Tugas Bab 11 “Boiler and Boiler Calculations”

1. Define boiler.
A boiler is a closed vessel in which water or other fluid is heated. A boiler or steam
generator is a device used to create steam by applying heat energy to water.

2. Classify the boilers and briefly describe each type of them

Water Tube Boiler: A boiler in which the water flows through some small tubes
which are surrounded by hot combustion gases, e.g., Babcock and Wilcox, Stirling,
Benson boilers, etc.

Fire-tube Boiler: The hot combustion gases pass through the boiler tubes, which are
surrounded by water, e.g., Lancashire, Cochran, locomotive boilers, etc.

3. Enlist the requirements of a good boiler.

A good boiler should have the following characteristics:
- The boiler should have maximum steam generation rate with minimum fuel
consumption.
- It can be started or stopped quickly
- Its initial cost, running and maintenance cost should not be high.
- Its erection time should be less and its parts should be easily dismantable.
- The boiler should have reliable controls and safety apparatus.
- It should have high rate of heat transfer and better combustion efficiency.
- It should be able to accommodate the load variation.
- It should occupy less floor space
- It should be trouble free and require less attention and less maintenance.
- It should be free from manufacturing defects.
- Mud should not get deposited on the heating surface. Soot or scale should not be
deposited on the tubes.
- All parts of boiler should be accessible for cleaning and inspection.

4. Differentiate between fire tube and water tube boilers.

Water Tube Boiler: A boiler in which the water flows through some small tubes
which are surrounded by hot combustion gases
 Fire-tube Boiler: The hot combustion gases pass through the boiler tubes, which are
surrounded by water.

5. Describe briefly a vertical boiler. Also give its’ neat sketch.

A vertical boiler is a type of fire-tube or water-tube boiler where the boiler barrel is
oriented vertically instead of the more common horizontal orientation. Vertical boilers
were used for a variety of steam-powered vehicles and other mobile machines,
including early steam locomotives.

6. Sketch and completely label a Lancashire boiler. Also explain its’ working

- Principle of Lancashire Boiler:

This boiler works on the basic principle of heat ex-changer. It is basically a shell
and tube type heat ex-changer in which the flue gases flow through the tubes and
the water flows through shell. The heat is transfer from flue gases to the water
through convection. It is a natural circulation boiler which uses natural current to
flow the water inside the boiler.

- Working:
 The Lancashire boiler is a shell and tube type heat ex-changer. The fuel is burn at
the grate. The water is pumped into the shell through the economizer which
increases the temperature of water. Now the shell is half filled with water. The fire
tube is fully immersed into the water. The fuel is charged at the grate which
produces flue gases. These flue gases first passes through the fire tube from one
end to another. This fire tubes transfer 80-90% of total heat to the water. The
backward flue gases passes from the bottom passage where it transfer 8-10% heat
to water. The remaining flue gases passes from the side passage where it transfer
6-8% of heat to water. The brick is the lower conductor of heat, so work as heat
insulator. The steam produces in drum shell it taken out from the upper side where
it flows through super heater if required. So the steam produce is taken by out for
process work.

7. Sketch and describe working of Locomotive boilers.

– Working :

 In locomotive boiler, first the solid fuel (coal) is inserted on the grate and is
ignited from the fire hole. The burning of the fuel starts and it creates hot flue
gases. A fire brick arch is provided that makes the flow of hot flue gasses to a
definite path before entering into the long tubes (fire tubes). It also prevents the
entry of burnt solid fuel particles into the fire tubes.
 The hot flue gases passes through the long fire tubes and heats the water
surrounding them. Due to the heating the water gets converted into saturated
steam and gets collected at the top.
 The saturated steam from the dome enters into the main steam pipe through the
regulator valve. The steam travels in the main steam pipe and reaches to the
superheater header. Form header, the steam enters into super heater element pipes.
Here it is superheated and then the superheated steam enters into the steam pipe of
the smoke box.
 The steam form the superheater goes to the cylinder containing piston. The
superheated steam made the piston moves within the cylinder. The piston is
connected to the wheels of the steam engine and the wheels start rotating.
 The exhaust steam from the cylinder enters into the blast pipe. The burnt gases
and smoke after passing through the fire tubes enters into the smoke box. The
 exhaust steam coming out from the blast pipe pushes the smoke out of the boiler
through the chimney. Here the smoke cannot escapes out form the boiler by its
own, so artificial draft is created by exhaust steam coming out from the steam
engine. This artificial draft created pushes the smoke out of the smoke box and
creates suction for the hot flue gases.

- Sketch :

8. What do you understand by high pressure boilers?

High pressure boiler" means a boiler in which steam or other vapor is generated at a
pressure of more than 15 psig, or water is heated to a temperature greater than 250°F
and pressure greater than 160 psig for use external to itself. High pressure boilers
include at the following:

- Electric boilers;
- Miniature boilers;
- High temperature water boilers; and
- High temperature liquid boilers (other than water).

9. Explain working of Bacock and Wilcox boiler.

Working :
 - First water is filled in the water drum through feed pump. The drum is half filled
with water and the upper half is for steam.First flue is fired at the grate.
- The flue gases generate by burning of fuel. These gases start flowing from one
end to another end of boiler.
- The flue gases passes by the water tubes and exchange heat with water. The
baffles are provided in the way, which deflects the flue gases before escaping
from the chimney. Due to this deflection, the flue gases pass more than one time
through water tubes, which cause more heat transfer.
- The water flows from the drum to the water tube through down take header.
- The water tube nearer to the furnace heated more than the other, so the density of
water decrease in this tube which causes the flow of steam from tube to drum
through uptake header. At the same time the water from the drum enters into the
tubes through down take header.
- The circulation of water from drum to tubes and again tubes to drum is natural,
due to density difference.
- The steam separates in the drum at the upper half. This is saturated
steam. This steam sends to the super heater through steam pipe. The steam is
heated again by the flue gases in the super heater and taken out for process work.
- The flue gases send to the atmosphere from the super heater.
- This process repeat until sufficient amount of steam generates. This boiler
can generate 20 ton steam per hour.

10. Sketch and describe a Stirling boiler.

Stirling Boiler: A boiler in which the water flows through some small tubes which are
surrounded by hot combustion gases.
11. Sketch and describe working of Loeffler boiler.
Loeffler Boiler is a forced circulation, high pressure, and water tube boiler with
internally fired furnace. In this boiler, the 2/3 of superheated steam is used to
evaporate the water in the evaporating drum and remaining 1/3 of the steam from the
superheater is used by the turbine. A steam circulating pump is used to circulate the
steam into the boiler
Working Principle :
Its main working principle is to evaporate the feed water by the use of superheated
steam from the superheater. 2/3 of the total steam generated by the superheater is
made to flow into the evaporator drum. The superheated steam changes the feed water
into saturated steam. And 1/3 part of the superheated steam is used by the turbine to
do work.
12. Differentiate between mountings and accessories.
- Mountings are components used for ensuring the safety of boiler operation.
These are generally mounted on the surface of the boiler.Control fluid parameters
at the inside of the boiler shell. The mountings are the essential part of a boiler,
without which boiler operation is impossible.
- Accessories are the auxiliary items required for proper operation of boiler and
improve the efficiency of it. These are integral parts of the boiler, but not mounted
on it. Control fluid parameters at outside of the boiler. These are not essential
parts of the boiler, without which boiler can operate though at lower efficiency.