BOILERS

AIR

BOILER/STEAM GENERATOR
AIR
AIR
CHIMNEY
STEAM
FUEL

TURBINE
ASH WATER

WATER
WATER SOURCE

SIMPLE LAYOUT OF POWER PLANT

Definition of boiler
Steam boiler or simply a boiler is basically a closed vessel into which
water is heated until the water is converted into steam at required
pressure and quality.
It can be said that older/conventional steam generators were
commonly termed as boilers and worked at low to medium pressure
(1–300 but, at pressures above this, it is
more usual to speak of a steam generator
Working principle of boiler
The boiler is essentially a closed vessel inside which water is stored
Fuel (generally coal) is bunt in a furnace and hot gasses are produced
These hot gasses come in contact with water vessel
where the heat of these hot gases transfer to the water
and consequently steam is produced in the boiler
Then this steam is piped to the turbine of thermal power plant
 Steam Generation Theory

• Within the boiler, fuel and air are

force into the furnace by the
burner.
• There, it burns to produce heat.
• From there, the heat (flue gases)
travel throughout the boiler.
• The water absorbs the heat, and
eventually absorb enough to
change into a gaseous state -
steam.
• To the left is the basic theoretical
design of a modern boiler.
• Boiler makers have developed
various designs to squeeze the
most energy out of fuel and to
maximized its transfer to the water.
 Classification of Boilers
1. According to relative position of water and hot gases
a) Water tube boiler
• A boiler in which the water flows through the tubes
which are surrounded by hot combustion gases i.e.
Babcock and Wilcox, Stirling, Benson boilers etc
b) Fire tube boiler
• The hot combustion gases pass through the boiler
tubes, which are surrounded by water i.e. Lancashire,
Cochran, Locomotive boilers etc.
2. According to water circulation arrangement
a) Natural circulation: Water circulates in the boiler due to
density difference of hot and cold water
Babcock and Wilcox boiler, Lancashire boiler, Locomotive
boiler etc.

b) Forced circulation: A water pump forces the water

along its path, therefore, the steam generation rate
increases
Benson, La Mont, Velox boilers
3. According to position of furnaces
a)Internally fired
The furnace is located inside the shell
Cochran, Lancashire boilers

b)Externally fired
The furnace is located outside the boiler shell

Babcock and Wilcox, Stirling boilers

4. According to the axis of the shell
Horizontal boiler
Cornish, lancashire and scotch

Vertical boiler
a type of fire-tube or water-tube boiler where the
boiler barrel is oriented vertically instead of the more
common horizontal orientation
Locomotive boilers

Inclined boiler
5. Higher Pressure and Low Pressure Boilers
The boiler which produce steam at pressures of 80 bar and
above are called high pressure boilers.
Examples: Babcock and Wilcox, Velox,Lamomt,Benson
Boiler
The boilers which produce steam at pressure below 80 bar
are called low pressure boilers.
Examples: Cochran, Cornish, Lancashire and Locomotive
boiler
6. Stationary and Portable
Stationary boilers are used for power plant steam, for
central station utility power plants, for plant process
steam etc.
Mobile boilers or portable boilers include locomotive
type, and other small units for temporary use at sites.
 Boiler Accessories
The accessories are mounted on the boiler to increase
efficiency
These units are optional
For the proper working of the boiler
1. Economizer
2. Super heater
3. Air pre heater
4. Feed water pump
5. Steam Trap
6. Steam Separator
ECONOMIZER
An economizer is a heat
exchanger, used for
heating the feed water
before it enters the
boiler. The economizer
recovers some of waste
heat of hot flue gases
going to chimney. It
helps in improving the
boiler efficiency. It is
placed in the path of flue
gases at the rear end of
the boiler just before air
pre-heater.
 SUPER HEATER
It is a heat exchanger
in which heat of
combustion products
is used to dry the wet
steam, pressure
remains constant, its
volume and
temperature increase.
Basically, a super
heater consists of a set
of small diameter U
tubes in which steam
flows and takes up the
heat from hot flue
gases.
 AIR PRE-HEATER
The function of an air pre-heater is similar to that of an
economizer. It recovers some portion of the waste heat of hot
flue gases going to chimney, and transfers same to the fresh
air before it enters the combustion chamber.

