BASIC MECHANICAL ENGINEERING

UNIT-I- ENGINES
INTERNAL AND EXTERNAL COMBUSTION ENGINE
HEAT ENGINE OR ENGINE
Engine is a device used for converting heat energy into mechanical energy. In engine, heat energy
obtained by combustion of fuel.
CLASSIFICATION OF HEAT ENGINE
I.C. Engine: In internal combustion engine, combustion of fuel takes place inside the cylinder of
engine. Example: diesel, petrol engine.
E.C. Engine: In external combustion engine, combustion of fuel takes place outside the engine
cylinder. Example: steam engine.
 CLASSIFICATION OF I.C ENGINES:
I.C. engine are classified on the following basis:
1. Number of stroke:
a) Two stroke engine b) Four stroke engine
2. Fuel used:
a) Petrol engine b) Diesel engine c) Gas engine
3. Working cycle:
a) Otto cycle b) Diesel cycle c) Dual combustion cycle
4. Fuel supply:
a) Carbureted type b) Injection type
5. Method of ignition:
a) Spark ignition b) Compression ignition
6. Speed:
a) Low speed engine b) Medium speed c) High speed engine
7. Cooling system:
a) Air cooled engine b) Water cooled engine
8. Cylinder Arrangement or engine design:
a) Inline engine c) Radial engine
b) V engine d) Vertical engine
e) Opposed cylinder engine
9. Valve location:
a) Over head valve location b) Side valve location
10. Lubrication:
a) Wet sump lubrication b) Dry sump lubrication
11. Application:
 a) Stationary engine d) Automobile engine
b) Marine engine e) Aircraft engine
c) Locomotive engine

MAJOR PARTS OR COMPONENTS OF AN IC ENGINE

Cylinder
It is a round cylindrical casting in which a piston slides in and out to make strokes. Combustion of fuel takes
place inside the cylinder. The cylinder is closed by a cylinder head.
Material: Grey cast iron, Aluminium.

Cylinder head
It is fitted to the top of the cylinder. It has inlet and outlet valves, spark plug, Fuel injector, water jackets.
Material: Cast iron, Aluminium.
Piston
It is a device which transmits the energy (or) force of the expanding gas to the connecting rod. It slides up
and down inside the cylinder. It has three grooves to accommodate piston rings.
Material: Cast iron, Aluminium alloy, Nickel iron alloy and Cast steel.
Piston rings
Piston rings are inserted in the grooves of piston. There are two types of rings.
Oil ring (one ring is used), Compression ring (two rings are used)
Material: Alloy cast iron, placed with chromium or cadmium.
Connecting rod
It converts the reciprocating motion of the piston into rotary motion of crankshaft. The small end of the
connecting rod is connected to piston and the big end is connected to the crankshaft.
Material: Plain carbon steel, Aluminium alloys, Nickel alloy steel.
Crankshaft
It is the device used for getting power from the motion of the piston and connecting rod and this power is
applied to the flywheel. Material: Alloy steel, SG iron.
Camshaft
It operates the opening and closing of the engine valves. It has number of cams which are driven by
crankshaft through timing gears. The function of the cam is to convert the rotary motion into linear
reciprocating motion. Material: Alloy steel.
Crank case
It is the bottom portion of the I.C. engine and holds the cylinder and the crank case. It also serves as a sump
for the lubricating oil. Material: Cast iron, Aluminium alloy.
Flywheel
It is a big wheel attached with crankshaft. It maintains the speed of the engine.
Valves
The function of the valve is to admit the fresh charge in the cylinder and to send the exhaust gases out. There
are two valves namely inlet valve and outlet valve.
Material: Inlet valve: Nickel chrome, Chrome molybdenum
Outlet valve: Nickel chrome, Stainless steel, Tungsten steel, Silicon chrome steel.

