INDIABOILER DOT COM

TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION

DLP/BOE-II/ 3 – II/16122001

CHAPTER – 9
DRAUGHT SYSTEM OF BOILERS

1.0 Introduction:
We know that supply of Oxygen is essential for perfect combustion of any substance and
hence supply of atmospheric air, being the prime source of Oxygen, is a must for support
of combustion of a fuel. The rate of raise in steam generation is proportional to the
amount of fuel burnt in the furnace and to ensure efficient combustion of fuel,
proportionate quantity of continuous supply of air is to be maintained. A Boiler is
essentially equipped with a combustion control system, which maintains regular supply
of combustion air, at required pressure and temperature, in proportion to the fuel burnt.
Unless the product of combustion is also simultaneously evacuated, a good combustion
regime cannot be maintained inside the furnace.
The system, which ensures continuous supply of combustion air and the evacuation of
product of combustion, is known as draught system. Hence by ‘Furnace Draught’ it is
meant, creation of an ideal combustion regime or the furnace condition, in which desired
differential pressure as compared to outside atmosphere is maintained to establish
uninterrupted flow of combustion air to get mixed thoroughly with the fuel and support
sustained combustion, simultaneously allowing to help the products of combustion be
evacuated to atmosphere through the height of the stack.”

2.0 Objective of a good Draught System:

The objective of producing draught in a boiler is
a) To supply or assist in drawl of required quantity of air for efficient combustion of
fuel in boiler furnace
b) To evacuate the resulting products of combustion through the system.
c) To discharge and let out hot gases to atmosphere through the chimney.

2.1 Measurement of Furnace Draught:

A draught gauge or a Manometer is used to measure Furnace Draught. It is expressed in
millimeter or inches of water column. A Manometer consists of ‘U’ tube, one end of
which is connected to the furnace and the other end is left open to the atmosphere. The
‘U’ tube is filled with colored water without any air bubble entrapped into it. The
difference in water level in the two legs of the Manometer indicates draught inside
furnace in mm or inches of water column.

3.0 Classification of Draught Systems:

Draught may be classified mainly as,

3.1 Natural Draught:

It is the draft system in which suction of combustion air is created with the natural effect
of height of the chimney without any external aid. Drawl of hot gases is effected by
creation of negative pressure inside the furnace by the density difference between the
column of hot gases and the column of atmospheric air. The hot gases are lighter because
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
of higher temperature, whereas the atmospheric air is heavier, and hence the movement
of hot gases takes place upwards continuously. Atmospheric air enters the combustion
zone, while the hot gases are sucked out and discharged through the chimney. Hotter the
flue gas, lighter it becomes, but the atmospheric air almost remain constant, without any
significant variation. Hence higher the temperature of the flue gas at entry to chimney
better is the draught effect in the furnace. The height of the chimney also matters in
creating the draft effect. If the chimney height is more, better draught will be induced due
to high difference in weight of column of hot flue gas inside the chimney and the cold
column of atmospheric air outside the chimney. When the created draft effect is high
inside furnace, more combustion air will be induced into the furnace, assisting in
improved combustion of fuel.
Natural Draught system may be adopted only for small capacity package type Boilers. It
may not be suitable for high capacity Boilers, wherein bulk fuel is handled, needing huge
amount of combustion air at higher pressure and temperature. For supply of large volume
of combustion air and to create adequate draught inside the furnace, some kind of
mechanical device is required to be used.

3.2 Artificial Draught:

The draught system in which draught is created with the external assistance by a steam jet
or with the action of Forced and Induced draught Fans, either independently or in
combination, in addition to the chimney effect is called artificial draught.
Artificial draft may be further classified as described below. The artificial draught
system, induced in a furnace may be positive or negative, depending on the type of
draught system adopted.
A system in which furnace pressure is maintained above atmospheric pressure is known
as Pressurized Draught System.
A system in which the furnace is maintained below atmospheric pressure through out by
an induced action of any device or a exhaust fan is called Negative Draught System.

4.0 The Factors Affecting The Furnace Draught:

Important factors, which affect or determine the draught requirement inside a furnace, are
as following:
a) Rate of supply of fuel for combustion.
b) The type of fuel, whether solid, liquid of gaseous, being burnt
c) The type of combustion system adopted and the design of fuel burning equipment.
d) The type of atomization being deployed and size of the fuel particles.
e) Depth of fuel bed and type of mechanism adopted for fuel feed in case of stoker
fired are the fluidized bed furnace
f) The resistance offered to flow of air, in the combustion air path, through the length
of ducts, baffles, bends and dampers.
g) The resistance offered to flow of flue gas, in the flue gas path by arrangement of
tubes in Super-heaters, Economizer, Air Pre-heater and through the length of ducts,
baffles, bends, dampers and the stack height
h) The size and Design of the combustion chamber or furnace.
i) Barometric pressure and ambient condition.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
5.0 Factors Influencing Natural Draught:
The Natural Draught is influenced by the following factors.
a) Climatic conditions which determines the density of atmospheric air
b) Flue gas temperature at entry to chimney.
c) The height of the chimney.
Natural draught is effective only for small package type boilers as the available
Furnace draught is very low.

6.0 The Advantages of Natural Draught:

a) No additional energy is required to produce draught.
b) Low initial investment & very less maintenance cost.
c) Reduces pollution as the flue gas is discharged at sufficient height.
d) The overall life is more.

7.0 The Disadvantages of Natural Draught:

a) The maximum furnace draught that can be achieved is just10 to 20 mm of WC due
to low-density difference between hot flue gas column and atmospheric cold air
column.
b) To achieve better draught, flue gas is to be discharged at high temperature, which
means loss of efficiency.
c) Due inadequate draught effect, the incoming air velocity will be low as a result of
which efficiency of combustion will be affected. Due to low flue gas velocity, heat
transfer will not be effective.

8.0 Steam Jet System for Artificial Draught:

A simple device for creation of artificial draught, generally used in locomotives, is a
steam jet ejector mechanism. A steam line tapped off from the main steam outlet is
allowed to jet out through a nozzle fitted inside the throat of a convergent divergent
shaped smoke outlet. The jetting steam will create vacuum, which will be filled in by the
flow of flue gas from the furnace. As the flue gas is constantly extracted out from the
furnace, fresh air will enter the combustion chamber.

9.0 Induced and Forced Draught Fans:

Big fans may be used for sucking and throwing out the flue gas through the chimney,
thereby creating adequate draught inside the furnace. Such Fans are termed as Induced
Draught Fans. Forced draught Fans may also be deployed for supply of required quantity
of combustion air and maintaining a positive draught inside the furnace. The flue gas will
be pushed out the stack with the draught pressure available in the furnace.

10.0 Classification of Artificial Draught System:

Artificial system can be again classified into following;
a) Forced Draught System
b) Induced Draught System
c) Balanced Draught System

10.1 Forced Draught:

Air drawn from atmosphere is forced into the furnace, at a pressure higher than the
outside atmosphere, by big centrifugal fan or fans to create turbulence and to provide
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
adequate Oxygen for combustion. Hence the system is known by the name Forced
draught system and the fan, used to push through combustion air under pressure, is
called Forced Draught Fan. F D fan is normally located at the front or sideways of the
furnace.
The furnace and ash pits at the bottom are so designed that they are airtight and does not
allow air to leak out. Air from discharge of the fan is regulated and passed through an air
register, to give adequate swirling and mixing for combustion of fuel. By the action of
Forced Draught Fan, through out the furnace a positive draught is created mechanically
and the furnace is always kept pressurized. The positive pressure created is so effective to
push out the product of combustion through the chimney. Since the furnace is kept under
pressure in the forced draught system, there could be possibility of external air leakages,
unless the furnace is designed airtight.

