EXPERIMENT 2:

BOILERS
BOILERS ARE DEFINED AS:
 Boiler is a closed vessel in which water or other liquid is heated, steam or vapor is
generated, steam is super-heated, or any combination thereof, under pressure or
vacuum, for use external to itself, by the direct application of energy from the
combustion of fuels, from electricity or nuclear energy.

HOW DOES A BOILER WORK?

 A boiler consists of a furnace in which fuel is burned, surfaces to
transmit heat from the combustion products to the water, and a space
where steam can form and collect.

APPLICATIONS OF A BOILER:
 Boilers are integral in numerous industries, such as railways, ships, thermal power
plants, hotels, offices, and buildings. They find applications in various factories,
including food and beverage, pharmaceuticals, textiles, paper mills, metal
production, and sugar mills. Even in healthcare, boilers play a vital role.

PRIMARY REQUIREMENTS OF A BOILER:

 The boiler should be capable to generate steam at the required pressure and quantity as
quickly as possible with minimum consumption of fuel.
 The initial cost, installation cost and the maintenance cost should be as low as possible.
 The boiler should be light in weight and occupy small surface area.
 The boiler should be able to meet fluctuating demands without pressure fluctuations.
 All the parts of the boiler should be easily approachable for cleaning and inspection.
 The boiler should have minimum joints to avoid leaks which may occur due to expansion
and contractions.
 The water and flue gas velocities should be high for high heat transfer rates with
minimum pressure drop through the system.
 There should be no deposition of mud and foreign materials on the inside surface and
soot deposition on the outer surface of the heat transferring parts.
 TYPE OF BOILER AND CLASSIFICATION OF
BOILER

There are following Boilers Types:

1.According to the position of water and hot gasses

Fire Tube Boiler

Water Tube Boiler
Dissolved Gases in Feed Water and Its Effect

2.According to Axis of Shell

Horizontal Boiler
Vertical Boiler
Small Boiler

3.According to the position of the boiler

External Fired Boiler
Internally Fired Boiler
Pressure Reduction System

4.According to the pressure

Low-Pressure Boiler
High-Pressure Boiler

5. According to the method of circulation

Natural Circulation Boiler
forced Circulation Boiler

6. According to use of boilers

Mobile Boiler
Stationary Boiler
7. According to drums
Single drum Boiler
Multi drum Boiler

8. According to the nature of drought

Forced drought Boiler
Natural drought Boiler

9. According to furnace
Single furnace Boiler
Dual furnace Boiler

10. According to fuel firing

Solid fuel-fired Boiler
Liquid fuel-fired Boiler
Gaseous fuel-fired Boiler
FIRE TUBE BOILER
 WHAT IS A FIRE TUBE BOILER?
 A fire-tube boiler is a type of boiler in which the water or other fluid to be heated
flows through tubes that are surrounded by fire. This is in contrast to a watertube
boiler, in which the fire flows through tubes that are surrounded by water. Fire-tube
boilers are typically used for smaller applications, such as heating homes or
businesses, while water-tube boilers are used for larger applications, such as
generating steam for power plants.

 There are two main types of firetube boilers: horizontal fire-tube boilers and vertical
firetube boilers. Horizontal firetube boilers are the most common type and are
typically used for residential and commercial applications. Vertical fire-tube boilers
are less common but are used in some industrial applications.

WHAT IS THE WORKING PRINCIPLE OF A

FIRE TUBE BOILER?
The working principle of a fire tube boiler is relatively straightforward. In a fire tube boiler,
hot gases pass through a series of tubes that are immersed in water within the boiler shell.
The heat from the gases is transferred through the walls of the tubes to the water, creating
steam.

