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BOILERS

CLASSIFICATION OF BOILERS
Broilers can be classified in to various types based on the following heads.

I. Classification Based on Flow of Water and Hot Gases- (1) fire tube boiler (2) Water tube boiler

Fire tube Boiler In this case, the hot gases produced from combustion of fuel passes through tubes
which are surrounded by water which is to be converted into steam. Example- Vertical, Cochran,
Lancashire and Locomotive boilers.

Water Tube Boilers- In this case, as the name implies, water flows through number of tubes and hot
gases pass around them. Example- Babcock and Wilcox boiler

II. Classification based on Axis of shell-(1) Vertical boiler (2) Horizontal boiler.

Vertical boiler In this type the axis of shell is vertical. Example- Cochran boiler.

Horizontal boiler -In this type, the axis of the shell is horizontal. Example- Lancashire, Locomotive,
Babcock and Wilcox boilers.

III. Classification based on Position of furnace (1) Externally fired boiler (2) Internally fired boiler.

Externally fired boiler - These boilers will have a separate furnace built outside the boiler shell and
usually below it. The horizontal return tube (HRT) boiler is an example of this type.

Internally fired boiler-This is the most common type of boiler in which the furnace forms the integral part
of the boiler itself. Example Cochran locomotive, Babcock and Wilcox boiler.

IV Classification based on Application (1) Stationary boiler (2) Mobile boiler.

Stationary Boiler- It is a one which is installed permanently on the land.

Mobile Boiler- A marine boiler is a typical example for this case, This Marine boiler is meant for ocean
cargo and passenger ship. Another example for mobile boiler is a locomotive boiler.

V Classification based on steam Pressure-(1) Low pressure boiler (2) Medium pressure boiler (3) High
pressure boiler.

VI Classification based on Number of tubes (1) single tube boiler (2) Multi tube boiler.

Single Tube Boiler- It is a case in which only one fire tube or water tube will present. Example
Lancashire, Cochran , Babcock and Wilcox boiler.

Multiple Boiler- In this case, two or more water tube (or) fire tubes are present. Example Lancashire,
Cochran, Babcock and Wilcox boiler.
VII. Classification based on Method of Circulation of Water and Steam (1) Natural circulation boiler, (2)
Forced circulation boiler.

Natural circulation boiler- The boiler, in which circulation of water effected by natural convection
currents, are called as natural circulation boiler. Example Cochran boiler, simple vertical boiler.

Forced Circulation boiler- In this type, the circulation of water is effected by means of a centrifugal
pump. Example La-Mont boiler, Benson boiler.

DESCRIPTION

It is the simplest formof internal furnace, vertical fire tube boiler. Its only advantage is portability and
very small floor area is repuired. Steam rating normally do not exceed 2500 Kg/hr and pressure is
normally limited to about 7.5 to 10 bar.

(i) Cylindrical Shell


It is vertical and attached at the bottom of the fire box. Greater portion of the shell is full of
water which surrounds the box also. Remaining is steam space. The shell may be of about
1.25m diameter and 2m height.

(ii) Stack or Chimney

It passes from the crown of the fire box through the top of shell. Its objective is to carry the
exhaust waste gas to greater height and release it, so that it does not affect the environment
very much.
(iii)Man-hole
It is used for cleaning th einteriorof boiler shell and exrerior of the combustion chamber and
stacd. Its other purpose, is to inspect the boiler periodically and repair the defected surgace or
object , if any . It helps to run the boiler sage.
(iv)Hand Hole
It is provided for cleaning the cross tubes which are mostly provided across the fire box.
(v) Cross tubes
One or more cross tubes which are either flanged or reverted to the firebox to increase the
heating surface and to improve water circulation.
(vi)Ash pit It is placed at the bottom of the grate to collect the ash of the burnt coal which is
periodically removed. This is provided to minimize the heat loss, since the ash absorbs some
heatfrom the burnt coal.
(vii)Furnace
It is a place where combustion of coal takes place. This is normally cylindrical in shape and the
furnace is madeof good conducting material, so that the heat produced can be iffectively
transferred to produce steam of high temperature.
(viii)Grate
It is placed at thte bottom of the fire box and coal is fed on it through the fire hole and is
allowed to burn.

Working
The fuel is fed into the grate through the fire hole and is allow to burn. The hot flue produced
as a result of combustuin of fuel in the furnace box, is allowed to pass around the cross tubes.
The heat from the hot flue gases is utilized to produce steam by heating the water by
convection. The water circulates due t convection current produced by heat . The circulation is
from lower end of the cross thube to the higer end of the cross tube. The working pressure does
not exceed 70 N/cm2 i.e 7 bar.

