DEPARTMENT OF MECHANICAL ENGINEERING

POLITEKNIK KOTA KINABALU

SESSION: 2: 2023/2024

DJJ52012
ENG. PLANT REPORT 1 MARKS
TECHNOLOGY
NAME : I. IZZATUL NADWA TAIDIN
II. ABBY GLINGIE AK CHARLIE
III. SYLZIA RABECCA RADIN
I. 07DKM21F2043
MATRIC NO. :
II.
III.
07DKM21F2003
07DKM21F2025
100
CLASS : DKM5A

LECTURER : PETRUS BANATI @ FAZZERIUS

CHAPTER 1 : STEAM POWER PLANT

: Identify and analyse well-defined engineering problems reaching
PLO 2 substantiated conclusions using codified methods of analysis specific to
their field of activity
: Classify the concepts and technology of power plant system and components
CLO 1
to solve related problem based on its application and functions.
C2 : Understand DK3 : Engineering Fundamentals DP1 : Depth of Knowledge
C3 : Apply DK4 : Specialist Knowledge DP4 : Familiarity of Issues
C4 : Analyze DP5 : Extent of Applicable Code

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INTRODUCTION BOTH OF BOILER

(Lancashire boiler – fire tube) AND (Yarrow boiler-water tube)

Lancashire and Yarrow boilers are two distinct types of boilers utilized in industrial settings for steam generation.
The Lancashire boiler, a classic fire tube design, features two large flues and a horizontal shell, providing ample
heating surface for efficient combustion of fuel. On the other hand, the Yarrow boiler employs a water tube
configuration, where water circulates through a series of tubes heated by combustion gases, promoting rapid steam
production and efficient heat transfer. While the Lancashire boiler is renowned for its simplicity and reliability,
the Yarrow boiler excels in compactness and high steam generation rates, making each suitable for various
industrial applications depending on specific requirements and operational conditions.

Lancashire boiler

Yarrow boiler

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TITLE FIRE TUBE; Lancashire Boiler
The question:

As an Assistant Engineer in Luminoduth Sdn.Bhd company, you are required to present a proposal for the
purchase of a boiler. The selection of the boiler must comply with Factory & Machinery Act 1967, (Act 139)
Factories & Machinery (Steam Boiler & Unfired Pressure Vessel) Regulations, 1970.

Introduction

The Lancashire boiler, so named because of the county in which it was developed in England, is a well-
known kind of fire-tube boiler that was widely used in industrial settings in the late 19th and early 20th centuries.
Two sizable cylindrical shells joined by a bridge in its design house fire tubes that allow combustion gasses to flow
through. This boiler, made of wrought iron or steel, has a furnace at one end that burns fuel, heating water around
the fire tubes to produce steam. In addition to having flues for the evacuation of exhaust gas and safety features
like water level indicators and safety valves, Lancashire boilers were frequently built in brick environments.

William Fairbairn created it in the year 1844. The operating principle of the Lancashire Boiler is identical
to that of a simple Fire Tube Boiler; also, its construction and operation are similar to that of the Cornish Boiler;
the only difference between the two is the number of Fire Tubes. The Cornish Boiler has a single fire tube, but the
Lancashire Fire Tube Boiler has two.

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 A) Lancashire Boiler Parts in Power Plants.

In power plants, Lancashire boilers were integral components of steam generation systems. Here are the
key parts of a Lancashire boiler commonly found in power plants:

• Furnace: The furnace is the combustion chamber where fuel, such as coal or oil, is burned. In power
plants, the furnace of a Lancashire boiler would be designed to efficiently combust large quantities of
fuel to produce heat.
• Fire Tubes: Lancashire boilers feature multiple fire tubes that run through the boiler's cylindrical
shells. These tubes are where the heat from combustion gases is transferred to the water, generating
steam. In power plants, these fire tubes are crucial for efficient heat exchange.
• Shell: Lancashire boilers consist of two large cylindrical shells connected by a bridge. These shells
contain the water and steam, providing the structural framework for the boiler.
• Bridge: The bridge connects the two cylindrical shells of the Lancashire boiler and forms part of the
combustion chamber. It supports the firebox and helps maintain the structural integrity of the boiler.
• Grate: The grate is located at the bottom of the furnace and supports the fuel during combustion. In
power plants, the grate is designed to accommodate the specific fuel used, whether it's coal, oil, or
biomass.
• Water Level Indicator: A crucial safety feature in Lancashire boilers, the water level indicator
monitors the water level within the boiler. This ensures proper water levels are maintained to prevent
overheating and damage to the boiler.
• Safety Valve: Safety valves are essential components that release excess steam to prevent pressure
buildup within the boiler. They are critical for maintaining safe operating conditions in power plant
boilers.
• Steam Outlet: The steam outlet is where the generated steam exits the boiler and is directed to the
turbines or other steam-powered equipment in the power plant.

In power plants, Lancashire boilers were typically employed as part of larger steam generation systems,
often working in conjunction with turbines to produce electricity. These boilers provided a reliable and efficient
means of generating steam for various industrial processes, making them essential components of power plant
infrastructure.

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How it operates;

As with other types of boilers, the coal or other fuel is combusted in the furnace, which allows it to pass
into the fire tube. The increase in water volume will automatically increase the grate space. Due to the presence
of a damper, the fuel gases are directly guided into the fire tubes. The heat of the gases observed by the water
through the walls of tubes is called thermal conduction. Once, the water temperature reaches boiling, the water is
converted into steam and then moves upwards of the boiler, which further into the turbine through the steam stop
valve.

The Lancashire boiler is a shell-and-tube-type heat exchanger. The fuel is burned at the grate. The water
is pumped into the shell through the economizer, which increases the temperature of the water. Now the shell is
half filled with water. The fire tube is fully immersed in the water. The fuel is charged at the grate, which
produces flue gases. These flue gases first pass through the fire tube from one end to another. These fire tubes
transfer 80–90% of the total heat to the water. The backward flue gases pass from the bottom passage, where
they transfer 8–10% heat to water.

The remaining flue gases pass through the side passage, where they transfer 6–8% of the heat to water.
The brick is the lower conductor of heat, so it works as a heat insulator. The steam produced in the drum shell is
taken out from the upper side, where it flows through the super heater if required. So the steam produced is taken
out for process work.

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Work Principle of a Lancashire Boiler;

• Fuel Combustion: The process begins with the combustion of fuel, such as coal or oil, in the furnace of
the Lancashire boiler. The fuel is ignited, generating heat energy in the form of hot gases and flames.
• Heat Transfer: The heat produced by combustion is transferred to the water surrounding the fire tubes
within the boiler. These fire tubes run through the length of the cylindrical shells of the boiler. As the hot
gases pass through the fire tubes, they transfer heat to the water, raising its temperature.
• Water Circulation: The heated water absorbs energy from the combustion gases, causing it to boil and
generate steam. The steam bubbles rise to the top of the boiler and collect in the steam space above the
water level.
• Steam Generation: The steam collected in the steam space is then ready for use. It can be directed to
various industrial processes or machinery, such as turbines for power generation or heating systems.
• Continuous Process: The process of combustion, heat transfer, water circulation, and steam generation
continue continuously as long as the boiler is operational and fuel is supplied to the furnace. The
Lancashire boiler is designed to maintain a steady supply of steam to meet the demands of the industrial
processes it serves.
• Safety Measures: Lancashire boilers are equipped with various safety features to ensure safe operation.
These include safety valves to prevent pressure buildup, water level indicators to monitor water levels,
and pressure gauges to measure steam pressure. These safety measures are essential for maintaining
optimal operating conditions and preventing accidents.

