Thermal Power Generation Plant or Thermal Power

Station
Under Electrical Power Generation
Thermal power generation plant or thermal power station is the most conventional source of
electric power. Thermal power plant is also referred as coal thermal power plant and steam
turbine power plant. Before going into detail of this topic, we will try to understand the line
diagram of electric power generation plant.

Theory of Thermal Power Station

The theory of thermal power station or working of thermal power station is very simple. A
power generation plant mainly consists of alternator runs with help of steam turbine. The steam is
obtained from high pressure boilers. Generally in India, bituminous coal, brown coal and peat are
used as fuel of boiler. The bituminous coal is used as boiler fuel has volatile matter from 8 to 33 %
and ash content 5 to 16 %. To increase the thermal efficiency, the coal is used in the boiler in
powder form.

In coal thermal power plant, the steam is produced in high pressure in the steam boiler due to
burning of fuel (pulverized coal) in boiler furnaces. This steam is further supper heated in a super
heater. This supper heated steam then enters into the turbine and rotates the turbine blades. The
turbine is mechanically so coupled with alternator that its rotor will rotate with the rotation of
turbine blades. After entering in turbine the steam pressure suddenly falls and corresponding
volume of the steam increases. After imparting energy to the turbine rotor the steam passes out of
the turbine blades into the condenser. In the condenser the cold water is circulated with the help of
pump which condenses the low pressure wet steam. This condensed water is further supplied to low
pressure water heater where the low pressure steam increases the temperature of this feed water, it
is again heated in high pressure.

For better understanding we furnish every step of function of a thermal power station as follows,

1) First the pulverized coal is burnt into the furnace of steam boiler.
2) High pressure steam is produced in the boiler.
3) This steam is then passed through the super heater, where it further heated up.
4) This supper heated steam is then entered into a turbine at high speed.
5) In turbine this steam force rotates the turbine blades that means here in the turbine the stored
potential energy of the high pressured steam is converted into mechanical energy.
Line Diagram of Power Plant

6) After rotating the

turbine blades, the steam has lost its high pressure, passes out of turbine blades and enters into a
condenser.
7) In the condenser the cold water is circulated with help of pump which condenses the low
pressure wet steam.
8) This condensed water is then further supplied to low pressure water heater where the low
pressure steam increases the temperature of this feed water, it is then again heated in a high
pressure heater where the high pressure of steam is used for heating.
9) The turbine in thermal power station acts as a prime mover of the alternator.
Overview of Thermal Power Plant
A typical Thermal Power Station Operates on a Cycle which is shown below.

The working fluid is water and steam. This is called feed water and steam cycle. The ideal
Thermodynamic Cycle to which the operation of a Thermal Power Station closely resembles is the
RANKINE CYCLE.
In steam boiler the water is heated up by burning the fuel in air in the furnace & the function of the
boiler is to give dry super heated steam at required temperature.
The steam so produced is used in driving the steam Turbines. This turbine is coupled to
synchronous generator (usually three phase synchronous alternator), which generates electrical
energy.
The exhaust steam from the turbine is allowed to condense into water in steam condenser of
turbine, which creates suction at very low pressure and allows the expansion of the steam in the
turbine to a very low pressure. The principle advantages of condensing operation are the increased
amount of energy extracted per kg of steam and thereby increasing efficiency and the condensate
which is fed into the boiler again reduces the amount of fresh feed water.
The condensate along with some fresh make up feed water is again fed into the boiler by pump
(called the boiler feed pump).
In condenser the steam is condensed by cooling water. Cooling water recycles through cooling
tower. This constitutes cooling water circuit.
The ambient air is allowed to enter in the boiler after dust filtration. Also the flue gas comes out of
the boiler and exhausted into atmosphere through stacks. These constitute air and flue gas circuit.
The flow of air and also the static pressure inside the steam boiler (called draught) is maintained by
two fans called Forced Draught (FD) fan and Induced Draught(ID) fan.
The total scheme of a typical thermal power station along with different circuits is illustrated below.
 Inside the boiler there are
various heat exchangers, viz. Economiser, Evaporator (not shown in the fig above, it is
basically the water tubes, i.e. downcomer riser circuit), Super Heater (sometimes Reheater,
air preheater are also present).
In Economiser the feed water is heated to considerable amount by the remaining heat of flue gas.
The Boiler Drum actually maintains a head for natural circulation of two phase mixture (steam +
water) through the water tubes.
There is also Super Heater which also takes heat from flue gas and raises the temperature of steam
as per requirement.
Efficiency of Thermal Power Station or Plant
The overall efficiency of a thermal power station or plant varies from 20% to 26% and it depends
upon plant capacity.
Installed plant capacity Average overall thermal efficiency

upto 1MW 4%

1MW to 10MW 12%

10MW to 50MW 16%

50MW to 100MW 24%

above 100MW 27%

Thermal Power Plant Location

A thermal power station or thermal power plant has ultimate target to make business profit. Hence
for optimizing the profit, the location of the station is much important factor. Power generation
plant location plays an optimizing part in the economy of the station.
The most economical , location of power plant can be determined by graphical method as described
below, The most economical and ideal power plant location is the center of gravity of the load
because for such a power generation plant the length of the power transmission network will be
minimum, thus the capital cost to the system is reduced. Lets explain the graphical method, say, X
and Y be two reference axes. Lets Q 1(x1, y1), Q2(x2, y2), Q3(x3, y3), Q4(x4, y4),
.and Qn(xn, yn) are n numbers of load centers. From the above
graph we get, the coordinates of the center of gravity of the load, Q(x, y) where

