BGMEA University of Fashion and Technology (BUFT)

Department of Textile Engineering Lab Manual

Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
Experiment No. 01
Experiment Name: Study of Cochran Boiler and Babcock and Wilcox Boiler

1. Objectives
a) To study the working procedure and different parts of Cochran boiler (an example of fire tube boiler)
b) To study the working procedure and different parts of Babcock and Wilcox boiler (an example of water
tube boiler)

2. Apparatus
a) Model of Cochran Boiler.
b) Model of Babcock and Wilcox Boiler

3. Theory
3.1 Boiler
Steam boiler is a closed vessel in which heat produced by the combustion of fuel is utilized to generate steam
from water, at desired temperature and pressure. According to IBR (Indian Boiler Regulation) boiler is defined
as “Boiler is a closed pressure vessel with capacity exceeding 22.75 liters used for generating steam under
pressure.”
The steam produced may be supplied:
a) For generating power in steam Engine or steam turbines.
b) At low pressures for industrial process work in cotton mills, sugar factories, etc., and
c) For producing hot water for supply of hot water and for heating the buildings in cold weather.

3.2 Boiler Classification

1. According to relative position of water and hot gases
a) Fire Tube boiler - hot gases pass through fire tubes which are surrounded by water. Examples:
Lancashire, locomotive, Cochran and Cornish boiler
b) Water tube - water flows inside the tubes and the hot flue gases flow outside the tubes.
Examples: Simple vertical boiler, Babcock and Wilcox boiler
2. According to the axis of the shell
a) Vertical boiler – the axis of the shell is vertical. Examples: Cochran boiler, vertical boiler etc.
b) Horizontal boiler – the axis of the shell is horizontal. Lancashire boiler, Locomotive boiler,
Babcock and Wilcox boiler etc.
c) Inclined boiler – the axis of the boilers is inclined.

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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
3. According to the method of firing
a) Externally fired boilers – furnace is located outside the shell. Example: Babcock and Wilcox
boiler.
b) Internally fired boilers – furnace is located inside the shell, means combustion takes place
inside the boiler shell. Example: Simple vertical boiler, Lancashire boiler, Cochran boiler
4. According to the method of water circulation
a) Forced Circulation boilers - water is circulated by pumps which is driven by motor.
Example: Velox boiler, LaMont boiler, Loffler boiler.
b) Natural Circulation boilers - water is circulated by natural convection currents which are set
up due to the temperature difference produced by the application of heat. Example: Babcock
& Wilcox boiler, Lancashire boiler, Cochran.
5. According to the pressure of steam
a) Low pressure boilers – boilers working pressure is between 15 to 20 bars (process heating).
Example: Cochran and Cornish boiler.
b) Medium pressure – boiler pressure 20-80 bars (for power generation or combined use of
power generation and process heating). Example: Lancashire and locomotive boiler.
c) High pressure boilers – working pressure is more than 80 bars (for power generation).
Example: Babcock and Wilcox boiler, LaMont boiler etc.
d) Sub-critical boiler: Boiler pressure which is less than the critical pressure (220 bars for water),
it is called a subcritical boiler. Example: Drum-type steam generator
e) Supercritical boiler: Boiler pressure is greater than the critical pressure around 220-280 bars,
540ºC for water.
f) Ultra-Supercritical boiler: These boilers provide steam at a pressure greater than the critical
pressure (300 bars, 600ºC) for water.
6. According to the mobility of boiler
a) Stationary boilers – it is used for stationary plants. Example: Lancashire, Babcock and Wilcox
boiler, vertical boiler
b) Mobile boilers – it can move from one place to another. Example: Locomotive boiler.
c) Locomotive: Produce steam to drive railway engines.
d) Marine boiler: Used on ships.
7. According to the number of tubes in the boiler
a) Single tube boilers – they have only one fire or water tube.
b) Multi tube boilers – they have more than one fire or water tubes.
8. According to fuel charge in the furnace
a) Pulverized fuel
b) Supercharged fuel
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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
c) Fluidized bed combustion boilers
9. According to the draft used
a) Natural draft: Boilers need supply of air for combustion of fuel. If the circulation of air is provided
with the help of a chimney, the boiler is known as natural draft boiler. Example: Simple vertical
boiler, Lancashire boiler.
b) Artificial draft boilers: When either a forced draft fan or an induced draft fan or both are used to
provide the flow of air the boiler is called artificial draft boiler. Example: Babcock and Wilcox
boiler, Locomotive boiler
10. According to type of fuel used
a) Solid Fuel: The boiler in which heat energy is obtained by the combustion of solid fuel like coal
or lignite is known as solid fuel boiler.
b) Liquid or gaseous: A boiler using liquid or gaseous fuel for burning is known as liquid or gaseous
fuel boiler.
c) Electrical or Nuclear energy: Boilers in which electrical or nuclear energy is used for generation of
heat are respectively called as electrical energy headed boilers and nuclear energy heated boiler.

