Water-Tube Package Boilers

Reliable and Economical Steam Production

Water-Tube Package Boilers:
Proven Design for Economical
Steam Production

Since 1867, The Babcock & Wilcox Company (B&W) has

been designing, manufacturing and installing the world’s

most reliable and efficient energy-generating systems and

environmental equipment. B&W also services, repairs,

▲ upgrades and replaces existing systems and associated

To meet varying space, fuel, steam
and economic conditions, B&W
offers a complete line of auxiliary
equipment. A package boiler
burner system is shown. equipment, regardless of the original manufacturer. With

boiler installations operating in more than 90 countries,

B&W has the experience and flexibility to meet the ever-

changing needs of both our utility and industrial customers.

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B&W: the Single-Source Supplier of Innovative
Energy Solutions and Total-Scope Services
Dependable performance for a wide ■ Burner
variety of industries ■ Controls Support services
■ Fan
B&W’s water-tube package boiler (FM) ■ Economizer In addition to equipment supply, B&W
continues this tradition of excellence with ■ Sootblowers offers comprehensive support services,
more than 4,200 units in operation. Our ■ Added options (feed pumps, including:
established reputation for reliability and deaerators, chemical feed systems) ■ Field engineering services
proven performance is continually ■ SCR and CO catalyst ■ Inspection and maintenance services
enhanced by incorporating the latest ■ Engineered upgrades
technological advancements into our Wide capacity range ■ Long-term service programs
design. B&W is dedicated to providing its ■ Training programs
water-tube package boilers to a variety of B&Wwater-tube package boilers are ■ Operating instructions
industries, including: available in a wide range of capacities: ■ Start-up services
■ Hospitals ■ Steam flow from 8,200 to 260,000 lb/h ■ Spare parts manuals
■ Universities (1 to 33 kg/s) ■ Replacement parts
■ Manufacturing and ■ Superheat temperatures up to 875F ■ Sales assistance
processing facilities (468C)
■ Utilities ■ Design pressures from 250 to 1250 psi
■ Petrochemical (1.7 to 7.2 MPa)
■ Pulp and paper
■ Pharmaceuticals High capacity package boilers are also
available for both oil and gas firing. B&W
System components complement provides the high capacity FM (HCFM)
operation and the PFM boiler engineered with the
same quality standards as our smaller pack-
Specifically designed to complement each age boilers. These units feature multiple
other in operation, all major components in burners for increased capacity. The HCFM
the FM package boiler system are supplied can be either shop, dock or field assembled, ▲
while the PFM must be assembled either at The compact, efficient design of
by B&W: B&W’s water-tube package boilers
the dock or field location. Both types of allows for economical shipment via
■ Boiler
units are shipped by barge or ocean vessel. rail or truck.
▲

B&W’s engineering
expertise and complete
project management
skills help to ensure
that a project is right
the first time and on
time without additional
costs.

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Water-Tube Package Boilers: B&W’s Engineering
Expertise Offers Many Benefits
Long-term reliability
B&W maintains the same cornerstone
company values as we did in 1867 when
the first B&W water-tube steam boiler
was patented. These values include a
commitment to excellence, outstanding
customer service, quality and continuous
improvement, integrity, technology leader-
ship, accountability and a commitment to
our people. Based on these values, B&W
builds equipment that is designed to last.
In fact, many 1950s-vintage B&W package
boilers are still in service today.

Fast load response

B&W’s 2.5 in. (6.35 cm) tubes are spaced
1 in. (2.54 cm) 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
B&W’s 2.5 in. (6.35 cm) tubes spaced 1 in. (2.54 cm) apart (tube panel in
background) increase the overall water-cooled tube furnace surface and circulation disruptions or carryover.
reduce the membrane area between the tubes compared with competitors’ Connections for lower drum heating
units that are designed with 2 in. (5.08 cm) tubes spaced 2 in. (5.08 cm) coils are also standard.
apart (tube section in foreground). This helps to prevent membrane
thermal cracking and contributes to a faster load response.
Low operating and
maintenance costs
The B&W package boiler drives
maintenance to a minimum with:
■ No reliance on refractory seals

■ Positive circulation, 100% water-cooled

rear wall
■ A fully drainable superheater located in

the convection bank

■ Galvanized, primed and enamel-painted

exterior lagging
■ Hinged drum manways for improved

waterside access

Controlled emissions
B&W’s combustion design engineers work
with outside burner suppliers to meet your
stringent requirements. The elimination of
▲
floor brick gives our furnace more water-
B&W’s water-tube package boiler offers more water-cooled surface, which cooled surface, thereby helping to meet
in turn helps to meet today’s stringent emissions regulations. today’s tough emissions limits.

