In the process of setting up or renewing production lines, the provision of capital-heavy equipment such as boilers is faced with many sensitivities. Any flaw in the alloy, poor quality in welding, or neglect of mandatory safety standards can cause irreparable damage. For this reason, project managers and employers prefer to buy directly from reliable factories without intermediaries. As a direct designer and manufacturer, Pars Bohar Industry Group has provided the possibility of complete customization of capacity, working pressure and burner type based on the operational needs of every workshop and factory in Isfahan and all over Iran. In the continuation of this specialized article, we will comprehensively examine all technical dimensions, requirements of national and international standards, specifications of raw materials and technological differences in the construction of steam boilers.
The importance of Iran's national standard in boiler design and production
The boiler is an extremely sensitive pressure vessel. In accordance with the regulatory rules of Iran's General Directorate of Standards, all pressure vessels and industrial boilers are subject to the mandatory standard ISIRI 4231 (equivalent to the valid international standard BS 2790). Acquiring the National Standard Mark is not just an advertising label, but the result of the implementation of a step-by-step and unforgiving control protocol by third-party technical inspection companies. In case of any kind of accident caused by the explosion of non-standard and workshop boilers, the employer will face severe legal, criminal and insurance responsibilities; Because insurance companies do not accept liability for equipment without a valid national standard license plate.
Engineering and inspection procedures in the boiler manufacturing center of Pars Bohar industry
To transform raw steel plates into an ultra-advanced thermal boiler, the production and assembly lines of Pars Bohar industry go through strict standards. Before reaching the stage of painting and packaging, each steam boiler undergoes various tests so that there is no risk of leakage, durability or breakage of the material in the future.
Checking possible internal and surface defects of connections requires specialized non-destructive tests (NDT). In the Pars Bohar factory in Isfahan, the connecting lines of the boilers are subjected to industrial radiography test (RT) according to the standard requirements to the extent of 100% for longitudinal welding lines and standard percentages for peripheral welding. In addition to radiography, magnetic particle (MT) and penetrating liquid (PT) tests are implemented on the roots and nozzles to ensure the absence of any kind of cracks, undercuts or lack of penetration. After confirming all welding tests, the tank is subjected to hydrostatic test. At this stage, the boiler is filled with water and subjected to hydraulic pressure up to 1.5 times the maximum allowable working pressure (Design Pressure) and is tested and reviewed for a specified period under the supervision of the resident inspector.
Choosing the right material; The main foundation of boiler manufacturing quality in Isfahan
The durability of an industrial boiler depends more than anything on the type of steel used in the shell, tubes and furnace. Boilers built with conventional sheet construction and seamed tubes quickly suffer from premature fatigue, localized stresses, and pitting when exposed to continuous heating and cooling cycles. In Pars Bohar Industry Complex, as the hub of steam boiler manufacturing and sales in Isfahan, the selected material is determined exactly based on the requirements of the engineering codes.
Sheets used in the shell, grid and combustion chamber of the boiler of Pars Bohar industry are exclusively prepared from manganese alloy steels resistant to heat and pressure, such as 17Mn4 alloy sheet according to DIN 17155 or ASTM equivalent grades such as A516 Grade 70. These sheets have extremely high flexibility, excellent yield strength and creep resistance. Also, seamless boiler tubes are selected based on DIN 17175 grade St35.8 standard, which provide high heat transfer ability and permanent direct flame tolerance. The use of low-quality pipes carries the risk of severe sedimentation, overheating, and eventually rupture of the tubes, while the useful life of the tubes reaches several decades in the production boilers of the Pars Bohar industry.
Variety of products in the boiler sales center in Isfahan
Production units require different boiler designs according to the amount of steam consumption in the process line and the available space in the engine room. Sanat Pars Bokhar designs and manufactures a wide range of steam boilers in a completely customized way in order to provide the best engineering solution for every need.
Horizontal Firetube Steam Boilers are the most common and stable option for medium and heavy capacities in large factories in Isfahan. In these boilers, the hot gases from combustion pass through the pipes and heat the water around the pipes. These products can be made in two types of Wet Back and Dry Back. Pars Bohar industry prioritizes the construction of three-pass wetback boilers, because in the wetback structure, the end of the gas return chamber is surrounded by water. This system creates a more uniform heat transfer, reduces wear and tear of pipes, improves the efficiency of the system to more than 88% without an economizer, and prevents extensive waste of thermal energy from the back of the boiler.
On the other hand, for smaller industries, sewing workshops, laundries, mushroom workshops, and greenhouses that face a severe limitation of the occupancy level in the engine room, a vertical steam boiler is suggested. The vertical steam boilers produced in Pars Bohar industry, by occupying the least floor space, reach the desired working pressure at a high speed and feed clean and fluctuating steam to the system. All standards of welding, stress relief and material quality are observed in the construction of standing boilers, just like huge industrial boilers.
Wide applications of standard steam boilers in Isfahan industries
Isfahan has a set of the most diverse industrial clusters in the country and the thermal systems made by Pars Bohar industry are being used in all these vital industries. Knowing the thermal requirements of each industry has helped us to design boilers with fully targeted efficiency.
