It is a great pleasure to present this project report carried out in the

BIRSA INSTITUTE OF TECHNOLOGY, SINDRI.

I express my heartily gratitude to
P ROF . S .C. R OY
(HOD, Mechanical Engineering Department) who gave me an
opportunity to undergo this project.
I am very thankful to
PROF. MANOJ KUMAR SINGH
(ASSOCIATE PROFESSOR , MECHANICAL ENGINEERING)
for his excellent guidance and co-operation for the successful completion of my
project.

PRESENTED BY:
1. AKASH CHOUDHARY (1300006)
2. ANUJ KUMAR DAS (1300016)
3. BOBBY KARMALI (1300021)
4. CHANDAN KUMAR (1300023)
5. JUNED ALAM (1300032)
6. PAWAN KUMAR MEHTA (1300052)
7. PRAKASH KUMAR AGARWAL (1300056)
8. RAHUL KUMAR BHARTI (1300060)
9. SANJAY KUMAR (1300080)
10.SUDEEP MUKHERJEE (1300090)
11.JAI PRAKASH MAHTO (1400004D)
12.AJAY KUMAR SAO (1400005D)
13.RANJEET KUMAR MEHTA (1400006D)
 INDEX

1. BABCOCK AND WILCOX (WATER TUBE BOILER)

2. BOILER TERMINOLOGY
3. COMBUSTION EQUIPMENT FOR STEAM BOILER
4. BOILER MOUNTING
5. BOILER ACCESSORIES
6. CONSTRUCTION OF BOILER
7. BIBLIOGRAPHY
Babcock and Wilcox Boiler is a water tube boiler which is mainly used in steam
power plants. Steam power plants operation is based on fluid flowing inside the
tubes absorbs heat from hot gases which flow over the tubes. The same way, in
Babcock and Wilcox boiler water gets circulated inside the tubes where hot
gases flow over the tubes. These types of boilers are mainly helpful for usage in
stationary and marine engines. These types of boilers are also used in Royal
Navys.
OUR BOILER MODEL:
OUR MODEL

WORKING

FEATURES

1. The evaporative capacity of this boilers high compared

with other boilers (20,000 to 40,000kg/hr).The operating
pressure lies between 11.5 to 17.5 bar.

2. The draught loss is minimum compared with

other boilers.

3. The defective tubes can be replaced easily.

4. The entire boiler rests over an iron structure,
independent of brick work, so that the boiler may expand
or contract freely. The brick walls which form the
surroundings of the boiler are only to enclose the furnace
and the hot gases

INTRODUCTION TO BOILERS

The steam generator or boiler is an integral component of a steam

engine when considered as a prime mover. However it needs be treated
separately, as to some extent a variety of generator types can be
combined with a variety of engine units. A boiler incorporates
a firebox or furnace in order to burn the fuel and generate heat. The
generated heat is transferred to water to make steam, the process of
boiling. This produces sa t urated steam a t a rate which can vary
according to the pressure above the boiling water. The higher the
furnace temperature, the faster the steam production. The saturated
steam thus produced can then either be used immediately to produce power via a
turbine and alternator, or else may be further superheated to a
higher temperature; this notably reduces suspended water content
making a given volume of steam produce more work and creates a greater
temperature gradient, which helps reduce the potential to
form condensation. Any remaining heat in the combustion gases can then either
be evacuated or made to pass through an economiser, the role of which is to
warm the feed water before it reaches the boiler. Boilers have several
strengths that have made them a common feature of buildings. They have
a long life, can achieve efficiencies up to 95% or greater, provide an
effective method of heating a building, and in the case of steam systems,
require little or no pumping energy .However, fuel
costs can be considerable, regular maintenance is required, and if
maintenance is delayed, repair can be costly. Guidance for the
construction, operation, and maintenance of boilers is provided
primarily by the ASME (American Society of Mechanical Engineers),
which produces the following resources:
 Rules for construction of heating boilers, Boiler and Pressure Vessel Code
, Section IV-2007