Advantages of Lancashire Boiler;

• The Lancashire Fire Tube Boiler can be easily designed and constructed.
• The operation of this boiler is easy.
• It is more reliable and requires less maintenance.
• As it is a low-pressure boiler, the Lancashire Boiler is perfect for small and medium industries.

Disadvantages of Lancashire Boiler;

• The Lancashire Fire Tube Boiler is horizontally constructed, which requires large floor space.
• As the fire tubes are surrounded by a large quantity of water, they develop a low steam production rate.
• Due to the limited number of fire tubes (two fire tubes), the heat loss chances are higher.
• Lancashire Fire Tube Boiler has low efficiency, which is around 65 to 75%

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TITLE WATER BOILER; Yarrow Boiler
Introduction
Yarrow boilers are a popular type of high-pressure water-tube boiler. They were created and widely
utilized on ships, especially warships, by Yarrow & Co. (London), Shipbuilders and Engineers.
The Yarrow boiler design is typical of three-drum boilers: two banks of straight water tubes are arranged
in a triangular row, with a single furnace between them. A single steam drum is mounted between them, with
smaller water drums at each bank's base. This tube bank has both upward and downward circulation. The use of
straight tubes and two-way circulation occurring inside the tube bank rather than using external downcomers
were two of the Yarrow's unique characteristics.

Yarrow boiler, with the flue and outer casing removed ;

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 B) Yarrow Boiler Parts in Power Plants.

A particular kind of water-tube boiler used in power plants is the yarrow boiler, which is essential for producing
steam, which is used to generate electricity. A complex process intended to maximize efficiency and safety
drives the operation of the Yarrow boiler.
The Yarrow boiler is based on a series of water-filled tubes that are heated externally by combustion
gases. These tubes are arranged in a specific pattern to facilitate the transfer of heat from gases to water. As the
combustion gases pass through the tubes, heat is transferred to the water, causing it to reach high temperatures
and transform into steam.
A primary benefit of the Yarrow boiler is its small size, which facilitates effective heat transfer and best
use of available space in the power plant. Rapid steam generation is another benefit of the water-tube
arrangement, which makes it an excellent choice for adjusting to changes in the demand for electricity.
In addition, the Yarrow boiler is well known for its sturdy design and dependability, guaranteeing
continuous operation even in the most trying circumstances. Protection against overheating and pressure buildup
is incorporated into its design, ensuring the safety of personnel and equipment.

Parts of Yarrow Boiler;

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 The Yarrow boiler, a popular type of water-tube boiler used extensively in power plants, is made up of
several key components that work together to help with steam generation. The water drum, a cylindrical
container that holds the water supply needed to produce steam, is at the canter of the boiler. Many small-
diameter tubes that are carefully arranged to form the main heat transfer surface surround this drum. These tubes
are exposed to the extreme heat produced in the furnace, which is the main combustion chamber where fuel is
burned.

Water drums;

The first Yarrow water drums or "troughs" were D-shaped with a flat tubeplate to make mounting the tubes
easier. The tubeplate was bolted to the trough but could be disassembled for maintenance and tube cleaning.
This D shape, however, is not suitable for a pressure drum because pressure will distort it into a more circular
section. Boiler explosion experience had demonstrated that sharp internal corners were also vulnerable to erosion
through grooving. Even though it was challenging to insert and seal the tube ends when they were no longer
perpendicular, later boilers used a more rounded section. The ends of these later drums featured an access
manhole.

Downcomers;

A bank's inner and outer tube rows' respective temperatures, and particularly their rates of boiling, were critical
to the circulation in a Yarrow boiler. While this is easy to maintain at low powers, a higher-pressure Yarrow
boiler has less temperature difference and thus less effective circulation. By placing external downcomers
outside the heated flue area, this effect can be mitigated. Although most Yarrow boilers did not require
downcomers, some were equipped with them.