Obviously the location of thermal power station is best at the center of gravity of the load, but
many times it is not possible to establish a thermal power plant at the CG of the load. Since
normally CG point of the load may be at the heart of the city. so other many points to be considered
to decide the best optimized location of the power plant.
1) The electric power generation plant must be constructed at such a place where the cost of land
is quite reasonable.
2) The land should be such that the acquisition of private property must be minimum.
3) A large quantity of cooling water is required for the condensers etc of thermal power
generation plant, hence the plant should preferably situated beside big source of natural water
source such as big river.
4) Availability of huge amount of fuel at reasonable cost is one of the major criterion for choosing
plant location.
5) The plant should be established on plane land.
6)The soil should be such that it should provide good and firm foundation of plant and buildings.
7) The thermal power plant location should not be very nearer to dense locality as there are
smoke, noise steam, water vapors etc.
8) There must be ample scope of development of future demand.
9) Place for ash handling plant for thermal power station should also be available very near by.
10) Very tall chimney of power station should not obstruct the traffics of air ships.
Advantages & Disadvantages of Thermal Power Station
Advantages: 1) Economical for low initial cost other than any generating plant.
2) Land required less than hydro power plant.
3) Since coal is main fuel & its cost is quite cheap than petrol/diesel so generation cost is
economical.
4) There are easier maintenance.
5) Thermal power plant can be installed in any location where transportation & bulk of water are
available.
Disadvantages: 1) The running cost for a thermal power station is comparatively high due to
fuel,maintenance etc.
2) Large amount of smoke causes air pollution.The thermal power station is responsible for Global
warming.
3) The heated water that comes from thermal power plant has an adverse effect on the lives in the
water and disturbs the ecology.
4) Overall efficiency of thermal power plant is low like less 30%.
Thermal Power Plant

Steam Boiler | Working principle and Types of Boiler

Boiler or more specifically steam boiler is an essential part of thermal power plant.

Definition of Boiler

Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the
water is converted into steam at required pressure. This is most basic definition of boiler.

Working Principle of Boiler

The basic working principle of boiler is very very simple and easy to understand. The boiler is
essentially a closed vessel inside which water is stored. Fuel (generally coal) is burnt in a furnace
and hot gasses are produced. These hot gasses come in contact with water vessel where the
heat of these hot gases transfer to the water and consequently steam is produced in the boiler.
Then this steam is piped to the turbine of thermal power plant. There are many different types of
boiler utilized for different purposes like running a production unit, sanitizing some area,
sterilizing equipment, to warm up the surroundings etc.

Steam Boiler Efficiency

The percentage of total heat exported by outlet steam in the total heat supplied by the fuel(coal)
is called steam boiler efficiency.

It includes with thermal efficiency, combustion efficiency & fuel to steam efficiency. Steam
boiler efficiency depends upon the size of boiler used. A typical efficiency of steam boiler is
80% to 88%. Actually there are some losses occur like incomplete combustion, radiating loss
occurs from steam boiler surrounding wall, defective combustion gas etc. Hence, efficiency of
steam boiler gives this result.
Types of Boiler

There are mainly two types of boiler water tube boiler and fire tube boiler.

In fire tube boiler, there are numbers of tubes through which hot gases are passed and water
surrounds these tubes. Water tube boiler is reverse of the fire tube boiler. In water tube boiler the
water is heated inside tubes and hot gasses surround these tubes.

These are the main two types of boiler but each of the types can be sub divided into many
which we will discuss later.

Fire Tube Boiler

As it indicated from the name, the fire tube boiler consists of numbers of tubes through which hot
gasses are passed. These hot gas tubes are immersed into water, in a closed vessel. Actually in
fire tube boiler one closed vessel or shell contains water, through which hot tubes are passed.
These fire tubes or hot gas tubes heated up the water and convert the water into steam and the
steam remains in same vessel. As the water and steam both are in same vessel a fire tube boiler
cannot produce steam at very high pressure. Generally it can produce maximum 17.5 kg/cm 2 and
with a capacity of 9 Metric Ton of steam per hour.

Types of Fire Tube Boiler

There are different types of fire tube boiler likewise, external furnace and internal furnace fire
tube boiler. External furnace boiler can be again categorized into three different types-

1) Horizontal Return Tubular Boiler.

2) Short Fire Box Boiler.

3) Compact Boiler.

Again, internal furnace fire tube boiler has also two main categories such as horizontal tubular
and vertical tubular fire tube boiler.

Normally horizontal return fire tube boiler is used in thermal power plant of low capacity. It
consists of a horizontal drum into which there are numbers of horizontal tubes. These tubes are
submerged in water. The fuel (normally coal) burnt below these horizontal drum and the
combustible gasses move to the rear from where they enter into fire tubes and travel towards
the front into the smoke box. During this travel of gasses in tubes, they transfer their heat into
the water and steam bubbles come up. As steam is produced, the pressure of the boiler
developed, in that closed vessel.

Advantages of Fire Tube Boiler

1) It is quite compact in construction.

2) Fluctuation of steam demand can be met easily.

3) It is also quite cheap.

