To study the model of Lancashire and Babcock & Wilcox Boiler

Boiler- A boiler or steam generator is a device used to create steam by applying heat
energy to water.

Types of Boilers-

Fire Tube Boiler-

In Fire-tube boilers hot flue gases pass through tubes and water surrounds them. These are
operated at low pressures up to 20 bar. It requires more floor area for a given output. Overall
efficiency is up to 75%.

Water Tube Boiler-

In Water-tube boilers water passes through tubes and hot flue gasses surround them. The working
pressure is high enough, up to 250 bar in super critical boilers. It requires less floor area for a
given output. Overall efficiency with an economizer is up to 90%.

Lancashire Boiler:

Construction-
Lancashire Boiler is a stationary, fire tube, internally fired, horizontal and natural circulation
boiler. Lancashire boilers are reliable and bear over load. They are economical within their
operating capacity. However, they are bulky and initially raise steam very slowly. Working
pressure in lancashire boilers are in the range of 0.7 MPa to 2 MPa and efficiency of the boiler is
about 65%–70%. Size of these boilers depends upon size of shell which may be 2 m to 3 m in
diameter and 6m to 10m in length.

Figure: Lancashire Boiler

Cylindrical shell
Lancashire Boiler consists of a horizontal cylindrical shell of 1.75m to 2.75m diameter. Its length
varies from 7.25m to 9m. It is partly filled up with water. The water level inside the shell is
above the furnace tubes.

Dampers
Dampers are fitted at the end of side flues to control the drought (rate of flow of air) and thus
regulate the rate of generation of steam. These dampers are operated by chain passing over a
pulley on the front of the boiler.

Fire Bridge
Fire bridge is provided to prevent fuel from falling over the end of furnace. Fire bridge also helps
in producing a better mixture of air and gases for perfect combustion by partly enveloping the
combustion space.

Grate
The fire grate is provided at one end of the flue tubes on which solid fuel is burnt (where
combustion of coal takes place).

Furnace tubes, bottom flue and side flues

Lancashire Boiler consists of two internal flue tubes having diameter about 0.4 times that of
shell. The flues are built-up of ordinary brick lined with fire bricks. One bottom flue and two side
flues are formed by brick setting, as shown in the figure.

Blow off cock

It is used for removing mud etc. that settles down at the bottom of the boiler, by forcing out some
of the water. It is also used to empty water in the boiler.

Working-
In Lancashire Boiler first coal is fed on the grate where combustion of coal takes place. The Flue
gases pass through the internal flue tubes and then pass downwards. The flue gases travels
through the bottom flue to the front of the boiler. Then they are split up into two steams and flow
through the side flues to the rear end of the boiler. Flue gases then pass through the dampers into
the main flue and are finally discharged through the chimney into the atmosphere. The heat of
flue gases is transferred to the water to generate steam.
Babcock & Wilcox Boiler:
Construction-
It is horizontal, stationary multi-water tube boiler. It consists of a large cylindrical shell made of
steel plates. There is large number of parallel tubes inclined at an angle of 5 O – 15O to the
horizontal. The upper ends of the tubes are enclosed in a chamber known as UPTAKE HEADER
while the lower ends of the tubes are enclosed in another chamber called DOWNTAKE
HEADER. There is an arrangement for the grate below the uptake header. Below the grate there
is an ash pit. Where the ash produced by the combustion of the coal is collected. There are FIRE
BRICK BAFFLES for reflecting the hot gases. First the hot gases rise upward and then go down
and then rise up again and finally escape to the chimney. Thus these hot gases conduct maximum
amount of heat to the water available inside the tubes as maximum surface area of the tubes is
exposed to them. At the lower end of the down take header there is a blow off cock fitted for the
removal of impurities of water from time to time. There is a super heater fitted for super heating
the steam, which increases the efficiency of the boiler. The outer surface of the inclined water
tubes and half of the bottom cylindrical surface of the Drum form the heating surface through
which heat is transferred from the hot gases to the water. The various fittings of this boiler are:
1. Feed Check Valve
2. Pressure gauge
3. Water Level Indicator
4. Safety valve
5. Steam Stop Valve
6. Blow off Cock
7. Fusible Plug
8. Super Heater
These are used in the boiler to increase the temperature of steam above its saturation
temperature. Passing the steam through a small set of inclined tubes and hot gases over them do
this. Super heated steam is absolutely essential for power generation.
 Figure: Babcock & Wilcox Boiler

Working-
Water is fed into the boiler shell through the feed check valve. It goes into the cylindrical
horizontal tube and inclined tubes. The water level gauge indicates the level of water. Coal is
added to the grate and fired. Water in the upper portion of the tubes get heated first and rises up
due to decreased density and passes into the drum when steam and water are separated. Now
cold water from the down take header comes to take the place. In this way natural circulation of
water is carried on by keeping the tubes inclined to an angle of about 15 O to the horizontal.
During the first turn of the super heater becomes super heated steam. Now the super heated
steam coming out through the super heater is supplied through the steam stop valve. The damper
controls the rate of burning and thereby the steam generation. A chain passing through a set of
pulleys operates the damper.
At the end of the down take header, a mud box is connected from where impurities can be
removed. As shown in the sketch, the boiler is provided with two INSPECTION DOORS,
Compared to the fire tube boiler, evaporative capacity, the pressure of steam and thermal
efficiency of the boiler will be higher. It is suitable for small size thermal power plants and other
industrial units.