(The Boiler System)

xxxx-xx-xxxx
CODE STANDARD xx-xxxx-xx-xxxx
ISBN xxx-xxxx-xx-x

x
25xx

( )

( )


1.
2.
3.
4.
5.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

1.1
1.2
1.3
1.4
1.5
1.6

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8

1
1
1
2
3
10
13
14
14
14
17
18
27
30
37
42
43
43
43
43
43
44
47
49
52
56
57
57
57
57
59
63
70
81
82

(Insulator)
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14

6.1
6.2
6.3
6.4
6.5
6.6
6.7

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10

(Heating Value)

8.1
8.2

84
84
84
84
85
86
86
90
94
95
97
98
105
105
107
118
117
117
117
122
122
122
125
132
133
133
133
134
137
139
156
158
159
160
160
161
190
190
190

8.3
8.4
8.5
8.6
8.7

9.1
9.2
9.3
9.4
9.5
9.6

10
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11
10.12
10.13
10.14
10.15
10.16
10.17
10.18

11
11.1
11.2
11.3
11.4
11.5

12

194
207
219
229
239
240
240
240
241
246
256
261
262
262
262
263
263
263
268
268
269
274
277
279
280
281
281
285
288
289
290
291
291
291
291
292
303
304
310

12.1
12.2
12.3
12.4
12.5
12.6
12.7

310
310
311
311
312
312
318

319
319
321

1.1

1.1.1 American Society of Mechanical Engineers (ASME) Standard Boiler and Pressure Vessel Code, 2007
1.1.2 Technical Rules for Steam Boilers (TRD) (German Standard)
1.1.3 British Standards Institution (BSI)
1.1.4 Standardization Administration of China (SAC) Code GB
1.1.5 International Organization for Standardization (ISO) TC 11 Boiler and Pressure Vessels
1.1.6 American Petroleum Institute (API) Standard
1.1.7 Japanese Industrial Standards (JIS) Standard
1.1.8 Department of Standard Malaysia , ISC F Standard (Malaysia Standard)
1.1.9 Bureau of Indian Standard (BIS)
1.1.10 Productivity and Stands Board (PSB) (Singapore Standard)
1.1.11 National Fire Protection Association (NFPA) 850 Recommended Practice for Fire Protection for Electric
Generating Plants and High Voltage Direct Current Converter Stations
1.1.12 Shanghai Power Equipment Research Institute, 1998
1.1.13 Approved Code of Practice for Pressure Equipment (Excluding Boiler), 1996
1.1.14 Approved Code of Practice for The Design, Safe, Operation, Maintenance and Servicing Boiler, 2001
1.1.15 Deutsche Institute fur Normung, e.v. (DIN)
1.1.16 American Society for Testing and Materials (ASTM)
1.1.17 American National Standards Institute (ANSI)

1.2


1.2.1
.. 2549
1.2.2
.. 2552
1

1.2.3 1 .. 2457
1 .. 2465
1.2.4
.. 2549
1.2.5 .. 2549
1.2.6
.. 2549
1.2.7
.. 2549
1.2.8
.. 2549
1.2.9 .. 2534
1.2.10 (.) 855-2532
1.2.11 , , 1, 2540

1.3
1.3.1

1.3.2

1.3.3 1000 kg 100 oC

1 626.94 kW
1.3.4 15.4 kg (34.5 lbm)
100 oC (212 oF) 1 9.819 kW
1.3.5 (kg/hr)
(Ton/hr)
1.3.6
1.3.7

1.3.8

1.3.9

1.3.10

1.4


(Once Through Boiler)
1.4.1

1.1

2 3


800 oC 150 200 oC
(

1.1
1.2
1 2
3
4
5
3

 17
7 8 9
10 11 12

13 14
20

15

24

23
22

16

2 Plate Front

15
21

14

Shell 1

12

13

11

4
10
20
17

19

8
9

18

1.2
16

21
19
4

 22
1.3 3

1.3 3
1.4.2
1.4 5
6

10

8 ,11 12

11

1 3

11

7
1

12
11

9
10
5

8
3

1.4
9

1.4.3
(Once Through Boiler) 1.5

50 kg/hr 4,000 kg/hr
1.6

 1.5
3

15

1
16
10

13
2

11

4
7

12

14

1.6

 1
2 3
11 5
6 4
7
7
9
16 10
15

1.4.4

2.0 MPa (Retort)
(Autoclave) (Steam Cooker)

1.7

12 20

1.7

1.4.5

1.8

1.9

1.8

1.9

1.5



1.10 3
1.1

10

 1.10 3
11

 1.1 3
1 ()
(Shell)
2 ()
(Furnace)
3
(Reverse Box)
4
(Front Plate)
5
(Back Plate)
6
(Front Reverse Plate)
7
(Rear Reverse Plate)