Mountings

Mountings are devices which are attached to the boiler to run the boiler sately at designed
condition.
Pressure Gauge
It indicates the pressure of steam inside the boiler. Since the increase in pressure above normal
pressure leads to drastic accident, the use of pressure gauge prevents this accident.
Water Gauge
This indicates the water level in the boiler. If the water level decreases below the limiting value,
then the boiler will get overheated and the tubes may burnt out.
Safety Valve
The Function of safety Valve is to prevent the increase of steam pressure above design pressure
when the pressure increases above design pressure, the valve opens and discharges the stean
to the atmosphere. When this pressure falls just below design pressure, the valve closes
automatically.
Steam Stop Valve
It regulates the flow of steam supply outside. The steam from the boiler first enters into an anti
priming pipe where most of the water particles associated with stem are removed.

COCHRAN BOILER
Description and operation
Cochran boiler is a vertical, multibular firetu be boiler, commonly used for small capacity steam
generation. It is made in different sizes of evaporative capacities ranging from 150-3000Kg/hr
and working pressure upto 20 bar, It is the modification of a simple vertical boiler where
heating surface has been increased by means of a number of fire tubes.
The boiler consists of a cylindreical shell with its crown having a hemispherical shape. The
furnace is also hemispherical in shape. The grate is placed at the bottom of the furnace and the
ash-pit is located below the grate. The coal is fed into th grate through the fire door and ash
formed is collected in the ash pit located just below the grate and then it is removed manually.
The furnance and the combination chamber are connected through a pipe. The back of the
combustion chamber is lined with fire bricks. The hot gases from the combustion chamber flow
through the nest of horizontal fire tubes (generally 6.25 cm is external diameter and 165-170 in
number). The gases passing htrough the fire tubes transfer a large portion of the heat by
convection. The flue gases combing out of fire tubes are finally discharged to the atmosphere
through chimney.
The spherical top and spherical shape of firehbox are the special features of this boiler. These
shapes require least material for the volume. The hemispherical crown of the boiler shell gives
maximum strength to with stand the pressure or the steam inside the boiler . The
hemispherical crown of the firebox is advantageous for resistiog intense heat . this shape is also
advantageous for the absorption of the radiant heat from the source.
Coal or oil can be used as fuel in this boiler. If oil is used as fuel, no grate is provided but the
bottom of the furnace is lined with fire bricks. Oil burners are fitted at a suitable location below
the fire door.
A man hole near the grate is caused by means of the draught produced by the chimney. A
damper is placed inside the chimney to control to control the discharge of hot gases from the
chimney and therby the supply of air to the grate is controlled.. The chimney may also be
provided with a steam nozzle to discharge the flue gases quickly.

Salient Features
1. It is very compact and requires minimum area.
2. Any type of fuel can be used in boiler
3. Well suited for small capacity scheme.
4. It gives about 70% thermal efficiency with coal firing and 75% with oil firing.

Mountings
Apart from pressure gauge, water gauge, safety valve and steam stop valve, blow off cock
and fusible plug is used.

Fudible plug
If the water level in the boiler falls below predetermined level. The boiler shell and tubes
will be overheated. Abd if et is continued, the tubes may burn. It can be prevented by
stopping the burning fuel on Grate.
Blow-off Cock
The water supplied to the boiler always contains impurities like mud, sand and salt. During
heating these are deposited at the bottom of the boiler, and if they were not removed,
they accumulated at the bottom of the boiler and reduces its capacity and heat transfer
rates, These deposited salts are removed with the help of blow off cock.
BABCOCK AND WILCOX BOILER

Description and Operation

It is a water tube boiler. The water is circulated inside the tubes and hot gases flow over the tubes.

The boiler shell known as water and steam drum is made of high quality steel. It is connected by short
tubes with the uptake header or riser and by longer tubes to the down take header. The water level in
the drum is slightly above the centre. The water tubes are connected to the top and bottom header and
kept inclined at an angle of 150 to the horizontal. The headers are provided with hand holes in front of
the tubes and are covered with caps. This arrangement helps in cleaning of the tubes. The inclined
position helps the flow of water.

The furnace is arranged below the uptake header. Coal is fed to the grate through the fire door. Two fire
brick baffles are arranged in such a manner that the ht gases from the grate are compelled to move in
the upward and downward directions. First the hot gases rise upward and then go downand then rise up
again and finally escape to the chimney through the smoke chamber.

The outer surface of the water tubes and half of the bottom cylindrical surface form the heating surface
through which heat is transferred from the hot gases to the water.

The fron portion of the water tubes come in contact with the hot gases at higher temperature. So the
water from this portion rises in the upper direction due to decreased density and passed into the drum
through the uptake header. Here the steam and water are separated and the steam being lighter is
collected in the upper part of the drum. From the back portion of the drum, the water enters the water
tubes through the down take header. Thus a continuous circulation of water from the drum to the water
tubes and water tubes to the drum is maintained. The circulation of water is maintained by convective
currents and is known as natural circulation.

