Thermal Engineering-l 12

2.9.1 Boiler Mountings

Following are the common boiler
mountings used
1) Pressure gauge 2) Water level indicator
3) Safety valve 4) Fusible plug
5) Steam stop valve
They are explained below
1) Pressure Gauge
The Fig. 2.8 shows pressure
gauge.
Pressure gauge is used to read the pressure in boiler.
I t controls boiler
operation.

****************v********r********************

Pointer AA- Electrical spring tube

Pointer B-
Toothing sector (T)

Pointer C-

Link L
Hallow block

Steam
Three way clock-

-Water

Pipe

Plug

Fig. 2.8 Pressure gauge

2) Water Level Indicator
The Fig. 2.9 shows water level indicator
Water level indicator is used to measure level of water in water drum and tube.
Thermal Engineering-I
***
2- 13
Boilers

Flange (F) - Ball (B)

Plug (P)
Steam.

Steam Stuffing box (SB)

cock (SC) -

Glass tube (GT)

Flange (F)
-

Stuffing box (SB)

Water

Ball (B) Plug (P)

Water
cock (WC)
Cock (C)
aAnAananonean**anaaaanarenasanaansaaaranmnananas

Fig. 2.9: Water level indicator

3) Safety Valve
Fig. 2.10 shows safety valve.

- Valve

-Plunger
Spring

ww

230000

****a**a******
amananaoa* n s n a n a n e * e a dnaa***a********

Fig. 2.10: Safety value

Satety valve is used to bypass the steam under critical condition. ***********
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4) Fusible Plug
.The Fig. 2.11 diagram shows fusible plug.
Fusible plug present in furnace and measures furnace temperature.

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

*******

*********a***************.onuhusnnasa sanussnannsna usn*s**nsasnousa***sanansna****

Hollow gun metal
plug

Fusible Hexagonal flange

metal

Gun metal
plug

Gun metal -Hexagonal flange

body

Crown
plate

Fig. 2.11: Fusible plug

5) Steam Stop Valve

The Fig. 2.12 shows steam stop valve.
I t is used to control the steam under risk condition.

anaanoanna*mananaananoasonanarasn

AAAAAAAAA

Handle

Spring

Plunger

From boiler

Fig. 2.12 Steam stop value

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2.9.2 Boiler Accessories

Eallowing are the common bO1ler accessories used.

1) Super heater

2) Economizer

3) Air-preheater

They are explained below.

1) Super Heater
*******************

*******a**** ********** a n a e

Steam
dome
Saturated Exhaust
Safety valve steam outlet gasses

Large flues
Small flues

Superheater
Fuel header

Superheater
elementss
Fire grate

Superheated
steam
****annnamaasmaanaaan

Fig. 2.13: Super

heater
The diagram shows super heater.
The super heaters are used to make steam
to super heated with
high temperature.
Super heated steam increases quality of steam and turbine life.
2) Economizer
The Fig. 2.14 diagram shows economizer.
*******

ww.ww w
Flue gases in
Tubes Water in
Baffles

Flue gases out

Water out
****************** a* ansaons so-enaeno- a euura **********a
*************************************************
e******

**** Fig. 2.14 Economlzer

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 water.
the
Thermal Engineering-l

is used
to pre-heat
Economizer
of boiler.
improves
the efficiency
Economizer

3) Air pre-heater

Air
Flue gas
Flue gas in
-

Hot air out

OOoOOO
Tubes-
OOOO00
O o00
OOOOOO

o00000

Baffles
Fresh air in
stack
Flue gas to

Hopper

Fig. 2.15 : Alr pre-heater

shows Air
heater.
diagram pre
The above combustion.
for
heater is used to pre-heat the air
Air
-

pre
of boiler.
A i r pre
- heater improves efficiency

Introduction to IBR
2.10 boilers are
manufactured in India follows
Indian boiler regulation, the
BR is a

The standards of IBR

approved by IBR.
and design to be
The boiler house plan IBR Engineer.
manufacturing to be approved by
boiler and method for
The scale of the
should not be exceed
30 m from floor space.
Chimney height
color strips.
be printed with proper
Chimney should
submitted to IBR.
The
chimney to be
required height if the
standard.
should not be exceeds government
The emissions of chimney
accessories to be added to boiler.
Required mountings and

2.11 Analysis of Boiler

boiler.
The analysis of boiler includes to study the performance of the
boiler.
The following parameters are required to study the performance of the

