A NOTE ON

Chapter 1:
BOILER OR
STEAM
GENERATORS

Prepared by-
Ms. Suni Pegu,
Lecturer, Mechanical Engg. Deptt.,
H.R.H The P.O.W.I.E.T, Jorhat, Assam
(i) DEFINITION OF A BOILER

A boiler, also called as steam generator may be defined as a closed pressure

vessel in which steam is produced from water by combustion of fuel at a pressure
higher than atmospheric pressure.
▪ The steam generated is employed for the following purposes:
(i) For generating power in steam engines, steam turbines.
(ii) In textile industries for sizing & bleaching etc and many other industries like
sugar mills, chemical industries etc.
(iii) For heating the buildings in cold weather and for producing hot water for hot
water supply.

(ii) CLASSIFICATION OF A BOILERS

Boilers are classified on the basis of the following: -

i. Nature of use: According to nature of use, boilers are classified as stationary
boilers, locomotive boilers and marine boilers. For generation of thermal power
and for process work (in chemical, sugar and textile industries), boilers used are
called stationary boilers. Boilers used in locomotive steam engines are called
locomotive boilers. Boilers used in steam ships are called marine boilers. Babcock
& Wilcox boiler is a stationary boiler.

ii. Relative positions of water and flue gases in boiler: According to the relative
positions of water and flue gases, boilers are classified as fire tube boilers and
water tube boilers.

In the fire tube boilers, the hot gases are inside the tubes and the water surrounds
the tubes. Examples are: Cochran, Lancashire and Locomotive boilers. Fire tube
boilers are known as Smoke tube boilers.

In the water tube boilers, the water is inside the tubes and hot gases surround
them. Examples: Babcock and Wilcox, Benson, Stirling, Yarrow boiler etc.

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 iii. Position of the axis of the boiler shell: According to the position of the axis of
the boiler shell, boilers are classified as vertical and horizontal boiler. If the boiler
axis is vertical, it is called vertical boiler. If the boiler axis is horizontal, it is called
horizontal boiler. Cochran boiler is a vertical boiler. Lancashire boiler is a
horizontal boiler.

iv. Position of the furnace: According to the position of furnace, boilers are
classified as internally fired boiler and externally fired boiler. When the boiler
furnace is located inside the boiler, it is called internally fired boiler. When the
boiler furnace is located outside the boiler, it is called externally fired boiler.
Lancashire boiler is an internally fired boiler. Babcock and Wilcox is an externally
fired boiler.

v. Nature of fuels used: According to nature of fuels used, boilers may be solid fuel
fired, gas fired, liquid fuel fired, electrically fired or nuclear fuel fired. Babcock and
Wilcox boilers use solid or gaseous fuel: Volex boiler uses oil fuel.

vi. Nature of circulation: According to nature of circulation, boilers may be of

natural/ free circulation and forced circulation. Lancashire, Cochran, Babcock &
Wilcox boiler are of free circulation boilers. Modern high-pressure boilers like
Benson boiler, La Mont boiler and Lo-effler boiler etc. are of forced circulation
type.

vii. Nature of tubes used: According to the number of tubes, boilers may be classified
as single and multi-tube boiler, depending upon whether the fire tube is one or
more than one. Cornish boiler may be termed as single tubular boiler because it
has only one flue tube. Cochran boiler may be termed as multi tubular boiler
because it has number of flue tubes.

▪ Factors that should be considered while selecting a boiler:

(i) Steam generation rate.
(ii) Floor area available.
(iii) Accessibility for repair and inspection.
(iv) Comparative initial cost.

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 (v) The portable load factor.
(vi) The fuel and water available.
(vii) Operating and maintenance costs.

▪ Essentials of a good steam boiler:

1. It should be capable of quick starting.
2. There should be an easy access to the various parts of the boiler for repairs
and inspection.
3. The boiler components should be transportable without difficulty.
4. The installation of the boiler should be simple.
5. The tubes of the boiler should not accumulate soot or water deposits and
should be sufficiently strong to allow for wear and corrosion.