Here are the key steps in the working principle:

1. Fuel Combustion: The boiler is fueled, typically with coal, wood, or oil. The fuel undergoes
combustion in the furnace, generating hot gases.
2. Gases Flow Through Tubes: The hot gases produced during combustion travel through
the tubes that are submerged in water.
3. Heat Transfer: As the hot gases move through the tubes, heat is transferred from the
gases to the water surrounding the tubes. This heat transfer raises the temperature of the
water and converts it into steam.
4. Steam Generation: The steam produced is collected in the upper part of the boiler, ready
for use in various applications such as power generation or heating.
5. Exhaust: After transferring heat to the water, the cooled gases exit the boiler through the
chimney or stack.
 FIRE TUBE BOILER CONSTRUCTION
 Fire tube boiler consists of a vertical, cylindrical shell, equipped with a firebox in the bottom,
water space in the middle portion,, and steam space in the upper portion.
The fire grate is placed at the bottom of the firebox and coal is fired at the firebox. An ash pit
is located at the bottom of the grate to collect the ash of burnt coal, which is periodically
removed.

 One or more cross tubes are either flanged or riveted to the water space located in the
firebox to increase the heating surface area to improve the water circulation.
A short chimney is connected at the top of the firebox to discharge the waste flue exhaust
gases at some greater height. Manhole and hand holes are provided for cleaning the
interior of the boiler shell and cross tubes.

 The boiler consists of a pressure gauge, water level indicator, safety valve, steam stop
valve, and a manhole as mountings to provide safety and ease of working.

FIRE TUBE BOILER WORKING

 Fuel burns on the grate in the firebox. The resulting hot flue gases are allowed to
pass around the cross tubes.

 The water surrounding the cylindrical firebox also receives heat

by convection and radiation. Thus steam is produced. The water circulation in the
boiler depends on the density difference in water, created by the temperature
difference in water.

TYPES OF FIRE TUBE BOILERS

1. Cornish boiler
2. Lancashire boiler
3. Locomotive boiler
4. Scotch marine boiler
5. Admiralty-type direct tube boiler
6. Horizontal return tubular boiler
7. Immersion fired boiler
8. Vertical fire-tube boiler (Cochran Boiler)
WATER TUBE BOILER
 WHAT IS A WATER TUBE BOILER?
 A watertube boiler is a type of boiler in which water circulates through tubes that
are heated externally by the fire. Fuel is burned inside the furnace, creating hot gas
which boils water in the steam-generating tubes. The heated water/steam mixture
then rises into the steam drum. Here, saturated steam is drawn off the top of the
drum.

 Watertube boilers are typically larger and can handle higher pressure and
temperatures than firetube boilers. They also have a higher thermal efficiency, which
means they can convert a larger amount of fuel into useful energy. Watertube boilers
are used in thermal power plant, industrial facilities, and ships.

WHAT IS THE WORKING PRINCIPLE OF WATER TUBE

BOILER?
 Fuel combustion: The first step is to burn fuel in the furnace. The fuel can be any type of
combustible material, such as coal, oil, or natural gas. The combustion process creates hot
gases, which are the source of heat for the boiler.
 Water heating: The hot gases from the furnace flow through the water tubes, heating the
water inside the tubes. The water tubes are made of a material that can withstand high
temperatures, such as steel or copper. The water is heated until it reaches the boiling point,
at which point it turns into steam.
 Steam separation: The steam rises to the steam drum, where it is separated from the water.
The steam drum is a large vessel that is located at the top of the boiler. The steam is drawn
off from the steam drum for use in various applications.
 Water circulation: The remaining water flows back down to the furnace, where it is reheated
and the process repeats. The water circulation process is driven by the difference in density
between hot water and cold water. Hot water is less dense than cold water, so it rises to the
top of the boiler. This creates a circulation loop, with the hot water rising to the top and the
cold water flowing down to the bottom.
 WATER TUBE BOILER CONSTRUCTION
 Furnace: The furnace is where the fuel is burned to create heat. The heat from the furnace
is transferred to the water in the tubes.

 Water tubes: The water tubes are the channels through which the water flows. The water is
heated by the hot gases that flow around the tubes.

 Steam drum: The steam drum is a large vessel at the top of the boiler where water and
steam are separated. The steam is drawn off from the steam drum for use in various
applications.

