Lectut MIN 210 PDF 02 Steam Generators 5f7vpu5

Boilers
RAVI KUMAR
IIT Roorkee
BOILERS
A BOILER is an enclosed pressure vessel where heat
generated through the combustion of fuel is used for
converting water into steam.
The volume of water increases 1600 times when
converted into steam.
February 16, 2016
Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering
IIT Roorkee
boilers
Boiler is an gadget to produce steam

Thermal energy released through combustion of fuel is
used to generate steam at the desired temperature and
pressure.
The steam is expanded in steam engine or steam turbine
to produce mechanical work.
Process Industries
HVAC applications
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IIT Roorkee
boilers
IBR Steam Boiler

Any closed vessel exceeding 5 gallons of volume i.e. 22.75 liters
and used for steam generation under pressure (Section 28&29
IBR act.).
IBR Steam Pipe
Any pipe through which steam passes from a boiler to a prime
mover or other user or both, if pressure at which steam passes
through such pipes exceeds 3.5 kg/cm2 gauge or such pipe
exceeds 254 mm in diameter.
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IIT Roorkee
Boiler Systems
Water Treatment system
Feed Water system
Steam System
Blow down System
Fuel Supply system
Air Supply system
Flue Gas system
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Type of Boilers
IIT Roorkee
Fire Tube Boiler

Water Tube Boiler
Packaged Boiler
Fluidized Bed Combustion Boiler
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IIT Roorkee
Fire Tube Boilers
Fire tube boilers, typically have a lower initial cost, are more fuel
efficient (82%) and easier to operate, but they are limited generally
to capacities of 25 tons/hr and pressures of 17.5 kg/cm2. The
steam variation is less.
IIT Roorkee
Water Tube Boilers

Used in Power Plants
Steam Capacity 4.5-120 T/hr
High Capital Cost
Used for high pressure high
capacity steam boiler
Demands more control
Calls for very stringent water
quality
More efficient than fire tube
boiler.
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IIT Roorkee
Merits of water tube boiler over fire tube boiler

Steam generation is quick as the saturation temperature in
attained in short time.
Large evaporative capacity and the steam pressure can go
up to -20 MPa.
Heat exchange is effective as the flue gases travel at right
angles to the direction of water flow.
High combustion efficiency due to complete combustion of
fuel in the larger space of shell.
Uniform temperature due to quick circulation of water
keeps the thermal stresses low.
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IIT Roorkee
merits of water tube boiler over fire tube boiler

Easy to transport and erect.
Damage due to the bursting of water tube is less
serious. Therefore, water tube boilers are sometimes
called safety boilers.
All parts of the water tube boilers are easily accessible
for cleaning, inspecting and repairing.
The water tube boiler's furnace area can be easily
altered to meet the fuel requirements.
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Demerits
It is less suitable for impure and sedimentary water, as a small
deposit of scale may cause the overheating and bursting of
tube. Therefore, use of pure feed water is essential.
They require careful attention. The maintenance costs are
higher.
Failure in feed water supply even for short period is liable to
make the boiler over-heated.
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Advantages of Fire Tube Boiler

Low cost
Fluctuations of steam demand can be met easily
It is compact in size.
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Classification of water tube boilers

Horizontal straight tube boilers
Longitudinal drum
Cross-drum.
Bent tube boilers
Two drum
Three drum
Low head three drum
Four drum.
Cyclone fired boilers
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classification of water tube boilers

According to position of furnace.
i) Internally fired
(ii) Externally fired
In internally fired boilers the grate combustion chamber are
enclosed within the boiler shell, whereas, in case of extremely
fired boilers and furnace and grate are separated from the
boiler shell.
According to the position of principle axis
i) Vertical (ii) Horizontal (iii) Inclined
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classification of water tube boilers

According to application
i) Stationary (ii) Mobile, (Marine, Locomotive)
According to the circulating water
i) Natural circulation (ii) Forced circulation
According to steam pressure
i) Low pressure (ii) Medium pressure (iii) Higher pressure
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Packaged Boiler
Generally shell type with fire
tube design
High heat release rate in small
combustion space
More number of passes
Large number of small diameter
tubes leading to good
convective heat transfer
Higher thermal efficiency
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packaged boiler
Small combustion space and high heat release rate