(iii) DEFINITION OF SIMPLE VERTICAL BOILER

It is a cross tube internally fired natural draught boiler.
Working Principle: It consists of a cylindrical shell, the greater portion of which is
full of water (which surrounds the fire box also) and remaining is the steam space. At
the bottom of the fire box is grate on which fuel is burnt and the ash from it falls in
the ash pit.
The fire box is provided with two cross tubes. This increases the heating surface
and the circulation of water. The cross tubes are fitted inclined. This ensures efficient
circulation of water. At the ends of each cross tube are provided with hand holes to
give access for cleaning these tubes. The combustion gases after heating the water
and thus converting it into steam escape to the atmosphere through the chimney. Man
hole, is provided to clean the interior of the boiler and exterior of the combustion
chamber and chimney.

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(iv) COCHRAN BOILER

Definition: Cochran boiler is a vertical drum axis, natural circulation, natural draft,
low pressure, multi-tubular, solid fuel fired, fire tube boiler with internally fired
furnace. It is the modified form of simple vertical boiler. In this boiler, the fire tubes
are placed horizontally.

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 Construction and working of Cochran boiler:

Fig. Cochran Boiler

The dimensions, working pressure, capacity, heating surface and efficiency are given
below:
Shell diameter……………….. 2.75 m
Height …………………………… 5.79 m
Working pressure ………… 6.5 bar (max. pressure = 15 bar)

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 Steam capacity……………… 3500 kg/hr (max. capacity = 4000 kg/hr)
Heating surface …………….. 120 m2
Efficiency ……………………… 70-75% (depending on the fuel used)

Cochran boiler consists of a cylindrical shell with a dome shaped top where
the space is provided for steam. The furnace is one piece construction and seamless.
Its crown has a hemispherical shape and thus provides maximum volume of space.
The fuel is burnt on the grate and ash is collected and disposed off from the ash pit.
The gases of combustion produced by burning of fuel enter the combustion chamber
through the flue tube and strike against the fire brick lining which directs them to
pass through number of horizontal tubes, being surrounded by water. After which the
gases escape to the atmosphere through smoke box and chimney. A number of hand
holes are provided around the outer shell for cleaning purposes.

The various boiler mountings are (i) Water Level Gauge (ii) Safety Valve
(iii)Steam Stop Valve (iv) Blow off cock (v) Man Hole (vi) Pressure Gauge etc.

The path of the combustion of gases & circulation of water are shown by
arrows in the figure.

(v) LANCASHIRE BOILER

DEFINITION: It is a stationary, fire tube, horizontal straight tube, internally fired,

natural circulation boiler. Its normal working pressure range is up to 15 atm and
evaporative capacity up to approx. 8000 kg/h. The size varies from 7-9 m in length
and 2-3 m in diameter.

▪ CONSTRUCTION AND WORKING

The cylindrical shell contains two tubes called flue tubes which are symmetrical in
dimension and which run parallel to the axis of the shell and are covered with water. The
furnace is placed at the front end of each tube and they are known as furnace tubes. The coal
is introduced through the fire hole into the grate. There is low brickwork Fire Bridge at the

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back of the grate to prevent the entry of the burning coal and ashes into the interior of the
furnace tubes.

The combustion products from the grate pass up to the back end of the furnace tubes
and then in downward direction. Thereafter they move through the bottom channel or
bottom flue up to the front end of the boiler where they are divided and pass up to the side
flues. Now they move along the two side flues and come to the chimney flue from where they
lead to the chimney. To control the flow of hot gases to the chimney, dampers (in the form of
sliding doors) are provided. As a result, the flow of air to the grate can be controlled. The
various mountings used on the boiler are shown in the fig.

Uses: It is commonly used in sugar mills and textile industries.

Fig. Lancashire boiler

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(vi) LOCOMOTIVE BOILER

DEFINITION: It is a multitubular, internally fired boiler. It is manly employed in

locomotives though it may also be used as a stationary boiler. It can raise large
quantity of steam rapidly.