4
Water-Tube Package Boilers: Capacities to Meet the Most
Demanding Requirements
Capacity
Boilers Range* Length Width Height Drum
(lb/h) Size
FM 9-22 7 ft 7 in.
26 8 ft 11 in.
30 9 ft 11 in. 36 in. Steam
34 8,200 11 ft 3 in. Drum
39 to 12 ft 7 in. 10 ft 2-7⁄ 8 in. 12 ft 4 in.
43 40,000 13 ft 11 in. 24 in. Lower
48 15 ft 3 in. Drum
52 16 ft 7 in.
57 17 ft 11 in.
FM 10-52 16 ft 7 in.
57 17 ft 11 in. 36 in. Steam
61 35,000 19 ft 3 in. 10 ft 10-5⁄ 8 in. Drum
66 to 20 ft 7 in. 13 ft 6 in.
70 75,000 21 ft 11 in. 24 in. Lower
79 24 ft 7 in. Drum
FM 101-88 27 ft 3 in. 11 ft 2-3⁄ 8 in.

42 in. Steam
FM 103-70 70,000 21 ft 3-3⁄16 in. Drum
79 to 23 ft 11-3⁄16 in. 11 ft 9 in. 13 ft 9- ⁄4 in.
3

88 100,000 26 ft 7-3⁄16 in.

24 in. Lower
97 29 ft 11 in.
Drum

FM 106-79 23 ft 11-3⁄16 in. 48 in. Steam

88 100,000 26 ft 7-3⁄16 in. 11 ft 9 in. 14 ft 3 in. Drum
97 to 29 ft 3-3⁄16 in.
FM 117-88 155,000 26 ft 7-3⁄16 in. 11 ft 11-1⁄4 in. 15 ft 4-1⁄2 in. 24 in. Lower
97 29 ft 3-3⁄16 in. Drum

54 in. Steam
FM 120-97 155,000 29 ft 3-3⁄16 in.
Drum
112 to 33 ft 7-3⁄16 in. 12 ft 5- ⁄8 in.
3
16 ft 10- ⁄2 in.
1

124 260,000 37 ft 3-3⁄16 in.

24 in. Lower
FM 160-124 37 ft 3-3⁄16 in. 14 ft 0-3⁄8 in. 20 ft 0-1⁄2 in.
Drum

Steam capacity Steam pressure Steam temperature

HCFM
200,000 to 350,000 lb/h to 1250 psig (7.2 MPa) to 825F (441C)
(25.2 to 44.1 kg/s)

PFM
200,000 to 600,000 lb/h to 1800 psig (12.4 MPa) to 900F (482C)
(25.2 to 75.6 kg/s)

NOTES: 2. Because of B&W’s constant METRIC CONVERSIONS: * Steam capacities shown are saturated
steam. Capacities shown will vary depending
1.All package boilers are of effort to improve design, inches x 25.4 = mm on conditions and limitations.
membrane construction. equipment supplied may inches x 2.54 = cm
differ slightly from that feet x 0.3048 = m
described above. lb/h x 0.000126 = kg/s
.

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Water-Tube Package Boilers: Unique Features, Rugged
Construction Enhance Operation
cyclone-type (shown in main illustration, left)
for 1 ppm solids. Both designs incorporate
corrugated-type secondary scrubbers. Dry
pipe steam separation is also available for
0.5% moisture steam.

6) Water wash troughs and drains are

standard on every new package boiler.

7) Grooved tube seats with polished tube

ends provide maximum protection during
Superheater
(optional)
To Stack or
Economizer
initial handling and transportation, as well
Boiler Sidewall
as against leakage throughout the life of the
unit. B&W’s tube seats provide maximum
holding power and seal integrity.
Boiler Screen Division Wall Windbox
▲