resulting in faster evaporation.
Large number of small diameter tubes leading to good
convective heat transfer.
Forced or induced draft systems resulting in good
combustion efficiency.
Number of passes resulting in better overall heat
transfer.
Higher thermal efficiency levels compared with other
boilers.
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Fluidized Bed Boiler
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Boilers
IIT Roorkee
Lancashire Boiler
Cochran Boiler
Locomotive boiler
Babcock Wilcox Boiler
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Lankashire Boiler
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Lankashire Boiler
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Lankashire Boiler
It is a stationary, fire tube, internally fired boiler. The size is
approximately from 7-9 meters in length and 2-3 meters in
diameter.
It is stationary fire tube, internally fired, horizontal, natural
circulation boiler.
This is a widely used boiler because of its good steaming quality
and its ability to burn coal of inferior quality.
It has two large internal flue tubes having diameter between 80
cm to 100 cm in which the grate is situated.
This boiler is set in brickwork forming external flue so that the
external part of the shell forms part of the heating surface.
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Construction of Lancashire Boiler

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Cylindrical shell
Furnace tubes, bottom flue and side flues
Grate
Fire bridge
Dampers
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Features of Lankashire Boiler

The feed pipe projecting into the boiler is perforated to ensure
uniform water distribution.
Heating surface area per unit volume is considerably large.
Maintenance is easy.
Suitable where a large reserve of hot water is needed.
This boiler due to the large reserve capacity can easily meet
load fluctuations.
Super-heater and economizer can be easily incorporated into
the system, therefore; overall efficiency of the boiler can be
considerably increased(80-85%).
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Mountings
Pressure gauge and water level indicator provided at the front.
Safety valve, steam stop valve, low water and high steam safety
valve and man-hole are provided on the top of the shell.
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mountings
High steam low water safety valve

It is a combination of two valves. One is lever safety valve, which
blows-off steam when the working pressure of steam exceeds.
The second valve operates by blowing-off the steam when the
water level falls below the normal level.
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mountings
Blow-off clock
It is situated beneath the front portion of the shell for the
removal of mud and sediments. It is also used to empty the water
in the boiler during inspection.
Fusible plug
It is provided on the top of the main flues just above the grate. It
prevents the overheating of the boiler tubes by extinguishing the
fire when the water level falls below a particular level. A low
water level alarm is mounted in the boiler to give a warning when
the water level falls below the preset value.
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Cornish Boiler
One large flue tube.
Shell length 4- 7 m
Shell diameter 1.25-1.75 m
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Chochran Boiler
It is very compact and requires
minimum floor area.
Any type of fuel can be used with
this boiler
Well suited for small capacity
requirements.
It gives about 70% thermal
efficiency with coal firing and about
75% with oil firing
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Chochran Boiler
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Babcock and Wilcox boiler
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Babcock and Wilcox Boiler

The evaporative capacity of this boilers is high compared with
other boilers (20 to 40 T/hr). The operating pressure lies
between 11.5 to 17.5 bar.
The draught loss is minimum compared with other boilers.
The defective tubes can be replaced easily.
The entire boiler rests over an iron structure, independent of
brick work, so that the boiler may expand or contract freely.
The brick walls which form the surroundings of the boiler are
only to enclose the furnace and the hot gases.
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Locomotive Boiler
Locomotive boiler is a horizontal fire tube type mobile boiler.
The main requirement of this boiler is that it should produce
steam at a very high rate.
Therefore, this boiler requires a large amount of heating
surface and large grate area to burn coal at a rapid rate.
In order to provide the large heating surface area, a large
number of fire tubes are setup and heat transfer rate is
increased by creating strong draught by means of steam jet.
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Advantages
Large rate of steam generation per square metre of heating
surface. To some extent this is due to the vibration caused by
the motion.
It is free from brickwork, special foundation and chimney. This
reduces the cost of installation.
It is very compact. The pressure of the steam is limited to about
20 bar.
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Boiler Mountings
Components which are mounted over the body of the boiler
itself for the safety of the boiler and for complete control of the
process of steam genertion. They are integral part of the boiler.
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As per IBR following mountings should be fitted:

Two safety valves
Two water level indicators
Pressure gauge
Fusible plug
Steam stop valve
Feed check valve
Blowoff Cock
Man and mud hole
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Safety Valve
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Blow off the steam when pressure exceeds the working

pressure.
Dead weight Safety valve
Spring loaded safety valve
Lever safety valve
High steam low water safety valve
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Dead weigh safety valve
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Lever Safety Valve
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Spring Loaded Safety Valve
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High Steam Low Water Safety Valve

To blow off steam when pressure is high
To blow off steam when water level is low
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Water Level Indicator