In the steel and foundry industries of Isfahan, steam is used for washing parts, acid washing and degreasing, preheating petroleum fluids and lubricants. In the food and dairy industries, hot steam is essential for pasteurization, sterilization of piping and bottling lines, distillation process and cooking pots; The purity of the steam coming out of the boiler is the number one priority in these industries. The textile industry of Isfahan, as the cradle of Iran's textile industry, uses steam for fabric finishing, dyeing, degreasing and stabilization of fibers, which requires a completely stable steam pressure. Also, in petrochemical complexes, pharmaceuticals, concreting units for concrete processing and carton and packaging factories, the precise operation of steam boilers plays a key role in reducing production waste. The steam boilers made in Pars Bohar Industrial Center with various capacities from 100 kg per hour to several tons of steam per hour have responded to these heterogeneous industrial needs in the best way.
Control accessories and reliability factor in boilers of Pars Bohar industry
A national standard steam boiler is as dependent on the mechanical quality of the body as it is on the intelligence and accuracy of its accessories and control devices. The use of first-class European equipment or the best Iranian standard brands is one of the fundamental differences between the products of the Pars Bohar industry and non-professional assembly workshops.
Each boiler is equipped with an accurate level control system for constant monitoring of the water level in the tank. The use of reliable level controllers such as electronic probes or magnetic floaters ensures that the boiler never operates in low water conditions; A fatal accident that is the root of most boiler explosions in the world. Two standard safety valves are installed on each boiler, which are activated independently at specified pressures and safely discharge the excess pressure if the load exceeds the permissible limit. Pressure switches, accurate manometers and intelligent switchboard system based on PLC or reliable industrial relays manage the fully automatic operation of the burner and add uninterrupted security to the user circuit.
Comparison of buying a new boiler versus a second-hand boiler
One of the most controversial decisions among industrialists is choosing between a new boiler or used and second-hand models. At first glance, it seems that the price of a second-hand boiler has a higher economic value, but a detailed technical and financial analysis shows the hidden dangers of this decision.
Factors affecting the price and order of steam boiler in Isfahan
Steam boiler pricing is a result of mechanical specifications, control components and the level of customization requested by the buyer. In the boiler production and sales center of Pars Bohar industry, pre-invoices are issued with full transparency and all parts are attached with the mention of the brand and technical certificate.
Steam production capacity in kilograms or pounds per hour is the first defining characteristic. Of course, as the capacity of the boiler increases, the weight of the sheets, the number of alloy tubes and the overall dimensions of the furnace, and thus the final price, will change. The second factor is working pressure; Boilers with working pressures of 6 bar, 10 bar, 16 bar or higher require sheets with increased thickness and flanges and valves with a higher pressure class. The type of fuel consumed and the chosen burner, either single-burner (gas-burner or diesel-burner), double-burner or diesel-burner, the quality of the feed water pump (Feed Water Pump), the type of electrical panel and the installation of heat recovery systems such as economizer and superheater are considered as other components that affect the final price of the boiler. Buying without an intermediary from the main producer eliminates the commission of market dealers and offers the best price to the buyers.
Guide to operation, water treatment and boiler maintenance
Achieving a lifespan of more than thirty years in a standard boiler requires compliance with the principles of boiler feed water maintenance engineering. Urban hard water or wells in industrial areas of Isfahan are rich in calcium, magnesium, silica and soluble gases such as oxygen and carbon dioxide. The continuous evaporation of the water inside the boiler increases the concentration of these salts up to thousands of times and creates a non-conductive layer of calcium deposits on the pipes.
Creating a deposit even one millimeter thick on the heat exchange surfaces can increase the fuel consumption of the boiler up to ten percent and cause the metal to overheat and burn the tubes due to the lack of proper cooling of the tubes by water. In addition to manufacturing and selling boilers in Isfahan, Pars Bohar technical engineering team designs and installs complete water treatment packages including fully automatic resin hardeners, reverse osmosis (RO) devices, deaerators (oxygen remover) and anti-corrosion and anti-foam injection package systems according to the boiler capacity. Also, the technicians of Pars Bohar industry teach the buyer operators how to carry out the blowdown process regularly to drain the sludge and control the water hardness (TDS) so that the efficiency of the device remains at its peak forever.
Why Pars Bohar industry is the best choice for Isfahan and Iran industries?
Furthermore, all stages of making the boiler are protected by thermal insulation coating with high density stone wool and matte or shiny steel coating, which reduces surface heat loss to the lowest possible level. The support of the Pars Bohar industry team after the sale also continues with installation services, boiler piping, initial combustion tests, burner balance and official start-up at the employer's factory, and includes comprehensive training of the operating personnel to fully ensure the safety of the workshop.
summary
Setting up a standard and powerful engine house is a prerequisite for the prosperity and continuity of industrial production lines in Isfahan and other cities of the country. As the most dangerous and yet the most critical component of a factory, the boiler must be designed and built according to the strictest metallurgical and welding engineering standards. Pars Bohar Industry Group, as the best steam boiler manufacturing and sales center in Isfahan, along with the national standard, supplies a series of horizontal and vertical firetube boilers to the industrial markets with the highest quality refractory sheets, strict NDT inspections and official certificates. Entrusting the responsibility of building your heating system to Pars Bohar industry is a smart step in the direction of improving thermal efficiency, ensuring the safety of personnel and continuous peace of mind from return on investment in today's highly competitive industrial environment.