Recommended rules for the care and operation of heating boilers,

Boiler and Pressure Vessel Code, Section VII-2007

3.COMBUSTION EQUIPMENT FOR

STEAM BOILER:

LPG cylinder with burner was used in our project as a combustion equipment.
Liquefied petroleum gas or liquid petroleum gas (LPG or LP gas), also referred to
as simply propane or butane, are flammablemixtures of hydrocarbon gases used
as fuel in heating appliances, cooking equipment, and vehicles.
It is increasingly used as an aerosol propellant and
a refrigerant, replacing chlorofluorocarbons in an effort to reduce damage to theozone
layer. When specifically used as a vehicle fuel it is often referred to as autogas.
Varieties of LPG bought and sold include mixes that are mostly propane (C3H8),
mostly butane(C4H10)
and, most commonly, mixes including both propane and butane. In the northern
hemisphere winter, the mixes contain more propane, while in summer, they contain
more butane.In the United States, mainly two grades of LPG are sold: commercial
propane and HD-5. These specifications are published by the Gas Processors
Association (GPA) and the American Society of Testing and Materials (ASTM).
 4.BOILER MOUNTING
Mainly four (4) mountings have been used in this Boiler

1. Water level indicator. (Water gauge)

2. Main steam stop valve.
3. Pressure gauge
4. Safety valve
.

1. WATER LEVEL INDICATOR

FUNCTION:
It indicate the water level inside the boiler vessel. It shows the
level in the boiler drum.

CONSTRUCTION:
Normally two water level indicator are fitted to the boiler. these are
fitted at the front end of every boiler. Water level indicator consist
three cock as steam cock, water cock, drain cock and glass tube. The
steam cock connect or disconnects the glass tube with steam space.
while water cock connect or disconnect the glass tube with water in
the boiler. the drain cock is used to drain out the water in from glass
tube at interval to ensure that the steam
 and water cock are clear in operation. The glass tube protected by
means of a cover,and made of specially

WORKING:
When steam cock and water cock opened, steam rushes from upper
passage and water rushed from lower from passage to the glass tube.
This will indicate the level of water in the boiler.
Two ball are places at the junction of metal tube. Under normal
operating condition the ball are kept. full line circle in case the
glass tube is broken, steam will rushes from upper passage and
water from lower passage due to pressure difference between boiler
pressure at atmospheric pressure. the ball are carrier along the
passage to and of glass tube and then closed passages. This position
of ball sown in fig by dotted circle. Thus flow of water and steam
out of boiler is prevented.

2. STEAM STOP VALVE:

FUNCTION:It regulate the flow of steam from boiler to the

steam pipe or from one steam pipe to the other.
CONSTRUCTION:

The common type of steam stop valve. The flange of valve body
bolted to the boiler at the highest part of steam space. It consist of
valve seat and nut. The main body of valve is made of cast iron and
valve seat made from gun metal.
when steam stop valve is placed directly over the boiler and
connected to the steam pipe line is called the junction valve. If it is
placed near to prime mover than normally called steam stop valve.

WORKING:
The spindle it rotated by help of hand wheel due to rotation of
spindle the valve move up and down. When the valve sits over the
valve seat, the passage of steam is completely closed. The steam passage
may be partially or fully opened by moving the valve up, help of
rotating the hand wheel the clearance (passage) between valve and
valve seat regulates the flow of steam out of boilers. in locomotive
boilers, the supply of the steam is
regulated by means of a regulator which is placed inside boiler cell
and operated by a handle from drivers cabin.
 3.PRESSURE GAUGE
FUNCTION : It indicates the pressure of steam in boiler.

CONSTRUCTION:
The gauge is usually mounted on the front top of the shell or on the drum.
It is having dial which graduated to read pressure in bar, above
atmosphere A bourdon tube gauge with its interior mechanism is shown in
fig. The circular bent bourdon tube of oval-cross section is close at one end
and connected at the other end to steam space of boiler through siphon
(U-tube). The siphon is filled with water which prevents hot steam from
entering the pressure gauge and keeps the gauge cool. Closed end
of bourdon tube is attached to a toothed quadrant with help of link and
pin. This quadrant meshes with a small pinion on the central spindle.

