careful study of this course can help you acquire useful knowledge of steam generation, types of

boilers pertinent to boiler operations, various fittings commonly found on boilers, and so on. The
primary objective of this chapter is to lay the foundation for you to develop skill in the operation,
maintenance, and repair of boilers. A boiler is an enclosed vessel that provides a means for combustion
and transfers heat to water until it becomes hot water or steam. The hot water or steam under
pressure is then usable for transferring the heat to a process. Water is useful and cheap medium
for transferring heat to a process. When water is boiled into steam its volume increases about 1,600
times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be
extremely dangerous equipment and should be treated carefully. Liquid when heated up to the gaseous
state this process. The heating surface is any part of the boiler; hot gases of combustion are on one side
and water on the other. Any part of the boiler metal that actually contributes to making steam is
heating

International Journal of Current Trends in Engineering & Research (IJCTER) Volume 02, Issue 04; April
– 2016 [Online ISSN 2455–1392] @IJCTER-2016, All rights Reserved 462 surface. The amount of
heating surface of a boiler is expressed in square meters. The larger the heating surface a boiler has,
the more efficient it becomes. The boiler system is made up of: 1. Feed water system 2. Steam system
3. Fuel system The feed water system provides water to the boiler and regulates it automatically to
meet the steam demand. The water supplied to boiler that is converted to steam is called feed water.
The sources of feed water are: 1. Condensate or condensed steam returned from the processes 2. Make
up water which is the raw water which must come from outside. The steam system collects and
controls the steam produced in the boiler. Steam is directed through a piping system to the point of use.
Throughout the system, steam pressure is regulated using valves and checked with steam pressure
gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat.
The equipments required in the fuel system depend on the type of fuel used in the system. Boilers are
pressure vessels designed to heat water or produce steam, which can then be used to provide space
heating and or service water heating to a building In most commercial building heating
applications, the heating source in the boiler is a natural gas fired burner. Oil fired burners and electric
resistance heaters can be used as well. Steam is preferred over hot. water in some applications,
including absorption cooling, kitchens, laundries, sterilizers, and steam driven equipment. Boilers have
several strengths that have made them a common feature of buildings. They have a long life, can
achieve efficiencies up to 95% or greater, provide an effective method of heating a building, and in
the case of steam systems, require little or no pumping energy. However, fuel costs can be
considerable, regular maintenance is required, and if maintenance is delayed repair can be costly.
Guidance for the construction, operation, and maintenance of boilers is provided primarily by the
ASME(American Society of Mechanical Engineers), which produces the following resources, Rules for
construction of heating boilers, Boiler and Pressure Vessel Code, Section IV-2007Recommended rules
for the care and operation of heating boilers , Boiler and Pressure Vessel Code, Section VII-2007 Boilers
are often one of the largest energy users in a building. For every year a boiler system goes unattended,
boiler costs can increase approximately 10% . Boiler operation and maintenance is therefore a good
place to start when looking for ways to reduce energy use and save money. The steam generator or
boiler is an integral component of a steam engine when considered as a prime mover. However it
needs be treated separately, as to some extent a variety of generator types can be combined with
a variety of engine units. A boiler incorporates a firebox or furnace in order to burn the fuel and
generate heat. The generated heat is transferred to water to make steam, the process of boiling. This
produces saturated steam at a rate which can vary according to the
pressure above the boiling water. The higher the furnace temperature, The faster the steam
production. The saturated steam thus produced can then either be used immediately to produce
power via a turbine and alternator, or else may be further superheated to a higher
temperature, this notably reduces suspended water content making a given volume of steam produce
more work and creates a greater temperature gradient, which helps reduce the potential to form
condensation. Any remaining heat in the combustion gases can then either be evacuated or made to
pass through an economizer, the role of which is to warm

