Unit IV

Internal Combustion
Engines

1
 Introduction

Heat Engine:
•Heat Engine is a machine which
converts heat energy supplied to it
into mechanical work.
•Heat energy is supplied to the engine
by burning the fuel.
2
 Classification of Heat Engines
•Internal Combustion Engines (IC Engines)
In IC engines, combustion of fuel takes place
inside the engine cylinder.
Examples: Diesel Engines, Petrol Engines, Gas
engines.
•External Combustion Engines (EC Engines)
In EC engines, combustion of fuel takes place
outside the working cylinder.
Examples: Steam Engines and Steam turbines
3
 Classification of IC Engines

IC Engines are classified into,

(2) Cycle of operation (No of Strokes per cycle)
• Two Stroke cycle Engines
• Four Stroke Cycle Engines
(2) Thermodynamic Cycle or Method of Heat addition:
• Otto Cycle Engines (Combustion at constant volume)
• Diesel Cycle Engines (Combustion at constant Pressure)
• Semi Diesel Engines (Dual Combustion Engines)

4
 Classification of IC Engines

(3) Types of Fuel Used :

• Petrol Engines
• Diesel Engines
• Gas Engines
(4) Ignition Method :
• Spark Ignition (SI)
• Compression Ignition (CI)
5
 Classification of IC Engines

(5) Cooling System:

•Air cooled Engines
•Water Cooled Engines
(6) Valves Location :
•L head (Side valve) engine
•T Head (Side valve) engine
• I head (over head valve) engine
•F head (over head inlet and side exhaust) engine

6
 Main Components of IC Engines

Cylinder Block:
•It is the main block of the engine.
•It contains cylinders accurately finished to
accommodate pistons
•The cylinder block houses crank, camshaft, piston and
other engine parts.
•In water cooled engines, the cylinder block is provided
with water jackets for the circulating cooling water.
•The materials used for cylinder are grey cast iron,
aluminium alloys etc.,
•It is usually made of a single casting
7
Main Components of IC Engines

Cylinder block of motor Cylinder block of

cycle Car

8
 Main Components of IC Engines

Cylinder Head:
•The cylinder head is bolted to the cylinder
Block by means of studs.
•The water jackets are provided for cooling
water circulation.
•The materials used for cylinder head are cast iron,
aluminium alloy etc.,
•This is also generally made of single cast iron.

9
 Main Components of IC Engines

Cylinder Liners:
The liner is a sleeve which is fitted into the
cylinder bore.
It provides wear resisting surface for the
cylinder bores.
Liners are classified into
(a) Wet liner (b) Dry liner

10
 Main Components of IC Engines

Cylinder Liners
Wet Liner : These liners are surrounded or wetted by cooling
water.
It provides wear resisting
surface for the piston to reciprocate.
Also it acts as a seal for the water jacket.

11
 Main Components of IC Engines

Dry Liner :Dry liners have metal to metal contact

with the cylinder block. They are not directly in
touch with the cooling water.
Liner Materials:
•Liner material should withstand abrasive
wear and corrosive.
•Chromium plated mild steel
•tubes are used as liners.

12
 Main Components of IC Engines

Crankcase :
It may be cast integral with the cylinder
block.
Some times, it is cast separately
and then attached to the block.
These materials are used for crank case are cast iron,
aluminium alloys or alloy steels.
13
 Main Components of IC Engines

Oil pan or oil sump:

Oil sump is the bottom
part of the engine.
It contains lubricating oil.
A drain plug is provided the
oil sump to drain out the oil.
It is made of the pressed sheet.

14
 Main Components of IC Engines

Piston :
The piston serves the following purposes
• It acts as a movable gas tight seal
to keep the gases inside the cylinder
•It transmits the force of explosion
in the cylinder to the crankshaft
through the connecting rod.
•Some of the materials used for
piston are cast iron, aluminium alloy,
chrome nickel alloy, nickel iron alloy and cast steel.
15
 Main Components of IC Engines

Piston rings :
Piston rings are inserted in the grooves
provided in the piston. Two types of piston
rings are used in the piston.
3. Compression rings
4. Oil rings or oil control rings.

