ME 267: Fundamentals of

Mechanical Engineering
Steam Generator
 A boiler (or steam generator, as it is commonly called) is a closed
vessel in which water, under pressure, is transformed into steam by
the application of heat
In the furnace, the chemical energy in the fuel is converted into heat,
and it is the function of the boiler to transfer this heat to the water in
the most efficient manner
Open vessels, generating steam at atmospheric pressure are not
considered to be boiler

ME 267
Department of Mechanical Engineering, BUET
 1. Simplicity in construction, materials conductive to low maintenance
cost, high efficiency, and high availability
2. Design and construction to accommodate expansion and contraction
properties of materials
3. Adequate steam and water space, delivery of clean steam, and good
water circulation
4. A furnace setting conducive to efficient combustion and maximum
rate of heat transfer
5. Responsiveness to sudden demands and upset conditions
6. Accessibility for cleaning and repair
7. A factor of safety that meets code requirement

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Department of Mechanical Engineering, BUET
 1. Electric power generation
2. Heating
o Space heating
o Hot water supply
3. Industrial Processes
Sugar mills
Chemical industry
Paper Industry
4. Marine Application

ME 267
Department of Mechanical Engineering, BUET
 The boiler must be conservatively designed to ensure reliable
performance over the life of the plant
The term boiler setting was applied originally to the brick walls
enclosing the furnace and heating surface of the boiler. As the
demand grew for larger-capacity steam generating units, the brick
walls gave way to air-cooled refractory walls and then to water-cooled
tube walls
A boiler should be designed to absorb the maximum amount of heat
released in the process of combustion. This heat is transmitted to the
boiler by radiation, conduction, and convection, the percentage of
each depending on the boiler design

ME 267
Department of Mechanical Engineering, BUET
 More emphasis is being placed on flexibility, boiler availability, safety,
efficiency of the fuel-burning equipment, and efficiency of the heat
transferred
The newer boilers are designed to be fully automated; their design
also must take into account the environmental control equipment that
is mandatory under regulations
Many boilers are designed to burn multiple fuels in order to take
advantage of the fuel most economically available

ME 267
Department of Mechanical Engineering, BUET
 Boiling: After the boiling temperature is reached (e.g., 212F at an
atmospheric pressure of 14.7 psia), instead of the water temperature
increasing, the heat energy from the fuel results in a change of phase
from a liquid to a gaseous state, i.e., from water to steam. A steam-
generating system, called a boiler, provides a continuous process for
this conversion
Circulation: For most boiler or steam generator designs, water and
steam flow through tubes(water tube boiler). In order for a boiler to
generate steam continuously, water must circulate through the tubes.
Two methods are commonly used: (1) natural or thermal circulation
and (2) forced or pumped circulation

ME 267
Department of Mechanical Engineering, BUET
 For a natural circulation system The fluid flow is induced by the
difference in the specific weight of the water and the average specific
weight of the water steam mixture
The total circulation rate depends on four major factors:
1. Height of boiler
2. Operating pressure
3. Heat input
4. Free-flow area
For a forced circulation system a pump is added to the flow loop, and the
pressure difference created by the pump controls the water flow rate.
These circulation systems generally are used where the boilers are
designed to operate near or above the critical pressure of 3206 psia

ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
 Steam-water separation:

The steam-water mixture is separated in the steam drum. In small,

low-pressure boilers, this separation can be accomplished easily
with a large drum that is approximately half full of water and having
natural gravity steam-water separation
In todays high-capacity, high-pressure units, mechanical
steamwater separators are needed to economically provide
moisture-free steam from the steam drum

ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
 Products of combustion pass through
tubes that are surrounded by water
They may be either internally fired or
externally fired
Internally fired boilers are those in
which the grate and combustion
chamber are enclosed within the
boiler shell
Externally fired boilers are those in
which the setting, including furnace
and grates, is separate and distinct
from the boiler shell

ME 267
Department of Mechanical Engineering, BUET
 Fire-tube boilers are further classified as vertical tubular or horizontal
tubular

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Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
 The products of combustion (called
flue gas) pass around tubes containing
water.
The tubes are interconnected
to common water channels and to the
steam outlet.
For some boilers, baffles to direct
the flue gas flow are not required.
For others, baffles are installed in
the tube bank to direct the flue gas
across the heating surfaces and to
obtain maximum heat absorption.

ME 267
Department of Mechanical Engineering, BUET
 Advantages: Disadvantages:
Compactness Use of high voltage
No emissions High power costs
No stack requirements Availability, if it must be used
Quiet operation during other than off-peak
Low maintenance periods
Safety of operation Initial Cost
Absence of fuel storage
tanks
Ability to use electric power
during off-peak periods
Responsiveness to demand.

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Department of Mechanical Engineering, BUET
 Comparison is made based on the following points

Contents in the Tube

Capacity: 28,000 lb/h, 200,000 lb/h
Steam pressure: 24.5 bar, 165 bar
Efficiency: around 70%, > 90%
Initial and Operating cost.
Compactness & floor space.
Circulation & Response to changes in demand.
Maintenance
Temperature Limit

ME 267
Department of Mechanical Engineering, BUET
 These are the devices which are used as integral parts of a boiler and
help in running efficiently.

Feed Pump
Super-heater
Economizer
Air Pre-heater

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Department of Mechanical Engineering, BUET
 A boiler feed pump that transfers feedwater from the feedwater
heaters to the economizer or the boiler steam drum.

Boiler feed pumps are of the centrifugal pump.

