STEAM BOILER

Steam

 The vapor into which

water is converted
when heated,
forming a white mist
of minute water
droplets in the air.
Steam Boiler
A steam boiler is a power generation device,
used for generating steam by applying the heat
energy to water. It is a closed vessel, generally
made of steel, in which water is heated by
some source of heat produced by combustion
of fuel and ultimately to generate steam.
Steam Boiler
Parts of Boiler
 Burner – the burner is the area where the air
mixes with your fuel source and combusts.
 Combustion chamber/firebox – this is the
chamber where the combustion from the burner
heats the heat exchanger; this chamber can
reach temperatures of several hundred degrees.
 Heatexchanger – the heat exchanger allows the
heat from the combustion chamber to heat the
water in the boiler’s tank.
Parts of Boiler
 Aquastats– these components sense the
temperature of the water in your boiler and tell
the burner when to start and stop.
 Expansion tank – the expansion tank is a small
tank off the main boiler that helps protect your
system from excessive pressure.
 Backflow valve – a backflow valve is a safety
device that allows water to flow in a single
direction only.
Parts of Boiler
 Circulator pump – a circulator pump is used with
boilers that use hot water to heat; the circulator
pump pushes the hot water through your system,
allowing it to circulate to the various outlets.
 Supplylines – supply lines are the pipes that deliver
the heated water or steam to the distribution points.
 Return lines – when the water cools, or the steam
cools and changes states back to water, the return
lines bring this water back to the boiler for re-
heating.
Classification of Boiler
 Horizontal, Vertical or Inclined Boiler - if the
axis of the boiler is horizontal, the boiler is
called horizontal, if the axis is vertical, it is
called vertical boiler and if the axis is inclined
it is called as inclined boiler. The parts of
horizontal boiler is can be inspected and
repaired easily but it occupies more space.
The vertical boiler occupies less floor area.
Classification of Boiler
 Stationary, Portable and Marine boilers -
Stationary boilers are used for power plant
steam, for central station utility power plants,
for plant process steam etc. Mobile boilers or
portable boilers include locomotive type, and
other small units for temporary use at sites.
Marine boilers used in ships today are mostly
for auxiliary purposes in vessels that run on
marine diesel engines or diesel electric
propulsion.
Classification of Boiler
 Water Tube and Fire Tube Boilers - In the fire
tube boilers, the hot gases are inside the
tubes and the water surrounds the tubes.
While on the water tube boilers, the water is
inside the tubes and hot gases surround them.
Classification of Boiler
 SingleTube and Multi Tube Boilers - A
single tube boiler is a boiler that has exactly
one tube. While a multi tube boiler, is a boiler
that consist more than one tube boiler. The fire
tube boilers are classified as single tube and
multi-tube boilers, depending upon whether
the fire tube is one or more than one.
Classification of Boiler
 Internally Fired and Externally Fired Boilers
- The boiler is known as externally fired if
the fire is outside the shell and if the furnace
is located inside the shell then it is an
internally fire tube boilers.
Classification of Boiler
 Naturally Circulated and Forced Circulated
Boilers - In forced circulation type of boilers,
the circulation of water is done by a forced
pump. While in natural circulation type of
boilers, circulation of water in the boiler takes
place due to natural convention currents
produced by the application of heat.
Classification of Boiler
 Source of heat (solid fuel, liquid and gaseous
fuel, electrical and nuclear energy) – The
steam boilers may also be classified according
to the source of heat supplied for producing
steam. The source may be combustion of solid,
liquid or gaseous fuel, hot waste gases as by
product of boiler chemical processes, electrical
energy or chemical energy.
Classification of Boiler
 Low pressure, medium pressure and high
pressure boilers - The boiler which produce
steam at pressures of 80 bar and above are
called high pressure boilers. If the boiler has a
working pressure of steam at 20-80 bar, it is
called medium pressure boiler and a boiler
that has a working pressure below 20 bar is
called low pressure boiler.
DIFFERENCE BETWEEN FIRE TUBE
BOILER AND WATER TUBE BOILER
 DIFFERENCE BETWEEN FIRE TUBE
BOILER AND WATER TUBE BOILER
Basis of Comparison Fire Tube Boiler Water Tube Boiler
Position of water and hot Hot gases inside the Water inside the tubes
gases. tubes and water outside and hot gases outside the
the tubes. tubes.
Operating pressure Limited to 25 bar More than 125 bar
Rate of steam generation Lower higher
Suitability Not suitable for large Suitable for large power
power plants plants
Chance of explosion Less due to low pressure More due to high
pressure
Floor space requirement More Less
Difference between fire tube boiler
and water tube boiler
Basis of Comparison Fire Tube Boiler Water Tube Boiler
Cost Less More
Requirement of skill Require less skill for Required more skill and
efficient and economic careful attention efficient
working and economic working
Use For producing steam For producing steam for
power generation as well as
process heating.
Scale deposition & over There are no water tubes, Small deposition of scale
heating no problem of scale will cause over heating &
deposition and less problem bursting of the tubes.
of over heating & bursting
Example Lancashire boiler Babcock boiler
2.2 CONSTRUCTIONAL
FUTURES OF BOILERS
(a) Cochran Boiler
(a) Cochran Boiler
This is a vertical, fire tube boiler commonly used for
small capacity steam generation. It is an improved type of
simple vertical boiler in order to minimize heating surface.
Total heating surface area is 10-25 times the grate area and
the working pressure is up to Kgf/cm2 and steam generating
capacity from 20 Kg/hrs to 3000 Kg/hrs. Boiler has
dimensions ranging from 1 m diameter and 2 m height to 2 m
diameter and 6 meter height.
(a) Cochran Boiler
Working Principle
(a) Cochran Boiler
It is provided with all required mountings as:
 Pressure gauge
 Water level indicator
 Safety valve
 Fusible plug
 Blow off cock
 Steam stop valve
 Feed check valve
(a) Cochran Boiler

