a McDermott company

Water-Tu be
Package Boilers
P r o v i d e R e l i a b l e , E c o n o m i c a l S t e a m P r o d u c t i o n
Sin ce 1867, Babcock &Wilcox has been design -
in g, manu factu ring an d in stallin g the worlds
most reliable an d eff icien t en ergy-gen eratin g
systems an d en vironmental equ ipmen t. B&W
also services, repairs, upgrades an d replaces
existin g systems an d associated equipmen t,
regardless of the origin al manufactu rer. With
boiler in stallation s operatin g in more than
85 countries, B&W has the experien ce an d
f lexibility to meet the ever-changing n eeds of
both the u tility an d in du strial markets.
Water-Tu be Package Boilers:
Proven Design for Economical
Steam Production
To meet va r ying spa ce, fuel, st ea m
a nd economic condit ions, B& W
offers a complet e line of a uxilia r y
equipment . A pa cka ge boiler burner
syst em is show n.
2
Dependable perf ormance in
a wide variety of industries
B&Ws water-tube package boiler
continues this tradition of excellence
with more than 4,200 units in
operation. Our established reputation
for reliability and proven performance
is continually enhanced by incorporat-
ing the latest technological advance-
ments into our design. B&W is
dedicated to the water-tube package
boiler market, which is comprised of
industrial and institutional markets
such as:
~Hospitals
~Universities
~Manufacturing and processing
facilities
~Utilities
~Petrochemical
~Pulp and paper
System components
complement operation
Specically designed to complement
each other in operation, B&W supplies
all the major components in the FM
package boiler system:
~Boiler
~Burner
~Controls
~Fan
~Heat traps
~Sootblowers
~Added options (feed pumps,
deaerators, chemical feed systems)
Broad capacity range
B&W water-tube package boilers are
available in a wide range of capacities:
~Steam ow from 8,200 to 240,000
pounds per hour (1 to 30 kg/ sec)
~Superheat temperatures up to
900F (482C)
~Design pressures from 250 to
1050 psi (17 to 72 bar)
Support services
In addition to equipment supply,
B&W offers comprehensive support
services, including:
~Field service engineering
~Inspection and maintenance services
~Engineered upgrades
designed to last
~Long-term service partnering
programs
~Training programs
~Operating instructions
~Spare parts manuals
~Startup services
~Sales assistance
Babcock &Wilcox: Asingle-source supplier of
innovative energy solutions and total-scope ser vices.
B& W s engineering expert ise
a nd complet e proj ect
ma na gement skills help t o
ensure t ha t a proj ect is right
t he rst t ime a nd on t ime
w it hout a ddit iona l cost s.
The compa ct , ef cient design of B& W s
w a t er- t ube pa cka ge boilers a llow s for
economica l shipment via ra il or t ruck.
3
N O TES:
1 . Al l p ackag e b o i l er s ar e o f
m em b r an e co n st r u ct i o n .
2 . Becau se o f t h e co m p an ys
co n st an t ef f o r t t o i m p r o ve
d esi g n , eq u i p m en t su p p l i ed
m ay d i f f er sl i g h t l y f r o m t h at
d escr i b ed ab o ve.
3 . Packag e b o i l er cap aci t i es
g r eat er t h an 2 4 0 , 0 0 0 l b / h r
ar e avai l ab l e i n B& Ws
h i g h -cap aci t y ser i es.
M ETRI C CO N VERSI O N S:
i n ch es x 2 5 . 4 = m m
i n ch es x 2 . 5 4 = cm
f eet x 0 . 3 0 4 8 = m
l b / h r x 0 . 0 0 0 12 6 = kg / sec
Water -Tu be Package Boilers: Capacities to
Meet the Most Demanding Requirements
* Steam capacities shown are saturated steam.
Capacities shown will vary depending on
conditions and limitations.
