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Objective:

The objectives of this experiment are: 1. To study different parts of the boiler 2. To study operation of the boiler

SPECIFICATION OF THE BOILER:

Brand Name: Phillipp Loos. Model : FH 1600/16

Country of make: Germany. Capacity: 1600 kg/hr Maximum working pressure: 16 bar Type of Burner: Gas Burner. Fuel/ fuels used: Natural Gas.

Diagram of a fire tube boiler:

Figure: A typical fire tube boiler

Figure: A typical fire tube boiler

Mountings:
Boiler mountings are the machine components that are mounted over the body of the boiler itself for the safety the of the boiler and for complete control of the process of steam generation.The important boiler mountings are:

Water Level Indicator: They show the operator the level of fluid in the boiler.

Pressure Gauge: It is need to measure the pressure of the steam inside the steam boiler.

Safety Valves:

It is used to relieve pressure and prevent

possible explosion of the boiler. Steam Stop Valve: It is used to control the flow of steam

from the boiler to the main steam pipe and to shut off steam completely when required. Blow off Cock: Blow of cock empty the boiler whenever which are

required and to discharge the mud, sediments accumulated at the bottom of the boiler.

Feed Check Valve: Its main purpose is to regulate the supply of water, which is pumped into the boiler, by the feed pump.

Accessories:
These are the devices which are used to improve the efficiency of a boiler.The important boiler accessories are:

Feed Pump:

It delivers water to the boiler for continuously converting into steam.It may be of Centrifugal or Reciprocating type.

Super Heater: It is placed in the path of hot flue gases from the furnace and its purpose is to increase the temperature of saturated steam without rising its pressure.

Fuel Flow Circuit:


Gas (Supply Line) ON-OFF Valve
Pressure Gauge

Flow meter

ON-OFF Valve

Cross-Flow mixing Chamber

Solenoid Valve

Pressure Gauge

Regulator

Filter

Air

Blower

Water Flow Circuit:


Water Tank (Reservoir) Water Treatment Feed Tank Gate Valve

Boiler

Non-return Valve

Feed Pump (Centrifugal)

Pressure Gauge

Definition: Tonnage Rating:


The Tonnage Rating shows the amount of steam in kg/h. It is the amount of water evaporated from feed water at 100 C and formed into dry and saturated steam at 100 C at normal atmospheric pressure. Each kilogram of steam would then have received 2 257 kJ of heat from the boiler.

Kilo-Watt Rating:
Seldom boiler rating is given in kW. This is subject to the same Tonnage Rating.To establish the actual evaporation by mass, it is first necessary to know the temperature of the feed water and the pressure of the steam produced, in order to establish how much energy is added to each kg of water. The following equation can then be used to calculate the steam output:

Boiler hp Rating(bhp):
One bhp is the evaporation of 15.648 kg of water per hour from a temperature of 100oC into dry saturated steam at the same temperature. Equivalent to 35.291 MJ/h.

Operations of air and fuel flow for firing a Boiler


Blow out of the exhaust gas. Checking the water level in the boiler and if level is below the safety level water is refilled. Air is blown in by starting blower. Natural Gas acts as fuel passes through pressure gauge, regulator, solenoid valve and finally enters into the burner. Air and gas mixes in proportional limit and produce spark in the electric spark rod. Pilot flame is established then full combustion starts. The fire or hot flue gasses from the burner is channeled through tubes that are surrounded by the fluid to be heated.

Control of water level indicator:


Steam boilers are fitted water level indicators. Boilers with a rating of 100 kW or more should be fitted with two indicators. The indicators are referred to as gauge glasses complying with BS 3463.

Figure: Water Level Gauge Glass in Steam Boiler

To test a gauge glass, the following procedure should be followed:


Close the water cock and open the drain cock for approximately 5 seconds. Close the drain cock and open the water cock. Water should return to its normal working level relatively quickly. If water doesnt return, then the blockage in the water cock sholud be identified, and remedial action should be taken as soon as possible. Close the steam cock and open the drain cock for 5 seconds. Close the drain cock and open the steam cock. If the water does not return to its normal working level relatively quickly, a blockage may exist in the steam cock. Remedial action should be taken as soon as possible.

The authorized attendant should systematically test the water gauges at least once each day and should be provided with suitable protection for the face and hands, as a safeguard against scalding in the event of glass breakage. Functions and pressure setting of safety valve: Safety valve is a protective device that be used in the steam boiler to avoid overpressure.

Figure: A typical safety valve

The function of a safety valve is to blow off the steam when the pressure of steam inside the boiler exceeds the working pressure. The safety valve used in this fire tube steam boiler is spring loaded safety valve. It is loaded with spring instead of weights. The spring is made of round or square spring steel rod in helical form. The spring may be in tension or compression, as the steam pressure acts along the axis of the spring. Usually, the spring is placed in compression. When the pressure in boiler space exceeds a certain limit, then safety valve opens and remove excess amount of pressure to the atmosphere. Thus safety valve prevents building excessive pressure in the boiler. It is situated at the top of the boiler.

Hydraulic test of a boiler:


Hydrostatic test is the test to ensure completion , compliance and safety before the boiler produces steam. For the test, the safety valves should be removed and the bush plugged off. The club pressure gauge must be connected. The test pressure shall be 1.5 x the working pressure, held for a minimum of ten minutes. Every part is subject to more than the maximum stress it will normally encounter. This is an endurance test; any weak link fails during the test.

Discussion:

In this experiment, we got to know about a fire tube boiler and its mountings and accessories. Boiler mountings ensure the safety and proper running of the boiler while the boiler accessories increase its efficiency. From our observation we learned about the functions and purposes of various mountings and accessories. We also learned about the water treatment plant which has a great significance for efficiency and long term well being of the boiler. We came to know about several technical terms such as boiler ratings, hydraulic test etc. We also learned about inspection of a boiler.

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