16
 Main Components of IC Engines
Piston Rings (Compression and Oil
rings)

17
 Main Components of IC Engines

Compression rings :
• Compression rings provide an effective
seal for the high pressure gases
inside the cylinder.
• They prevent the leakage of high
pressure gases from the combustion
chamber into the crank case.
• Each piston is provided with atleast
• two compression rings.
18
 Main Components of IC Engines

Oil rings :
• Oil rings wipe off the excess oil from the cylinder
walls.
• It also returns excess oil to the oil sump, through the
slots provided in the rings.
The materials used for piston rings should be wear
resistant.
Normally piston rings are made of alloy steel iron
containing silicon, manganese alloy steels etc.,
19
 Main Components of IC Engines
Connecting Rod:
• It connects the piston and crank shaft.
• It transmits the force of explosion during power stroke to the
crankshaft.
• The connecting rod has bearings at both ends.
• The small end of the connecting has a solid or split eye and contains a
bush.
• This end is connected to the piston by means of a gudgeon pin.
• The other end is called as big end of the connecting rod.
• The connecting rods must withstand heavy thrusts.
• Hence it must have strength and rigidity.
• They are usually drop forged I sections.
• The materials used are plain carbon steel, aluminium alloys, nickel
alloy steels etc,

20
 Main Components of IC Engines
Crank Shaft :
• It is the main rotating shaft of the engine.
• Power is obtained from the crank shaft.
• The crank shaft is combination with connecting rod
converts reciprocating motion of the piston into rotary
motion.
• The crank shaft is held in position by the main bearings.
• There are two main bearings to support the crank shaft.
• The materials used for crank shaft are billet steel, carbon
steel, nickel chrome and other heat treated alloy steels.

21
 Main Components of IC Engines
Camshaft:
• Camshaft contains number of cams.
• It is used to convert rotary motion into linear or straight
line motion.
• It has so many cams as the number of valves in an engine.
• An additional cam is also provided to drive the fuel pump.
• A gear is provided in the cam shaft to drive the distributor
or oil pump.
• The opening and closing of the engine valves are
controlled by the cams provided on the cam shaft.

22
 Petrol Engines

Classification of Petrol Engines

•Two Stroke cycle Petrol Engines

•Four Stroke cycle petrol Engines

23
Two Stroke cycle Petrol
Engines

24
 Two Stroke cycle Petrol
Engines
Working

25
 Two Stroke Cycle Petrol Engine -
Construction
Construction :
•A piston reciprocates inside the cylinder
•It is connected to the crankshaft by means of connecting
rod and crank
•There are no valves in two stroke engines, instead of
valves ports are cut on the cylinder walls.
•There are three ports, namely inlet, exhaust and
transfer ports.
•The closing and opening of the ports are obtained by the
movement of piston. The crown of piston is made in to a
shape to perform this.
•A spark plug is also provided.
26
Two stroke cycle Petrol Engines - Working
First Stroke : (Compression, ignition and inductance) (Upward
stroke of piston)
(b) compression:
• The piston moves up from Bottom Dead Centre (BDC)
to Top Dead Centre (TDC)
• Both transfer and exhaust ports are covered
by the piston.
• Air fuel mixture which is transferred
already into the engine cylinder is compressed
by moving piston.
• The pressure and temperature increases
• at the end of compression. 27
 Two stroke cycle Petrol Engines -
Working
First Stroke : (Compression, ignition and inductance)
(Upward stroke of piston)
(b) Ignition and Inductance:
• Piston almost reaches the top dead centre
•The air fuel mixture inside the cylinder is ignited by means of an
electric spark produced by a
spark plug
•At the same time, the inlet port is
uncovered by the plane.
•Fresh air fuel mixture enters the
crankcase through the inlet port. 28
 Two stroke cycle Petrol Engines -
Working
Second Stroke: (Downward Stroke of the engine) :
(c)Expansion and Crankcase compression
•The burning gases expand in the cylinder
•The burning gases force the piston to move down. Thus
useful work is obtained.
•When the piston moves down, the
air fuel mixture in the crankcase
is partially compressed.
This compression is known as
Crank case compression. 29
 Two stroke cycle Petrol Engines -
Working
Second Stroke: (Downward Stroke of the engine) :
(d) Exhaust and transfer:
•At the end of expansion, exhaust port is uncovered.
•Burnt gases escape to the atmosphere.
•Transfer port is also opened. The partially compressed air fuel
mixture enters the cylinder through the transfer port.
•The crown of the piston is made of a
deflected shape. So the fresh charge
entering the cylinder is deflected
upwards in the cylinder.
•Thus the escape of fresh charge
along with the exhaust gases is reduced.
30
 Two stroke cycle Diesel Engines-
Construction
Construction :
• Two stroke cycle diesel engines require air supply
•This air is used to blow out the exhaust gases and to
fill the cylinder with clean air
•This air is supplied by a blower or air compressor
which is driven by engine itself.
•These engines may be valve or port type.
•A plate is provided in the crank case to admit air into
the crank case.
•Transfer and exhaust ports are provided in the
cylinder.
•These ports are covered and uncovered by the moving
piston. 31
 Two stroke cycle Diesel Engines-
Working

