STEAM BOILERS,

MOUNTINGS
&
ACCESSORIES
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

STEAM GENERATOR/
BOILER

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 STEAM BOILERS, MOUNTINGS & ACCESSORIES

The equipment used for

producing and transferring
steam is called
Steam generators/
Boilers.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

Principle of Steam Generators/ Boilers:

The fluid (water) contained in the boiler

called shell and the thermal energy released
during combustion of fuel, which may be
solid, liquid or gaseous, is transferred to
water and this converts water into steam at
the desired temperature and pressure.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

Commercial usage of

Steam
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 STEAM BOILERS, MOUNTINGS & ACCESSORIES

Commercial usage of Steam:

i) Power generation
ii) Heating the residential and
commercial buildings in cold
weather countries.
iii) Other industrial usages e.g. sugar
industries and chemical industries
etc.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

Classification of

Boilers
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

Classification of Boilers:
Boilers may be classified according to the following-
1. Relative position of Hot gases and Water
a) Fire tube boiler:
The hot gases passes through the tubes that are
surrounded by water. Fire tube boilers are also
known by certain common names-
i) Horizontal return tubular
ii) Locomotive fire box
iii) Scotch marine and,
iv) Vertical tubular
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

b) Water tube Boiler:

The water passes through the tubes and the hot

gases produced by combustion of fuel, flow
outside. This type of Boilers designated by the
following common names:
i) Babcock and Wilcox Boiler (straight but
inclined tubes which connect the headers).
ii) Stirling Boiler (multitubular boiler having bent
tubes that connect boiler drums to headers).
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

2. Method of firing
a) Internally fired Boilers:

The furnace is provided inside the boiler shell

and is completely surrounded by water cooled
surfaces. This method of firing is used in:
• Lancashire Boilers
• Locomotive Boilers and
• Scotch Boilers
 STEAM BOILERS, MOUNTINGS & ACCESSORIES
b) Externally fired Boilers:

The furnace is provided outside/ under the boiler. It has

an advantage that its furnace is simple to construct and
can easily be enlarged, as and when required. This
method of firing is used in Babcock and Wilcox Boiler.

3) Pressure of Steam:

i) High pressure Boilers:

Boilers producing steam 80 bar and above are called
High pressure boilers. E.g.
* Babcock and Wilcox Boiler
* Lamont Boilers
* Velox Boilers and
* Benson Boilers etc.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

ii) Low pressure Boilers:

Boilers producing steam Lower than 80 bar are called

Low pressure boilers. E.g.

• Cochran Boilers
• Cornish Boiler
• Lancashire Boiler
• Locomotive Boiler
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

4. Method of circulation of water:

a) Natural circulation method

Circulation set up by convection current or by
gravity.
b) Forced circulation method
Circulation set up for high pressure steam through
pumps.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

5. Nature of service to be performed:

a) Land Boilers:
Boilers which are used with stationary plants
b) Portable Boilers:
Boilers which can be readily dismentaled and easily
carried out from one site to another.
c) Mobile Boilers:
Boilers which are fitted on mobile carriages are called
Mobile Boilers. E.g. marine and locomotive boilers.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES
6. Once through Boilers:
The boilers in which no circulation of water takes
place i.e. the feed water leaves the tube as steam
e.g. Benson Boilers.
7. Position and No. of Drums:
Single or multidrums may be positioned
longitudinally or crosswise.
8. Design of gas passages:
a) Single pass
b) Return pass
c) Multipass
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

9. Nature of Draught:
a) Natural Draught:
when the fuel burns in the furnace of the boiler, with
the circulation of air, the draught is named as Natural
Draught.
b) Artificial Draught:
When the air is forced by means of forced fan, the
draught is named as Artificial Draught.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

10.Heat Source:
a) Combustion of solid, liquid or gaseous fuel.
b) Electrical and nuclear energy.
c) Hot waste gases of other chemical reactions.

