NAME 177: THERMAL ENGINEERING

Steam Generator or
Boilers

 A steam generator or boiler is usually a closed vessel
made of steel. Its function is to transfer the heat produced
by combustion of fuel (solid, liquid or gaseous) to water,
and ultimately to generate steam. The steam can be used:
1. To an external combustion engine-steam engines and
turbines
2. At low pressures for industrial process work in cotton
mills, sugar factories etc.
3. For producing hot water that can be used for heating
installations at much lower pressures.
Important Terms for Steam
Generator or Boilers
1. Boiler Shell

2. Furnace:
 Combustion Chamber: in which the combustion takes
place.
 Grate: for supporting fuel
 Ash pit: for collecting and catching the refuses from the
fuel during combustion.
3. Heating Surface: the part exposed to fire or hot gases
from fire.
4. Mounting: like pressure level indicator, safety valves.
5. Accessories: superheater, economiser.
Steam Generator or Boilers


 Essentials of a Good Boiler

 It should produce maximum quantity of steam with the
minimum fuel consumption.
 It should be economical to install and should require
little attention during operation.
 It should rapidly meet the fluctuation of load.
 It should be capable of quick starting.
 It should be light in weight.
 It should occupy a small space.
 The joints should be few and accessible for inspection.
 The mud and other material should not collect on the
heating plates.
 Essentials of a Good Boiler

 The refractory

material should be reduced to a
minimum but it should be enough to secure easy
ignition and combustion of the fuel.
 The tubes should not accumulate soot or water
deposits, and should have a reasonable margin of
strength to allow for wear or corrosion.
 The water and flue gas circuits should be designed to
allow a maximum fluid velocity without incurring
heavy frictional losses.
 It should comply with safety regulations as laid down
in the Boilers Act.
 Selection of Steam Boiler

The selection of type and size of a steam boiler depends
upon the following factors:
1. The power required and the working pressure.
2. The rate at which steam is to be generated.
3. The geographical position of the power house.
4. The fuel and water available.
5. The type of fuel used.
6. The probable permanency of the station.
7. The probable load factor.
 Classification of Steam Boiler

1. According to the contents of the tube:
a) Fire Tube Boiler:
A fire-tube boiler is a type of boiler in which hot gases
from a fire pass through one or more tubes running
through a sealed container of water. The heat of the
gases is transferred through the walls of the tubes,
heating the water and ultimately creating steam.
Fire Tube Boiler:

 Classification of Steam
Boiler

 Water tube boiler:
A water tube boiler is a type of boiler in which water
circulates in tubes heated externally by the fire.
Fuel is burned inside the furnace, creating hot gas
which heats water in the steam-generating tubes.
Water tube boiler

 Classification of Steam Boiler

According to the axis of the shell:

Horizontal boiler: The axis of the shell is horizontal.

Vertical Boiler: the axis of the shell is vertical.
Classification of Steam Boiler


Vertical Boiler Horizontal boiler

 Classification of Steam Boiler

According to the number of tubes:
Single tube boiler
Multitubular boiler
According to the method of circulation of water and
steam:
Natural circulation boiler: the circulation is by
natural means.
Forced circulation boiler: the circulation is done by a
centrifugal pump driven by external power.
 Classification of Steam
Boiler

According to use:
Stationary boiler: They are used in power plants and
in industrial process work.
Mobile boiler: these boilers move form place to
place. i.e, locomotive boiler.
 Simple vertical boiler

 It produces steam at a low pressure and in small quantities.
It is therefore used in low pressure generation or where
space is limited.
 The fuel (coal) is fed into the grate through the fire hole and
is burnt. The ash pit placed below the grate collect the ashes
of the burning fuel.
 The combustion gas flows from the furnace, passes around
the cross tubes and escapes to the atmosphere through the
chimney.
 Water goes by natural circulation due to convection
currents, from the lower end of the cross tube and comes out
from the higher end.
Simple vertical boiler


Simple Vertical Boiler

 Cochran Boiler

 It is considered as the most efficient vertical mutitubular boiler.
 Coal is fed into the grate through the fire hole and burnt. Ash
formed during burning is collected in the ashpit provided just
below the grate and then it is removed manually.
 The host gases from the grate pass through the flue pipe to the
combustion chamber. The hot gases from the combustion
chamber flow through the horizontal fire tubes and transfer the
heat to the water.
 The flue gases coming out of fire tubes pass through the smoke
box and are exhausted to the atmosphere through the chimney.
 Smoke box is provided with a door for cleaning the fire tubes
and smoke box.
Cochran Boiler


Cochran Boiler
 Locomotive Boiler

 It is a mutitubular, horizontal, internally fired and mobile boiler. The
principal feature of this boiler is to produce steam at a very high rate.
 The locomotive boiler consists of a series of tubes designed to
operate at extremely high temperatures. An accessible tank called a
firebox contains the burning fuel, usually coal.
 Although any combustible material could be used, coal is the most
efficient fuel for this kind of engine. Exhausted fuel falls through a
grate in the bottom of the firebox as ash for later disposal.
 The heat from the firebox travels through a series of large and small
tubes to the front of the boiler. These tubes are called flues or fire
tubes.
 The fire tubes pass through a central tank filled with water, and heat
from the tubes converts the water to steam.
Locomotive Boiler

Locomotive Boiler

 Boiler Mountings

 These are the fitting which are mounted on boiler for its
proper and safe functioning.
1. Water level indicator: It indicates the level of water
inside the boiler.
2. Pressure Gauge: A pressure gauge is used to measure
the pressure of the steam inside the steam boiler.
3. Safety Valve: These are devices attached to the steam
chest for preventing explosions to excessive internal
pressure of steam. In brief the function of the safety
valve is to blow off the steam when the pressure of
steam inside the boiler exceeds the working pressure.
 Boiler Mountings

4. Steam stop valve: The principal functions of this valve
are-
To control the flow of steam from the boiler to the main steam
pipe.
To shut of the steam completely when required.
5.Blow off cock: The principal functions of a blow off cock are-
To empty the boiler when required.
To discharge the mud, scale or sediments which are
accumulated at the bottom of the boiler.
6.Feed check valve: It regulates the amount of water which is
pumped into the boiler.
 Boiler accessories

 These are devices which are used as an integral part of a
boiler and help in running efficiently.
1. Feed Pump: As water in continuously converting into steam
into the boiler, a feed pump is needed to deliver the water to
the boiler.
2. Superheater: A superheater increases the temperature of the
steam without increasing it’s pressure. The heat given up by
the hot flue gases are used for superheating the steam.
3. Economiser: It is a device used to heat feed water by utilising
the heat in the flue gases before leaving through the chimney.
4. Air preheater: It is installed between the economiser and the
chimney. It recovers the heat from the exhaust flue gases.
Boiler Accessories

To Engine
Steam

Economiser Air To
preheater Chimney
Boiler Superheater

Gases

Ash
Feed Pump
Water

Air
Water
Air