FOUR STROKE ENGINES

In a four stroke engine, one power stroke is completed for every four strokes of the piston or during two
revolutions of the crankshaft.
 Petrol Engine (or) spark ignition engine
Petrol engine is also known as spark ignition (SI) engine.
Four strokes Petrol engine requires four strokes of the piston for one cycle of operation.
The four strokes are
(a) Suction stroke
(b) Compression stroke
(c) Expansion stroke
(d) Exhaust stroke
Working Principle:
 Petrol from the fuel tank flows to the engine through carburettor. In the carburettor, the petrol evaporates
and mixes with the air.
 Pistons inside the engine slides up and down and vacuum is created. This vacuum sucks the petrol-air
mixture and compresses it.
 An electric spark from the spark plug ignites the mixture. The hot combustion product pushes the piston
down. The crank shaft connected with the piston converts the up and down motion into rotary motion.
 The burnt gases are sent cur through the exhaust. Valves are used to inlet the air fuel mixture and exhaust
burnt gases.
 Cam shaft is used to guide the opening and closing of valves. This is known as “Otto cycle”.

Working principle of four stroke petrol engine

1. Suction stroke (or) Induction stroke
 During this stroke, piston moves from Top Dead Center (TDC) to Bottom Dead Center (BDC). So,
the inlet valve opens and the air fuel mixture enters into the cylinder.
 Valve position: Inlet valve open, Outlet valve closed.
 Piston movement: TDC to BDC.
2. Compression stroke
 In this stroke, petrol-air mixture is compressed by the movement of piston from Bottom Dead Centre
(BDC) to Top Dead Centre (TDC).
 At the end of compression, the air fuel mixture is ignited by means of an electric spark from the spark
plug. This increases the pressure and temperature of the combustion products.
 Valve position: Both Inlet and Outlet valves are closed.
 Piston movement: BDC to TDC.
3. Working stroke (or) power stroke (or) Expansion stroke
 During this stroke, a high pressure gas product moves the piston from Top Dead Centre (TDC) to
Bottom Dead Centre (BDC) position.
 So, the force exerted on the piston is transmitted to the crankshaft through the connecting rod.
 Valve position: Both valves are closed.
 Piston movement: TDC to BDC.
4. Exhaust stroke
 During this stroke, piston moves from Bottom Dead Center (BDC) to Top Dead Center (TDC). The
exhaust gases are sent through exhaust valve.
 Valve position: Inlet valve open Outlet valve closed.
 Piston movement: BDC to TDC.
 Immediately after the exhaust stroke, i.e., after the piston reaches TDC, the exhaust valve closes. The
inlet valve opens slightly before the TDC. Then this cycle is repeated.
 During this cycle, the crankshaft makes two revolutions.

DIESEL ENGINE (OR) COMPRESSION IGNITION ENGINE (C.I ENGINE)

Diesel Engine is also known as compression ignition (C.I) engine.
Working Principle:
 Air enclosed in the cylinder is compressed and its temperature rises. Diesel which cannot be vaporised
is injected into the cylinder in the form of fine spray with the help of fuel pump and injector.
 The mixture ignites spontaneously and here no sparkplug is required for igniting the air-fuel mixture.
 The temperature and pressure increases and this makes the piston move. The up and down motion of
piston is converted into rotary motion by the crankshaft.
 The working is similar to that of a petrol engine and the only difference is a fuel injector is present
instead of a spark plug. This is known as “Diesel cycle”.
 The following figure shows the working principle of four stroke diesel engine.
1. Suction stroke
 During this stroke, the piston moves from Top Dead Centre (TDC) to Bottom Dead Centre (BDC).
Vacuum is created inside the cylinder. So, the air is drawn into the cylinder through the inlet valve.
 Valve position: Inlet valve open, Outlet valve closed.
 Piston movement: TDC to BDC.
2. Compression stroke
 During this stroke piston moves from BDC to TDC. The air is compressed inside the cylinder. So,
high pressure and temperature of air is obtained.
  Just at the time of completion of the stroke fuel (diesel) is injected in the form of very fine spray by
the injector. The air and the fuel are mixed in correct proportion and the mixture is ignited due to the
high temperature of air.
 Valve position: Inlet valve and Outlet valve are closed.
 Piston movement: BDC to TDC.
3. Power (or) Working stroke (or) Expansion stroke
 During this stroke, the burnt air-fuel mixture expands inside the cylinder and moves the piston from
TDC to BDC. This force is transmitted to the crankshaft through connecting rod. Thus effective
power is obtained.
 Valve position: Inlet valve and Outlet valve are closed.
 Piston movement: TDC to BDC.
4. Exhaust stroke
 During this stroke, piston moves from BDC to TDC. The exhaust gases are pushed out through the
exhaust valve and then this cycle is repeated. During this cycle, the crankshaft makes two revolutions.
 Valve position: Inlet valve closed Outlet valve open.
 Piston movement: TDC to BDC.

