of a
set of pressure safety valves (PSV) or pressure relief valves (PRV), which also includes relief valves,
safety relief valves, pilot-operated relief valves, low pressure safety valves, and vacuum pressure
safety valves. Safety valves were first used on steam boilers during the Industrial Revolution. Early
boilers operating without them were prone to accidental explosion. A gate valve also known as a
sluice valve, is a valve that opens by lifting a round or rectangular gate wedge out of the path of the
fluid. The distinct feature of a gate valve is the sealing surfaces between the gate and seats are planar,
so gate valves are often used when a straight-line flow of fluid and minimum restriction is desired.
The gate faces can form a wedge shape or they can be parallel.
IX. CONCLUSION
A miniature steam power plant was presented. Construction and operation details were
explained. The voltage generated by the power plant is enough to lighten two LEDS. Energy
efficiency is very low. This is because the built miniature power plant is far from being optimized
like a real world one is. From the description presented is the text although the working principle is
the same there are profound differences between a real steam power plant and the model described in
this paper that directly affect efficiency. The major difference is the steam temperature difference
between steam going to and existing the turbine. In a real world plant steam enters the turbine at
550°C and exit at a relatively low temperature although higher them ambient temperature. In this
model the steam enters the turbine at about 120°C and leaves the turbine still very hot, steam
temperature was not measured but it is hot enough to burn the skin. Despite very poor efficiency the
device is very eye-catching and especially suitable for science fair events.
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