Laboratory Class of Mechanical

Engineering
Sub. Code: DIPEMING501

Arnab Swarnakar
 Title of the Experiment

Exp.No. 1
Study & sketch of Lancashire,
Cochran, Babcock & Wilcox boiler
DESCRIPTION OF COCHRAN BOILER
Cochran Boiler is a multi-tubular vertical fire tube
boiler having a number of horizontal fire tubes. It
is the modification of a simple vertical boiler
where the heating surface has been increased by
means of a number of fire tubes.
The efficiency of this boiler is much better than
the simple vertical boiler.
COCHRAN BOILER
COCHRAN BOILER LABEL DIAGRAM
 MAIN PARTS OF COCHRAN BOILER
1. Boiler Shell
It is made up of steel plates bent into a cylindrical form
and riveted or welded together. The ends of the shell are
closed by means of endplates. A boiler shell should have
enough capacity to include water and steam.
2. Combustion Chamber
The combustion chamber is the space, usually below the
boiler shell, meant for burning fuel in order to generate
steam from the water contained in the shell.
3. Grate
The grate is a platform, in a combustion chamber, upon which
fuel is burnt. The grate generally consists of cast iron bars that
are spaced apart so that air (required for combustion) can
pass through them. The surface area of the grate, over which
the fire takes place, is called the grate surface.
 MAIN PARTS OF COCHRAN BOILER
4. Furnace
It is the space, above the grate and below the boiler shell, in
which the fuel is actually burnt. The furnace is also called a
firebox.
5. Fire Tubes
It is a horizontal tube placed between the combustion
chamber. The flue gases from the combustion chamber flow
to the smoke box through the number of fire tubes. These fire
pipes help in the exchange of heat from hot flue gases to
water.
6. Chimney
A chimney is provided at the top of the boiler connected to
the smoke box. The exhaust gases coming out of fire tubes
pass through a smoke box and escape to the atmosphere
through a chimney.
 MAIN PARTS OF COCHRAN BOILER
7. Fire Hole
The fire hole is provided at the bottom of the
combustion chamber to fire the fuel inside the
furnace.
8. Man Hole
A manhole is provided for the cleaning, repairing,
and inspecting of the boiler shell.
9. Flue Pipe
The firebox and the combustion chamber are
connected through a short pipe called flue pipes.
The hot flue gases from the grate insert into the
combustion chamber through the flue pipe.
 WORKING PRINCIPLE OF COCHRAN BOILER
• The coal is placed on the grate through a fire hole.
• Air is entering the chamber through the atmosphere.
• Fuel is sparked through the fire hole.
• Tufted gases flow into the hemisphere’s dome-
shaped partition chamber.
• These flue gases go further into the fire pipe.
• Heat is the interaction of water in gases to fire tubes.
• The steam is collected in the upper part of the shell,
and when necessary pressure is produced, it is
pumped out.
• The flue gases now send Dennis through a firebox
where it releases into the atmosphere.
MOUNTING & ACCESSORIES OF COCHRAN BOILER
1. Water Level Indicator
The water level indicator is an important fitting, which indicates
the water level inside the boiler. It is a safety device, upon
which the safe working of the boiler depends.
2. Pressure Gauge
The pressure gauge is used to measure the pressure of the
steam inside the steam boiler. The pressure gauge is fixed in
front of a steam boiler.
3. Safety Valve
The safety valve is an instrument attached to the steam boiler
for preventing explosions due to excessive internal pressure of
steam. Thus, a safety valve ensures safety to a boiler from being
damaged due to excessive steam pressure.
4. Stop Valve
The function of a stop valve is to control flow within the boiler
and to stop it completely when required.
MOUNTING & ACCESSORIES OF COCHRAN BOILER
5. Blow off Valve
The function of a blow-off valve 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.
6. Feed Check Valve
The function of a feed check valve is to control the flow of
water from the feed pump to the boiler and to prevent the
backflow of water from the boiler to the pump when the
pump pressure is less than the boiler pressure or when the
feed pump ceases to work.