TWO STROKE ENGINES

In two stroke engines, the cycle of operation is completed in two strokes of the piston (or) one
revolution of the crankshaft.
In two stroke engines, the charging of cylinder with air fuel mixture (or) air is done by the following two
methods.
1. By using closed crank compression
In this method, the piston movement is caused by air in the crankcase. So, the compressed air is admitted
into the cylinder.
2. Separate pump method
In this method, the charge of air (or) Air fuel is compressed by a separate pump and the pump is driven by
engine itself. This method is used in multi cylinder engine.

TWO STROKE PETROL ENGINE

Working principle of a two stroke petrol engine
 In two stroke engine, one power stroke is completed for every two strokes of the piston or in one
revolution of the crankshaft.
 A two stroke engine has no valves and only ports are present. There are three ports namely inlet port,
exhaust port, and transfer port.
The two strokes are:
1. First stroke (compression, suction and ignition)
 2. Second stroke (Expansion and Exhaust)

FIRST STROKE (UPWARD MOVEMENT OF PISTON)

(a) Compression, Suction and Ignition
 The piston moves from BDC to TDC, the transfer port and the exhaust port are closed. The charge
inside the cylinder is compressed. So, at the end of compression, pressure and temperature of air fuel
mixture is increased.
 When the piston almost reaches the TDC, the compressed air fuel mixture is ignited by means of an
electric spark from spark plug. At the same time, inlet port is opened by the movement of the piston.
So, the fresh charge enters into the crank case.

SECOND STROKE (DOWNWARD MOVEMENT OF PISTON)

(b) Expansion and exhaust
 The burnt gas expands inside the cylinder and the gases push the piston downwards.
 Due to the downward movement of the piston, the exhaust port is opened and the burnt gases are sent
to the atmosphere through the exhaust port. At the same time, the partially compressed air fuel mixture
enters into the cylinder through the transfer port.
 The top of the piston is made of a deflected shape, so that the escape of air fuel mixture along with
exhaust gases is avoided and the charge entering the cylinder is deflected upwards. The cycle is
repeated again.
 During this cycle, the crank shaft makes on revolution. This is obtained by two strokes of piston. So,
this cycle is called as two stroke cycle.
 TWO STROKE DIESEL ENGINE
Working principle of two stroke diesel engine
The figure shows the working principles of two stroke diesel engine.

FIRST STROKE (UPWARD MOVEMENT OF PISTON)

(a) Compression and Ignition
 The piston moves from BDC to TDC. Both the transfer port and exhaust port are closed. At this time
air inside the engine cylinder is compressed. At the end of compression, pressure of temperature of
air is increased.
 At the same time, fresh air enters into the crank case, through the inlet port. When the piston almost
reaches the TDC, the fuel is injected into the cylinder. The fuel is mixed with the high temperature
air incorrect proportion and gets ignited.

