Basic Concept of Boiler
Basic Concept of Boiler
Basic Concept of Boiler
BOILER
BOILER
means any closed vessel exceeding 22.75 litres in capacity and is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel which is wholly or partly under pressure when the steam is shut off.
- IBR
STEAM
Steam
is the technical term for water vapor, the gaseous phase of water, which is formed when water boils
STEAM PIPE
STEAM PIPE means any pipe through which steam passes from a boiler to a prime mover or other user or both if pressure at which steam passes through such pipes exceeds 3.5 kg/cm2 above atmospheric pressure or such pipe exceeds 254 mm in internal diameter and includes in either case any connected fitting of a steam pipe. - IBR
BOILER CODES
Boiler Codes have been written by various nations in the past century to ensure safety of personnel and to avoid loss of property. Boiler codes cover the whole gamut of activities including Design, Fabrication, Testing, Construction and Operation. The various aspects of IBR Regulations are called out and consolidated against major items like drum, headers, lines & links, etc. The following codes have been used widely.
1. 2. 3. 4.
SENSIBLE HEAT
The Heat required to bring the water from 00c to
boiling point is the enthalpy or heat content of the liquid measured in Kcal/Kg. OR The sensible heat of a thermodynamic process may be calculated as the product of the body's mass (m) with its specific heat capacity (c) and the change in temperature ( T): Q=mc T
LATENT HEAT
Latent heat is the amount of energy in the form of heat
released or absorbed by a substance during a change of phase (i.e. solid, liquid, or gas), also called a phase transition
SUPERHEAT
When the steam is heated out of contact with water ,
the steam temperature increases above saturation temperature .Such a heating is known as super Heating OR In physics, superheating (sometimes referred to as boiling retardation, or boiling delay) is the phenomenon in which a liquid is heated to a temperature higher than its boiling point, without boiling
CRITICAL POINT
With the increase in pressure for steam generation , the sensible heat required increases with decrease in latent heat. At every pressure between saturated water and saturated steam a phase called wet steam exists. However at one point the water turns into steam on addition of sensible heat alone without going through the phase of wet steam . This occurs at temperature of 374oC and 224.6kg/cm2 absolute pressure. This is called critical point.
C E F
24 deg C
A -273
Entropy KJ / Kg K
Energy is an amount of work generated or used, and has units such as Joules, BTU, calories, or or watthours or kW-hours.
Power is the RATE of generating or using energy, and has units of watts, which are Joules per second. Or kW or MW (standard SI prefixes apply)
MEANING OF 1 MW POWER
If 10 bulbs of 100 Watt glows at a time in one home. It will consumes 1 kilo-watt of power. Let us assume, load of one home is 1 kilo watt 1 MW = 1000 kW = 1000 X 1000 W
kilo watt hour (1kwhr) of power. this is called as 1 unit in our electricity bills.
If 500 MW plant, when run for one full day, it will produces
500 mw = 500 mw x 24 hr = 12,000 mw hr = 12,000 x 1,000 kW- hr = 1,20,00,000 units of electricity (12 million units per day)
EFFICIENCY
Efficiency of any plant or equipment is the ratio of output to its input.
HEAT RATE
Heat rate is the ratio of heat added to steam in boiler (in Kcal) to the Electrical energy sent out (in kWh) Efficiency and Heat Rate are related terms. Lower the heat rate more efficient is
the plant.
Heat rate for thermal project is in the range of 2200 to 1950 Kcal / kW-hr
EFFICIENCY
84-92 %
TURBINE (2)
GENERATOR (3)
84-92 %
96-98 %
50-55 % 34-40 %
CRITICAL POINT
Increasing the pressure of steam will increase saturation
saturated vapour line meets, so that associated latent heat for phase conversion is zero, that point is called Critical Point.
The critical pressure & temperature for water are Pressure = 224.56 Kg / cm2 Temperature = 374.15 deg C
BOILER CLASSIFICATION
TYPES OF BOILERS
(A) BASED ON APPLICATION :
1. Utility Boilers are large capacity steam generators used purely for electrical power generation.
2. Industrial Boilers are small capacity boilers intended for use in the process industries.
Types Of Boilers.contd
(B) BASED ON CONSTRUCTION:
1. Vertical Recovery-V2R
7. Close couple
8. Box Type 9. Tower Type
Types Of Boilers.contd
Single Pass (Tower type) :
If boiler configuration is such that flue gases from furnace continue to rise upward and all subsequent heat absorbing coils are kept in this vertical passage, boiler is referred as tower type boiler.