7. Fusible Plug
The function of the fusible plug is to put off the fire in the
furnace of the boiler when the water level falls below an
unsafe level and thus avoids the explosion, which may take
place due to overheating of the tubes and the shell.
 ABOUT LANCASHIRE BOILER
• Lancashire Boiler is a horizontal type and stationary fire
tube boiler. This boiler was invented in the year 1844, by
William Fairbairn.
• This is an internally fired boiler because the furnace uses
to present inside the boiler. This boiler generates low-
pressure steam and it is a natural circulation boiler.
• It has high thermal efficiency of about 80 to 90 percent.
• Lancashire boiler works on the principle of the heat
exchanger. The heat is a transfer from exhaust gases to the
water through convection. It is a natural circulation
boiler which uses natural current to flow the water inside
the boiler.
• It is basically a shell and tube type heat exchanger in which
the exhaust gases flow through the tubes and the water
flows through shell.
LANCASHIRE BOILER
 Parts Of Lancashire Boiler
1. Water Level Indicator
It indicates a level of water in the boiler. It is located in
front of the boiler. There are two water level indicators
are used in boilers.
2. Pressure Gauge
The pressure gauge is adapted to measure the pressure of
the steam inside the boiler. It fixed in front of the boiler.
3. Safety Valve
A safety valve is an important device in the boiler which
ensures safety to a boiler from being damaged due to
excessive steam pressure.
4. Steam Stop Valve
Its purpose is to prevent and allow the flow of steam from
the boiler to the steam pipe.
 Parts Of Lancashire Boiler
5. Feed Check Valve
The function of a feed check valve is to control the
flow of water from the feed pump to the boiler and
to prevent the backflow of the water from the
boiler to the pump.
6. Blow off valve
The function of a blow-off valve is to eliminate
periodically the sediments deposited at the bottom
of the boiler while the boiler is in operation.
7. Man Hole
It is a hole situated on the boiler so that a man can
easily enter the boiler for the purpose of cleaning
and repairing it.
 Parts Of Lancashire Boiler
8. Fusible Plug
The function of the fusible plug is to put-off the
fire in the furnace of the boiler when the water
levels fall below the unsafe level.
9. Grate
The Grate is a floor that is used to burn coal.
10. Fire Door
It is used to burn the fuel inside or outside the
boiler.
11. Ash Pit
The function of the ash pit is to collect fuel ash
after burning the fuel.
 Boiler Mounting & Accessories Of Lancashire Boiler
1. Economizer
In the economizer, heating the feed water does the recovery of heat
in the flue gases. the economizer is placed in the path of the gases.
It improves the overall efficiency of the boiler.
2. Air Pre-heater
The air pre-heater is an accessory that recovers the heat in the
exhaust gases by heating the air supplied to the furnace of the
boiler. It improves the thermal efficiency of the boiler.
3. Super heater
The super heater is an accessory used in superheating steam
generated in boilers. Its main purpose is to raise the temperature of
saturated steam without any change in pressure.
4. Feed Pump
A feed pump is a boiler accessory required to force the feed water
at high pressure into the boiler.
Working Principle of Lancashire Boiler
Lancashire boiler is a shell and tube type, heat exchanger. The
fuel is burned at the grate. The water is pumped into the shell
through the economizer which increases the temperature of
the water. Now the shell is filled with water. The fire tube is
fully immersed in the water. The fuel is charged at the grate
produces exhaust gases.
These flue gases first pass through the fire tubes from one end
to another. This fire tubes transfer 80% to 90% of the heat to
the water. The backward flue gases pass from the bottom
passage where it transfers 8-10% heat to water.
The remaining flue gases pass from the side passage where it
transfers 6-8% of the heat to the water. The brick is the lower
conductor of heat, so work as a heat insulator. The steam
produces in drum shell is taken out from the upper side where
it flows through super heater if required. So the steam
About Babcock & Wilcox Boiler
Babcock And Wilcox Boiler is a stationary water tube boiler.