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Fusible Plug
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Steam Stop Valve/Junction Valve
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Feed Check Valve
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Blow off Cock

To empty the boiler
when it is required
to be cleaned.
To reduce the water
level in case it is
high.
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Man Hole
A opening in boiler through which a man can enter a boiler for
cleaning and inspection purposes.
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Boiler Accessories
Installed either inside or outside the boiler to increase
efficiency of the boiler and to assist in the proper working of
the boiler.
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Various boiler accessories

Air Pre heater
Economise
Super heater
Feed Pump
Injector
Steam Trap
Steam Separator
Pressure Reducing Valve
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Air Preheater
It is a waste heat recovery device which is placed in the path of
the waste flue gases going to the chimney thereby abstracting
heat from the flue gases and transferring it to air before it is
used for combustion.
It is placed in the chimney above the preheater.
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Economiser
It recovers a part of heat from the heat carried away in the flue
gases up the chimney or stack and to utilize it for heating the feed
water supplied to the boiler.
Function: It is a device in which the waste heat of the flue gases is
utilsed for heating the feed water.
Advantages :
The temperature range between various parts of the boiler is
reduced which results in reduction of stresses due to unequal
expansion.
If the boiler is fed with cold water it may result in chilling the boiler
metal.
Evaporative capacity of the boiler is increased.
Overall efficiency of the plant is increased.
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Superheater
To increase the temperature of the steam above its saturation
point.
Super heaters are heat exchangers in which heat is transferred
to the saturated steam to increase its temperature.
Superheated steam has the following advantages :
Steam consumption of the engine or turbine is reduced.
Losses due to condensation in the cylinders and the steam
pipes are reduced.
Erosion of turbine blade is eliminated.
Efficiency of steam plant is increased.
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Steam Trap
Steam traps are a type of automatic valve that filters out
condensate (i.e. condensed steam) and non-condensable gases
such as air without letting steam escape.
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Steam Separator
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Feed Pump
To pump feed water to the boiler.
The reciprocating pumps run by steam from the same boiler to
which water is to be fed.
Rotary feed pumps are run either by a small steam turbine or
by an electric motor.
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HIGH PRESSURE BOILER

Low pressure Boiler <20 bar
Medium Pressire 20<p<75 bar
High Pressure >75 bar
Pressure higher than 75 bar goes up to 200 bar.
Max stem temperature 600 oC.
Forced circulation of water
To avoid the resistance to flow parallel set of tube arrangement
is made.
Small steam separation drum and sometimes free from drum.
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high pressure boilers

The efficiency and the capacity of the plant can be increased as
reduced quantity of steam is required for the same power
generation if high pressure steam is used.
The forced circulation of water through boiler tubes provides
freedom in the arrangement of furnace, in addition to the reduction
in the heat exchange area.
The tendency of scale formation is reduced due to high velocity of
water.
The danger of overheating is reduced as all the parts are uniformly
heated.
The differential expansion is reduced due to uniform temperature
and this reduces the possibility of gas and air leakages
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La-Mont Boiler
First introduced by La-Mont
in the year 1925.
The capacity of La-Mont
boiler is about 50 T/hr of
superheated steam at a
pressure of 170 bar and at a
temperature of 500 oC.
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La-Mont boiler
Small diameter tubes are

used, so that high heat
transfer rate is
maintained.
The multiple tubes circuit
gives flexibility for
suitable location of heat
transfer equipment.
A high evaporation rate is
achieved in this boiler
due to forced circulation
of water.
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Benson Boiler
Capacity 150 T/hr at a pressure of 200
bar and at a temperature of 650 oC.
This boiler has a unique characteristic
of absence of steam separating drum.
The entire process of heating, steam
generation and superheating is done in
a single continuous tube.
Economiser
The feed water by means of the feed
pump is circulated through the
economiser tubes.
Hot flue gases pass over the economiser
tubes and the feed water is preheated
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Benson boiler
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Benson boiler
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Benson boiler
Salient features of Benson Boiler

