Boiler
Boiler
Boiler
Prepared By :
Brijesh P.Ghadiya
Introduction
The boiler used for power generation is have considerably large capacity and
steam is produced at high pressure to get high efficiency of turbine. The
boiler used for process heating and is generate steam at a lower pressure. It is
generally smaller in size and simpler in design.
Classification of Boilers
(b) Mobile boiler : It is portable boiler and can be easily transported (moved)
from one place to another place. This boiler is used in marine and
locomotive. Example: Locomotive boiler.
(b) Multi-tube boiler : This boiler having two or more fire or water tubes for
the circulation of hot gases or water.
Example : Locomotive, Cochran, Lancashire, Babcock & Wilcox
Water Tube Boiler Over The Fire Tube
Boiler
(1) Cylindrical shell: It is shell in which different parts of the boiler are
enclosed and on which the different mountings are fitted.
(3) Furnace (fire box): It is a chamber formed by the space above the boiler
shell in which combustion take place. It is also called a fire box. This
chamber contains hot gases produced by combustion of fuel.
(4) Fire hole : It is the hole through which coal is added to the furnace.
(5) Ash pit (ash pan): It is the area in which the ash of burnt coal is collected.
(6) Smoke chamber (smoke box): The waste gases are collected here and then
releases to the chimney and then to atmosphere.
(7) Man hole : It is a hole provided on the boiler shell so that a workman can
go inside the boiler for inspection, cleaning and maintenance.
(8) Hand holes : It is a hole provided on the shell to give easy access for the
purpose of cleaning the water tubes or some other internal parts of boiler.
They are also fitted with covers.
(8) Mud box: It collects all impurities present in the water. It is at the bottom
of barrel or shell. This impurities are removed time to time by help of
blow off cock.
(9) Steam collecting pipe (Antipriming pipe): When the steam leaving the
boiler, it contains certain amount of water. Antipriming pipe is used to
separate water particles from the steam and to collect dry steam from
boiler.
Cochran boiler (Vertical multi-tabular
boiler)
Characteristics of boiler: A
vertical, multifire-tube, internally fired,
natural circulated boiler.
Working :
The water is supplied to the boiler through feed check valve and the Coal is
introduced to the grate through the fire door.
The hot gases produced from furnace enters combustion chamber and passes
through horizontal fire tubes.
Heat transfer take place from flue gases to water surrounded the tubes by
convection.
The flue gases coming from of fire tubes enter into smoke box. Finally they
discharge to atmosphere through a chimney.
Disadvantages :
(1) Steam raising capacity is less due to vertical design.
(2) Water along with steam may enter the steam pipe under
heavy loads due to small steam space.
(3) Efficiency is poor in smaller sizes.
Babcock Wilcox Boiler
Characteristics:
Horizontal, Multi-Water
tube, Externally fired,
Natural circulation, High
pressure boiler.
Babcock and Wilcox water tube boiler
Construction:
It consists of inclined water tubes, a steam and water drum, a mud box and
super heater as shown in figure. The drum is connected to up take and down
take header by tubes.
The water tube inclined to the horizontal about 15° or above to bring natural
circulation of water.
The coal is introduced to furnace grate by help of stroker and the damper
control the flow of air into the furnace.
Due to heating the density of water decreases. Low density water moves
upward in water tubes. The water tubes just above furnace is heated
comparatively at a higher temperature than the rest of it. Therefore low density
water gradually converted to steam in their path and rises into the drum through
the uptake header.
Thus a continuous circulation of water from drum to water tubes and water
tubes to drum is maintained due to density difference of water and gravity,
without any pump.
The steam then enters through the antipriming pipe and flows in the super
heater tubes where it is further heated and is finally taken.
Advantages :
(1) The steam generation capacity of the boiler is very high,
about 2000 to 40,000 kg/ hr.
(2) Replacement of defective tubes is easy.
(3) The draught losses as compared to other boilers is minimum.
(4) It is used in power station for generating large quantity of
steam.
(5) Boiler is required less space area compared to fire tube boilers,
and offers greater operational safety.
Lancashire Boiler
Lancashire boiler
Characteristics
• Horizontal, Stationary, Multi-fire tube, Internally fired,
Natural circulation, Medium pressure boiler.
Construction :
It consists of a cylindrical shell and two fire tubes. The cylindrical shell is
placed over the brick structure.
The grates are provided at the front end and inside of two main fire tubes.
Super heater is provided at the end of the main flue tubes in passage of flue
gases. While an economizer is at the end of the side flues, before exhausting
the gases to chimney.
Working :
The coal is introduced to the grate through fire holes. The combustion of coal
takes place in presence of air which is regulated by damper. The combustion will
produce hot gases.
The hot gases from the grate pass to back end of the tubes and then in the
downward direction (FT to BF). They move by the bottom flue to the front of
the boiler where they are divided into two streams and pass into the side flues
(BF to SF). They move along two side flues and enter the chimney and
discharged to atmosphere.