Due to preheating of air, the furnace temperature increases.

It results in rapid combustion of fuel with less soot, smoke
and ash. The high furnace temperature can permit low grade
fuel with less atmospheric pollution. The air pre-heater is
placed between economizer and chimney.
 Feed Water Pump
It is used to feed the water at a high pressure against the high
pressure of steam already existing inside the boiler.

STEAM TRAP
Steam trap is a device used to drain off the condensed
water accumulating in the steam pipe lines while at the
same time the high pressure steam does not escape out of it
STEAM SEPARATOR
A steam separator separates the water particles from the
steam flowing in the pipe lines.
It is installed very close to the steam engine or turbine on the
main supply line
 Boiler Mountings

• The boiler mountings are the part of the boiler and are
required for proper functioning.
• In accordance with the Indian Boiler regulations, of the
boiler mountings is essential fitting for safe working of a
boiler
• complete controlling of the steam generation
• measurement of some of the important steam
properties
• To provide safety to the boiler
 1. Water level Indicator
• Water level indicator is located in front of boiler in such a position
that the level of water can easily be seen by attendant
• Two water level indicators are used on all boilers.

2. PRESSURE GAUGE
• A pressure gauge is fitted in front of boiler in such a position that the
operator can conveniently read it
• It reads the pressure of steam in the boiler and is connected to steam
space by a siphon tube.
• Bourdon pressure gauge is used.
 3. SAFETY VALVE
• Safety valves are located on the top of the boiler
• They guard the boiler against the excessive high pressure
of steam inside the drum
• If the pressure in boiler drum exceeds the working
pressure then the safety valve allows blow-off the excess
quantity of steam to atmosphere
• Thus the pressure of steam in the drum falls
• The escape of steam makes a audio noise to warm the
boiler attendant.
There are four types of safety valve
1. Dead weight safety valve
2. Spring loaded safety valve
3. Lever loaded safety valve
4. High steam and low water safety valve
 4. FUSIBLE PLUG
• Protects the fire tube boiler against overheating
• located just above the furnace in the boiler
• Consists of gun metal plug fixed in a gun metal body with
fusible molten metal
• During the normal boiler operation, the fusible plug is
covered by water and its temperature does not rise to its
melting state
• When the water level falls too low in the boiler, it uncovers
the fusible plug
• Furnace gases heat up the plug and fusible metal of plug
melts, the inner plug falls down The water and steam then
rush through the hole and extinguish the fire before any
major damage occurs to the boiler due to overheating
 5. Blow-Off Cock
• Discharge mud and other sediments deposited in the
• bottom most part of the water space in the boiler
• It can also be used to drain-off boiler water
• When it is open, water under the pressure rushes out,
thus carrying sediments and mud

6. Feed Check Valve

 The feed check valve is fitted to the boiler, slightly below
the working level in the boiler
 It is used to supply high pressure feed water to boiler
 It also prevents the returning of feed water from the boiler
if feed pump fails to work
 7. Steam Stop Valve
• The steam stop valve is located on the highest part of the steam
space
• It regulates the steam supply to use
• The steam stop valve can be operated manually or automatically

8. Manhole
 Its an opening
in the boiler
shell through
which a man
can go in for
periodic
inspection
and cleaning.
 LANCASHIRE BOILER

A stationary, fire tube, internally fired boiler. The size is

approximately from 7-9 meters in length and 2-3 meters in
diameter
 LANCASHIRE BOILER
1. Safety valve
2. Man hole
3. Steam pipe
4. Steam stop
valve
5. Safety valve
6. Pressure
gauge
7. Feed check
valve
8. Water gauge
9. Blowoff valve
10. Fusible plug

B: Bottom central channel D: Dampers S: side channels

C: Chimney E: Fire grate F :Flue tube K: Main channel
 LANCASHIRE BOILER

Grate
The grate is provided at the front end of the main flue tubes.
Coal is fed to the grate through the fire hole