10.2 Induced Draught:

Instead of drawing atmospheric air and pushing through furnace, a centrifugal fan can be
deployed to draw out the air from the furnace and throw out through the chimney, thereby
creating negative pressure in the combustion zone and maintain the negative draught
through out the furnace. The system is called Induced Draught system and the fan
deployed for this purpose is known as Induced Draught Fan.
In the Induced Draught system, the fan is fitted at back end of the furnace or near the
base of the chimney. Due to the negative pressure created inside the furnace, by the
action of the fan, atmospheric air enters and aids combustion. The entry of air is regulated
through air registers and dampers.
For similar capacity boilers, the size of an induced draught fan will be more than the size
of the forced draught fan required for a forced draught system. This is because the
products of combustion is always much higher in volume than the volume of combustion
air handled by the forced draught fan. Further the flue gas is hotter and the density is less.
Hence the volume is much more. According to Charles Law, when a gas is heated the
volume will proportionately increase at constant pressure, with the raise in temperature.
According to Boyles Law, if pressure inside a vessel is increased, the volume will
proportionately decrease and the vice-versa is also true (P ∝ 1/V).

10.3 Balanced Draught:

The system in which combustion air is supplied under pressure through a Fan and a
negative draught is created by the suction of another is called Balanced Draught
System. It is a combination of the forced and induced draught system. In a balanced
draught system, air for combustion is supplied at required pressure by the action of the
Forced Draught Fan and the extraction or removal of flue gas is assisted by the Induced
Draught Fan, thus a balanced draught is maintained. The control of fuel air ratio in the
furnace is accomplished by both forced and induced draught fans, so that draught is
regulated and balanced with the amount of supply of combustion air and flue gas
generated, so that the draught pressure at the back of the furnace is null and zero.
Starting from the null point the Induced draught fan maintains negative draught and pulls
out the gases and throws out to atmosphere.

11.0 Comparison between Forced and Induced Draught Systems:

 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
a) Forced draught system requires less fan power, since the fan has to handle only cold
air, where as in induced draught system, fan has to handle comparatively more
volume of hot flue gases.
b) Forced draught gives better control than induced draught, as air penetrates into the
fire-bed or helps in good turbulence and thorough mixing of fuel than in induced
draught system and hence rate of burning of fuel is faster and efficient.
c) With forced draught system, possibility of gas leakage is always outward and hence
there is always risk of hot gas blowing out if any peep hole or inspection doors are
kept open.
d) With induced draught, all leakages of air are inward and therefore, heavy air
infiltration will occur if refractory and brick work etc. in the flue gas path is not
maintained in good condition, resulting in over loading of Induced Draught Fan.
e) Blades of an Induced Draught Fan get eroded and corroded faster than a forced
draught fan, since it has to handle erosive and corrective combustion products. Hence
Induced Draught Fans are require more maintenance.

11.1 Advantages of the Artificial Draught System over the Natural Chimney Draught
System:
a) Higher evaporative capacity of the boiler since required quantity of air at required
pressure can be supplied for combustion.
b) Easy to burn even low-grade / low calorific value fuels.
c) Better control of combustion is possible and hence burning efficiency can be
improved.
d) Comparatively less emission through Stack.
e) Chimney height required can be less.

11.2 The Disadvantages of Artificial Draught System:

a) Initial cost is very high as fans are required
b) Power consumption is more and auxiliary power consumed increases.
c) The overall construction of the plant is complicated
d) Equipment maintenance cost is high.

12.0 Chimney Height:

The extent of the natural draught produced in a boiler depends on the height of the
Chimney and the difference between temperature of the hot flue gases leaving the boiler
and that of the outside cold air.
There is a relationship between chimney height and the draught produced, which can be
deduced in the following manner:
Let
w = Weight of air required in kg for burning 1 kg of fuel
T = Average absolute temperature of gas passing through chimney in deg. K
Ta = Absolute temperature of air outside the chimney in deg. K
h =Furnace Draught in mm of water.
H = Height of chimney in meters
W + 1 = Weight of the flue gas produced in kg per kg of fuel burnt.

The volume of chimney gases produced may be taken as equal to the volume of air
supplied. Since the volume of the solid or liquid fuel burnt is so small as compared with
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
the volume of air supplied that it may be neglected.

Fig .1

Taking the volume of 1 kg of air at 0 oC and 760 mm of Hg as 0.7734 m3,

Volume of gases at 0 oC = 760 w m3 per kg of fuel burnt.
Since volume of gas is proportional to its absolute temperature (by Charle’s law),
Volume of chimney gases at T K = 0.7734 w * T/ 273 m3/kg of fuel burnt,

And density of chimney gases at temperature T K

= (w+1)/(0.7734 w* (T/273))=(w+1)/0.7734 * 273/T kg/m3.

Similarly, the density of atmospheric air at Ta k

=w/(0.7734 w * T/273) = (w+1)/0.7734w * 273/T kg/m3

Let H be height of the chimney required in metres measured from the level of furnace
grate.

The pressure exerted per square metre at the furnace grate level by a column of hot gas
one metre in height = density of the gas.

Pressure exerted by a column of hot chimney gas of H meters height,

= ρAHg/A = ρgH N/m2

= density * 9.81 N/m2

 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
= w + 1 / 0.7734 w * 273/T * 9.81H N/m2

Similarly, pressure due to column of outside (cold) air of same area and H metres height
= 1 / 0.7734 * 273/Ta * 9.81 H N/m2

Let P be the pressure causing the draught in N/m 2 . Since the pressure causing the
draught is due to the difference of pressure due to column of hot gases within the
chimney and the pressure due to an equal column of outside (cold) air,

P = {1 / 0.7734 * 273 / Ta – w + 1/ 0.7734w * 273 / T} * H * 9.81

= 273 * 9.81 H / 0.7734 {1/Ta – w + 1/ W * 1/ T} N/m2

Since the density of water is 1,000 kg/m3, a water column of 1 m or 1000 mm height will
exert a pressure of 1000 * 9.81 N/m2.

Let h be draught pressure in mm of water, then the draught pressure, P in N/m2 is given
as

P = ρgh = 1000 * 9.81 * h / 1000 = 9.81h N/m2

h = P/9.81 mm of water

Substituting the value of P we have

h = 273 H/0.7734 [1/Ta – w + 1/ w * 1/T] mm of water

h = 353 H [1/Ta – w + 1 / w * 1/ T] mm of water

The draught available by above formulae is known as theoretical or static draught. But
the actual or available natural draught is comparatively less the theoretical. The reasons
are as follows:
a) Frictional resistance to the flow of flue gases in the flue passages induced due to duct
surface, dampers, baffles, air heater tubes etc. and the arrangement of pressure parts
such as Superheater, economizer etc.
b) Energy required to impart velocity to the flue gas
c) Losses in the bends, curves, change of directions etc. in the flue gas passages.