The dimensions and specifications of locomotive boilers are given below:

Barrel diameter……………………….. 2.095 m

Length of the barrel……………..…… 5.206 m
Size of the tubes (super heater)………. 14 cm
No. of super heater tubes…………….. 38
Size of ordinary tubes ………………… 5.72 cm
No. of ordinary tubes ………………… 116
Steam capacity…………………………. 9000 kg/h
Working pressure …………………….. 14 bar
Efficiency ……………………………….. 70%

❖ CONSTRUCTION AND WORKING OF LOCOMOTIVE BOILER

Construction: It consists of a cylindrical barrel with a fire box at one end and smoke
box at the other end. The coal is fed into firebox through fire door. The flue gases
from the grate are deflected by an arch of fire box and thus whole of the fire box is
properly heated. The fire box is entirely surrounded by water except for the fire hole
and ash pit which is situated below the fire box which is fitted with dampers at its
front and back ends. The dampers control the flow of air to the grate. The hot gases
pass from the fire box to smoke box through a series of fire tubes and then they are
discharged into the atmosphere through the chimney. The fire tubes are placed inside
the barrel. Some of these tubes are of larger diameter and some are of smaller
diameter. The super heater tubes are placed inside the fire tubes of larger diameter.

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 ❖ Working: The heat of the hot gases is transmitted into the water through the heating
surface of the fire tubes. The steam generated is collected above the water surface. A
dome shaped chamber known as steam dome is fitted on the upper part of the barrel,
from where the steam flows through a steam pipe into the chamber. The flow of steam
is regulated by means of a regulator. From the chamber, it passes through the super
heater tubes and returns to the superheated chamber from which it is led to the
cylinders through the pipes, one to each cylinder.

Fig. Locomotive boiler

(vii) BABCOCK & WILCOX BOILER

DEFINITION: Babcock and Wilcox boiler, a water-tube boiler, is an example of

horizontal inclined tube boiler. It also a high-pressure boiler.

CONSTRUCTION & WORKING

The particulars (dimensions, capacity etc.) relating to this boiler are given below:
Diameter of drum…………….. 1.22 to 1.83 m
Length ……………………….. 6.096 to 9.144 m
Size of the water tubes ……….. 7.62 to 10.16 m

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 Size of the super heater tubes ……………… 3.84 to 5.71m
Working pressure…………………. 40 bar (max.)
Steaming capacity …………….. 40000 kg/hr (max.)
Efficiency ……………………….. 60 - 80%
Construction: Babcock and Wilcox boiler has a longitudinal drum. It consists of a
drum connected to a series of front end and rear end header by short riser tubes. To
these headers are connected a series of inclined water tubes of solid drawn mild steel.
The angle of inclination of the water tubes to the horizontal is about 15° or more.

Working: Through the fire door, the fuel is supplied to grate where it is burnt. The
hot gases are forced to move upwards between the tubes by baffle plates provided.
The water from the drum flows through the inclined tubes via down take header and
goes back into the shell in the form of water and steam via uptake header. The steam
gets collected in the steam space of the drum. The steam then enters through the anti-
priming pipe and flows in the super-heater tubes where it is further heated and is
finally taken out through the main stop valve and supplied to the Steam turbine or
Steam engine when needed. At the lowest point of the boiler is provided a mud
collector to remove the mud particles through a blow-down-cock.

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 Fig. Babcock & Wilcox Boiler

❖ HIGH PRESSURE BOILERS

In all modern power plants, boilers raising steam at pressures greater than
75 bar are universally used. These are called high pressure boilers.

(viii) LA MONT BOILER

Definition: This boiler works on a forced circulation and the circulation is maintained
by a centrifugal pump, driven by a steam turbine using steam from the boiler. Fig.
below shows a La Mont boiler.
Small diameter tubes are used in evaporating section which gives
flexibility in placing the heat transfer surfaces. The drum may be placed well away
from the furnace. These boilers have been built to generate 45-50 tonnes of
superheated steam per hour at a pressure of 170 bar and 500ᵒC.

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 Working: The feed water from the hot well is supplied to the boiler through the
economiser. A pump circulates the water through the evaporator tubes which in turn
sends a mixture of steam and water to the drum. The steam in the drum is then drawn
through the superheater. The superheated steam so obtained is then supplied to the
prime mover.