This boiler has the following important classification:

 It is a vertical boiler  Steam generation capacity 3000 –
4000 Kg/hr
 It is a multi tube boiler
 Working pressure 7 bar (max 15
 It is a fire tube boiler
bar)
 It is an internally fired boiler
 Efficiency of boiler 70 to 75%
 It is low pressure boiler
 Tube diameter : 6.25 cm (external
 It is a stationary boiler diameter)
 It is a naturally circulated boiler  No of tubes : 165 – 170 numbers
 It is solid or liquid fuel burning  Provided main hole at the top for
boiler cleaning purpose
 Shell diameter : 2.75 m Height : 6  Commonly used for small capacity
m steam generation
(a) Cochran Boiler
Uses of Cochran Boiler

The Cochran boiler was produced by

Cochran & Co. of Annan, Scotland. It is
widely used in marine practice, either fired
directly by coal or oil fuels, or else used for
heat recovery from the exhaust of large
diesel engines. The boiler is a cylindrical
vertical water drum with a hemispherical
domed top.
(b) Lancashire Boiler
(b) Lancashire Boiler
 It is a stationary, fire tube, internally fired, horizontal and
natural circulated boiler. It is where working pressure and
power required are moderate.
 These boilers have a cylindrical shell of 2 m in diameter
and its length varies from 8 m to 10 m. Two fire tubes run
throughout the length of the boiler. Fire tubes are of
diameter less than half the diameter of shell.
 This boiler is mounted on brick work setting with front
end of shell sloping about 1:250 for empty shell.
(b) Lancashire Boiler

The features of this boiler are:

 Its maintenance is easy
 It is suitable where a large reserve of hot water is needed
 Superheated and economizer can be easily incorporate
into the system to improve the efficiency of the boiler.
This boiler is used in sugar mills and textile industries
(b) Lancashire Boiler
It is provided with all required mountings as:
 Pressure gauge
 Water level indicator
 Safety valve
 Fusible plug
 Blow off cock
 Steam stop valve
 Feed check valve
 Combined high steam low water safety valve
 (b) Lancashire Boiler
This boiler has the following important
classification:
 It is a horizontal boiler
 It is a multi tube boiler (two tubes)
 It is a fir tube boiler
 It is an internally fired boiler
 Boiler have cylindrical shell
 It is a stationary boiler
 It is a naturally circulated boiler
 diameter of boiler shell: 1.74 to 2.75
m 
 Length of boiler shell : 7.25 m to 9 m
 Steam generation capacity 8500 Kg/hr
 Working pressure 7 bar to 20 bar
 Efficiency of boiler 65 to 70%
 Tube diameter : 6.25 cm (external
diameter)
 No of tubes : 165 – 170 numbers
 This boiler mounted on brick work
 Chimney is used for smoke
Slop of shell 1:250
(c) Babcock and Wilcox Boiler
(c) Babcock and Wilcox Boiler

 It is a straight tube, stationary type water tube boiler.

This boiler can generate steam at a pressure varying from
11.5 Kgf/cm2 to 17.5 Kgf/cm2. It can generate steam at
the rate from 20,000 Kg/hr to 40,000 Kg/hr.
 It was discovered by George Herman Babcock and
Stephen Wilcox in the year 1967.
(c) Babcock and Wilcox Boiler

It has three main parts:

 Steam and water drum
 Water tubes
 Furnace
(c) Babcock and Wilcox Boiler

Steam and water drum

 Steam and water drum is a long drum
fabricated using small shells riveted
together. End cover plates can be opened
as and when required. Drum is followed
by water tubes which are arranged below
the drum, and connected to one another
and drum through headers.
(c) Babcock and Wilcox Boiler

Water Tubes
 A number of small-diameter steel tubes
are fitted at an angle of 5 to 15 with
the horizontal to promote the water
circulation. These steel tubes are arrange
in the combustion chamber in a zigzag
way so that more surface area of the
tube is exposed to hot gases
(c) Babcock and Wilcox Boiler

Furnace
 The furnace is the place where the fuel
burns. This is situated at the down side
of the water tubes. When the fuel burns,
the flue gases generate. This gases flow
upper side and passes through water
tube, which heat the water and convert
it into steam.
(c) Babcock and Wilcox Boiler
A Babcock and Wilcox boiler fitted with the following
mountings for safe working of the boiler:
 Pressure gauge
 Water level indicator
 Safety valve
 Fusible plug
 Blow off cock
 Steam stop valve
 Feed check valve
(c) Babcock and Wilcox Boiler

Working Principle
(c) Babcock and Wilcox Boiler
This boiler is a large sized boiler and cannot be easily transported from one place to the
other. It is very popular boiler to be used in power station. This boiler has the following
important classification:
 It is a horizontal boiler  Steam generation capacity 40000 Kg/hr
 It is a multi tube boiler  Working pressure up to 40 bar
 It is a water tube boiler  Efficiency of boiler 60 to 80%
 It is an externally fired boiler  Tube inclined at an angle of 15 0C
 It is a stationary boiler  Drum fitted with water up to ⅔ part
 It is a naturally circulated boiler  Boiler drum is made of steel
 It is a medium/high pressure boiler  The Babcock and Wilcox boiler are
generally used to produce high pressure
 Diameter of boiler drum : 1.2 to 1.8 m
steam in power generation industries. The
 Length of boiler shell : 6 m to 9 m high pressure steam so generated is used
to produce electricity.
(d) Locomotive Boiler
(d) Locomotive Boiler
Construction
 Multi tubular barrel containing an envelope of water in
which fire tubes are immersed
 Fire box which has flat side. This forms a combined grate
and combustion chamber. Grate is a platform in the
combustion chamber upon which fuel is burnt.
 Smoke box equipped with a very short chimney. The coal
introduced into the fire box through the fire hole, is burnt
on the grate which slopes downwards towards the front.
The boiler also provides manhole for cleaning purposes
and a large door for excess to the smoke box and tubes for
cleaning.
(d) Locomotive Boiler
Working Principe
(d) Locomotive Boiler
This boiler has the following important classification:
 It is a horizontal boiler
 It is a multi tube boiler
 It is a fire tube boiler
 It is an internally fired boiler
 It is a portable boiler
 It is a naturally circulated boiler
 It is a low pressure boiler
 Size and number of tubes: 14 cm and 38
numbers
 Steam generation capacity: 9000 Kg/hr
 Working pressure: 14 bar
 Maximum steam pressure: 20 bar
 Rate of evaporation: 55 to 70 Kg/s
 Heating surface and grate area: 271 m2
and 4.2 m2
 Dom is provided in which steam regulator
is there
(d) Locomotive Boiler