13.0 Condition for Maximum Discharge of Hot Flue Gases:

We can modify the expression in the following manner:
h = 353H [1/Ta - w + 1/w x 1/T]
to express the draught in terms of column of hot gas.
Let, hg = height of column of hot gas which would produce pressure P
Pressure exerted by this column of hot gas
P = density x hg
P = {(w+1) / 0.7734 w} x {(273/ T) x hg}
It is expressed that,
hg = H [( w / w+1 x T / To) – 1] ---------------------------------- (1)

The chimney draught is more effective when the chimney discharges maximum weight of
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
hot gas in a given time, which is proportional to the product of its density and velocity of
discharge.
V2 = 2ghg i.e. V = √ 2ghg, substituting value of hg
V = √ 2gH [ ( w/w+1)x ( T / Ta) – 1 ]

Since the density of the hot gases is proportional to 1/T, the weight of the hot
Gases discharged.
W = A/T √ 2gH [ ( w/w+1)x ( T / Ta) – 1 ]
Where A= constant of proportionality & putting B as another constant.
W = B/T √ [ ( w/w+1)x ( T / Ta) – 1 ]
= B √ [ ( w/w+1)x ( 1 / Ta x T ) – 1 / T 2]……
After differentiating and for maximum discharge,
dW / dT = 0

(w / w+1) x ( 1 / Ta x T2 ) = 1 / T3
(w / w+1) x ( 1 / Ta ) = 2 / T
T = 2 x ( w+1 / w) x Ta
This shows that, maximum weight of hot gases are discharged when,
T = 2 [(w+1/w) x Ta] ----------------------------(2)
Substituting this value of T in equation (1)
hg = H ( 2 – 1 ) = H mtrs
hg = H metres
Which means that when maximum discharge takes place, height of column of
Hot gases expressing the draught pressure will be equal to the height of the
Chimney.

14.0 Power Required To Drive The Draught Fan:

The capacity of the Fan or the air horsepower is defined as the power required to move
air or gas by the fan, through the furnace and push through the chimney.
If P = draught pressure in kg/m2=h (where h = draught in mm of water)
V = volume of air or gas handled by fan per minute in m3
Then, Work done by fan = P x V kg-m/minute &
Air H P = (P x V) / 4500
If ‘η’ is the efficiency of the fan,
Then, power (BHP of motor) required to drive the fan = (P x V) / 4500 x η ------(1)
New, volume V of air handled by a forced draught fan can be calculated as under:
If w = quantity of air supply per kg of fuel burnt
W = weight of fuel burnt/minute
Then quantity of air supplied per minute = w x W kg
If Ta = absolute temp. of outside (cold) air
To = absolute temp. of air at NTP (273 deg K) &
Vo = volume of 1 kg of air at NTP (0.7734 m3)
Then, V = w x W x Vo x Ta / To m3 /sec-------------------------------------(2) Substitute
value of (2) in equation (1)
Power required to drive a forced draught fan i.e.

B.H.P. of motor = P x w x W x Vo x Ta --------------------------------(3)

4500 x η x To
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

And Volume V of flue gases handled by an induced draught fan can be calculated as
given hereunder:
The wt. of flue gases formed per kg of fuel = (w+1) kg
∴ wt. of flue gases handled by induced draught fan per minute = w (w+1) kg
(W kg of fuel is burnt per minute)
If T = absolute temperature of flue gases, assuming density of flue gases to be that of
air) V = (w+1) W x Von x T / To -------------------------------------- (4)
Substituting value of (4) in equation (1),

Power required to drive an induced draught fan i.e. B.H.P. of motor

= P x (w+1) W x Vo x T --------------------------------(5)
4500 x ηx To

Now comparing of BHP for forced & induced draught when both the fans
have same efficiency & produce equal draught.

H.P. required for induced draught fan = (w+1 / w) x T / Ta --------------- (6)

H.P. required for forced draught fan

Where, T = absolute temp of flue gases handled by I.D. fan

Ta = absolute temp. of air handled by F.D. fan &
W = weight of air used in kg to burn 1 kg of fuel.

BOILER CIRCULATION SYSTEM

1.0 Boiler Circulation System:

We have already seen that Boiler is a closed vessel, wherein water is converted to vapour
or gaseous form, called steam, by the application of heat. Steam is continuously being
raised and sent out for external usage and hence it is necessary to keep on feeding boiler
with fresh water. The water in boiler is to be kept in continuous circulation through the
heat flux zone, so that the circulating water picks up the heat and evaporates. It is
essential to have a motive force to keep the water in continuous circulation. Such a
motive force may be induced internally due to formation of water to vapour form or it
may be through application of a mechanical force. The pressure parts are exposed to
enormous heat source and are required to be cooled, to protect them from temperature
rise. It is the water or the vapour, which is flowing through boiler tubes, keeps the tube
metal temperature within limits by absorbing the heat from the high heat zone, through
tube walls.

2.0 Certain Terminologies used in modern high capacity boilers:

 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
Steam and Water Drum:
It is a big drum type vessel which can withstand high pressure and act as a storage tank of
water in a boiler. Feed water from economizer enters the drum through a feed header.
Steam and water mixer from furnace wall tubes enters the drum through separators,
where water and steam gets separated. Steam rises up and passes through secondary
separators and goes out for superheating. Denser water particles trickle down to water
level in drum.
Down Comer:
Down comer is a few big pipes which carry water downwards from drum and feed to
bottom headers of furnace wall tubes. These tubes are generally located outside the heat
zone i.e. outside the furnace.
Spider Tubes:
These are small branches of feed water piping, connecting Down Comer pipes and the
water wall bottom headers on all the sides.

Furnace Water Wall:

Modern high pressure Boiler furnace is formed by water cooled tubes, arranged in a
panel, with the tubes running very close to each other and form a wall to the furnace on
each side. The wall tubes are all connected to a long common header at bottom and at the
top, on each side separately. In modern Boilers the wall tubes are welded to each other
with fin plates and forms a leak tight chamber for combustion. It will have openings for
viewing flame condition, opening for manholes and soot blowers.
Raiser tubes:
These are the tubes which connect the top headers of water wall and the drum. These
tubes carry the water and vapour mixer, rising up the water wall tubes.
Saturated steam pipes:
These are the pipes, which interconnect Steam drum and the Ceiling Superheater. These
tubes carry dry saturated steam from drum to Superheater.
Ceiling Superheater:
A panel of small bore tubes interconnecting long header at both ends, forms the roof of
the furnace and the second pass of flue gas path. From here the steam flows through
different stages of superheating.
Primary Superheater or the Low Temperature Superheater (LTSH):
A panel of small bore tubes formed in “U” shaped coils is connected to long headers on
either ends and located horizontally in second Pass of the flue gas path above the
economizer. Superheated steam from Ceiling Superheater enters at inlet and gets heated
further, raising the steam temperature. It is located in the low temperature region of flue
gas path. The steam just gets superheated and the temperature range to which the steam is
heated is very low compared to the final outlet steam temperature and hence called Low
Temperature Superheater.
Platen or pendent panel Superheater:
Steam from Primary Superheater enters the Platen Superheater. The Platen Superheater is
located just above the combustion zone at the top of the furnace. Mainly it receives
radiant heat from the furnace and the steam is further superheated. They are hanging
panels arranged in rows across the width of the furnace. Each panel is connected with its
own small inlet and outlet headers, which are in turn is connected to the big and long
common headers, on both inlet and outlet sides.
Convection Superheater:
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
From Platen Superheater the steam enters the next stage of superheating, which is called
Convection Superheater. Convection Superheater is located away from radiant zone of
the furnace and the heat transfer takes place by convection process, when the mass of flue
gases pass through and across the convection Superheater coils. The steam gets its final
heat addition while flowing through the final Superheater stage and flows out through
main steam pipes, for the end use.