 Circulation system: The circulation system is responsible for circulating the water through
the tubes. The circulation system can be natural circulation or forced circulation. In natural
circulation, the water is circulated by the difference in density between hot water and cold
water. In forced circulation, the water is circulated by pumps.

 Safety valves: Safety valves are valves that open to release steam if the pressure gets too
high. This prevents the boiler from exploding.

 Water level indicator: The water level indicator is a device that shows the water level in
the boiler. This is important to ensure that the boiler does not run out of water.

WATER TUBE BOILER WORKING

1. Water is pumped into the boiler from an external source, such as a tank or a water
treatment system.

2. The water flows through a series of tubes, which form the walls of the boiler’s furnace. Fuel,
such as natural gas, coal, or oil, is burned, and the resulting hot gases flow over the tubes.

3. Heat from the combustion gases is transferred to the water inside the tubes, causing it to
heat up and generate steam.

4. The steam rises to the top of the boiler and is collected in a steam drum, where it is
separated from any remaining water.

5. The dry steam is then piped out of the drum and used for energy generation or other
processes.
TYPES OF WATER TUBE BOILER

 DRUM WATER TUBE BOILER

 HORIZONTAL WATER TUBE BOILER (BABCOCK-WILCOX BOILER)
 SUPERHEATER WATER TUBE BOILER
ADVANTAGES OF WATER TUBE BOILERS

Water tube boilers offer a range of advantages over other types of boilers, making them a
preferred choice for various applications. Their key benefits include:

 Enhanced Efficiency: Water tube boilers boast superior efficiency in converting fuel
into usable energy. The direct contact between the combustion gases and the tubes
minimises heat loss, maximising the energy extracted from the fuel.

 Boosted Safety: Water tube boilers are designed with safety in mind. The water-filled
tubes efficiently dissipate heat, preventing overheating and reducing the risk of
explosions or other safety hazards.

 Rapid Steam Generation: Water tube boilers are engineered to generate steam
quickly. The rapid movement of water within the tubes expedites heat transfer,
leading to faster steam production compared to firetube boilers.

 Reduced Sediment Deposition: Water tube boilers typically experience less

sediment buildup than firetube boilers. The high-pressure steam flow within the
tubes helps prevent sediment accumulation, minimising maintenance requirements
and enhancing overall efficiency.

 Versatility and Adaptability: Water tube boilers can be tailored to a wide range of
applications, accommodating various fuel sources and operating pressures. They
can be customised to meet specific steam production requirements, making them
versatile solutions for diverse industrial and commercial needs.

 Long-Term Reliability: Water tube boilers are known for their durability and longevity.
Their robust construction and well-designed components ensure a long lifespan,
minimising downtime and maximising return on investment
Definition of Boiler Mountings and Their Distinction
from Boiler Accessories
Boiler mountings are essential components integrated into a boiler system to ensure its safe
and efficient operation. These mountings serve critical safety and control functions by
regulating various parameters within the boiler. Unlike boiler accessories, which enhance
the overall system’s performance, mountings are primarily concerned with maintaining
safety and operational integrity.

Explanation of Safety and Control Functions

Served by Boiler Mountings:
Boiler mountings play a pivotal role in ensuring the safety of boiler operations and the
personnel working with them. They also contribute to controlling and maintaining optimal
operational conditions. The key safety and control functions of boiler mountings include:

1. Pressure Regulation: Pressure control is crucial to prevent overpressure

situations that could lead to boiler explosions. Safety valves and pressure
gauges are key mountings that address this concern.

2. Water Level Maintenance: Maintaining an appropriate water level within the

boiler is essential to prevent damage due to low water or carryover. Water
level indicators are employed for accurate monitoring.

3. Steam Flow Control:** Proper control of steam flow is necessary for efficient
energy transfer and process operation. Steam stop valves help regulate
steam release to the distribution system.

4. Impurity Removal:Blowdown valves are used to periodically remove

impurities, sediment, and dissolved solids from the boiler water, preventing
scale formation and corrosion.