(ix) BENSON BOILER

In La Mont boiler, the disadvantage is the formation of bubbles on the inner

surfaces of the tubes. The attached bubbles on tube surfaces reduce the heat transfer
rate and steam generation. Benson in 1922 argued that if the boiler pressure was
raised to critical pressure (225 atm.), the steam and water have the same density and
therefore, the danger of bubble formation can be easily eliminated.

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 This boiler too makes use of forced circulation and uses oil as fuel. Fig. below
shows a benson boiler. This boiler does not use any drum. The feed water is passed
through the economiser and the radiant evaporator where a major part of water is
converted into steam. The remaining water is evaporated by hot gases in the
convective evaporator. The supercritical pressure steam is then passed through the
superheater after which it is supplied to the prime mover.

The maximum pressure and temperature of steam obtained from this

boiler are 500 bar and 650ᵒC respectively, and generating capacity of 150 tonnes/h.

The major difficulty in the operation of this boiler is the

deposition of salt and sediments on the inner surface of water tubes.

Fig. Benson Boiler

BOILER MOUNTINGS AND ACCESSORIES

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 (x) BOILER MOUNTINGS
DEFINITION: Boiler Mountings are different fittings and devices which are necessary
for the operation and safety of a boiler. Usually, these devices are mounted over boiler
shell.

Some are listed below:

i. Water level indicator

ii. Pressure gauge
iii. Safety valve
iv. Blow off cock
v. Feed check valve
vi. Stop valve
vii. Fusible plug

(xi) BOILER ACCESSORIES

DEFINITION: Boiler accessories are those appliances which are installed along with
a boiler to improve the operating condition and overall efficiency of the boiler plant.
Some of the boiler accessories are listed below:
i. Feed pump
ii. Economiser
iii. Super heater
iv. Air preheater

(xii) DIFFERENT BOILER MOUNTINGS ARE:

i. WATER LEVEL INDICATOR: The function of water gauge /water level
indicator is to indicate the water level of the boiler constantly. Each boiler should
be provided with two water gauge in front of it. It consists of three cocks and a
glass tube. The steam cock (SC) keeps the glass tube in connection with steam
space and water cock (WC) puts the glass tube in connection with the water space
in the boiler. The drain cock (C) is used to drain out the water from the glass tube

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 at intervals to ascertain that the steam and water cocks are clear in operation. The
glass is generally protected with a shield.
For the observation of water level in the boiler, the steam and water cocks
are opened and the drain cock is closed. The rectangular passage at the ends of
the glass tube contains two balls. If the glass tube is broken, the balls are carried
along its passage to the ends of the glass tube and flow of water and steam out of
the boiler is prevented.

Fig. Water Level Indicator

ii. PRESSURE GAUGE: It is an apparatus to indicate the pressure of steam in a

boiler. This is also called a steam gauge. The gauge is normally mounted in the
front top of the steam drum. The commonly used pressure gauge is the Bourdon
type pressure gauge. It consists of an elastic metallic tube of elliptical cross-
section bent in the form of circular arc. One end of the tube is fixed and connected
to the steam of the boiler and the other end is connected to a sector wheel through
a link. The sector remains in mesh with a pinion fixed on a spindle. A pointer is
attached to the spindle to read the pressure on a dial gauge.
When high pressure steam enters the elliptical tube, the tube section tends
to become circular, which causes the other end of the tube to move outward. The
movement of the closed end of the tubes is transmitted and magnified by the link

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 and sector. The sector is hinged at a point on the link. The magnitude of the
movement is indicated by the pointer on the dial.

Fig. Pressure Gauge

iii. SAFETY VALVES: The function of a safety valve is to release the excess steam
when the pressure of steam inside the boiler exceeds the rated pressure. A safety
valve is generally mounted on the top of the shell. Every boiler must be fitted with
at least two safety valves.
The various types of safety valves are:
a) Dead weight safety valve
b) Lever safety valve
c) Spring loaded safety valve
d) High steam and low water safety valve.