3.0 Classification of Boiler Circulation System:

The boiler Circulation can be classified into three different types of systems: (See Fig 2)
a) Natural circulation system
b) Controlled circulation system
c) Combined circulation system

TO SUPER HEATER
TO SUPER HEATER

STEAM DRUM
STEAM DRUM

FURNACE WALLS
FURNACE WALLS

ECON
ECON

ORIFICE

DISTRIBUTOR
CIRC PUMP HEADER

NATURAL CONTROLLED
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

TO SUPER HEATER

MIXING
VESSEL

FURNACE WALLS
ECON

ORIFICE

CIRC PUMP DISTRIBUTO

R HEADER

COMBINED

Fig. 2

3.1 Natural circulation system

Water pumped under high pressure, by Boiler Feed Water pumps, enters the boiler at
economizer inlet, after getting preheated in the High Pressure Heaters. The temperature
of water entering economizer will be well below the saturation level corresponding to the
pressure at which it is pumped. The feed water, when it flows through the economizer,
gets further heated very close to the saturation temperature by the hot flue gas and gets
into the drum. In a boiler the steam-water drum acts as a storage vessel. Water inside the
drum finds its way flowing down the Downcomer pipes and gets distributed by the
supply pipes to bottom headers of the water wall. The Downcomer pipes and supply
tubes are located outside the boiler-heating zone. Then the water rises through the water
tubes, which are exposed to furnace heat. When the water rises up the water tubes, a
portion of the water is converted into vapour and continues to rise upwards as a mixture
of steam and water, till it flows back into the drum, through steam water separators.
Inside the drum, the steam, separated from water, enters the Superheater zone, for further
increase in the temperature and is sent to the turbine. Remaining water mixes up with the
incoming water from the economiser, and the cycle is repeated.
The circulation, in this case, takes place on the thermo-siphon principle. The Downcomer
contains relatively cold water, whereas the riser tubes contain a steam water mixture,
whose density is comparatively less. This density difference is the driving force, for the
mixture. Circulation takes place at such a rate that the driving force and frictional
resistance are balanced.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

Fig. 3
As the pressure increases, the difference in density between water and steam decreases.
(See Fig. 3). Thus the hydrostatic head available will not be able to overcome the frictional
resistance for a flow corresponding to the minimum requirement of cooling of water wall
tubes. Therefore natural circulation is limited to boiler with drum operating pressure around
175 kg/cm2.

3.2 Controlled circulation system

If the Operating pressure is beyond 180 kg/cm 2, circulation is to be assisted with
mechanical pumps, to overcome frictional losses. To regulate the flow through various
tubes, orifice plates are used. This system is applicable in the high sub-critical regions (say
200 kg/cm2).

3.3 Combined circulation system

Beyond the critical pressure, phase transformation is absent, and hence a once through
system is adopted. However, it has been found that even at supercritical pressures, it is
advantageous to re-circulate the water through the furnace tubes at low loads. This protects
the furnace wall tubes and simplifies the start-up procedure. A typical operating pressure
for such a system is 260 kg/cm2.

4.0 THEORY OF CIRCULATION

The natural circulation is based on thermo siphon principle. Some of the terms which are of
interest in circulation are explained below.

4.1 Nucleate boiling:

 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
When vigorous combustion is taking place, high heat flux is generated in the radiant zone
of the furnace. As heat flux increases, the water wall tubes get more heat and the
temperature of the metal surface tends to increase fast. But the film layer of water adjacent
to the inner wall of the tube receives the heat and the water temperature near the surface
starts increasing. The temperature of the water at this location reaches saturation point. At
this point the transformation from liquid to vapour stage occurs locally at the layer of water
adjacent to the tube inner wall. Since bulk of water inside the tube at subsequent layers
does not reach the same level of temperature to reach saturation point. The water vapour
near the inner wall of the tubes bubble out and travel towards core of the water flow in the
tube. As soon as the bubbles enter the inner core, the stream of water, which has not yet
reached saturation temperature, receives the heat from the bubbles of vapour. The vapour
bubbles collapse giving away their latent heat to raise the temperature of water. As long as
this process of bubbling close to inner metal surface and collapsing when it travels towards
core of the water, tube metal is kept under safe temperature limit, the condition is known as
‘Nucleate Boiling’. Nucleate boiling regimes are characterized by high heat transfer
coefficients.

Fig. 4 Occurrence of DNB with difference of heat flux.

4.2 Departure from Nucleate Boiling (DNB).

Beyond nucleate boiling region (i.e. at still higher heat fluxes) the bubbles coalesce to form
a film of superheated steam over part or all the heating surfaces, a condition, where the
bubbles do not die down, since the core of water too is heated to saturation point, and is not
in a position to absorb the latent heat of the vapour bubbles. This condition is known as
film boiling. The point, beyond which nucleate boiling stops and the film boiling occurs, is
known as ‘Departure from Nucleate Boiling (DNB)’. At this point of occurrence of DNB
metal, temperature is slightly above the water temperature. When water starts boiling and
bubbles out continuously, the metal temperature is slightly above the saturation
temperature. But when DNB is vigorous, the metal temperature shoots up much faster than
the saturation temperature. (See fig. 4).

5.0 CRITERIA FOR DESIGN OF CIRCULATION SYSTEM:

 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
The primary requisite of a circulation system design is to ensure that there is no departure
from nucleate boiling point, for all anticipated operating conditions.
A usual design criterion is the acceptable percent steam by volume (SBV) or the
corresponding percent steam by weight (SBW), throughout the fluid flow path. The inverse
of SBW is the circulation number, which is the ratio of the quantity of steam produced in
the circuit, to the quantity of steam produced in the circuit. At low pressures circulation is
not a critical problem; but at pressures above 80 atm this attains significant importance.
The permissible limit of SBV and SBW is a function of many variables including pressure,
heat flux and mass velocity. For each pressure and heat flux, there is a maximum
permissible quality which is dependent on mass velocity. At constant heat flux and mass
velocity, the DNB occurs at a lower percentage of steam by volume as pressure increases.
High-pressure designs require a detailed analysis of the probable distribution of heat fluxes,
throughout the furnace during operation. These fluxes are a function of heat input, which in
turn is decided by the factors such as the design and location of fuel firing equipment, the
type of fuel fired, the quantum of fuel supplied etc. It therefore becomes necessity to
investigate all the factors that affect the quality to ensure that the final circulatory
arrangement will have an acceptable percent steam by weight not only on the top of the
riser circuit, but also incrementally along its length. Minimum acceptable internal velocity
that is an interdependent variable with quality and heat flux distribution is also an
important criterion. Low velocities in slopping tubes may lead to steam blanketing, and
eventual failure. Solid deposition may occur at low velocities, leading to subsequent
overheating and failure.

6.0 Design of Circulation piping.

A high shock loss at entrance to the circulating piping at boiler drum is to be avoided when
water entering the piping is at saturation temperature. Under these conditions, the entrance
loss will reduce the pressure below the vapour pressure of water and a definite portion of
the water will immediately flash into stem. This steam will condense again, when the
increased pressure due to change in elevation equals the sum of pressure losses due to
shock at entrance and friction loss. Condensation of steam bubbles at lower elevation may
take place with a sudden collapse having all the characteristics of an explosion thus
producing water hammer pressure of great intensity in the piping.
Tubes should have an entrance velocity of not greater than 3 m/sec and should have a
vertical drop of not less than 1m before turning in a horizontal plane or connecting to a
header. The piping sizes must be selected so that with the desired rate of flow, the friction
and shock losses in the downcomers when subtracted from the hydrostatic head will
provide an available head equal to friction and hydrostatic head in the heated tubes and
risers. The piping size therefore is fixed by the physical arrangement and the desired
circulation ratio.