Boiler feed pumps wear and must be overhauled at regular intervals to
ensure continuous operation.
The pressure of steam inside a boiler is high. So the pressure of feed
water has to be increased proportionately before it is made to enter the
boiler. Generally, the pressure of feed water is 20% more than that in the
boiler.

ME 267
Department of Mechanical Engineering, BUET
 The function of the superheater is to increase the temperature of
saturated steam without raising its pressure.
Placed in the path of hot flue gases from the furnace.

ME 267
Department of Mechanical Engineering, BUET
 An economizer is a heat exchanger located in the gas passage
between the boiler and the stack, designed to recover some of the heat
from the products of combustion.
Located after the superheater and the reheater and it increases the
temperature of the water entering the steam drum.
Consists of a series of tubes through which water flows on its way to
the boiler.
It may be-
Parallel flow: The flue gas and water flow in the same direction.
Counter flow: The flue gas and water flow in the opposite
direction.
Combination of the two.

ME 267
Department of Mechanical Engineering, BUET
 An air preheater is used to recover heat from the exhaust flue gases.
Installed between the economizer and chimney.
Air required for the purpose of combustion is drawn through the air
preheater where its temperature is raised.
Advantages-
Gives higher furnace temperature more heat transfer increase
steam raising capacity of boiler.
Uses the lost heat and thus increase the efficiency around 2-10%.
Better combustion with less soot, smoke and ash.
Gives opportunity to use a low grade fuel.
Disadvantages-
Air preheaters increase the efficiency, this increase must be
evaluated against the added cost of installation, operation, and
maintenance

ME 267
Department of Mechanical Engineering, BUET
 Air preheater (or air heater) consists of plates or tubes
having hot gases on one side and air on the other.
Generally two types- 1. Tubular or recuperative and 2.
Regenerative.
The tubular type consists of a series of tubes through which
the flue gases pass, with air passing around the outside of the
tube.
The regenerative air preheater transfers heat in the flue gas
to the combustion air through heat-transfer surface in a rotor
that turns continuously through the flue gas and airstreams at
slow speeds (1 to 3 rpm).

ME 267
Department of Mechanical Engineering, BUET
ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings

These are the fittings, which are mounted on the boiler for its proper
and safe functioning.

Water Level Indicator

Pressure gauge
Safety valves
Steam stop valve
Blow off cock
Fusible plug
Feed Check valve

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Water Level Indicator

The water level indicator

is needed to ascertain the
water level of a boiler.

Two water level indicators

should be fitted for each
boiler in such a place that
the water level can be
constantly seen.

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Pressure Gauge

Fig.: A Bourden Tube Pressure Gage

A pressure gauge is an instrument by means of which the pressure
exerted inside a vessel can be measured.
There are two types of pressure gauges, one is Bourden tube
pressure gauge and the other is diaphragm type gauge.

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Safety Valve

The safety valve (pressure relief valve) is

used in a boiler to relieve the pressure of
steam when it is above the working pressure.
Its function is to discharge a portion of the
steam from the boiler automatically when the
steam pressure exceeds the normal limit. It is
mounted on the top of the shell.
As per boiler regulation two safety valves are
required to be fitted in each boiler.
Safety valve may be four types-
1. Lever type 2. High Steam and Low water
3. Dead Weight 4. Spring Loaded safety valve
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Department of Mechanical Engineering, BUET
 Boiler Mountings: Fusible Plug

Fitted to the crown

plate of the furnace or the
fire.
Function is to
extinguish the fire in the
furnace when the level of
water in the boiler falls to
an unsafe limit.
Avoids the explosion
which may take place due
to overheating of the
furnace plate.

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Steam Stop Valve

It is the largest valve on

the boiler and, usually,
fitted to the highest part of
the boiler shell.
The function of the stop
valve or junction valve is to
regulate the flow of steam
from the boiler to the main
steam pipe.
To shut off the steam
completely when required.

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Feed Check Valve

It is a non-return valve, fitted to a

screwed spindle to regulate the lift.
It is fitted over the shell slightly
below the normal water level of the
boiler.
Its function is to control the
supply of water to the boiler and to
prevent the escaping of water from
the boiler when the pump pressure
is less or the pump is stopped.
This valve must have its spindle
lifted before the pump is started.

ME 267
Department of Mechanical Engineering, BUET
 Boiler Mountings: Blow off Cock

The principal functions of a blow off cock are-

To empty the boiler whenever required.
To discharge the mud, scale or sediments which are
accumulated at the bottom of the boiler.
The blow off cock is fitted to the bottom of the boiler drum.

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Department of Mechanical Engineering, BUET
 Schematic of A Boiler Plant

ME 267
Department of Mechanical Engineering, BUET
 Boiler Ratings and Performance

Modern Steam Generators are rated in terms of steam

capacity(lbm/h) along with steam outlet pressure and temperature

The figure of merit for operation of a boiler is boiler efficiency
sg
It is the ratio of the energy transferred to or absorbed by the working
fluid in the boiler to the input chemical energy of the fuel
Two ways to calculate boiler efficiency
Direct method:

sg =
total energy added to the working fluid
100
total fuel - input energy

ME 267
Department of Mechanical Engineering, BUET
 Boiler Ratings and Performance

Indirect Method:

HHV of fuel - total losses
= 100
sg HHV of fuel

Six major boiler losses are: DGL, ML, MCAL, ICL, UCL, RL

Self Study: Steam-Water Separation

ME 267
Department of Mechanical Engineering, BUET