(a) DEAD WEIGHT SAFETY VALVE: Here, the steam pressure in the upward
direction is balanced by the downward force of dead weights acting on the
valve. It is generally used on low capacity boilers like Lancashire boiler.
The bottom flange is directly connected to seating block on the boiler shell.

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 Fig. Dead weight safety valve
(b) LEVER SAFETY VALVE: When the steam pressure becomes greater than
the normal working pressure, the valve is lifted with the lever and weight.
Consequently, the steam escapes through the passages between the valve
and seat and steam pressure decreases.

Fig. Lever Safety Valve

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 (c) SPRING LOADED SAFETY VALVE: It consists of two separate valves and
seatings having one lever, bearing on the two valves and loaded by a spring,
the spring being placed in between the valves. The tension on the spring
can be adjusted by the nuts. By pulling or raising the lever, the operator
can relieve the pressure from either valve separately, and ascertain it is not
sticking on the seating.
It is used in locomotives and marine engines as spring loaded valve
is unaffected by vibrations.

Fig. Spring Loaded Safety Valve

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 (d) HIGH STEAM AND LOW WATER SAFETY VALVE: It serves two purposes:
i. The steam automatically escapes out when the level of water falls
below a certain level.
ii. It automatically discharges the excess steam when the pressure of
the steam rises above a certain pressure.
It is generally used in Lancashire or Cornish boiler. It cannot be used on mobile
boilers. Fig. below shows the details of Hopkinson’s high steam and low water
safety valve.

It consists of a valve V resting on the valve seat VS and the valve U loaded with
weights W rests on the valve V. Now, when the steam pressure rises above the rated
pressure of the boiler, the valve V is uplifted along with the valve U and the steam
escapes out. Therefore, in case when the steam pressure exceeds the rated pressure,
top valve acts a lever safety valve. F1 is the fulcrum, W1 is the weight suspended on
one end of the lever L1.
Another important arrangement is of lever L2 with fulcrum F2. On one
end is attached to a float E, usually made of tile and on the other end is fixed a balance

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 weight W. when the float E is submersed in water, the lever L2 is balanced about
fulcrum F2. When the water level falls below a certain level, the weight of the float E
increases and it produces a swing towards the right so that the knife edge K lifts the
spindle C which opens the valve U and thus the steam rushes out. This escape of steam
acts as a warning for the boiler attendant as it produces sufficient noise.

iv. BLOW OFF COCK: Its function is to remove periodically the sediments deposited
at the bottom of the boiler while the boiler is in operation and to empty the boiler
while it is to be cleaned or inspected.
It consists of a conical plug fitted accurately into a similar casing. The plug has
a rectangular opening which may be brought into the line of the passage of the
casing by rotating the plug. This causes the water to be discharged from the boiler.
The discharge of water may be stopped by rotating the plug again. The blow off
cock/blow down cock should be opened when the boiler is in operation for quick
forcing out of sediments.

Fig. Blow Off Cock

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 v. FUSIBLE PLUG:
The function of fusible plug is to protect the boiler from being damaged against
overheating caused due to low water level. It is fitted on the fire box crown plate
or over the combustion chamber at its appropriate place.

Fig. Fusible Plug

These plugs have fusible material. So, when the temperature exceeds from certain
limit, the material melts & water will flow into the fire tube & to the grate or it will
take away the heat from fire tube & ultimately heating in the boiler reduces. Water
enters the grate & extinguish the fire & accident is prevented. But the boiler will
shut down. Fusible plug has to be replaced & then we have to restart the boiler.

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 vi. STEAM STOP VALVE OR JUNCTION VALVE
The function of a stop valve (also called main stop valve) or junction valve is to
regulate the flow of steam from one steam pipe to the other or from the boiler to
the steam pipe. A common type of stop valve is shown in Fig. below.

Fig. Stop Valve

It consists of valve V which is attached to the valve spindle VS. The spindle is
connected to hand wheel H and passes through a screwed portion like the nut and
through a gland or stuffing box G to prevent leakage of steam.
On turning the hand wheel H the spindle is raised or lowered depending upon
the sense of rotation of wheel (clockwise for lowering and anti-clockwise for
raising). The passage of steam flow on opening is shown by arrows.