(1) Due to three passes of flue gases, the heating surface area per unit volume of
boiler is large.
(2) The fluctuations in load can be easily met by this boiler due to large
reservoir.
(3) Easy operation, low maintenance costs, easy to clean and inspect.
(4) By use of economiser and super heater, maximum heat of flue gases is
utilized, so efficiency of boiler can be increased.
Disadvantages :
Firebox entirely surrounded by water except for the fire hole and the ash pit
which is situated below the fire box.
The dampers control the flow of air to the grate. The fire box is connected
with smoke box by series of fire tubes.
The fire tubes are placed inside the barrel. Some of these tube are of larger
diameter, in which super heater tubes are placed.
Locomotive
Boiler
Working :
The coal is introduced through the fire hole into the fire box. The hot gases
which are generated due to burning of the coal are deflected by an arch of
fire bricks, so that walls of the fire box may be heated properly.
The hot gases pass from the fire box to the smoke box through a series of
fire tubes and then they are discharged into the atmosphere through the
chimney.
The heat of the hot gases is transferred into the water through the heating
surface of the fire tubes. The steam generated is collected in a dome shaped
chamber above the water surface.
Advantages :
(1) High steam capacity.
(2) Low cost of construction.
(3) Compact and portable.
(4) Good response against fluctuating demands.
Disadvantages :
(1) There are chances of corrosion and scale formation in the water
space due to the accumulation of sediments and the mud particles.
(2) It is difficult to clean some water spaces.
(3) It may be damaged by overheating during overloads.
High pressure boiler
But the steam requirement is above 30 bar pressure and higher rate, the fire tube
boilers will be very bulky and difficult to transport to the site.
Therefore, water tube boiler are generally preferred for high pressure and high
steam generating capacity whereas fire tube boiler for low pressure and low
capacity.
(1) Due to forced circulation of water, evaporative capacity of boiler is increased and
size of drum is reduced.
(2) The tendency of scale formation is eliminated due to high velocity of water through
the tubes.
(3) Smaller diameter tubes are used, which increases heat transfer rate and reduces fuel
consumption.
(4) The cost of foundation, the time of erection and cost are reduced due to less weight
of the tubes used.
(5) Pressurized combustion is used which increases rate of firing of fuel thus increasing
the rate of heat release.
(6) These boilers are compact and hence less floor space is required.
(7) Due to uniform heating of all parts, there is less chances of overheating.
(8) The efficiency of plant is increased up to 40 to 42% by using high pressure and high
temperature steam.
(9) The steam can be raised quickly to meet the variable load.
(10) A very rapid start from cold is possible.
Boiler mountings:
These are different fittings and devices which are necessary for the
operation and safety of a boiler. Normally these device are mounted over
boiler shell.
According to IBR the following mountings should be fitted to the boilers.
(1) Two safety valves (2) Two water level indicators
(3) A pressure gauge (4) A steam stop valve
(5) A feed check valve (6) A blow off cock
(7) Mud holes or sight holes (8) A man hole
(9) An attachment for inspector's test gauge
Boiler Accessories:
These are auxiliary plants or parts required for steam boilers for
their proper operation and increases efficiency of the boiler.
Commonly used boiler accessories are as
(1) Feed pumps
(2) Economizer
(3) Air preheater
(4) Super heater
(5) Steam separator
(6) Steam strap
Boiler mountings
Pressure Gauge:
Construction :
The gauge is usually mounted on the front
top of the shell or the drum. It is designed to
read pressure in kgf/cm2 or bar, above
atmosphere.
The flange of valve body bolted to the boiler at the highest part of steam
space.
It consist of valve seat and nut. The main body of valve is made of cast
iron and valve seat made from Gun metal.
When steam stop valve is placed directly over the boiler and connected to
the steam pipe line is called the Junction valve. If it is placed near to prime
mover than normally called steam stop valve.
Working :
The spindle is rotated by help of a hand wheel. Due to rotation of spindle
the valve move up and down.
When the valve sits over the valve seat, the passage of steam is
completely closed.
The steam passage may be partially or fully opened by moving the valve
up, help of rotating the hand wheel.
Feed Check Valve
Function:
It is used to control the supply
of water to the boiler & to
prevent the escaping of water
from the boiler when the pump
pressure is less or pump is
stopped.
• Construction:
The feed check valve is fitted in the water space of the boiler just below the
normal level of the water.
It consist of non-return valve, water inlet pipe, outlet pipe, spindle, gland and
hand wheel.
outlet pipe of valve connected with boiler and inlet pipe connected with end of
delivery pipe of feed pump.
• Working :
Inlet and outlet pipe of valve is exposes
different pressure. At inlet of valve the feed
pump pressure acts and outlet pipe of valve
the boiler pressure act.
When feed pump is in
operation, the pressure on
the feed pump side (inlet) is
more than pressure on the
boiler side (outlet). This
pressure difference lifts the
non return valve, and allows
water flow into boiler.
Blow-off cock :
Function : The blow-off cock or valve performs the two functions.
