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1. Define boiler.
A boiler is a closed vessel in which water or other fluid is heated. A boiler or steam
generator is a device used to create steam by applying heat energy to water.
Water Tube Boiler: A boiler in which the water flows through some small tubes
which are surrounded by hot combustion gases, e.g., Babcock and Wilcox, Stirling,
Benson boilers, etc.
Fire-tube Boiler: The hot combustion gases pass through the boiler tubes, which are
surrounded by water, e.g., Lancashire, Cochran, locomotive boilers, etc.
6. Sketch and completely label a Lancashire boiler. Also explain its’ working
This boiler works on the basic principle of heat ex-changer. It is basically a shell
and tube type heat ex-changer in which the flue gases flow through the tubes and
the water flows through shell. The heat is transfer from flue gases to the water
through convection. It is a natural circulation boiler which uses natural current to
flow the water inside the boiler.
- Working:
The Lancashire boiler is a shell and tube type heat ex-changer. The fuel is burn at
the grate. The water is pumped into the shell through the economizer which
increases the temperature of water. Now the shell is half filled with water. The fire
tube is fully immersed into the water. The fuel is charged at the grate which
produces flue gases. These flue gases first passes through the fire tube from one
end to another. This fire tubes transfer 80-90% of total heat to the water. The
backward flue gases passes from the bottom passage where it transfer 8-10% heat
to water. The remaining flue gases passes from the side passage where it transfer
6-8% of heat to water. The brick is the lower conductor of heat, so work as heat
insulator. The steam produces in drum shell it taken out from the upper side where
it flows through super heater if required. So the steam produce is taken by out for
process work.
In locomotive boiler, first the solid fuel (coal) is inserted on the grate and is
ignited from the fire hole. The burning of the fuel starts and it creates hot flue
gases. A fire brick arch is provided that makes the flow of hot flue gasses to a
definite path before entering into the long tubes (fire tubes). It also prevents the
entry of burnt solid fuel particles into the fire tubes.
The hot flue gases passes through the long fire tubes and heats the water
surrounding them. Due to the heating the water gets converted into saturated
steam and gets collected at the top.
The saturated steam from the dome enters into the main steam pipe through the
regulator valve. The steam travels in the main steam pipe and reaches to the
superheater header. Form header, the steam enters into super heater element pipes.
Here it is superheated and then the superheated steam enters into the steam pipe of
the smoke box.
The steam form the superheater goes to the cylinder containing piston. The
superheated steam made the piston moves within the cylinder. The piston is
connected to the wheels of the steam engine and the wheels start rotating.
The exhaust steam from the cylinder enters into the blast pipe. The burnt gases
and smoke after passing through the fire tubes enters into the smoke box. The
exhaust steam coming out from the blast pipe pushes the smoke out of the boiler
through the chimney. Here the smoke cannot escapes out form the boiler by its
own, so artificial draft is created by exhaust steam coming out from the steam
engine. This artificial draft created pushes the smoke out of the smoke box and
creates suction for the hot flue gases.
- Sketch :
High pressure boiler" means a boiler in which steam or other vapor is generated at a
pressure of more than 15 psig, or water is heated to a temperature greater than 250°F
and pressure greater than 160 psig for use external to itself. High pressure boilers
include at the following:
- Electric boilers;
- Miniature boilers;
- High temperature water boilers; and
- High temperature liquid boilers (other than water).
Working :
- First water is filled in the water drum through feed pump. The drum is half filled
with water and the upper half is for steam.First flue is fired at the grate.
- The flue gases generate by burning of fuel. These gases start flowing from one
end to another end of boiler.
- The flue gases passes by the water tubes and exchange heat with water. The
baffles are provided in the way, which deflects the flue gases before escaping
from the chimney. Due to this deflection, the flue gases pass more than one time
through water tubes, which cause more heat transfer.
- The water flows from the drum to the water tube through down take header.
- The water tube nearer to the furnace heated more than the other, so the density of
water decrease in this tube which causes the flow of steam from tube to drum
through uptake header. At the same time the water from the drum enters into the
tubes through down take header.
- The circulation of water from drum to tubes and again tubes to drum is natural,
due to density difference.
- The steam separates in the drum at the upper half. This is saturated
steam. This steam sends to the super heater through steam pipe. The steam is
heated again by the flue gases in the super heater and taken out for process work.
- The flue gases send to the atmosphere from the super heater.
- This process repeat until sufficient amount of steam generates. This boiler
can generate 20 ton steam per hour.