BOILERS

Prepared By: Mayank Parekh

Boilers
● Steam generators
● Closed vessels
● made of steel
● used for generation of steam
● vaporizing water
●
combustion of fuels
●
eg. coal,coke,oil,wood,saw dust and begesse etc.
● Steam used for producing power,for industrial process work or
for heating proposes.
Requirements of a Perfect Steam Boilers

Should be absolutely reliable,capable of producing maximum steam at required pressure for minimum
of fuel consumption,with minimum attention and minimum initial cost and operating cost.

Simple constructions

Quick starting from cold

Strong enough against temp. stress & strains

Well design combustion chamber

Less floor area, space & light weight

Best gauges,safety valves and other mountings

Easily accessible for inspection,cleaning and repairs

Classification of Steam Boilers

Vertical or Horizontal.
Stationary(Power plant, industrial, central heating and combined
power and heating boilers.),Portable, Locomotive or Marine
Internally Fired or Externally Fired (Lancashire and Locomotive
Boilers)
Solid, Liquid or Gas Fired
Fire(Smoke)Tube: Water is outside the tubes while the hot gases are
inside the tubes eg.Vertical,
Cochran,Lancashire,Cornish,Locomotives,etc) or Water Tube: Contain
a large number of small tubes through which water circulates,the fire
and hot gases being outside of the tubes.eg.Babcock and Wilcox,
Stirling and High pressure Boilers etc.)
Vertical Boilers

Used in small factories,small water supply

plants,cranes,excavators,winch engines in mines and on sites
of temporary nature such as construction work etc.
Required minimum floor space,not required elaborate
foundations,and is portable.
Cheap,easy to start but inefficient due to large wastage of fuel
and less heating surface.
Vertical Boilers are:Simple(having one to three cross tubes),
fire tubes and water tubes types.
Simple Cross tube vertical boiler

consists of a cylindrical shell surrounding a cylindrical fire box.

heating surface is about 8-10 times the grate area.

50% efficiency
Cochran Boiler
 Cochran Boiler

It is well design of a Vertical multitubular fire tube boiler

Improvement over the simple vertical boiler as it provides
greater heating surface.
Total heating surface area is about 10-25 times the grate area
Efficiency 70-75%
Ranges from 1m dia.X2m high,evaporation 20kg/hr to 3m dia
X6m high,evaporation 3000kg/hr.
Lancashire Boiler
Is horizontal smoke tube boiler size range from a
shell 2m diaX6m long to 3m diaX10m long
Working pressure range are up to 20kgf/cm2
Ratio of heating surface to grate area is 24-30
Efficiency is about 56% without economizer and
75% with economizer.
Similar to Cornish boiler,in Lancashire Boiler two
flue tubes but in Cornish boiler only one flue tubes
are there.
Lancashire Boiler
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Second level
● Third level

● Fourth level

● Fifth level
Lancashire Boiler

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● Third level

● Fourth level

● Fifth level
Babcock and Wilcox Boiler

Water tube boiler having lager pressure ranges and larger

sizes.
It is horizontal boiler
It is stationary boiler
It is externally fired
It has natural circulation of water
Three main parts, steam and water drum, water tubes and
furnace.
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Second level
● Third level

● Fourth level

● Fifth level
Stirling Boiler
Example of water tube boiler where bent tube are used instead of
straight tube which are used in Babcock and Wilcox boiler
Water tube boiler

n Water is inside the tube and hot gases are out side the tube
n It is externally fired
n It can well operating on 125 bar steam preesure
n Large number of tubes of smaller diameter
Fire tube boiler
Hot gases are inside the tube and water is out side the tube

It is generally internally fired

It is only worked on 25 bar.

Flue gases passing through the boiler tube

Fire tubes Vs water tubes Boilers

Fire tubes boilers has a large volume of water,therefore more flexible and
can meet the sudden demand of steam without much drop of pressure.
Fire tubes boiler is rigid and of simple mechanical construction, so greater
reliability and low in first cost.
Fire tube boilers can be made in smallest sizes therefore simple to
fabricate and transport, occupies less floor space but more height.
Due to mostly externally fired water tubes boiler so furnace can be altered
considerably to meet the fuel requirements.
Water tubes boilers are more readily accessible for cleaning, inspection
and repairs, compared to the fire tube boilers.
Modern trend is in the favors of water tube boiler due to continuous
increase in capacities and steam pressures.
 Boiler Mountings

Fitting and devices which are necessary for the safety and control are knows as boiler
mountings

Fittings which are essential from the safety point of view are as follows:
Ø Water level indicators
Ø Safety valves
Ø Combined high steam and low water safety valve
Ø Fusible plug
Ø Pressure gauge
Ø Man hole
Ø Blow of cock
Ø Feed check valve
Boiler mounting
n FUSIBLE PLUG
n It prevent bursting of the boiler when water level in the boiler falls
and causing over heating
n It only one mounting is fitted in boiler shell.

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Second level
● Third level

● Fourth level

● Fifth level
Pressure gauge
It is indicate steam pressure in the boiler shell
It is mostly plased on the top of the boiler
It can be fitted in such a way that it can be read from ground.
Water level indicator
It is indicate the water level in the boiler drum.

It is indicate the maximum and minimum level of water in the boiler shell

It is placed on the boiler , one end is placed in the steam space and other end
is placed on water space.
Safety valve
The valve is opened when the steam pressured in the boiler exceeds the set
pressure, the excess steam goes out from the boiler till the pressure is
reached to set pressure.

It is placed on the upper part of the boiler shell.

It’s one end is placed in boiler shell.

Boiler Accessories

Fitting or devices which are provided to increase the

efficiency of the boiler and help in the smooth working of
the plant are knows as boiler accessories.

The important accessories are:

Ø
Super heater
Ø
Economizer
Ø
Feed pump
Ø
Feed water heater
Economizer

It is to increase the temperature of the feed water entering the boiler using
waste heat to increase the boiler efficiency

It is placed after super heater in the boiler plant in the path of hot flue gases.
Feed water heater
It is to use the waste heat carried by the steam to increase boiler economy.

It is placed in line coming from the condenen and entering the feed pump

It is use for generally to warm the water.

Super heater
It is increase the temperature of steam above the saturation point

It is located in the path of furnace hot gases so that heat is recovered by the
steam to super heat it.

It is very important accessories of a boiler.

It can be used in both fire and water tubes boiler.

In small boiler are not commonly provided with the super heater.