As there are no drums, the total weight of benson bolier is 20%
less than other boilers. This also reduces the cost of the boilers.
As no drums are required, the transfer of the Benson parts is
easy. Majority of the parts may be carried to the site without
pre-assembly.
Since no drum is used, this is an once-through boiler and the
feed water entering at one end is discharged as superheated
steam at the other end.
4Circulating pump and down comers are dispensed with.
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Loeffler Boiler
Capacity 100 T/hr Pressure 140
bar. T= 500 oC
Water is heated solely by the
superheated steam
Furnace heat is supplied to
economizer and super heater
only.
This boiler can carry higher salt
concentration.
More compact than any
indirectly heated boilers having
natural circulation.
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Loeffler boiler
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Velox Boiler
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Boiler Performance
Evaporative capacity can be expressed in terms of:
kg of steam/hr
kg of hour/hr/m of heating surfacecs
kg of steam/kg of fuel fired
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Boiler Efficiency
Combustion Efficiency
indicates a burners ability to burn fuel measured by unburned
fuel and excess air in the exhaust.
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boiler efficiency
Thermal Efficiency
indicates the heat exchangers effectiveness to transfer heat from
the combustion process to the water or steam in the boiler,
exclusive radiation and convection losses
Fuel to Fluid Efficiency
indicates the overall efficiency of the boiler inclusive thermal
efficiency of the heat exchanger, radiation and convection losses output divided by input.
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Heat Provided by Fuel

Gross Calorific Value
This is the theoretical total of the energy in the fuel. The gross
calorific value of the fuel includes the energy used for
evaporating the water in the combustion process. The flue gases
from boilers are in general not condensed. The actual amount of
heat available to the boiler plant is therefore reduced.
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Net calorific value

This is the calorific value of the fuel, excluding the energy in the
water vapour discharged to the stack in the combustion process.
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Calorific value of Fuel

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Bituminous coal
17- 23
Butane
49
Carbon
34
Charcoal
29
Coal (Lignite - Anthrasite) 15- 27
Coke
28- 31
Diesel
42
Ethanol
30
Kerosone
35
Lignite
16
Methane
55
Petrol
44
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Green Boiler Technology

98% thermal efficiency
Environmentally Friendly, Ultra-Low NOx
Less than 20ppm NOx (standard)
Less than 10ppm NOx (optional)
Thoughtful Design Reflects Lessons Learned in the Field
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Excess air
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Energy Performance Assessment of Boilers

Evaporation rate
Quantity of water evaporated in steam per hour expressed in
kg of steam/hour
kg of stem/hr/m2 of heating surface area
kg of stem/hr/m3 of heating surface volume
Kg of stem/hr/kg of fuel burnt
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Equivalent Evaporation
Equivalent of evaporation of one kg of water at 100 oC at
standard atmospheric pressure of 101.3 kPa. Hence, equivalent
evaporation of 1 kg of water needs 2257 kJ of energy.

=
2257
Ms = kg of steam/kg of fuel
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Factor of Evaporation
Ratio of heat absorbed by 1 kg of feed water under working
conditions to that absorbed by 1 kg of water from and at 100 oC
and 101.3 kPa pressure.

=
2257
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Boiler Efficiency
Ratio of heat energy utilized by feed water for steam formation to
the generation of heat energy supplied by fuel.
Ma mass of steam/h
Mf mass of fuel/h
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Heat Loss in Boilers

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Hot flue gases

Radiation from furnace
Incomplete combustion
Presence of moisture in fuel
Unburnt fuel going to ash pit
Boiler design
Properties and characteristics of fuel
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Boiler Power
ASME has recommended a unit called boiler power which may be
used to measure the capacity of boiler.
=
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21.296
100
"
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Numerical #1
Calculate the equivalent evaporation and efficiency of the boiler for
the following data:
Pressure of steam
900 kPa
Quality
0.9
Quantity of steam
5000 kg/h
Feed water temperature
30 oC
Coal consumption
700 kg/h
C.V. of coal
31.4 MJ/kg
What will be the saving in coal consumption per hour if the by putting
an economizers the temperature of feed water is raised to 95 oC and
other data remains the same except the boiler efficiency by 5%.
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Numerical #2
A boiler generates steam at 1.6 MPa pressure and 320 oC
temperature. The feed water temperature is 60 oC. The
calorific value of fuel fired in the boiler is 46.8 MJ/kg. the
ultimate analysis of fuel gives C=85% and H2=15%. Calculate:
minimum quantity of air required for complete combustion
of the fuel
Gross Calorific value of fuel
overall efficiency of boiler if the steam produced is 13 kg/kg
of fuel fired.
Latent heat of water vaour in the flue gases may be assumed
as 2510 kJ/kg.
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Boiler Trial
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To determine the efficiency of boiler.

