Lecture:1

Boilers Introduction
Contents
Boiler Definition
Schematic Diagram
Classification Of Boilers
Types Of Boilers
Principle Of Boiler
Construction Of Boiler
Boiler Mounting/Accessories
Boiler Efficiency
Safety Measures
Boiler Definition:

“ Boiler is Self Contained closed vessel used to transmit

heat from an external source to the fluid contained
within the boiler itself”
Boiler is actually meant for heating that may lead to
change in state (from liquid to gas) depending upon
the type of output we need for our use.
Schematic Diagram
 Boiler

A boiler is used to generate steam at a desired pressure

and temperature by transferring heat produced by
burning fuel to water to change it to steam.
Steam is used for the following purposes:
Power generation
Processing
Heating
Boiler
This is the schematic view of a water tube boiler. From
this we
can see the basic parts, input and Output of a boiler.

 Combustion Chamber/Burner
 Water Tubes (Fire Tubes)
 Container
 Inlets
 Outlet
Input:
 Water
 Fuel
 Air
Output:
 Steam
 Flue
 Hot Water
Classification:
Boilers are classified on the basis of their:
 Uses
 Size
 Tube shape
 Tube position
 Tube contents
 Heat source
 Material
 Pressure
Explanation:
Boilers are classified on the basis of nature of service to be
performed.
E.g. stationary boilers are used for plant processes and portable
boilers are normally used for oil fields and marine.

Boilers may be high pressure or low pressure.

Boilers are also classified on the basis of the material used in

their construction like high pressure boilers are made from steel,
where as low pressure are made from cast iron. Some boilers are
made from copper also.
Boilers are having different positions of tubing:
 Horizontal
 Vertical
 Inclined

Boilers are also classified on the basis of tube shapes e.g.

 Straight Tubes.
 Bent Tubes.
Type Of Boilers w.r.t working Principle:
There are mainly two type of boilers depending upon the
contents of tube:

 Water Tube Boilers

 Fire Tube Boilers.

These types are further subdivide into different types which we

study further.

P.T.O
Water Tube Boiler
 Water tube boiler contains water in the tubes and hot
combustion gases around those tubes in order to
produce steam from water.
 Water tube boilers are normally use for the collection
of high pressure steam (High pressure applications)
 Water tube boilers are expensive as compared to fire
tube boiler.
 Water tube boilers are large in size as compared to fire
tube.
Fire Tube Boiler
 Combustion product in the tubes(fire tubes) and water
(which is to be vaporized) is around those tubes.
 Fire Tubes are in a shell.
 Fire Tube Boiler is used for low pressure applications.
 Fire Tube Boilers are having low initial cost.
 Easy to construct and handled.
Types of Boiler w.r.t Construction
D-Type Boiler
A-Type Boiler
O-Type Boiler
D-Type:
D-Type contains:
1 Steam Drum.
1 Mud Drum.
And tubes are bent into D-shape
Types of Boiler w.r.t Construction
A-Type:
A-Type contains:
1 Steam Drum
2 Mud Drums below.
O-Type:
O-Type contains:
1 Steam Drum.
1 Mud Drum.
Tubes are bent in such a manner to give O-shape.
Electric Boilers

In electric Boilers a coil is immersed in the water

,when current passes through the coil, it heats up the
water up to boiling point to make vapors.
Principle Of Boiler
Burner is a heart of the boiler which converts water to steam. This
burner is heated by supplying fuels into it.

The water stored in the vessel when heated to a desired temperature

level by burning natural gases, coal and wood pellets can be defined
as a boiler. The steam produced by the boiler when heated is piped to
a spot which can be is utilized for different purposes such has
running the production units, sanitizing some area, sterilizing
equipments, to warm up the surroundings, to heat up the water, and
many more.
.
P.T.O
Construction Of Boiler
Boiler consist of following basic parts:

 Shell
 Tubes
 Passes
 Smoke Box
 Interior Baffles
 Nozzles
 Openings
 Supports
Construction Of Boiler
Shell:
The boiler consists of a steel shell, which includes the
boiler tubes, the outer firebox wrapper plate, the inner
firebox, boiler back plate, smoke box, tube plate and
throat plate.
Shell is a cylindrical metal covering in case of fire tube
boiler, which holds fire tubes in it.
Tubes:
Tubes contain fire in case of fir tube(heating/combustion
material) and water(to be heated) in case of water tube
boiler.
Construction Of Boiler
Passes:
Passes are placed at the edges of tubes to control the passage
way(direction) of the running fluid in the tubes. There may be 1-4
number of passes(minimum 1 and maximum of 4 passes) that can be
placed in front of tubes.
It is important to know that maximum number of passes will generate
higher efficiency.
Smoke Box:
The smoke box is an extension of the front end of the boiler barrel.
Exhaust steam from the cylinders passes through the blast pipe into the
chimney and creates a partial vacuum. This causes hot gases to be drawn
through the tubes which, in turn, draws air into the firebox through the
grate and fire hole door. The smoke box contains exhaust for the
Vacuum Ejector where fitted.
Construction Of Boiler
Interior Baffles:
Interior Baffles is a metal plate which control the
circulation during the boiler cycle.
Construction Of Boiler
Nozzles/Openings:
There are certain openings and nozzles for intake and
output purposes, boiler mountings and accessories are
also placed on different openings in order to control
the overall performance of boiler.
Supports:
Certain supports are also required under shell and tubes
to give the boiler structure a proper stand over.
Boiler Mountings & Accessories
Boilers are equipped with two categories of
components:
Boiler mountings are the machine components that
are mounted over the body of the boiler itself for the
safety of the boiler and for complete control of the
process of steam generation.
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.
Boiler Mountings & Accessories