SECOND STROKE (DOWNWARD MOVEMENT OF PISTON)

(b) Expansion and Exhaust
 The burnt gases expand inside the cylinder and force the piston downwards. So, the power is obtained.
At this time, air in the crank case gets compressed.
 When the piston reaches the BDC, the exhaust port is opened. The exhaust gases are sent to the
atmosphere through the exhaust port.
 At the same time transfer port is opened. The compressed air in the crankcase enters into the cylinder
through transfer port.
 Due to the deflected shape of the piston escape of air through exhaust port is avoided. Again the piston
moves up, transfer port and the exhaust port is closed. The air in the cylinder is compressed.
 When the piston reaches almost near to the TDC the inlet port is opened. Now the fresh air enters into
the crankcase. At the same time fuel is injected and this cycle is repeated.
 During the cycle, the crankshaft makes one revolution. This is obtained by two strokes of piston. So,
this cycle is called as two stroke cycle.
DIFFERENCE BETWEEN TWO STROKE AND FOUR STROKE CYCLE ENGINE

S.NO Four stroke engine Two stroke engine

1. One power stroke is obtained in two One power stroke is obtained in each
revolutions of crankshaft. revolution of crankshaft.
2. Valves are provided. Ports are provided.

3. The engine is cooled by water. The engine is cooled by air.

4. De-Merits More space required for same Merits Less space required for same power.
power.

5. Heavier flywheel required. Lighter flywheel required.

6. Requires more lubrication. Lubrication is not essential.

7. Torque is not uniform. Torque is uniform.

8. Volumetric efficiency is more. Volumetric efficiency is less.

9. Complicated in design. Simple in design.

10. Difficulty to maintain. Easy to maintain.
11. The turning moment of crank shaft is not The turning moment of crank shaft is
uniform. uniform.
12. Engine costs more. Engine cost less.
13. Heavier engine. Engine is light.
14. Merits Less fuel consumption. De-Merits More fuel consumption.
15. Thermal efficiency is more. Less Thermal efficiency.
16. The fuel-air charge (mixture) is Sometimes fresh charge is not completely
completely utilized. utilized because escape with exhaust gases.
17. The exhaust is less noisy. The exhaust is noisier.
18. 4- Stroke engine used for heavy vehicles 2-Stroke engine used for light vehicles like
like Car, buses, Aero planes. Scooter, mopeds.

DIFFERENCE BETWEEN PETROL AND DIESEL ENGINE

S.NO Petrol Engine Diesel Engine
1. Operate on the principle of Otto cycle. Operates on the principle of diesel cycle.
2. Fuel in ignited by spark plug. Fuel in injected by hot compressed air.
3. Fuel is sent to cylinder through Fuel is sent through fuel injector.
carburetor.
 4. During suction air and fuel mixture are During suction only air is admitted.
admitted
5. Low compression ratio (6 to 8). High compression ratio (15 to 20).
6. Merits Operates at high speed. De-Merits Operates at Low speed.
7. Lighter in weight. Heavier in weight.
8. For same power output, petrol engine For same power output, diesel engine
occupies less space. occupies more space.
9. Engine starting in cold condition is easy. Engine starting in cold condition is hard.
10. Less vibration. More vibration.
11. De-Merit Maintenance requires because Merits Fuel injector does not require
change of spark plug after few thousand frequent maintenance.
kilo-meters.
12. Fuel used is Petrol and costly. Fuel used is Diesel and cost is less.
13. Fuel consumption is more Less fuel consumption.
14. Petrol is highly volatile. So, handling is Diesel is less volatile. So, handling is not
more risk. risky.
15. Vehicle chassis is not made very strong. Vehicle chassis is made very strong.

Valve timing diagram:

A valve timing diagram is a graphical representation of the exact movement, in the sequence of operation at
which the two valves open and close as well as firing of the fuel.

BOILER

Boiler also knows as steam generator is a closed vessel in which steam is generated from water by the
application of heat and the pressure being higher than the atmosphere.

The main function of a boiler is to evaporate water into steam at a higher pressure.