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 vii. BLOW-OFF COCK
 Its function is to remove periodically the sediments deposited at the bottom of the
boiler while the boiler is in operation and to empty the boiler whenever necessary
while it is to be cleaned or inspected. It is fitted on the boiler shell directly or to a
short branch pipe at the lowest part of the water space.
 Fig. below shows a common type of plug.

The plug of the cock is conical and fits into the casing C which is packed with asbestos
packing in grooves round the top and bottom of the plug. A shank of the plug passes
through a gland and stuffing box in the cover. The plug is held down by a yoke and
two studs. There are the vertical slots for fixing the box spanner, on the top of the
yoke. The plug spindle is generally rotated by means of the box spanner.
The plug has a hole. When this hole is brought in line with the casing
hole by rotating the spindle, the water flows out of it. And the water cannot flow when
the solid portion of the plug is infront of the casing hole.

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 viii. FEED CHECK VALVE
 The function of the feed valve is to control the supply of water from the feed
pump to the boiler and to prevent the back flow of water from the boiler to the
pump when the pump pressure is less than the boiler pressure or when the
pump ceases to work.

It is placed in the water space of the boiler slightly below the

normal level of the water.

Fig. below shows a common design of a feed check valve.

Fig. Feed Check Valve

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 It consists of a check valve CV which moves automatically up and down under the
pressure of water on its gun metal seat. FV is the feed check valve which can be raised
or lowered on its gun metal seat, thereby opening the delivery passage and its
opening controls simultaneously lift of the check valve CV. F is the flange which is
bolted to the front end of the boiler shell at a point from which an internally
perforated pipe leads the feed water & distributes it near the working level of the
water in the boiler. The feed check valve CV is operated by the handwheel H to control
the supply of water to the boiler to maintain the water level constant.

(xiii) BOILER ACCESSORIES

Some commonly used accessories are as follows:
(i) FEED PUMPS
The feed pump is a pump which is used to deliver feed water to the boiler. Two
types of pumps are commonly used as feed pumps which are (a) reciprocating
pump and (b) rotary pump.
The reciprocating pump may be of two types:
1. Single acting pump & 2. Double acting pump.
In single acting pump, the water is displaced by one side of the piston only and
so the water is discharged in alternate strokes. In double acting pump, the
water is discharged in each stroke of the piston since the water is displaced by
both sides of the piston.

(ii) ECONOMISER
 Economiser is a plant in which the feed water is pre-heated before it enters into
a boiler, the heat being taken from the waste flue gases of the boiler. It ensures
economy of fuel, hence, it is called economiser.

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 Fig. Economiser
Fig. above shows a Green’s economiser. It consists of a large number of vertical cast iron
pipes which are connected with two horizontal pipes, one at the top and the other at the
bottom. A is the bottom pipe through which the feed water is pumped into the
economiser. The water comes into the top pipe B from the bottom pipe (via vertical
pipes) and finally flows to the boiler. The flue gases move around the pipes in the
direction opposite to the flow of water. Consequently, heat transfer through the surfaces
of the pipes takes place and water is thereby heated.
A blow-off cock is provided at the back end of the vertical pipes to remove
sediments deposited in the bottom boxes. The soot of the flue gases which gets deposited
on the pipes reduces the efficiency of the economiser. To prevent the soot deposit, the
scrapers move up and down to keep the external surface of the pipe clean (for better heat
transfer).

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(xiv) Advantages of installing an Economiser in a Boiler Plant:
The advantages achieved are:
a) Saving of fuel.
b) Increase of evaporative capacity of the boiler.
c) Long life of the boiler.
d) Overall efficiency of the plant is increased.