Disadvantages of Fire Tube Boiler

1) As the water required for operation of the boiler is quite large, it requires long time for rising
steam at desired pressure.

2) As the water and steam are in same vessel the very high pressure of steam is not possible.

3) The steam received from fire tube boiler is not very dry.

Water Tube Boiler

A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot

gasses surround them. This is the

basic definition of water tube boiler. Actually this boiler is just opposite of fire tube boiler where
hot gasses are passed through tubes which are surrounded by water.

Types of Water Tube Boiler

There are many types of water tube boilers, such as

1) Horizontal Straight Tube Boiler.

2) Bent Tube Boiler.

3) Cyclone Fired Boiler.

Horizontal Straight Tube Boiler again can be sub - divided into two different types,

i) Longitudinal Drum Water Tube Boiler.

ii) Cross Drum Water Tube Boiler.

Bent Tube Boiler also can be sub divided into four different types,

i) Two Drum Bent Tube Boiler.

ii) Three Drum Bent Tube Boiler.

iii) Low Head Three Drum Bent Tube Boiler.

iv) Four Drum Bent Tube Boiler.

Advantages of Water Tube Boiler

There are many advantages of water tube boiler due to which these types of boiler are
essentially used in large thermal power plant.

1) Larger heating surface can be achieved by using more numbers of water tubes.

2) Due to convectional flow, movement of water is much faster than that of fire tube boiler,
hence rate of heat transfer is high which results into higher efficiency.

3) Very high pressure in order of 140 kg/cm2 can be obtained smoothly.

Disadvantages of Water Tube Boiler

1) The main disadvantage of water tube boiler is that it is not compact in construction.

2) Its cost is not cheap.

3) Size is a difficulty for transportation and construction.

Fire Tube Boiler | Operation and Types of Fire Tube Boiler

Under Electrical Power Generation

Fire tube boiler is one of the most basic types of boiler and the design is also very old. It was
popular in 18th century. It was mainly used for steam locomotive engines.
Operation of Fire Tube Boiler

Operation of fire tube boiler is as simple as its construction. In fire tube

boiler, the fuel is burnt inside a furnace. The hot gases produced in the
furnace then passes through the fire tubes. The fire tubes are immersed in
water inside the main vessel of the boiler. As the hot gases are passed through
these tubes, the heat energy of the gasses is transferred to the water
surrounds them. As a result steam is generated in the water and naturally
comes up and is stored upon the water in the same vessel of fire tube boiler.
This steam is then taken out from the steam outlet for utilizing for required
purpose. The water is fed into the boiler through the feed water inlet.

As the steam and water is stored is the same vessel, it is quite difficult to produce very high
pressure steam from. General maximum capacity of this type of boiler is 17.5 kg/cm 2 and with a
capacity of 9 Metric Ton of steam per hour. In a fire tube boiler, the main boiler vessel is under
pressure, so if this vessel is burst there will be a possibility of major accident due to this explosion.

Types of Fire Tube Boiler

According to the location of furnace there are two types of fire tube boiler and these are external
furnace and internal furnace type. There are mainly three types of external furnace fire tube boiler.

1) Horizontal return tubular fire tube boiler.

2) Short fire box fire tube boiler.

3) Compact fire tube boiler.

There are also two types of internal furnace fire tube boiler

1) Horizontal tubular.
2) Vertical tubular fire tube boiler.

Working Principle of Horizontal Return Fire Tube Boiler

Horizontal return fire tube boiler is most suitable for low capacity thermal
power plant. The main constructional features of this boiler are one big size
steam drum which lies horizontally upon supporting structures. There are
numbers of fire tubes come from furnace and also aligned horizontally inside
the drum. When the drum is filled with water these tubes are submerged in

water.

The fuels (normally coal) burnt in the furnace and combustible gasses move into the fire tubes,
travel through these tubes from rear to front of the boiler drum and finally the gases come into the
smoke box. The hot gasses in the tubes under water transfer heat to the water via the tube walls.
Due to this heat energy steam bubbles are created and come upon the water surface. As the amount
of steam is increased in that closed drum, steam pressure inside the drum increases which increase
significantly the boiling temperature of the water and hence rate of production of steam is reduced.
In this way a fire tube boiler controls its own pressure. In other words this is a self pressure
controlled boiler.

Advantages of Fire Tube Boiler

1) Compact in construction.

2) Fluctuation of steam demand can be met easily.

3) Cheaper than water tube boiler.

Disadvantages of Fire Tube Boiler

1) Due to large water the required steam pressure rising time quite high.

2) Output steam pressure cannot be very high since the water and steam are kept in same vessel.

3) The steam received from fire tube boiler is not very dry.

4) In a fire tube boiler, the steam drum is always under pressure, so there may be a chance of huge
explosion which resulting to severe accident.

Water Tube Boiler | Operation and Types of Water Tube Boiler

Under Electrical Power Generation

A water tube boiler is such kind of boiler where the water is heated inside tubes and the hot gasses
surround them. This is the basic definition of water tube boiler. Actually this boiler is just opposite
of fire tube boiler where hot gasses are passed through tubes which are surrounded by water.

Advantages of Water Tube Boiler

There are many advantages of water tube boiler due to which these types of boiler are essentially
used in large thermal power station.

1) Larger heating surface can be achieved by using more numbers of water tubes.

2) Due to convectional flow, movement of water is much faster than that of fire tube boiler, hence
rate of heat transfer is high which results into higher efficiency.