Ca pa cit y
Sca le Boilers Ra nge* Lengt h W idt h H eight D rum
1 ' =
1
1 6 " ( lb/ hr) Siz e
FM 9 -2 2 7 ' 7 "
2 6 8 ' 1 1 "
3 0 9 ' 1 1 " 3 6 " St eam
3 4 8 , 2 0 0 1 1 ' 3 " D r u m
3 9 t o 1 2 ' 7 " 1 0 ' 2
7
8 " 1 2 ' 4 "
4 3 4 0 , 0 0 0 1 3 ' 1 1 " 2 4 " Lo w er
4 8 1 5 ' 3 " D r u m
5 2 1 6 ' 7 "
5 7 1 7 ' 1 1 "
FM 1 0 -5 2 1 6 ' 7 "
5 7 1 7 ' 1 1 " 3 6 " St eam
6 1 3 5 , 0 0 0 1 9 ' 3 " 1 0 ' 1 0
5
8 " D r u m
6 6 t o 2 0 ' 7 " 1 3 ' 6 "
7 0 7 5 , 0 0 0 2 1 ' 1 1 " 2 4 " Lo w er
7 9 2 4 ' 7 " D r u m
FM 1 0 1 -8 8 2 7 ' 3 " 1 1 ' 2
3
8 "
FM 1 0 3 -7 0 7 0 , 0 0 0 2 1 ' 3
3
1 6 "
4 2 " St eam
7 9 t o 2 3 ' 1 1
3
1 6 " 1 1 ' 9 " 1 3 ' 9
3
4 "
D r u m
8 8 1 0 0 , 0 0 0 2 6 ' 7
3
1 6 "
2 4 " Lo w er
9 7 2 9 ' 1 1 "
D r u m
FM 1 0 6 -7 9 2 3 1 1
3
1 6 " 4 8 " St eam
8 8 1 0 0 , 0 0 2 6 ' 7
3
1 6 " 1 1 ' 9 " 1 4 ' 3 " D r u m
9 7 t o 2 9 ' 3
3
1 6 "
FM 1 1 7 -8 8 1 5 5 , 0 0 0 2 6 ' 7
3
1 6 " 1 1 ' 1 1
1
4 " 1 5 ' 4
1
2 " 2 4 " Lo w er
9 7 2 9 ' 3
3
1 6 " D r u m
FM 1 2 0 -9 7 1 5 5 , 0 0 0 2 9 ' 3
3
1 6 "
5 4 " St eam
1 1 2 t o 3 3 ' 7
3
1 6 " 1 2 ' 5
3
8 " 1 6 ' 1 0
1
2 "
D r u m
1 2 4 2 4 0 , 0 0 0 3 7 ' 3 3
3
1 6 "
2 4 " Lo w er
D r u m
4
Long-term reliability
B&W maintains the same cornerstone
company values as we did in 1867 when
the rst B&W water-tube steam boiler
was patented. These values include a
commitment to excellence, outstanding
customer service, quality and continu-
ous improvement, integrity, technology
leadership and a global outlook. Based
on these values, B&W builds equipment
that is designed to last. In fact, many
1950 vintage B&W package boilers are
still in use today.
Fast load response
B&Ws 2
1
2" tubes are spaced 1" apart.
This provides a larger volume of water
in our furnace walls and contributes
to a faster load response. In addition,
our uniquely designed drum internals
can handle varying loads without
circulation disruptions or carryover.
Connections for lower drum heating
coils also are standard.
Low O&M costs
The B&W package boiler drives main-
tenance to a minimum with:
~No reliance on refractory seals
~Positive circulation, 100%
water-cooled rear wall
~Bricks on oor for long-term
protection
~A fully drainable and 100%
convection superheater
~Galvanized, primed and enamel-
painted exterior lagging
~Hinged drum manways for better
waterside access
Controlled emissions
B&W has its own staff of combustion
design engineers and works with outside
burner suppliers to meet your stringent
requirements. Our furnace has more
water-cooled surface, thereby helping to
meet todays tough NO
x limits.
Water -Tu be Package Boilers: B&Ws
Engineering Expertise Offers ManyBenefits
B& W s w a t er- t ube pa cka ge boilers offer more w a t er- cooled sur fa ce, w hich in t urn
helps t o meet t oda ys st ringent emissions regula t ions.
This phot ogra ph cont ra st s t he differences bet w een B& W s 2
1
2 " t ubes spa ced
1" a pa rt ( t ube pa nel in ba ckground) , a nd compet it ors 2 t ubes spa ced 2 " a pa rt
( t ube sect ion in foreground) . As show n, B& W s 2
1
2 " t ubes on 3
1
2 " cent ers increa se
t he overa ll w a t er- cooled t ube furna ce sur fa ce a nd reduce t he membra ne a rea
bet w een t he t ubes. This helps t o prevent membra ne t herma l cra cking a nd
cont ribut es t o a fa st er loa d response.