7.0 FACTOR AFFECTING CIRCULATION

The following factors affect the circulation system:
a) The demand on load from the boiler
b) The operating pressure
c) The fluctuation in drum level associated with disturbance in boiler load conditions
d) Change in rate of fuel firing and the and variations in pattern of heat loading inside
the furnace
Let us review the effect of the above conditions on circulation
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

7.1 Heat input to the water walls:

In a boiler circulation system, more and more water is put in circulation, when the firing
rate is increased to meet the increased demand on boiler load. When the maximum
circulation is reached, any further increase in heat input tends to bring down the circulation
(Figure 5).

Fig. 5
With increase in fuel firing, more is the heat generated and more is the steam produced.
With increase in steam output, there is increase in specific volume, associated with increase
in velocity in riser tubes. This is resulted in increased losses in the circuit. At a particular
stage the losses become more than the gain due to increased density difference and
circulation reduces to minimum. The objective of a system design should be to design all
circuits in the rising part of the curve. In this region a natural circulation boiler tends to be
self compensating for numerous variations.

7.2 System Pressures

At lower pressures, circulation ratio increases mainly because of the increased difference in
density between water and steam. As the system pressure increases, the density difference
is narrowed down affecting the circulation.

7.3 System Disturbances:

The wide fluctuations in drum level have a pronounced effect on circulation. As the drum
level changes the feed input to drum is also correspondingly changed. When the feed water
flow is increased to bring up the drum level, the temperature of water in the Downcomer
gets reduced. With the fall in water temperature, water density in Downcomer tends to go
up and hence circulation in furnace wall tubes increases.
Opposite effect is noticed when feed flow is reduced.
7.4 Heat loading pattern:
Heat absorption rate along the riser tubes vary as shown in Fig. 6.
When more heat is added in the lower portion, more generation of steam takes place in
the lower portions. With the increase in steam generation, the average specific volume of
the mixture increases and hence the velocity is increases over a longer length. This
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
contributes to higher losses and decreased CR. When the quantity of steam is increased
near the burner, where the heat loading is highest, chances of DNB are more.

Fig. 6

8.0 CIRCULATION PERFORMANCE

8.1 Circulation Ratio (CR)
For high capacity high pressure utility boilers, the Circulation ratio is preferable to be
maintained between 6 and 9. For medium pressure Industrial boilers usually a higher
circulation ratio is adopted, since these boilers have to respond to quick load changes. The
value of CR varies from 8 to 30 in industrial boilers.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

EXAMPLES

Example:(1) What draught is produced by a chimney 70 mtr high, temperature

of flue gas at chimney base is 180 deg.C (outside temperature is 35 deg. C ) ?
(8-2-1988)
Solution:Here, H = 70 mtr
T = 180 C = 180 + 273 = 453 K
Ta = 35 C = 35 + 273 = 308 K

Now, h = 353H [ 1/Ta - w + 1/w x 1/T ]

Here, air required for combustion is not given, so w+1 can be neglected,
being almost equal

H = 353 x 70 [ 1/308 - 1/453]

Draught Produced, h = 25.68 mm of water column ------- Ans

Example: (2) Estimate the mean temperature of the flue gases leaving the chimney
30 mtr high to produce a draught of 16 mm water column, if 18 kg of air are required
Per kg of fuel burnt on the grate, the temp of atmospheric air is 27 deg. C. Take the
Density of air at 0 deg. C and 760 mm Hg as 1.293 kg/m3
(7.8.1989)

Solution : Here, H = 30 mtr

h = 16 mmWC
w = 18 kg/kg of fuel
Ta = 27 C = 27+273 = 300 K

Now, h = 353H [ 1/Ta - w + 1/w x 1/T ]

∴ 16 = 353 x 30 [ 1/300 - 19/18 x 1/T]

∴ Mean temperature of flue gases T = 578.8 K

= 305.8 C --------------------------- Ans.

Example:(3) Compare the fan powers expended for induced & forced draught &
also the quantity of heat carried away by the flue gses per kg of fuel burnt in each
case. Assume specific heat of flue gases to be 0.24. Temp. of the gases leaving
boiler is 150 deg. C and temp. of outside air is 15 deg. C. Air supplied per kg of fuel
is 18 kg. (13.2.1991)

Solution : Here, T = 150 C = 150 + 273 = 423 K

Ta = 15 c = 15 + 273 = 288 k
sp. heat of flue gases kp = 0.24
w = 18 kg/ ks of fuel.
Making comparison.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
HP required for induced draught fan = (w+ 1) x T / Ta
HP required for forced draught fan w

= (18 + 1)/ 18 x 423/288

= 1.55
i.e. H.P. required for induced draught fan is 1.55 times higher than that of forced
draught fan ------------------------------------------------------------- Ans.

Now, in case of forced draught system,

Volume of air V = w x W x Vo x Ta / To m3
= 18 x 1 x 0.7734 x 288/273 ------ here, w = 1 kg
= 14.686 m3
& in case of induced draught system,
Volume of gases V = (w+1)W x Vo x T1/ To
= 19 x 1 x 0.7734 x 423/273
= 22.769 m3
Now, considering no H2 present in fuel, heat carried away
by dry flue gases per kg of fuel burnt
= Wg x Kp x (t1 - to)
= 19 x 0.24 x (150-15)
= 615.6 kcal / kg of fuel -----(ans)

Example:(4) Determine the height of chimney to produce a static draught of

20 mm water. The mean flue gas temp in the chimney is 270 c and the
atmospheric. The characteristic gas constant R for air is 29.27 kgfm/kg k and for
chimney gas it is 26 kgfm/kgk (13.2.1991)
Solution : Here, h = 20 mmWC ∴ P = 20 kg/cm 2

Mean flue gas temp. = T = 270 C = 270+ 273 = 543 K

Atmospheric air temp. = Ta = 20 = 20 + 273 = 293 K
R for air = 29.27 kg m /kg K
R for chimney gases = 26 kg m / kg K
∴Height of chimney = ?

As we know, in MKS system,

MR = 848, where M= the molecular weight of the gas in kg
R = characteristic gas constant
Using equation, for Air,
PV = MRT
1.033 x 104 x Vair = 848 x 293
∴Vair = 24.05 m3/ kg mole & Again PV = m
1.033 x 104 x 24.05 = mair x 29.27 x 293
∴mair = 28.97 kg.
Similarly for Gas,
PV = MRT
10350 x Vgas = 848 x 543
Vgas = 44.49 m3/ kg mole & Again PV = mRT
10350 x 44.49 = mgas x 26 26 x 543
mgas = 32.62 kg.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
Density of air = mass / volume = 28.97 / 24.05 = 1.21 kg / m3 &
Density of flue gases = mass / volume = 32.62 / 44.49 = 0.733 kg / m3

Let H be the height of the chimney in meters and A be the area of the cross section of
The chimney in meters
Difference in weight = A x H ( 1.21 – 0.733 ) kg. ------------(1)

The draught is 20 mm of WC which is equivalent to a pressure of 20 kg / m2

Difference in weight = 20 x A kg. -------------------------------(2)

By equating two differences in weight from equations (1) & (2),

20 x A = A x H X ( 1.21 – 0.733 )
∴ H = 41.93 metres ----------------------------------------------------Ans.