Dampers
Dampers is in the form of sliding doors are placed at the end
of the side flues to control the flow of gases from side flues to
the chimney flue.
 LANCASHIRE BOILER
• Lancashire boiler had twin furnace tubes side-by-side,
which gave it a much larger heating surface
• To produce steam, coal was shovelled through the fire-
doors at the end to maintain a fire in each of the furnace
tubes
• Lancashire boilers were surrounded by brickwork flues
• This meant that the hot flue gases produced by burning
coal could circulate under and along the sides of the boiler
before reaching the chimney
• Thus, instead of escaping straight up the chimney and
being wasted, the flue gases helped to heat the water in
the boiler.
 LANCASHIRE BOILER

• To avoid accident due to excessive pressure, boilers are

fitted with safety valves. These valves made a loud noise,
as they released excess steam, to draw the attention of the
engineer
• The water level would be maintained by opening the water
feed valve, as required, to replace the water that had been
converted to steam

• The level of the water in the cylinder which surrounded

the internal fire tubes, could be monitored by checking
the glass gauges on the front of the boiler
• The steam pressure in the boiler was indicated by the
steam pressure gauge
 Babcock and Wilcox boiler
It is a water tube boiler used in steam power plants. In this, water is
circulated inside the tubes and hot gases flow over the tubes.
Babcock and Wilcox boiler
Steam and water drum (boiler shell)
One half of the drum which is horizontal is filled up with
water and steam remains on the other half. It is about 8
meters in length and 2 meter in diameter.

Water tubes
Water tubes are placed between the drum and furnace in an
inclined position (at an angle of 10 to 15 degree) to promote
water circulation. These tubes are connected to the uptake-
header and the down-comer as shown

Uptake-header and down-corner (or downtake-header)

The drum is connected at one end to the uptake-header by short tubes
and at the other end to the down-corner by long tubes.
Grate: Coal is fed to the grate through the fire door.
Furnace : Furnace is kept below the uptake-header
Baffles: The fire-brick baffles, two in number, are provided
to deflect the hot flue gases.
Superheater: The boiler is fitted with a superheater tube
which is placed just under the drum and above the water
tubes
Inspection doors: Inspection doors are provided for cleaning
and inspection of the boiler.
Mud box: Mud box is provided at the bottom end of the
down corner. The mud or sediments in the water are
collected in the mud box and it is blown-off time to time by
means of a blow –off cock.
Flow of flue gases
• The hot flue gases rise upward and pass across the left-
side portion of the water tubes
• The baffles deflect the flue gases and hence the flue gases
travel in the zig-zag manner
• The hot gases are deflected by the baffles to move in the
upward direction then downward and again in the upward
direction
• Over the water tubes and along the superheater
• The flue gases finally escape to atmosphere through
chimney.
 Water circulation

• That portion of water tubes which is just above the

furnace is heated comparatively at a higher temperature
than the rest of it
• Water, its density being decreased, rises into the drum
through the uptake-header
• Here the steam and water are separated in the drum
• Steam being lighter is collected in the upper part of the
drum The water from the drum comes down through the
down –comer into the water tubes
• A continuous circulation of water from the drum to the
water tubes and water tubes to the drum is thus
maintained
• The circulation of water is maintained by convective
currents and is known as “natural circulation”
Advantages of water tube boilers
• Steam can be generated at very high pressures
• Heating surface is more in comparison with the space
occupied, in the case of water tube boilers.
• Steam can be raised more quickly than is possible with a
fire tube boiler. Hence, it can be more easily used for
variation of load.
• The hot gases flow almost at right angles to the direction of
water flow. Hence maximum amount of heat is transferred
to water.
• Bursting of one or two tubes does not affect the boiler very
much with regard to its working. Hence water tube boilers
are sometimes called as safety boilers.
• The different parts of a water tube boiler can be separated.
Hence it is easier to transport.
• It is suitable for use in steam power plants
Disadvantages of water tube boilers

• It is less suitable for impure and sedimentary water, as a

small deposit of scale may cause the overheating and
bursting of tubes. Hence, water treatment is very essential
for water tube boilers
• Maintenance cost is high
• Not suitable for mobile application
• High initial cost and hence not economical