Safety Valves: 
It is used to relieve pressure and prevent
possible explosion of boiler. Normally Alarm and LED’s
are attached to the safety valves to generate threatening
signals in order to take corrective/safety measures at
proper time

Water level indicators: 

They show the operator the level of fluid in the boiler,
also known as a sight glass, water gauges or water
column are also provided for this purpose.
Boiler Mountings & Accessories

Pressure Gauge:
Pressure Gauge is calibrated gauge in order to record
the pressure of steam produced. Pressure gauges help
to attain the required pressure as proper pressure is
being recorded and checked through pressure gauges.
Feed Check Valves:
Feed Check valve is a non-return stop valve in the feed
water line, having following purposes :
 Allow the feed water to pass into the boiler.
 To prevent the back flow of the water
Boiler Mountings & Accessories

Man & Mud Holes:

For the proper and timely inspection, Repair and
cleaning of the Boiler, these holes are present to allow
the men to enter in the boiler.
Economizer:
Economizer recover/recycle some of heat being carried
over by exhaust gases.
Feed Pump:
Water enter into the boiler through feed check valve, but
that water is being forced under high pressure through
feed pump.
Efficiency Of Boiler:
Requirements of an efficient boiler

1) Should generate maximum amount of steam at a

required pressure and temperature and quality with
minimum fuel consumption.

2) Should be light in weight and should not occupy

large space.

3) Should conform to safety regulations.

Requirements of an efficient boiler
4) Should have low initial cost, installation cost and
maintenance cost.

5) Should be able to cope with fluctuating demands of

steam supply.

6) All parts and components should be easily

accessible for inspection and repair.
Efficiency Of Boiler:
The term “boiler efficiency” is often substituted for
thermal efficiency or fuel-to-steam efficiency.
Fuel-to-steam efficiency is a measure of the overall efficiency of
the boiler. It accounts for the effectiveness of the heat exchanger
as well as the radiation and convection losses.
The following are the key factors to understanding efficiency
calculations.
1. Flue gas temperature
2.Fuel specification
3.Excess air
4.Ambient air temperature
5.Radiation and convection losses.
How To Increase The Efficiency Of Boiler
High boiler efficiency is the result of specific design
criteria, including:
- Number of boiler passes
- Burner / boiler compatibility
- Repeatable air/fuel ratio control
- Heating surface
- Pressure vessel design
How To Increase The Efficiency Of Boiler
Number Of Passes:
There are minimum of 1 and maximum of 4 passes in a
boiler.
Higher the number of passes greater will be the
efficiency. As the no. of passes will be more less fuel
would be used resulting in low fuel cost.
Burner & Boiler Compatibility:
Boiler and burner manufacturers should be same as
maximum compatibility is attained in that case.
How To Increase The Efficiency Of Boiler
Air-to-Fuel Ratio:
Proper Air to fuel ratio throughout the firing is
necessary for the maximum efficiency of boiler.
Air-Fuel Ratio should be uniform during a firing
order.
Heating Surface:
Wider Heating surface generate maximum efficiency
of the boiler. As larger area is available for the
production of steam.
Safety Measurements
Current Inspection Certificate:
For every Boiler a Current Inspection Certificate is
generated, This certificate is issued on the basis of boiler’s
life time, working and safety measures to be adopted
while usage. Engineers should study that detailed manual
before and during the usage of boiler.
Leakage Inspection:
There should be no leaks from any part of boiler or piping
external to boiler.
Safety Measurements
Particle Accumulation:
Remove Mud from boiler periodically because it causes
corrosion and blockages in the boiler tubes which leads to
burst and leakages to the boiler tubes.
Uniform Flame:
Flame should be correct and uniform throughout the
working cycle of boiler.
Valves & Gauges Inspection:
All gauges, valves and meters should be checked
periodically. If any defect found should be repaired on
time.
Safety Measurements
Trash Control:
No trash (plastic, paper) or combustible material near
boiler as it causes serious damage or even bursting of
boiler.