Application
 Locomotive boilers are mostly used in
railways and marines. The efficiency of this
boiler is very less. It cannot work in heavy-
load conditions because this leads to the
overheating of the boiler and finally gets
damage. They are also used in traction
engines, steam rollers, portable steam
engines, and some other steam road
vehicles.
BOILER MOUNTINGS

These are the different fittings and devices necessary for the operation
and safety of a boiler. These devices are usually mounted on the boiler
shell.
Main Boiler Mountings:
1. Water Level Indicator
2. Pressure Gauge
3. Safety Valve
4. Steam Stop Valve
5. Blow Off Cock
6. Feed Check Valve
7. Fusible Plug
Water Level Indicator
 Water Level Indicator
-It is a safety device, upon which the correct
working of the boiler depends. It shows the level
of water inside the boiler to an observer.

-It consists of three cocks and a glass tube. (1)

Stem Cock keeps the glass tube in connection
with the steam space. (2) Water cock puts the
glass tube in connection with the water in the
boiler. (3) Drain cock is used at frequent intervals
to ascertain that the steam and water cocks are
clear.

-The lower end of this indicator communicates

with water and the upper end with steam in the
boiler.
 Working Principle of Water Level
Indicator
The steam and water cocks are opened and the
drain cock is closed (handles/levers are placed in
a vertical position). The rectangular passage at
the ends of the glass tube contains two ball
valves. In case the glass tube is broken, the two
ball valves are carried along its passages to the
ends of the glass tube. It is to prevent water and
steam to escape out. Then, the glass tube can be
easily replaced by closing the steam and water
cocks and opening the drain cock.
Pressure Gauge
 Pressure Gauge
-It is used to measure the pressure of the
steam inside the boiler. The pressure
gauges generally used are Bourdon tube
type.
-Pressure is continuously monitored so as
to avoid occurrence of over shooting of
boiler pressure.
-It is usually mounted at the front top of
the boiler shell or drum so that attendant
can easily read the pressure reading.
 Pressure Gauge

It consists of an elliptical elastic tube XYZ

bent into an arc of a circle. This bent up tube is
called Bourdon’s tube. One end of the gauge is
fixed and connected to the steam space in the
boiler. The other end is attached by links and pins
to a toothed quadrant. This quadrant meshes with
a small pinion on the central spindle.
 Working Principle of Pressure Gauge

The steam under pressure flows into the tube.

As a result of this increased pressure, the tube
tends to straight itself. Since the tube is encased
in a circular curve, therefore it tends to become
circular instead of straight. With the help of
simple pinion and sector arrangement, the elastic
deformation of the Bourdon tube rotates the
pointer. This pointer moves over a calibrated
scale, which directly gives the gauge pressure.
Safety Valves
-These are the devices attached to the steam chest for preventing
explosions due to excessive internal pressure of steam.
-A steam boiler is usually provided with two safety valves.
-The function of a safety valve is to blow off the steam when the pressure
of steam inside the boiler exceeds the working pressure.
There are four types of safety valves usually used in boilers:
1. Lever safety valve
2. Dead weight safety valve
3. Spring loaded safety valve
4. High steam and low water safety valve
 Lever Safety Valve