First Stroke (Upward Stroke of the piston)

(b) Compression and inductance:
• The piston moves upwards from Bottom Dead
Centre (BDC) to Top Dead Centre (TDC).
• Both transfer and exhaust ports are covered.
• Air which is transferred already into the engine
cylinder is compressed by moving piston.
• The pressure and temperature of the air increases.
• At the same time, fresh air is admitted into the
crankcase through the plate valve (reed valve)
32
 Two stroke cycle Diesel Engines-
Working

First Stroke (Upward Stroke of the piston)

(b) Ignition and inductance.
• Piston almost reaches the top dead centre.
• The fuel is injected into the hot compressed air
inside the cylinder. The fuel mixed with hot air and
burns.
• The admission of fresh air into the crankcase
continues till the piston reaches the top centre.

33
 Two stroke cycle Diesel Engines-
Working

Second Stroke (Downward Stroke of the piston)

(c) Expansion and crank case compression:
•The burning gases expand in the cylinder.
•Burning gases force the piston to move down. Thus
useful work is obtained.
•At the same time, the air in the crank case is
compressed by the movement of the piston.
•All the ports and the plate valve are in closed position

34
 Two stroke cycle Diesel Engines-
Working
Second Stroke (Downward Stroke of the piston)
(d) Exhaust and Transfer:
• At the end of expansion, the exhaust port is uncovered.
•The burnt escape to the atmosphere through the exhaust port.
•Transfer port is also uncovered shortly after the exhaust port is
opened.
•The partially compressed air from crank case enters the
cylinder the transfer port.
•This air is deflected upwards by the deflected shape of the
piston.
•Thus the entering air helps in forcing out the combustion
products from the cylinder
•The plate valve remains during this period.
35
 Four stroke cycle Petrol Engines

Construction :
•A piston reciprocates inside the cylinder
•The piston is connected to the crank shaft
by means of a connecting rod and crank.
• The inlet and exhaust valves are
Mounted on the cylinder head.
•A spark is provided on the cylinder
Head.
• The fuel used is petrol
36
Four Stroke Petrol Engine- Working

37
Four Stroke Petrol Engine - Working
(a) Suction Stroke (First Stroke of the Engine)
• Piston moves down from TDC to BDC
• Inlet valve is opened and the
exhaust valve is closed.
• Pressure inside the cylinder is
reduced below the atmospheric
pressure.
• The mixture of air fuel is
sucked into the cylinder through
the inlet valve 38
Four Stroke Petrol Engine - Working
(b) Compression Stroke : (Second Stroke of the
piston)
• Piston moves up from BDC to
TDC
• Both inlet and exhaust valves
are closed.
• The air fuel mixture in the
cylinder is compressed.

