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Process Technology Equipment Chapter 14 Boilers
Page 1
CHAPTER 14 Boilers
Table of Contents
Contents
Page
Chapter Overview
2
Class Preparation Checklist
2
Chapter Objectives
2
Agenda
3
Lesson Plan
4
14.1 Boiler Components
14.2 Types of Boilers
6
8
14.3 Principles of Operation
10
14.4 Potential Problems
14.5 Safety and Environmental Hazards
14.6 Process Technician’s Role
14.7 Typical Procedures
13
14
15
16
Summary and Wrap-Up
16
Suggested Student Activities
17
End of Chapter Review Questions
17
Clicker Questions
Appendix
26
30
Process Technology Equipment Chapter 14 Boilers
Page 2
CHAPTER 14 Boilers
Chapter Overview
Steam has many applications and a long history in the process industries. Steam
provides efficient heat transfer and high latent heat. It is used to heat and cool process
fluids, power and purge equipment, fight fires, facilitate distillation, and induce other
physical and chemical reactions.
Boilers are an important source of energy in the process industries because they supply
steam energy to process equipment and produce the steam used throughout the
process facility. Examples of process equipment that use steam energy include
turbines, reactors, distillation columns, stripper columns, and heat exchangers.
Class Preparation Checklist
1.
Familiarize yourself with the chapter content.
2.
Bring cutaways or other hands-on teaching aids if available.
3.
Copy and distribute any fill-in-the-blank handouts for today's content.
4.
Safety Minute prepared or assigned.
5.
Review the PowerPoint slides associated with this chapter (if used) and
make sure that your computer is correctly set up to navigate the slide deck
smoothly.
6.
Request the appropriate A/V equipment (if needed) and make sure that
your computer is correctly synched with the projector to avoid any delays in
the classroom.
Chapter Objectives
14.1 Identify the components of boilers and the purpose of boilers in the process
industries (NAPTA Boilers).
14.2 Identify the common types of boilers and their applications (NAPTA Boilers).
14.3 Explain the operating principles of boilers (NAPTA Boilers).
14.4 Identify potential problems associated with boilers (NAPTA Boilers).
14.5 Describe safety and environmental hazards associated with boilers (NAPTA
Boilers).
14.6 Describe the process technician’s role in safe boiler operation, maintenance, and
operator qualification (NAPTA Boilers).
14.7 Identify typical procedures associated with boilers (NAPTA Boilers).
Process Technology Equipment Chapter 14 Boilers
Page 3
Class Agenda
Activity
Minutes
PPTs
Handouts
(title, if any)
1. Welcome to Class
1
1
2. Introduction and Agenda
1
2
3. Safety Minute
1.5
3
4. Objectives
2
4
5. Terms
2
5
6. Terms (cont.)
2
6
7. Boiler Components
1
7
8. Types of Boilers
0.5
8
9. Water Tube Boilers
2
9
10. Waste Heat Boilers
2
10
11. Fire Tube Boilers
2
11
12. Principles of Operation
2
12
13. Water Circulation
2
13
14. Superheated Steam
2
14
15. Desuperheated Steam
1
15
16. Boiler Feedwater
3
16
17. Water Treatment Methods
4
17
18. Water Treatment Methods (cont.)
3
18
19. Burner Fuels
1
19
20. Potential Problems
3
20
21. Potential Problems (cont.)
2
21
22. Safety and Environmental Hazards
2
22
23. Safety and Environmental Hazards (cont.)
2
23
24. Process Technician’s Role
2
24
25. Typical Procedures
1
25
26. Summary and Wrap-Up
3
26
Process Technology Equipment Chapter 14 Boilers
Page 4
Chapter 14 Lesson Plan
Welcome Everyone to Class
Time: 1 minute
Resources: Slide 1
Introduction and Agenda
Time: 1 minute
Resources: Slide 2
Safety Minute
Time: 1.5 minutes
Resources: Slide 3
(Note to Instructor: Follow this procedure for the Safety Minute.)
• Announce who has responsibility for today’s Safety Minute.
• Have the student present the Safety Minute.
• Announce who is presenting the Safety Minute next class.
Objectives
Time: 2 minutes
Resources: Slide 4
Process Technology Equipment Chapter 14 Boilers
Page 5
Terms
Time: 2 minutes
Resources: Slide 5
Sample Instructor Script:
Turn to the terms page in today’s chapter in the textbook. I’ll call on some of you to take
turns reading the term and definition aloud and then using that term in a sentence. We’ll
begin with the following terms:
Terms (cont.)