5
Proven D-type construction,
which has separate boiler and furnace
sections, creates proper geometry
of the burning chamber. As a result,
combustion efciency is increased and
the following benets are added:
'Furnace wall water cooling includes
not only the side walls, roof and oor,
but the high-duty rear wall as well
eliminating refractory and its attendant
maintenance. This unique boiler
feature locates total water cooling
where it can contribute most to keeping
maintenance costs down, and each
rear wall tube is a single ow path
between drums to assure proper
circulation and cooling.
^Gas -tight setting membrane pro-
vides the gas-tight setting absolutely
necessary on all package boilers. This
construction eliminates dew-point
sulfur corrosion and outages caused
by gas leaks. B&Ws membrane panels
use large diameter tubes and small
membrane spacing, which provides the
best combination of heat transfer
efciency and maintenance accessibility.
Scalloped seal plates (illustrated in
2-A) on the membrane design also
provide a continuous gas-tight seal
between the tube membrane and
drums. Where inner-cased construction
is used, a 10-gauge plate is welded to
the tie bars, instead of directly to the
pressure parts (shown in 2-B). To
maintain casing above the dew point
temperature, the plate is formed
around the tie bar to ensure close
plate-to-tube contact.
Rugged steel -base f rame supports
the entire boiler, and allows jacking
and skidding of the boiler. A concrete
slab with no special saddle, supports
or piers is all that is needed for the
package boiler. To ease installation
and relocation, B&Ws frame has
built-in lifting lugs and jacking pads.
Outer steel lagging is galvanized,
primed and painted, making it weather-
tight for outdoor installations. The
12-gauge roof casing also provides a
surface strong enough to walk on.
IDrum internals provide high steam
purity and ensure positive circulation.
There are two primary steam separators
to choose from a bafe-type for 3 ppm
solids or an optional cyclone-type for
1 ppm solids. Both designs incorporate
corrugated-type secondary scrubbers.
Dry pipe steam separation also is
available for
1
2% moisture steam.
IWater wash troughs and drains are
standard on every new package boiler.
IGrooved tube seats with polished
tube ends provide maximum protection
during initial handling and transporta-
tion, as well as against leakage through-
out the units life. B&Ws tube seats
provide more holding power and
seal integrity.
ISootblowers are properly located
for effective convection bank cleaning.
Sootblower bearings, wallbox(es) and
tube openings are standard on all
package boilers, regardless of fuels
red. An additional B&W boiler
feature is that the alternating front-
to-rear bank spacing allows removal
of any tube if necessary (illustrated
in 8-A).
^Front wall re brick is designed for
expansion and protection of the front
corner seals, and the front wall tile is
anchored by a oating alloy retainer.
To protect the corner seals, the front
wall of the membrane unit is set inside
furnace D tubes (illustrated in 9-A).
1Thermal sleeve connections for
lower drum heating coils are standard.
Heating coils can reduce the time from
light-off to full load by several hours.
Water -Tu be Package Boilers: Unique Features
and Rugged Construction Enhance Operation
B& W s w a t er- cooled pa cka ge boilers a re designed for
relia ble, ef cient opera t ion in a w ide va riet y of indust ries.
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Superhea t er
( opt iona l) Boiler Sidew a ll
To St a ck or
Economiz e
Boiler Screen
D ivision Wa ll
Furna ce
W indbox
Furna ce Sidew a ll
Furna ce Rea r
Wa ll Tubes
O D =
2
1
2 "
3
1
2 "
1
4 " Thick
M embra ne
4
1
8 "
3 " 3 "
M embra ne
Ba r
Sca lloped
Sea l Pla t e
Pla t e
Ca st ing
D rum I nt erna ls, Type "B"
D rum I nt erna ls, Type "C"
Genera t ing
Ba nk
Tubes
Soot blow er
Element s
W indbox
Furna ce Burner Wa ll
Furna ce
"D " Tubes
Low er
D rum
Therma l Sleeve
Connect ions
Tie Ba r
Ba se Fra me FM - 9 , 1 0 , 1 0 1
Low er D rum
Wa sh Wa t er D ra ins
Genera t ing Ba nk
Tubes Ca n Be Removed
Brick H older
Grooved Tube Sea t
Front Wa ll Tile Front Pla t e
1 2 - Ga uge Roof Ca sing
A- A
A
A
1
2-B
5
8
9-A 10
8 -A 9
6 7
3 4
2 2-A
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Even when load changes are wide or frequent
enough to affect water level in the drum, positive
circulation is assured with B&W drum internals.
