.

, BOILE1-q
GUIded by Submlt(cd bv
Mr. G.l).Aganval
Jfa rjim!!' r .\"jll/
11arr/J (Ju/lli.
..
M-2
_.' DBJEel': To study the Nestler Boiler
,: SPECIFICATION: Packagetype Nestlerboiler, self-contained three
pas's, smoke tube, oil fireJ horizontal package boiler
BoilerH.P. - 1 = 772RO \\1 = 77.2HO K\V
HeatingSurface- 562SCj. feet - 52.21 I11
2
Nornina] Ratio (steam/hL) = 35()O at 2 or: 1585.5 kgat lOCtC
\\'orkingPressure = IS() p.si = 1S() X II ::::: 10.33 bar
Condition ofsteam produced superheated steam can be produced.
Powersupply ("or 111(' l)(llicrIS) 1'h(lSl', '\-1\) Y, 1 lIP.
I'uci L1sed I'urnace ()i\.
TypeofoIl burner air assisted prcssunzed type.
j WORKING:-
First the Nestler boiJer IS heated burning furnace oil. The oil is first
pressurized by high-pressure oil pump ilnd is atomized by passing this high-
pressureoil through nozzle. Before burning thIS oil in furnace, it is preheated in
oil preheater where it acquires a temper:1tufc close to its ihrnition tcmpcf;1ture,
/\djllSI11lg Ihe (llci cock c()ntrols 111(' lIIng(Ifboiler. The flue gas Ihus ohtained
h\ 11ll' C()1l1hll';IH)1l or (\1('1 IS Cirsl 1);1' ',('(i Ihmug!. the maIn large lulle 111 the
mIddle This is pass. During second pass the flue ga:;cs pa:;s through
number of small tubes 111 tbe lower pan of the boiler and reach the fronl
]')()[tlon Thcn ['Ul' gascs again pass thmugh 110, ofsmall tubes rd pass) , III the
upper ],O[tlO11 , to reach the back lrtl
f
)ll, where smoke chalT1ber is l'!(n'iJcd
)
These tuhes afC kepi immersed in waier. The wateris during these three passes.
The space abO\'C t he water is steam space. The hotj2;ascs from srnoke chamber
pass over to super-heater tubes and by absorbing heat from the flue gases,
steam becomes super-heated. The condition of the steam thus obtained IS
checked by separating and throttling calorimeter, attached to steam pipeline.
The flue gases arc thrown outofthe smokechamberbychimney.
Q.1. J-Iow oil is preheated and why is it preheated?
Ans. Theoil is preheated in an otl-preheaterby extractingsomeofthe (waste)
heat available 111 the outgoing gases from the combustion clumber. Oil IS
preheated s() thaI it mit\, become less viscous and acquires temperature close to
Its 1!:,:tt11tlon temp. , thus makmg burning caSler at later stage.
.boilerefficict1EY.
) Q.2. Whatis pIjrharyandsecondaryair?\Vhatis ratio ofsecondaryair to
the totalair?,/
/
Ans. all' j:; uappul il1 the lowerinitially when 1<; /
kcpt.z(osed is required for uming the fuel compjL>{(;ly. Seconclay(
/ / /
tl.1!' IS aIr suppllyd/ovu fuel bed l!,t.(;;'ugh specially aWl.ngec.1 inlet valve)( tlK
/
/
/
/
.
door oftheY;iler so there IS suffJticnt air for combustion
// / "' ../
Ratio air to thK'total air is orO.yg,
;Q.3. Howthe flo,,, ofairis regulated?

