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Scotch Marine Boiler Design: Wetback Vs Dryback

The document compares wetback and dryback designs for Scotch Marine boilers. [1] Wetbacks have separate rear tube sheets that allow for expansion and contraction, while drybacks use a common rear tube sheet causing thermal stress. [2] Wetbacks have a water-backed rear turnaround for improved efficiency, while drybacks use a refractory wall that deteriorates over time and reduces efficiency. [3] Maintenance costs for drybacks are much higher due to the need to regularly replace the refractory rear door and proprietary sealing kits.

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Gopal Ramalingam
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192 views24 pages

Scotch Marine Boiler Design: Wetback Vs Dryback

The document compares wetback and dryback designs for Scotch Marine boilers. [1] Wetbacks have separate rear tube sheets that allow for expansion and contraction, while drybacks use a common rear tube sheet causing thermal stress. [2] Wetbacks have a water-backed rear turnaround for improved efficiency, while drybacks use a refractory wall that deteriorates over time and reduces efficiency. [3] Maintenance costs for drybacks are much higher due to the need to regularly replace the refractory rear door and proprietary sealing kits.

Uploaded by

Gopal Ramalingam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 24

1

Scotch Marine Boiler Design

Wetback vs Dryback
2

Goal
The purpose of this presentation is to
provide project decision-makers with
fundamental, and critical, boiler design
information.

Wetback vs Dryback
3

Two Basic Designs


Dominate the Scotch Marine
Boiler Market:
Wetback
Dryback

Wetback vs Dryback
4

Wetback vs. Dryback


This presentation will show you the differences

Basic construction comparison


Design principles
Technical considerations
Total operating costs comparison

Wetback vs Dryback
5

Three-Pass Wetback

Wetback vs Dryback
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 Dryback
7

Four-Pass Dryback

Wetback vs Dryback
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 Dryback
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 Dryback
10

Rear Tube Sheets

Wetback is Separate Dryback is Common

Wetback vs Dryback
11

Rear Turnaround
Wetback Dryback
Surrounding water Rear refractory wall
absorbs burner heat, reflects burner heat,
improving efficiency by promoting greater
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 Dryback
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 Dryback
15

Doors
Wetback

Front Doors are typically split-hinged, or davited


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

Doors
Wetback

Larger models typically feature hinged, or davited


rear doors
Split doors maintain efficient functional footprint
Wetback vs Dryback
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 Dryback
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 Dryback
19

Sealing Kits
Wetback

Simplified design requires far fewer seals


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

Sealing Kits
Dryback

Watch Case design requires numerous proprietary sealing


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

Dont 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 Dryback
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 Dryback
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 Dryback
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 Dryback
27

Add In Consideration to
Sustainable Efficiency
Improvement.

Dont You Think Someone


Should Know That Before Making
an Equipment Decision?

Any Questions?
Wetback vs Dryback

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