3) Very high pressure in order of 140 kg/cm2 can be obtained smoothly.

Working Principle of Water Tube Boiler

The working principle of water tube boiler is very interesting and simple. Let us draw a very
basic diagram of water tube boiler. It consists of mainly two drums, one is upper drum called
steam drum other is lower drum called mud drum. These upper drum and lower drum are connected
with two tubes namely down-comer and riser tubes as shown in the picture. Water in the lower
drum and in the riser connected to it, is heated and steam is produced in them which comes to the
upper drums naturally. In the upper drum the steam is separated from water naturally and stored
above the water surface. The colder water is fed from feed water inlet at upper drum and as this
water is heavier than the hotter water of lower drum and that in the riser, the colder water push the
hotter water upwards through the riser. So there is one convectional flow of water in the boiler
system. More and more
steam is produced the pressure of the closed system increases which obstructs this convectional
flow of water and hence rate production of steam becomes slower proportionately. Again if the
steam is taken trough steam outlet, the pressure inside the system falls and consequently the
convectional flow of water becomes faster which result in faster steam production rate. In this way
the water tube boiler can control its own pressure. Hence this type of boiler is referred as self
controlled machine.

Types of Water Tube Boiler

There are many types of water tube boiler .

1) Horizontal Straight Tube Boiler

2) Bent Tube Boiler.

3) Cyclone Fired Boiler.

Horizontal Straight Tube Boiler again can be sub-divided into two different types, such as

i. Longitudinal Drum Boiler

ii. Cross Drum Boiler.

Bent Tube Boiler also can be sub-divided into four different types, such as

i. Two Drum Bent Tube Boiler.

ii. Three Drum Bent Tube Boiler.

iii. Low Head Three Drum Bent Tube Boiler.

iv. Four Drum Bent Tube Boiler.

Horizontal or Longitudinal or Babcock Wilcox Water Tube Boiler

Construction of Babcock Wilcox Boiler

Babcock Wilcox Boiler is also known as Longitudinal Drum Boiler or Horizontal Tubes
Boiler . In this type of boiler, one cylindrical drum is longitudinally placed above the heat chamber.
In rear of the drum down comer tube is filled and in front of the drum riser tube is fitted as shown
in the figure. These down-comer tube and riser tube are connected to each other by 5 o to 15o
straight water tubes as shown in the figure.

Working Principle of Longitudinal Drum Water Tube Boiler

 Working principle of
Babcock Wilcox Boiler depends upon thermonyphon principle. The
longitudinally placed drum as mentioned in the construction of longitudinal
drum boiler, is fed by colder mater at its rear feed water inlet. As the colder
water is heavier it falls down through down-comer fitted at the rear part of the
drum. From down-comer the water enters in to horizontal water tube where it
becomes hot and lighter. As the water becomes lighter, it passes up through
these inclined horizontal tubes and ultimately comes back to the boiler drum
through riser. During travelling of water through inclined water tubes, it
absorbs heat of the hot gases, surrounds the water tube, consequently steam
bubbles are created in these tubes. These steam bubbles then come to the
steam drum through riser and naturally separated from water and occupies the
space above the water surface in the longitudinal drum of Babcock Wilcox
Boiler.

Cross Drum Water Tube Boiler

Construction of Cross Drum Water Tube Boiler

Cross Drum Boiler is essentially a variant of the Longitudinal Drum Boiler.

In Cross Drum Boiler the steam drum is placed at cross ways to the heat
source as shown in the figure. Here, the down-comer is fitted on the bottom of
the drum and riser is fitted on the top of the drum via a horizontal tube as
shown in the figure. 5o to 15 o inclined water tubes are connected with down-
comer and riser tubes in same manner of Babcock-Wilcox boiler.

Working Principle of Cross Drum Boiler

The working principle of cross drum boiler is same as longitudinal drum boiler .

1) The feed water is fed to the cross drum through feed water inlet.

2) Then this water comes down through the down-comer pipe and enters into inclined water tube
placed in hot chamber.

3) Here, the water becomes hot and steam is produced in the water which comes into steam
chamber.
4) Here in the steam drum steam is separated from water in natural way.

Bend Tube Boiler or Sterling Boiler

Bend Tube Boiler or Sterling Boiler is the developed version of water tube boiler. The working
principle of bend tube boiler is more or less same as other water tube boilers, but it utilizes four
drums.

Construction of Bend Tube Boiler

,Three drums are placed on the heat source as shown on the figure. Fourth drum is placed inside the
heat chamber and this fourth drum is connected to upper three steam drums with help of bend water
tube. Upper three drums are connected with equalizer tubes as shown in the figure. Steam is taken
from equalizer tubes.

Working Principle of Bent Tube or Stirling Boiler

The feed water first enters into right most upper drum. Due to more density this water comes down
in the lower water drum. The water within that water drum and the connecting pipes to the other
two upper drums, are heated up and consequently steam bubbles are produced. This is the most
basic working principle of bent tube boiler .
Capacity of Stirling Boiler

Capacity of Stirling Boiler is much higher than Babcock - Wilcox boiler as high as 50,000kg per
hour and pressure as high as 60kg/cm 2.

Steam Boiler Furnace Grate Firebox Combustion

Chamber of Furnace
Under Electrical Power Generation

The heat required for producing steam in a boiler is generated at boiler furnace by combustion of
fuel.