39
Four Stroke Petrol Engine - Working
(c) Working or Power or Expansion Stroke: (Third
Stroke of the Engine)
• The burning gases expand rapidly. They exert
an impulse (thrust or force) on the piston.
The piston is pushed from TDC to BDC
• This movement of the piston is
converted into rotary motion of the
crankshaft through connecting rod.
• Both inlet and exhaust valves are
closed. 40
Four Stroke Petrol Engine - Working
(d) Exhaust Stroke (Fourth stroke of the piston)
• Piston moves upward from BDC
• Exhaust valve is opened and the inlet valve is closed.
• The burnt gases are forced out to the atmosphere
through the exhaust valve (Some of the burnt gases
stay in the clearance volume of the cylinder)
• The exhaust valve closes shortly after TDC
• The inlet valve opens slightly before TDC
and the cylinder is ready to receive fresh charge to
start a new cycle.
41
Four Stroke Petrol Engine - Working
Summary :

• Compression ratio varies from 5 to 8

• The pressure at the end of compression is
about 6 to 12 bar.
• The temperature at the end of the
compression reaches 250o C to 350o C

42
Four Stroke Diesel Engine

43
 Four Stroke Diesel Engine

Construction:
•A piston reciprocates inside the cylinder
•The piston is connected to the crankshaft by
means of a connecting rod and crank.
• The inlet and exhaust valves are mounted on the
cylinder head.
•A fuel injector is provided on the cylinder head
•The fuel used is diesel.
44
 Four Stroke Diesel Engine - Working

(a) Suction Stroke (First Stroke of the piston)

• Piston moves from TDC to BDC
• Inlet valve is opened and the exhaust valve is
closed.
• The pressure inside the cylinder is reduced below
the atmospheric pressure.
• Fresh air from the atmosphere is sucked into the
engine cylinder through air cleaner and inlet
valve.
45
 Four Stroke Diesel Engine - Working

(b) Compression stroke (Second stroke of the

piston)
• Piston moves from BDC to TDC
• Both inlet and exhaust valves are closed.
• The air is drawn during suction stroke is
compressed to a high pressure and temperature

46
 Four Stroke Diesel Engine - Working

(c) Working or power or expansion stroke (Third

stroke of the piston)
• The burning gases (products of combustion)
expand rapidly.
• The burning gases push the piston move
downward from TDC to BDC
• This movement of piston is converted into rotary
motion of the crank shaft through connecting rod.
• Both inlet and exhaust valves are closed.
47
 Four Stroke Diesel Engine - Working

(d) Exhaust Stroke (Fourth stroke of the piston)

• Piston moves from BDC to TDC
• Exhaust valve is opened the inlet valve is closed.
• The burnt gases are forced out to the atmosphere
through the exhaust valve. (some of the burnt
gases stay in the clearance volume of the
cylinder)
• The exhaust valve closes shortly after TDC
• The inlet valve opens slightly before TDC and the
cylinder is ready to receive fresh air to start a new
48
cycle.
 Scavenging

Scavenging :
•It is the process of forcing out the burnt
exhaust gases from the cylinder for admitting
the fresh charge into the cylinder.
•This action takes place in the two stroke
cylinder.

49
 Scavenging Process
• The charge (air fuel mixture or air) enters the engine cylinder
from the crank case at a pressure higher than the exhaust gases.
• This fresh charge forces the exhaust gases to the atmosphere
through the exhaust port.
• During the period both the transfer and exhaust ports are kept
open for a short period.
• Hence there is a possibility of the fresh charge escaping out with
the burnt gases.
• This is over come by designing the piston to have a deflected
shape.
• This shape of piston deflects the fresh charge upward in the
engine cylinder.
•It also helps out in forcing out the exhaust gases to atmosphere.
50
•This process is known as Scavenging.
Comparison between SI and CI Engines
(General Comparison)
S.No Spark Ignition Compression Ignition
. Engines (SI) Engines (CI)
1 It draws air fuel mixture It draws only air into the
into the cylinder during cylinder during suction stroke.
suction stroke
2 Petrol engines operate Diesel engines operate with
with low pressure and high pressure and temperature
temperature
3. Pressure ranges from 6 Pressure ranges from 35 to 40
to 12 bar bar
Temperature ranges Temperature ranges from 600o
from 250o to 300o C to 700o C 51
Comparison between SI and CI Engines
(General Comparison)
S.No Spark Ignition Compression Ignition
. Engines (SI) Engines (CI)
4 It is fitted with It is fitted with fuel injection
carburettor and spark pump and injectors
plugs
5 The burning of fuel The burning of fuel takes place
takes place at constant at constant pressure
volume
6. Ignition of air fuel Ignition of air fuel takes placed
mixture takes place by by a injection of fuel into the
an electric spark hot compressed air.
produced by spark plug
52
 Comparison between SI and CI Engines
(General Comparison)
S.No. Spark Ignition Compression Ignition
Engines (SI) Engines (CI)
7 Petrol engines are quality Diesel engines are quantity
governed engines. The governed engines. The speed of
speed of petrol engines diesel engines are controlled by
are controlled by varying varying quality of air fuel
the quantity of air fuel mixture. (rich or weak mixture)
mixture.
8 Petrol engines are widely Diesel engines are widely used
used in automobiles and in heavy vehicles, such as buses,
aeroplanes etc., lorries, trucks etc.,