Example: (5) A chimney has a height of 24 Mt. The ambient temp is 25 deg. C temp.
of flue gases passing through the chimney is 300c. If the air How through the
Combustion space is 20 kg/ks of fuel burnt, find the following.
1. The theoretical draught in cm of water
2. Velocity of flue gases passing through the chimney if 50 percent of the theoretical
draught is lost in friction at the grate & passage. (16.8.1994)
Solution: Here, H = 24 meter
Ta = 25 C = 298 K
T = 300 C = 573 K
w = 20 kg / ks of fuel burnt.
As we know, theoretical draught
h = 353H [ 1/Ta - w + 1/w x 1/T ] mmWC
= 353 x 24 { 1/298 - 21/20 x 1/573 }
= 12.91 mmWC ~ 1.291 cm of water -----------------------------------Ans.
Now, available draught is 50 % of the theoretical draught available draught
= 0.5 x 12-91
= 6.455 mmWC
Velocity V = √ 2ghg
= √ 2 x 0.006455 x 9.81
∴ V = 0..3559 m/sec ---------------------------------------------------Ans.

Example:(6) Estimate the height of a chimney to produce a static draught of 20

mm of water if the mean temp. of flue gases in the chimney is 250 deg. C. The
densities of atmospheric air and flue gases at NTP are 1.293 & 134 kg/m3
respectively. The temp. of outside air is 20 deg.C (16.8.1994)
Solution : Here,
h = 20 mm of WC
T = 250 C = 523 K
Ta = 20 C = 293 K
Density of air = 1.293 kg/m3
Density of Hot gases = 1.34 kg/m3
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
The total static draught is the pressure difference which results due to the difference in the
weights of flue gases inside the chimney and a column of the outside air of the same area &
height.
∴Density of air at 20 C = (1.293 x 273) / (273 + 20) = 1.206 kg/m3
& Density of flue gases at 250c = (1.34 x 273) / (273 + 250) = 0.7 kg/m3

Let, H be the height of the chimney in meter and A m2 be the area of cross section
of the chimney.
Difference in weight = A x H (1.206 - 0.7) kg ------ (i)
The draught is 20 mmWC which is 20 kg/m2
Different in weight = 20 x A ------------------------- (ii)
By comparing (i) & (ii),
20 xA = A x H x (1.206 - 0.7)
H = 20 / (1.206 – 0.7) = 39.6 meters -------------------------------------------Ans.

Example: (7) Forced draught fan delivers air at 10 meters/sec against a draught of 25 mm of
water across the fuel bed on the grate. Determine the HP required to drive 13 kg of air is
required per kg of coal burn. Barometer reading is 1 kg/cm2. Boiler house temperature is 20
deg.C. Assume the efficiency of the fan to be 81.5% "R" gas constant or air = 29.27 kg
m//kg/ C. (16–08-1994)
Solution : Here,
Velocity of air V = 10 m/sec
∴Velocity head to be imparted to the air = V2/2g = 10 x 10/2 x 9.81
= 5.1 meter
Pressure equivalent of this velocity head = 5.1 x 1 x1.293
= 6.594 kg/m2
Draught loss through the grate = 25 mmWC
= 25 kg/m2
Total draught created by forced draught fan = 6.594 + 25 = 31.594 kg/m
∴Amount of air handled by = (10000 x 13) / 60 = 2166.67 kg / minute
Now, PV = mRT will give volume of the air
P = 1 kg/cm2 = 10000 kg/m2
T = 20 + 273 = 293 K

m = 2166.67 & R = 29.27 kg-m/kg/ C

If V be the volume of air handled by the fan per minute in m3, then,
10000 x V = 2166.67 x 29.27 x 293
∴ V = 185.16 m3
Now, efficiency of this FD fan is 81.5 %

B.H.P. of forced draught fan = (31.594 x 1858.16) / 4500 x 0.815

= 16.00 ----------------------------------------------- Ans.

Example:(8) A Boiler is equipped with a chimney of 24 m height. The ambient

temp. is 25 deg. C. The temperature of the flue gases passing through the chimney
is 300 deg. C. If the air flow through the combustion chamber is 20 kg/kg fuel
burnt, find:
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
(1). The theoretical draught in mm of water
(2). The velocity of the flue gases passing through the chimney if 50% of the
theoretical draught is lost in friction at grate & passage. (Feb 1995 )
Solution : Here,
H = 24 metre
Ta = 25 C = 298 K
K = 300 C= 573 K
w = 20 kg/kg of fuel burnt.
As we know, theoretical draught
h = 353H [ 1/Ta - w + 1/w x 1/T ] mmWC
= 353 x 24 [ (1/ 298) – [( 21/ 20) x (1 / 573)] ]
∴ h = 12.91 mmWC ----------------------------------------------------- Ans.

Now, 50% of the theoretical draught is lost in friction

∴Available draught = 0.5 x h =0.5 x 12.91
hg = 6.45 mmWC
∴Velocity of flue gases passing through chimney
V = √ 2ghg
= √ 2 x 9.81 x 0.00645
V = 0.3557 m/sc ------------------------------------------------------------Ans.

Example:(9) Estimate the minimum height of a chimney required to produce a

draught of 16 mm of water if 19 kg of air is required per kg of coal (fuel) burnt on
the grate. The mean temp of flue gases inside the chimney is 626 deg. F and that of
atmospheric air is 86 deg.F. (Oct 10,1995)

Solution : Here, h = 16 mmWC

w = 19 kg/kg of fuel burnt
T = 626 F As we know C =5/9 (F-32) =5/9 (626-32)
=330 C =603 K
Ta = 86 F = 303 K
H =?
Now, we know that,
h = 353H [1/Ta – (w + 1/w) x 1/T] mmWC
16 = 353 x H [1/303 – (20 /19) x 1/603]
16 = 0.5448 H

∴Chimney height H = 29.15 metres ------------------------------------------Ans.

Example :( 10) Estimate the mean temperature of the flue gases leaving the chimney
30 m high to produce a draught of 16 mm of water column if 18 kgs of air is
required atmospheric air is 80.6 deg.F.Take density of air at 0 deg.C and 760 mm of
Hg as 1.293 kg/m3 (5 - 8 – 1996)
Solution : Here,
h = 16 mm WC
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
H = 30 m
w = 18 kg / kg of fuel burnt
Ta = 80.6 F = 300 K
As we know,
h = 353H [1/Ta – (w + 1/w) x 1/T] mmWC
∴ 16 = 353x30 [1/300 – (19/18) x 1/T]
16 = 10590 {0.0033 -1.056/T}
∴ 0.00151 = 0.0033 - 1.056 / T
: 1.056/T = 0.0033-0.00151 : T = 1.056/0.00179

∴ Mean temp of flue gases = 589.94 K = 316.94 C ----------------------------Ans

[Q] State whether TRUE or FALSE. If FALSE, then rewrite the sentence.
When maximum discharge takes place, the height of the column of hot gases
Expressing the draught pressure will be equal to the twice the height of chimney.
Ans: False. “The height of the column of hot gases expressing the draught
Pressure will be exactly equal to the height of chimney.”

Example: (11) A 30 m high chimney is used to discharge hot gas at 297 deg. C to
the atmosphere at 27 deg. C. Find the mass of air, actually used per kg of
Fuel if the draught produced is 15 mm of water. (1.9.1997)
Solution: Here, H = 30 meter
h = 15 mm of WC
Ta = 27 C = 300 K
T = 297 C = 570 K
W =?
As we know,
h = 353H [1/Ta – (w + 1/w) x 1/T] mmWC
15 = 353 x 30 [1/300 – (w+1/w) x 1/570 ]
15 = 10590 {0.00333 - w+1/w x 0.00175}
0.00142 = 0.00333 - w+1/w x 0.00175
0.00175 {w+1/w} = 0.00333 - 0.00142
w+1/w = 1.093
w+1 = 1.093 w
0.093 w = 1

∴ w = 10.75 kg/kg of fuel burnt. ----------------------------------------Ans.