What is Combustion?

Combustion is a chemical process during which oxygen is combined with different elements of
fuel. During this combination, a definite amount of heat is produced per unit mass of combustible
element depending upon the element with which the oxygen combines. The elements participate in
combustion process are oxygen, hydrogen, carbon and sulfur. There are various other elements in
the fuel (coal) which do take part in combustion process such as iron, silicon etc. They usually exist
in small amount and are classed as impurities of fuel. These impurities producer certain waste
during combustion of coal and remain in the form of ash and stored in the ash pit of steam boiler
furnace , after combustion. The combustion of fuel including coal requires three stages to be
completed.

1) The absorption of heat to rise the temperature of the fuel to the point of ignition.
2) The distillation and burning of volatile gasses.
3) Combustion of fixed carbon.
While the coal is fed to the boiler furnace in a pulverized form, the temperature of the coal is first
raised to its ignition point the volatile matters of the coal so called hydrocarbons, such as marsh
gas, tar, pitch, naphtha are separated from the coal and driven of in the gaseous form. These gases
then combine with oxygen of air which is supplied through the bed of the hot bed of fuel (coal) of
the steam boiler furnace . After the hydrocarbons are driven off from the coal, the solid carbon
unites with oxygen of air and forms carbon monoxide and carbon dioxide. Any substances of the
coal which are not combustible fall through the grate into the pit below the boiler furnace in form
of ash. So far combustion process, sufficient air to be supplied in furnace. Generally approximately
12 pound of air is required to complete combustion of one pound of coal. But in practice twice or
more of this quantity of air is supplied in the furnace by forced draft since ideal condition of
combustion can not be achieved practically. It is always quite difficult to supply air to the all part of
the steam boiler furnace uniformly. In the other hand, too mush air should not be supplied to the
furnace. If air is supplied is in very higher rate than its specified rate then there may be a chance of
blowing off the hydrocarbon gases before the combustion process is completed. So the air should
be supplied to the furnace in high but controlled rate.

The main design and operation of

the boiler furnace is to obtained combustion with minimum smoke. Smoke less combustion is
proffered for mainly two reasons,
1) the smoke is a main cause of air pollution.
2) smoke is the indication of incomplete combustion. The unburned visible gases are shown in the
form of smoke.
The principle of complete combustion is quite simple but is not always possible to carry out in
steam boiler furnace . Introducing coal into the boiler furnace, rising the temperature to the
burning point, and supplying enough air for the combustion may not be sufficient for a successful
combustion. There is another factor which to be kept in mind during designing a furnace. It is
equally important to mix up the air with combustible gases thoroughly and that is to be maintained
at a sufficiently high temperature during the process. When fresh bituminous coal is fired, on the
fuel bed of boiler furnace, the combustible gases are driven off and large portion of which remain
unburned and are carried into the chimney if air is not mixed up with them properly.
There are many air mixing processes developed for steam boiler furnace. One of the popular
methods of boiler furnace is to providing fire brick lined combustion chamber of ample size with
suitable baffles for proper mixing the gases with the air, the introduction of sufficient heated air in
the combustion to consume the combustible gages before reaching the heating surface of the boiler.

Construction of Boiler Furnace

For successful combustion a boiler furnace has some essential parts in its construction, such as
1) a grate for supporting fuel (coal).
2) combustion chamber in which the combustion takes place Means of supplying fresh air.
3) an ash pity for collecting and catching the refuses from the fuel during combustion.

Boiler Furnace Grate

Grate is provided in a steam boiler furnace for supporting the solid fuel in the furnace. Grate is so
designed that it can also allow air to admit air in the solid fuel for combustion. The openings of the
grate must not be so large that they allow the unburned fuel partials to fall through and on the other
hand these openings must not be so narrow that they obstruct sufficient amount of air to pass
through the fuel.

Firebox and Combustion Chamber of Furnace

Firebox of boiler furnace is the place just above the grate and combustion chamber is the
extension of this where combustion of volatile hydrocarbons take place. The heat is produced due
to combustion is absorbed by the steam boiler surface at the top of the combustion chamber.
Different fire bricks wall and baffles are provided in the combustion chamber proper mixing of air
with combustible gases.

Ash Pit
Ash pit of steam boiler furnace is a chamber provided below the grate to catch the refuse (ash)
from the fire above. Ash pit also functions as supply chamber of air through the grate. There must
be sufficient height between the bottom floor of the ash pit and the grate to give plenty of air space.
In common practice to slope the pit floor towards the front, to facilitate the removal of ashes.

Boilers can be classified as follows:

1. According to the flow of water and hot gases fire tube (or smoke tube) and water tube boilers.

In fire tube boilers, hot gases pass through tubes which are surrounded with water. Examples: Vertical,
Cochran, Lancashire and Locomotive boilers. There may be single tube as in case of Lancashire boiler or
there may be a bank of tubes as in a locomotive boiler.

In water tube boilers, water circulates through a large number of tubes and hot gases pass around them.
Eg., bobcock & Wilcox boiler.

2. According to the axis of the shell vertical and horizontal boilers.

3. According to location or position of the furnace. Externally and internally fired boilers.

In internally fired boilers, the furnace forms an integral part of the boilers structure. The vertical tubular,
locomotive and the scotch marine boilers are well known examples.

Externally fired boilers have a separate furnace built outside the boiler shell and usually below it. The
horizontal return tube (HRT) boiler is probably the most widely known example of this type.