53
 Comparison between SI and CI Engines
(Merits and Demerits)
S.No. Spark Ignition Compression Ignition
Engines (SI) Engines (CI)
1 Merits: Otto cycle is Demerits: Diesel engines works
employed in petrol on diesel cycle. Diesel cycle is
engine. Otto cycle is less efficient than Otto cycle for
more efficient for a a given compression ratio.
given compression ratio.
2 Operating speed is more. Operating speed is less. Speed
Speed range is 3000 to range is 400 to 3500 rpm.
6000 rpm
3. Starting is easy, since Starting is difficult since more
cranking effort required cranking effort is required.
is less 54
 Comparison between SI and CI Engines
(Merits and Demerits)
S.No. Spark Ignition Compression Ignition
Engines (SI) Engines (CI)
4 Merits: Initial cost and Demerits: More initial and
maintenance cost are less maintenance costs since the
construction is heavy and sturdy.
5 Produces less noise. Produces more noise.

6 Weight per unit power is Weight per unit power is more.

less

55
 Comparison between SI and CI Engines
(Merits and Demerits)
S.No. Spark Ignition Compression Ignition
Engines (SI) Engines (CI)
4 Demerits: Thermal Merits: Thermal efficiency is
efficiency is less, since high since compression ratio is
compression ratio is high. 12 to 18.
limited. 5 – 8
5 Specific fuel Specific fuel consumption is less
consumption is more.

6 The fuel used is petrol. It The fuel used is diesel. It is

is costlier than diesel. It cheaper than petrol. It is less
is volatile and fire hazard volatile and fire hazard is less.
is more 56
Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No. Two Stroke Cycle Four Stroke Cycle Engine
Engine
1 Merits: One power Demerits: One power stroke in
stroke in one revolution two revolutions of the crank
of the crankshaft shaft
2 Power developed for the Power developed for the same
same engine speed engine speed is theoretically half
theoretically twice that that of two stroke engine.
of a four stroke engine
3 Simple design and For the same power complicated
lighter in construction design and heavier in
for the same power construction 57
Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No. Two Stroke Cycle Four Stroke Cycle Engine
Engine
4 Merits: Demerits:
Uniform torque is Non uniform torque on the
obtained. Hence a lighter crankshaft. Hence a heavier
fly wheel can be used flywheel is required for
5 Design of ports is balancing.
Design valve mechanism is
simpler. Hence initial cost difficult. Hence initial cost is
is less more.
6 Mechanical efficiency is Mechanical efficiency is less.
high. No moving parts Power is lost due to friction
like cam, follower, rocker caused by valve mechanism 58
arm valves etc.,
Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No. Two Stroke Cycle Four Stroke Cycle Engine
Engine
7 Merits: Starting is easy Demerits: Starting is not so easy

8 These engines are These engines are generally

generally air cooled water cooled.

59
 Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No Two Stroke Cycle Four Stroke Cycle Engine
. Engine
1 DeMerits: Merits:
Consumption of lubricating Consumption of lubricating oil is
oil is more, because less time less, because more time is allowed
is available to remove the for removing heat from the
heat cylinder.
2 More wear and tear of Less wear and tear of parts is less
moving parts.

3 Some of the fresh air fuel Fuel cannot escape with exhaust
mixture may escape with gases. Hence fuel consumption is
exhaust gases. Hence fuel less. 60
consumption is more
Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No Two Stroke Cycle Four Stroke Cycle Engine
. Engine
4 DeMerits: Merits:
Thermal efficiency is less. Thermal efficiency is more.