It consists of the steam-water drum. a short tube connects
the steam water drum with the uptake header and down
header as shown in the figure. A mud box is equipped with
each down space header and the mud collected, is removed.
There is a slow-moving chain on which coal is fed from the
hopper. The firebricks baffle wall deflected the hot gases and
help the hot gases to leave the chimney. The dampers are
used to regulate the draught and are operated by a chain
and a pulley.
The Babcock and Wilcox boiler are also is known
as Longitudinal Drum Boiler or Horizontal Tubes Boiler it is
water tube boiler in water tube boiler water remains inside
the tube and hot gases are remains outside the tubes. This
type of boiler is used to produce high pressure steam.
Label Diagram of Babcock & Wilcox Boiler
 Parts of Babcock & Wilcox Boiler
1. Water Drum
It is a horizontal axis drum containing water and steam. It is connected
by a short tube with an uptake header or riser at the back end.
2. Downtake Header
This is present at the rear end of the boiler and joins the water tubes
to the rear end of the drum. It collects the water from the drum.
3. Uptake Header
It is present at the front end of the boiler and is attached to the front
end of the drum. It transmits the steam from water tubes to the drum.
4. Water Tubes
These are the tubes in which water passes and changes into steam.
The water tubes (10 cm diameter) are inclined to the horizontal and
connect the uptake header to the down take header. Due to its
inclination, the water tubes are not completely filled with water, and
water and steam are easily separated.
 Parts of Babcock & Wilcox Boiler
5. Baffle Plates
The Baffle plates are present within the water tubes. It causes hot gases to move
upwards and downwards and again upwards before leaving the chimney. Baffle
plates are provided to deflect hot flue gases.
6. Fire Door
It is applied to burn solid fuel in the furnace.
7. Grate
It is a platform, in which the solid fuel (coal) is burnt.
8. Mud Box
A mud box is provided with each down take header and the mud, that is settled
down is removed.
9. Feed Check Valve
It is employed to fill water in the drum.
10. Furnace
The furnace is placed under the uptake header. In which the fuel is actually burnt.
11. Dampers
The dampers are operated by a chain that passes over a pulley to the front of a
boiler to regulate the draught.
Boiler Mounting & Accessories of Babcock & Wilcox Boiler
1. Water Level Indicator
It is an important fitting, which indicates the water level inside the
boiler drum to an observer.
2. Pressure Gauge
A pressure gauge is used to measure the pressure of the steam inside
the boiler drum.
3. Safety Valve
This a device attached to the steam chest for preventing explosions
due to excessive internal pressure of steam.
4. Superheater
A superheater is the main part of a steam-generating unit. The
superheater is used to increase the temperature of saturated steam
without raising its pressure.
5. Stop Valve
It is the largest valve on the boiler. It is used to control the flow of
steam from the boiler to the main steam pipe and to shut off the
steam completely when required.
 Working of Babcock & Wilcox Boiler
Coal is fed to the grate through the fire door and is burnt. The hot exhaust gases
expand upward and pass across the left side of the water tubes. The baffles
deflect the flue gases and hence the flue gases travel in a zigzag manner over the
water tubes and along with the superheater. The exhaust gases leave the
atmosphere through the chimney.
The portion of the water tubes, which is just above the furnace, is heated
comparatively to a higher temperature than the rest of it. Water rises into the
drum through the uptake header. Here the steam and water are distributed in
the drum. Steam, which lighter is being collected in the upper part of the drum.
The water from the drum comes down through the down header into the water
tubes.
Continuous circulation of water from the drum to the water tubes and vice versa
is thus maintained. The circulation of water is maintained by convective currents
and is known as “nature circulation”. Steam is taken from the steam space
through tubes to the superheater. Steam is superheated in the superheater.
The boiler is fitted with the necessary mountings for safe operation. The water
level indicator and pressure gauge are attached to the boiler at its left end. The
stop valve and steam safety valve are mounted on the upper side of the drum.
Blow-off cock is provided for the periodical removal of mud and sediments
collected in the mud box.