Silver Oak University

Subject: Basic of Mechanical Engineering

Hitesh Prajapati
Assistant Professor
Mechanical Engg. Department
Silver Oak University
Ahmedabad
 Cahpter-6: Steam Boiler

Introduction
Classification of boiler
Comparison of Fire tube & water tube boiler
Factor affecting the selection of boiler
Requirement for good boiler
Simple vertical boiler
Cochran boiler
Lancashire boiler
Babcock & Wilcox boiler
 Introduction

•Steam boiler is a closed vessel in which heat produced by the combustion of fuel is utilized to
generate steam from water, at desired temperature and pressure.
•According to IBR (Indian Boiler Regulation) boiler is defined as
“Boiler is a closed pressure vessel with capacity exceeding 25 liters used for
generating steam under pressure greater than or equal to 1 kg/cm^2 and water is
heated at 100°C or above..”

• The steam produced may be supplied:

a. For generating power in steam Engine or steam turbines.
b. At low pressures for industrial process work in cotton mills, sugar factories, etc., and
c. For producing hot water for supply of hot water and for heating the buildings in cold
weather.
 Classification

1. According to relative position of water and hot gases

a. Fire Tube boiler - hot gases pass through fire tubes which are surrounded by water.
b. Water tube - water flows inside the tubes and the hot flue gases flow outside the tubes.
2. According to the axis of the shell
a. Vertical boiler – the axis of the shell is vertical.
b. Horizontal boiler – the axis of the shell is horizontal.
c. Inclined boiler – the axis of the boilers is inclined.
3. According to the method of firing
a. Externally fired boilers – furnace is located outside the shell.
b. Internally fired boilers – furnace is located inside the shell, means combustion takes place
inside the boiler shell.
4. According to the method of water circulation
a. Forced Circulation boilers - water is circulated by pumps which is driven by motor.
b. Natural Circulation boilers - water is circulated by natural convection currents which are set
up due to the temperature difference produced by the application of heat.
5. According to the pressure of steam
a. Low pressure – boilers working pressure is less than3.5 to 10 bars. Example Cochran and
Cornish boiler.
b. Medium pressure boilers – working pressure is 10 to 25 bars. Example: Lancashire and
locomotive boiler
c. High pressure boilers – working pressure is above 25 bars. Example: : Babcock and Wilcox
boiler
6. According to the mobility of boiler
a. Stationary boilers – it is used for stationary plants.
b. Mobile boilers – it can move from one place to another.
7. According to the number of tubes in the boiler
a. Single tube boilers – they have only one fire or water tube.
b. Multi tube boilers – they have more than one fire or water tubes.
Comparison of fire tube & water tube boiler
 Factor affecting the selection of boiler

•Working pressure
•Quality of steam
•Steam generation rate
•Floor area available
•Quality & quantity of fuel & water available
•Initial cost
•Operation & maintenance cost
•Accessibility of repair & maintenance
 Essential requirements for good boiler

•Produced maximum steam per unit fuel consumption

•Steam production rate should be as per requirements
•It is in light weight & occupy minimum space
•It should be as per IBR
•It should achieve variable rate
•Velocity of water & fire gases should be minimum for less frictional losses
•Tube should be sufficiently strong
•Mud & other deposit should not be deposit
Simple vertical boiler
•A simple vertical boiler produces steam at low pressure and in small quantities.
•It is, therefore, used for low power generation or at places where space is limited.
• The construction of this type of boiler is shown in the figure.

Main characteristics :
•Portable
•Vertical
•Water tube
•Multi tube
•Internally fired
•Natural circulation
•Low pressure
Parts of Simple Vertical Boiler
1. Ash pit
2. Grate
3. Feed check valve
4. Fire hole
5. Firebox
6. Hand-hole
7. Cross tubes
8. Fusible plug
9. Water level indicator
10.Cylindrical shell
11.Manhole
12.Pressure gauge
13.Steam stop valve
14.Safety valve
15.Chimney
1. Ash Pit
The purpose of the ash pit is to collect fuel ash after burning the fuel.
2. Grate
The grate usually consists of cast iron bars which are spaced aside so that the air (required
for combustion) can pass through them. It is a platform, in the combustion chamber, upon
which the fuel is burnt.
3. Feed Check Valve
The purpose of a feed check valve is to regulate the flow of water from the feed pump to the
boiler and to prevent the backflow of the water.
4. Fire Hole
The Fire hole is hole provided at the air rear end of the boiler. The solid fuel is inserted and
burned into the furnace through this hole.
5. Fire Box
The firebox is a type of a box in this the burning of the solid fuel takes place.
6. Hand hole
The hand hole is provided in the shell opposite the ends of each cross tube for cleaning the
cross tube.
7. Cross Tubes
One or more cross tubes are either fastened or flanged into the furnace to enhance the
heating surface and improve water circulation.
8. Fusible Plug
The function of the fusible plug is to put-off the fire in the furnace of the boiler when the
water level falls below an unsafe level and thus avoids the explosion, which may take place
due to overheating of the tubes and the shell.
9. Water Level Indicator
It is an important device, which indicates the water level inside the boiler. It is a safety device
upon which the safe working of the boiler depends.
10. Cylindrical Shell
The shell is in a vertical position and is attached to the bed of the furnace. The greater part
of the shell is filled with water which also surrounds the furnace. The remaining part is the
steam space. The shell can be about 1.25 m in diameter and 2.0 m in height.
11. Man Hole
The manhole is provided at the top of the shell to allow a man to enter into it to repair and to
inspect the boiler from inside. It is also for cleaning the inner part of the boiler shell and the
outer part of the combustion chamber and the chimney.
Advantages:
•Compact & require less space
•Not require any foundation