REQUISITES OF A BOILER

 A good boiler should be capable of producing maximum amount of steam with minimum initial cost
 It should be compact in size and safe in working
 It should be able to meet rapid load variations.
 The components and parts should be easily accessible for inspection and repair.
 The heat produced by the fuel in the furnace should be utilized maximum.
CLASSIFICATION OF BOILERS

The steam boilers are classified as follows:

1. According to the flow of water and hot gases

a) Fire tube boiler (or) Smoke tube boiler:
In fire tube boiler, hot gases pass through tubes which are surrounded with water.
Eg.Cochran, Lancashire and Locomotive boilers.
b) Water tube boilers:
In water tube boiler, the water is circulated through the tubes and hot gases flow over the tubes.
Eg.Babcock and Wilcox boiler.
2. According to the method of firing (or) location of furnace
a) Internally fired boilers:
In an internally fired boiler, the combustion of fuel takes place inside the boiler shell.
Eg.Lancashire and Locomotive boiler.
b) Externally fired boilers:
In an externally fired boiler, the furnace is placed outside and combustion takes place outside the
boiler.
Eg.Babcock and Wilcox boiler.
3. According to method of water circulation
a) Natural circulation boilers:
The water is circulated by natural convection currents caused by the temperature difference.
Eg.Lancashire boiler.
b) Forced circulation boilers:
The water is circulated by a pump driven by a motor.
Eg.La-Mont boiler, Velox boiler.
4. According to the pressure developed
a) Low pressure boilers:
The pressure of steam produced is lower than 80 bar.
Eg.Cochran, Lancashire boiler.
b) High pressure boilers:
The pressure of steam produced is greater than 80 bar.
Eg.Babcock and Wilcox, Lamont boiler.
5. According to the axis of the shell
a) Vertical boilers:
The axis of the shell is vertical.
Eg.Cochran boiler.
b) Horizontal boilers:
 The axis of the shell is horizontal.
Eg.Locomotive boiler, Lancashire boiler.
6. According to the use of the boiler
a) Stationary boilers:
The boilers are at a fixed place and used for power generation.
Eg.Industrial boilers, Babcock and Wilcox boilers.
b) Mobile boilers:
The boilers move from one place to another to supply power.
Eg.Locomotive boiler.

LOW PRESSURE BOILERS

The boilers producing steam at a pressure of less than 80 bar are termed as low pressure boilers. Fire tube
boilers are generally preferred for low pressure steam production.

Eg.Cochran boiler, Lancashire boiler, Locomotive boiler.

1. SIMPLY VERTICAL BOILER

A simply vertical boiler is shown. It is an internally fired low pressure vertical fire tube boiler.

DESCRIPTION
The boiler contains the following parts:
1. Cylindrical shell:
The shell is a steel plate in cylindrical form attached to the bottom of the furnace. Greater portion of
shell is filled with water and the remaining portion is steam space.
 2. Furnace (or) Firebox:
Furnace is the place where combustion of coal takes place. A grate is provided at the furnace on which
fuel is burnt. An ash pit is provided for collection the ash.
3. Cross tubes:
One or more cross tubes are laid across the furnace to increase the heating area. They are placed
slightly in inclined position to increase the circulation of water.
4. Fire hole:
It is provided in front side of the boiler above the grate level. Coal is fed to the grate through this
hole.
5. Chimney:
It is a large tube starting from the top of the fire box to let out the exhaust flue gases.
6. Manhole:
It is provided on the top of the shell for the purpose of inspection and repairs.
7. Hand holes:
Hand holes are provided in the shell for cleaning the cross tubes.
Specifications:

1. Diameter of the shell 1.5 m

2. Height of the shell 2m
3. Working pressure 7 bar
WORKING

 The fuel is fed into the grate through the fire hole and is burnt. The burnt out fuel is collected as ash in
the ash pit placed below the grate.
 The hot gases flows from the furnace, passes around the cross tubes and heats the surrounding water.
 Water goes from lower end of the cross tube and comes out from higher end by natural circulation due
to convection currents.
 Steam is produced and gets collected above the water, which is tapped off through a suitable value.

The following mounting are fitted in the boilers for the safety of boilers and control of steam generation.

1. Pressure gauge – It indicates the pressure of steam generated inside the boiler.
2. Water gauge – It indicates the level of water inside the boiler. It is also called water level
indicator.
3. Safety valve – It prevents the increase of pressure of steam in the boiler above the desired
pressure.
4. Stop valve – It regulates the supply of steam according to the requirements.
 2. COCHRAN BOILER

Cochran boiler is shown. It is a vertical, multi-tubular low pressure fire tube boiler. It is the modification of
a simple vertical boiler. It has many horizontal fire tubes and hence the heating surface has been increased.
DESCRIPTION
The various parts of the boiler are described below.