1) Evaporation or Evaporation capacity of the boller

The evaporation is also termed as capacity of boiler.
The amount of steam generated by a boiler in kg/hr at full load condition.
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 2-18
Thermal Engineering- - ***
**** *******AAA
Boilen
2) Equivalent evaporation (m,) i) Boiler efficiency (M b)

me s ( h - h a ) m,
b
(h -hm)13000 (257040x4.187
2257 mxCV 1250x 30,000

m = S =9.23 nb= 0.8328 or 83.28 % An

Tmf ***
**** ***

Ex.2.6 The following particulars refer to a stea

m= 11.109 kg/kg of fuel. power plant consisting of a boiler, superheater a
*** *********************t**seesso*t*****s**sss*** ************************************** **************************************sssseesss
economizer. Steam pressure = 20 bar, Mass of stean
Ex. 2.3 A boiler evaporates 3.6 kg of water per kg of
coal into dry saturated steam at 10 bar. The temperature generated = 10000 kg/hr., Mass of coal sed
offeed water is 32 °C. Find equvalent evaporation from 1300 kg/hr, CVfor coal 29000 klkg. Temperahe
and at 100 °C. of feed water entering the economizer = 35°. temperatug

105 °C., Dryney

Sol.: Given Data: of feed water leaving the economizer
ms= 3.6 kg. Pb 10 bar,
fraction of the steam leaving the boiler = 0.98

mf Temperature of steam leaving the superheater = 350 C

T 32 c Determine -

1) Overall efficiency of the boiler plant.'

To find : me
2) Equivalent evaporation of the given boiler from and a
m,(h-h) 36(hf +hfg-h) 100 °C. in kg of steam generatedkg of coal burnt and
me
2257 2257 3) Percentage of heat utilized in economizer, boiler an

me
3.6 (762.6+2013.6-32x4.187) super heater.
2257
Sol. : Given Data: P 20 bar, m, = 10,000 kg/hr,
m. 4.2 kg/kg of fuel
****** m =
1300 kg/hr, CV
=29000 kJ/kg. Twl 35 °C,
Ex. 2.4 In a boiler test 1250 kg of coal consumed in Tw2 105 °C, Tsup = 350 °C, x = 0.98

24 hrs. Mass of water evaporated is 13000 kg and mean

effectve pressure is 7 bar. Feed water temperature was To find: i) nr i) me
40 C and heating value of coal is 30,000 kJkg. Taking i) Percentage of heat utilized in boiler, super heater
enthalpy of 1 kg of steam at 7 bar as 2570 k), find and economizer.
equivalent evaporation per kg of coal and boiler
i) Overall efficiency of plant (nover)
eficiency
Sol: Given Data: me = 1250 kg, t = 24 hrs.,
Finally the boiler is producing heated steam.

m, 13000 kg, P= 7 bar, Tw = 40 °C, m, (hsup-h)

Tlover m XCV
CV 30,000 kJ/kg, h = 2570 kJkg.

Tofind: i) me ii) Mb h sup h +hg +Cps llsup-ts]

i) Equivalent evaporation (m,) 908.69+1890.0 + 2.1 [350 -21=
=

me
m,(h-h) h sup 3088.49 kJ/kg.
2257
10,000 (3088.49-35x 4.187)
10.4 (2570-40x 4.187) over
1300x 29000
2257
Mover0.7803 or 78.03 %
m 11.07 kg/kg of fuel. AnsS.

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Thermal Engineering-I 2-19

pressure
of 1.4 feed
from
at a fired
i) Equivalent evaporation (m,): Ex. 2.6: A boiler working coal
95 % %
per kg of valve
is
evaporates 8 kg of 100
C
the s t o p

Me
m (h sup-hp) 39 °C. The
steam at and
at

2257 Water at evaporatie

from

Determine the equivalent

in kg steam/kg coal.
ms
ms 000 =
7.692 kg/kg
mf 1300 of fuel. Sol. : Given Data = 0.95,
x
1.4x 100 = 14 bar;
Pb1.4MN/m = 103
7.692 (3088.49- 105 x 39 °C
4.187)
=

me ms8 kg/kg of fuel, Ty

2257

9.027 To find: i) me
=
kg/kg of fuel
(me)
i) Equivalent evaporation
ii) Percentage of heat utilized
hm
economizer: ms(h-
Heat utilized in m
=

2257
m,(h-h)
CV h hf +xhfg
7692 (105x 4.18735x4.187)1a0 = 830.1 +0.95 x (1957.7)
x100
29000 2689.9 kJ/kg
% heat in economizer= 7.77 % 4.187 = 39x 4187
h Tw x

