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    Scotch Marine Boiler Design: Wetback Vs Dryback

    Uploaded by

    RaviIdhayachander
    This document compares wetback and dryback boiler designs. Wetback boilers have separate tube sheets between passes which allows for expansion without stress. They do not require expensive refractory maintenance. Dryback boilers have common rear tube sheets which experience thermal stress. Their rear refractory wall requires periodic replacement. Overall, wetback boilers have lower maintenance costs and more sustainable efficiency due to their water-backed rear turnaround.

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    © All Rights Reserved
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    Scotch Marine Boiler Design: Wetback Vs Dryback

    Uploaded by

    RaviIdhayachander
    99 views24 pages
    This document compares wetback and dryback boiler designs. Wetback boilers have separate tube sheets between passes which allows for expansion without stress. They do not require expensive refractory maintenance. Dryback boilers have common rear tube sheets which experience thermal stress. Their rear refractory wall requires periodic replacement. Overall, wetback boilers have lower maintenance costs and more sustainable efficiency due to their water-backed rear turnaround.

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    Wetback-Dryback

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    This document compares wetback and dryback boiler designs. Wetback boilers have separate tube sheets between passes which allows for expansion without stress. They do not require expensive refractory maintenance. Dryback boilers have common rear tube sheets which experience thermal stress. Their rear refractory wall requires periodic replacement. Overall, wetback boilers have lower maintenance costs and more sustainable efficiency due to their water-backed rear turnaround.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    99 views24 pages

    Scotch Marine Boiler Design: Wetback Vs Dryback

    Uploaded by

    RaviIdhayachander
    This document compares wetback and dryback boiler designs. Wetback boilers have separate tube sheets between passes which allows for expansion without stress. They do not require expensive refractory maintenance. Dryback boilers have common rear tube sheets which experience thermal stress. Their rear refractory wall requires periodic replacement. Overall, wetback boilers have lower maintenance costs and more sustainable efficiency due to their water-backed rear turnaround.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    1

    Scotch Marine Boiler Design

    Wetback vs
    2

    Goal

    The purpose of this presentation is to


    provide project decision-makers with
    fundamental, and critical, boiler design
    information.

    Wetback vs
    3

    Two Basic Designs


    Dominate the Scotch Marine
    Boiler Market:
    Wetback
    Dryback

    Wetback vs
    4

    Wetback vs. Dryback


    This presentation will show you the differences

    • Basic construction comparison


    • Design principles
    • Technical considerations
    • Total operating costs comparison

    Wetback vs
    5

    Three-Pass Wetback

    Wetback vs
    6

    Wetback Design Principles


    • Separate tube sheets between all major
    temperature changes (between tube passes)
    • Rear turnaround is totally surrounded by water
    • No expensive refractory to maintain
    • Rear doors are either lightweight lift off type or
    split-hinged
    • Sealing materials are inexpensive, non-proprietary
    • Efficient “functional footprint”

    Wetback vs
    7

    Four-Pass Dryback

    Wetback vs
    8

    Dryback Design Principles


    • Common rear tube sheet between passes
    • Rear turnaround is a refractory wall
    • Door refractory is a maintenance item
    • Rear door is vessel-sized in diameter,
    extremely heavy, and hinged or davited
    • Sealing materials are typically proprietary
    • Large “functional footprint”

    Wetback vs
    9

    Tube Sheets
    Wetback Dryback
    Separate rear tube Common rear tube
    sheets sheet

    • Separate tube sheets • Common tube sheet


    are free to expand and experiences extreme
    contract at their own thermal stress in
    rate in response to the response to temp.
    1300 – 1600 F temp. differentials,
    differential between increasing the
    passes. likelihood of leaks.

    Wetback vs
    10

    Rear Tube Sheets

    Wetback is Separate Dryback is Common

    Wetback vs
    11

    Rear Turnaround
    Wetback Dryback
    • Surrounding water • Rear refractory wall
    absorbs burner heat, reflects burner heat,
    improving efficiency promoting greater
    by 1 to 3%. exterior radiation losses.
    • Efficiency is • Hot flue gases erode
    sustainable, as refractory baffle
    turnaround does not resulting in “short
    deteriorate over time. circuiting,” and loss of
    efficiency.

    Wetback vs
    14

    Rear Refractory Replacement


    Wetback Dryback
    • NO expensive • Refractory must be
    refractory to maintain inspected regularly
    and replaced
    • Significant periodically
    maintenance cost • Replacement costs are
    savings over the life of burdensome, involving
    ownership proprietary sealing
    kits, special rigging
    and down time

    Wetback vs
    15

    Doors
    Wetback

    • Front Doors are typically split-hinged, or davited


    • Rear Doors are lightweight (< 60#) lift-type
    Wetback vs
    16

    Doors
    Wetback

    • Larger models typically feature hinged, or davited


    rear doors
    • Split doors maintain efficient “functional footprint”
    Wetback vs
    17

    Doors
    Dryback

    Annual inspections are typically more costly for the dryback, requiring proprietary door sealing
    kits, special tools, and considerable manpower in “muscling” massive, and typically sagging,
    doors into “bolt-thru” alignment.
    Wetback vs
    18

    Doors
    Dryback
    • Large, heavy, single
    front door offers
    complicated multi-
    sectioned design
    • Additional costs for
    seal kits and labor can
    significantly impact
    annual operating
    expenses

    Wetback vs
    19

    Sealing Kits
    Wetback

    Simplified design requires far fewer seals


    All are non-proprietary, inexpensive, and easy to install
    Wetback vs
    20

    Sealing Kits
    Dryback

    “Watch Case” design requires numerous proprietary sealing


    kits for each inspection, and every vessel service
    Wetback vs
    21

    Functional Footprint
    Dryback

    Wetback

    • Dryback: Vessel-diameter door means a larger functional footprint, demanding


    additional floorspace

    •Wetback: Lift-type or split-hinged doors have minimal impact on floorspace


    requirements
    Wetback vs
    23

    The Wetback Advantage:


    Summary
    Wetback Boilers -
    • Offer far fewer maintenance concerns:
    - No rear door refractory to repair
    - No refractory baffling to burn-out
    - Far less thermal stress on tube sheets, and tube ends

    • Don’t require proprietary parts

    • Offer maximum sustainable efficiency: Maintenance-free water backed


    turnaround provides better heat absorption at the most critical heat transfer point.

    Wetback vs
    24

    Maintenance Costs Comparison


    Bottom Line
    We surveyed a few of our service reps who perform
    repair/maintenance work on boilers and specifically asked
    them to share dryback expenses.
    We averaged them together and came up with the following
    maintenance report;

    Wetback vs
    25

    Based on repairs costs of a 300 HP boiler with


    a life span of 25 years

    • Average cost to replace refractory rear


    door; $6,000 each time
    • Average cost to replace proprietary door
    gaskets; $500 each time

    Wetback vs
    26

    The rear door needs to be replaced every 3


    years, or 8 times. The gaskets need replaced
    2-3 times per year.
    • Refractory door; $6,000 x 8 times = $48,000
    • Door gaskets; $500 x 2 times/year x 25 = $25,000
    • Wetback gaskets; $30 x 1/year x 25 years = $750
    Total maintenance costs for 25 years $72,250

    They could have bought a new boiler and


    burner!!
    Wetback vs
    27

    Add In Consideration to
    Sustainable Efficiency
    Improvement.

    Don’t You Think Someone


    Should Know That Before Making
    an Equipment Decision?

    Any Questions?
    Wetback vs

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