Abstract: A boiler system comprises a housing with a generally cylindrical shape extends between first and second walls to provide a generally cylindrical space. A fire tube is positioned near a bottom of the generally cylindrical housing and extends longitudinally from a first wall of the cylindrical housing to a fire tube end wall. The boiler system also includes a burner with a generally cylindrical housing which defines a generally cylindrical chamber and an end plate. The burner extends into the fire tube, and the fire tube provides a combustion chamber where combustion of an air-fuel mixture is accomplished using the burner. The end plate of the burner is adjustable so as to adjust the flame that extends from within the burner housing into the fire tube.

Abstract: Systems and methods for anticipating shutdown alarms for a boiler system by way of one or more machine learning (ML) or artificial intelligence (AI) models are disclosed herein. In an example embodiment, a method for anticipating shutdown alarms with respect to a boiler by way of a ML model includes receiving and storing, at one or more storage devices, a plurality of types of boiler-related data that are received at least indirectly from a plurality of internet of things (IoT) devices. The method also includes preprocessing and feature engineering the plurality of types of boiler-related data to arrive at a training data set, training the ML model, and deploying the trained model. The method further includes receiving additional boiler-related data concerning the boiler and, by way of the model, determining an alarm prediction concerning an anticipated alarm, and taking at least one action based at least upon the prediction.

Abstract: Boiler systems having convection sections containing a set of boiler tubes having boiler tube inserts, boiler tubes for use in the convection section of a boiler system, and boiler tube inserts for boiler tubes for use in the convection section of a boiler system are provided herein. The boiler tube inserts are positioned in a first section of each boiler tube, where the first section extends from a front tube end the receives combustion gases from a furnace. The first section of the boiler tubes can be a plain tube section, and the boiler tubes can have a second section that includes a finned structure. The boiler tube inserts can be helical and can be made of a ceramic material.

Abstract: A boiler system having a generally cylindrical housing or shell includes a main or fire tube with a furnace or combustion chamber extending longitudinally near the bottom of the housing and a burner to accomplish combustion within the combustion chamber. The combustion chamber opens at its rear end to furnace tube sheet, and to a first set of tubes extending longitudinally of the boiler. The first set of tubes extends to and through the rear tube sheet of the boiler to a turnaround space, which transitions to a second set of tubes located above the combustion chamber and first set of tubes to generally span a length extending from the rear tube sheet of the boiler to the front tube sheet. The boiler system as disclosed has a reduced size while maintaining efficiency in steam and hot water applications.

Abstract: Boiler systems and associated control systems, methods for operating same, are described herein. In one example embodiment, a boiler system includes a furnace, an exhaust passage, an air passage, a FGR passage, a flue gas valve that is adjustable by way of a first actuator, a NOX gas sensor, an oxygen gas sensor, and an additional valve that is adjustable by way of a second actuator. Further, the boiler system includes at least one processing device coupled to the NOX gas sensor, the oxygen gas sensor, the first actuator and the second actuator. The at least one processing device is configured to generate control signals that are provided to the first actuator and second actuator, and also configured to generate correction factors by way of a calibration process and to utilize one or more of the correction factors in determining one or more of the control signals.

Abstract: A boiler system comprises a housing with a generally cylindrical shape extends between first and second walls to provide a generally cylindrical space. A fire tube is positioned near a bottom of the generally cylindrical housing and extends longitudinally from a first wall of the cylindrical housing to a fire tube end wall. The boiler system also includes a burner with a generally cylindrical housing which defines a generally cylindrical chamber and an end plate. The burner extends into the fire tube, and the fire tube provides a combustion chamber where combustion of an air-fuel mixture is accomplished using the burner. The end plate of the burner is adjustable so as to adjust the flame that extends from within the burner housing into the fire tube.

Abstract: A boiler system having a generally cylindrical housing or shell includes a main or fire tube with a furnace or combustion chamber extending longitudinally near the bottom of the housing and a burner to accomplish combustion within the combustion chamber. The combustion chamber opens at its rear end to furnace tube sheet, and to a first set of tubes extending longitudinally of the boiler. The first set of tubes extends to and through the rear tube sheet of the boiler to a turnaround space, which transitions to a second set of tubes located above the combustion chamber and first set of tubes to generally span a length extending from the rear tube sheet of the boiler to the front tube sheet. The boiler system as disclosed has a reduced size while maintaining efficiency in steam and hot water applications.

Abstract: A boiler system comprises a housing with a generally cylindrical shape extends between first and second walls to provide a generally cylindrical space. A fire tube is positioned near a bottom of the generally cylindrical housing and extends longitudinally from a first wall of the cylindrical housing to a fire tube end wall. The boiler system also includes a burner with a generally cylindrical housing which defines a generally cylindrical chamber and an end plate. The burner extends into the fire tube, and the fire tube provides a combustion chamber where combustion of an air-fuel mixture is accomplished using the burner. The end plate of the burner is adjustable so as to adjust the flame that extends from within the burner housing into the fire tube.

Abstract: Boiler systems and associated control systems, methods for operating same, are described herein. In one example embodiment, a boiler system includes a furnace, an exhaust passage, an air passage, a FGR passage, a flue gas valve that is adjustable by way of a first actuator, a NOX gas sensor, an oxygen gas sensor, and an additional valve that is adjustable by way of a second actuator. Further, the boiler system includes at least one processing device coupled to the NOX gas sensor, the oxygen gas sensor, the first actuator and the second actuator. The at least one processing device is configured to generate control signals that are provided to the first actuator and second actuator, and also configured to generate correction factors by way of a calibration process and to utilize one or more of the correction factors in determining one or more of the control signals.

Abstract: A boiler system having a generally cylindrical housing or shell includes a main or fire tube with a furnace or combustion chamber extending longitudinally near the bottom of the housing and a burner to accomplish combustion within the combustion chamber. The combustion chamber opens at its rear end to furnace tube sheet, and to a first set of tubes extending longitudinally of the boiler. The first set of tubes extends to and through the rear tube sheet of the boiler to a turnaround space, which transitions to a second set of tubes located above the combustion chamber and first set of tubes to generally span a length extending from the rear tube sheet of the boiler to the front tube sheet. The boiler system as disclosed has a reduced size while maintaining efficiency in steam and hot water applications.