Ans. Regulator controis the flow ofair. In order to control the flow ofair th('
ratio of jlnm;\n al1d sccond;trl' ;lit' is mamtaincd and checked at reg'll!:.!
inlel'\'als In hlower thl',;ur 1<; C()l1tl()lkd \\lth the help ofgrill and by c1ungll\L',
tlle r.pm. ofthe blowcr.
QA. I-low the lengthofthe flame is changed?
Ans. By 1he amount()Csee(l!1lLm :['1', the length offlame IS changed
Q.5. J--Iow oil is pressurized and atomized?\Xihy atomization is done?
AIR BLOWER
Ans. The oil is first pressurized br a hIgh-pressure uil pump and is atomized
bv passing thIs high-pressure nil through nozzle. I\tomizatlon is done I()
facilitate proper mixing of air with fuel and hence to facilitate better
combustionand ignition.
Q.6. Drawlinediagram for (1) Oil (2) Oiland flue gases.
Ans. 1. Oil.
[OIL ..
2. Oiland flue gases
}-"'[OIL PUMp]-'{ OIL FILTER PREHEATEH ]

[-surER HEATER I3" PASS H''''PASS }PASS I
, I UlltNEY I
Q.7. \X/hat are mountings and accessories of boilers? List their
functions.
Ans. MOUNTINGS: - r;ittingsl devices that are necessary for the safety
and for controllingthe workingofthe hoiler are called boiler1110untmgs
A. Safetydevices:
they pruYldClJ lit I he I( II' of the botler lind prevent the steam
pressure in the boiler to excecU the predetermined working pressure by
au\()maticallv openingthe \"hc.
1
2 II' 'I,!.I\\: it is a safety device that indicates the
waterlc\'cl inside the b()iler and is fitted in the front portl()n ofh(lder.
3 1"/{.I//;/I',{!/1!)!;. Its function is l'O put off fire when the water level 111 the
bOiler falls below an unsafe level an'd thus saves the boiler from gelling
exploded \vhich may take place due to over heating ofthe bOiler tube
;J,nd shell.
B. Controldevices:
1. i>.!JJ)J1frt?,l;(Jl(J!,/': it is provided atthe frontofshell or drum. Its fUnC(1(1l1 is
to indicate the steampressureofboiler.
2, I 'uriC/Jed".: Jt permits the flow ofwater in one direction only and
prevent the bllCk flow ofwater. The amount ofwater entering can be
adjusted by the hfe ()f the spindle.
It is fixed at the highest pomt of the boiler. Its
function is to regulate the flm\' ()fsteam fromboiler.
4. WQIJLJl!lll'll__ il is fit ted ill Ihe lowesc portion and is u:;nl fo!'
fdlowillg (unctions
i) To emp!\' the boiler when necessary for cleaning, repair, and
111SpeCt1011.
To discharge the mud and sediments carried with feed water
and accumulated at rhe bottomoftheboiler.
BOILER ACCESSORIES: DeVices that are required for smooth
operClrton rather than safety aspects ofbOller, and are useful in increasmg the
efflcicl1C\' ofthe plant
hWUlJ.!fLj2l1!!!/J;.The feed \vater pllmp IS needed to force water int() Ihe
boile!' through feed check valve. Two type offeed pumps ;11'e (1)\(olan'
pump b) ReClprncatlllg pump
2. '111c\ arc used to 1l1CrCllSe thc tcmpcraturcofsteam above
Its saturation ICI11pl'l'atulc
It is placed 111 the passage of flue gases in between the exit
lmm the boiler and elltr\' to the chttnney It ITI11()\TS the heat [rol11 I he
flue gases and preheats the water
'1. ,///(\.ili(lI), :-;IC;tl11 can he taken nut l() rUIl (Jllier l'l1gme
mechanism running on steam,
Q.8. How can you find the condition of the steam at outlet?
Ans. The condition of the steam at outlet is found by separating and
throttling calorimeter, I t indicates the steam pressure dryness fraction (moisture
content),
Q.9. Draw the line diagram for steam and steam passage.
Ans.
BOlLEn
\VeI steam
SUPEH-i

