Experiment no.
Boiler Safety Precautions & Importance:
Boiler explosion history tells that an industrial boiler is a potential bomb. Steam Boiler have been known to
explode when not maintained. We found reported incidents in Unchahar NTPC Power Plant and Bihar boiler
blast.
Boiler Explosion Image
Main Possible Causes of Boiler Explosions:
Exports say, based on steam boiler explosions history & analysis, boiler explosions can always be prevented.
There are few common failures and causes of boiler explosions in power plant, such as
✓ Failure of the safety valve, Corrosion in boilers.
✓ Reckless management is the main cause of every accident.
Precautions to be carried out Regularly:
❖ Never operate boiler above the design pressure and check for the safe operation of Safety valves as well
as fusible plugs.
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❖ Regular cleaning of the perforated line is necessary.
❖ Stainer must be installed before the pump & check for its proper functioning to remove dirt particles from
boiler feed water as this prevents the blockage of a feed line.
❖ Water must be treated before feeding it to the boiler to prevent the accumulation of dirt in a Boiler shell.
❖ Regular inspection and maintenance of boiler including its accessories and valves to check for possible
failures and cracks are necessary.
❖ Make sure that the boiler vents are not restricted by any kind of obstruction such as cloth etc.
❖ Always check for the leakages of steam, water, air and flue gases from any suspicious place.
❖ Follow boiler manual for safe and efficient working of your boiler
❖ The panel should be cleaned regularly and should be kept in a cool and an isolated place away from your
boiler.
❖ Check if all the hot parts of the boiler are insulated, do not touch the parts with bare hands where the
insulation is not provided.
❖ Maintenance of both FD fan and ID Fan is important and regularly check for greasing in all the movable
parts for the ease of operation.
❖ Regular cleaning of movable mechanical parts is necessary.
❖ Do not increase the frequency of a drive above 50 Hz for the safe operation of motors.
❖ Pressure switch, Mobrev and Pressure Gauge should be checked for their proper
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Boiler & its Different Types
What is a Boiler?
A boiler is a closed vessel which is used to convert the water into high pressure steam. The high pressure
steam so generated is used to generate power.
Working Principle of Boiler:
The boiler works on the same principle as the water is heated in a closed vessel and due to heating, the water
changes into steam. This steam possesses high-pressure kinetic energy. The boiler contains water. The water
is heated to its boiling temperature by the use of heat from the furnace. Due to the heating of water, it gets
converted into high-pressure steam. The steam generated is passed through the steam turbines. As the high-
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pressure steam strikes the turbine, it rotates the turbine. A generator is attached to the turbine and the generator
also starts to rotate with the turbine and produces electricity.
Different Types of Boiler:
Boilers can be classified on the different basis but here I am discussing the only important basis of boiler
classification.
Boiler According to Tubes
1. Fire Tube Boiler:
In fire tube boiler the fire or hot gas are present inside the tubes and water surrounds these fire tubes. Since
fire is inside the tubes and hence it is named as fire tube boiler. The heat from the hot gases is conducted
through the walls of the tube to the water.
➢ The examples of the fire tube boiler are: simple vertical boiler, Cochran boiler, Lancashire boiler, Cornish
boiler, Locomotive boiler, Scotch marine boiler and Velcon boiler.
2. Water Tube Boiler:
In water tube boilers, the water is present inside the tubes and the fire or hot gases surrounds these water tubes.
➢ Examples of water tube boilers are: La-Mont boiler, Benson boiler, Stirling boiler, Babcock and Wilcox
boiler, Yarrow boiler and Loeffler boiler.
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According to the Position of the Furnace
1. Internally Fired Boilers:
The boilers in which the furnace is located inside the boiler shell are called internally fired boilers.
➢ Among all the fire tube boilers, most of the boilers are internally fired boilers.
2. Externally Fired Boilers:
In externally fired boilers, the furnace is located outside the boiler shell. In this the furnace is arranged
underneath in brick work setting.
➢ Water tube boilers are always externally fired boilers.
According to the Axis of the Shell
1. Vertical Boilers:
The boilers in which the axis of the shell is vertical are called vertical boilers.
➢ Examples of vertical boilers are: simple vertical boiler and Cochran boiler.
2. Horizontal Boilers:
When the axis of the shell in a boiler is found horizontal than it is called a horizontal boiler.
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Main Types of Valve in Boiler
1) Ball Valve:
Ball Valve
Ball Valve is a quarter turn operated valve. Ball Valves consists of a closure membrane which is a spherical
plug with a through hole.
When the valve is open the through hole is in line with the fluid flow and it allows the fluid to flow through
it. The valve can be closed by rotating the globe by 90 deg. such that the hole now becomes perpendicular to
the flow and thus stops the flow. These valves are not recommended to be used in partial open conditions.
2) Gate Valve:
Gate valve is a sliding type of Boiler valve. In the gate valve the closure membrane is a metal gate.
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These gates slide down to close the valve. The flow area is equal to the area of the pipe in fully open condition
which results in negligible pressure drop across the valve. These valves are usually used in on/off condition.
In partially open conditions due to vibrations the valve is exposed to quick wear and tear.
3) Plug Valve:
Plug Valve
Like a ball valve, these valves are quarter turn valves. These boiler valves consist of a plug which can either
be in the shape of a cylinder or [Link] plug also consists of a through slit which remains in-line with the
flow in the open condition.
When the plug is rotated by 90 Deg., this slit becomes perpendicular to flow and valves get closed.
4) Butterfly Valve:
Butterfly Valve
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These are the most simple and versatile steam boiler valves. These are also quarter turn operated [Link]
turn operation ensures quick operating of the [Link] opening condition there is minimum hindrance to the
flowing fluid through the valves. This results in very less pressure drop across the valve.
Due to its unique mode of operation, the valve can be actuated easily without requiring wear and [Link]
advantage is its compact size which makes its installation process easy.
5) Globe Valve:
Globe Valve
Globe valve is a linear motion type of valve and is typically used in both on/off conditions globe valves, the
flow of the fluid through the valve follows an S-path.
These valves can be used in three configurations, depending upon the applications.
6) Globe Valve:
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These are also called as non return valves as they allow the flow to pass through them only in one direction
and stop the flow in another direction. Because of this unique property check valves are used in some critical
applications in steam systems.
There are four major types of disc check valves as follows:
➢ Lift Check Valve
➢ Swing Check Valve
➢ Spring Loaded Check Valves
➢ Diaphragm Type Check Valve
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Experiment no. 2
Objective:
• Water PH test Boiler
Apparatus:
• PH Meter
• Screw Driver
• Electrode
Theory:
➢ Calibration:
• Dip the tip of electrode in a sample of Ph 7.01 buffer at room temperature.
• Allow the reading to stabilize.
• Use a small screwdriver to adjust the ph 7 trimmer until the display reads 7.01.
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• Raise the electrode with water and dip it in sample of ph 4.01 or 10.01 buffer solution.
• Allow the reading to be stabilize.
• With a small screwdriver adjust pH 4/10 trimmer until the display reads the chosen buffer value.
➢ Procedure:
• Clean the tip of electrode with distilled water.
• Wipe gently with soft tissue papers.
• Immerse the electrode in sample solution.
• The instrument will display pH
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