 Shell: The shell is cylindrical in shape, the top of the shell being hemispherical dome in shape. Space
is provided for steam at the top.
 Furnace: Furnace has a dome shaped top and fuel is fed into the furnace through fire hole. The dome
shape helps the gases to deflect back till they are passed through the flue pipe. A grate is placed at the
bottom of the furnace on which fuel is burnt. Ash pit collects the ash.
 Flue pipe: It is a short passage connecting the furnace with the combustion chamber.
 Combustion chamber: It is lined with fire bricks on the sides of the shell. It prevents overheating of
shell.
 Chimney: The flue gases escapes to the atmosphere through the smoke box and chimney.
 Man Hole: It is provided for inspection and repair work of the interior of the shell.

SPECIFICATION

Diameter of the shell 2.75 m

Height of the shell 5.8 m
 Working pressure 6.5 bar- 15 bar
Steam capacity 3500 kg/hr
Efficiency 72%
Number of tubes up to 165
WORKING

Coal is fed into the grate and is burnt. The ash formed is collected and disposed off. The hot gases of
combustion enter the combustion chamber through the flue pipe. The brick lining directs them to pass through
the horizontal tubes.

The heat is transferred to the water by convection. Water gets converted into steam. The flue gases escapes
to the atmosphere through smoke box and chimney.

The following mounting are fitted to the boiler.

 Water gauge: It indicates the level of water inside the boiler. The water is maintained at a particular
level inside the boiler to avoid overheating.
 Safely valve: Safely valve is used to prevent the increase of steam pressure above its normal working
pressure.
 Steam stop valve: It regulates the flow of steam supply.
 Blow off cock: It is used to push the water by the high pressure steam and drains out the impurities like
sand, mud, sediments etc. in the water.
 Fusible plug: It is used to protect the fire tubes from burning when the water level in the boiler below
the safe limit.

Salient Features

 The dome shape of the furnace causes the hot gases to deflect back and pass through the flue pipe.
 The hemispherical shape of the shell provides maximum volume of space.
 It occupies less floor area and hence compact.

LOCOMOTIVE BOILER

Characteristics It is horizontal tube boiler.

It is horizontal. It is movable.
It is a fire tube boiler.
The number of tubes are more. Specifications
It is internally fired. Barrel Diameter = 2.095 m
It has natural circulation. Length of the barrel = 5.206 m
Solid fuel can be burnt. Size of the tubes (superheater) = 14 cm
 No. of superheater tubes = 38 Steam Capacity = 20,000 to 40,000kg/hr
Size of ordinary tubes = 5.72 cm Working Pressure = 20 bar
No. of ordinary tubes = 116 Efficiency = 70%

Advantages

 Large rate of steam generation per square metre of heating surface.

 Low cost of construction.
 Portability.
 Low installation cost because it is free from brickwork, special foundation and chimney.
 It is very compact.

Disadvantages
 There is more chances of corrosion and scale formation in the water legs due to the accumulation of
sediments and the mud particles.
 Large flat surfaces need bracing.
 It cannot carry high overloads without being damaged by overheating.
 There are practical constructional limits for pressure and capacity which do not meet requirements.
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LANCASHIRE BOILER:

Characteristics Specifications
It is horizontal. Shell diameter = 2 to 3.5 m
It is a fire tube boiler. Length = 8 to 9 m
The number of tubes are more. Working pressure = 15 to 20 bar
It is internally fired. Steam capacity = 8000 kg/hr (max = 4000 kg/hr)
It has natural circulation. Efficiency = 70%
Solid fuel can be burnt.
It is stationary.
It is horizontal tube boiler.
Advantages

 Due to three passes of flue gases, the heating surface area per unit volume of boiler is large.
 The fluctuations in load can be easily met by this boiler due to large reservoir.
 Easy operation, low maintenance costs, easy to clean and inspect.
 By use of economizer and super heater, maximum heat of flue gases is utilized, so efficiency of boiler can be
increased.