Super
heated
Steam

GENEHATOR I
Q.lO. is utility of chimney? What other nlcthods of draughting
can be used?
Ans. TIll' chllnner IS a type of natural clraughtll1g. The ad\'antages arc:
L II rcmm'l'S the product o[ comhllstio1l iO atmosphere and helps III puuing
out burneeJ gases [ron, boiler
2 II ;tiso calries I he )cluct o[ combustion to such a height bc[mc d1scharg1ng
them that H 1S not IS lW\ objcct10nablc to the surround1ng.
L\rUGS:j;ll_I2.Gl!J,uJJL In rillS method draught is produced by some artificIal
means. J f draught IS produced bv fan, then it is called mechanIcal draught. I fIt
IS done by hIgh-pressure steam, It IS known as jet draught.
Q.l1. What is the function of relief door valve and where they arc fittetl?
Ans. Relief door valve is used as safety device. In case safety valve fails and
pressure exceeds, then relief door valve opens, thereby reducing the pressure. If
the \valer level recluccs, the temperature inside increases. This in turn increases
the pressure. To recluce this pressure, the relief door valve opens. ] t is fiued at
the top of the boller over the fusible plug
Q.12. At what pressure the safety valve is likely to blow?
Ans. /\t a pressure of approximately 160 ps.1. (6(Yo above the working
I pressure).
I
.J Q.13. What will happen if gauge glass will hreak? Why there are two
gauge glasses?
Ans. j 11 case the gauge glass IS broken the balls arc carried along its passage
tu 1\)(' ends of glass tube and now of water and steam (Jut of boiler is
prevented. In boiler the second gauge is used purely for cross checking the
water lc\cl. lts use 15 purely on precautionary baSIS of the failure of the first
gauge glass.
I
j Q.14. What do you know about boiler certificate? What tests are
preformed under this test?
Ans. The boilers arc tested and inspected regularly as per Indian Boiler Act'
am.l I hell brlllcr eert ificalcs ;H(' Issued.
Ikfore inspection, boiler should be made empty and all manhole, duoI',
caps, mud drurns should be removcd and boiler should be cleaned and then
I tVlc1raJ,Ji1LJL<;t: 1his test is performed t() check for leakages from the Jilin t s. The
mountings sh()ukl be fitteu lIgh! except safely valves. The upening ()f the safe
\alves shou\l he cioscd. /\J] loints she d be made tight. BOller IS filled wl1 h
waler. TIICl] I hdr;ltdlC Tesl IS (IJ!llluClcd at Lwice \vorking pressure ()[ b()lier,
which is confirmed by boiler insrec\oc
Stl:jlm leU: 1 t IS C()IHJucted to check whether the safety valves operate properly
tn rdievc the steam when the steam pressure inside boiler exceed;.; the ratecl
rrcssure. The safety valves arc fitted to the boiler. The operation of safety valve
is tested at the prcssu re 10% abm<c the rated pressure, keeping the feed check
valve and stealll stop valve closed
,.\[Ier performing these lests boiler certificate is issued br boiler
l11SpcctOL
Q.:13. \V'hat is the cost of funning Nestler boiler pef hour?
Ans. CO.I/ ollm!
I-'ud consumed per hour er - 24 Ii tre
Cost or oil/litre = Rs. l()
Tulal cost of oil 24 x}(l =!Z" 24(L
COJ/o/e/eeilicil)'."
Power consumed br blower ~ .) I fP. = 3 x .796 ](\'(1= 2.2UR K\X
Power consumed br water pump (2111 no.) - 2 x 51-l.P.-1Ux.736
=7.36K\X',
Power consumed br fuel pump 1. H.P. 1. x .736 = 2 ~ ~ [(\\'
p 1 b 1 I ...,) I<"w/'.
l/ov:cr COl1SUllle( \' 01 pre 1catcr '>. V\
'rota! power consumed .- 22( IR+ 7. 76+1.288+ 3 11.856 K\X'
Pr)\\Tr consumed ill ()ne In. (N(). or units) --13.856 xl::: 13.856 [(\\/11
Cost of one unit - 1Zs. 3
Tota! cost of clectricin' =) :; 13.856 - Rs. 41.568
Cost ()f running boiler/In 24{)+ 41.568 =lZs. 281.568
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