Babcock and Wilcox Boiler 1

Water Tube and Fire Tube Boiler
1. WATER TUBE BOILER

Babcock and Wilcox boiler
Babcock and Wilcox is a water-tube boiler is an example of horizontal inclined tube boiler it also
a High Pressure Boiler.
Construction: Babcock and Wilcox boiler with 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.
Fig. 01: Babcock and Wilcox Boiler
Working: 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 ant priming pipe and flows in the superheated 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.
The pressure of steam in case of cross drum boiler may be as high as 100 bar and steaming
capacity up to 27000 kg/h.
At the lowest point of the boiler is provided a mud collector to remove the mud particles through
a blow-dawn-cock.
Capacity and Utility
 Evaporative capacity ranges from 20000 to 40000 kg/hr
 Operative pressure ranges from 11.5 to 17.5bar.
 Steam formed from such boilers is primarily used to run steam turbines and generate
electric power.
Salient Aspects:
1. Draught loss is minimum.
2. The replacement of the defective tubes can be made readily.
3. The unit has a capability to quickly cope with high peak loads which are generally needed at
thermal power stations.
4. Inspection can be carried out even when in operation.
2. FIRE TUBE BOILER
Cochran boiler
It is one of the best types of vertical multi-tubular boiler, and has a number of horizontal fire
tubes it also a Low Pressure Boiler.
Construction: 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 is seamless. Its crown has
a hemispherical shape and thus provides maximum volume of space.
Working: The fuel is burnt on the grate and ash is collected and disposed of from ash pit. The
gases of combustion produced by burning of fuel enter the combustion chamber through the flue
tube and strike against 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.
Fig. 02: Cochran Boiler

Specifications:
 Shell diameter 2.75 m
 Height 5.79 m
 Working pressure 6.5 bar (max. pressure = 15 bar)
 Steam capacity 3500 kg/hr (max. capacity = 4000 kg/hr)
 Heating surface 120 m2
 Efficiency 70 to 75% (depending on the fuel used)
Locomotive boiler
Internally fired, horizontal, multi-tubular, natural circulation, artificial draft fire tube type
portable boiler with furnace located in tubes.
Fig.03: Locomotive Boiler

Construction and working
The boiler consists of large number of smaller diameter tubes located in a cylindrical shell along
with a rectangular fire box at one end and a smoke box at the other end. Fuel burn on the inclined
grate and flue gases enter into the tubes because of fire bridge arch.
The flue gases pass through number of tubes. Water is surrounded to the tubes. There is an
exchange of heat between water and flue gases. The water convert into steam and the flue gases
at lower temperature enter into chimney. The steam enters the super heater and the superheated
steam is supplied to the steam engine via steam stop valve. The draft created in above case is of
artificial type.
The chimney of this boiler is very short. As such enough draft cannot be created by chimney.
The draft is obtained by passing the steam exhausted from the engine through a blast-pipe
located in the smoke box. The steam passing through the nozzle above the blast pipe creates
enough suction to draw in the air through the tubes. A circular door is provided at the end of
smoke box for inspection and cleaning.
The rate of steam generation accelerated due to vibrations caused by the movement of the boiler.
The boiler has a very low efficiency and cannot carry high overloads without suffering heavy
damage due to overheating.
Utility/Application
It is a mobile boiler and steam generation rate is higher. The locomotive boiler is so designed
that it is capable of meeting sudden and fluctuating demand of steam, which may be imposed due
to variation in power and speed.
 Uses in railways, road rollers etc.
 Also used in agricultural fields, saw mill plants and stationary power services where
semi- portability is desired.
Advantages
Large rate of evaporation (55to70kg/sec) per sqm of heating surface.
Freedom from brickwork, chimney and special foundations, which reduces the cost of
installation.
Reasonable low cost and compactness makes it ideal for portable unit.
Disadvantages
Incapable of meeting very high overloads because of danger of being damaged due to overheat.
Max. Steam pressure is limited to 20 bars.
Leakage occurs frequently at the place where the tube joins the plate.
Large flat surface needs bracing.
Accumulation of mud particles in water lags cause scale formation.
Comparison between water tube and fire tube boiler
Water Tube Boiler Fire Tube Boiler
Water is inside the tube and flue gases Flue gases inside the tube and water
Surrounded to it. Surrounded to it.
Operating pressure is up to 170-180 bar Operating pressure is up to 25 bar (low and
(high pressure boilers). medium pressure boilers).
Steam generation rate is very high (more Less steam generation rate.
than 3000 kg/hr)
Suitable for power plants. Suitable for small industries.
Chance of explosion is more due to high Chance of explosion is less due to low
steam pressure. Steam pressure.
Provide steam in power plants to develop Provide steam in chemical and
electrical energy. Pharmaceutical industries.
Small chance of scale formation due to More chance of scale formation
flue gases are in shell
Example: Babcock and Wilcox boiler Example: Vertical boiler, locomotive boiler,
Lancashire boiler.

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Water Tube and Fire Tube Boiler

1. WATER TUBE BOILER

Fig. 02: Cochran Boiler

Fig.03: Locomotive Boiler

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