Boiler 2013

BOILER
INTRODUCTION
Boiler, also called steam generator is the engineering device which generates steam at constant pressure. It is a closed vessel, generally made of steel in which vaporization of water takes place. Heat required for vaporization may be provided by the combustion of fuel in furnace, electricity, nuclear reactor, hot exhaust gases, solar radiations etc. TYPES OF BOILERS Boilers are of many types. Depending upon their features they can be classified as given under: (a) Based upon the orientation/axis of the shell: According to the axis of shell boiler can be classified as: (i) Vertical boiler has its shell vertical. (ii) Horizontal boiler has its shell horizontal. (iii) Inclined boiler has its shell inclined. (b) Based upon utility of boiler: Boilers can be classified as (i) Stationery boiler, such boilers are stationery and are extensively used in power plants, industrial processes, heating etc. (ii) Portable boiler, such boilers are portable and are of small size. These can be of the following types, 1. Locomotive boiler, which are exclusively used in locomotives. 2. Marine boiler, which are used for marine applications. (c) Based on type of firing employed: According to the nature of heat addition process boilers can be classified as, (i) Externally fired boilers, in which heat addition is done externally i.e. furnace is outside the boiler unit. Such as Lanchashire boiler, Locomotive boiler etc. (ii) Internally fired boilers, in which heat addition is done internally i.e. furnace is within the boiler unit. Such as Cochran boiler,Babcock Wilcox boiler etc.

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(d) Based upon the tube content: Based on the fluid inside the tubes, boilers can be, (i) Fire tube boilers, such boilers have the hot gases inside the tube and water is outside surrounding them. Examples for these boilers are, Cornish boiler, Cochran boiler, Lancashire boiler, Locomotive boiler etc. (ii) Water tube boilers, such boilers have water flowing inside the tubes and hot gases surround them. Examples for such boilers are Babcock-Wilcox boiler, Sterling boiler, La-Mont boiler, Benson boiler etc. (e) Based on type of fuel used: According to the type of fuel used the boilers can be, (i) Solid fuel fired boilers, such as coal fired boilers etc. (ii) Liquid fuel fired boilers, such as oil fired boilers etc. (iii) Gas fired boilers, such as natural gas fired boilers etc. (f) Based on circulation: According to the flow of water and steam within the boiler circuit the boilers may be of following types, (i) Natural circulation boilers, in which the circulation of water/steam is caused by the density difference which is due to the temperature variation. (ii) Forced circulation boilers, in which the circulation of water/steam is caused by a pump i.e. externally assisted circulation.

REQUIREMENTS OF A GOOD BOILER

Different requirements of a good boiler are given below. In general boiler is supposed to generate large quantity of steam at desired pressure and temperature quickly and efficiently. (a) It should be capable of generating steam at desired rate at desired pressure and temperature with minimum fuel consumption and cost. (b) It should have sufficient steam and water storage capacity to meet fluctuation in demand and to prevent fluctuation in steam pressure or water level. (c) Boiler should have a constant and thorough circulation of water. (d) It should be equipped with all necessary mountings. (e) Boiler should have capability to get started quickly from cold.

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(f) Its construction should be simple and have good workmanship for the ease of inspection and repairs i.e. easily accessible parts. (g) Boiler should have its heating surface nearly at right angle to the current of hot gases for good heat transfer. (h) There should be minimum frictional power loss during flow of hot gases and water/steam i.e. pressure drop throughout the system should be minimum. (i) Tubes should be so designed so as to have minimum soot deposition and good strength against wear. Boiler should have a mud drum to receive all impurities. (j) Boiler should have strength to withstand excessive thermal stresses. (k) Boiler should occupy less floor area and space.

WATER TUBE BOILER

The water-tube boiler was patented in 1867 by American inventors George Herman Babcock and Stephen Wilcox. A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the fire. Water tube boilers are used for high-pressure boilers. Fuel is burned inside the furnace, creating hot gas which heats water in the steam-generating tubes. In the water-tube boiler, water flowed through tubes heated externally by combustion gases, and steam was collected above in a drum. Water tube boilers are very huge and their water holding capacity is enormous. The water-tube boiler became the standard for all large boilers as they allowed for higher pressures than earlier boilers, higher than 30 bar. Example, Babcock & Wilcox boiler manufactured at Thermax Boilers Ltd., Pune. It is a horizontal, externally fired, stationary, high pressure, water tube boiler with a super heater as shown below.