WORKING:
When pressure is applied to inside of oval bourdon tube. It cross
section tends to becomes circular, and free end of bourdon tube try to
becomes straight, so turning the spindle by the links and gearing. This
causes the needle to move and indicate pressure on graduated dial.
4. SAFETY VALVE:
Function :
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
of steam in the boiler drum exceeds the working pressure then the safety
valve allows blow-off the excess quantity of steam to the atmosphere. Thus
the pressure of steam in the drum falls. The escape of steam makes a audio
noise to warm the boiler attendant

DEAD WEIGHT SAFETY VALVE

CONSTRUCTION:
It consists of valve V is placed upon a valve seat which is fix upon a long
vertical pipe having a flange at the bottom for fixing at the top of the
boiler. The weight carrier D suspended from the top of the valve which
carries cast iron rings (weight) as shown figure. The total
weight must be sufficient to keep the valve on it seats against the
normal working pressure
WORKING:
When the steam pressure exceeds the normal limits, this high pressure
stream creates upward force on valve, thus valve V lift with its weights
and the excess steam escapes through the pipe to the outside.
The construction of this valve is simple. It gives satisfactory operation for
low pressure and stationary boilers. It is not suitable for
moving boilers as the force of the weights should always work vertically
downward.

5.BOILER ACCESSORIES
These are auxiliary plants or parts required for steam
boilers for their proper operation and to increased
efficiency of the boilers

(1) Feed pump

(2) Injector
(3) Economiser
(4) Air preheater
(5) Superheater
(6) Steam separator
(7) Steam trap

FEED PUMP:
FUNCTION:
The feed pump is a pump which is used to deliver feed
water to the boiler.
Double feed pump is commonly employed for medium size
boilers.
Types of Feed pumps
There are Three types of feed Pumps mainly:
Reciprocating pumps {simplex,duplex,Triplex}
Rotary pumps
Centrifugal pumps

RECIPROCATING DUPLEX PUMP:

Duplex pump is very common steam driven reciprocating
pump. It consist of two steam cylinder placed side by side.
There are two steam ports for each of the cylinders.

INJECTORS:

FUNCTION : Injector is used to feed water in the boiler.

It is commonly employees for vertical boiler and does not
find its application in large capacity high pressure
boilers . it also uses more space is not available for the
installation for feed pump.
 Construction: It consists of spindle,a steam cone ,a
combine cone,a delivery cone and a handle
The lower end of the spindle works as the valve and the
upper end is fitted with the handle.The rotation of the
handle cause an upward or downword movement of the
steam cone.

ECONOMISER:
FUNCTION: Economiser increases the temperature of feed
water using waste of heat to flue gases leaving the boiler
through chimney.

CONSTRUCTION: It consists of spindle,a steam cone

,a combine cone,a delivery cone and a handle
The lower end of the spindle works as the valve and the
upper end is fitted with the handle.The rotation of the
 handle cause an upward or downword movement of the
steam cone.
WORKING:
Economiser consist of a large vertical cast iron or steel
water pipes,one end of vertical pipes is connected with
vertivcal pipes A and other end with B. Hot flue gases from
boiler pass over the vertical tubes .The heat transfer take
place from flue gases to cold water rising in vertical tubes

SUPERHEATER:
The function of super heater is to increase the temperature of the
steam above its saturation point.

WORKING:
To superheat the steam generated by boiler.
Super heaters are heat exchangers in which heat is
transferred to the saturated steam to increase its
temperature.
Superheated steam has the following
advantages :
i) Steam consumption of the engine or turbine is reduced.
 ii) Losses due to condensation in the cylinders and the
steam pipes are reduced.
iii)Erosion of turbine blade is eliminated.
iv) Efficiency of steam plant is increased

SPECIFICATIONS & MATERIAL:

DRUM THICKNESS: 0.5 CM=5MM (MILD STEEL)

SAFETY VALVE (BRASS)
WATER TUBE (COPPER) = 0.5 INCH
RISER (COPPER) AND DOWNCOMER (COPPER): 1 INCH(DIAMETER)
STAND : MILD STEEL
ANGLE: 15 DEGREE
RISER HEIGHT :14 INCH
DOWNCOMER HEIGHT: 17 INCH
REFERENCES
1. Capehart, B., Turner, W. and Kennedy, W., 2006.

Guide to Energy Management

2. ASHRAE Handbook, HVAC Systems and Equipment, 2008.

3. Boiler and Heaters, Improving Energy Efficiency, Canadian Industry Program for
EnergyConservation, August 2001
http://oee.nrcan.gc.ca/publications/infosource/pub/cipec/boilersheaters.PDF

4. Federal Energy Management Program Fact Sheet, PNNL, January

2005.http://www1.eere.energy.gov/femp/pdfs/om_combustion.pdf

5. FEMP O&M Best Practices, a Guide to Achieving Operational Efficiency, U.S.Department of

Energy, August
2010.http://www1.eere.energy.gov/femp/pdfs/omguide_complete.pdf

6. Efficient Boiler Operations Sourcebook, Fourth Edition, F. William Payne

and Richard E.Thompson, 1996.7. The Control of Boilers, 2nd Edition, Sam G. Dukelow,
1991.

O th e r Re s o ur c e s

1. The National Board of Boilers and Pressure Vessel

Inspectors,http://www.nationalboard.org/default.aspx.2. 2010 ASME Boiler
and Pressure Vessel Code
2.BOILER TERMINOLOGY
Absolute pressure - The pressure above zero pressure, equal; to gauge
pressure plus atmospheric pressure.
Air-fuel ratio - The ratio weight, or volume, of air to fuel.
Air heater or air preheater - Heat-transfer apparatus through which air
is passed and heated by a medium of higher temperature, such as the
products of combustion or steam.
Allowable working pressure - The maximum pressure for which the
boiler was designed and constructed; the maximum gauge pressure on a
complete boiler; and the basis for the setting on the pressure relieving
devices protecting the boiler.
Atomizer - part of an oil gun which breaks up the fuel oil flow into tiny
particles by both mechanical means the use of an atomizing medium. The
oil and atomizing medium mix together in the atomizer and then flow to
the oil tip to be discharged into the furnace.
Blowdown - The drain connection including the pipe and the valve at the
lowest practical part of a boiler, or at the normal water level in the case of
a surface blowdown. The amount of water blown down.
Blower - A fan used to force air under pressure.
Bourdon tube - A hollow, metallic tube, bent semicircular, which forms
the actuating medium of a pressure gauge.
Burner - A device which combines fuel and air in proper proportions for
combustion and which enables the fuel-air mixture to burn stably to give a
specified flame size and shape.
Check valve - A valve designed to prevent reversal of flow. Flow in one
direction only is permitted.
Corrosion - The wasting away of metals as a result of chemical action. In
a boiler, usually caused by the presence of O2, CO2, or an acid.
Critical pressure and critical temperature - That point at which the
difference between the liquid and vapor states for water completely
disappears.
Economizer - A series of tubes located in the path of flue gases.
Feedwater is pumped through these tubes on its way to the boiler in order
to absorb waste heat from the flue gas.
Firebox - The equivalent of a furnace. A term usually used for furnaces of
locomotive boilers and similar types of boilers.
Firetube - A tube in a boiler having water on the outside and carrying the
products of combustion on the inside.
Flue - A passage for products of combustion.
Flue gas - The gaseous products of combustion in the flue to the stack.
Forced-draft fan - A fan supplying air under pressure to the fuel burning
equipment.
Fouling - The accumulation of refuse in gas passages or on heat
absorbing surfaces which results in undesirable restrictions to the flow of
gas or heat.
Makeup water - The amount of raw water necessary to compensate for
the amount of condensate that is not returned in the feedwater supply to
the boiler.

Manhole - An access opening to the interior of a boiler, elliptical and 11

in. by 15 in. or larger or circular 15-in. diameter or larger.