MELab

Experiment Title: Steam Generator Familiarization

Objectives:

a. To determine the basic components and parts of a steam generating unit.

b. To be familiarized with the functions of each components in the generation of steam by a fire
tube boiler.

Introduction:

Steam generators are widely used in industrial processes and power generation. The steam generators
or boilers utilize the heat generated from the combustion of fuel and air to vaporize the steam as a
supply to a certain application.

The steam generators or boilers are integral components of steam turbines which are used as prime
movers to drive generators to produce electricity in all thermal and nuclear power plants. These are
used in the industry for example in heating systems or for cement production, and textiles. These are
used to produce distilled water for medicines, pharmaceuticals and other usage. The boilers are used in
cold countries for heating large buildings, in agriculture as well for soil steaming.

Basic types of Boiler:

a.) Water tube boiler
b.) Fire Tube boiler

A. Water Tube Boiler

A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot gasses
surround them. There are advantages of water tube boiler that are mainly used in large thermal power
stations because it has a larger heating surface area that can be used due to increasing the number of
water tubes. Water tube boilers are also more advantageous compared to others because the flow of
water is much faster due to conventional flow. These advantages lead to its capacity to operate in very
high pressure yet still operates smoothly.

Working Principle

The water tube boiler consists of two drums- upper and lower called steam drum and mud drum
respectively. These drums are connected with two tubes as shown in Fig. 1. Water in the lower drum
and in the riser connected to it, is heated and steam is produced in them which comes to the upper
drum naturally. The steam is separated from water naturally and stored above the water surface in the
upper drum. The cold water is fed through feed water inlet at upper drum as this water is heavier than
the hotter water upwards through the riser. There is one convectional flow of water in the boiler
system. More and more steam is produced the pressure of the closed system increases which obstructs
this convectional flow of water and hence rate production of steam becomes slower proportionately.
Again if the steam is taken trough steam outlet, the pressure inside the system falls and consequently
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the convectional flow of water becomes faster which result in faster steam production rate. In this way
the water tube boiler can control its own pressure. Hence this type of boiler is referred as self-controlled
machine.

Figure 1. Water Tube Boiler flow Diagram

B. Fire Tube boiler

Fire tube boiler is one of the most basic types of boiler and the design is also very old. It was
popular in 18th century. It was mainly used for steam locomotive engines.

Working Principle

In fire tube boiler, the fuel is burnt inside a furnace. The hot gases produced in the furnace
then passes through the fire tubes. The fire tubes are immersed in water inside the main vessel
of the boiler. As the hot gases are passed through these tubes, the heat energy of the gasses is
transferred to the water surrounds them. As a result steam is generated in the water and
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naturally comes up and is stored upon the water in the same vessel of fire tube boiler. This
steam is then taken out from the steam outlet for utilizing for required purpose. The water is
fed into the boiler through the feed water inlet. As the steam and water is stored is the same
vessel, it is quite difficult to produce very high pressure steam from. General maximum capacity
of this type of boiler is 17.5 kg/cm2 and with a capacity of 9 Metric Ton of steam per hour. In a
fire tube boiler, the main boiler vessel is under pressure, so if this vessel is burst there will be a
possibility of major accident due to this explosion.

Figure 2. Fire Tube boiler flow Diagram

Main Components of a Fire Tube boiler

1. Feed Water System

2. Fuel System
3. Draft System
4. Steam System
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*Assume open system
13 WATER TANK
14
12

FUEL TANK

4 1
3 2

7 5

6
16 15

17

Motor

10 11
8 9
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I. Define/Explain the functions of the following parts corresponding to the numbers
in the schematic diagram.

1. Steam Pressure Indicator

2. Cut in valve
3. Cut off valve
4. Relief valve
5. Supply pipe
6. Fire tubes
7. Surface blow down
8. Burner
9. Fire Hole/Furnace
10. Bottom blow down
11. Feed water pump
12. Condensate pump
13. Heat Exchanger
14. Steam Trap
15. Bend
16. Water level indicator
17. Vent valve

II. Identify the parts of the boiler in the actual picture.

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