A lever safety valve consists of a valve

body with a flange fixed to the steam boiler.
The bronze valve seat is screwed to the body,
and the valve is also made of bronze. The
thrust on the valve is transmitted by the
strut. The guide keeps the lever in a vertical
plane.
When the pressure of steam exceeds the
safe limit, the upward thrust of steam raises
the valve from its seat. This allows the steam
to escape until the pressure falls back to its
normal value. The valve then returns back to
its original position.
Dead Weight Safety Valve
When the steam pressure exceeds the
normal limits, this high-pressure steam
creates upward force on the valve, thus
valve lift with its weights and the excess
steam escapes through the pipe to the
outside.
Weights put to manipulate the
internal pressure in the boiler.
Spring Loaded Safety Valve

This valve consists of a cast iron

body having two branch pipes. Two
valves sit on corresponding valve
seats at the end of the pipes. The
lever is placed over the valves
utilizing two pivots. The lever is held
tight at its position utilizing a
compression spring. One end of this
spring is connected with the lever
while the other end with the body of
the valve.
 Spring Loaded Safety Valve
Under normal conditions, the spring pulls the
lever down. This applies downward force on
valves which is greater than the upward force
applied by steam.
When steam pressure exceeds normal value,
upward force becomes, larger than the
downward force on the valve due to spring. Thus
the valves are lifted from their seats, opening
the passage for steam to release out. The valve
closes due to spring force when the pressure in
the boiler becomes normal.
 High Steam and Low Water
Safety Valve
This valve has a combined safety
arrangement against (a) high steam
pressure in the boiler and (b) low
water level in the boiler.
It consists of lever A which is hung
inside the boiler shell and it is hinged
at point C.
One end of the lever carries a balance
weight and the other end carries an
earthen float immersed in water. The
balance weights are kept in such a way
that the knife-edge of the lever just
touches the projection when the float
just dips into the water. It also consists
of two valves. One is the main valve V1
which rests on its seat. The edge of the
central opening in the valve V1 forms
the seat for the hemispherical valve V2
and the end of the valve rod carries a
weight.
Steam Stop Valve
Steam Stop Valve
-This valve is usually mounted over the boiler drum, in the
steam pipe leading to-the steam turbine/engine, and
between the steam, pipes to stop or regulate the flow of
steam.
-It can be easily operated by rotating the hand wheel which
causes lifting or lowering of spindle, thus causing opening or
closing of valve.
-Steam stop valve generally has main body of cast steel.
Valve, valve seat and nut etc. are of brass.
 Working Principle of Steam Stop
Valve
When the valve sits over
the valve seat, the passage of
steam is completely closed.
The passage may be partially
or fully opened for the flow of
steam by moving the valve up,
rotating the hand wheel.
Blow Off Cock
Blow Off Cock
It is used to:
-blow out sediments, precipitated sludge, loose scale, or other impurities
periodically when the boiler is in operation.
-empty the boiler when necessary for cleaning, repair, and inspection.
-permit a rapid lowering of water level in the boiler if accidentally it
becomes too high.
It is fitted to the bottom of boiler shell. Blow off cock has a plug of conical
type put into the mating casing. Plug position is altered for opening and
closing the flow.
Working of Blow Off Cock

When the plug slot is brought in

line with the flow passage of the
body by rotating the hand wheel,
the water from the boiler comes
out with a great force. If
sediments are to be removed,
the blow off cock is operated
when the boiler is on. This forces
the sediments quickly out of the
boiler.
Feed Check Valve
 Feed Check Valve
-It is a non-return valve at the end of
delivery pipe from feed water pump
and is placed on boiler shell slightly
below normal water level. It has a
check valve whose opening and closing
are regulating by the position of
spindle.
-This valve must have its spindle lifted
before the pump is started.
-Pump pressure acts from below the
non-return valve and boiler pressure
acts from above it.
 Working of Feed Check Valve