•Disadvantages:
•Due vertical orientation lot of heat loss to atmosphere
•Can produce 10 bar and generation rate possible up to 2500 kg/hr
Cochran boiler
•It is one of the best type of vertical multi-tubular boiler. It is fire tube boiler and used for
steam generation at lower rate.

Specification
•Shell diameter = 2.75 m
•Height = 5.75 m
•Working pressure = 6.5 bar
•Heating surface area 120 m2
•Steam capacity = 3500 kg/hr (Max. = 4000 kg/hr)
• Efficiency = 70 to 75 %

Characteristics of boiler
•It is a vertical, multi tubes, fire tube, internally fired, natural circulation boiler.
Construction
•The boiler consists of a cylindrical shell, hemispherical fire box, fire tubes and chimney. The top
of the shell having hemispherical shaped crown as shown in fig.
•The hemispherical crown of boiler gives good strength to withstand pressure of steam inside
the boiler.
•The hemispherical shape of furnace can withstand high heat and it is also useful to increase
radiant heat transfer.
•The grate is placed at the bottom of furnace and ash pit is located below the grate. The furnace
and the combustion chamber are connected by short flue pipe.
• The wall of the combustion chamber is lined with the fire bricks.
Working
•The water is supplied to the boiler through feed check valve. The level is adjusted with the
help of water level indicator.
•Coal is added through the fire-hole or door to the grate and burnt. The hot gases produced
are collected in the fir box.
•These hot gases enter into horizontal fire tubes. Heat transfer takes place from flue gases
passing inside the tubes to water surrounded the tubes.
• The flue gas coming from the fire tubes enter into smoke box. Finally they discharged to
atmosphere through a chimney.
•The ash formed is collected in ash pit. The steam is collected through anti priming pipe on the
top of the shell.
Advantages
1. It is compact and portable boiler therefore minimum floor area is required.
2. Initial cost of boiler is less
3. It can be moved and set up readily in different locations.
4. Quick and easy installation.
5. Any type of fuel can be used. (Coal or Oil)

Disadvantages
1. Steam raising capacity is less due to vertical design.
2. Water along with steam may enter the steam pipe under heavy loads sue to small steam
space.
3. Efficiency is poor in smaller sizes.
Lancashire boiler
•It is simple in design, easy to operate and less operating and maintenance cost. It is one of
the most commonly used stationary boilers.
• It is normally used in sugar mills, textile industries where power generation as well as
process heating is required.

