In this research, a three-pass fire tube Boiler has been numerically simulated in order to investigate temperature distribution of combustion products in different parts of a sample Boiler. The turbulent flow of the flame and combustion products are simulated by the finite volume approach by using Discrete Ordinates model to simulate radiation and Species Transport model to simulate combustion phenomenon. Each part has been separately simulated with inlet characteristics of the outlet of the last part and the smoke temperature distribution in each part has been presented. In addition, effective parameters of burner capacity, furnace type (corrugated or plain), furnace and tube length and diameter have been studied on the temperature distribution of combustion product and Boiler performance. According to the obtained results, with increasing the length by 55% or diameter by 54% of the furnace, steam production increases by 6.56% and 1.5% respectively. With corrugating the furnace, the gas outlet temperature reduces and the Boiler capacity of steam production increases. Reducing the diameter of the tubes by 20% and increasing the length of the tubes by 25% in the 2nd pass and 18% in the 3rd pass (with the same heat transfer surface of the tubes in pass 2 and 3), leads to steam production increase by 3% and 1.68%, respectively. Results showed that for larger proportion of 3rd pass tubes, Boiler performance increases. Also increasing in the burner capacity (by 33%) leads to same value increase in the steam production.

The current electricity demand is increasing, and now the government has involved third parties in the implementation of electricity so that investors compete for building infrastructure in order to apply electricity. Thermal power is one source that has a fast break event point compared to other resources that more interested investors even with all forms of pollution caused. A form of heat power using a vapor pressure is fired into the turbine so that it will cause a rotating force that will turn the generator of an electric generator. thermal power has the ability to generate electricity large, but if there is a failure in operation, then the burden will quickly lose power sources that can cripple production activities. FMEA is one of the most widely used tools for the industry to analyze the root cause of the system so that the system is protected from small and large damage and can disrupt the stability of the industrial operating system. The reliability of the machine must always be maintained so that with this method it is expected to help the power service providers to maintain the availability of its services. With the implementation of FMEA, we get an overview of the steps to be taken for the future so that the reliability of a steam generator Boiler system can be improved.

This paper deals with failure investigation of Boiler feed pump’s shaft of a steam power plant. Boiler feed water pump is a specific type of pump used to pump, feed water into a steam Boiler and is one of most important part of steam power plants. Feed pumps failure may cause failure of other parts of steam power station, therefore keep them safe, which is an important problem. There are 12 feed pumps in Bandar Abbas power plant. They are old and due to failure of feed pumps because of trying to avoid repetition problem, working condition of 3 dimensional pump’s shaft is modeled with Abaqus software via finite element method analysis.Causes of pump failure and stresses exerted on it are investigated and finally appropriate suggestions such as smooth starting and inverter are proposed.

This research utilizes MATLAB and Python coding to optimize the thermal design of an industrial shell and tube steam Boiler with an internal superheater. The paper outlines a systematic approach to steam Boiler design, including heat transfer dynamics analysis, superheater configuration optimization, and implementation. They take action to enhance the performance of the third pass. The shell and tube steam Boiler specifications, including an internal superheater, have been determined, with a steam capacity of 5 tons/hour and operating at a working pressure of 10 bar. According to the results, the opt substantially impacted 71 tubes in the second pass, each with a diameter of 5 cm, and an additional 82 tubes of identical size in the third pass (which includes revisions). To achieve a desired temperature increase of 15 ℃ in the superheater, incorporating the superheater section into the fire tube resulted in a 23.72% increase in the third pass level compared to the scenario without a superheater. For every 5 ℃ temperature increase in the superheater, the steam velocity in the third pass tubes decreases by approximately 1m/s. Adding the superheater to the end of the third pass  reduces the temperature of this area from 525 ℃ to 500 ℃. Leveraging machine learning algorithms enabled the identification of parameters influencing the rise in superheater temperature. Linear regression emerged as the best predictor of superheater temperature increase among the eight models considered.

The water level control in Boiler drums is a crucial process in many process industries. In industries, water spillage or overheated tubes of the water Boiler are the serious consequences of extremely high or low-level drum water level maintenance. The Boiler drum is a MIMO system, consists of dead time nonlinearity and thereby there exists a transportation lag between the input and the system. Also, they possess high dynamic variations. Hence, the control of the Boiler drum level is of great importance. Though, conventional PID controllers are employed in industries, due to the presence of nonlinearity, Boiler drum performance can be affected when it is controlled by a PID controller. Moreover, the PID controller produces a larger settling time. Here, a robust controller for the Boiler drum level control based on the H-infinity technique is designed. The first-principle mathematical model of the Boiler drum is formulated. The uncertainties namely: structured uncertainty, unstructured uncertainty, and nonlinear uncertainty are modeled by incorporating the Boiler drum dynamics including its inherent nonlinearity. The Boiler drum level control is carried out using the H-infinity controller scheme with the uncertainties accounted for and the performance is compared with that of a conventional PID controller. The qualitative and quantitative comparison of performances of the above control schemes reveals that the H-infinity controller has a quick rise time and faster settling time.