Disadvantages

 Maximum working pressure is limited to 16 bars.

 Due to brick work, more floor area is required.
 Response of pressure build up is less.
 The furnace is inside the tubes therefore the grate area is restricted
 HIGH PRESSURE BOILER

The boilers producing steam at a pressure of more than 80 bar are termed as high pressure boilers. The high
pressure boiler can deliver 40 to 1600 tonnes/hr of superheated steam. Water tubes boilers are generally
preferred for high pressure boilers.

Eg. Babcock and Wilcox boiler, Lamont boiler, Benson boiler.

BOILERS MOUNTINGS

Boiler mountings are the devices mounted on the boiler surface for safe operation, proper maintenance and
control of steam generation.

Boiler mountings include,

 Pressure gauge  Water gauge

 Safety valve  Fusible plug
 Steam stop valve  Blow off cock

PRESSURE GAUGE:

Function:

 Pressure gauge is used to indicate the steam pressure inside the boiler.
Description:

 The pressure gauge consists of a curved metallic tube (Bourdon tube) of elliptical cross section. The tube
is made of bronze alloy.
 One end of the tube is connected to the toothed sector by a link and the other end is open and is connected
to the steam space of the boiler. The sector is in mesh with a pinion which is containing a pointer.
Working:

 When steam enters the elliptical tube, the elliptical cross section of the tube tends to become circular.
This causes the free end of the tube to move. The movement is transmitted by the link to the toothed
sector and hence the pointer moves over the graduate scale to indicate the steam pressure.

WATER GAUGE (WATER LEVEL INDICATOR)

Function:

Water gauge indicated the level of water inside the boiler. It warns the operator if the level goes below
a fixed mark.

Description:

 The water gauge consists of a glass tube protected with a cover. The glass tube is connected with fun
metal tubes on both of its end. The gun metal tubes connect the glass tube with the steam and water
spaces of the boiler. Cocks are provided in the mental tubes.
 One is steam cock which connects steam space to glass tube and other is water cock that connects water
space to the glass tube. A drain cock is used to drain the water from glass tube at regular intervals to
avoid accumulation of dust.
Working:

 The water and steam cocks are opened and the drain cock is closed. The steam enters from the upper
metal tube and water enters from the lower metal tube into the glass tube. Hence water in the glass tube
is at the same level as in the boiler.
 Balls are provided in the junctions to prevent the water and steam entering into the glass tube, if the glass
tube gets accidentally broken.
SAFETY VALVE:
Safety valves are of different types namely,
1. Dead weight safety valve.
2. Lever safety valve.
3. Spring loaded safety valve.

Function:
 Safety valves are used to maintain a constant safe pressure inside the boiler. When the pressure inside
the boiler exceeds the safe limit, the valve automatically relieves the excess pressure.
Description:
 Lever safety valve is shown. It consists of a valve resting over a metal seat. The valve seat is mounted
over a block which is fixed to the boiler shell. One end of the lever is hinged to the mounting block and
the other end carries weight. The lever is pivoted at the fulcrum.
Working:
 The valve is kept in the seat at normal steam pressure by adjusting the position of weight along the length
of the lever. When the steam pressure exceeds the safe limit, the valve is lifted off its seat. The excess
steam escapes to the atmosphere till the pressure falls back to the normal value.
 The weight W required at the end of the lover for maintaining the pressure P in the boiler is obtained.
By taking moments about the hinged point,

P.A.L1 = W.L2
Where,
P – Normal steam pressure.
 A – Area of the value exposed to steam.
L1 – Distance between valve center and hinged point.
L2 – Distance between center of the weight and hinged point.

