Boiler safety
When water is converted to steam it expands in volume over 1,000 times and travels down steam pipes at over 100 kilometers/hr. Because of this, steam is a good way of moving energy and heat around a site from a central boiler house to where it is needed, but without the right boiler feed water treatment, a steam-raising plant will suffer from scale formation and corrosion.
At best, this increases energy costs and can lead to poor quality steam, reduced efficiency, shorter plant life and an operation which is unreliable. At worst, it can lead to catastrophic failure and loss of life. While variations in standards may exist in different countries, stringent legal, testing, training and certification is applied to try to minimize or prevent such occurrences. Failure modes include:
- over pressurization of the boiler
- insufficient water in the boiler causing overheating and vessel failure
- pressure vessel failure of the boiler due to inadequate construction or maintenance.
Double Boiler
The Double steam car uses a once-through type contraflow generator, consisting of a continuous tube. The fire here is on top of the coil instead of underneath. Water is pumped into the tube at the bottom and the steam is drawn off at the top. This means that every particle of water and steam must necessarily pass through every part of the generator causing an intense circulation which prevents any sediment or scale from forming on the inside of the tube. Water enters the bottom of this tube at the flow rate of 600 feet (183 m) a second with less than two quarts of water in the tube at any one time.
As the hot gases pass down between the coils, they gradually cool, as the heat is being absorbed by the water. The last portion of the generator with which the gases come into contact remains the cold incoming water. The fire is positively cut off when the pressure reaches a predetermined point, usually set at 750 psi (5.2 MPA), cold water pressure; a safety valve set at 1,200 lb (544 kg) provides added protection. The fire is automatically cut off by temperature as well as pressure, so in case the boiler were completely dry it would be impossible to damage the coil as the fire would be automatically cut off by the temperature.
Similar forced circulation generators, such as the Pritchard and Lamont and Velox boilers present the same advantages.
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When the gasket becomes damaged or gets old, smoke starts to come out of the boiler in the case of the water tube boiler. In the smoke tube boiler, the water starts to leak outside the boiler.
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