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The coal is fed from hopper on to the grate where it is burnt. The flue gases are deflected by the fire brick baffles so that they pass across the left side of the tubes in a beneficial path transferring heat to water in the tubes and to the steam in the super heater and finally they escape into the atmosphere through the chimney. The drought is regulated by a damper placed at the back chamber. The position of water tubes near the furnace is heated to a highertemperature than the rest. Owing to higher temperature, the density of water decreases and hence the water rises through the uptake header and short tube to the drum. The water at the back end, which is at a lesser temperature now travels down through the long tube and the down-take header. Thus, a continuous circulation of water called as natural circulation is established between the water tubes and the drum. The steam produced gets collected above the water in the drum. Here, saturated steam is drawn off the top of the drum. Since water droplets can severely damage turbine blades, dry steam from the steam drum is again heated to generate superheated steam at 730F (390C) or higher in order to ensure that there is no water entrained in the steam. Cool water at the bottom of the steam drum returns to the feed water drum via large-bore 'downcomer tubes', where it helps pre-heat the feedwater supply.

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To increase the economy of the boiler, the exhaust gasses are also used to preheat the air blown into the furnace and warm the feedwater supply. Such water-tube boilers in thermal power station are also called steam generating units.

Water tube boilers may be further classified based on type of tubes employed. These can be A. Straight water tube boilers: Straight water tube boilers are those in which tubes carrying water are straight from one end to the other end. B. Bent water tube boilers: Bent water tube boilers are those in which bent tubes are employed for carrying water. Bent water tubes are advantageous over straight water tubes in many respects. Bent tubes offer better access into boiler and ease of inspection and maintenance. Also tube arrangement can be modified so as to maximize heating surface and exposure of tubes to hot gases.

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 by thermal conduction, heating the water and ultimately creating steam. This has a cylindrical barrel containing the fire tubes, but also has an extension at one end to house the "firebox". This firebox has an open base to provide a large grate area and often extends beyond the cylindrical barrel to form a rectangular or tapered enclosure. Firetube boilers are often characterized by their number of passes, referring to the number of times the combustion (or flue) gases flow the length of the pressure vessel as they transfer heat to the water. Each pass sends the flue gases through the tubes in the opposite direction. To make another pass, the gases turn 180 degrees and pass back through the shell. The turnaround zones can be either dryback or water-back. In dryback designs, the turnaround area is refractory lined. In water-back designs, this turnaround zone is water-cooled, eliminating the need for the refractory lining.

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The number of passes the boiler contains affects the boiler efficiency, and its first cost to manufacturer. The more heat transfer surfaces the boiler has, the more efficient it can be. However, this also increases the amount of material it contains and therefore the first cost.

TYPES OF FIRE-TUBE BOILER:

I. II. III. IV. V. VI. VII. Cornish boiler. Lancashire boiler. Scotch marine boiler Locomotive boiler Vertical Fire-Tube boiler Horizontal Return Tubular boiler Immersion fired boiler

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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

Construction of Babcock and Wilcox Boiler

The Babcock and Wilcox Boiler consists of 1. Steam and water drum (boiler shell) 2. Water tubes 3. Uptake-header and down corner 4. Grate 5. Furnace 6. Baffles 7. Super heater 8. Mud box 9. Inspection door 10.Damper

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.

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SUPERHEATER: The boiler is fitted with a superheater tube which is placed just under the drum and above the water tubes. MUD BOX: Mud box is provided at the bottom end of the down comer. 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. INSPECTION DOORS: Inspection doors are provided for cleaning and inspection of the boiler.

WORKING BABCOCK AND WILCOX BOILER:

Coal is fed to the grate through the fire door and is burnt. 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 (i.e., 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. A damper is fitted as shown to regulate the flue gas outlet and hence the draught. The boiler is fitted with necessary mountings. Pressure gauge and water level indicator are mounted on the boiler at its left end. Steam safety valve and stop valve are mounted on the top of the drum. Blow-off cock is provided for the periodical removed of mud and sediments collected in the mud box.

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ADVANTAGES AND DISADVANTAGES OF WATER TUBE BOILERS OVER FIRE TUBE BOILERS: ADVANTAGES WATER TUBE BOILERS 1. Steam can be generated at very high pressures. 2. Heating surface is more in comparison with the space occupied, in the case of water tube boilers. 3. Steam can be raised more quickly than is possible with a fire tube boiler of large water capacity. Hence, it can be more easily used for variation of load. 4. The hot gases flow almost at right angles to the direction of water flow. Hence maximum amount of heat is transferred to water. 5. A good and rapid circulation of water can be made. 6. 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. 7. The different parts of a water tube boiler can be separated. Hence it is easier to transport. 8. It is suitable for use in steam power plants (because of the various advantages listed above). DISADVANTAGES OF WATER TUBE BOILERS 1. 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. 2. Maintenance cost is high. 3. Failure in feed water supply even for a short period is liable to make the boiler overheated. Hence the water level must be watched very carefully during operation of a water tube boiler.