FUSIBLE PLUG:

Function:
 Fusible plug put-off the fire in the oiler furnace, when the water level falls below on unsafe limit. It
prevents overheating of tubes and shell thereby avoiding explosion of the boiler.
Description:
 It consists of a gun metal body with a hexagonal flange screwed with the firebox crown plate. A hollow
gun metal plug is screwed into the gun metal body. Another copper plug is locked with the hollow plug
by a low melting point fusible metal (tin or lead).
Working:
 The fusible plug is submerged in water during the normal operation. When the water level falls below
the safe limit, the fusible plug is uncovered form water. The plug gets overheated and the fusible metal
melts be the heat of the furnace.
 The copper plug thus drops down and steam rushes into the furnace extinguishing the fire. Ribs in the
gun metal body prevents the plug from falling into the furnace.

BOILER ACCESSORIES
Boiler accessories are the devices fitted in boiler to increase the efficiency of the boiler and for proper
working of the boiler.
Boiler accessories include,
1. Economizer.
2. Air preheated.
3. Super heater.
4. Steam separator.
Some of the boiler accessories are described below:

ECONOMIZER:

Function:
 Economizer extracts the heat of the flue gases to preheat the water before it is fed into the boiler.
Description:
 The economizer consists of vertical cast iron pipes. The iron pipes are fitted with two headers one at the
top and other at the bottom. A set of scrapes are fitted over the pipes to prevent the deposition of soot
from the flue gases.
Working:
 The feed water is passed through the bottom header, economizer pipe and top header and on to the boiler.
The hot gases pass over the external surface of the water tubes. The heat from the hot gases is given to
the feed water through the tube surface.

AIR PREHEATER:

Function:
Air preheater preheats the air supplied to the combustion chamber by using the heat of the flue gases.
Description:
It consists of a number of parallel plates. Baffles are placed to deflect the air. A hopper is provided
at the bottom to remove the soot and other industries.
Working:
 The hot flue gases are passed through the tubes and air circulates around them. Air is deflected by baffles
and made to move in a zigzag path for a number of times. The air gets effectively heated. Impurities are
collected in the hopper and removed periodically.

SUPER HEATER:

Function:
Super heater increases the temperature of the steam above its saturation temperature.
Description:
 It consists of two headers and a set of super heater tubes made of high quality steel. The tubes are U-
shaped. A damper is provided to control the amount of hot gases passed over the super heater tubes.
Working:
 Hot gases are allowed to pass over the super heater tubes. The amount of hot gases passed should be in
proportion to the amount of super-heated steam passing through the tubes. The excess amounts of hot
gases are diverted by the damper provided.
 The temperature of the steam coming out of super heater is always maintained constant irrespective of
amount of steam passing through the super heater.

STEAM SEPARATOR
Function: The steam separator is fitted before the steam engine or steam turbine to separate water particles
from steam.
DIFFERENCE BETWEEN BOILER MOUNTING AND BOILER ACCESSORIES:

S.NO FIRE TUBE BOILER WATER TUBE BOILER

1 Hot flue gases flow inside the tubes and Water flows inside the tubes and hot gases
water outside the tubes. outside the tubes.
2 Generally internally fired. Externally fired.
3 DE-MERITS: Steam pressure is lower MERITS: Steam pressure is higher
(50bar). (340bar).
4 Steam production is low. Steam production is high.
5 Not suitable for power plant. Suitable for power plant.
6 In case of explosion it causes heavy No serious explosion occurs.
damage.
7 MERITS: Less maintenance cost. DE-MERITS: More maintenance cost.
8 Requires less skill labour. Requires more skill labour.
9 Involves lesser risk of explosion due to Involves more risk of bursting due to high
low pressure. pressure.

S.NO. BOILER MOUNTING BOILER ACCESSORIES

1. Devices mounted on the boiler surface for Devices fitted in the boiler to increase the
safe operation of boiler and control of efficiency and proper working of the
steam, generation. boiler.
Eg: Pressure gauge, Water gauge, Safety Eg: Economizer, Air preheater, Super
valve, Fusible plug. heater.
2. They are usually mounted on the boiler They are usually installed outside the
shell. boiler shell.
3. A boiler should not be operated without A boiler can be operated without
necessary mountings. accessories.