A superheater is placed between the drum and water tubes. During the first turn of the hot gases, te
gases are passed over the superheater tubes and the steam is passed through the superheater and
becomes superheated steam. The steam is taken into the superheater from the steam space of the
drum through a tube. The superheated steam coming out through superheater is supplied through
steam pipe and steam stop valve to the turbine. When the steam is being raised from boiler, the
superheater is filled with water to the drum water level. This is essential to prevent overheating of the
super-heater tubes. The superheater remains flooded until the steam reaches the working pressure.
Once the rated pressure is achieved in the boiler, then the water from the superheater is drained and
steam is fed to it for superheating purposes.

A mudbox is fitted to the downheader. The impurities and mud arties from the water are collected in
the mudbox and they are blown-off from time to time by means of a blow off-valve.
The access to the interior of the boiler is provided by the doors. This is necessary for cleaning the tubes
and removing the rusts from their surfaces. The draught is regulated by a damper which is provided in
the back chamber. The damper portion is controlled with the help of chain connected to it from the
pulley.

Outstanding features

i) The evaporating capacity of this boiler is high compared with other boilers (20,000-40,000
kg/hr). The operating pressure lies between 11.5-17.5 bar.
ii) The draught loss is minimum.
iii) The defective tubes can be replaced easily.
iv) The entire boiler rests over an iron structure, independent of brick work, so that boiler may
expand or contract freely. The brick walls which form the surroundings of the boiler are only
to enclose the furnace and the hot gases.

HIGH PRESSURE BOILERS

LA- MONT BOILER

{figure}

It is a modern high pressure water tube type steam boiler working on forced circulation system or
principle.

Working Principle:

La-mont boiler consists of:

1. Steam Separator Drum


2. Circulating Pump
3. Distributing Header
4. Evaporator
5. Convection Superheater
6. Economiser and
7. Air pre-heater.

1. Steam Separator Drum


A drum is placed wholly outside the boiler mounting. It receives a mixture of steam from the
evaporator tubes and feed water from the economiser. Here the steam is separated from
water.
2. Circulating Pump
Water from the steam separator drum is then pass into the circulating pump which circulates
the water throughout the boiler.
3. Distributing Header
The circulating pump delivers the feed water to the distributing header with orifices at pressure
above the drum pressure.
4. Evaporator
Here the feed water from the distributing header is partially evaporated and a mixture of steam
and water from these tubes enters the steam separator drum.
5. Convection Superheater
The steam produced is the evaporator tube is nearly saturated. To produce superheated steam,
a convection superheater is used. Saturated steam from the drum enters the superheater and
ere it is superheated by hot flue gases flowing from the combustion chamber, entirely by
convective heat transfer.
The superheated steam from the superheater passes out to the steam turbine through the seam
outlet.
6. Economiser
Economiser is a device which is used to pre-heat the feed water necessary for steam
production.
Economiser receives feed water from feed water pump. The feed water get pre-heated by hot
flue gases passing over the economiser tubes. Due to this pre-heating of feed water, it requires
only a small amount of heat to be supplied in the boiler, resulting in some saving of fuel burnt.
This increases the boiler efficiency.
7. Air pre-heater
It is used to pre-heat the air required for combustion in the combustion chamber. Air is also pre-
heated in the same manner as that of feed water (i.e.) by means of hot flue gases flowing
towards chimney from combustion chamber.

Capacity-50 Tonnes/hr of superheated steam at a pressure of 170 kgf/cm2 (bar) and a temperature of
5000C.

BENSON BOILER

The major disadvantage in the other boiler is the presence of steam bubbles in contact with the surface
of tubes which reduces heat transmission from the flue gases to water. This difficulty is overcome in
Benson boiler by raising the boiler pressure to the critical pressure of steam. At the critical pressure,
water and steam have the same density and no bubbles form.

{figure}

Working Principle:

1. Economiser
Economiser receives feed water from tank through feed water pump. The feed water is
preheated by hot flue gases form combustion chamber.
2. Radiant Evaportator
The preheated water then enters the radiant evaportator where the majority of water is
converted into steam by receiving heat from hot flue gases by radiation process.
3. Convention Evaporator
The mixture of steam and water enters the convection evaporator where the remaining water
gets evaporated. The evaporator receives heat from flue gas by convection process.
4. Convention Superheater
The saturated steam then enters the convection superheater. Hence the steam is superheated
to a temperature of about 6500 C. The superheated steam is then supplied to steam turbine
through steam outlet.

Capacity: 150 Tonnes/hr of superheated steam at a pressure of 210 kgf/cm2 (bar)and at a temperature
of 6500 C.

Salient Features

i) Total weight of Benson boiler is 20% less than other boilers due to absence of drums. So
cost is also low.
ii) Benson boiler is portable one due to absence of drums.
iii) Since there are no drums, this is a once-through boiler i.e., the feed water entering at on
end is discharged as superheated steam at the other end.
iv) Circulating pump and down corners are dispensed.

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