Types Of Boilers.contd
Top Suspended Boiler:
When all heat absorbing surfaces are suspended from top structure and are free to expand downward, the boiler is referred as top suspended. Some boilers are bottom supported also. (like CFBC Boilers)
But invariably large capacity boilers are top suspended for distinctive advantage of smooth down ward expansion of pressure parts.
Types Of Boilers.contd
(C) BASED ON FUEL FIRING: 1. 2. 3. 4. 5. Oil Fired Only Coal ( Sub-Bituminous) Fired Lignite Fired (CFBC Boiler) Black Liquor (For Paper Mills) Baggase (Stoker Fired)
Types Of Boilers.contd
(D) BASED ON TYPE OF FIRING:
1. 2. 3. WALL FIRING ( Only in CFBC Boilers) CORNER TANGENTIAL FIRING STOKER
Types Of Boilers.contd
Corner Tangential Fired Boiler
When burners are located in corners of furnace wall
such that the protruded flames from them form a tangent to an imaginary circle in the center of the furnace, the furnace (boiler) is called tangential fired boiler.
210/250/270/500MW boiler is invariably of this
design. Boiler)
Types Of Boilers.contd
(E) BASED ON NO. OF DRUMS:
1. SINGLE DRUM 2. BI- DRUM 3. NO DRUM (Vertical Separator)
Types Of Boilers.contd
(F) BASED ON CIRCULATION:
1. NATURAL 2. CONTROLLED
Boiling Mechanism
Circulation refers to flow of steam and water mixture generated in water walls to drum. Steam generated forms bubbles which in any case should immediately flow and should not stick to water wall surface, which is termed as Nucleate Boiling. In case, the bubbles formed are not able to flow and sticks to water wall, thus making a film that disrupts contact with flowing water for heat transfer is termed as Film Boiling which is not desirable. Thus Deviation from Nucleate Boiling (DNB) leads to tube failures due to higher metal temperatures. Rifled tubing (Inside surface has Helical profile) avoids the deviation from Nucleate Boiling
Smooth Tubing
Rifled Tubing
Generated Q
Q ua lit y
uali ty
Al lo w ab le
30%
Elevation
Elevation
DNB Region
y Qualit e l b a Allow
10%
Gen e ra t
ed Q
DNB Region
Circulation in Boiler
The ratio of the weight of water to the weight of steam in the mixture leaving the heat absorption surfaces is called Circulation Ratio.
Controlled circulation system use of controlled circulation pump used for pressure up to 194kg/cm2 (sub critical pr.) circulation ratio > 1
Natural Circulation
At lower drum operating pressure (below 175 kg/cm2), there is a considerable difference in densities of water and steam. Drum and down comers are full of relatively cold water whereas upper portion of water walls and risers tubes are full of wet steam. The circulation in furnace, in this case, takes place due to Thermo-Siphon principle. The density difference is the driving force and this balances the frictional losses, establishes a rate of circulation. The furnace is called Natural Circulated. Thus Natural circulation is the ability of water to circulate continuously, with gravity and changes in temperature being the only driving force known as "thermal head.
Forced Circulation
Beyond 175 kg/cm2 operating pressure, the driving force due to density difference reduces considerably and unable to establish such circulation. Now circulation is assisted by providing pumps in down comer path to over come frictional losses. The amount of water, flowing in water wall tubes, is controlled by providing orifice in each tube. The boiler (furnace) is referred as Controlled Circulated. 500MW boilers need controlled circulation. Less than 500MW units are generally natural circulation type.
Diff in Density
Types Of Boilers.contd
(F) BASED ON DRAFT:
1. Forced draft 2. Induced Draft
3. Balanced Draft
Types Of Boilers.contd
Balanced Draft Furnace
When the secondary air being supplied to furnace by
Forced Draft (FD) fans to facilitate combustion and flue gases of combustion from furnace are suck out by the Induced Draft (ID) fans are adjusted in such a way that the interior pressure of furnace is maintained at slightly negative pressure (minus 10 mm of water column as compared to atmospheric pressure), the boiler is categorized as Balanced Draft furnace.
210/250/270/500 MW boiler is invariably a balanced
draft boiler
PRESSURE PARTS
(A) BASED ON CONFIGURATION :
1. HEADERS
Downcomers
There are down comers in boiler ( 6 no. in 270 MW) which
WATER WALLS
HEATING AND EVAPORATING THE FEED WATER SUPPLIED TO
MEANS OF DOWNCOMERS CONNECTED BETWEEN DRUM AND WATER WALLS LOWER HEADER.
APPROXIMATELY 50% OF THE HEAT RELEASED BY THE
walls:
When tubes are welded together using either welded metal between tubes (membrane walls) or a filler plate welded to both adjacent tubes (fin welded), the wall is called Welded Wall.