5 It produces more noise due to Noise is less is less. Exhaust gases

sudden release of exhaust are released in separate stroke.
gases
6 Scavenging is poor, since Scavenging is better, since there is
exhaust port is open only for a separate exhaust stroke for the
a short time removal of exhaust gases
61
Comparison between Four stroke cycle and two
stroke cycle engine
(Merits and Demerits)
S.No. Two Stroke Cycle Four Stroke Cycle Engine
Engine
7 Merits: Demerits:
Poor scavenging leads to Better performance and
mixing of fresh charge efficiency is more
with exhaust gases. This
results in poor
performance, slow
running
8 Used in light vehicles, Used in heavy vehicles, like
like bikes, scooters, buses, lorries, trucks etc.,
mopeds, etc., 62
 I.C ENGINE TERMINOLGOGY
The standard terms used in I.C Engines are
1. Bore: Inside diameter of the cylinder is termed as
Bore.
2. Top Dead Center (TDC): The extreme position
reached by the piston at the top of the cylinder in
the vertical engine is called Top Dead center.
3. Bottom Dead Center (BDC): The extreme
position reached by the piston at the Bottom of the
cylinder in the vertical engine is called Bottom
Dead center.
63
 I.C ENGINE TERMINOLGOGY
4. Stroke: The nominal distance travelled by the
piston in the cylinder between the extreme
upper and lower positions of the piston (TDC
&BDC) is termed as stroke.
5. Compression ratio (r): It is the ratio of
Maximum cylinder volume to the Clearance
volume.
6. Cylinder volume (v): It is the sum of swept
volume and the Clearance volume.
V = Vs + Vc
64
 I.C ENGINE TERMINOLGOGY

7. Swept volume (Vs): It is the volume of

space generated by the movement of piston
from one dead center to another dead center.
8. Clearance Volume( Vc): It is the space in
the cylinder, when the piston is at Top Dead
Center

65
 Major parts of an IC engine

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

66
 Major parts of an IC engine

2. Cylinder head
It is fitted to the top of the cylinder. It has inlet and
outlet values, spark plug, Fuel injector, Water jackets.
Material: C.I, Aluminium
3. 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.
Material: C.I, Aluminium alloy, Cast steel

67
 Major parts of an IC engine
4. Piston rings: Piston rings are inserted in the grooves
of piston. There are two types of rings.
1) Oil ring ( One ring is used)
2) Compression ring( Two ring is used)
5. 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

68
 Major parts of an IC engine

6. Crank shaft: 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: Alloys steel.
7. Camshaft: It operates the opening and closing of the engine
values. It has number of cams which are driven by crank
shaft through timing gears. The function of the cam is to
convert the rotary motion into the linear reciprocating
motion
Material: Alloys steel

69
 Major parts of an IC engine

8. 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 pump for the
lubricating oil.
Material: Aluminium alloy, Cast iron
9. Flywheel: It is a big wheel attached with
crankshaft. It maintains the speed of the
engine.

70
 Major parts of an IC engine

10. Valves: The function of the value is to

admit the fresh charge in the cylinder and to
send the exhaust gases out. There are two
values namely inlet value and outlet value.
Material: Inlet value: Nickel chrome.
Outlet value: Nickel chrome,
Stainless steel etc

71
 Major parts of an IC engine

11. Water Jackets: Water jackets are

provided in the cylinder head. The purpose
of water jackets is to keep the walls of the
engine cool.

72
 Steam Boilers

• Generates steam by transferring heat by

burning of fuel to water.
•Energy released by burning fuel (solid,
liquid or gaseous) is transferred to the
water in the boiler.

73
 Classification of boilers

The steam boilers are classified as

• According to flow of water and hot
gases.
4. Fire Tube Boilers
5. Water Tube Boilers

74
 Classification of boilers

• According to the method of firing.