Double-ended boilers;

In 1905, the Spanish government ordered the construction of the first double-ended boiler. Since the design was
already suitable for both ends to be fired, it was found that double-ended boilers operated marginally more
efficiently. Yarrow's shipyard was always limited in its ability to build larger ships. Many of their boilers were
designed for larger warships, which Yarrow supplied as components to the building yards with larger slipways.

Superheaters;

Early Yarrow boilers were not superheated, but with the introduction of steam turbines, there was an increasing
demand for higher steam temperatures.

Asymmetric Boilers;

Hairpin tubes that ran parallel to the current steam generator tubes made up the Yarrow superheater. One bank of
generator tubes was divided into two, with each having its own lower water drum. The superheater was placed in
the gap formed by these, with both ends of its tubes connected to a single superheater header drum, and an
internal baffle to separate wet and dry steam.

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Controlled flow;

Only one superheater was ever installed, and it was only on one side of the boiler. The most basic and diminutive
boilers shifted their exhaust flue to this side, allowing the exhaust to pass through the bank alongside the
superheater in its entirety. Since the boiler was now asymmetric, it could send a single flow type of exhaust gas
through the superheated side. The other bank, which frequently had fewer rows of tubes, was still in use for
radiative heating only.

Alternatively, the boiler known as "double flow" maintained complete gas flow via both sides; however, only
one of these units had a superheater. A controllable baffle on the non-superheated side could be closed to
improve flow through the superheater. Usually, these boilers had extra feedwater heaters installed in the
updraught above these baffles.

Admiralty three drum- boiler;

This was essentially the same as later, oil-fired, high-pressure Yarrow models. The waterdrums were cylindrical,
and downcomers were occasionally, but not always, used. The tube banks were the sole materially different.
Each tube was mostly straight, but cranked toward the ends instead of being straight like tubes. These were
installed in two separate groups within the bank, creating a gap between them. Superheaters were positioned
within this opening. The superheaters' placement here had the benefit of raising the temperature differential
between the bank's inner and outer tubes, which promoted circulation.

How it operates;

The Yarrow boiler runs on a methodical process intended to produce steam effectively for a variety of
industrial uses, most notably in power plants. The water drum is first filled with water and is used as the main
boiler feedwater reservoir. When the fuel ignites in the furnace or combustion chamber, intense heat is produced,
which is transferred to the water-filled tubes that surround it. As combustion gases flow through these tubes, heat
is exchanged, causing the water inside to boil and transform into steam. This steam rises into the steam drum,
where it is separated from any remaining water or moisture, yielding dry, high-quality steam.
The steam is then directed out of the boiler through steam outlets to power turbines or other uses. Any
water that is left over is recycled back into the system as feedwater, where it is heated in economizers (if any are
installed) and then goes back into the water drum to start the cycle again. Throughout the process, rigorous
monitoring and control mechanisms are in place to regulate parameters such as steam pressure, water level, and
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fuel flow, ensuring safe and efficient operation. The Yarrow boiler is a key piece of equipment for industrial steam
generation because of its consistent shutdowns for cleaning, maintenance, and inspection, which further preserve
the boiler's dependability and efficiency.

Work Principle of a Yarrow Boiler;

The Yarrow boiler operates on the principle of forced circulation and efficient heat transfer through water-filled
tubes. It's a type of water-tube boiler, which distinguishes it from fire-tube boilers by having water circulate
through the tubes while hot gases pass around them. Here's how the Yarrow boiler's work principle unfolds:

• Forced Circulation: The boiler's design promotes forced circulation, meaning water is pumped
through the tubes under pressure. This circulation is typically facilitated by a feed pump. By
maintaining a constant flow of water through the boiler, heat transfer is optimized, and the risk of
overheating is minimized.
• Heat Transfer: Fuel, often coal, oil, or gas, is burned in the combustion chamber or furnace,
generating intense heat. This heat is transferred to the water circulating through the tubes. The water
absorbs the heat and begins to boil, forming steam.
• Steam Separation: As steam is generated, it rises naturally into the steam drum located above the
water drum. Here, any remaining water droplets are separated from the steam, ensuring that only dry,
high-quality steam exits the boiler.
• Pressure Regulation: The pressure within the boiler is carefully regulated to ensure safe and
efficient operation. This is typically achieved through a combination of controls, including pressure
relief valves and steam pressure gauges.
• Steam Distribution: Once separated, the steam is directed out of the boiler through steam outlets. It
can then be utilized for various applications, such as driving turbines for power generation or
providing heat for industrial processes.
• Feedwater Treatment: The remaining water, which may contain impurities or minerals, is circulated
back into the boiler as feedwater. This feedwater is often treated to remove impurities and maintain
water quality, preventing scale buildup and corrosion within the boiler.
• Continuous Monitoring: Throughout the operation, the boiler's performance is continuously
monitored. Parameters such as steam pressure, water level, and fuel consumption are closely watched
to ensure optimal efficiency and safety.
• Maintenance and Cleaning: Regular maintenance and cleaning are essential to uphold the boiler's
performance and longevity. This includes inspections, repairs, and periodic cleaning of internal
components to prevent buildup and ensure efficient operation. Overall, the Yarrow boiler's work
principle revolves around efficient heat transfer, forced circulation of water, steam separation, and
careful pressure regulation to generate high-quality steam for various industrial applications. Its
design emphasizes reliability, efficiency, and safety in steam generation processes.

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Advantages of Yarrow Boiler;

• The steam quality is better compared to a fire tube boiler.

• A water boiler can be used in a large power plant.
• Load fluctuation, or the fluctuation of the load, can be easily handled.
• The direction of water circulation is specified.

Disadvantages of Yarrow Boiler;

• The design is complex in the water boiler.

• For operation, a skilled operator is required.
• The maintenance cost is high.
• The cost of a water boiler is high for the same power output.

C) Explain and summarize the advantages and disadvantages both of boiler.

Yarrow Boiler:

Advantages:

1. Higher Efficiency: Yarrow boilers typically offer higher efficiency due to their water-tube design, which
allows for better heat transfer and faster steam generation.

2. Compact Size: They are relatively compact compared to some other boiler types, making them suitable for
installations where space is limited.

3. Quick Start-Up: Yarrow boilers have a quick start-up time, allowing for rapid production of steam.

4. Efficient Handling of Fluctuating Steam Demands: They can efficiently handle fluctuating steam demands,
making them versatile for various industrial applications.

Disadvantages:

1. Complexity: Yarrow boilers can be more complex to manufacture and maintain due to their intricate water-
tube design, potentially leading to higher initial costs and maintenance expenses.

2. Limited Durability: Some Yarrow boilers may have limited durability compared to other types, particularly
in harsh operating conditions.

Lancashire Boiler:
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 Advantages:

1. Simple Design: Lancashire boilers have a relatively simple design, making them easier to manufacture and
maintain compared to water-tube boilers.

2. Lower Initial Costs: Due to their simpler design, Lancashire boilers often have lower initial costs than water-
tube boilers.

3. Large Steam Capacity: They have a large steam capacity, making them suitable for applications requiring
high steam outputs.

4. Ability to Handle High Steam Pressures: Lancashire boilers can handle high steam pressures, allowing for
efficient steam generation.

Disadvantages:

1. Slower Steam Generation: Lancashire boilers generally have slower steam generation rates compared to
water-tube boilers, which may affect overall efficiency and productivity.

2. Less Efficient Heat Transfer: Their fire-tube design may result in less efficient heat transfer compared to
water-tube boilers.

3. Requires More Space: Lancashire boilers typically require more space due to their larger size, which may limit
their applicability in certain installations.