Percentage of heat utilized in superheater

= 163.29 kJ/kg.
ms (hsup -h)
8 (26899-163.29)
CV me 2257

h h f +x hfg = 8.955 kg/kg of fuel

=
908.69 +0.98 (1890.0)
= 2760.89 kg/kg. 2.12 Solved Examples
% of heat used 7.692 (3088.49-2760.89) x 100
Ex.2.7: The following readings were recorded during
in super heater 29000 boiler trial of 6 hour duration Pressure of steam
generated -12 bar, Mass of
steam generated 40000 kg,
= 8.68 % Dryness fraction of steam generated 0.85, Feed water
Percentage of heat utilized boiler temperature 30 °C, Coal used - 4000 kg. Calorific value
-

ofcoal
m,(h-h 33400 kJ/kg. Find : i) Factor
of equivalent
CV Equivalent evporation from and evaporation,
at 10o
ii) Eficiency of boiler. C
7.692 (2760.89-105x4.187)00
29000
Sol.: Given data : p =
12 bar, ms
x =
0.85, Tw 30 C, mf =
=
40000 kg,
=
4000 kg,
Percentage of heat utilized in boiler 61.5% CV 33400 kJ/kg

To find: i) Factor
of equivalent
ii) evaporation
Equivalent evaporation from and at °C
ii) Efficiency of boiler
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 Thermal Engineering-1I 2-20 ****
Boilers

45,000 kJ/ko The

Step 1 Calculate equivalent evaporation 180 °C, CV =

T3300 °C, T4
=

me mh-hf1) m 19 kg/kg of fuel.

2257
To find:
ms ms40000=10
mf 4000
kg/kg of fuel i) Equivalent evaporation with and withoun
economizer at 100 °C.
with and withou
me
10 (2782.7- 30x 4.187) ii) Thermal efficiency of boiler
257 economizer.

. Ans.
m. 11.77 kg/kg of fuel
Step 1 Calculate equivalent evaporation with and
without economizer at 100 °C.
Step 2 Calculate efficiency of boiler
i) With economizer
b s(h-hf)
m XCV
m,(h-h)
me
2257
40000 (2782.7- 30x 4.187)
4000x 33400 = hf +xh f = 908.5+ 0.96 (1888.7)

0.7955 79.55 % Ans.

or
2721.652 kJ/kg
=
nb

Step 3 Calculate factor of equivalent evaporation h 50x4.187 209.35

h-hf1(2782.7- (30x 4.187) 12(2721.652-209.35)
2257 2257 me 2257

fe = 1.177 . . AnsS.
m. 13.357 kJ/kg of fuel Ans.

Ex. 2.8 The following data relates to a trial on boiler ii) Without economizer:
using economizer air preheater and superheater
Condition of steam at exit of boiler = 20 bar, 0.96 dry, mh)12x2721.652
me 2257 2257
Temperature of steam at exit of superheater = 300 °C,

Steam evaporation rate/kg of fuel= 12 kg. Room

m 14.47 kg/kg of fuel .Ans.
temperature, 1o
=
25 °C, Temperature of feed water at

exit of economizer, t = 50 °C, Temperature of air at

Step 2 Calculate thermal efficiency of boiler wit
exit of air preheater, 1a =
70 °C, The temperature of fue and without economizer
gases at inlet to superheater economizer, air preheater
th
m,h- hn)
and exit of air preheater are respectively 650 °C, 430 °C, CV
300 °C, and 180 °C respectively. Assume that air supplied
is 19 kg/kg of fuel of calorific vaBue of 45,000 kl/kg. 12 (2721.652 -209.35)
find: 45,000
i) Equivalent evaporation with and without economizer, . A D S

th 0.6699 = 66.99 %
from and at 100 °C.
i) Thermal efficiency of the boiler with and without ii) Without economizer
economizer
m,h)12 (2721.652)
Sol. : Given data,: P, = 20 bar, x = 0.96 dry, Tth CV 45,000
Tsup 3 0 0 °C, m, = 12 kg/kg of fuel, to = 25 °C,
AT
th 0.7257 72.57 %
t 5 0 °C, ta 70 °C, Ti = 650 °C, T, = 430 °C,
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Thermal Engineering-I
2-21 Boilers
-
2.9 In a
EY.
boiler test 1250 kg of coal is consumed in Step I : Heat carried away by hot flue gases (Qc)
24 hours, mass of water
evaporated is 13000 kg and
boil pressure
of7 bar. Feed water
temperature was
40C and heating value of coal is 30000 Qc mxCpg X(T -T)
equivalent evaporation per kg of coal and boiler
kJ/kg,
Find
Step IV: Heat carried away by
moisture (0 D
efficiency. (Take enthalpy of kg of steam at boiler exit
as 2570 kI/kg). QD Mm Ih +hfg +Cps ITsup-T,]- hp]
where hf2 Enthalpy of boiler house
Sol. : Given Data: mf 1250 kg, t =
24 hrs.,
m, 13000 kg, P 7 bar, T Step V: Heat un-accounted (Q
40 °C
cV 30,000 kJ/kg, h = 2570 kJ/kg. QE F A -1OB +Qc +Qp]