8-13
14
15
16
17
18-19
20

()
(Gusset Stay)

(Cover Plate)

(End Cover)

(Stay Rod)

(Lifting)

(Saddle)

(Main Steam Box)

21
22
23
24
25
26
27

(Water Box)
3
(Smoke Tube 3 rd)
2
(Smoke Tube 2 nd)

(Plate Flange (Man Hole))

(Man Hole)

(Stand)

(Plate)

12

28
29
30
31
32
33
34

(Channel)

(Level Gouge Valve)

(Plate Flange (Level Glass))

(Plate Flange (Level Control))

(Plate Flange (Water Inlet))

(Plate Flange (Safety Valve))

(Plate Flange (Electrode Control))

35
36
37
38
39
40

(Plate Flange (Surface Blow down))

(Plate Flange (Main Steam))

(Plate Flange (Man Hole))

(Plate Flange (Blow down))

(Plate Flange (Hand Hole))

(Reducing Tube)

1.6





1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
1.6.7
1.6.8

()



Spirax Sarco (Thailand) Co., Ltd

13

2.1
-

2.2
2.2.1
(Fire-tube Steam Boiler)
(Water-tube Steam Boiler) (Combination Steam Boiler)


2.2.2
2.2.2.1 2.0

1.5


2.2.2.2

14

2.2.2.3


2.2.2.4

2.2.2.5 (Boiler Capacity)

kW
kJ/s

kilo Watt
kilo Joule/second

2.2.2.6 (Evaporation Rate)

ton of steam per hour From & At 100 oC
ton/h F&A 100 oC

2.2.2.7 1
100 oC 1,000 kg
100 oC 1
2,257,000 kJ

1

2,257,000
kJ/h

1,000 kg

100 oC

15

2,257,000 kJ/h
626.94 kJ/s
626.94 kW

1,000 kg

100 oC

2.2.2.8 (Boiler Horse Power, BHP)

1 ton/h 63.898 BHP
1 ton/h

63.898 BHP
1 BHP

15.65 kg/h
2.2.2.9 (Conduction Heat Transfer)




2.2.2.10 (Convection Heat Transfer)

2.2.2.11 (Radiation Heat Transfer)

2.2.2.12 (Sensible heat)

2.2.2.13 (Latent heat)

2.2.2.14

2.2.2.15 (Circulation ratio, CR)

10 1,000 kg
10 1,000 kg
100 kg
2.2.2.16 (Furnace)

2.2.2.17 (Steam drum)

2.2.2.18 (Evaporator)

2.2.2.19 (Super heater)

16

2.2.2.20 (Economizer)

2.2.2.21 (Air pre-heater)

2.3
130

.. 1765

2
(combustion System)
(Water-Steam System)
2.3.1



(Waste heat boiler)





(Burner)


(Stoker)

(Spreader stoker) (Underfeed stoker) (Vibrating grate stoker)
(Traveling grate stoker)

17

2.3.2

2.4

2.4.1

2.1

18

 2.2
2.2 1
2


(Reverse chamber) 3
4
(Front
smoke box) 5
(Rear smoke box) 6


3
3 2
4 3

19





(Radiation
Zone) (Convection Zone)

2.3
2.3

(Water level controller)







15-50 1

20

2.4.2

2.4

2.5

21

 2.5 1
2
3
(Screen tube) 4
5 6
7 8

(Exhaust treatment unit) 9 10

(Water wall membrane)

22

 2.6
2.6


(Modulating water feed)


(Down comer pipe) (Lower header)





(Riser tube)

70 bar gauge
15-30 1 100-150 bar gauge 4-8 : 1

23


(Overflow)