3.3 Fire Tube Boiler

The boilers in which the hot gases are inside the tubes and the water is surrounding the tubes is called fire tube
boiler. The various fire tube boiler is following:
a) Lancashire boiler
b) Locomotive boiler
c) Scotch marine
d) Cochran boiler
e) Cornish boiler

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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
3.3.1 Cochran Boiler
3.3.1.1 Characteristics of Cochran Boiler
 Vertical
 Portable
 Fire-tube
 Multi-tube
 Internally fired
 Natural circulation
 Solid as well as liquid fuel can be burnt
 These boilers are manufactured in 23
different sizes and are easily
transportable. The shell diameter ranges
from 0.9 m to a maximum of 2.75 m.

3.3.1.2 Boiler Specification (For Shell

diameter 2.75 m)
Figure 1.1 Cochran boiler.
 Shell: diameter : 2.75 m, Height : 5.75 m
 Working pressure : 6.5 bar (Maximum 15 bar)
 Steam capacity : 3500 kg/hr (Maximum 4000kg/hr)
 Heating surface area : 120 m2
 Efficiency : 70% to 75%

3.3.1.3 Components of Cochran boiler

1. Shell: It has a vertical axis cylindrical drum with hemispherical dome type shell at the top.
2. Grate: It is the platform on which the solid fuel is burnt.
3. Combustion Chamber: The burning of fuel takes place in the combustion chamber.
4. Fire Tubes: Cochran boiler has multi tubular fire tubes. The hot flue gases from the combustion
chamber travels to the smoke box through these fire tubes. The fire tubes helps in the exchange of
heat from the hot flue gases to the water.
5. Fire Hole: It is the hole provided to fire the fuel inside the furnace.
6. Furnace: It lies at the bottom of the boiler. Furnace is the place where all the fuel is burnt. Without
furnace the working of this boiler is not possible.
7. Chimney: The chimney is attached to the smoke box. It transfers smoke to the environment. The
size of chimney is small as compared with other boiler.

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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
8. Fire Brick Lining: The fire brick lining is present in the combustion chamber and helps in the
combustion of the fuel.
3.3.1.4 Working Procedure
 The water is feed into boiler through feed check valve.
 Level is adjusted to help of water level indicator.
 Coal is added trough a fire hole to grate and then burnt.
 The hot gases produced are collect in firebox.
 From fire box the gas passes on to the combustion chamber through short flue pipes are to
considerable velocity.
 The firebrick lining in the combustion chamber deflects the hot gases to pass through horizontal
tubes.
 From here the hot gases through smoke box enter the chimney.
 Water is evaporated and steam is collected at top.
 Steam is then taken out through steam stop valve.
3.3.1.5 Advantages of Cochran Boiler
i. Cochran boiler occupies less floor space
ii. Construction cost of Cochran boiler is low
iii. Cochran boiler is semi-portable and hence easy to install and transport

3.3.1.6 Disadvantage of Cochran Boiler

i. Steam raising capacity is less
ii. Difficulty in cleaning and inspection
iii. The capacity and pressure are limited
iv. The boiler requires high head room
3.4 Water Tube Boiler
In the water tube boilers, the water is inside the tube and hot gases surrounds the tubes.
The various water tube boiler are following:
a) Babcock & Wilcox boiler
b) Sterling boiler
c) LaMont boiler
d) Loeffler boiler
e) Benson boiler
f) Velox boiler

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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
3.4.1 Babcock and Wilcox Boiler
3.4.1.1 Characteristics
 Horizontal
 Stationary
 Water – tube type
 Multi-tube boiler
 Externally fired
 Having natural
circulation of water
 Having forced-
circulation of air and
hot gases
 Solid as well as liquid
fuel fired
3.4.1.2 Boiler Specification
(For Shell diameter
2.75 m)
Figure 1.2 Babcock and Wilcox boiler.
 Diameter of the Drum 1.22 to 1.83 m
 Length 6.096 to 9.144 m
 Size of the water tubes 7.62 to 10.16 cm
 Size of superheated tubes 3.84 to 5.71 cm
 Maximum working pressure 40 bar
 Maximum steam capacity: 40,000 kg/hr
 Efficiency 60% to 80 %