As hot furnace ue gas crosses the rst row of
tubes in the boiler bank, a considerable amount
of steam is generated. This quantity is substantially
greater on higher-capacity units for essentially
the same drum length, imposing a tremendous
burden on drum internals.
B&W separation equipment is specically
designed to effectively handle this rapid, intense
generation of steam. Diffuser bafes direct
portions of the steam to less turbulent zones of
the drum, making use of the entire length of
scrubbing elements to remove unwanted
moisture droplets.
Superheater tube f ailures eliminated
When superheaters or special processes require
it, steam with less than one ppm solids can be
obtained. Turbine blades are kept cleaner, and
costly superheater tube failures are eliminated. An
equally important feature designed into B&Ws
drum internals is the supply of bubble-free solid
water back to the downcomer circuits for positive
circulation. The drum internals design also
allows free end ow to minimize turbulence and
end-to-end level uctuation.
Water -Tu be Package Boilers: Efficient Separation
and Positive Circulation Assure Dependability
Adequa t e slope is designed on a ll hea t - a bsorbing sur fa ces, a nd
a ll dow ncomers a re loca t ed in t he cooler z one of t he convect ion
ba nk for proper circula t ion. Ea ch t ube is complet ely dra ina ble.
B&W designs a nd ma nufa ct ures a ll our
ow n drum int erna ls, including cyclone
st ea m sepa ra t ors.
Type B Internals
Type C Internals
D iffuser Ba f e
St ea m O ut let
Seconda r y
St ea m Scrubber
Cyclone Sepa ra t or
St ea m O ut let
Seconda r y
St ea m Scrubber
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Economizers, superheaters, burners
and controls are available from B&W
for package boilers in accordance with
operating and economic design con-
siderations. Additional accessory
equipment, including a forced draft
fan and drive, a junction piece, ues
and ducts, stacks, feedwater pumps,
deaerator, and an oil pump and
heater set can be ordered to simplify
planning and engineering.
Economizers
increase efciency
Economizers are available for
increased efciency. Pre -engineered
arrangements of extended surface
or bare-tube economizers are offered
to meet varying fuel, space and
economic considerations.
Fully drainable superheaters
Proven, dependable and fully drain-
able superheatersespecially designed
for package boilers also are an avail-
able accessory. The vertical-tube design
provides positive bottom support and
excellent expansion characteristics.
Multi-pass steam ow ensures high
steam velocities and good distribution
of uid throughout, effectively cooling
each tube. Because it is positioned out
of the full radiant heat zone, it has a
convective -radiant temperature char-
acteristic for a relatively constant
superheater steam temperature over
the load range. For further conve-
nience, the steam outlet is located
near oor level. To protect the thicker
wall drums in the superheater area,
refractory drum protection is provided.
Water -Tu be Package Boilers: Complemented
bya Complete Line of Auxiliar yEquipment
To meet your required st ea m condit ions,
a superhea t er unit ca n be a dded t o
B& W pa cka ge boilers. B& W a lso offers
pre- engineered a rra ngement s
of ext ended sur fa ce or ba re-
t ube economiz ers.
For oil- red a pplica t ions, soot blow ers
a re a t ypica l fea t ure. The soot blow er
supply a nd superhea t er out let
connect ion a re pict ured t o t he left .
Ref ra ct or y drum
prot ect ion sa fe-
gua rds t he t hicker
w a ll drums in t he
superhea t er a rea .
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B&Ws extensive, worldwide experi-
ence allows us the exibility to easily
meet diverse project requirements
anything from a knock-down boiler to
an entire steam island. We can pack-
age your boiler system with properly
sized, quality auxiliaries to match your
needs and our standards of excellence.
Typical project scope
Although every project is unique in
scope, a typical project includes:
~FD fan and drive
~Burners and fuel trains
~Deaerator and feedwater pump set
~Burner management system
~Combustion controls jackshaft
to DCS
~Economizer
~Stack
~Platforms
Stringent quality
control standards
At B&W, quality assurance is integral
to our design, engineering and manu-
facturing processes. To ensure all codes
and specications are met, B&W uses
stringent quality control procedures
and sophisticated testing apparatus.
Rigid standards have been established
for our material suppliers as well.