2.4.3

2.7

24

 2.8
2.8 1
2
3
4
5
6

7
8
9 10

25

2.9
2.7
()

26

2.5
ASME , EN
, JIS

2.5.1 (Burner Selection)

4 ton/h F&A 100 oC 85% (Boiler back
pressure) 8 mbar

4 x 2257000/3600 =
2508 kW

2508 / 0.85
=
2950 kW
2.10 mbar
kW
BT 300 DSPN

Back pressure 8 mBar

2950 kW

2.10

27

2.5.2 (Blow-down Valve Selection)

6
(Total
dissolved solid) TDS ppm TDS
(Total suspended solid, TSS) TDS

TDS
(Blow-down rate)
TDS 6
(Blow-down rate)
2.11 TDS 300 ppm
TDS 3500 ppm
6% 1,000 kg/h 60 kg/h
60 kg/h

2.11

28

 3
(Manual blow-down)

(Intermittent blow-down valve with manual lever) 2.12

2.12
(Timing blow-down)
(Timer)

(Intermittent blow-down valve with pneumatic actuator) 2.13

2.13

29

 (Continuous blow-down)
(Conductivity probe)
TDS TDS
(Blow-down controller)
TDS (Blow-down control valve)

2.14

2.6



2.6.1
2.6.1.1 (Level sight glass / Level gauge)

1
2

30

 2.15
2.6.1.2

(On-off feed water control)

(Max)
(Min)

31

 2.16

2.17

32

 (Modulating feed water control)

2.18
2.6.1.3 (Extra low level sensor)

2.19

100 mm
100 mm

33

2.6.2
2.6.2.1

2
50 m2
1.1
1.03
(Max. allowable working pressure)

2.20

34


6,000 kg/h 10 bar gauge 2.1
DN 50 7290 kg/h 9.1-16 bar
2.1

35

2.6.2.2 (Pressure switch)

2.21
2.6.3
2.6.3.1

2.22

36

2.7
4

(Preparation Period)
(Installation Period)
(Start-up and Commissioning Period)
(Handover Period)

2.7.1 (Preparation Period)

2.7.1.1 (Engineering Data)
(Packing list and weight information)
(Plant general arrangement drawing)
(Foundation drawing)
(Shop drawing)
(Process & Instrument diagram, P&ID)
(Piping drawing)
(Erection drawing)
(Ground pressure information)
(Material specification)
(Machinery specification)
(Electrical works specification)
(Instrument works specification)
(Refractory works specification)
(Insulation works specification)
2.7.1.2 (Installation Data)

(Master plan)
(QA/QC plan)
(Material arrival status)
(Welding procedure specification, WPS)
(Bench marking and lay-out data)
(Hydrostatic pressure test procedure)
(Flushing procedure)
(Safety valve setting data)
(Instrument calibration data)

37

 (Functional test procedure)

(Commissioning guidance)
(Performance examination)
2.7.1.3 (Manpower Preparation)
(Project organization)
(Manpower schedule)
(Safety management)
(Welder qualification)
2.7.1.4 (Equipment and Tool Preparation)
(Transportation arrangement)
(Lifting crane arrangement)
(Tool preparation)
(Tool calibration)
(Personal protection equipment, PPE)
(Fire extinguisher)
(Necessary communication devices)
(Vehicle)
2.7.1.5 (Site Preparation)
(Project scheduling)
(Document control)
(Project bench marking and lay-out)
(Ground pressure inspection)
(Foundation measurement)
(Battery limit)
(Facilities and security)
(Crane and lifting gear inspection)
(Tools inspection)
(Mobilization)
2.7.2 (Installation Period)
2.7.2.1 (Erection of Component)
(Transportation of component)
(Component dress-up)
(Lifting gear set-up)
38

(Crane set-up)
(Crane positioning)
- (Scaffolding and/or temporary support)
(Erection)
(Static alignment)
(Demobilization of equipment)

2.7.2.2 (Piping Works)

