STEAM BOILERS, MOUNTINGS & ACCESSORIES

STEAM BOILERS, MOUNTINGS & ACCESSORIES

STEAM GENERATOR/ BOILER

STEAM BOILERS, MOUNTINGS & ACCESSORIES

The equipment used for producing and transferring steam is called

Steam generators/ Boilers.

STEAM BOILERS, MOUNTINGS & ACCESSORIES

Classification of

Boilers

STEAM BOILERS, MOUNTINGS & ACCESSORIES

Classification of Boilers:
Boilers may be classified according to the following1. 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 namesi) chocran Boiler

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).

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 (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.

WATER TUBE

FIRE TUBE
passes through

Water passes through water Hot gases tubes. tubes. steam capacity (high speed)

Steam capacity (Slow speed)

COMPARISION Between

Complexity in design requires Simple & rigid construction quick examination by skilled hence greater reliability & low hands. operating cost. Operating pressure up to 200 Pressure ranges from 17.5 bar bar. to 24.5 bar Evaporation rate ranges from Evaporation rate 900kg/hr. 20,000 to 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 Smaller in size, used only for power plants small power plants Transportation and installation Transportation and installation is easy due to handling of is difficult due to large size of dismentaled parts shell. Externally fired boilers, furnace Internally fired boilers, furnace size can be varied. size can not be varied.

WATER TUBE
&

FIRE TUBE BOILERS

Requires more floor area

Requires less floor area

ESSENTIALS OF A GOOD BOILER

ESSENTIALS OF A GOOD BOILER

1. a)

b)
c) d)

Steam generation capability should be at: Required pressure Required quality Fast speed 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

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

Boiler Accessories:
The devices which are installed in the boiler for their efficient operation and smooth working are called

Boiler Accessories.

Boiler Mountings for safety:

1. 2.

3.
4.

water level indicators safety valves. Combined high steam and low water safety valve. Fusible plug.

Boiler Mountings for control:

1. 2.

3.
4. 5.

Pressure gauge Junction or stop valve Feed check valve Blow-off cock Man hole and mud hole

Boiler Accessories for efficient operation:

1.
2. 3.

4.
5.

Water heating devices. Water feeding devices. Super heater Economizer Air preheater

BOILER MOUNTINGS

BOILER MOUNTINGS
1.

WATER LEVEL INDICATOR

BOILER MOUNTINGS

2. PRESSURE GAUGE (Bourdons)

a)
b)

Records gauge pressure

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
LEVER SAFETY VALVE Dead Weight safety valve

SAFETY VALVES
SPRING LOADED SAFETY VALVE
HIGH STEAM AND LOW WATER 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 (Nonreturn 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: Open Heater- Direct mixing Closed heater- Indirect convection

WATER DEVICES
boiler

FEEDING

Used to supply water while the is in operation. These

devices include the use of feed pumps either reciprocating type or centrifugal type.

1. 2.

SUPER HEATERS

ECONOMISER

AIR PREHEATER

High Pressure Boilers

A boiler which generates steam at a pressure of 85 kgf/sq.cm or above is termed as ahigh pressure boiler. The present tendency is towards the use of high pressure boilers in power plants. The modern high pressure boilers used for power generation have capacities of 40 to 1600 tonnes/hr of superheated steam with a pressure upto 210 kgf/sq.cm and a temperature of about 650C. Water tube boilers are generally preferred for high pressure and high output whereas fire tube boilers for low pressure and low output.

Advantages of high pressure boilers

Method of water circulation In high pressure boilers, water circulation is made with the help of a centrifugal pump which forces water through the boiler tubes. This is called forced circulation of water. Forced circulation increases the rate of heat transfer and hence increases the steam generating capacity of boilers.

Size of drums The high pressure boilers are characterized by the use of very small steam separating drums or by the complete absence of any drum.

Type and arrangement of tubes The heat of combustion is utilized more efficiently by the use of small diameter and light weight tubes in large numbers. To avoid large resistance to the flow of water , the high pressure boilers have a parallel set of arrangement of tubes.

Efficiency The efficiency of the power plant is increased up to 40%, by using high pressure superheated steam. Also steam can be raised quickly after the boiler is fired. Scale formation The tendency of scale formation is eliminated due to the high velocity of water through the boiler tubes. Cost of electricity Since efficiency of the plant is increased by using high pressure boilers, the cost of electricity production is reduced.

La Mont Boiler
This is a modern high pressure boiler (water tube type steam boilers) working on forced circulation system.

La Mont Boiler

The capacity of la-mont boiler is about 50 Tonnes/hr of superheated steam at a pressure of 170 kgf/sq.cm. and at a temperature of 500 C.

Loeffler Boiler
The novel feature of the Loeffler Boiler is to evaporate water solely by means of superheated steam. The furnace heat is supplied only to economiser and superheater. In other words, steam is used as a heat absorbing medium. The major difficulty experienced in La-Mont boiler is deposition of salt and sediment on the inner surfaces of water tubes. The deposition reduces the heat transfer, ultimately, the generating capacity. This difficulty was solved in Loeffler boiler by preventing the flow of water into the boiler tubes.

Loeffler Boiler

Capacity of the Loeffler boiler is about 100 Tonnes/Hr of superheated steam generated at a pressure of 140 kgf/sq.cm and at a temperature of 500C.

Benson Boiler

The presence of steam bubbles in contact with the surface of tubes seriously impairs heat transmission from the flue gases to water. By rising the boiler pressure to the critical pressure of steam (225 kgf/sq.cm.), this difficulty is overcome, as suggested by Mark Benson in 1922. At the critical pressure water and steam have the same density and no bubbles are formed. This boiler has a unique characteristic of absence of steam separating drum. The entire process of heating, steam generation and superheating is done in a single continuous tube.

Working principle of Benson Boiler:

Radiant evaporator The feed water from the economiser flows into the radiant evaporator with radiant parallel tube sections. The radiant evaporator receives heat from the burning fuel through radiation process and majority of water is converted into steam in it. Convection Evaporator The remaining water is evaporated in the convection evaporator, absorbing the heat from the hot gases by convection. Thus the saturated high pressure steam at a pressure of 210 kg/sq.cm is produced. Convection superheater The saturated steam is now passed through the convection superheater where the saturated steam os superheated to 650C. The radiant evaporator, the convection evaporater and the convection superheater are all arranged in the path of the flue gases.

Benson Boiler Cont

Capacity of benson boiler is about 150 tonnnes/hr at a pressure of 210 kgf/sq.cm. and at a temperature of 650C. (Efficiency may be improved by running the boiler at a pressure slightly lower than the critical pressure).

Velox Boiler

This boiler can generate a pressure of about 84 kg/cm2

Pipe Fitting is the occupation of installing or repairing piping or tubing systems that convey liquid, gas, and occasionally solid materials. This work involves selecting and preparing pipe or tubing, joining it together by various means, and the location and repair of leaks.

Various fittings

Pipe or tube fittings

Connectors

Thread fittings

Lagging
Insulation used to prevent heat diffusion, as from a steam pipe.

Performance of boilers
Evaporative capacity Equivalent of Evaporation Factor of evaporation Boiler efficiency