BOILERS - 1

What is a Boiler?

A closed vessel in which steam is

produced from water by combustion
of fuel.

Working of a Boiler

Water is pumped into the boiler at operating pressure

Heat of flue gases vaporises water to form steam

Steam formed is passed into steam space above the water

space

This steam is always wet

Superheated steam is obtained by passing wet steam through

super-heater, where it is dried and then superheated

To increase efficiency, water is passed through an economiser

where its temp. is increased and then it is pumped into the
boiler. This way less heat is required to heat the steam.

Steam Generator
A combination of apparatus for producing, furnishing or
recovering heat together with the apparatus for
transferring the heat so made available to the fluid being
heated and vapourised.
Components of a steam generator

Boiler drum
Super heater
Economiser
Air Preheater

Function of a Boiler
Controlled release of heat in the fuel.
Efficient transfer of heat to the feed water to
produce steam at desired P, T and quality.
Steam to be supplied from boiler at constant
P by maintaining the steam generation rate
and steam flow rate equal.
Water must be contained safely.

Requirement of a Good Boiler

1.

Capable of producing maximum amount of steam with minimum

fuel consumption.

2.

It should occupy less space and be light in weight.

3.

Capable of quick starting and should rapidly meet the fluctuation in

load.

4.

Safe in working.

5.

Economical and should require very little attention during operation.

6.

All parts should be easily accessible for inspection and repairs.

7.

Components should be transported without difficulty.

Requirement of a Good Boiler

8.

Installation should be simple.

9.

Tubes should not accumulate soot or water deposits and should

be sufficiently strong to allow for wear and corrosion.

10.

Water and gas circuits should be such as to allow minimum fluid

velocity for low frictional losses.

11.

Should have as less joints as possible to avoid leaks, which may

occur due to expansion and contraction.

12.

Velocities should be high for high heat transfer rates with

minimum pressure drop through the system.

13.

Should confirm to safety regulations laid down in Boiler Act.

Selection of a Boiler
1.

Operating Pressure

2.

Steam Generating Rate

3.

Quality of steam required

4.

Availability of floor space

5.

Fuel to be used

6.

Nature of the load on the boiler

7.

Initial cost

8.

Operating and maintenance cost

9.

Availability of water

10.

Accessibility for repair and inspection

Classification of Boilers
1.

Position of flue gases and water

Fire tube, water tube

2.

Axis of shell
Horizontal, vertical, inclined

3.

Location of furnace
Externally fired, internally fired

4.

Method of circulation
Natural, Forced

Classification of Boilers
5.

Mobility
Stationary, Portable

6.

Usage
Packaged, Unpackaged

7.

Pressure
High, Low

8.

Tubes
Single, Multi

Fire Tube Boilers

Fire Tube Boiler

Furnace is located inside the Boiler Drum or shell.

Hot flue gases are fed through the tubes.

Tubes are surrounded by water.

Boiler shell contains water and steam under pressure.

Tube contains grate.

Air for combustion of fuel, flowing beneath the grate moves

upwards through the fire bars.

Superheater tubes placed at exit of the flue gases.

Used generally for up to 10000 kg/hr and low pressures upto 20

bar

Advantages of Fire-Tube Boiler

Low initial cost
Large water content provides safety in
operation, during failure of feed water
supply
Suitable for fluctuating loads
Space occupied

Disadvantages of Fire tube Boilers

Rate of evaporation is low and reaches operating
pressures slowly
Suitable only for low capacities.
Shell size 2.4m, shell thickness 3 cm, stress
considerations limit generation pressure to 20kg/cm 2
Lower efficiency
Explosion is very dangerous due to large water
content
Transportation is difficult due to large shell size
Useless for steam power plants due to slow rate of
steam generation
Difficult design
Less accessible to repairs

Water Tube Boilers

Water Tube Boilers

Furnace is outside the drum
Small parallel tubes contain water connected to
drum with the header
Gases pass outside tubes containing water
Flow of water is downward
Steam returns to drum through uptake header

Advantages of Water tube boilers

High pressures and capacity

Operating temps and pressures reached faster due to smaller
water to steam content
Hot gases travel at right angles to water flow so heating surfaces
are effective
Combustion space is larger so complete combustion possible with
better efficiency
Thermal stresses low as all parts are at uniform temp due to quick
circulation
Less serious damage compared to others due to lesser water
content.
Furnace area can be altered
Higher Efficiency
Suitable for power plant
Parts easily accessible for cleaning
Easily transported
Simple design

Disadvantages of Water tube Boilers

High initial cost
Impure and dirty water not suitable as a small deposit
can cause explosion
Failure in feed water supply can cause boiler overheat

Comparision of Fire tube and water

tube boilers
Criterion

Fire Tube

Water tube

Flow of hot gases

and water

Gases in tubes
surrounded by
water outside

Water in tubes and

gases flow outside

Location of
furnace

Internal

External

Floor area for

given output

Large

Small

Capacity

10000kg.hr

50000kg/hr

Evaporation

Slow

Fast

Comparision of Fire tube and water

tube boilers
Criterion

Fire Tube

Water tube

Pressure range

15 to 20 bar

170 to 200 bar

Eff

80%

92%

Safety

Large water content Small water content and

and low steam so large steam generation.
Needs expert attention.
better safety

Explosion

Lesser risk due to

lower P

Higher risk due to

higher P

Application

Not suitable for

large power plant

Suitable

Comparision of Fire tube and water

tube boilers
Criterion

Fire Tube

Water tube

Skill

Less

More

Water Treatment

No

Yes

Construction

Difficult

Simple

Shell Diameter

More

Less

Transportation

Difficult

Simple

Boiler terms and details

Shell
Furnace
Grate
Scale
Blowing Off
Refractory

Water flow path

Steam flow path
Gas flow path
Water space
Steam space
Water level
Fittings/mountings
Accessories