(1) To discharge periodically a portion of water which contains mud, scale or
sediments at bottom of boiler vessel while boiler is in operation.
(2) To empty the boiler when necessary for cleaning, inspection and repair.
Working:
Fusible
plug
Working:
In the normal working conditions of the boiler, the fusible plug is fully
submerged under water.
When the water level falls below the fusible plug, the plug gets uncovered
from water. The upper portion of the plug gets exposed to the steam space.
As soon as pressure of steam inside the boiler increases higher than the safe
pressure, safety valve automatically opens and excess steam rushes out into
the atmosphere still pressure drops down to normal value.
Safety valve is generally mounted on the top of the shell. All boiler should have
at least two safety valves.
Construction : A valve is placed upon a valve seat which is fixed upon a long
vertical pipe having a flange at the bottom for fixing at the top of the boiler.
When the steam pressure exceeds the normal limits, this high pressure steam
creates upward force on valve, thus valve lift with its weights and the excess
steam escapes through the pipe to the outside.
• Advantages :
(2) It gives satisfactory operation for low pressure and stationary boilers.
• Disadvantages :
Inside the boiler, a lever L1 is hinged at the fulcrum. One end of lever L2
attached to a float E and other end carries weight W.
Working:
When steam pressure rises
above the normal pressure of
the boiler, the valve V lifted
along with valve U
(hemispherical valve) and
excess steam escapes out.
• one end of the lever a weight is attached and other end is hinged.
• When the pressure exceeds the normal limits, the upward force on the
valve is become higher than the downward thrust on valve due to weight
W on lever.
• Thus the valve lifted from its seat with its weight and excess steam will
come out of the boiler.
Construction:
• It consists of a cast iron body having two branch pipes.
• Two separate valve V are placed over the valve seat as shown in figure.
• In normal condition, the downward force due to spring is higher than upward
force applied by steam.
• When steam pressure exceeds normal limit upward force due to steam
pressure is become higher than downward force due to spring.
• Thus, the valves are lifted from their seats opening the passage for steam to
release out of boiler.
• The spring loaded safety valve is used for stationary as well as mobile boiler
and boiler operation is not affected by vibrations and jerks.
BOILER ACCESSORIES
Rotary pumps
Centrifugal pumps
Pistons of steam and water cylinders are connected by connecting rod and
drive for carrying out the reciprocating movement of piston.
2.Economiser
Function: Economiser increases the temperature of feed water using
waste of heat to flue gases leaving the boiler through chimney.
Construction and working:
Economiser consists of a large number of a vertical cast iron or steel water
pipes located between two horizontal pipes.
Feed water enters into economiser through bottom pipe. From bottom pipe
water is comes into the top pipes through vertical pipes and then comes into
boiler.
The hot flue gases passes over the vertical tubes. And heat transfer take place
from flue gases to cold water in a vertical tubes.
During this soot of flue gases are deposited on the outer surfaces of vertical
tubes which reduces the efficiency of the economiser.
To prevent soot deposition scrapers are provided which move up and down
by chain gear arrangement to clean the vertical tubes.
3.Air Preheater
Function: The function of air preheater increases the temperature of air
before it supply to the furnace using heat from flue gases before passing through
chimney.
Construction and Working
An air preheater is installed between economiser and chimney.
It consists of large number of tubes which arranged in the path of flue gases
shell and hot gases passes through tubes.
Hot flue gases enters into tubes from the top of shell and leaves from the
bottom to the chimney. The inlet air at room temperature is admitted into shell
at the lower end with the help of fan.
The air passes around the tubes in the opposite direction to the flow of hot
gases.
Baffles are provided inside the air preheater, this increases the total path
length of air and thus increases heat transfer.
Soot hoppers are provided to collect soot during cleaning operation of the
tubes.
4.Superheater
Function:The function of super heater is to increase the temperature of the
steam above its saturation point.
Construction and Working:
This super heater consists of a set of super heater tubes in form of U-tubes
and two headers.
The set of U tubes is connected with main steam pipes through headers and
U-tubes placed in the path of flue gases.
The amount of hot gases passed over the super heater tubes should be in
proportion to the steam passing through tubes and degree of superheat
required.
The degree of superheat is controlled by the damper with the help of hand
wheel.
When valve v1 and v2 are opened, valve v3 closed, steam is passed through
the superheater. so superheater is in action.
But when superheating is not required, the valves v1 and v2 closed and valve
v3 is opened, the steam is passed from boiler drum to main steam pipe no
superheating takes place
5.Steam Separator
Function: It removes the suspended water particles from the steam.
Construction and working
It consists of inlet and outlet steam pipes, baffles and water drain cock.
The steam enters at the inlet pipe A and flows down. In its passage it strikes
with the baffles, as a result it gets deflected, but water particles having
greater density and inertia fall to bottom of the separator.
The dry steam moves up and discharge through outlet pipe B. The water
collected at the bottom of the separator is drain through a drain cock C
periodically.