[Q] Derive that,

Draught required h = 353 H[ 1/T1 – (M+1/M) x 1/T2 ]
Where, H = height of chimney above the fire grate in meters,
T1 = Temp. of air outside the chimney in K
T2 = Temp. of flue gas inside the chimney in K
& M = Mass of air actually used in kg/kg of fuel (1.9.1997)
Ans: Let, W = weight of air used in kg to burn 1 kg of fuel
T = average absolute temp. of chimney gases in K
Ta = absolute temp of air outside the chimney in K
∴Weight of flue gases produced = ( W + 1) kg per kg of fuel burnt.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
The volume of chimney gases produced may be taken as equal to volume of air
supplied, since the volume of the solid or liquid fuel burnt is 500 small as
compared with the volume of air supplied that it may be neglected.

Taking the volume of 1 kg of air at 0 c & 760 mm of Hg as 0.7734 m3.

Volume of gases at 0 c = 0.7734 w m3 per kg of fuel burnt since the volume of
Gas is proportional to its absolute temp according to charge's Law.
Volume of chimney gases at T deg.K = (0.7734 x w x T) / 273 m3/kg of fuel
burnt and the density of chimney gases at temp. T deg. K
= (w+1) / 0.7734 w x T kg/m3
273
Similarly, the density of atmospheric air at Ta deg. K
= w / 0.7734 w x Ta kg/m3
273
Now, Let H = height of the chimney (measured from the furnace grate level)
The pressure exerted per m2 at the furnace grate level by a column of hot gas

One meter in height = density of the gas

Pressure exerted by a column of
Hot chimney gases of H meters height = density x 9.81 x H N/M2
= [(w+1) / 0.7734 x w] x [273 / w] x 9.81 x H N/M2
Similarly, pressure due to a column of
Outside (cold) air of the same area and H meters height
= [ ( 1 / 0.7734)] x [273 x Ta] x 9.81 x H N/M2

Now, Let P = pressure causing the draught in kg/m2 since the pressure causing
the draught is due to the difference between the pressure due column of hot gases
within the chimney and the pressure due to an equal column of cold air outside.
P = [{(1/ 0.7734) x (273/Ta) x H} -{(w+1/w) x(1/ 0.7734) x (273 x T )] x H x 9.81

= (273 x 9.81 x H) / 0.7734 [[1/Ta] – [ (w+1/ w) x (1/ T)] ]

The chimney draught (pressure) is usually expressed in terms of mmWC
(Shown by manometer)
Now, Density of after = 1000 kg/m3
∴A water column of 1-meter (1000-mm) height will exert a pressure of
1000 x 9.81 N/M2
Let, h = draught pressure in Mk
Since this pressure is proportional to the height of column,

∴ P / 1000 = (h x 9.81) / 1000 ∴ P = h x 9.81  substituting this value

h = 273 H / 0.7734 [ (1/Ta) – { ( w+1)/w x 1/T ) } ]

h = 353H [(1/Ta) – {(w+1)/w x 1/T)} ] mmWC

This is a theoretical draught, which is also known as static draught. The actual
(Available) draught is always less than this.
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
Example: (12) A FD Fan discharges 1200 m3 of air/min through the outlet of
2.1 m2 area and maintain a static pressure of 100 mmWC. The temp. of air is 27 C.
Calculate the B.H.P. of the motor to drive the F.D fan if the efficiency of fan is 80%.
Assume the weight of air at NTP is 1.293 kg. (1.9.1997)
Solution: Here,
Volume of air = 1200 m3/min
h = 100 mm WC
Ta = 27 C = 300 K
Efficiency = 80% & weight of air w = 1293 kg
B.H.P. of motor =?
B.H.P. of motor = P x V / 4500 x n
= 100 x 1200 /4500 x 0.8
= 33.33 --------------------------------------------Ans

Example: (13) Forced Draft fan supplies air to boiler at draught of 37 mm WC.
What is the absolute pressure? (15.6.1998)
Solution: Here,
Draught = 37 mmWC
= 37 kg/m2 which is a gauge pressure
Now, atmospheric pressure = 1.033 kg
= 10330 kg/m2
The absolute pressure = gauge pr + atm. Pr
= 37 + 10330
= 10367 kg/m2
= 1.0367 kg/cm2 ---------------------------Ans.

Example: (14) Calculate the draught in mm WC produced by chimney 30 mtrs

high when the average gas temperature of hot gases is 225 deg.C & temp. of
outside air is 20 c. The quantity of air supplied is 18 kg/kg of fuel.
(15.6.1998)
Solution: Here,
H = 30 mtrs
T = 225 c = 498 K
Ta = 20 C = 293 K
h=?
W = 18 kg /ks of fuel
As we know,
h = 353H [ 1/Ta - w + 1/w x 1/T ] mmWC
= 353 x 30 [ {1/ 293} - {19/18} x {1/498}]
∴ h = 13.697 mm of W C ------------------------------------------ Ans.

Example:(15) Calculate the static draught produced by a chimney of 35 mtr

height when the mean gas temp. is such as to cause the weight of these gases
Discharge in a given time to be maximum. The temp. of atm. air is 25 deg C.
(8.2.1999)
Solution : As we know,
Under the condition of maximum discharge,
T = 2 {[(w+1) / w – Ta]} Here, H = 35 mts & Ta = 25 C = 298 K
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
Substituting values in equation,
h = 353H [1/Ta - w + 1/w x 1/T] mmWC
= 353 H [ 1/ Ta – 1/ 2Ta ]

= 353 H [ (1/Ta) ( 1 –0.5)]

= 353 H x 0.5 / Ta
= 353 x 35 x 0.5 / 298
∴ h = 20.73 m of WC -------------------------------------------Ans.

[Q] True or False?

For maximum discharge of flue gases through a chimney draught in mm of WC
is equal to 176 H/T1,
Where H = Height of chimney in metre
T1 = Temp. of flue gases in K (2.8.1999) & (7.2.2000)
Ans: False It should be equal to 176.5 H / T1.

Example: (16) Calculate the draught in mm of water column produced by a

Chimney 30 mts. high when the average temp. of her gases is 225 deg. C and the
temp. of outside air is 20 deg. C. The quantity of air supplied is 18 kg/kg of fuel.
(7.8.2000)
Solution: Here,
H = 30 mts
T = 225 C = 498 K
Ta = 20 C = 293 K & W = 18 kg /kg of fuel
h=?
As we know,
h = 353H [ 1/Ta - w + 1/w x 1/T ] mmWC
= 353 x 30 [ (1/293) – { ( 19/18) x (1/498)}]

∴h = 13.697 mm of WC ------------------------------------Ans.

Example:(17) Determine the efficiency of a chimney as an instrument for creating

the draught in a natural draught system from the following data.
The height of chimney is 30 mtr, the mean temp. of the flue gases leaving the
chimney is 300 deg.C and the quantity of air supplied per kg of fuel is 20 kg. The
mean temp. of the flue gases leaving boiler plant in artificial draught system
would be 125 deg.C. The mean specific heat of the flue gases is 0.24 & the boiler
room temp. is 13 deg.C. (7.8.2000)
Solution: Here,
H = 30 mtr
T1 = 300 C = 573 K -----> in case of natural draught
Ta = 13 C = 288 K
W = 20 kg/kg of fuel.
T2 = 125 C = 398 K -----> in case of artificial draught.
As we know,
h1 = 353 H [1/Ta – (w + 1/w) x 1/T] mmWC
= 353 x 30[(1/288)-{(21/20) x (1/573)}]
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

∴ h1 = 17.37 mm WC -----> in case of natural draught boiler.