(iii) Air Preheater

➢ The function of an air pre-heater is to increase the temperature of air
before it enters the boiler furnace.
It is generally placed after the economizer so the flue gases pass
through the economizer and then to the air pre-heater.
There are mainly three main types of air pre-heaters:
1. Tubular type 2. Plate type 3. Storage type.
Fig. below shows a tubular type air-preheater. After leaving the boiler or
economizer, the gaseous products of combustion travel through the inside of the
tubes of air preheater in a direction opposite to that of air travel and transfer some of
their heat to the air to be supplied to the furnace. Baffles are provided across the tubes
to make air follow a zigzag path a number of times to utilize more heat of flue gases.
Thus, the air gets initially heated before being supplied to the furnace. The gases
reverse their direction near the bottom of the air heater & a soot hopper is fitted to
the bottom of air heater casing to collect soot.
In the plate type air preheater, the air absorbs heat from the hot gases being
swept through the heater at high velocity on the opposite side of a plate.
In storage type, the air preheater is divided into two rotating
compartments. The heating surfaces are made up of a series of corrugated sheets
between which the hot flue gases pass upwards on one side and the combustion air
passes down on the other side. Due to the rotation of preheater at a very low speed,
the heater surface comes in contact with combustion air and the cooled surface is

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 again heated by the flue gases. This alternate heating and cooling of heating surface
is called regenerative heating and is more efficient than other types.

Fig. Tubular Air-preheater Fig. Plate type Air-preheater

Fig. Storage type Air-preheater

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 (iv) Superheater
➢ The function of a superheater is to increase the temperature of steam
above its saturation point.
Superheaters are located in the path of the furnace gases so that heat is
recovered by the superheater from the hot gases. Superheaters are used
in steam turbines for electricity generation, steam engines etc.

▪ Types of Superheater
 There are two types of superheaters: -
1. Convective superheater.
2. Radiant superheater.

Convective superheater makes use of heat in flue gases whereas a

radiant superheater is placed in the furnace and wall tubes receives heat from
the burning fuel through radiant process. Fig. below shows a Sugden’s
Superheater installed in a Lancashire boiler.

Fig. Sugden’s Superheater

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 It consists of two steel headers to which are attached solid drawn ‘U’ tubes of
steel. These tubes are arranged in groups of four and one pair of headers generally
carries ten of these groups or total of forty tubes. The steam from the boiler enters
and leaves the headers as shown by the arrows. Fig. also shows how the steam pipes
may be arranged so as to pass the steam through the superheater or direct to the main
steam pipe. When the steam is taken from the boiler direct to the main steam pipe,
the valves C and B are closed and A is opened; when the steam is passes through the
superheater i.e when the superheater is in action, the valve A is closed and valves B
and C are opened.
The path of the gases is controlled by the damper which is operated by
the hand wheel.

(v) Steam Separator

Saturated steam obtained from all types of industrial boilers contains some
water particles which decreases the economy and efficiency of steam engines and
steam turbines. For this, a steam separator is fitted before the steam engine or steam
turbine to separate water particles from steam.
Thus, the function of steam separator is to remove the entrained water
particles from the steam conveyed to the steam engine or turbine.

Fig. Baffle plate steam separator

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 Fig. above shows baffle plate steam separator. The steam enters the flange
A and flows down. In its passage it strikes the baffles B; as a result, it gets deflected,
but water particles having greater density and greater inertia fall to the bottom of the
separator. The drier steam discharges through the flange C. To see the level of water
collected, a water gauge is provided. The water collected in the vessel is removed at
intervals through the drain pipe.

(vi) Steam Trap

The function of a steam trap is to drain away automatically the condensed steam
from the steam pipes, steam jackets and steam separators without permitting any
steam to escape.

Fig. Inverted Bucket Steam Trap

Through the inlet, steam, air and condensate goes into the inverted bucket. If the
inverted bucket is as shown in fig., the valve will be kept open & if it goes up, the valve will be
closed. The opening & closing of valve is operated with the help of lever. As the steam pushes
the bucket upwards, the valve will be closed. Through the vent hole, non-condensable gases
like air, CO2 goes out. Since there is continuous flow of condensate through the inlet, as bucket
is filled with condensate, the bucket goes down & valve is opened. The condensate which
surrounds the bucket will be collected through the outlet.

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