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(Steam Generator)
Design
Anil Palamwar
anilpalamwar@yahoo.com
adp/my/documents/npti/AHP 12
Boiler types contd
3] Fluidised Bed --- 5-10-30-60-100-200 MW
adp/my/documents/npti/AHP 14
P.F. Steam Generator (Boiler) -Types
Single pass -Tower Design - Height
increases Erosion in 2nd pass is avoided.
Double pass more conventional most units
are this type.
Height is less so construction cost is less
also maintenance is easier.
Coal mills Location
Front - Rear - Sides.
APH - Tubular or Rotary.
NPTY BOILER DESIGN 15
Main & Auxiliary Elements of Boiler
BOILER- Furnace, Drum,Water walls, S/H, R/H,
Eco, APH, Air & Gas Cycle. Ducting,ESP,Chimney
Boiler Input :- Fuel + water + Air
Coal Handling Plant-including Railway siding.
D.M.Plant
Boiler Output:-
Flue Gas
Ash Handling Plant
Ash Dumping Pond.
NPTY BOILER DESIGN 16
BOILER DESIGN FACTORS
1. Capacity Steam Flow Tons/Hour
2. Efficiency- 70% to 92 %
3. Stoker / Pulverized / F.B.C./ C.F.B.C.
4. Steam Pressure Sub Critical /Supercritical.
5. Steam Temperature
6. Flue gas outlet temperature
7. Fuel- Coal / Oil /Bio mass / Gas
8. Fuel Properties-Ash Fusion Temperature.
9. Redundancy for RELIABILTY(S/B coal
mills/Pumps/Fans etc)
32 M.
61.4 M
198 T/H
19
Influence of FUEL & ASH
Once all other things are decided,the biggest
factor to be considered is the influence of ASH
on Boiler Design.
In India, many early units based on
American/European design could not perform at
design capacity as available coal was much
inferior.
Now the practice in to INDIANIZE the design.
R(b/a)=R(b/a) x % Sulphur
The basis for this is that part of Sulphur is
pyrites(FeS).
When heated, its residue acts as a fluxing agent.
High values of R(b/a) may cause severe slagging.
1. Furnaces
2. P.F.Burners-Types & Location
3. P.F.Milling Plant
4. Oil Burners-Types & Location
5. Arrangement of Oil Handling
Plant.
7000
6000
5000
4000
3000
2000
1000
0
20 21 22 23 24 25 26 27 28 29 30
AREA-M2 VOLUME-M3
NPTY BOILER DESIGN 39
BOILER AREA & VOLUME V/S WIDTH AND DEPTH
8000
7000
6000
5000
4000
3000
2000
1000
0
15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20
AREA-M2 VOLUME-M3
q = K*S*(t1-t2)/ L
q = U * S * (T1-T2)
Where,
U = Convection film conductance in K.Cal./ Sq.Mtr /Deg.C./Hr.
S = Heat Transfer Area in Sq.Mtrs.
(T1-T2) = Temperature difference between Hot surface and Bulk
fluid .
Here the fluid is moved by external means like fans, pumps etc.
Most of Heat Transfer in a Boiler is of this type.
Some dimensionless numbers are important in Forced Convection.
1) Reynolds Number = (density x velocity x diameter) /
absolute Viscocity.
The flow is LAMINAR when Reynolds No. is below 2000.
Above 12000 , the flow becomes turbulent.
Between 2000 to 12000, (transition zone), the degree of turbulence
will vary.
The BOUNDRY LAYER THICKNESS reduces as flow becomes
turbulent . This increases the HEAT TRANSFER.
Counter Flow
450
400
250
200
150
0
1 2 3 4 5 6 7 8 9 10 11
FLOW PATH HotGas ColdAir
250
200
150
100 Air Flow
50
0
1 2 3 4 5 6 7 8 9 10 11
FLOW-PATH
HotGas ColdAir
COAL
.
AIR
F.D. A.P.H. WIND FURNACE S/H
FAN air BOX
100
Temperature % of Design Temp.
80
60
40
20
0
10 20 30 40 50 60 70 80 90 100
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Pressure Resistance
STEAM
DRUM F
U
ECONOMISER
R
N
A
C
E
W
A
L
L
S
STEAM
DRUM F
U
ECONOMISER
R
N
A
C
E
W
A
L
L
S
ORIFICES
CIRCULATING
NPTY BOILERPUMP
DESIGN 78
To S/H
Once Through F
U
Super critical ECONOMISER
R
Boilers MIXING N
A
VESSEL
Note that the C
E
DRUM
is replaced by a W
A
Mixing Vessel L
L
(which is much S
smaller) ORIFICES
CIRCULATING PUMP
NPTY BOILER DESIGN 79
Boiling Types
Nucleate Boiling.- Tube metal temperature is slightly above the
water temperature.Bubbles formed at surface soon collapse.
When saturation temperature is reached water boils (Steam bubbles
do not collapse.)
Now the tube metal temperature is slightly above the saturation
temperature.