Now due to the flue gas temp. being higher in natural draught system, the extra
heat carried away by 1 kg of flue gases = mass x sp heat x diff in temp
= 1 x 0.24 x (300 - 125)
= 42 kcal/kg
∴Mechanical equivalent of the heat =42 x 426.7 = 17920 kg- m/

Now, the draught pressure in meter of hot gases

h’ = H [{(w/w+1) x ( T/ T1 )} - 1 ]
Here,
T = 300 + 273 = 573 K
T1= 273 + 13 =286 K
H = 32 mtrs & w = 20 kg/kg of fuel
h’ = 32[{(20/20+1) x ( 573/ 286 )} - 1 ]
= 29.06 metre
The maximum energy which total static head of 29.06 mtr will impart to 1 kg of
flue gas = 1 x 29.06
= 29.06 kg-mtr.
The efficiency of the chimney = (29.06 / 17920) x 100 = 0.162 % -------- Ans.

Example: (18) Find the difference in horsepower required for a boiler having
Following data if a forced draught fan is used in place of an induced draught fan.
Boiler House temp = 20 C
Mean temp of flue gases leaving boiler = 109 C
Air supplied per kg of fuel burnt = 19 kg
Density of air under given condition = 1.205 kg/m3
Density of flue gases at specified temp.= 0.769 kg/m3
Combustion rate = 150 kg of fuel per hour.
Fan draught required in both the cases = 75 mmWC
Efficiency of fan in both cases = 50%
Allow 20% leakage air in case of induced draught fan & 10% leakage in case of
forced draught fan. (5.8.1996)
Solution : Case - 1 Induced Draught Fan
weight of fuel burnt per minute = 150/60 = 2.5 kg

weight of flue gases produced per kg of fuel = 19+1 = 20 kg

weight of gases handled by fan/minute = 2.5 x 20 = 50 kg

∴V = 50/0.769 x 1.2 (Here, 20% leakage air is considered)

= 78.05 m3
Draught pressure P = (75 / 13.6) x ( 10000 / 735.6 ) = 75 kg/m2
Using equation,
BHP of motor to drive ID fan =(P x V) / 4500 x η
(75 x 78.05) / (4500 x 0.5)
= 2.596 ------------------------------ (1)
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
Case - 2 Forced Draught Fan

Volume of air to be handled by FD Fan per minute V = [(19 x 2.5)/ (1.205)] x 1.1
(Here, 10% leakage air is considered)
= 43.39 m3
& Draught pressure is same as above as above i,e. 75 kg/m2
Using equation,
BHP of motor to drive FD Fan = (P x V) / 4500 x η
= (75 x 43.39) / 4500 x 0.5 -- efficiency of
fan is also same
= 1.445 --------------------------- (2)
∴Difference between Horse power = 2.596 - 1.445 = 1.151 ----------------Ans.
∴ This much more BHP required in case of ID Fan.
OR
Comparing the horsepower = HP for ID fan = 2.596
HP for FD fan 1.445

=1.8 (Ratio of HP) -----------------------------Ans.

Examples for practice

Q.1 Write short notes on Natural draught of the boiler,

IID/17.3.94, II-D/11.10.95

Q.2 Estimate the height of a chimney to produce a static draught of 20 mm of water if the
mean temp of flue gases in the chimney is 250°C. The densities of atmospheric air and
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001
flue gases at NTP are 1.293 nad 1.34 kg/cu.meter respectively. The temperature of
outside air is 20°C.
IIB/16.8.94 ,II-A/2.8.99

Q.3 Forced draught fan delivers air at 10 meters/sec. against a draught of 25 mm of water
across the fuel bed on the grate. Determine the HP required to drive the fan if 10,000 kg
of coal is burnt per hour with 13 kg. of air is required per kg of coal burnt. Barometer
reading is 1 kgf/cm2. Boiler house temperature is 20°C. Assume the efficiency of the fan
to be 81.5 percent ‘R’ gas constant for air = 29.27 kg.m/kg/°C.
IIB/16.8.94

Q.4 Find the difference in horse power required for a boiler having following data if a force
draught fan is used in place of an induced draught fan.
Boiler house temperature = 20°C
Mean temperature of flue gases leaving boiler = 190°C
Air supplied per kg of fuel burnt = 19 kgs.
Density of air under given condition = 1.205 kg/M3
Density of flue gases at specified temp is 0.769 kg/M3
Combustion rate = 150 kg of fuel per hour
Fan draught required in both the cases = 75 mm of water
Efficiency of fan in both cases 50%. Allow 20% leakage air in case of induced draught
fan and 10% leakage in case of forced draught fan.
II-A/5.8.96

Q.5 Estimate the height of chimney to produce a static draught of 20 mm of WC If the mean
temp. of gas in the chimney is 250 C and the temp. of outside air is 20 C. The density of
atmospheric air and flue gases at NTP are 1.293 & 1.34 kg/m3 respectively.

2.8.1999
 INDIABOILER DOT COM
TUTORIAL FOR SECOND CLASS BOILER ENGINEER’S PROFICIENCY EXAMINATION
DLP/BOE-II/ 3 – II/16122001

ASSESSMENT SHEET

Q.1 A chimney has a height of 24 m. The ambient temperature is 25°C. Temperature of flue
gases passing through the chimney is 300°C. If the air flow through the combustion space
is 20 kg/kg of fuel burnt, find the following:-
i) The theoretical draught in cm of water.
ii) Velocity of flue gases passing through the chimney if 50 percent of
the theoretical draught is lost in friction at the grate and passage.
IIA/16.3.94

Q.2 (a) What is the function of a boiler chimney?

(b) Why is there no chimney in the case of a locomotive boiler?
(c) What are the advantages of artificial draught over natural draught?
(d) How draught is measured?
IIC/17.3.94
Q.3 Differentiate between Induced draught and Forced draught
IID/17.3.94, II-D/6.8.96 ,II-B/1.9.97

Q.4 Estimate the minimum height of a chimney required to produce a draught of 16 mm of

water if 19 kg. of air is required per kg of fuel burnt on the grate. The mean temperature
of flue gases inside the chimney is 626°F and that of atmospheric air is 86°F.
IIA/10.10.95

Q.5 a) A boiler is equipped with a chimney 25 mtrs high. The temperature of outside air is
25ºC and average temperature of flue gas in the chimney is 320ºC. The boiler is supplied
with 20 kg of air/kg of fuel. Calculate
i) The theoretical draught created in cms of water column
ii) The velocity of flue gases in the chimney if 60% of the draught is list in the friction of
the grate and passages.
b) Steam leaving the boiler at pressure of 12 bar, enter the super heater where it receives
heat at constant pressure. The condition of steam entering the superheater is 0.95 dry and
leaves it at temperature of 250ºC.
Calculate the heat received by the steam in superheater and increase in volume of steam
as it passes through the superheater.
II-A/7.2.2000

Q.6 What is balance draught? Give merits and demerits in using it.
II-C/11.10.95

Q. 7A chimney of 30 m height is full with hot gases at a temperature of 288 o C. The outside air
temperature is 21 o C. If the available draught is 80 % of the theoretical draught, calculate the
available draught. The air supplied for combustion is 18 kg per kg of fuel burnt. Take density of
air at 0 o C and 760 mm of Hg to be 1.28=93 kg/m3