4. According to the application stationery and mobile boilers. A stationary boilers is one of which is
installed permanently on a land installation.

A marine boiler is a mobile boiler meant for ocean cargo and passenger ships with an inherent fast
steaming capacity.

5. According to steam pressure low, medium and high pressure boilers.

 Types of boilers:

Water Tube Boilers

Fire Tube Boilers

Babcock and Wilcox Boiler

Simple Vertical type boiler

High Pressure Boilers
Cochran Boiler
Lancashire Boiler La-Mont Boiler
Locomotive Boiler Loeffler Boiler
Benson Boiler

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Babcock and Wilcox Boiler

It is a water tube boiler used in steam power plants. In this, water is circulated inside the tubes and hot gases flow

over the tubes. C...

It is a water tube boiler used in steam power plants. In this, water is circulated inside the tubes and hot
gases flow over the tubes.

Construction of Babcock and Wilcox Boiler

 The Babcock and Wilcox Boiler consists of

1. Steam and water drum (boiler shell)

2. Water tubes
3. Uptake-header and down corner
4. Grate
5. Furnace
6. Baffles
7. Super heater
8. Mud box
9. Inspection door
10. Damper

Steam and water drum (boiler shell):

One half of the drum which is horizontal is filled up with water and steam remains on the other half. It is
about 8 meters in length and 2 meter in diameter.

Water tubes:
Water tubes are placed between the drum and furnace in an inclined position (at an angle of 10 to 15
degree) to promote water circulation. These tubes are connected to the uptake-header and the down-
comer as shown.

Uptake-header and down-corner (or downtake-header)

The drum is connected at one end to the uptake-header by short tubes and at the other end to the down-
corner by long tubes.

Grate: Coal is fed to the grate through the fire door.

Furnace : Furnace is kept below the uptake-header.

Baffles: The fire-brick baffles, two in number, are provided to deflect the hot flue gases.

Superheater: The boiler is fitted with a superheater tube which is placed just under the drum and above
the water tubes

Mud box: Mud box is provided at the bottom end of the down comer. The mud or sediments in the water
are collected in the mud box and it is blown-off time to time by means of a blow off cock.

Inspection doors: Inspection doors are provided for cleaning and inspection of the boiler.

Working Babcock and Wilcox Boiler:

Coal is fed to the grate through the fire door and is burnt.

Flow of flue gases:

The hot flue gases rise upward and pass across the left-side portion of the water tubes. The baffles deflect
the flue gases and hence the flue gases travel in the zig-zag manner (i.e., the hot gases are deflected by
the baffles to move in the upward direction, then downward and again in the upward direction) over the
water tubes and along the superheater. The flue gases finally escape to atmosphere through chimney.

Water circulation:

That portion of water tubes which is just above the furnace is heated comparatively at a higher
temperature than the rest of it. Water, its density being decreased, rises into the drum through the uptake-
 header. Here the steam and water are separated in the drum. Steam being lighter is collected in the upper
part of the drum. The water from the drum comes down through the down comer into the water tubes.

A continuous circulation of water from the drum to the water tubes and water tubes to the drum is thus
maintained. The circulation of water is maintained by convective currents and is known as natural
circulation.

A damper is fitted as shown to regulate the flue gas outlet and hence the draught.

The boiler is fitted with necessary mountings. Pressure gauge and water level indicator are mounted on
the boiler at its left end. Steam safety valve and stop valve are mounted on the top of the drum. Blow-off
cock is provided for the periodical removed of mud and sediments collected in the mud box.

Salient features of Babcock and Wilcox Boiler:

1. Its overall efficiency is higher than a fire tube boiler.

2. The defective tubes can be replaced easily.
3. All the components are accessible for inspection even during the operation.
4. The draught loss is minimum compared with other boiler.
5. Steam generation capacity and operating pressure are high compared with other boilers.
6. The boiler rests over a steel structure independent of brick work so that the boiler may expand or contract
freely.
7. The water tubes are kept inclined at an angle of 10 to 15 degree to promote water circulation.

Advantages and disadvantages of water tube boilers over fire

tube boilers:

Advantages water tube boilers

1. Steam can be generated at very high pressures.

2. Heating surface is more in comparison with the space occupied, in the case of water tube boilers.
3. Steam can be raised more quickly than is possible with a fire tube boiler of large water capacity. Hence, it
can be more easily used for variation of load.
4. The hot gases flow almost at right angles to the direction of water flow. Hence maximum amount of heat is
transferred to water.
5. A good and rapid circulation of water can be made.
6. Bursting of one or two tubes does not affect the boiler very much with regard to its working. Hence water
tube boilers are sometimes called as safety boilers.
7. The different parts of a water tube boiler can be separated. Hence it is easier to transport.
8. It is suitable for use in steam power plants (because of the various advantages listed above).

Disadvantages of water tube boilers

1. It is less suitable for impure and sedimentary water, as a small deposit of scale may cause the overheating
and bursting of tubes. Hence, water treatment is very essential for water tube boilers.
2. Maintenance cost is high.
3. Failure in feed water supply even for a short period is liable to make the boiler overheated. Hence the water
level must be watched very carefully during operation of a water tube boiler.

Lancashire Boiler

It is a stationary, fire tube, internally fired boiler. The size is approximately from 7-9 meters in length and 2-3 meters

in diameter. ...