Time: 2 minutes
Resources: Slide 6
Process Technology Equipment Chapter 14 Boilers
Page 6
14.1 Boiler Components
Time: 1 minute
Resources: Slide 7
Sample Instructor Script:
Boilers are devices in which water is boiled and converted into steam under controlled
conditions. Boiler components can vary, but the most common components include a
firebox, burners, drums, an economizer, a steam distribution system, and a boiler
Process Technology Equipment Chapter 14 Boilers
Page 7
the saturated steam to collect and pass out of the header. Sediment accumulates
in the bottom of the mud drum and is removed through blowdown, which can be
either continuous or intermittent.
Most steam used in the process facility is ultimately condensed to water. This
condensation takes place in various types of heat exchangers. Condensate is
typically reused as boiler feedwater and returned through condensate return
systems.
When a facility contains a steam system, it usually is composed of two or three
piping systems with different pressure steam headers. Another method of
supplying steam to headers of different pressures is by piping the exhaust of
steam turbines into headers.
Depending on the individual characteristics of the raw water, boiler feedwater can
be treated by clarification, sedimentation, filtration, ion exchange, deaeration,
membranes, or a combination of these methods.
Process Technology Equipment Chapter 14 Boilers
Page 8
14.2 Types of Boilers
Time: 0.5 minute
Resources: Slide 8
14.2.1 Water Tube Boilers
Time: 2 minutes
Resources: Slide 9
Sample Instructor Script:
Water tube boilers are so-called because they contain water-filled tubes that allow water
The most common components of a water tube boiler system are as follows:
Process Technology Equipment Chapter 14 Boilers
Page 9
14.2.2 Waste Heat Boilers
Time: 2 minutes
Resources: Slide 10
Sample Instructor Script:
14.2.3 Fire Tube Boilers
Time: 2 minutes
Resources: Slide 11
Process Technology Equipment Chapter 14 Boilers
Sample Instructor Script:
14.3 Principles of Operation
Time: 2 minutes
Resources: Slide 12
14.3.1 Water Circulation
Time: 2 minutes
Resources: Slide 13
Sample Instructor Script:
The circulation of boiler water is based on the principle of convection. A fluid that is
Process Technology Equipment Chapter 14 Boilers
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14.3.2 Superheated Steam
Time: 2 minutes
Resources: Slide 14
Sample Instructor Script:
Saturated steam is steam in equilibrium with water (that is, steam that holds all of the
moisture it can hold and still remain a vapor).
14.3.3 Desuperheated Steam
Time: 1 minute
Resources: Slide 15
14.3.4 Boiler Feedwater
Time: 3 minutes
Resources: Slide 16
Sample Instructor Script:
Page 12
14.3.5 Water Treatment Methods
Time: 4 minutes
Resources: Slide 17
Sample Instructor Script:
Raw water can come from a variety of sources, such as lakes, rivers, or wells.
14.3.6 Water Treatment Methods (cont.)
Time: 3 minutes
Resources: Slide 18
Sample Instructor Script:
Common methods of water treatment are:
Process Technology Equipment Chapter 14 Boilers
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14.3.7 Burner Fuels
Time: 1 minute
Resources: Slide 19
14.4 Potential Problems
Time: 3 minutes
Resources: Slide 20
Sample Instructor Script:
Process Technology Equipment Chapter 14 Boilers
Page 14
14.4.1 Potential Problems (cont.)
Time: 2 minutes
Resources: Slide 21
Sample Instructor Script:
Other contributing factors that can lead to boiler problems are:
14.5 Safety and Environmental Hazards
Time: 2 minutes
Resources: Slide 22
Sample Instructor Script:
Process Technology Equipment Chapter 14 Boilers
Page 15
14.5.1 Safety and Environmental Hazards (cont.)
Time: 2 minutes
Resources: Slide 23
Sample Instructor Script:
Process technicians must also have knowledge of:
14.6 Process Technician’s Role
Time: 2 minutes
Resources: Slide 24
Sample Instructor Script:
Process technicians are responsible for performing specific procedures to safely
operate and maintain boiler system equipment.
Process Technology Equipment Chapter 14 Boilers
14.7 Typical Procedures
Time: 1 minute
Resources: Slide 25
Sample Instructor Script:
Process technicians should be aware of several boiler procedures, including the
Process Technology Equipment Chapter 14 Boilers
Suggested Student Activities
End of Chapter Review Questions
(Note to Instructor: If you have time, you can use these questions to test your
students’ knowledge of the content presented in this chapter.)
1. What component of a boiler is used to preheat feedwater before it enters the
main boiler system?
A. Burners
B. Boiler feedwater system
C. Economizer
D. Steam distribution system
