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Fabrication of Pilot Multi-Tube Fire-Tube Boiler Designed for Teaching and Learning Purposes in Mechanical Laboratory

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Fabrication of Pilot Multi-Tube Fire-Tube Boiler Designed for Teaching and Learning Purposes in Mechanical Laboratory Proceedings of the World Congress on Engineering 2014 Vol II, WCE 2014, July 2 - 4, 2014, London, U.K. Fabrication of Pilot Multi-Tube Fire-Tube Boiler Designed For Teaching and Learning Purposes in Mechanical Laboratory Gbasouzor Austine Ikechukwu, Member IAENG Abstract - The aim of this research is to design and The first reaction-type turbine was built by Hero of fabricate pilot multi-tube boiler using a diesel fired Alexandria in the 1st century AD. In his aeolipile, steam was burner (C13H25)9 to generate 80kg of steam per hour. The fed into a sphere that rotated as steam expanded through two boiler tank is made of pure mild steel. Mild steel is used tangentially mounted nozzles. No useful work was produced to fabricate the fire tubes and other parts such as the by the aeolipile. Not until the 19th century were attempts furnace, smokestack and return chamber that make up made to utilize steam turbines for practical purposes. In 1837 the boiler. The heating surface area was increased for a rotating steam chamber with exhaust nozzles was built to sake of efficiency and fast steam generation by reversing drive cotton gins and circular saws. A single-stage impulse the direction of the gas through a second and third turbine was designed by the Swedish engineer Carl Gustaf de parallel tube (three pass). The boiler (which is fired by a Laval in 1882. A later American design had multiple impulse diesel burner) generates dry saturated steam at a wheels mounted on the same shaft with nozzle sections pressure of 1. Stars and temperature of 111.40C. It can be located between each wheel. Subsequent advances in the used for domestic and industrial purposes. design of steam turbines and boilers allowed for higher pressures and temperatures. These advances led to the huge Keywords: Diesel fired burner, pure mild steel, sake of and efficient modern machines, which are capable of efficiency Domestic and Industrial purposes. converting more than 40 percent of the energy available in the fuel into useful work. I. INTRODUCTION The word 'boiler', in everyday use, covers a wide range of Watt is credited as being the first inventor to separate the equipment, from simple domestic hot water boilers to boilers steam engine, and the boiler, into two separate units in the housed within a power generation plant to convert fossil fuel latter part of the 18th Century. In these early times, the to electricity. Generally, domestic hot water boilers do not primary use of the boiler was to generate steam for steam produce steam and should operate at low pressure. While driven engines. some combination boilers now operate at the pressure of the incoming cold water mains, this is still far below the normal As steam driven engines replaced the horse, as a means operating pressure of steam-raising boilers. of motive power, it followed that steam driven engines were The basic operation of steam turbines employs two rated in 'Horsepower'. concepts, which may be used either separately or together. In Boiler design progressed from what was essentially a kettle an impulse turbine the steam is expanded through nozzles so to a relatively large-diameter flue pipe submerged in water - that it reaches a high velocity. The high-velocity, low- thus the first fire-tube boiler, pressure jet of steam is then directed against the blades of a As power and pressure requirements increased, boilers spinning wheel, where the steam's kinetic energy is extracted became larger and the single-flue pipe became a larger while performing work. Only low-velocity, low-pressure number of smaller diameter flue tubes combined with an steam leaves the turbine. external, or internal, furnace for the combustion of the fuel. In a reaction turbine the steam expands through a series The modern-day 'modified Scotch Marine' boiler, generally of stages, each of which has a ring of curved stationary comprising horizontal steel furnace combustion chambers) blades and a ring of curved rotating blades. In the rotating and/or fire-tube convective pass(es), in 'dry-back' or 'water- section the steam expands partially while providing a reactive back' configurations, owes its heritage to these early multi- force in the tangential direction to turn the turbine wheel. The tube boilers and their application in ships constructed on stationary sections can allow for some expansion (and Scotland's River Clyde. increase in kinetic energy) but are used mainly to redirect the The primary application of the boiler was still motive steam for entry into the next rotating set of blades. power; whether for pumping water from mines, driving In most modern large steam turbines, the high-pressure machinery in mills, propelling steam locomotives or ships. steam is first expanded through a series of impulse stages sets Therefore, boiler ratings