To estimate evaporative capacity of boiler.
To draw up the heat balance sheet of the boiler.
CV OF Fuel
Heat utilized for steam raising
Heat carried away by flue dry gases
Heat carried away by the moisture
Heat to surrounding air and unburnt fuel
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Numerical #3
During the boiler trial following data were obtained:
Coal analysis dry: C=85.2%, H=4.8%, ash = 10%, GCV of dry coal
35 MJ/kg; moisture content 1.8%; coal consumption 1450 kg/h;
Boiler room temperature 25 oC; feed water temperature 55 oC;
steam pressure 1.2 MPa, steam temperature 250 oC; steam
raised 12500 kg/h; Analysis of dry flue gases by volume of
gases: CO2 =9.4%, O2 =11.1%, N2= 79.5%. The temperature of
gases in the uptake was 300 oC. Mean specific of dry gases
1.005 kJ/kg.
Prepare a complete balance sheet per kg of dry coal.
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boiler trial
Steam generated per kg of coal
Heat supplied per kg of coal
=> ?
9:
;
<=
kg/kg of coal
@@ ?"> A?"
Minimum air required per kg of dry coal

Excess air
Mass of flue gases = air + fuel (0.9)
Mass of water in products = H2 conversion + moisture
Mass of dry gas
Mass of dry gasses excluding excess air
Heat Loss in dry products
Heat loss in excess air
Heat loss in vapour in flue gases
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boiler trial
Heat supplied by coal
Heat in steam
Heat in dry products
Heat in vapour and gas
Heat in excess air
Heat unaccounted
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DRAUGHT
Small pressure difference causing flow of air and gases
through the boiler.
It is essential to supply a sufficient quantity of air for
combustion and to remove the product of combustion.
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Type of Draught
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Natural
Artificial
Steam Jet
Induced
Forced
Mechanical Jet
Induced
Forced
Forced
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Natural Draught
Difference between the pressure of column of hot gases in
chimney or stack and equal column if cold outside air.
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draught
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+ CD = CD
2ED + CD =ED O
GH
=F
I
0.287 273
=F
= 0.7734 F@
101.3
0.287 HN
HN
=F
=F
101.3
353
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Calculation of Chimney Height and Cross-section

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Volume of air at NTP=
GH
= 0.7734 F@
HN
Volume per kg of air at HN = 0.7734
273
HN
Volume m kg of air at HN =0.7734
F
273
H
Volume 1+m kg of air at H =0.7734
F+1
273
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calculation of chimney height and cross-section

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HN
Volume m kg of air at HN =0.7734
F
273
; < O
273 F
PN =
0.7734 F HN
273
PN = 1.293
HN
353
PN =
HN
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calculation of chimney height and cross-section
; < O : F
273 F + 1
<Q ; ;P =
0.7734 F H
F + 1 273
F + 1 353
P = 1.293
=
F
H
F
H
For the chimney height H pressure drop
= QE PN P
1 F+1 1
= 353QE
HN
F H
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Height of Hot gases Column

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E =
P Q
1 F+1 1
F H
HN
E = 353QE
F + 1 353
.
.Q
HN
F
F H
E =E
1
F + 1 HN
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Cross Section Area of Chimney

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2Q E E
E
1
E
= 4.43 E
S
=T E
K = 1.1 for steel chimney and 0.825 for brick chimney
E
1.1 = 4.3 1
E
S
E
18.4
=
E
19.6
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Artificial draught
Advantages
Capable of consuming low grade fuel
Increase in evaporative power of boiler
Easy control of combustion and evaporation
Reduction of chimney height
Prevention of smoke
Improved efficiency
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Draft
Induced Draft Fan type
Forced Draft Fan Type
Advantages of forced draft over induced draft
Small fan size
No water cooled bearing
Less leakage
No heat loss
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THE END
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Chimney Efficiency
Ratio of the energy equivalent of draught produced by the fan
and the additional heat carried away by the gases in natural
draught system.
UVWXYZ[\ =
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E
:] H H ,
103

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Boilers

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Boiler is an gadget to produce steam

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

IBR Steam Boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Fire Tube Boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Fire Tube Boilers

Water Tube Boilers

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Merits of water tube boiler over fire tube boiler

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

merits of water tube boiler over fire tube boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Advantages of Fire Tube Boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Classification of water tube boilers

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

classification of water tube boilers

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

classification of water tube boilers

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Small combustion space and high heat release rate

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Fluidized Bed Boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Construction of Lancashire Boiler

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Features of Lankashire Boiler

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

High steam low water safety valve

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016

Prof. Ravi Kumar, Department of Mechanical & Industrial Engineering

February 16, 2016