BOILER

THEORETICAL OVERVIEW
• CAMP FIRE

• For a long time, camp fire was

the only one utilization
method, which supplies heat
for heating and for cooking
• Heat demands were supplied
with ovens and stoves till the
mid of 18th century
• An energy transfer medium is
needed to deliver generated
heat from the fire place to heat
demand
• Boilers were made for the first
time only for steam generation
PURPOSE OF BOILER

• Heat generation
 FUNCTION OF BOILER
Boiler, as a name suggests, is a device/
equipment to ‘boil’ the fluid
(generally Water).

•Steel tank
•Water
•Fuel
- solid FUEL
- liquid
 COMPONENTS OF BOILERS
1. Feed Pump
2. Boiler shell/Stream
drum – steel plates –
rolled and riveted
3. Combustion chamber –
where fuel burns
4. Concrete/fire bricks
5. Grate/Stoker – cast iron
rods – fuel placed on it
and burnt
6. Furnace – fire box
7. Ash pit
8. Heating surface – water
pipes
 BOILER MOUNTINGS
• Fittings on a boiler to ensure its safe operation
• Integral parts of boilers
BOILER ACCESSORIES
- To increase efficiency
 FUNCTION OF BOILER
• Main purpose of boiler is to heat water and
generate steam
• Steam produced can be used in variety of
purposes like:
 Power generation
 Space heating
 Sterilization
 Water heating
 Dying etc.
POWER GENERATION SPACE HEATING
 DYING
STERILIZATION
WATER HEATING HUMIDIFICATION
 ADVANTAGES
• Initial cost is less
• Installation is easy and quick
• Any type of fuel can be used
• Can be moved and set up quickly

DISADVANTAGES
• Steam rising capacity less due to vertical design
• Poor efficiency with small boilers
• It’s difficult to clean inside
• Large flat surface is needed
 TYPES OF BOILERS

WATER-TUBE BOILER FIRE-TUBE BOILER

 FIRE-TUBE BOILER
• Combustion gasses passes through inside of
tube and water surrounding it.
• Fuel burnt is firebox to produce combustion
gasses
• Hot gasses flowing in firetube heat the water
and produce saturated steam
• Steam rises to highest point of boiler steam
dome where it is collected
 APPLICATIONS
• Operation of steam locomotives
• Small factories and industries
• Home heating system
• Textile industries
• Wood industries
 WATER-TUBE BOILER
• Exact opposite of fire-tube boiler
• Water flowing inside tube is externally heated
by fire
• Fuel is burnt inside furnace creating hot gasses.
• Hot gases surrounds tubes and heats the water
inside the tubes
• The heated water then rises into steam drum
• To make boiler economical exhaust gases are
used to pre-heat the air blown into furnace and
heat the water feed
 APPLICATIONS
• Oil refineries
• Steel mills
• Chemical plants
• Paper mills.
• FAILURES DUE TO CORROSION:
Various corrosion mechanisms contribute to boiler
tube failure. Some are given below:
1_Stress Corrosion Cracking:
It is caused by a combination of metal stress and the
presence of a corrosive
REMEDY: A metallurgical examination of the failed
area is required to confirm the specific type of
cracking.
2_dissolved oxygen:
Oxygen is highly corrosive when present in hot
water. Iron oxide generated by the corrosion can
produce iron deposits in the boiler.
REMEDY:
•Phosphate-based treatments are used
•Use of oxygen scavengers, like catalyzed sodium
sulfite, hydrazine, and organic scavengers are
used
•Demineralizing and Chelant are used
 BURNER

Burner is the area where the air mixes

with your fuel source and combusts
MATERIAL:
Stainless steel

CAUSES OF FAILURE: REMEDY:

 Boiler fuel supply malfunction
 filter gets choked
 Improper air steam ratio
 There could be short circuit in the pumping
system of fuel
 Starting from diesel to heavy oil stopping
from heavy oil to diesel
 Proper air fuel ratio
 AQUASTATS

Senses temperature of water

and control’s burner on the call
of thermostat

CAUSES OF FAILURE: REMEDY:

 Temperature set too low or too high  Adjust temperature

 Water pressure is too high  Relief valve operation
 Sensors not working properly  Replace the sensors
 WATER FEED PUMP:

Feeds the water into the boiler

CAUSES OF FAILURE: REMEDY:

Electrical corrosion Diamond coating mechanical
seals are used
 ECONOMIZER TUBES:

Used to pre-heat the water

CAUSES: REMEDY:
Improve water treatment
oxygen pitting