11. Fluid Used:

a) Steam Boilers- use water as a fluid.
b) Mercury Boilers- use mercury as a fluid.
c) Other Boilers- use special chemicals as a fluid.
 STEAM BOILERS, MOUNTINGS & ACCESSORIES

12. Material of construction of Boiler Shell:

a) Cast Iron Boilers: Low pressure heating

Boilers.
b) Steel Boilers: Low pressure heating Boilers.
c) Copper and Stainless steel Boilers: Miniature
Boilers.
FIRE TUBE BOILER
 Fire tube boiler
• Cochran Boiler
• Simple vertical boiler
• Suitable for small plants
require small quantity of
steam.
• Size = 1 m Dia. x 2 m high
(evaporation 20kg/hr.)
• Size = 3 m Dia. x 6 m high
(evaporation 3000kg/hr.)
• Heating surface= 10 to 25
times of grate area
• Steam pressure= upto 20 bar
• Efficiency = 70 to 75%
WATER TUBE BOILERS
BABCOCK & WILCOX BOILERS
BABCOCK & WILCOX BOILERS
(Constructional features)
 It consist of welded steel high
pressure drum mounted at the top.
 Drum is connected with uptake
header and down take header.
 Water tubes connected to the
headers are inclined at 150 to the
horizontal.
 Water tubes are straight and 10cm
diameter expended into the bored
holes of header.
 Serpentine from of header provides
complete heating surface to the flue
gases.
 Furnace is arranged below the
uptake header.
BABCOCK & WILCOX BOILERS
(Constructional features)
 Unit is provided with chain grate stroker.
 Speed of chain is adjusted with respect to
the complete combustion of coal.
 Deflectors to flue gases are provided in
the form of baffles.
 Mud Box: To collect the sedimentation in
water.
 Super heater tubes: To enhance the super
heated steam.
 Vents provided: safety valve, pressure
gauge, water level indicator, fusible plug
and feed check valve.
 Water tube and drum assembly hung on
steel girder frame called slings.
BABCOCK & WILCOX BOILERS
(Capacity and utility)

Evaporative capacity ranges from 20000 to 40000

kg/hr
Operative pressure ranges from 11.5 to 17.5 bar.
Steam formed from such boilers are primarily used
to run steam turbines and generate electric power.
BABCOCK & WILCOX BOILERS
(Salient Aspects)

 Capability to cope with high peak loads which are

generally needed in thermal power stations.
 Inspection of the boiler can be carried even when the
boiler is in operation.
 Draught loss is minimum.
 Replacement of defective tubes can be made easily.
COMPARISION Between
WATER TUBE & FIRE TUBE BOILERS
WATER TUBE FIRE TUBE
Water passes through water tubes. Hot gases passes through flues.
Water content: steam capacity low (high Water content: Steam capacity high (Slow
speed) speed)
Complexity in design requires quick Simple & rigid construction hence greater
examination by skilled hands. reliability & low operating cost.
Operating pressure up to 200 bar. Pressure ranges from 17.5 bar to 24.5 bar

Evaporation rate ranges from 20,000 to Evaporation rate 900kg/hr.

50,000kg/hr.
Increased heating surface area. Low heating surface area.
Low water to steam ratio Large water to steam ratio
Bigger in size, suitable for large power Smaller in size, used only for small power
plants plants
Transportation and installation is easy Transportation and installation is difficult
due to handling of dismentaled parts due to large size of shell.
Externally fired boilers, furnace size can Internally fired boilers, furnace size can
be varied. not be varied.
Requires more floor area Requires less floor area
ESSENTIALS OF A GOOD
BOILER

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 ESSENTIALS OF A GOOD BOILER

1. Heat generation capability should be at:

a) Required pressure
b) Required quality
c) Fast speed
d) Minimum fuel consumption
2. Economic :
a) Low initial cost
b) Low installation cost
c) Low operating cost
d) Low maintenance cost
 ESSENTIALS OF A GOOD BOILER

3. Construction:
a) Light in weight
b) Less amount of brick work
c) Occupy small floor area

4.Quick starting.
5.Capable to meet fluctuating demand of steam supply.
6. Easy availability of spare parts
BOILER MOUNTINGS AND
ACCESSORIES