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COCHRAN BOILER:
It is a multi-tubular vertical fire tube boiler having a number of horizontal fire tubes. T is the modification of a simple vertical boiler where the heating surface has been increased by means of a number of fire tubes

It consists of 1. Shell 2. Crate 3. Fire box 4. Flue pipe 5. Fire tubes 6. Combustion chamber 7. Chimney 8. Man-hole

Shell: It is Grate: It is

hemispherical on the top, where space is provided for steam. placed at the bottom of the furnace where coal is burnt.

Fire box (furnace): It is also dome-shaped like the shell so that the gases can be deflected back till they are passed out through the flue pipe to the combustion chamber. Flue pipe: It is a short passage connecting the fire box with the combustion chamber. Fire tubes: A number of horizontal fire tubes are provided, thereby the heating surface is increased. Combustion chamber: It is lined with fire bricks on the side of the shell to prevent overheating of the boiler. Hot gases enter the fire tubes from the flue pipe through the combustion chamber.

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Chimney: It is provided for the exit of the flue gases to the atmosphere from the smoke box. Manhole: It is provided for inspection and repair of the interior of the boiler shell. Normal size of a Cochran boiler: Shell diameter 2.75 meters:, Height of the shell 6 meters. WORKING OF THE COCHRAN 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 by convection. 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.

SALIENT FEATURES OF COCHRAN BOILER:

1. The dome shape of the furnace causes the hot gases to deflect back and pass through the flue. The un-burnt fuel if any will also be deflected back. 2. Spherical shape of the top of the shell and the fire box gives higher area by volume ratio. 3. It occupies comparatively less floor area and is very compact. 4. It is well suited for small capacity requirements. THE FOLLOWING MOUNTINGS ARE FITTED TO THE BOILER:

Pressure gauge: this indicates the pressure of the steam inside the boiler. Water gauge: this indicates the water level in the boiler. The water level in the
boiler should not fall below a particular level, otherwise the boiler will be over heated and the tubes may burn out.

Safety valve: the function of the safety valve is to prevent an increase of steam
pressure in the boiler above its normal working pressure.

Steam stop valve: it regulates the flow of steam supply to requirements. Blow-off cock: it is located at the bottom of the boiler. When the blow-off cock is
opened during the running of the boiler, the high pressure steam pushes (drains) out the impurities like mud, sand, etc., in the water collected at the bottom.

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LANCASHIRE BOILER
CONSTRUCTION OF LANCASHIRE BOILER: It consists of 1. Cylindrical shell 2. Furnace tubes, bottom flue and side flues 3. Grate 4. Fire bridge 5. Dampers

CYLINDRICAL SHELL: It is placed in horizontal position over a brick work. It is

partly filled up with water. The water level inside the shell is well above the furnace tubes.

FURNACE TUBES, BOTTOM FLUE AND SIDE FLUES: Two large internal furnace
tubes (flue tubes) extend from one end to the other end of the shell. The flues are built-up of ordinary brick lined with fire bricks. One bottom flue and two side flues are formed by brick setting, as shown in the figure.

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

FIRE BRIDGE: A brickwork fire bridge is provided at the end of the grate to prevent
the flow of coal and ash particles into the interior of the furnace (flue) tubes. Otherwise the coal and ash particles carried with gases form deposits on the interior of the tubes and prevent the heat transfer to the water.

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.

WORKING OF LANCASHIRE BOILER

Coal is fed to the grate fire burnt. The leaving move hot the along gases grate the through hole and the is

furnace (flue) tubes

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upto the back end of the shell and then in the downward direction to the bottom flue. The bottom of the shell is thus first heated. The hot gases, passing through the bottom flue, travel upto the front end of the boiler, where they divide into two streams and pass to the side flues. This makes the two sides of the boiler shell to become heated. Passing along the two side flues, the hot gases travel upto the back end of the boiler to the chimney flue. They are then discharged into the atmosphere through the chimney. With the help of this arrangement of flow passages of hot gases, the bottom of the shell is first heated and then its sides. The heat is transferred to water through the surface of the two flue tubes (which remain in water) and bottom and sides of the shell. The arrangement of flues increases the heating surface of the boiler to a large extent. Dampers control the flow of hot gases and regulate the combustion rate as well as steam generation rate. The boiler is fitted with necessary mountings. Pressure gauge and water level indicator provided at the front. Safety valve, steam stop valve, low water and high steam safety valve and man-hole are provided on the top of the shell. SALIENT FEATURES OF LANCASHIRE BOILER 1. The arrangement of flues in this boiler increases the heating surface of shell to a large extent. 2. It is suitable where a large reserve of steam and hot water is needed. Its maintenance is easy.

3. Superheated can be easily incorporated into the system at the end of the
main flue tubes. Thus overall efficiency of the boiler can be increased.

The End

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