Tofind: i) me i) Heat
supplied kJ Heat ased k
i) Equivalent evaporation (m,) QA
QB Heat B kJ

me m,h-hg) used convert

2257 steam

10.4 (2570- 40x 4.187) QA QA k J

mxCV
2257 for
1 kg fuel
m 11.07 kg/kg of fuel. .Ans. Qc Heat by Qc k
hot flue gases

) Boiler efficiency b)
Op Heat by Qp k
m,(h-h MOISTe
m xCV
Q Heat
un-accounted
13000 (2570-40x 4.187)
100 %
100%
1250x 30,000

..Ans.
b0.8328 or 83.28 % 2.14 Solved Examples
***********************

recorded
The following observation
were
Balance Sheet Ex. 2.10
2.13 Heat
:
65 kg /hr mass of the
boiler trial fuel used
=

utilization of
during
moisture in fuel is 2 % by
Heat balanced sheet is
used to determine steam kg/hr at 10 bar
=
540
the
determine steam generation. mass. The mass of dry
fuel gases is 9 kg kg of fuel
heat in the boiler to 32000 kJ/kg. The temperature of
lower calorific value is
28 °C feed
in Heat
Balance °C temperanure of boiler is
2.13.1 Steps
Involved fuel gases is 325 the
is 50 °C. The dryness fraction of
Sheet water temperature
heat of gas is I kJ/kg K specific
steam is 0.95 specific
Step I: Heat supplied QA heat of superheated
steam is 2.3 kJ/ kg K.
Determine the

QA mf CV following
i) Boiler efficiency ii) Equivalent evaporation
Heat used to
convert
steam (Q balance sheet
Step II: ii) Prepare the energy
-hm)
QB ms (h
ms
ms mf
v ow ****** ***"**r******************* **************************womm
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TECHNICAL
 2-22 Boile
Thermal Engineering-I by moisture (Qn
**** IV: Heat carried away Thermal En:
Step
65 kg/hr, m, =
540 kg/hr, -1,]-hn]
Mm hf +hfg*Cpssup
mf
Sol.: Given data:
OD
= 0.02 [762.6 + 2013.6 + 2.3 (325 - 179
mm
2 = 0.02 kg, m = 9 kg/kg of fuel,
99)
100
10 bar, x =
0.95, CV =
32000 kJ/kg, 117.236]
Ph
325 °C, Th =
28 °C, T= 50 °C, (economizer) QD 59.85 kJ/kg
Tr
Cpg 1 kJ/kg K, QE QA -[QB +Qc +Qpl
Cps2.3 kJ/kg K = 31360 - [20494 + 2673+ 59.85]

i) He=
i) Boiler efficiency (M) QE 8133.15 kJ/kg
ms (h-hn)540 (h-h) Heat supplied
Heat kJ/kg Step
xCV 65x 32000 tased
m QA
31360 OB 20494 65.3
540 (2675.52- 209.35) QA mxCV
65x 32000 for 1 kg. of Step
fuel * * * * * * * * * * * * * * * * * * * * *

h hr +xhf 762.6+(0.95)
2013.6
=
Qc 2673 8.5
59.85 0.19
= 2675.52 kJ/kg.
8133.15
50x4.187
=
209.35 kJkg
ha
100 % Total 31360 99.98
nb 64.03 %
observations a

Ex. 2.11 In the boiler trial following

Heat supplied Q
:
Step I 1520 kg/hr. The temperaure
recorded mass of fuel is St
32000
m f XCV
=
(1 -
0.02) x
water is 30 °C dryness
fraction of steam is 0.95. T
A feed
steam is 8.5 bar
coal burns per hr 200 k
pressure of
A 31360 kJ/kg Calorific value of the
coal is 27,300 kJ/kg. The
unburne

CV of 2000 kJI/kg. The

ma

Heat used to convert steam (Qp) coal collected is 16 kg /hr,

coal. The temperature of
h

Step :
offuel is 17.73 kg/kg of the
is
QBm, (h -hp) 330 °C. The boiler room temperarure
fuel gas 1 kJkg K estim
fuel Mean specific heat of the fuel gas
m =
==8.3076 kg/kg thermal etficiency and draw
heat balance sheet.
mf

209.35) Sol.: Given data: m,

=
1520 kg/hr, Tw
=

30
8.3076 (2675.52
QB 8.5 bar,
P,
=

330 °C, x =
0.95,
Tb 17 C, Tr =

- 20494 kJ/kg
CV 27300 kJ/kg, m,= 200 kg hr,
(2675.52-209.35)
m, (h-hg)8.30
Me
M. =
2257 m=17.73 kg/kg of fuel
2257
To find : i) Boiler efficiency (M)
Me = 9.069 kg/kg of fuel
ii) Heat balance sheet
(Qc)
Step II: Qu =1 Heat carried hot flue gases
i) Boiler efficiency (Mb):
Qc mg XCpg X(Tf -1b) m, (h - h)