3.4.1.3 Components of Babcock and Wilcox boiler

1. Drum: It is horizontal axis drum which contains water and steam.
2. Down Take Header: It is present at rear end of the boiler and connects the water tubes to the rear end
of the drum. It receives water from the drum.
3. Up Take Header: it is present at front end of the boiler and connected to the front end of the drum. It
transports the steam from the water tubes to the drum.
4. Water Tubes: They are the tubes in which water flows and gets converted into steam. It exchanges the
heat from the hot flue gases to the water. It is inclined at angle of 10-15 degree with the horizontal
direction. Due to its inclination the water tubes do not completely filled with water and the water and
steam separated out easily.
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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
5. Baffle Plates: Baffle plates are present in between water tubes and apply to provide the movement of
the flue gases and ensure proper heating in the water tubes. It allows the zigzag motion of hot flue gases
from the furnace.
6. Anti-Priming pipe: Is provided to separate water from the stream.
7. Fire Door: It is used to ignite the solid fuel in the furnace.
8. Grate: It is a base on which the burning of the solid fuel takes place.
9. Mud Collector: It is present at the bottom of down take header and used to collect the mud present in
the water.
10. Feed Check Valve: it is used to fill water into the drum.
11. Damper: It regulates the flow of air into the fire box of the boiler.
12. Superheater: The dry stream coming through the anti-priming pipe is supply to the super-heater tubes.
It increases the temperature of saturated steam to the required temperature (or superheated steam) before
discharging it from steam stop valve.
13. Pressure Gauge: It is used to check the pressure of steam within the boiler drum.
14. Water Level Indicator: It shows the level of water within the drum.
15. Safety Valve: It is a valve which acts when the pressure of steam within the boiler drum increase above
the safety level. It opens and releases the extra steam in the environment to maintain the desired pressure
within the boiler.

3.4.1.4 Working Procedure

 Water is fed in to shell through feed check value.
 Due to gravity water passes through the vertical tubes, headers and fills up the inclined tube first. The
water then collects in boiler shell.
 Water level is adjusted with help of water level indicator.
 Coal is added to trolley grate.
 Coal is then burnt.
 The trolley is then pushed into the fire space.
 In order to provide air for combustion of coal and circulation of hot gases, damper is lowered to the
furnace level.
 The baffle plates do not allow hot gases to pass to the right side.
 These gases heat the super heater and then move down.
 These gases travel in the sine wave form and then move to the smoke-box fitted with a long chimney.
 Water in the upper portion of the tubes is heated and rises up.
 The cold water from the down take header rises to take its place and water from the boiler drum flows
down. Thus, the natural circulation of water takes place by placing the water tubes at inclined.
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 BGMEA University of Fashion and Technology (BUFT)
Department of Textile Engineering Lab Manual
Faculty of Textile Engineering
MECH 2102: Elements of Mechanical Engineering (Lab)
Experiment No. 01
 Till the temperature of water in the tube and in the drum becomes uniform, the circulation of water
continues. Finally, the water in the upper portion of the tubes is converted into steam.
 It is then collected in the boiler shell.
 The steam collected above the surface of the water in the drum is wet steam. The super heater is used to
convert this wet steam into superheated steam.
 The superheated steam is then taken out through the steam stop valve fitted on the top of the boiler for
different uses.

3.4.1.5 Advantages of Babcock and Wilcox Boiler

i. The overall efficiency of this boiler is high.
ii. Steam generation capacity is high. It is about 2000 to 40000 kg/hr.
iii. It occupies less space.
iv. It is easy to repair and conduct maintenance procedures of this boiler.

3.4.1.6 Disadvantages of Babcock and Wilcox Boiler

i. It is less suitable for impure and sedimentary water, as a small deposit of scale may cause the
overheating and bursting of tubes. Hence, water treatment is very essential for water tube
boilers.
ii. Failure in feed water supply even for a short period is liable to make the boiler overheated.
Hence the water level must be watched very carefully during the operation of a water tube
boiler.
iii. Maintenance cost is high.

4. Assignments
1. Write down the characteristics of the Cochran and Babcock and Wilcox Boiler.
2. Explain the process of force circulation and natural circulation of water inside the boiler?
3. What is draft? Explain natural draft, forced draft, induced draft, and balanced draft.
4. Write down the applications of fire tube and water tube boiler.
5. Write down the differences between water tube boiler and fire tube boiler (At least 12).

5. References
i. Elements of Mechanical Engineering by R.K. Rajput
ii. An Introduction to Mechanical Engineering by Michael Clifford

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