2. Internally fired boilers
3. Externally fired boilers
• According to the Pressure developed
5. Low pressure boilers
6. High pressure boilers
75
 According to flow of water and hot gases

In fire tube boilers,

• The hot gases pass through the tubes
surrounded by water.
•The water is get heated up and converted
into steam
•The exhaust gases are sent to atmosphere
through chimney.
E.g Locomotive boiler, Lancashire boiler.
76
Fire Tube & Water Tube Boilers

77
 According to flow of water and hot gases

In water tube boilers,

• Water is circulated through number of tubes
and the hot flue gases flow over these tubes.
• A number of tubes are connected with boiler
drum through headers.
• The hot gases flow over these tubes many times
before escaping through the stack.
• The water is converted into steam and steam
occupies steam space.
E.g. Babcock & Wilcox, stirling, BHEL boiler,
Velox, Lamont, Lo-effler boilers.
78
 According to the method of firing

In internally fired boilers,

• The furnace grate is provided inside the
boiler shell.
(E.g Lancashire, Locomotive boilers)
In externally fired boilers,
• The furnace grate is provided outside or
built under the boiler shell.

79
Internally Fired Boiler

80
Externally Fired Boiler

81
 According to the Pressure Developed

In Low Pressure Boilers,

Steam is produced at a pressure lower than
80 bar.
(E.g. Cochran, Lancashire, Locomotive)
In High Pressure Boilers,
Steam is produced at a pressure more than
80 bar.
(E.g. Lamont, Velox, Benson, Lo-effler
boiler)
82
Cochran Boiler

83
 Cochran Boiler

• Coal is fed into the grate through the fire hole and burnt.
• Ash formed during the burning is collected in the ash pit
provided just below the grate.
• Ash is then removed manually.
• The hot gases from the grate pass through the combustion
chamber to the horizontal fire tubes and transfer the heat by
convection.
• The flue gases coming out of fire tubes pass through the
smoke box and escape to the atmosphere through the
chimney.
• Smoke box is provided with a door for cleaning the fire
tubes and smoke box.
• The working pressure and steam capacity of cochran
boiler are 6.5 bar and 3500 kg /hr respectively. 84
Lamont Boiler

85
 Lamont Boiler

• It is a water tube, forced circulation and

externally fired high pressure boiler.
• The capacity of the plant is 50 tonnes/hr
• Pressure of the steam generated is 170
bar.
• Temperature of the steam produced is
500o C
86
 Lamont Boiler
Working:
• Feed water is pumped to the boiler by the feed pump through
the economiser.
• Economiser preheats the feed water by using hot gases leaving
the boiler.
• The circulating pump circulates the water from the drum under
high pressure to prevent the tubes from being overheated
•Water is evaporated into steam when passing through these tubes.
• The water and steam from the tube enters the boiler drum where
the steam is separator.
• This steam is passed through a convection superheater and the
steam is superheated by the flue gases.
• This super heated steam is supplied to the prime mover through
steam outlet. 87
 Lamont Boiler
Working:
• The water level in the drum is kept constant by
pumping the feed water into the boiler drum.
• The air is preheated by the flue gases before entering
the combustion chamber to aid the combustion of the
fuel.
• This type of boiler has a working pressure of 170 bar.
• They can produce the steam at the rate of 45000 kg per
hour.

88
 Boiler Mountings & Accessories

Boiler Mountings:
• Boiler mountings are primarily intended for
the safety of the boiler and for complete
control of steam generation process.
Boiler Accessories :
• Boiler accessories are installed to increase
the efficiency of the boiler plants to help in
proper working of boiler unit.
89
 Boiler Mountings

Boiler Mountings:
• Dead weight safety valve.
• Spring loaded safety valve
• Fusible plug
• Pressure gauge

90
Dead Weight Safety Valve

91
 Dead Weight Safety Valve

• Weights are placed sufficiently in the weight

carrier.
• The total load on the valve includes the weight
of the carrier, the weight of the cover, the weight
of the discs and the weight of the valve itself.
• When the steam pressure exceeds the normal
limit, the valve along with the weight carrier is
lifted off its seat.
• Thus the steam escapes through the discharge
pipe.
92
Spring Loaded Safety Valve

93
 Spring Loaded Safety Valve

• The steam pressure acts below the valves.