It is a stationary, fire tube, internally fired boiler. The size is approximately from 7-9 meters in length and 2-
3 meters in diameter.

Construction of Lancashire Boiler:

It consists of

1. Cylindrical shell
2. Furnace tubes, bottom flue and side flues
3. Grate
4. Fire bridge
5. Dampers

Cylindrical shell
It is placed in horizontal position over a brick work. It is partly filled up with water. The water level inside
the shell is well above the furnace tubes.

Furnace tubes, bottom flue and side flues:

Two large internal furnace tubes (flue tubes) extend from one end to the other end of the shell. The flues
are built-up of ordinary brick lined with fire bricks. One bottom flue and two side flues are formed by brick
setting, as shown in the figure.

Grate
The grate is provided at the front end of the main flue tubes. Coal is fed to the grate through the fire hole.

Fire bridge:
A brickwork fire bridge is provided at the end of the grate to prevent the flow of coal and ash particles into
the interior of the furnace (flue) tubes. Otherwise the coal and ash particles carried with gases form
deposits on the interior of the tubes and prevent the heat transfer to the water.

Dampers:
Dampers is in the form of sliding doors are placed at the end of the side flues to control the flow of gases
from side flues to the chimney flue.

Working of Lancashire boiler

Coal is fed to the grate through the fire hole and is burnt. The hot gases leaving the grate move along the
furnace (flue) tubes upto the back end of the shell and then in the downward direction to the bottom flue.
The bottom of the shell is thus first heated.

The hot gases, passing through the bottom flue, travel upto the front end of the boiler, where they divide
into two streams and pass to the side flues. This makes the two sides of the boiler shell to become
heated. Passing along the two side flues, the hot gases travel upto the back end of the boiler to the
chimney flue. They are then discharged into the atmosphere through the chimney.

With the help of this arrangement of flow passages of hot gases, the bottom of the shell is first heated and
then its sides. The heat is transferred to water through the surface of the two flue tubes (which remain in
water) and bottom and sides of the shell.

The arrangement of flues increases the heating surface of the boiler to a large extent.

Dampers control the flow of hot gases and regulate the combustion rate as well as steam generation rate.

The boiler is fitted with necessary mountings. Pressure gauge and water level indicator provided at the
front. Safety valve, steam stop valve, low water and high steam safety valve and man-hole are provided
on the top of the shell.

High steam low water safety valve:

It is a combination of two valves. One is lever safety valve, which blows-off steam when the working
pressure of steam exceeds. The second valve operates by blowing-off the steam when the water level
falls below the normal level.

Blow-off clock:
It is situated beneath the front portion of the shell for the removal of mud and sediments. It is also used to
empty the water in the boiler during inspection.

Fusible plug:
It is provided on the top of the main flues just above the grate. It prevents the overheating of the boiler
tubes by extinguishing the fire when the water level falls below a particular level. A low water level alarm is
mounted in the boiler to give a warning when the water level falls below the preset value.

Salient features of Lancashire Boiler

The arrangement of flues in this boiler increases the heating surface of shell to a large extent.
It is suitable where a large reserve of steam and hot water is needed.
Its maintenance is easy.
 Superheated can be easily incorporated into the system at the end of the main flue tubes. Thus overall
efficiency of the boiler can be increased.

Note : The simple vertical Boiler, Cochran and Lancashire Boilers discussed till this post are Fire tube
boilers. In the upcoming posts, I will write about water tube boilers namely Babcock and Wilcox Boiler.

Cochran boiler

It is a multi-tubular vertical fire tube boiler having a number of horizontal fire tubes. T is the modification of a simple

vertical boile...

It is a multi-tubular vertical fire tube boiler having a number of horizontal fire tubes. T is the modification of
a simple vertical boiler where the heating surface has been increased by means of a number of fire tubes.

It consists of

1. Shell
2. Crate
3. Fire box
4. Flue pipe
5. Fire tubes
6. Combustion chamber
7. Chimney
8. Man-hole

Shell
It is hemispherical on the top, where space is provided for steam.

Grate
It is placed at the bottom of the furnace where coal is burnt.

Fire box (furnace )

It is also dome-shaped like the shell so that the gases can be deflected back till they are passed out
through the flue pipe to the combustion chamber.

Flue pipe:
It is a short passage connecting the fire box with the combustion chamber.

Fire tubes:
A number of horizontal fire tubes are provided, thereby the heating surface is increased.

Combustion chamber:
It is lined with fire bricks on the side of the shell to prevent overheating of the boiler. Hot gases enter the
fire tubes from the flue pipe through the combustion chamber.

Chimney:
It is provided for the exit of the flue gases to the atmosphere from the smoke box.

Manhole:
It is provided for inspection and repair of the interior of the boiler shell.

Normal size of a Cochran boiler:

Shell diameter 2.75 meters:
Height of the shell 6 meters.

Working of the Cochran boiler:

Coal is fed into the grate through the fire hole and burnt. Ash formed during burning is collected in the
ashpit provided just below the grate and then it is removed manually.

The host gases from the grate pass through the flue pipe to the combustion chamber. The hot gases from
the combustion chamber flow through the horizontal fire tubes and transfer the heat to the water by
convection.

The flue gases coming out of fire tubes pass through the smoke box and are exhausted to the atmosphere
through the chimney.
Smoke box is provided with a door for cleaning the fire tubes and smoke box.