= 9x1x[325-28] b m xCV

729.9 + 0.95
(P
Qc 2673 kJ/kg h hr +xhfo
=

*******************"*
**********"*********************************

A n thruct for knowledge

 Thermal Engineering-I
23 Boilers
= 2667.52 kJ/kg

ha 30x 4.187 125.61 kJ/kg Op 160 0.58

m,(h-hn) QE 2272 8.3
27300 Total 27300 9.88
CVxmf ddsodnssndstsceson

1520 (2667.52-125.61) Ex. 2.12: The following results obtained from boiler
= 70.7 % trial
200x27300
a. Feed water per hour 700 kg at 27 °C =

it) Heat baiance sheet : b. Steam pressure =8 bar

of dryness 0.97.
C. Coal
consumption 100 kg/hr. =

Step I Heat supplied

(Q d. C.V. of
coal
25000 kJkg.
e. Unburnt coal collected 0.6
QA mç xCV = 1 x 27300
=

kg/hr.
27300 kJ/kg. S. Flue gas formed per kg
327 °C
of fuel -
17.3 kg at

Step I Heat converted into steam (C, offue gas =

1.025 k/kg K.)
(QB & Room temperature = 16 °C
QB ms (h-h) Draw the heat balance sheet on kJ/min basis and boiler
m s15200 efficiency
=
7.6 kg/kg fuel
m
mf 200
Sol.: Given data :
kg/hr, Tw 27 °C,
m, =
700 -

h 2667.52 kJ/kg, hn =125.61 P 8 bar, x 0.97, mf 100 kg/hr,

=

kJkg
=

CV 25000 kJ/kg, m, 17.3 kg/hr,

T¢ =325 °C,
=

QB 7.6 (2667.52 - 125.61)

T 16 °C, Cp 1.025 kJ/Kg K.
= 19318.51 kJ/kg
To find : i) Draw heat balance sheet of kJ/min basis
Step Heat carried i) Boiler efficiency (nb)
away by lue gases (Qc)
Qc mg XCpg X(Tr-Ts)=17.73x1x [330-17] 1) Heat balance sheet on kJ/min basis :

Qc 5549.49 kJ/kg Step Heat supplied (QA)

QA = mf xCV
Step V Heat carried away by ash
(QD) 100
x25000 =
41666.7 kJ/min.
QD mash XC. V == x2000 160 kJ/kg 60
200
Step II Heat converted into
steam (QB)
QD 160 kJ/kg
Step V Heat
QBm (h-hn))=.700
60
+xhg-4.18x27)
unaccounted losses (QE)
OE =QA -[QB +Qc+QDl
Qe
Oa -

(720.9+0.97
60 x2046.5-4.18x27)
27300- [19318.5 +5549.49+160]
30253.35 kJ/min.
ywww
QE 2272 kJ/kg
 2-224
Thermal Engineering-I

IV Heat carried away by ash (QD Th= 16 °C, nb

=
7,
Step :

12000 =250.0 kJ/min m,(h-hn

b mf XCV
60

Step V: 'Heat Unaccounted (QE) h hr +Xhfg

= 781.1 +(0.96 x 1998.6)
QE = QA -IQB +Q¢ +Qp +Ql

= 2699.75 kJ/kg
QE =41666.7 [30253.35 +9191.3 +250]
1972.05 kJ/min
h 4187x75
QE =

= 314.025 kJ/kg
Heat balance sheet on minute basis:
4600 (2699.75 -314.025)
Heat supplied Heat kJ/min b 35700x 490
kJ/min
(QA) used
* * * * * * * * * * * * * * * * * *

***w

41666.7 30253.35 6 = 62.73 %

QA mXCV
for total fuel

9191.3 Step I : Heat supplied (Q)

2S0A 0.59 mf XCV
=
(1-004) x35700
www QA
A
1972.05 4.74 = 0.96x35700 34272 kJ/kg.
41666.7 41666.7 99.93

Step II: Heat converted into steam (QB)

i) Boiler efficiency (nb)
Qpm (h-hn)
m,(h- h
m xCV m, 46009.38
490
kg/kg ot T
mf
700(720.9+0.97x2046.5- 418x27)
100x 25000 QB 9.38 (2699.75 - 314.025)
QB 22378.1005 kJ/kg.
nb 0.7260 or 72.6 % w w w w w a m r r e w m e m

*******

were recorded Step l Heat carried hot flue gases (Qc)