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 BOILER MOUNTINGS AND ACCESSORIES

Boiler Mountings:
The necessary devices installed or mounted for the safety
of boiler and its control are called boiler mountings.
 BOILER MOUNTINGS AND ACCESSORIES

Boiler Accessories:
The devices which are installed in the boiler for their
efficient operation and smooth working are called Boiler
Accessories.
 BOILER MOUNTINGS AND ACCESSORIES

Boiler Mountings for safety:

1. Two water level indicators – 2

2. Two safety valves.
3. Combined high steam and low water safety valve.
4. Fusible plug.
 BOILER MOUNTINGS AND ACCESSORIES

Boiler Mountings for control:

1. Pressure gauge
2. Junction or stop valve
3. Feed check valve
4. Blow-off cock
5. Man hole and mud hole
 BOILER MOUNTINGS AND ACCESSORIES

Boiler Accessories for efficient operation:

1. Water heating devices.

2. Water feeding devices.
3. Super heater
4. Economizer
5. Air preheater
BOILER MOUNTINGS
 BOILER MOUNTINGS
1. WATER LEVEL INDICATOR
 BOILER MOUNTINGS

2. PRESSURE GAUGE
(Bourdon’s) (Dec 05)

a) Records gauge pressure

b) Elliptical spring tube is also called

Bourdon tube and is made up of special
quality Bronze.

c) Plug (P) is provided for cleaning the

siphon tube.

d) Siphon is filled with cold water to

prevent the hot steam entering into the
bourdon tube and spring tube remains
comparatively cool.
SAFETY VALVES
Dead Weight safety valve
LEVER SAFETY VALVE
SAFETY VALVES
SPRING LOADED SAFETY HIGH STEAM AND LOW WATER
VALVE SAFETY VALVE
JUNCTION VALVE:
The valve placed directly on a boiler in order to regulate the
steam supply from boiler to steam pipe is called the
Junction Valve.

STOP VALVE:
The valve used to regulate the steam supply from the steam
pipe to the prime mover (steam engine or steam turbine) is
called Stop Valve.
JUNCTION VALVE
FEED CHECK VALVE
1. Feed check valve
works as NRV
(Non- return
valve).
2. Prevents the back
flow of water from
the boiler when
the feed water
pump is either not
working or in case
of its failure.
BLOW-OFF COCK
FUSIBLE PLUG
 Plugs P and R are
made up of Gun
Metal.
 Plug S is made up
of Copper.
 Plug R is screwed
to the plug P.
 Plug S is locked
into plug R by a
metal like tin or
lead.
MANHOLE

This is provided at suitable position on the boiler

shell so that the man can enter into boiler shell for
inspection, maintenance and repairs. This hole is
usually made in elliptical shape of the size
convenient for a man to enter through this hole.
The opening is closed by steam tight cover.
STEAM TRAP
Steam trap is used to collect and automatically drain
away the water resulted from partial condensation
of steam without steam to escape with this
condensate through a valve. The valve after draining
the condensate is closed. Is presses the leakage of
steam from the trap.
ANTIPRIMING PIPE
It is attached below the stop valve to avoid the water
particles being carried away along with steam. It has closed
pipe with closed ends of 1m and 2m length. The top side of
the pipe has perforations. When the steam passes through it,
due to inertia effect, the moisture of steam falls into the
pipe and the steam with reduced moisture passes into the
stop valve.
BOILER ACESSORIES

The devices used to improve

the performance and operation
of the boilers are called boiler
accessories. Main accessories
used are:
BOILER ACCESSORIES
 WATER HEATING DEVICES
Used to heat the feed water before it is fed to boiler with the help of steam of
a steam engine.

Heating of feed water can be carried out either by:

1. Open Heater- Direct mixing
2. Closed heater- Indirect convection
WATER FEEDING DEVICES
Used to supply water while the boiler is in operation. These devices
include the use of feed pumps either reciprocating type or centrifugal
type.
INJECTOR
SUPER HEATERS
ECONOMISER
AIR PREHEATER