• When the steam pressure is normal the valves
are held in their seats tightly by the spring force.
• When the steam pressure in the boiler exceeds
the working pressure, both valves are lifted off
their seats.
• Thus the steam from the boiler escapes the
boiler and steam pressure is reduced.
• The blow off pressure is adjusted by loosening
or screwing the nut. 94
Fusible Plug

95
 Fusible Plug

• Under normal working conditions, the fusible plug is

completely covered with water.
• Hence the temperature of the plug is not increased
appreciably during combustion process.
• When the water level falls below the safe limit the
fusible plug is uncovered from water and exposed to
steam.
• The furnace heat over heats the plug and it melts the
fusible metal and copper plug falls down.
• Due to this water steam mixture rushes into the
furnace and the fire is extinguished.
96
Bourdan Tube Pressure Gauge

97
 Bourdan Tube Pressure Gauge

• The steam pressure is applied to the

Bourdon’s tube.
• The elliptical cross section of the tube to
straighten out slightly.
• The closed end of the Bourdon tube moves.
• This movement actuates the toothed sector
and pinion rotates.
• The pointer is mounted on the pinion. Hence
the pointer moves on the graduated dial in
clockwise, to indicate the steam pressure.
98
Water Level Indicator

99
 Water Level Indicator

• To know the water level in the boiler the

handles of the steam cock and water cock are
kept in vertical positions.
• Water rushes through the bottom casting and
steam rushes through the upper casting to the
gauge glass tube.
• The level of water corresponds to the water
level in the boiler.

100
 Boiler Accessories

Boiler Accessories:
• Economiser
• Air Preheater
• Super Heater
• Steam Separator
• Steam Trap
• Feed Pump

101
Economiser

102
 Economiser

• The feed water is pumped to the bottom

header and this water is carried to the top
header number of vertical tubes.
• Hot flue gases are allowed to pass over the
external surface of the tubes.
• The feed water which flows upward in the
tubes is heated by the flue gases.
• This preheated water is supplied to the water.
• Scrappers are moved slowly moved up and
down to clean the surface of the tubes.
103
Air Preheater

104
 Air Preheater.

• Hot flue gases pass through the tubes of air

preheater after leaving the boiler or
economiser.
• Air and flue gases flow in opposite directions.
• Baffles are provided in the air preheater and
the air passes number of times over the tubes.
• Heat is absorbed by the air from the flue
gases.
• This preheated is supplied to the furnace to
aid combustion.
105
Super heater

106
 Super heater

• Steam stop valve is opened.

• The steam from the evaporator drum is passed
through the super heater tubes.
• First the steam passed through the radiant super
heater and then to the convective super heater.
• The steam is heated when it passes through these
super heaters and converted into the super heated
steam.
• This superheated steam is supplied to the turbine
through the valve.
107
Steam Separator

108
 Steam Separator

• The steam is allowed into the separator.

• The steam strikes the baffle plates and the
direction of flow is changed.
• As a result, heavier particles in steam falls
down to the bottom of the separator.
• The separated steam is free from water
particles.
• It is passed to the turbine or engine through
the outlet pipe.
109
Stream Trap

110
 Stream Trap

• The condensed water enters the steam trap by

gravity.
• When the water level in the trap rises high
enough, the ball float is lifted.
• This causes the valve to open and the water is
discharged through the outlet.
• After the discharge of water, the float moves
down.
• This causes the valve to close again.
111
 Differences between Boiler mountings and
Accessories
Sl. Boiler Mountings Boiler Accessories
No.

1 Mountings are fitted for Accessories are fitted to

the safety of the boiler. increase the efficiency

2 They form integral parts of They are not integral

the boiler part of the boiler.

3 They are usually mounted They are usually

on the boiler shell. installed outside the
boiler shell.
4 A boiler should not be A boiler can be operated
operated without without accessories.
mountings 112
Animation of Crank shaft , connecting rod and
piston

113
Animation of Four stroke diesel engine

114
 References

• Ganesan.V, “Internal Combustion Engines”,

• Ballaney.P.L, “ Thermal Engineering”,
Dhanpatrai & sons.
• R.S. Khurmi, J.K.Gupta, “ Thermal
Engineering”, S.Chand & Co.,
• P.K. Nag, “Basic and Applied
Thermodynamics”, Tata McGraw Hill
Publishing Co.,

115
 Prepared by
A. R. Pradeep Kumar, M.E., MISTE.,
Assistant Professor,
Dhanalakshmi College of Engineering.
[email protected]

116