Energy and Steam

Introduction


Steam is mainly used in industries for power
generation and drying. To design any
application which is based on steam, it is
important to understand the behaviour of
steam under different conditions.

FORMATION OF STEAM
Steam boilers
The steam boiler may be defined as a closed
vessel which is used to convert water into
steam at required temperature and pressure
by the application of heat.

The fuel used in boiler may be solid, liquid or
gas. The fuel is burnt in a furnace to produce
heat. This heat is used to convert water in to
steam at required temperature and pressure.

Classification of a Boiler
1) Horizontal, vertical or inclined
If the axis of the boiler is horizontal is known as horizontal. If the axis of the
boiler is vertical is known as vertical boiler. If the axis of the boiler is
inclines is known as inclined boiler.

2) Fire tube boiler and water tube boiler
Fire tube boiler: In fire tube boiler the hot gases flows inside the tube and
the water surrounds the tube.
Water tube boiler: In water tube boiler the water flows inside the tube and
the hot gases flows around the tube.
3) Internally fired and externally fired boiler
Internally fired boiler: If the furnace is located inside the boiler shell is
known as internally fire boiler.
Externally fired boiler: If the furnace is located outside the boiler shell is
known as externally fired boiler.

4) Forced circulation and natural circulation
Forced circulation: In forced circulation boiler, the water is circulated in the
boiler is done with the help of pump in known as forced circulation.
Natural circulation: In natural circulation boiler, the water is circulated in
the boiler is due to convection currents is known as natural circulation
boiler.


5) High pressure boiler and low pressure boiler
High-pressure boiler: The high-pressure boiler is designed to
produce steam at very high pressure is known as high-
pressure boiler.
Low-pressure boiler: The low-pressure boiler is designed to
produce steam at low pressure is known as low-pressure
boiler.

6) Single tube and multi tube boiler
Single tube boiler: If the boiler contains only one fire tube is
known as single tube boiler.
Multi tube boiler: If the boiler contains more than one fire
tube is known as multi tube boiler.

7) Stationary and portable (locomotive) boiler
Stationary boiler: If the boiler is located at factory site
Example, power generation plant and the boiler used in
textile mills are known as stationary boiler.
Portable boiler: Portable boiler is a small boiler, which can
be used as a locomotive or temporarily used at factory
sites.

Lancashire boiler
The Lancashire boiler is a horizontal axis, fire
tube, multi tubular, low pressure, natural
circulation, internally fired, and stationary
boiler.

The parts of Lancashire boiler are flue tubes,
safety valve, steam stop valve, pressure gauge,
furnace, feed check valve, man hole, water level
indicator, fusible plug and blow off valve.

Construction and Working of Lancashire
Boiler

Babcock and Wilcox Boiler
Babcock and Wilcox boiler is horizontal boiler,
multi tube, externally fired, water tube, stationary,
low-pressure boiler and natural circulation boiler
Boiler mountings
The boiler mountings are necessary for the proper function and safety
of a boiler; with out mountings boiler will not function. The various
boiler mountings are listed below.

1. Safety valve
2. Water level indicator
3. Pressure gauge
4. Blow off valve
5. Steam stop valve
6. Feed check valve
7. Man hole

a) Safety valve : The boiler is designed for a pressure, but the working
pressure of a boiler is always less than the design pressure. The
function of a safety valve is to protect the boiler from excess pressure,
when the pressure inside the boiler exceeds the working pressure, the
safety valve opens and the excess pressure is released to atmosphere.

b) Water level indicator: The function of a water level indicator is to
indicate the actual level of water in the boiler. For proper function of a
boiler the water level in the boiler has to be maintained between
minimum and maximum level but, if the water level falls less than the
minimum results in rapid increase in pressure of steam leads to
explosion of a boiler. Always the water level indicator is located nearer
and easily visible for the operator.

c) Pressure gauge: The function of a pressure gauge is to indicate the
actual pressure inside the boiler. The pressure rating of a pressure
gauge, which is mounted on a boiler, should be twice the working
pressure of a boiler.

d) Blow off valve: The function of a blow off valve is to drain the
sediments from a boiler. This operation is carried out when the boiler
is not in use. Always the blow off valve is located at the lowest position
of a boiler so that it is easy to drain the sediments from the boiler.

e) Steam stop valve: The function of a steam stop valve is to
regulate the quantity of steam that is going to the application.
Always the boiler generates more steam than the quantity of
steam required for the application, hence steam stop valve
regulates the flow and delivers the required quantity of steam
to the application.

f) Feed check valve: The feed check valve is a unidirectional
valve; it allows the water from tank to the boiler and blocks
the steam from boiler to the water tank. When the pump is
on it feeds the water to the boiler and, when the pump is off
the high-pressure steam flows towards the feed check valve
but it blocks the leakage of steam from boiler to the water
tank.

g) Man hole: The boilers may be either water tube or fire tube
boiler. In both the boilers hot gases flow in or out side the
tubes leaves behind some quantity of ash. This ash deposit
will reduce the heat transfer rate, which leads to decrease the
efficiency of a boiler. When the boiler is not in use a person
enters the boiler through a man hole and cleans the surfaces
of the tubes.

Boiler accessories
Boiler accessories are auxiliary parts used in
steam boilers for their proper function and to
improve the efficiency of the power plant. The
various boiler accessories are listed below.
a) Super heater
b) Economizer
c) Air pre heater
d) Steam separator
e) Steam trap

a) Super heater: The function of a super heater is to increase the temperature of the steam
above its saturation temperature. The steam, which is delivered from the boiler is known as
wet steam, if wet steam is used for the application results in corrosion of parts and erosion of
turbine blades. The steam separator is in the form of U-tube, which is located just above the
furnace where the temperature is maximum.

b) Economizer: The function of a economizer (heat exchanger) is used to recover the waste heat
from the gases going to chimney, this is also known as waste heat recovery system. The heat
recovered from gases is used to heat the boiler feed water. The supply of preheated water to
the boiler reduces the amount of fuel required to raise water temperature from atmospheric
temperature to preheated water temperature.

c) Air pre heater: Air preheater is another heat exchanger is used to recover waste heat from the
gases. The air, which is fed to the furnace, is preheated to few degrees more than
atmospheric temperature. Due to this, the amount of heat to be added to the air in the
furnace is considerably reduced.

d) Steam separator: The function of a steam separator is used to separate the water particles
present in the steam. The presence of water particles in the steam gives rise to blades
erosion in turbines and corrosion of parts in steam engine.

e) Steam trap: The function of a steam trap is to drain the condensed steam automatically from
the steam pipes and steam separators with out permitting any water to escape to the
application