Ex. 2.13: The following particulars
during boiler working of pressure 11 bar mass of feed Qc mg XCpg X(T-1)
water is 4600 The temperature of feed water is
kg/hr.
is 0.96. Coal
= 18.57x0.97x[300-16]
75 C. The dryness fraction of the steam
used is 490 Calorific value of the coal is
kg/hr. 284x18.57x0.97 = 5115.66 k
35700 kJ/kg moisture in coal is 4 % by mass of dry fuel
is
gases is 18.57 kg/kg of fuel. Temperature of fuel gases Step V Heat by moisture (Qp)
300 °C. Boiler house temperature is 16 °C. Specific heat
of gases is 0.97 kJIkg K. Draw a heat balance sheet of a QD Mm lh +hfg +Cps (Tsup-t,)-hpl
boiler on per kg basis also determine efficiency of the
hp 4187x16 = 66.992 kJ/kg
boiler
QD = 0.04 [417.5+ 2257.92.1
Sol. kg/hr,
: Given data: P, =
11 bar, m =4600 [300 99.63] - 66.99]
Tw 7 5 C, x = 0.96, CV = 35,700 kJ/kg.

mm4 % =0.04, Cpg= 0.97 kJ/kg K,

=
0.04 [2675.4 + 353.785]
m 490 kg/hr, mg 18.57 kg/kg, Tr =
=
300 °C, QD 121.167 kJ/kg.
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Iner
called
Step V: Heat unaccounted (HE) combustion process
Heat is released during the
as Exothermic reaction.
QE QA -IQg +Qc +Qpl
combustion reaction is called
34272 [22378.1005 + 5115.66 Heat is absorbed during
=
-
+ 121.167]
as Endothermic reaction.
QE 6657.07 kJ/kg which releases heat
chemical fuel is a substance
eiww wgwoemwmnw.
A

Heat supplied energy on combustion.

Heat ased k.
(QA) for 1 kg

of Fuel
Qa
Hest
m XCV QA
supplied 34272 Hot comvert
22378.1005 65.29 %
2.16 Classification
kJ kg 1nto steam whether
for 1 kg of
Fuels can be classified according to
fuel.
in nature called primary fuels or are

Heat 5115.66 14.92 % 1 They occur

fuels.
by hot fuel prepared called secondary
in solid, liquid or gaseous state.
Q Heat 121.167 0.353 % 2 They are
by moisture
2.16.1 Solid Fuels
QF Heat 6657.07 19.43 %
constituents are carbon, hydrogen,
unaccounted Coal. Its main
moisture and ash.
100 % 99.98 % oxygen, nitrogen, sulphur,
during its
ww-
different stages
.Coal passes through
formation from vegetation.
2.15 Introduction to Fuels These stages are enumerated and discussed below
-Brown coal
of heat energy -Peat -Lignite
.Fuels can be defined as the source
Plant debris Bituminous coal Semi
reactive system by chemical or Sub-bituminous coal
which is released in a

nuclear reaction. bituminous.

coal Anthracite coal
anthracite
-

air is called reactant's(RR). .Coal-Semi

The mixture of fuel and
combustion formed are called Graphite.
The products of
formation of coal trom
.Peat. It is the first stage in the
products(P). of moisture and
wood. It contains huge
amount

Draught system

Natural draught
Artiftial draught
Mechanical
Steamjet draught
(fandraugh
Forced
Induced
draught draught Induced fan Balanced Forced fan
draught draught draught

**

Fig. 2.16

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Thermal Engineering-l1
the destructive distillation of certain kinds of coal
about 1 to 2 months before it
therefore it is dried for
and can be produced Therm
used as a domestic fuel in Europe is smokeless and clear fuel
is put to use. It is
used in blast fumae
several processes. It is mainiy 2.1
and for power generation in Russia. In India it does
not come in the categories of good fuels. produce heat and at the same time to reduce the
Na
ore.
Lignites and brown coals. These are intermediate me

stages between peat and coal. They have a woody or 2.16.2 Liquid Fuels va
often a clay like appearance associated with high alte
The chief source of liquid fuels is petroleum which
CO
moisture, high ash and low heat contents. Lignites are
obtained from wells under the earth's crust.
usually amorphous in character and impose transport Co
.These fuels have proved more advantageous
difficulties as they break easily. They burn with a
comparison to solid fuels in the following respects. Ca
smoky flame. Some of this type are suitable for local

use only.
Advantages
o Require less space for storage.
Bituminous coal. It burns with long yellow and
Higher calorific value.
and has high percentages of volatile
smoky flames CA
matter. The average calorific value of bituminous coal o Easy control of consumption.

is about 31320 kJ/kg. It may be of two types namely o Staff economy.

caking or noncaking o Absence of danger from spontaneous combustion.