Specification
•Shell diameter = 2 to 3 m
•Length of the shell = 7 TO 9 m
•Working pressure = 16 bar
•Steam capacity = 8000-9000 kg/hr
•Efficiency = 50 to 70 %
Characteristics
•Horizontal, stationary, fire tube, internally fired multi-tube (two fire tube), natural circulation
of hot gases, medium pressure boiler.
Construction
•It consists of a cylindrical shell and two fire tubes as shown in fig. The cylindrical shell is
placed over the brick structure.
•The boiler has three passes for flow of gases. One flue passes from inside of boiler and
through fire tubes, is called main flue (MF). Second flue passes froth below the shell is called
bottom flue (BF) and third from the side of boiler is called side flue (SF). The side flue and
bottom flue passes are formed by brick work.
•The fuel grates are provided at the front end and inside of two main fire tubes. A fire bridge
is provided at the end of the grate to prevent coal and ash particles entering into the interior
of the furnace tubes.
Superheater is provided at the end of the main flue tubes in passage of flue gases. While an
economiser is at the end of the side flues, before exhausting the gases to chimney.
•Dampers (sliding doors) are placed at the end of the side flues to control the flow of gases.
The pressure gauge and water level indicator and feed check valve are provided at front of
the boiler.
•On the front side, the blow off cock is provided at the bottom. The fusible plugs are mounted
on the top of the main flues just over the grate. The anti-priming pipe, safety valve, low water
and high steam safety valve and manhole are provided on the top of boiler shell.
Working
•The coal is introduced to the grate through fire holes. The combustion of coal takes place in
presence of air which is regulated by damper. The combustion will produce hot gases.
•Path of flue gases: The hot gases from the grate pass upto back end of the tubes and then in
the downward direction (MF to BF).
•They move by the bottom flue to the front of the boiler where they are divided into two
streams and pass into the side flues (BF to SF).
• They move along two side flues and enter the chimney and discharged to atmosphere.
Path of flue gases is as under
• Due to this flue gas path, the water in the shell is heated from bottom by the bottom flue,
from sides by side flue and from center by fire tubes.
•Damper regulates mass flow rate of flue gases. Ultimately it regulates fuel combustion rate as
well as steam generation rate.
•Dampers are opened by chain passing over a pulley outside the boiler.
Advantages
1. Due to three passes of flue gases, the heating surface area per unit volume of boiler is
large.
2. The fluctuations in load can be easily met by this boiler due to large reservoir.
3. Easy operation, low maintenance costs, easy to clean and inspect.
4. By use of economizer and super heater, maximum heat of flue gases is utilized, so
efficiency of boiler can be increased.

Disadvantages
1. Maximum working pressure is limited to 16 bar.
2. Due to brick work, more floor area is required.
Babcock & Wilcox boiler
• It is a water tube boiler and used in stationary and marine engine. The efficiency of this
boiler is much greater than that of the fire tube boiler.
•This boiler is exclusively used when pressure is above 10 bar and steam generating capacity
is required higher than 7000 kg/hr.

Specification
•Diameter of the drum = 2000 to 4000mm.
•Length = 6000 to 9000 mm.
•Size of the water tube = 76.2 to 101.6 mm
•Size of upper header tube = 38.4 to 57.1 mm
•Maximum working pressure = 42 bar
•Maximum steam capacity = 40,000 kg/hr
•Efficiency = 60 to 80 %
Construction
•Fig. shows a Babcock and Wilcox boiler. It consists of inclined water tubes, a steam and
water drum, a mud box and super heater.
•The drum is connected with uptake and downtake header by short riser tubes. These
headers are connected to series of inclined water tubes.
•The water tubes are inclined to horizontal about 15° or above to bring natural circulation of
water. The hand hole is provided in header in front of each tube for cleaning and inspection
of tubes.
•The baffles plates are provided in order to make the circulation of hot gases in sine wave
form. A damper is fitted at back of the boiler to regulate the draught and chain grate stoker
is used to feed the coal to furnace.
•Soot doors are provided to clean the outside of water tubes and to remove the soot. Soot
doors are alsohelpful to access the interior of the boiler.
Working
•The water fed into the boiler shell through the feed check valve. Due to gravity water
passes through the vertical tubes, headers and fills up the inclined tubes first.
•Then the water collects in the drum. Initially one half of drum is filled up with water.
•The coal is introduced to furnace grate by help of stoker. The coal is fired, hot gases
produced is first forced to move upward through passage between tubes.
•The baffles plates make flow of hot gases in sine wave, as move down and then move
upward over the water tubes. The damper controls the flow of air into the furnace.
•Water in the drum comes down through down take header and enter the tubes. They are
heated by hot gases coming from furnace. Due to heating of the water, density of water
decreases. Low density water moves upward in water tubes.
•The water tubes just above the furnace are heated comparatively at a higher temperature
than the rest of it. Therefore low density water is gradually converted into steam in their
path and rises into drum through up take header.
•Thus a continuous circulation of water from drum to water tubes and water tubes to drum is
maintained due to density difference of water and gravity, without any pump.
•The steam then enters to the anti-priming pipe and flows in the super heater tubes where it is
further heated and is finally taken out thorough the main steam stop valve and supplied to the
engine when needed.
•At lowest point of the header, mud collector is provided to remove the mud particles through a
blow down cock.
Advantages
1. The steam generation capacity of the boiler is very high, about 2000 to 40000 kg/hr.
2. Replacement of defective tubes is easy.
3. The draught losses as compared to other boilers are minimum.
4. It is used in power station for generating large quantity of steam.
5. Boiler is required less space area compared to fire tube boilers, and offers greater
operational safety.