The following mountings are fitted to the boiler:

Pressure gauge: this indicates the pressure of the steam inside the boiler.

Water gauge: this indicates the water level in the boiler. The water level in the boiler should not fall below
a particular level, otherwise the boiler will be over heated and the tubes may burn out.

Safety valve: the function of the safety valve is to prevent an increase of steam pressure in the boiler
above its normal working pressure.

Steam stop valve: it regulates the flow of steam supply to requirements.

Blow-off cock: it is located at the bottom of the boiler. When the blow-off cock is opened during the
running of the boiler, the high pressure steam pushes (drains) out the impurities like mud, sand, etc., in
the water collected at the bottom.

Fusible plug: it protects the fire tubes from burning when the water level in the boiler falls abnormally low.

Salient features of Cochran boiler:

1. The dome shape of the furnace causes the hot gases to deflect back and pass through the flue. The un-
burnt fuel if any will also be deflected back.
2. Spherical shape of the top of the shell and the fire box gives higher area by volume ratio.
3. It occupies comparatively less floor area and is very compact.
4. It is well suited for small capacity requirements.

Types of boilers:

Boilers can be classified as follows: 1. According to the flow of water and hot gases fire tube (or smoke tube) and

water tube boilers....

Diesel power plant

Lets discuss about diesel power plants in this post. Applications of diesel power plant Diesel power plants is in the

range of 2 to 50 MW ...

La Mont Boiler Working and Construction

A forced circulation boiler was first introduced by La-Mont in the year 1925 which is used in Europe and America.

This is a modern high pre...

Benson Boiler
 The presence of steam bubbles in contact with the surface of tubes seriously impairs heat transmission from the flue

gases to water. By ris...

Steam (Thermal) power Plant

A steam power plant, also known as thermal power plant, is using steam as working fluid. Steam is produced in a

boiler using coal as fuel an...

Loeffler Boiler

This is also a modern high pressure water tube boiler using the forced circulation principle and named after

Prof.Loeffler. Salient featu...

Simple vertical boiler:

The image shows the simplest form of an internally fired vertical fire-tube boiler. It does not require heavy foundation

and requires very ...

What is the function of the economizer?

Economizer economizes the power plant operation.
What are the functions of steam drum?
(a) steam separation, (b) steam-water circulation and (c) purifying steam.
What is the function of super-heater?
Super-heater is used to super heat the steam and get higher thermal Efficiency of the
plant.
Why large boilers are top supported?
(a) avoid buckling of furnace walls, (b) allow thermal expansion and (c) reduce thermal
loads.
Why steel structures (avoiding concrete) are used for boiler structures?
Steel structures are used for speeding - up the construction schedule and facilitate
changes.
What is resonance?
When the natural frequency and the induced frequency matches Resonance takes place.
Why resonance should be avoided?
During resonance, high vibration and stress will occur. Hence, resonance Should be
avoided.
What is the life of a power plant?
Life of the power plant is about 50 years. But, many components need Replacement and
repair.
What is safety requirement for boiler, in India?
The Indian Boiler Regulations, 1950 (with amendments).
What are the materials used for boiler pressure parts?
Carbon steel, low alloy steel, medium alloy steel and stainless steel.
What are the materials used for boiler structures?
Mild steel as per IS2062 is used. For fasteners, IS1367 is used.
What is the material used for boiler insulation?
Slag wool, mineral wool and glass wool are used.
What is the material used for boiler foundation?
Reinforced Cement Concrete (RCC) with a specification "M20" is used.
What are the types of bolted connections used for boiler structures?
Bearing type connection and Friction type connections are used. Bearing type is popularly
used.
What is a shear key?
Shear key are flat plates welded at the bottom of the structure base plates to transfer
shear forces.
What are the types of chimneys?
Rcc chimney and steel chimney are used.
What are the types of steel chimneys?
Self supporting type and guyed chimney are used.
Why conical chimneys are preferred?
Conical chimneys are economical.
What is the corrosion allowance used for steel chimney?
Corrosion allowance = 3.0 mm (typical).
Which boiler code is governing in India?
The Indian Boiler Regulations, 1950 (with amendments)is governing in India.
Who is the authorized inspector in India?
The Chief Inspector of Boiler (CIB) is the authorized inspector for the Respective states.
Which body is empowered to amend The Indian Boiler Regulation?
The Central Boiler Board (CBB) is authorized to amend the IBR.
Why steel is used for boiler pressure parts?
The cost to weight ratio is favorable for steel. Hence, steel is used.
What is the purpose of refractory?
Refractory is provided where the flue gas temperature is high (above 800 Degree C).
What is the purpose of refractory retainers?
Retainers are embed within the refractory and they retain the refractory to the surfaces.
What are the steps in design?
Design, engineering, process analysis, stress analysis, detailing, drafting, Documentation
and document approval.
What is DAS?
Data Acquisition System (DAS) is used record readings.
What is VLH?
Variable Load Hangers (CLH) are used for support, permiting limited Support load
variation.
What is CLH?
Constant Load Hangers(CLH) are used for support,permitting small load variations.
Why water quality is control of in boilers?
Water quality is controlled to avoid corrosion of boiler parts.
Why paints are required?
Paints are required to protect the surface of boiler.
Why rockers are used for boiler hanger supports?
Rockers reduce the induced bending load. This leads to economic design.