Semi-bituminous coal. It is softer than the anthracite. o Easy handling and transportation.
It burns with a very small amount of smoke. It o Cleanliness.
contains 15 to 20 percent volatile matter and has a
o No ash problem.
tendency to break into small sizes during storage or
oNon-deterioration of the oil in storage.
transportation. Petroleum. There are different opinions regarding t
Semi-anthracite. It has less fixed carbon and less
origin of petroleum. However, now it is accepted t
lustre as compared to true anthracite and gives out
petroleum has originated probably form organic mar
longer and more luminous flames when burnt.
like fish and plant life etc., by bacterial action or
Anthracite. It is very hard coal and has a shining their distillation under pressure and heat. It consists
black lustre. It ignites slowly unless the furnace a mixture of gases, liquids and solid hydrocarbe
temperature is high. t is non-caking and has high with small anmounts of nitrogen and sulpt
percentage of fixed carbon. It burns either with very compounds. In India, the main sources of petrolk"
short blue flames or without flames. The calorific Assam and
are Gujarat.
value of this fuel is high to the tune of 35500 kJ/kg
Heavy fuel oil or crude oil is imported and
and as such is very suitable for steam generation. retined at different refineries. The refining of cru0e
Wood charcoal. It is obtained by destructive supplies the most product called petrol. Petrol can
distillation of wood. During the process the volatile
be made by polymerization of refinery gases.
matter and water are expelled. The physical properties colloid
Other liquid fuels are kerosene fuels oils, o
of the residue (charcoal), however
depends upon the fuels and alcohol.
rate of heating and
temperature.
Coke. It consists of
carbon, mineral matter with about
2 %
sulphur and small quantities of hydrogen,
nitrogen and phosphorus. It is solid
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2-27 Boilers
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2.16.3 Gaseous Fuels

mainly marsh gas (CH) and is collected at large
Natural gas. The main constituents of natural
gas are disposal plants. It works as a fuel for gas engines
methane (CH,) and ethane (C,H). It has calorific which in turn drive the plant pumps and agitators.
value nearly 21000 kJ/m. Natural
gas is used Gaseous fueld are becoming popular beause of
alternately or simultaneously with oil for internal following advantages they possess.
combustion engines.
Advantages
.Coal gas. Mainly consists of hydrogen, carbon 1. Better control of combustion.
monoxide and
hydrocarbons. It is prepared by 2. Much less excess air is needed for complete
carbonisation of coal. If finds its use in boilers and combustion.
sometimes used for commercial purposes. 3. Economy in fuel and more efficiency of furnace

Coke-oven gas. It is obtained during the production of operation.

coke by heating the bituminous coal. The volatile 4. Easy maintenance of oxidizing or reducing
content of coal is driven off by heating and major atomosphere.
portion of this gas is utilised in heating the ovens. 5. Cleanlines.
This gas must be throughly filtered before using in No problem of storage if the supply is available
6.
from public supply line.
gas engines
even over a
Blast furnance gas. It is obtained from smelting 7. The distribution of gaseous fuels
lines and as
wide area is easy through the pipe
operation in which air is forced through layers of coke eliminated.
such handiling of the fuel is altogether
and iron ore, the example being that of pig iron
Gaseous fuels give economy of heat and produce
manufacture where this gas is produced as by product 8.
can be preheated in
monoxide (CO). After
higher temperatures (as they
and contains about 20 % carbon regenerative furnaces and thus
heat from hot flue
richer gas or used in
filtering it may be blended with gases can be recovered).
is
The geating value of this gas
gas engines directly.
Marks Questions with Answers
very low.
oxidation of
2.17 Two
Producer gas. It results from
the partial boiler ?
Q.1 What is the function of a
burnt with an
coke or peat when they
are
coal, is a closed vessel that produces
Boiler
is produced in specially Ans.
insufficient quantity of air. It saturated steam at the required pressure.
value and in
designed It has low heating
retorts.
the boiler mounting, and
installations. It is
also Q.2 Briefly explain
general is suitable for large name Its classifications ?
hearth furnaces.
used in steel industry for firing open Boiler mountings are the devise used for
blowing
Ans.
It is produced by the boiler and following are the commonly
Water or illuminating gas. safety of
or coal.
THe decomposition used mountings.
steam into white hot coke
and b. Water level indicator
free hydrogen a. Pressure gauge
or steam takes place linerating
to form
with carbon c. Fusible plug d. Steam stop valve
OxYgen in the steam combines
reaction
according to the e. Safety valve
carbon monoxide
C+H,O CO + H a. 3 What is a valve ?
varies as the hydrogen
content
if
n gas composition Ans. A valve is used to control the flow of fluid
the coal is used. inside the pipeline.
vats in
form sewage
disposal
Ewer gas. It is obtained consists of
occur.
It
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Q.4 Write the function of safety, Stop, and Ans. Negative draft is nothing but a negative
Feed check valves ? pressure maintained in the boiler using induced drat
Ans. Safety valve: This type of valve is used to fans
keep the boiler safe by controlling the working pressure Q.14 What is boller flue ?
in the boiler and resist the
blasting
due to the high Ans. A flue is a duct, pipe, or opening in
pressure the valve is mounted with boiler. a
chimney for conveying exhaust gases from a fireplace
Stop valve: This type of valve is used to control the furnace, water heater, boiler, or generator to the
tlow of steam from the boiler to the engine. outdoors.
Feed Check valve: This type of valve is used to
Q.15 What is the functlon of foed check valve ?
control the supply of feed water to the boiler. The
water level always remains constant when it works.
Ans. The high pressure feed water is supplied to
boiler through this valve against the boiler pressure.
Q.5 Why draught is produced in boiler ?
Ans. To provide an adequate supply of air for the .16 What are the advantages of Cochran
boiler ?
fuel combustion
To exhaust the gases of combustion from the Ans. Low initial installation cost.
combustion chamber I t requires less floor area.
To discharge the gases of combustion to the
Easy to operate and handle.
atmosphere through the chimney Transportation of Cochran boiler is easy.
Q.6 What is the function of a safety valve ?
.It can use all types of fuel.
Ans. To blow off steam when the pressure of what are the dis-advantages of Cochran
Q.17
steam inside the boiler exceeds the working pressure boiler ?

