The Babcock & Wilcox Company

Leakage
Continuing efforts have been made over the years to reduce air infiltration into boiler settings. Such in-leakage increases gas flow and the heat rejected to the stack, thereby lowering boiler efficiency and increasing the amount of induced draft fan power. (See Chapter 10.)

Corrosion
One of the advantages of membrane walls compared to cased walls is that they eliminate flue gas corrosion on the cold face of the enclosure walls. Most flue gases contain sulfur; therefore, metal parts of the setting must either be kept above the dew point of the gases or out of contact with the gases. (See Chapter 21.) The dew point generally ranges between 150 and 250F (66 and 12lC) and is dependent on the fuel, its sulfur content and the firing method. Flues carrying low temperature spent gases should be insulated on the outside to inhibit corrosion. This is particularly necessary on outdoor units. Watercooled doors and slag tap coils require water temperatures above 150F (66C) to keep the cooling coils above the dew point of the gases. When casing is located outside of insulation or refractory, it is still subject to the action of the flue gases. When this type of casing is subjected to a temperature below the dew point, an asphalt mastic or other type of coating is needed to protect it from corrosion on the inside. This problem requires special attention in the design of outdoor installations where temperatures may, at times, be below flue gas dew point temperatures.

Fig. 11 Heat loss from wall surfaces (radiation + convection) (Source ASTM Standards, Part 13, 1969).

Fig. 12 Radiation loss in percent of gross heat input (American Boiler Manufacturers Association).

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Fig. 13 Temperature gradients through tube and brick wall.

With the use of externally insulated casing, corrosion problems are greatly reduced because the flue gases are completely contained by a metal skin, which is well above the dew point temperature. However, even with the inner casing, seals and expansion joints must be insulated properly to avoid cold spots and consequent corrosion.

Fig. 15 Effect of surface film resistance on surface temperature and heat loss rate.

Resistance to weather
Outdoor boiler installations are possible in mild climates. While the initial cost of the plant is reduced, maintenance of the boiler and auxiliary equipment must be considered. Severe weather can extend outage time and increase maintenance expenses. These units must also have sufficient reinforcement to withstand the pressure and suction forces of the wind. Lagging is an outer covering over a wall used for protecting the insulation from water or mechanical damage. It is relatively simple to make a metal lagged unit rainproof. Joints and flange connections are overlapped and flashings are used around openings. Welding of joints or the use of mastic compounds is necessary in areas which are difficult to seal. Sloping roofs are required and are particularly important on aluminum lagging where pockets of water would eventually stain the surface. Direct contact between aluminum and steel must be avoided to prevent galvanic corrosion of the aluminum in the presence of moisture. Roof flashings should be designed so that water runoff does not wet the aluminum. Weather hoods should be used to keep rain, snow and ice from contacting outdoor safety valves. Nozzle and valve necks must be insulated and protected with sheet metal or outer waterproof covering. Outdoor control lines containing air or flue gas, drain and sampling lines and intermittently operated steam and water lines should be insulated and protected by electric resistance heating tape. Steam pipe tracer lines may also be used in some cases. Dry air should be supplied for control lines and sootblowers. Steam and water lines outside the setting must be completely drainable.
Steam 41 / Boiler Enclosures, Casing and Insulation

Fig. 14 Cavities tend to raise wall surface temperatures.

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