Under normal working

conditions, the pump delivery
pressure is higher than the boiler
pressure. So the valve is lifted
from its seat and allows the water
to flow to the boiler. The lift of the
valve is controlled by moving the
spindle up and down with the help
of the hand wheel. Thus, the flow
of water can be controlled.
Fusible Plug
Fusible Plug
-It is a safety device used for preventing the level of water
from going down below a critical point and thus avoids
overheating.
-It is fitted to the crown plate of the fire box.
Fusible Plug

-The construction of the fusible

plug consists of three plugs.
The hollow plug A having
hexagonal flanges is screwed to
the fire box crown plate. The
plug B gunmetal plug is
screwed to the body A. The
third plug C is made up of
copper is locked with metal
like tin or lead which has a low
melting point.
 Working of Fusible Plug
In normal working conditions, water
covers the fusible plug remains cool. In
case the water level falls below the
danger levels, the fusible plug gets
exposed to steam. This overheats the plug
and fusible metal having a low melting
point melts quickly. The opening so made
allows the steam to rush on to the
furnaces and extinguishes the fire or it
gives warning to the boiler attendant that
the crown of furnace is in danger of being
overheated.
BOILER ACCESSORIES
Important accessories fitted to the boiler

Super Heater

Economizer

Feed Pump

Air Pre-Heater

Steam Injector
 Super Heater

The Steam Superheater is

a coil type heat
exchanger which is used to
produce superheated steam or
to convert the wet steam to dry
steam, generated by a boiler.
Superheater
Benefits of Superheaters in Boilers
• Increase in efficiency of the steam power plant
• Minimized erosion of turbine blade
• Less steam consumption
• Reduction of condensation loss in the boiler steam
pipes
• Increases the temperature of saturated steam by
removing entrained water particles from turbines
steam
◼ Radiant Superheater
◼ Convective Superheater
Economizer

Economizers are
mechanical devices
intended to reduce
energy consumption
or perform a useful
function such as
preheating a fluid. In
basic terms, an
economizer is a heat
exchanger.
Economizer
In the boiler system,
as the flue gas exits the
boiler, it enters an
economizer with finned
tubes. The finned tubes
absorb the heat and
raises the temperature
of the boiler feed
water, lowering the
needed energy input.
Feed Pump

Boiler feed pumps

are used to supply
fresh water to a boiler.
Condensation that
forms in the boiler
systems is typically
recycled and fed back
into the boiler with
condensate return
pumps.
Types of Feed Pump
HORIZONTAL INLINE PUMP

VERTICAL INLINE PUMP

Feed water Pump
Air Pre Heater

The function of an air pre

heater is to heat the air
before it is
supplied to the furnace of
the boiler. It is placed near
chimney
and above economizer.
TYPES OF AIR PRE-HEATER
RECUPERATIVE
TYPE AIR
PREHEATER
Tubular air preheater
are known as
Recuperative type of air
preheater. This type of
air preheater are of
totally enclosed
rectangular box type
construction, consisting
of several straight tubes
connecting in two thick
end plates at the top and
bottom.
REGENERATIVE
TYPE OF AIR
PREHEATER
Regenerative type of air
preheater is used in large
capacity boilers due to its
compactness. It is
commonly used in power
plant, the design is permit
a single heat exchanger to
heat both primary air
which dry and transport
coal from coal mills to the
furnace and also secondary
air which is used at furnace
for combustion.
STEAM INJECTOR

In an injector, the water

is delivered to the boiler
by steam pressure, the
kinetic energy of the
steam is used to increase
the pressure and velocity
of the feed water.
 ADVANTAGES AND DISADVANTAGES OF
STEAM INJECTOR

ADVANTAGES: DISADVANTAGES
▪ Low initial cost ▪ Pumping efficiency
is low
▪ Simplicity
▪ Irregularity of
▪ Compactness operation under
▪ Thermal extreme variation in
steam pressure
efficiency very
▪ It cannot force very
high
hot water