B&W’s water-cooled package boilers

are designed for reliable, efficient
8) Sootblowers are properly located for
Furnace
operation in a wide variety of effective convection bank cleaning.
Furnace Sidewall industries. Sootblower bearings, wallbox(es) and tube
openings are standard on all package boilers,
Proven D-type construction, which has Scalloped seal plates (illustrated in 2-A, next regardless of fuels fired. An additional B&W
separate boiler and furnace sections, creates page) on the membrane design also provide boiler feature is that the alternating front-to-
proper geometry of the burning chamber a continuous gas-tight seal between the tube rear bank spacing allows removal of any tube
resulting in increased combustion efficiency. membrane and drums. Where inner-cased without removing adjacent tubes. (illustrated
construction is used, a 10-gauge plate is in 8-A, next page)
B&W’s package boiler designs offer many welded to the tie bars instead of directly to
other features and benefits not available the pressure parts (shown in 2-B, next page). 9) Front wall fire brick is designed for
with competitive units. The features To maintain casing above the dew point tem- expansion and protection of the front corner
described below are numbered to refer to perature, the plate is formed around the tie seals, and the front wall tile is anchored by a
the main illustration above and to the bar to ensure close plate-to-tube contact. floating alloy retainer. To protect the corner
detailed illustrations on the next page. seals, the front wall of the membrane unit
3) Rugged steel-base frame supports the is set inside furnace D tubes. (illustrated
1) Furnace wall water cooling includes not entire boiler and allows jacking and skidding in 9-A, next page)
only the side walls, roof and floor, but the of the boiler. A concrete slab with no special
high-duty rear wall as well – eliminating saddle, supports or piers is all that is needed 10) Membraned division wall prohibits
refractory and its inherent maintenance. for the package boiler. To ease installation furnace gases from bypassing the generating
This unique boiler feature locates total water and relocation, B&W’s frame has built-in tubes which can lead to high CO levels. The
cooling where it can contribute most to keep- lifting lugs and jacking pads. division wall stretches approximately three-
ing maintenance costs down. Each rear wall quarters of the furnace length.
tube is a single flow path between drums to 4) Outer lagging is galvanized, primed and
assure proper circulation and cooling. painted, making it weather-tight for outdoor 11) Superheaters are the inverted loop-type
installations. The side lagging is composed and are located in the first gas pass. Screen
2) Gas-tight setting membrane provides of 20-gauge corrugated aluminum. The tubes are provided in front of the super-
the gas-tight setting absolutely necessary on remaining exterior casing is 12-gauge steel. heater. The number of rows depends on the
all package boilers. This construction The 12-gauge roof casing also provides a desired temperature and on the number of
uniquely inhibits dew-point sulfur corrosion surface strong enough to walk on. superheater loops. The superheaters are
and outages caused by gas leaks. B&W’s completely drainable and designed for
membrane panels use large diameter tubes 5) Drum internals provide high steam puri- balanced flow throughout each tube for
and small membrane spacing that provide ty and ensure positive circulation. There are added longevity. Drum protection is also
the best combination of heat transfer two primary separators to choose from – a added to safeguard thicker wall drums in the
efficiency and maintenance accessibility. baffle-type for 3 ppm solids or an optional superheater areas.

6
1 2 2-A A
OD= .
21⁄2"

A
Scalloped
Membrane Seal
Bar Plate

31⁄2" .
1
⁄4" Thick
Membrane

Furnace Rear
Wall Tubes A-A

2-B 3 4
12-Gauge Roof Casing

Steam Drum
Tie Bar

Plate
Casing Base Frame FM-9, 10, 101

5 6 7 Grooved Tube Seat

Drum Internals, Type B

Lower Drum

Drum Internals, Type C

Water Wash Drains

8 8-A 9 Brick Holder

Tubes Can Be Removed
Generating 4 ⁄8"
1

Bank Sootblower
Elements 3" 3"
Tubes

Front Wall Tile Front Plate

Generating Bank

9-A Windbox

Furnace Burner Wall Furnace

D Tubes

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Water-Tube Package Boilers: Efficient Separation,
Positive Circulation Assure Dependability

Type B Steam Outlet Even when load changes are wide or frequent
Drum Internals enough to affect water level in the drum, positive
Secondary circulation is assured with B&W drum internals.
Steam Scrubber As hot furnace flue gas crosses the first row of
Diffuser tubes in the boiler bank, a considerable amount of
Baffle
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 specifically

designed to handle this rapid, intense generation
of steam effectively. Diffuser baffles direct por-
tions of the steam to less turbulent zones of the
drum, making use of the entire length of scrub-
bing elements to remove unwanted moisture
droplets.

Enhanced superheater reliability

Steam with less than 1 ppm solids can be obtained
when required by superheaters or special processes.
Turbine blades are kept cleaner, and the reliability
Adequate slope is designed on all heat absorbing surfaces, and of the superheater is greatly enhanced. An equally
all downcomers are located in the cooler zone of the convection important feature designed into B&W’s drum inter-
bank for proper circulation. Each tube is completely drainable. nals is the supply of steam-free solid water back to
the downcomer circuits for positive circulation.
Type C Steam Outlet The drum internals’ design also allows free end
Drum Internals flow to minimize turbulence and end-to-end water
Secondary level fluctuation.
Steam Scrubber
Cyclone
Separator

▲
B&W designs and manufactures its
drum internals, including cyclone steam
separators.

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Water-Tube Package Boilers: Complemented by a Complete
Line of Auxiliary Equipment
Economizers, superheaters, burners and characteristics. Multi-pass steam flow
controls are available from B&W for pack- ensures high steam velocities and good
age boilers in accordance with operating distribution of fluid throughout, effectively
and economic design considerations. cooling each tube. Because it is positioned
Additional accessory equipment, including out of the full radiant heat zone, it has a
a forced draft fan and drive, flues and convective-radiant temperature characteris-
ducts, stacks, feedwater pumps, deaerator, tic for a relatively constant superheater
and an oil pump and heater set can be steam temperature over the load range.
ordered to simplify planning and For further convenience, the steam outlet is
engineering. located near floor level. To protect the
thicker wall drums in the superheater area,
Economizers increase efficiency refractory drum protection is provided.

