Fire Tube Boiler – Types, Operation & Uses

Steam boilers were used earlier for the production of steam in trains. Later on, with the
development in the construction of these boilers, these boilers are classified into different
types based on the generation of steam. The steam generated should be of high pressure in
order to increase efficiency. So, to generate more steam, steam boilers are classified as water
tube and fire tube boilers. The water tube boiler generates more steam of high pressure
whereas a fire tube boiler generates steam of low pressure. We will discuss the fire tube
boiler, different types of firetube boilers, defects, and uses.

Fire Tube Boiler

In Fire Tube Boilers, hot flue gases will be flown inside the tube and these tubes are
surrounded by water. These are the low-pressure boiler which cannot generate much heat
compared to water tube boilers. As the production of heat is less the overall efficiency of this
boiler is also low. The figure which depicts the fire tube boiler is shown below.

Fire-tube boiler

Different Components & Mountings Placed on the fire tube boiler

Mountings are those which are used for the functioning of the boiler and these play a critical
role in the proper design of the Fire tube boiler

 Safety valve
 Feed check valve (a kind of non-return valve)
 Water level indicator
 Pressure gauge
 Steam stop valve

Pressure Gauge

The pressure gauge is mounted on the top of the shell. It indicates the amount of pressure
observed inside the boiler. It is a dial-type instrument that indicates pressure in different units
such as kgf/cm2 or K.pa or PSI. Now a day’s digital type instruments are also used where it
senses the pressure by some transducers and sends the signal to the display unit.
Water Level Indicator

During the operation of the boiler, the operator must know the level of water. If not knowing
the boiler cannot withstand the pressure and may lead to an explosion. So, a water level
indicator is mounted to the shell of the water tube boiler.

Safety Valve

Water at higher pressures has a lot of energy so, safety precautions should be taken to prevent
any loss. For this purpose, we install a safety valve to the boiler. Whenever the pressure is
above the prescribed limit I,e withstand capability then safety valve will be opened. At-least
two safety valves are to be provided.

Steam Stop Valve

A stop valve is provided to operate the steam control according to the requirement, the wet
steam in the shell is sent to the superheater to reheat. The reheated steam is resent to the shell
in this situation, the steam stop valve is operated to meet the requirements.

Feed Check Valve

It is used for the entry of feed water into the boiler and also used as a non-return valve to
prevent the feed water from returning.

Accessories are provided to increase the efficiency of the boiler. They are

 Superheater
 Economizer
 Air pre-heater

Without mountings, boilers cannot operate but without accessories, boilers can operate. The
efficiency will be low without accessories.

Types of Fire Tube Boilers

1) Cochran Boiler

It is a vertical, multi-tubular, internally fired, and naturally circulated type boiler. The shell of
this type of boiler is arranged in the vertical direction that has multi tubes. These multi tubes
arranged in vertical and the high pressurized flue gases will be passed through them. These
tubes are surrounded by water and will be heated by the hot flue gases passed through the
tubes. The combustion process takes when the hot flue gases are passed through the tubes that
heat the surrounding water. The heated water beyond its temperature limits will be converted
to steam that is further used for the production of electricity. This combustion process takes
place is of internally fired and water circulated naturally.

Components
The boiler shell is hemispherical and consists of a furnace, firebox, Grate, combustion
chamber, flue pipes, smokebox, chimney, boiler mountings, and accessories.

Construction

Shell is attached to a hemispherical head where steam is collected. The grate is provided with
some spaces such that to pass air which helps in the combustion of fuel. Ash pit is placed
below the grate to collect the unwanted particles. The firebox is provided above the grate
where the combustion of fuel takes place and the flue gases developed will travel from the
firebox to the flue tubes.

Cochran boiler

The waste material from flue gas which is not burnt is collected in the smokebox. This
material is exhausted into the atmosphere through a chimney provided at the top. A water
level indicator is provided at the top to check the level of water. Pressure gauge to check the
pressure and an Anti-priming pipe is provided in a hemispherical shell to reheat the wet steam
by super-heater. A Tap is provided at the bottom to remove the water for maintenance.

Working

The fuel can be Oil, gas or coal is burnt in the firebox placed over the grate. The flue gases
generated by the combustion of coal will be sent to the flue tubes which are surrounded by
water. The heat of flue gases gets transmitted to the water surrounded. The heated water gets
evaporated and converted into steam which is collected in the hemispherical shell.

Applications

 Cochran Boiler is used in small industries.

2) Locomotive boiler
It is a horizontal, multi-tubular, internally fired, and naturally circulated type boiler. This type
of boiler is mounted horizontally in direction and has multi tubes. In this type, the
combustion takes place internally and water will be circulated naturally. It operates similar to
that of a Cochran boiler but the construction is different. These individual types of boilers
have their own advantages and applications. As the operation is internally fired and uses
natural circulation, it is considered to be a fire tube boiler.

Components

Boiler shell is with a steam dome, furnace, firebox, Grate, combustion chamber, flue pipes,
smokebox, chimney, boiler mountings, and accessories.

Construction

Shell is attached to a steam head where steam is collected. Grate made of cast Iron is
provided with some spaces such that to pass air which helps in the combustion of fuel. Ash
pit is placed below the grate to collect the unwanted particles. The firebox is provided above
the grate where the combustion of fuel takes place and the flue gases developed will travel
from the firebox to the flue tubes. Locomotive Boiler is shown in the figure below.

Locomotive Fire Tube Boiler

The waste material from flue gas which is not burnt is collected in the smokebox. This
material is exhausted into the atmosphere through a chimney provided at the top. A water
level indicator is provided at the top to check the level of water. Pressure gauge to check the
pressure and an Anti-priming pipe is provided in a hemispherical shell to reheat the wet steam
by super-heater. It uses an artificial draught fan which sends the unwanted flue gases into the
atmosphere.

Working

The fuel can be oil, gas or coal is burnt in the firebox placed over the grate. The flue gases
generated by the combustion of coal will be sent to the flue tubes which are surrounded by
water. The working of the Locomotive fire tube boiler is shown in the figure below.
Locomotive boiler

The heat of flue gases gets transmitted to the water surrounded. The heated water gets
evaporated and converted into steam which is collected in the hemispherical shell.

Disadvantages

 It requires more space.

 Efficiency is less.
 Steam Generation is low.

Advantages

 It is a portable boiler.
 Low operating cost.
 The maintenance cost is low.

Applications

 It is used in small rated plants

3) Lancashire Boiler

Construction

Lancashire Boiler is enclosed in brickwork. It consists of fire tubes surrounded by water and
the fire tubes are conical towards the rear end. A brick arch is placed after the furnace in order
to increase the flow of hot gases. Dampers are provided at the end of the fire tubes for proper
passage of air. Feedwater valve, water level indicator, steam check valve, and a manhole are
provided on the top of the shell.
Lancashire boiler

Working

The fuel heated produces hot flue gases which further heats the water surrounded by the fire
tubes. The hot flue gases flow inside the firetubes heats the surrounded water. The heated
water is converted to steam at high temperatures. The produced steam travels to the anti-
priming pipe where the wet steam and hot steam is separated. the wet steam is further
superheated and the dry steam is fed to the steam stop valve. The generated steam is utilized
to drive a turbine which is used for the generation of Electricity. The end view of the
Lancashire boiler is depicted below.

Lancashire boiler end view

Advantages

 It is more reliable
 Less maintenance
 Less cleaning effort
 The good thermal efficiency of about 80%.
 Easy to operate.

Disadvantages

 Requires more space

 Takes more time to generate steam
 It cannot generate high-pressure steam.