Q.7 What is the function of economiser ? Ans. Low rate of steam generation.
Ans. To Increase thermal efficiency of boiler. maintenance is difficult.
Inspection and
Q.8 State the difference between cornish boiler for its installation due
High room head is required
and lancashire boiler.
to the vertical design.
Ans. Former contain one fire tube type and latter
I t has limited pressure range.
contains two water tube type boiler
Q18 State the advantages of water tube boilers
Q.9 What is the function of air preheater ? over fire tube boilers.
Ans. Air preheater is used to heat the air before Ans. Steam can be raised more quickly
blowing it into the furnace. Steam at higher pressures can be produced
Q.10 What is the necessity of preheating the Higher rate of evaporation
air ?
Failure of water tubes will not affect the working
Ans. The air is heated by the flue gas so asto
boiler
improve the performance of boiler.
tubs
Q.19 State the dis-advantages of water
Q.11 Name the various boiler mountings. boilers over fire tube boilers.
Ans. Boiler mountings are used to run a boiler in a Ans. Not suitable for ordinary water
safe way ex: safety valve, Water level indicators etc.
Not suitable for mobile application
Q.12 What is draught in boiler ?
.High initial cost and hence not economical
Ans. Boiler draught is the pressure
difference Q.20 Whlch are the methods used to fino
between the atmosphere and the pressure inside the
boiler the boiler efficiency ?

Q.13
Ans. Direct method
What is negative draft ?
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Boilers
Q.21 What is the
difference
and supercritical boiler ?between subcritical
Q.27 What is the function of blow-off-cock ?
Ans. Large supercritical boilers, Ans. It is a controllable valve opening at the
when operated at
nartial load, lower their pressure and bottom of water space in the boiler and is used to blow
subcritical. usually become off some water from the bottom which
carries mud or
Below the critical pressure, there other sediments settled
during the operation of boiler.
is a
great
difference between densities of liquid water and
Q.28 What is the function of steam
stop valve ?
steam
Ans. It is fitted over the boiler
in between the
Q,22 What do you mean by high pressure steam space and steam
supply line. Its function is
boiler ?
to
regulate the steam supply from boiler to the steam line.
Ans. A boiler is called a
high-pressure boiler when Q.29 What is preventive maintenance of
it operates with a steam pressure above 80 bars. bollers ?

Q,23 What is water level Ans. Blow down and test low water cut off
Indicator in boller ?
Blow down gauge glasses
Ans. Water gauge indicates the water level
inside
the boiler and is hence called as water level indicator. Blow down boiler

Q,24 What is benson boiler ? Check boiler and system for leaks
Check burner flame
Ans. The benson boiler is a water tube
boiler,
works on the basic principle of critical Q.30 What are the advantages of high pressure
pressure of
water.
boiler ?

Ans. They require less heat of vaporization.

Q.25 How does fusible plug work in a boller
They are compact and thus require less floor space.
Ans. Fusible is a small device installed in
plug
Due to the high velocity of water, the tendency of
small horizontal fire tube boilers between furnace and
boiler water drum for protection of boiler while lower scale formation is minimized.
water level in drum. All parts are uniformly heated and the danger of

Q.26 What is the function of spring loaded overheating is minimized.

safety valve ?
Review Questions
Ans.: Spring loaded safety valve is a safely
mounting fitted the boiler shell and is essentially
on . Explain with neat sketch Cochran boiler
required on the boiler shell to safeguard the boiler 2. What is the selection criteria of boiler?
against high pressure.
3 Distinguish beween fire tube and water rube
boiler.
4. Write a note on high pressure boiler.

5. Explain classification of fuel.

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