Chapter 2

Steam Generator/Boiler
Steam- the invisible vapor into which water is converted when heated to the boiling
point
Steam Generator- is a device used to create steam by applying heat to water
The boiler system comprises a feed-water system, steam system, and fuel system.
Classification of Boilers

Classification of Boilers

1. According to Relative Passage of water and hot gases

2. According to Water Circulation Arrangement
3. According to the Use
4. According to Position of the Boilers
5. According to Pressure of steam generated
6. According to the Position of Furnace

According to Relative Passage of water and hot gases

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

Fire-tube Boiler: The hot combustion gases pass through the boiler tubes, which are surrounded
by water, e.g., Cochran
According to Water Circulation Arrangement

1. Natural Circulation: Water circulates in the boiler due to density difference of

hot and water

2. Forced Circulation: A water pump forces the water along its path, therefore, the
steam generation rate increases , e.g., Benson, Velox Boilers
According to the Use

1. Stationary Boiler: These boilers are used for power plants or processes steam in
plants.
2. Portable Boiler: These are small units of mobile and are used for temporary uses
at the sites.
3. Locomotive: These are specially designed boilers. They produce steam to drive
railway engines.
4. Marine Boiler: These are used on ships.
According to Position of the Boilers
1. Horizontal Boilers
2. Inclined Boilers
3. Vertical Boilers
According to Pressure of steam generated
Low-pressure boiler: a boiler which produces steam at a pressure of 15-20 bar
is called a low-pressure boiler. This steam is used for process heating. (Fire Tube
Boilers)
Medium-pressure boiler: It has a working pressure of steam from 20 bars to 80 bars and
is used for power generation or combined use of power generation and process heating.
(Water Tube Boilers)
High-pressure boiler: It produces steam at a pressure of more than 80 bars.
(Water Tube Boilers)

Boiler Mountings
-These are the fittings, which are mounted or installed on the boiler for its
appropriate and safe working
1. Water level indicator
2. Pressure gauge
3. Safety valve
4. Steam Stop valve
5. Blow off cock
6. Feed check valve
7. Fusible plug

1. Water Level Indicator

Location: This fittings may be seen in front of the boiler.
Function: To indicate the water level inside the boiler.
Water level indicator are generally two in number.
2. Pressure Gauge
Location: It is fixed in front of the boiler.
Function: To measure the pressure of the steam inside of the steam boiler.

3. Safety valve
Location: These are attached to the steam chest
Function: To blow off the steam for preventing explosions when the pressure of the
steam inside of the boiler exceeds the working pressure.
 4. Steam Stop valve
Location: It is usually fitted to the highest part of the shell by means of a flanges.
Function: a) To control the flow of steam from the boiler to the main steam pipe. b) To
shut off the steam completely when required

5. Blow off cock

Location: It is located at the bottom of the boiler.
Function: To empty the boiler whenever required & To remove the mud, scale or
sediments accumulated at the bottom of the boiler.
 6. Feed check valve
Location: It is fitted to the shell slightly below the normal water level of the boiler. It is a
non return valve, fitted to a screwed spindle to regulate the lift.
Function: To regulate the supply of water, which is pumped into the boiler by the feed
pump.

7. Fusible plug
Location: It is fitted to the crown plate of the furnace or the fire box.
Function: To put off the fire in the furnace of the boiler when the level of water in the
boiler falls to an unsafe limit and thus avoids the explosion which may place due to
overheating of the furnace plate.
Boiler accessories
-are those components which are installed either inside or outside the boiler to
increase the efficiency of the plant and to help in the proper working of the plant.

Super Heater
-The function of super heater is to increase the temperature of the steam generated by
boiler above its saturation point, using the hot flue or exhaust gases coming from the
combustion chamber of the furnace. Super heaters are heat exchangers.
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.

Economizer - It is a device in which the waste heat of the flue gases is utilized for
heating the feed water. To recover some of the heat being carried over by exhaust
gases, this heat is used to raise the temperature of feed water supplied to the boiler.
Advantages :
i) The temperature range between various parts of the boiler is reduced which results in
reduction of stresses due to unequal expansion.
ii) If the boiler is fed with cold water it may result in chilling the boiler metal.
iii) Evaporative capacity of the boiler is increased.
iv) Overall efficiency of the plant is increased.
Feed Pump - 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.
• The reciprocating pump are continuously run by steam from the same boiler to which
water is to be fed.
• Rotary feed pumps are of centrifugal type and are commonly run either by a small
steam turbine or by an electric motor.

Air Preheater - It is a waste heat recovery device in which the air to on its way to the
furnace is heated utilizing the heat of exhaust gases/flue gases. The function of air pre-
heater is to increase the temperature of air before enters the furnace. It is generally
placed after the economizer; so the flue gases passes through the economizer and then
to the air preheater. An air-preheater consists of plates or tube with hot gases on one
side and air on the other. It preheats the to be supplied to the furnace. Preheated air
accelerates the combustion and facilitates the burning of coal.

Degree of Preheating depends on:

(i) Type of fuel.
(ii) Type of fuel burning equipment.
(iii) Rating at which the boiler and furnaces are operated.