B&Ws commitment to quality is
evident by our:
~Advanced technologyB&W builds
quality into its products during every
process and stage
~Strength in size and capacity facili-
ties, manpower and global presence
provide you with a complete range
of fabricating processes
~Outstanding responsiveness B&W is
equipped and structured to meet
your delivery needs and requirements
B& W s pa cka ge boilers a re being
fa brica t ed a t our West Point ,
M ississippi, U. S. A. , ma nufa ct uring
fa cilit y. This pla nt is I SO - 9 0 0 1
cert i ed, ASM E code a pproved, a nd
possesses a n out st a nding sa fet y record,
receiving O SH A St a r St a t us in t he
Volunt a r y Prot ect ion Progra m.
Manuf acturing and
saf ety excellence
B&Ws package boilers are designed,
engineered and manufactured at our
West Point, Mississippi, U.S.A. facility
one of seven B&W manufacturing
plants located worldwide. This plant
is ISO-9001 registered, ASME code
approved, and is in compliance with
AWS code requirements. B&Ws West
Point plant also maintains an outstand-
ing safety record and has been awarded
the OSHA Star Status in the Voluntary
Protection Program. Manufacturing
and safety excellence are a continuous
goal for B&W.
Worldwide, responsive service
and manuf acturing support
B&Ws network of domestic and
international sales representatives and
eld service engineers assures you of a
prompt response whether servicing
and upgrading your existing system
or specifying new equipment. We can
provide services ranging from routine
inspections and controls tuning to
capacity increase engineering studies,
low emissions conversions or new
digital control systems.
To meet the needs of the global
market, we also design, engineer
and manufacture package boilers in
accordance with all B&W standards at
six international operations. These
operations are Thermax B&W in Pune,
India, B&W BC in Beijing, Peoples
Republic of China, PT BWI in Batam,
Indonesia, B&W Gamma in Ankara,
Turkey, B&W Egypt in Cairo, Egypt,
and B&W Mexicana in Mexico City,
Mexico. These facilities are ASME
code approved and participate in
The McDermott Safety Program.
Reliable single -source
supplier
B&Ws proven expertise in boilers,
burners and controls makes us a
reliable and responsive single source
Water -Tu be Package Boilers:
Total-Scope Supplyand Ser vices
for package boilers and auxiliary
equipment. From engineering and
manufacturing to start-up and opera-
tion, B&W knows how to make it all
work together for maximum operating
efciency and dependability, and
keeps you in compliance with todays
environmental regulations.
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Through innova t ive
energy solut ions a nd
t ot a l- scope ser vices,
B& W is dedica t ed t o
p ow er in g t h e w or ld
in a n environment a lly
sa fe, ef cient a nd
economica l ma nner.
11
a McDermott company
I n a ll t he w orld, t here is only
one Ba bcock & W ilcox. O t hers
ma y copy our na me, but none
ca n duplica t e t he engineering
excellence a nd a dva nced
t echnologies developed by t he
origina l Ba bcock & W ilcox.
For more information, or a complete listing of
our sales and service offices worldwide, call
1-800-BABCOCK (222-2625) in North America.
Outside North America, call (330) 753-4511
or fax (330) 860-1886 (Barberton, Ohio, USA). Or
access our Web site at http:/ / www.babcock.com.
Canada:
Cambridge, Ontario
Edmonton, Alberta
Halifax (Dartmouth), Nova Scotia
Montreal, Quebec
Saint John, New Brunswick
Vancouver (Richmond), British Columbia
Czech Republic: Prague
Egypt: Cairo
England: London
India: Pune
Indonesia: Jakarta
Mexico: Mexico City
Peoples Republic of China: Beijing
Poland: Warsaw
Russia: Moscow
Taiwan: Taipei
Turkey: Ankara
United States of America:
Akron (Wadsworth), Ohio
Atlanta, Georgia
Charlotte, North Carolina
Cherry Hill, New Jersey
Chicago (Downers Grove), Illinois
Cincinnati, Ohio
Denver (Sheridan), Colorado
Houston, Texas
Kansas City, Missouri
San Francisco (Vacaville), California
Powering the World Through
Teamwork and Innovation
SM
The information contained herein is provided for general information
purposes only and is not intended or to be construed as a warranty, an
offer, or any representation of contractual or other legal responsibility.
The Babcock & Wilcox Company. All rights reserved.
Powering the World Through Teamwork and Innovation
is a service mark of The Babcock & Wilcox Company.
E101- 3155 5MAP6I