Module I

Steam Generators &

Indian Boiler Act
Steam Generator
• Steam generator is a closed vessel, strongly constructed of steel by the
application of heat. Steam produced in steam generator is used for
power generation, industrial process work and heating work.

• Function of Steam generator is to convert chemical energy of fuel by

combustion into heat and transfer this heat to water & produce steam.

• Following terms are commonly used in connection with various types of

steam generators:

Boiler shell: Consists of one or more steel plates bent into cylindrical
form and riveted/welded together. The ends of shell are closed by
means of end plates or heads which are made flat, convex or concave.
The shell together with closing heads is called the drum.
Steam Generator
Setting: Forms the wall of combustion chamber. It confines heat to the
boiler and forms a passage through which the gases pass. The
passages so formed for the gases are called flues. The boiler setting
provides support for some type of boilers.

Grate: In coal or wood fired boiler, grate is a platform in the furnace

upon which the fuel is burned. The grate consists of cast iron bars
which are spaced apart so that air for combustion can pass through
them.

Furnace: It is called the fire box. It is the space above the grate and
below the boiler shell in which the fuel is burnt.

Volume: Volume of the shell occupied by water is called water space.

The steam space is entire shell volume, excluding the volume occupied
by water and tubes.
Steam Generator
Water level: It is the level at which water stands in the boiler shell. The
remaining space above the water level is called steam space.

Heating surface: It is the part of the boiler surface that is exposed to

the fire and to the hot gases from the fire as they pass from the furnace
to chimney.

Mounting: It is the term usually referred to such items as safety valves,

main stop valve, high steam and low steam alarm, feed check valve,
pressure gauge, water level indicator, blow off cock etc… which
ensures the safe working of the boiler. Special provision is always
made on the boiler to mount them.

Accessories: It is the term applied to those items which form an integral

part of the boiler but are not mounted on the boiler. Superheater,
economizer, feed pump etc… are considered as boiler accessories.
Steam Generator
Blowing off: It is the act of removing floating impurities that float at
water level and is termed as surface blow off. This is done by means of
some kind of surface blow off appliance.
Classification of steam Generator
Boilers can be classified according to the relative position of the water and
the hot furnace gases under tow main classes

Fire tube boilers: In these boilers, furnace gases pass through the tubes
which are surrounded by water. The water accepts the heat from the
heated tubes and gets evaporated.

Cornish and Lancashire Boilers, Simple vertical tube boiler, Cochran

boilers, Locomotive boilers, Scotch marine boilers fall in this category.

Water tube boilers: The boilers in which the furnace gases pass over the
external surface of the tubes through which the water is circulated are
called water tube boilers.

Babcock and Wilcox boilers; Stirling boilers, Yarrow boilers fall in this
category.
Classification of steam Generator
Boilers may be further classified according to the following:

• Their form – Vertical or horizontal boilers

• Their construction – Tubular or Non tubular boilers

• The service to which that they are put – stationary, portable, marine or
locomotive boilers.
Water –Tube Vs Fire – Tube boilers
• Water tube boilers generate high pressure steam which has become a
present day demand.

• Water tube boilers raise steam quickly.

• Heating surface of water tube boiler is much more effective than an

equivalent area of surface in a fire tube boiler.

• Direction of water tube boilers is well defined. The circulation of hot

gases is rapid all over the boiler, keeping the boiler at a nearly constant
temperature.

• Arrangement of water tube boiler is such that it forms flexible

construction. Every member is free to expand without unduly
expanding or compressing any other member. This feature gives
prolonged life to the boiler.
Water –Tube Vs Fire – Tube boilers
• Water tube boilers are of sectional construction and therefore can be
transported more easily than other types of boilers

• An accident at any one tube or fitting does not produce the destruction
of the whole boiler. Hence water tube boilers are sometimes called
safety boilers.

• Water tube boilers are less suitable for use with impure and dirty water.
If the water contains scale forming materials, a small deposit of scale
will lead to overheating and bursting of tubes.