Film Boiling.
D.N.B. Departure from Nucleate Boiling
When heat flux is too high, the bubbles formed in nucleate boiling
combine and a film of superheated steam is formed on the inner side
of W/W tubes.
As this film is a bad thermal conductor, tube metal temperatures rise.
Overheating can occur.
NPTY BOILER DESIGN 80
Water Cooled Furnace
Modern high capacity boilers have water-cooled furnace.
Thus Furnace is designed not only for Combustion
but also for Heat Transfer.
Advantages : -
1. No refractory and its maintenance.
2. Heat absorption in W/W.s reduce furnace exit gas
temperature.Less ash / soot deposit on S/H and
convective heat transfer surfaces.
3. Higher heat loading is possible as heat transfer &
combustion is simultaneous.Hence less surface area
is required.
NPTY BOILER DESIGN 81
Furnace design aspects
1. Adequate height for Natural Circulation.
2. Size of furnace and location of burners No flame
impingement.
3. Uniform heat transfer on all furnace walls.
4. Furnace shape to ensure that gas flow Fills the furnace
and to provide maximum heat absorption.
5. Provision for ash removal.
6. Furnace to withstand static load, furnace pressure load, wind
and seismic loads.
7. Thus furnace must be well supported but must be free to
expand due to heating.
STEAM
FEED WATER
FEEDWATER BY PASS
FOR S/H TEMPERATURE
CONTROL
-
IBR
BOILER CODES
1. IBR 1950
2. ASME Section-I
3. BS 1113
4. DIN TRD 300.
TYPES OF BOILERS
1. Vertical Package- VP
2. Vertical Recovery-V2R
3. Vertical Unit 40-VU40
4. Vertical Unit 60-VU60
5. Modular Unit-MU
6. 2 Pass Single Arch
7. 2 Pass Double Arch
8. Close couple
9. Box Type
10.Tower Type
Types of Boilers.contd
1. OIL FIRED
2. OIL AND COAL FIRED
3. BLACK LIQUOR (For Paper Mills)
4. BAGGASE (Stoker Fired)
Types of Boilers.contd
1.WALL FIRING
2.CORNER TANGENTIAL FIRING
3.STOKER
Types of Boilers.contd
1.SINGLE DRUM
2.BI- DRUM
3.NO DRUM (Vertical Separator)
Types of Boilers.contd
1. NATURAL
2.1 FORCED Circulation (Pump)
2.2 CONTROLLED Circulation (+Orifice)
2.3 CC+ (Pump + Orifice + Rifled Tubing)
3. Once Through
BOILER PARAMETER:
(A) UTILITY BOILERS
1. Main Steam Flow T/Hr.
2. Main Steam Pressure Kg/Sq.cm.(g)
3. Main Steam Temperature - C
4. Reheater Flow T/Hr.
5. Reheater Pressure Kg/Sq.Cm.(g)
6. Reheater Temperature - C
PERFORMANCE PARAMETERS:
1. SIZE (Diameter)
2. SIZE (Thickness)
3. MATERIAL (Specification)
4. TRANSVERSE SPACING (ST)
5. LONGITUDINAL SPACING (SL)
6. HEATING SURFACE AREA
7. No. OF ELEMENTS
8. No. OF ASSEMBLIES
Pressure Parts ..contd
ARRANGEMENT REQUIREMENTS:
INTERFERANCE FREE ARRGT./ ROUTING OF
RISERS / PIPES / LINKS
WELD ACCESSIBILITY
TAKING CARE OF LAYOUT REQUIREMENTS (Ex.
Matching Components
TAKING CARE OF PERFORMANCE, DETAIL DESIGN &
STRESS ANALYSIS ASPECTS
DRUM AND DRUM INTERNALS:
CIRCULATION SYSTEM:
Adding chemicals.
FLOW
ROOF ELEVATION
FLOW FLOW
EXISTING ARRANGMENT
RH INLET HEADER RH OUTLET HEADERS
FLOW
ROOF ELEVATION
FLOW FLOW
RIHAND &
RAMAGUNADAM
REHEATER OUTLET
HEADER NIPPLE ARRGMT.
Divided Back pass and Horizontal Coils
Sl.
Design
No Description Material
Temp. C
.
SA 213
Tubes 413
T11
1. Roof
Header SA106 Gr
368
s C
SA210 Gr
Tubes 405
C
2. SC walls
Header SA106 Gr
368 -394
s C
Superheater System
Sl.
Design
No Description Material
Temp. C
.
Coils T11 404 - 477
LTSH Header SA106 Gr.
1.
s C 394 -452
SA335 P12
T11, T22,
Div. Coils 409 - 535
T91
2. Panelett
e Header
SA335 P12 420 - 496
s
T22, T91,
Coils 478 - 600
TP347H,
Reheater System
Sl.
Design
No Description Material
Temp. C
.
T11, T22,
Coils T91, 351 - 589
TP347H,
1. RH
Header
SA106 Gr C
s 361 - 590
SA335 P22