5. Temperature Monitoring:Monitoring and maintaining the correct temperature

prevents overheating and potential damage to the boiler. Temperature
indicators and controls are part of this function.

6. Emergency Safety Measures:Components like fusible plugs act as last-resort

safety measures by melting at a certain temperature and relieving pressure in
case of excessive heat buildup.
 7. Inspection and Maintenance Access:Manhole covers provide access to the
boiler’s interior for inspection, cleaning, and maintenance purposes.

Overview of Different Types of Boiler Mountings

1. Safety Valves

– Function: Safety valves release excess steam to prevent overpressure and potential
explosions.

– Types: Spring-loaded safety valves, lever safety valves, pilot-operated safety valves.

– Importance: Crucial for maintaining safe pressure levels within the boiler.

2. Water Level Indicator

– Function: Provides a visual indication of the water level inside the boiler, ensuring
proper water supply.

– Types: Gauge glass, magnetic level indicators, electronic sensors.

– Importance: Prevents dry firing and maintains efficient heat transfer.

3. Pressure Gauge

– Function: Measures and displays the pressure inside the boiler, aiding in pressure
regulation.

– Types: Bourdon tube, diaphragm, digital pressure gauges.

– Importance: Essential for monitoring and maintaining safe pressure conditions.

4. Steam Stop Valve

– Function: Controls the release of steam from the boiler to the steam distribution system.
 – Types: Globe valves, gate valves, angle valves.

– Importance: Regulates steam flow and enables safe shutdown.

5. Blowdown Valve

– Function: Releases a portion of boiler water to remove impurities and maintain water
quality.

– Types: Continuous blowdown, intermittent blowdown.

– Importance: Prevents scaling, corrosion, and improves boiler efficiency.

6. Fusible Plug

– Function: Acts as a safety measure by melting and relieving pressure during

overheating conditions.

– Importance: Prevents boiler explosions by releasing pressure in extreme situations.

7. Manhole Cover

– Function: Provides access to the boiler’s interior for inspection, cleaning, and
maintenance.

– Types: Elliptical, rectangular manhole covers.

– Importance: Facilitates routine maintenance and ensures safe access.

What are Boiler Accessories?
The devices which are installed in the boiler for their efficient operation and smooth working are
called Boiler Accessories. A superheater, an economiser, a feed compressor, etc. are some of them. It
should be mentioned that the accessories aid in effectively controlling and operating the boiler.

Economizer
An economizer is a heat exchanger that has been specifically designed to capture the thermal
energy of exhaust flue gases and use it to pre-heat boiler feed water. By improving the boiler's
thermal efficiency, it conserves heat energy and thereby fuel and lowers the running costs of the
boiler.

Construction & Working

Economisers are of two types as (i) External type (ii) Internal type. The flue gases from the boiler are
guided to flow through the external type economiser before escaping through the chimney because
it is built and placed separately from the boiler. A vertical tube external economizer is shown in Fig
5.

Figure 5: Economizer
It is used with boilers that operate at low-pressure levels. Here, a number of cast iron vertical
cylinders are joined to similar headers at the bottom and top. Feed water enters the bottom header
and exits the upper header through the vertical tubes. The feed water flowing inside the tubes is
indirectly heated by the hot flue gases that are guided to travel across the outside surface of the
tubes as they exit the boiler.

Tubular scrapers are installed over the tubes to prevent carbon buildup on the surface. These are
powered by a chain and pulley system, and as they move steadily up and down, they scrape soot off
the tubes' walls, speeding up the rate at which heat is transferred. An internal tube economiser is
fitted inside the boiler and is an integral part of it.

Air Preheater
The purpose of an air preheater is to further utilise the heat contained in flue fumes after they exit an
economizer by preheating air for use in an oil burner or furnace.

Construction & Working

Flue gases travel through tubes on one side of the plate while air passes through the other in this
plate-type, tubular-type, or storage heat exchanger. In the storage variety, a rotor equipped with
mesh or a matrix can instead be placed in the path of the air and flue gases, which allows heat to be
exchanged. A tubular type air-heater is as shown in Fig 6.