International Journal of Current Trends in Engineering & Research (IJCTER) Volume 02, Issue 04; April
– 2016 [Online ISSN 2455–1392] @IJCTER-2016, All rights Reserved 463 the feed water before it
reaches the boiler. Boilers have several strengths that have made them a common feature of
buildings. They have a long life, can achieve efficiencies up to 95% or greater, provide an effective
method of heating a building, and in the case of steam systems, require little or no pumping energy.
However, fuel costs can be considerable, regular maintenance is required, and if maintenance is
delayed, repair can be costly. Guidance for the construction, operation, and maintenance of
boilers is provided primarily by the ASME (American Society of Mechanical Engineers), which
produces the following resources: Rules for construction of heating boilers, Boiler and Pressure
Vessel Code, Section IV-2007 Recommended rules for the care and operation of heating boilers,
Boiler and Pressure Vessel Code, Section VII-2007 Boilers are often one of the largest energy users in a
building. For every year a boiler system goes unattended, boiler costs can increase approximately 10%
1.2 TYPES OF PRESSING 1. Under Pressing: Pressing from the wrong side of the garment. 2. Top
Pressing: Pressing from the face side of the garment In-Process Pressing, Pressing during the
garment manufacturing process 3. Finish Pressing: Adds the final shape to seams and garments 4. Buck
Presses: Used by manufacturers of slacks, skirts, and jackets and most of the dry cleaning plants A lower
buck and a complementary moveable head with a linkage system, buck padding, steam and vacuum
systems, frame and table, gauges and manual/automatic controls for steams, vacuum, heat and
pressure May be used for in-process pressing and finish pressing. 5. Iron Pressing: Manual molding
operation with pressure and heat application with a flat contact surface Consists of an iron, power
line, bed buck, and an iron support system Irons vary in weight and plate dimensions and characteristics
depending on the type of pressing operation, fabric, area to be pressed and quality specifications of
the operation Mostly used for under-pressing and are more versatile and mobile and are most common
in our daily life. 6. Block or Die Pressing: To establish a product’s conformance to a form May change
the surface characteristics and dimensions of a product An operator positions the component over a
die and engages the machine, and folding blades fold and hold the edges to the underside for creases
to be set May also be used to mould collars, collar stands and cuffs. 7. Form Pressing:
 International Journal of Current Trends in Engineering & Research (IJCTER) Volume 02, Issue 04; April
– 2016 [Online ISSN 2455–1392] @IJCTER-2016, All rights Reserved 464 Used for final pressing or
for renovating garments in dry cleaning plants Formed in approximate shapes as the finished garment
Designed to reduce the positioning and repositioning time Just smooth garment fabric but does not set
creases. 1.3 Boiler classification: 1. Tube content: (i) Fire tube boiler and (ii) water tube boiler 2. Axis
of shell: (i) Horizontal, (ii) vertical, (iii) inclined 3. Location of furnace: (i) Externally fired, (ii) internally
fired 4. Method of circulation: (i) Natural, (ii) forced 5. Mobility: (i) Stationary, (ii) portable 6. Usage: (i)
Packaged, (ii) unpackaged 7. Pressure: (i) High, (ii) low 8. Tubes: (i) Single-tube, (ii) Multi-tube 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/cm2 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. Water Tube Boiler: A water tube boiler is such kind of boiler where
the water is heated inside tubes and the hot. 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.

International Journal of Current Trends in Engineering & Research (IJCTER) Volume 02, Issue 04; April
– 2016 [Online ISSN 2455–1392] @IJCTER-2016, All rights Reserved 465 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. II.
PROBLEM DEFINITION All combustion equipment must be operated properly to prevent dangerous
conditions or disasters from occurring, causing personal injury and property loss. The basic cause
of boiler explosions is ignition of a combustible gas that has accumulated within the boiler. This
situation could arise in a number of ways, for example fuel, air, or ignition is interrupted for some
reason, the flame extinguishes, and combustible gas accumulates and is reignited. Another example is
when a number of unsuccessful attempts at ignition occur without the appropriate purging of
accumulated combustible gas. There is a tremendous amount of stored energy within a boiler. The state
change of superheated water from a hot liquid to a vapour (steam) releases an enormous amount of
energy. For example, 1 ft 3 of water will expand to 1600 ft3when it turns to steam. Therefore, “if
you could capture all the energy released when a 30 gallon home hot water tank flashes into explosive
failure at332oF, you would have enough force to send the average car (weighing 2,500 lbs) to a height of
nearly 125 feet. This is equivalent to more than the height of a 14 story apartment building, starting with
a lift off velocity of 85 miles per hour. Boiler safety is a key objective of the National Board of Boiler and
Pressure Vessel Inspectors. This organization reports and tracks boiler safety and the number of
incidents related to boilers and pressure vessels each year. Their work has found that the number one
incident category resulting in injury was poor maintenance and operator error. This stresses the
importance of proper maintenance and operator training. Boilers must be inspected regularly
based on manufacturer’s recommendations. Pressure vessel integrity, checking of safety relief
valves, water cut off devices and proper float operation, gauges and water level indicators should all
be inspected. The boiler’s fuel and burner system requires proper inspection and maintenance to
ensure efficient operation, heat transfer and correct flame detection. The Federal Energy Management
Project (FEMP) O&M Best Practices Guide to Achieving Operation Efficiency

Volume 02, Issue 04; April – 2016 [Online ISSN 2455–1392] @IJCTER-2016, All rights Reserved 464
Used for final pressing or for renovating garments in dry cleaning plants Formed in approximate shapes
as the finished garment Designed to reduce the positioning and repositioning time Just smooth
garment fabric but does not set creases. 1.3 Boiler classification: 1. Tube content: (i) Fire tube boiler
and (ii) water tube boiler 2. Axis of shell: (i) Horizontal, (ii) vertical, (iii) inclined 3. Location of furnace:
(i) Externally fired, (ii) internally fired 4. Method of circulation: (i) Natural, (ii) forced 5. Mobility: (i)
Stationary, (ii) portable 6. Usage: (i) Packaged, (ii) unpackaged 7. Pressure: (i) High, (ii) low 8. Tubes: (i)
Single-tube, (ii) Multi-tube 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/cm2 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. Water Tube Boiler: A water tube boiler is such kind of
boiler where the water is heated inside tubes and the hot. 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.

Boiler design is the process of designing boilers used for various purposes. The main function of a boiler
is to heat water to generate steam. Steam produced in a boiler can be used for a variety of purposes
including space heating, sterilisation, drying, humidification and power generation. The temperature or
condition of steam required for these applications is different, so boiler designs vary accordingly.