5. WATER WALL PANELS 5.1 Front 5.2 Rear 5.3 Side 5.4 Extended Side 6. WATER WALL Loose tubes (Arch, Extended Side, Hanger and screen) 7. Water wall outlet headers 8. Risers 9. Drum
Dry saturated steam exits the drum & enters into 1st stage of superheating
Via Downcomers
SH STEAM OUTLET
CRH IN DRUM
FRONT ROOF
HRH OUT
REAR ROOF
EXTENDED WW
LTSH
Economiser
WATER INLET
SH outlet headers
Transfer of Energy in SH
Super heater heats the high-pressure steam from its saturation temperature to a higher specified temperature.
Thermal Structure SH
SH Steam
Convection HT
Rise in Enthalpy of Steam
Rate of heat transfer from hot gas to cold steam is proportional to: Mean Temperature difference between Hot Gas and Cold Steam. Surface area of heat transfer Thot gas,in Tcold gas,out TSH steam,out Tcold steam,in
Platen Superheater
Flat panels of tubes located in the upper part of the furnace, where the gas temperature is high. The tubes of the platen SH receive very high radiation as well as a heavy dust burden. Mechanism of HT : High Radiation & Low convection Thermal Structure:
S1 S2
Convective super heaters are vertical type (Pendant ) or horizontal types. The Pendant SH is always arranged in the horizontal crossover duct. Pendant SH tubes are widely spaced due to high temperature of flue gas and ash is soft. Transverse pitch : S1/d > 4.5 Longitudinal pitch : S2/d > 3.5 The outside tube diameter : 32 51 mm Tube thickness : 3 7 mm
S1 S2
76
Reheater
The pressure drop inside re-heater tubes has an important adverse effect on the efficiency of turbine. Pressure drop through the re-heater should be kept as low as possible. The tube diameter : 42 60mm. The design is similar to Final (Pendant) super-heater.
CRH to HRH
HRH line CRH line
Reheater vertically placed rear outlet header
DeSH
5.
SPACERS FOR SH & RH: Spacer are used to maintain pitches along and across coil assemblies. The type of spacers generally used are transverse spacers and alignment ties. Fluid Cooled Spacers or Mechanical Spacer Bar are used as transverse spacers.
Alignment Ties are used to maintain pitch between tubes in the same assembly.
Flexible Connector and Alignment Band are used as alignment ties. Flexible connectors in combination with fluid cooled spacers are used. Mechanical spacer bars in combination with alignment band are used. The spacers are all made of stainless steel.
In pendant SH or RH assemblies the tie lugs are welded in between tubes at the top row to transfer the load from centre to end terminals
Economizer
Economiser are feed-water heaters in which the heat from waste gases is recovered to raise the temperature of feedwater supplied to the boiler.
Economizer
The economizer preheats the feed water by utilizing the residual heat of the
flue gas. It reduces the exhaust gas temperature and saves the fuel. Modern power plants use steel-tube-type economizers. Design Configuration: divided into several sections : 0.6 0.8 m gap
16 April 2013
PMI Revision 00
92
Advantages of Economizer
6oC raise in feed water temperature in economizer corresponds to a 1% saving in fuel consumption.
Placed ahead of air-pre heaters in back pass. Placed below the Low Temp Super-heater. Heat Transfer in counter-flow arrangement Horizontal in-line arrangement of tubes (facilitate complete draining) Recirculation valve and Non-return valve incorporated to ensure recirculation in case of no feed-flow Ash hopper placed below, as flue gas takes a turn.
Type of Construction
Plain Tube : Several banks of tubes with either-in-line or
staggered type formation. Staggered arrangement induces more turbulence than the in-line arrangement. This gives a higher rate of heat transfer and requires less surface but at the expense of higher draught loss. Welded Fin-tube : Fin welded design is used for improving the heat transfer.
Finned Economizers
Economizer System
S. Description No.
1. Economiser Coils Headers Material SA 210 GrA1 SA 106 Gr C
Circulating System
S. Description No. 1. 2. Drum
Material
SA 299 Tubes Headers SA210 Gr C SA 299, SA106 Gr C
Water Walls
Superheater System
Sl. Description Material No. Coils T11 LTSH 1. Headers SA106 Gr. C SA335 P12 T11, T22, Coils Div. T91 2. Panel Headers SA335 P12 3. Platen (Final) T22, T91, Coils TP347H, Headers SA335 P12 SA335 P22 Temp. Range 404 - 477 394 -452 409 - 535
420 - 496
478 - 600 489 - 572
Reheater System
S. Description No. Coils 1. RH Headers Material Temp. Range
T11, T22, 351 - 589 T91, TP347H, SA106 Gr C SA335 P22 361 - 590
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