• Water tube boilers requires frequent maintenance and the cost is high.

• Water tube boilers are somewhat more difficult to inspect.

Factors for boiler selection:
• Pressure at which boiler is to operate and the quality of steam required

• Rate of steam generation.

• Availability of floor area.

• Efficiency of boiler in the same range i.e. amount of steam extracted

per unit weight of fuel burnt.

• Easy accessibility for cleaning repairs and inspection.

• Comparative initial cost.

• Erection facility i.e. erection of boiler is easy or complex.

• Adherence to Indian Boiler Act.

INDIAN BOILER ACT, 1923:
• Boiler Act insists on registration and regular inspection of all boilers in
the country except those installed in ships or under control of railway
and military.

• This act is applicable to all boilers, feed pipes, steam pipes and all
economizers.

Registration of Boilers
• Boilers have to registered before they can be used. The owner of the
boiler shall give an application for the same.

• The inspector shall examine the boiler and find the maximum pressure
at which the boiler may be operated. He/she will submit the report to
the chief inspector and in turn the employer may be get authorized for
1 year to use the boiler.

• The employees shall not use the boiler for pressure higher than that
permitted by the chief inspector
INDIAN BOILER ACT, 1923:
Certificate of Renewal:
The certificate useful for the employer for using the boiler shall be
renewed
• After generally 12 months
• If the boiler is transferred from one place to another
• If some boiler accidents occur
• If some alterations are done in boiler parts

Duties of Inspectors:
• Confirms all boilers are registered and insured.
• Make sure that all boilers are working according to the Act.
• Check and examine boilers, their parts and mountings
• Advise the employer of boilers regarding the matters of boiler
maintenance, cleaning etc…
INDIAN BOILER ACT, 1923:
Duties of Inspectors: (Contd…)
The chief inspector shall
• Maintain the records of registered boilers
• Examine the boiler inspection reports produced by inspectors
• Decide whether to issue the certificate for the operation of boiler or not
• Supervise and control the work of inspectors

Transfer of Boilers:
• When a boiler is transferred from one state to another, permission
must be taken again from the chief inspector of new state for its
installation and operation
INDIAN BOILER ACT, 1923:
Inspection of Boilers:
Before inspecting the boiler, the following things are ensured:
• Boiler is cleaned
• All fittings such as burners, stokers etc… are removed
• Valves and safety locks are opened.
An inspector examines all parts of the boiler, carries the hydraulic test at
places, where water pressure is raised to hydraulic test pressure + 50 psi.
When the hydraulic test pressure is reached, the boiler is inspected for
water leakage of any.

Boiler repairs:
• Before carrying out boiler repairs, permission is obtained from chief
inspector. Major boiler repairs and replacement connected with furnace
etc… are undertaken in the presence of the inspector.
INDIAN BOILER ACT, 1923:
Boiler accidents:
• In case of boiler accidents, the employer shall inform the inspector with
full details of the same.
• The inspector shall carry out investigation and decide whether to permit
the use of the boiler in future and if so, the at what operating pressure.
The inspector shall inform the chief inspector about his investigation and
recommendations.

Boiler Mountings: (recommendations as per IBA, 1967 amendment)

• One blow off cock
• One feed pump
• One feed check valve
• One fusible plug
• Adequate number of manholes and sight holes
• Two safety valves
• Two water level indicator
• One safety valve after superheater
INDIAN BOILER ACT, 1923:
Penalties:
A fine up to Rs 5000 and then Rs 1000 per day additional after the first day
of the offence shall be imposed on the owner of the boiler, who

• Operates a boiler without getting registered.

• Refuses to surrender the certificate of operation of the boiler
• Does not report the transfer of boiler form one place to another and uses
it without inspection
• Does not report the accident of boiler
• Repairs or replaces boiler parts without prior permission of the inspector
• Violates any other provisions of the IBA, 1923
INDIAN BOILER ACT, 1923: