Boiler use to heat water and generates steam from water. Steam is use from food processing plan to power plant. In power plant steam uses to run steam turbine to generate electricity. Steam has an effective roll in our modern life. Generally there are two type of boiler are available. First one is water tube boiler and second one is fire tube boiler. Between these two types, you will find more categories. In this post we will learn “Industrial Boiler – How It’s Made?”
Industrial Boiler, How it’s Made:
Water inside the boiler is heated by the Oil, Natural GAS or Electricity. That’s means inside the boiler, there is lots of pressure. Making of industrial boiler starts with the plasma torch. This torch cut the holes in solid sheet of special steels. But the thickness of the steel sheet depends on the pressure inside the boiler need to be handled. If its need high pressure large amount of steam then the thickness of steel sheet will increases.
Then a worker bends this steel sheet by a hydraulic press. The steel sheet will become the inner shell of the boiler. This inner shell will be used to heat the water and generate steam. But remember worker was pressing a flat steel sheet to make it round inner shell. That’s means this steel sheet need to joint two sides together to make a complete round boiler inner shell. For this reason a worker make an edge at both sides of steel sheet by a grinding machine for welding.
When boiler inner shell come to it final shape then it time for welding. Worker use a submerge arc welding machine and deposited a special material during welding operation. This special material granular protects the welding from any air contamination. When welding is finish then worker removes the special material granular. By this way we can get a perfect welding.
In the next step worker welds boilers head or tube head inside the boiler shell by manual hand welding. Then they fit the steel pipe inside the boiler head from one end to another end. After inserting all steel pipe workers secure all pipe by welding. Next a combustion chamber insert into the remaining space of inner shell. Then they test this fully assembled pressure vassal by water and check any leakage. But these tests only perform between the combustion chamber and boiler shell. Because inside the combustion chamber a burner will fitted into the combustion chamber.
Next some insulation material will be warp with the pressure vassal. This insulation material helps to retain heat. Then they warp the outer jacket around the shell and secure in place by some sheet metal screws. After that a blower in installed with pressure vassal. This blower will supply the fresh air into the combustion chamber. Next worker attached a water column with outer shell of boiler. This water column provides some safety inspection like water level during operation. It also has some sensor that provides valuable data to the boiler operator.
Now come to the electrical control section. A worker install electrical control device that helps to operate this boiler automatically. Then they power up the boiler by firing the burner. After that they open the steam outlet pipe and on a test line and check all control device is working or not. This test includes water level and blower testing. When boiler generated correct amount of heat and steam then it pass the test. Then manufacturer labeling with each unite of boiler before it come to you.