Summarize

Both Yarrow and Lancashire boilers have distinct advantages and disadvantages. Yarrow boilers, with their water-
tube design, offer higher efficiency, compact size, quick start-up, and efficient handling of fluctuating steam
demands. However, they can be complex to manufacture and maintain, potentially leading to higher costs and
limited durability in harsh conditions. On the other hand, Lancashire boilers boast a simple design, lower initial
costs, large steam capacity, and the ability to handle high steam pressures. Yet, they have slower steam generation
rates, less efficient heat transfer, and require more space due to their larger size. Ultimately, the choice between
the two depends on factors such as space availability, steam requirements, and budget considerations.

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 D) Select and choose the best boiler.

Between this two boiler, Fire tube Boiler (Lancashire Boiler) and Water tube boiler (Yarrow Boiler), water tube
boiler is the best among this two boilers. This is due to the high efficiency and suitability for high pressure
applications. While fire tube boilers is simply design for low pressure and smaller scale operations.

Water tube boilers offers high efficiency due to:-

Firstly, water tube boilers have a larger heating surface area compared to fire tube boilers. This increased surface
area allows for more effective heat transfer from the hot gases to the water, resulting in improved thermal
efficiency. The water-filled tubes in a water tube boiler provide a larger contact area for heat exchange, enhancing
the overall efficiency of the system.

Secondly, water tube boilers can operate at higher pressures, which further improves their efficiency. The ability
to operate at higher pressures allows for higher steam temperatures and pressures, leading to better energy
conversion and higher thermal efficiency. This is particularly advantageous in industrial applications where high-
pressure steam is required for various processes.

Additionally, water tube boilers offer better steam quality and more consistent steam production compared to fire
tube boilers. The design of water tube boilers allows for better control over steam quality, resulting in drier and
more stable steam output. This is important in applications where precise control over steam parameters is
necessary for optimal performance and product quality.

Furthermore, water tube boilers are generally more responsive to load changes and can quickly adjust to varying
steam demands. This responsiveness allows for better efficiency during transient conditions, minimizing energy
wastage during start-up, shutdown, and load fluctuations.

Overall, the combination of larger heating surface area, ability to operate at higher pressures, better steam quality,
and responsiveness to load changes makes water tube boilers more efficient than fire tube boilers in many
14
applications. However, the choice between the two types ultimately depends on the specific requirements and
constraints of the application.

CONCLUSION
In conclusion, the water tube boiler stands out as the optimal choice among boiler options for several reasons. Its
design allows for efficient heat transfer, ensuring higher thermal efficiency and lower fuel consumption compared
to other types of boilers. Additionally, the ability to handle fluctuating steam demands with ease, coupled with its
compact size and faster startup time, make it a practical and versatile solution for various industrial and commercial
applications. Moreover, the water tube design offers enhanced safety features, such as reduced risk of catastrophic
failure due to its ability to contain higher pressures. Overall, the water tube boiler emerges as the superior option,
offering superior performance, reliability, and safety in meeting diverse heating and steam generation needs.

REFRENCES

• https://en.wikipedia.org/wiki/Yarrow_boiler
• https://wondersofworldengineering.com/yarrow-boiler.html
• https://www.scribd.com/doc/62813872/Yarrow-Water-Tube-Steam-Boiler
• https://www.alamy.com/stock-photo/yarrow-boiler.html?sortBy=relevant
• https://www.alamy.com/stock-photo/yarrow-boiler.html?sortBy=relevant
• https://www.coursehero.com/file/96846527/report-presentation-1docx/
• https://testbook.com/question-answer/lancashire-boiler-is-a-__________-boiler--
588c6ede995a2d1564c59133#:~:text=Lancashire%20boiler%20%3A,and%20power
%20required%20are%20moderate.
• https://www.britannica.com/technology/Lancashire-boiler
• https://www.croftonbeamengines.org/engines/the-
boilers/#:~:text=With%20the%20Cornish%20boiler%2C%20they,plate%20in%20t
he%20under%2Dflue.
• https://www.croftonbeamengines.org/engines/the-
boilers/#:~:text=With%20the%20Cornish%20boiler%2C%20they,plate%20in%20t
he%20under%2Dflue.
•

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