Figure 6: Air Pre-heater

Superheater
The purpose of a superheater is to raise vapour temperature above its saturation point. This kind of
thermal exchanger does that. The superheater comes first before the boiler when hot flue fumes exit
the burner. The primary benefit of superheating steam is that it can be used in power plants to
expand steam through a turbine. However, in a processing business, superheating is only necessary
to prevent pipe condensation. As a result, the superheater has limited benefits or uses in the
processing business and is frequently not used, though not always.

Construction & Working

In the steam drum area, water is separated from saturated vapour (at the boiling point), which is then
passed through the superheater tubes. For a specific boiler pressure, the superheater heats vapour
above its saturation temperature. Steam and hot combustion gases are located on opposite sides of
superheater pipelines.

Feed Pump
A feed pump is located close to the furnace and is used to supply the high-pressure boiler with
water. The function of the feed pump is not simply to supply water to the boiler. Rather, because the
boiler operates at high pressure, the feed pump's discharge pressure must be considerably higher
than this to force water into the boiler.

Construction & Working

The feed pump used in the boiler is of two types (i) Reciprocating (ii) Rotary. These two kinds both
use positive displacement to discharge against high pressure. A multistage centrifugal pump is used
as a boiler feed pump because a single-stage centrifugal pump's discharge pressure is insufficient to
surmount the high boiler pressure type.

A multistage centrifugal pump powered by an electrical motor is better suited for stationary low-
pressure boilers used in processing sectors. The impeller of each centrifugal casing in a multistage
centrifugal pump is mounted on a common shaft and driven by an electrical engine. The discharge
from the first stage flows to the second stage, the second stage to the third stage, and so on. The
water pressure rises with each step until it reaches a discharge pressure that is greater than the
internal pressure of the boiler. These compressors operate without interruption and smoothly.
Steam Injector
In order to remove the dissolved oxygen from feed tanks, steam nozzles are used. lowering the
number of compounds needed to scavenge oxygen. Steam injectors are used in maintaining high
and consistent feedwater temperatures in the steam boiler.

Construction & Working

The injector's handle is attached to a shaft at the top. The valve's function is carried out by its lower
extremity. A screw on the bottom portion of the spindle fits into a nut that is a structural component
of the steam cone. The key also verifies the steam cone's movement. The steam pipe, the water pipe
for the water inlet, and the delivery cone, which is where the pressure water exits, are all present.

The steam cone moves up and down with handle movement, and the valve regulates the steam flow
through the steam pipe. the water conduit letting in water. The movement of steam regulates the
passage of water. The steam pressure created by the water flow controls the sliding action of the
steam cone.

The combining cone is used to blend the steam and water. When the combination enters the
delivery cone, pressure energy is created from the mixture's kinetic energy.

Steam Trap
Any steam device must include a steam trap. It is a crucial component of effective steam and
condensate control, retaining steam inside the process to maximise heat utilisation while releasing
condensate and incondensable gases when necessary.

Construction & Working

An inverted bucket serves as the float device for the steam trap, and a linkage links the bucket to the
valve head. The valve shuts when the bucket fills with steam or air and becomes buoyant.
Condensate makes the bucket lose buoyancy and descend, which opens the valve and enables
condensate removal.
 Figure 8: Steam Trap

Steam Separator
A steam separator, sometimes referred to as a moisture separator or steam drier, is a device for
separating water droplets from steam. The steam separator's job is to separate the suspended water
particles carried by the vapour emerging from the boiler. On the main pipeline, it is always installed
as near as feasible to the engine or turbine.

Construction & Working

The dry tubing that makes up the steam separator has two holes at the bottom and numerous holes
at the top. Steam and water are mixed and forced through the upper half of a dry pipe, where
turbulent movement causes the water and steam in the mixture to separate. Water will fall through
the lower holes as steam flows to the steam line.
SOURCE
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