Economizers are available for increased

efficiency. Pre-engineered arrangements of
extended surface or bare-tube economizers
are offered to meet varying fuel, space and
economic considerations.
Refractory drum
▲

protection safe-
Fully drainable superheaters guards the thicker
wall drums in the
Proven, dependable and fully drainable superheater area.
superheaters – especially designed for ▲
For oil-fired applications, sootblowers
package boilers – are also available. The are a typical feature. The sootblower
vertical-tube design provides positive supply and superheater outlet
bottom support and excellent expansion connection are shown in this picture.

For higher steam capacities,

B&W offers HCFM and PFM boilers that
are engineered with the same quality
standards as our smaller package boilers.

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 Water-Tube Package Boilers:
Total-Scope Supply and Services
B&W’s extensive, worldwide experience ■ Advanced technology – B&W builds
allows us the flexibility to meet diverse quality into its products during every
project requirements easily – anything process and stage
from a knock-down boiler for field assem- ■ Strength in size and capacity – facilities,
bly to an entire steam island. We can pack- manpower and global presence provide
age your boiler system with properly sized you with a complete range of fabricating
auxiliaries to match your needs and processes
our standards of quality and excellence. ■ Outstanding responsiveness – B&W is
equipped and structured to meet your
Typical project scope delivery needs and requirements

Although every project is unique in scope, Manufacturing and safety excellence

a typical project includes:
■ FD fan and drive B&W’s package boilers are designed,
■ Burners and fuel trains engineered and manufactured at our West
■ Burner management system Point, Mississippi, U.S.A. facility. This
■ Combustion controls – jackshaft to DCS plant is ISO-9001 registered, holds ASME
■ Economizer Code stamps S, PP and U, and is in com-
■ Stack pliance with AWS code requirements.
■ Platforms B&W’s West Point plant also maintains an
■ Deaerator and feedwater pump set outstanding safety record and has been
■ Selective catalytic reduction (SCR) awarded the OSHA Star Status in the
system, when required Voluntary Protection Program.
Manufacturing and safety excellence are
Stringent quality control standards continuous goals for B&W.

At B&W, quality assurance is integral to Worldwide, responsive service and

our design, engineering and manufacturing manufacturing support ▲
B&W’s package boilers are fabricated
processes. To ensure all codes and specifi- at our West Point, Mississippi, manu-
cations are met, B&W uses stringent quality B&W’s network of domestic and interna- facturing facility in the United States.
control procedures and sophisticated tional sales representatives and field service This plant is ISO-9001 certified, holds
testing apparatus. Rigid standards have engineers assures you of a prompt response ASME Code stamps S, PP and U, and
– whether servicing and upgrading possesses an outstanding safety
been established for our material suppliers record.
as well. your existing system or specifying new
equipment. Our package boilers are also
B&W’s commitment to quality is evident available through various licensees around
by our: the world. We can provide services ranging from routine inspections and con-
trols tuning to capacity increase engineer-
ing studies, low emissions conversions or
new digital control systems.

Reliable single-source supplier

B&W’s proven expertise in boilers, burn-
ers and controls makes us a reliable and
responsive single source for package
boilers and auxiliary equipment. From
engineering and manufacturing to start-up
and operation, B&W knows how to make
it all work together for maximum operat-
ing efficiency and dependability.

10
 B&W is dedicated to
▲

generating powerful
solutions in an
environmentally
safe, efficient and
economical manner.

11
The Babcock & Wilcox Company – we’re
the original. We’ve been generating powerful
solutions in the design, construction and
service of steam generating systems since
1867. So put our experience and capabilities
to work for you today. Insist on us by name.

For more information, or a complete listing

of our sales and service offices, call ▲
B&W’s water-tube package
1-800-BABCOCK (222-2625), send an e-mail boilers provide dependable
to info@babcock.com, or access our Web site performance for a wide
range of industries and
at www.babcock.com.
applications.

The Babcock & Wilcox Company

20 S. Van Buren Avenue
Barberton, Ohio, USA 44203
Phone: (330) 753-4511
Fax: (330) 860 -1886

Babcock & Wilcox Canada Ltd.

581 Coronation Boulevard
Cambridge, Ontario, Canada N1R 5V3
Phone: (519) 621-2130
Fax: (519) 621-9681

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.

Generating Powerful Solutions is a service mark of The

Babcock & Wilcox Company.

© 2006 The Babcock & Wilcox Company. All rights reserved.

A McDermott company.

E101-3155A 5M?6F