were based on the size of the steam of nozzles that immediately lower the high initial pressure so engine that they were capable of driving. The quantity of that the turbine casing does not have to withstand the high steam required to operate a 1 horsepower steam engine pressures produced in the boiler. This is then followed by became known as 1 Boiler Horsepower. (Note that the water- many subsequent impulse or reaction stages (20 or more), in tube boiler was not prevalent until after the first water-tube each of which the steam continues to expand. boiler design patent of 1867; thus, the term Boiler Horsepower (Bhp) has been associated with fire-tube boilers Gbasouzor Austine Ikechukwu is a PhD researcher and Lecturer in the from the earliest days of boiler development). Department of Mechanical Engineering, Anambra State University, P.M. B. During this period, variations in steam engine efficiency 02 Uli. Nigeria, Email: [email protected] Phone: made it difficult to assign a qualified rating (i.e. Pounds per +2348034247458. Hour (PPH)) to the amount of steam required to drive a 1 ISBN: 978-988-19253-5-0 WCE 2014 ISSN: 2078-0958 (Print); ISSN: 2078-0966 (Online) Proceedings of the World Congress on Engineering 2014 Vol II, WCE 2014, July 2 - 4, 2014, London, U.K. horsepower steam engine. Tests, conducted in 1876, Compliance with the ASME Boiler and Pressure Vessel determined approximately 30 pounds of steam per hour was Code. required to produce 1 horsepower of mechanical work. In Compliance with required safety and installation Codes. 1889, the American Society of Mechanical Engineers The ability to meet the required efficiency and other (ASME) standardized the term "Boiler Horsepower" as being performance standards. based on a conventional steam engine evaporation rate of 30 The ability to meet the required level of pollutant pounds of steam per hour (PPH), at 70 PSIG pressure, and a emissions, feed water temperature of 100° F. This definition was Compliance with the requirements of the National Board subsequently modified to: Boiler Horsepower - the unit of of Boiler and Pressure Vessel Inspectors through local capacity expressed as the equivalent evaporation of 34.5 jurisdictions having authority (JHA), pounds of water per hour, from and at 212° F (33,475 The ability to meet the perceived needs of the customer Btu/hr.). in terms of operational performance, reliability and maintenance costs. Also, it was determined that for the steel fire-tube boilers of The ability to produce a competitively priced product the day, which utilized brick set bases incorporating large amounts of refractory, and generally coal fired, 10 square Fire-tube boiler manufacturers have established over the feet of fireside heating surface was necessary for a steam years that these criteria can be satisfied with varying fire-side engine to generate I mechanical horsepower. As a result it heating surface specifications. Thus, the nominal 5 square became an industry standard practice to rale lire-tube boilers feet of fire-side heating surface per boiler horsepower axiom in Boiler Horsepower, and to base this rating on fire-side is less important as a critical design consideration. heating surface (1 Bhp per 10 square feet of fire-side heating surface). B. High-pressure Competition between fire-tube boiler manufacturers While the advances of 18th century, the call was for higher eventually forced improvements in boiler design and fuel pressures; this was strongly resisted by Watt who used the burning equipment. This, together with a broad shift towards monopoly his patent gave him to prevent others from liquid and gaseous fuel utilization, resulted in cleaner and building high-pressure engines and using them in vehicles. more reliable combustion and improved heat transfer within He mistrusted the materials' resistance and the boiler the boiler. Progressive reduction in the fire-side heating technology of the day. surface required, per Boiler Horsepower, was therefore The important advantages of high pressure were: consistent with these advancements. By the I960's, the 10 1) They could be made much smaller than previously for a square feet of fire-side heating surface per Boiler given power output. There was thus the potential for Horsepower criterion decreased to 5 square feel of fireside steam engines to be developed that were small and heating surface per Boiler Horsepower - an axiom which is powerful enough to propel themselves and other objects. commonly cited today, particularly in the United States. As a result, steam power for transportation now became During the latter part of the 20 Century, many a practicality in the form of ships and land vehicles, manufacturers of fire-tube boilers designed which revolutionised cargo businesses, travel, military and marketed boilers with greater input capacity burners with strategy, and essentially every aspect of society. requisite steam nozzle and safety valve(s) characteristics 2) Because of their smaller size, they were much less which therefore permitted operation at less than 5 square feet expensive.
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