Introduction to Steam Generating Unit (Boiler)

A boiler is a closed vessel in which steam is produced from water by

combustion of fuel.
How a Boiler works:
Water is pumped into the boiler at operating pressure
Heat of flue gases vaporizes water to form steam
Steam formed is passed into steam space above the water space
Applications of steam generators (Boilers)

The steam generators or boilers are integral components of steam turbines which are used as prime
movers to drive generators to produce electricity in all thermal and nuclear power plants.
These are used in the industry for example in heating systems or for cement production, textiles.
These are used to produce distilled water for medicines, pharmaceuticals and other usage.
The boilers are used in cold countries for heating large buildings, in agriculture as well for soil steaming.
Components of a steam generator (Boiler)

Boiler drum, tubes, furnace

Boiler mountings
Boiler Accessories
Boiler mountings are devices which are required for proper operation, safety and control
of the boiler. Examples are water level indicator (WLI), pressure gauges (PGs), steam
stop valve, safety valves, fusible plug, feed-check valve, blow-off cock, manhole and
mudhole, etc.
Boiler accessories are devices which are used to increase the efficiency of a boiler.
Examples are air preheater, economizer, superheater, feedpump or injector, baffles, etc.

Boiler classification:

1. Tube content: (i) Fire tube boiler and (ii) water tube boiler
2. Axis of shell: (i) Horizontal, (ii) vertical, (iii) inclined
3. Location of furnace: (i) Externally fired, (ii) internally fired
4. Method of circulation: (i) Natural, (ii) forced
5. Mobility: (i) Stationary, (ii) portable
6. Usage: (i) Packaged, (ii) unpackaged
7. Pressure: (i) High, (ii) low
8. Tubes: (i) Single-tube, (ii) Multi-tube
How a Fire Tube Boiler works:

Hot flue gases are fed through the tubes.

Tubes are surrounded by water.

Cochran Boiler (A Fire Tube Boiler):

Fig: Cochran Boiler

9 Vertical mulititubular 9 Low initial cost

9 Efficiency 70 - 75% 9 Suitable for fluctuating loads
9 20 kg/hr to 3000 kg/hr
How a Water Tube Boiler works:

Small parallel tubes contain water connected to drum with the header

Gases pass outside tubes containing water

Babcock and Wilcox Boiler ( A Water Tube Boiler:

Fig: Babcock and Wilcox Boiler

9 High pressures and capacity
9 Higher Efficiency
9 Suitable for power plant
Comparision of Fire tube and water tube boilers

Criterion Fire Tube Water tube

1. Flow of hot gases and Gases in tubes surrounded by Water in tubes and gases flow
water water outside outside

2. Location of furnace Internal External

3. Floor area for given Large Small

output
4. Capacity 10000kg/hr 50000kg/hr
5. Evaporation Slow Fast
6. Pressure range 15 to 20 bar 170 to 200 bar
7. Efficiency 80% 92%
8. Safety Large water content and low Small water content and large
steam so better safety steam generation. Needs expert
attention.
9. Explosion Lesser risk due to lower P Higher risk due to higher P
10. Application Not suitable for large power Suitable
plant
11. Skill Less More
12. Water Treatment No Yes
13. Construction Difficult Simple
14. Shell Diameter More Less
15. Transportation Difficult Simple

Boiler Efficiency :
Boiler efficiency is the ratio of the quantity of heat utilized actually by the water and steam to
the quantity of heat supplied, i.e.,

Boiler efficiency = Heat actually absorbed by the water and steam / quantity of heat supplied

Boiler Capacity:
Boiler capacity is defined as the amount of steam a particular boiler can supply per hour
usually expressed in kg (of steam)/hr or tons/day.

Boiler Pressure:
The designated operating pressure of a boiler at which it can safely deliver the steam at
its rated capacity.
Boiler mountings and accessories:

Bourdon Tube Pressure Gauge Fusible Plug

Water Level Indicator

Lever Safety Valve Flue gas before entering chimney

Economizer and Superheater

Functions of Boiler mountings:

Water level indicator: This is required to indicate the safety level of water inside the
boiler shell.
Pressure gauge: This is required to indicate the steam pressure inside the boiler shell.
Steam Stop Valve: The valve used to regulate the supply of steam to the turbine.
Fusible plug: This is required to stop the boiler if the boiler gets dry to prevent damage to
the boiler. It is a metallic plug installed in the water pathway. If the boiler temperature
exceeds a safe value, it melts and allows shell water to pass through extinguish the furnace
fire.
Safety valves: These are required to release the internal boiler pressure if the pressure
exceeds a predetermined safety level.

Functions of Boiler accessories:

Air preheater: This is usually used to utilize the waste heat of the chimney to preheat the
furnace air thus increasing the boiler efficiency.
Economizer: This is usually used to utilize the waste heat of the chimney to preheat
the boiler feed water thus increasing the boiler efficiency.
Superheater: This is usually used to utilize the waste heat to dry and/or superheat the steam
leaving the boiler on the delivery side, thus increasing the steam quality and boiler efficiency.
Baffles: These are built inside the boilers. These baffles significantly increase the efficiency
by helping feed water in extracting heat from the flue gas.