(Equipment and tool preparation for piping works)
- (Scaffolding and/or temporary support)
(Material inspection)
(Pipe support and pipe rack and installation)
(Pipe line fit-up partially)
(Pipe line installation)
(Pipe line alignment inspection)
(Pipe welding)
(Welding joint inspection)
(Welding joint painting)
(Hydrostatic pressure test)
(Pipe line flushing)
- (Scaffolding and/or temporary support)
2.7.2.3 (Brick and Refractory Works)
- (Scaffolding and/or temporary support)
(Y-anchor installation)
(Brick and refractory making)
(Brick and refractory inspection)
- (Scaffolding and/or temporary support)
(Refractory curing)
(Refractory visual check)
2.7.2.4 (Insulation Works)
- (Scaffolding and/or temporary support)
(Insulation frame support fixing)
(Insulation blanket cladding)
(Insulation cover sheet cladding)
- (Scaffolding and/or temporary support)
39

2.7.2.5 (Trimming Part Installation)

(Water pump installation)
(Valve and instrument installation)
(Safety valve setting)
2.7.2.6 (Electrical Works)
(Material inspection)
(Cable tray installation)
(Control panel installation)
(Electric motor and sensor probe installation)
(Grounding installation)
(Cable wiring)
(Wiring inspection)
(Main power connect)
(Individual power test)
(Overload setting)
(Signal transmitter and receiver setting)
(Controller setting)
(Control loop test)
(Functional test)
2.7.3 (Start-up and Commissioning Period)
2.7.3.1 (Water System Examination)
(Boiler and water pipe line flushing)
(Water level controller setting)
(Water level alarm test)
(Water pump synchronized control test)
(Blow-down functional test)
2.7.3.2 (Fuel System Examination)
(Fuel controller setting)
(Fuel system functional test)
(Dry learn for fuel burning rate)
(Synchronizing control test)
2.7.3.3 (Air Feeding System Examination)
(Air fan individual test)
40

 (Synchronizing control test)

2.7.3.4 (Ash or Residual Removal System Examination)
(Ash conveyor individual test)
(Synchronizing control test)
2.7.3.5 (Start-up and Boil-out)
(Initial start-up)
(Emergency stop test)
(Boiler run-in)
(Instrument
calibration)
(Fine tune of controller)
(Boil-out)
2.7.3.6 (Boiler Commissioning)
(Fuel burning rate tune-up)
(Draft pressure tune-up)
(Water feeding rate adjusting)
(Blow-down rate adjusting)
(Steam Temperature and Pressure control
system adjusting)
(Safety valve test)
(Boiler performance data recording)
(Blow-down test)
2.7.4 (Handover Period)
2.7.4.1 (Performance Examination)
2.7.4.1.1 (Evaporation Rate Examination)
2.7.4.1.2 (Fuel consumption Rate Examination)
2.7.4.1.3 (Combustion Efficiency Examination)
2.7.4.1.4 (Boiler Efficiency Examination)
2.7.4.2 (Handover Packages)
2.7.4.2.1 (Manufacturing Report)
2.7.4.2.2 (Installation Report)
2.7.4.2.3 (Commissioning Report)
2.7.4.2.4 (Performance Examination)
41

2.7.4.2.5 (Operation Manual)

2.7.4.2.6 (Maintenance Manual)
2.7.4.2.7 (Boiler Certificate)

2.8
2.8.1 THERMODYNAMICS: An Engineering Approach, Yunus A. Cengel, Michael A. Boiles, ISBN 0-07100494-7
2.8.2 Boilers, Evaporators & Condensers, Sadik Kakac, ISBN 0-47-162170-6
2.8.3 Mekaterm Boiler Installation Guidance, Thai K. Boiler Co., Ltd.
2.8.4 , , ISBN 9-74-512572-5
2.8.5 , , ISBN 9-74-812185-2

42

3.1

3.2
3.2.1


3.2.2

3.3
ASME , BS
, EN , JIS
3.3.1 A516, SB46

3.3.2 SUS304 SUS316

3.3.3 ,

3.4




-
(Stag)
43


3.1 950 mm 1,180 mm 885
liters

3.1

3.5


121 oC 0.1 MPa
15


-



3.2
T1
a d d
e e f
ae heating time e
f cooling time a b lag phase
b c d
f
44

T1

3.2
http://pirun.ku.ac.th/~g4765306/thermal_proc/formula_method.htm .




(Come Up Time) 3.3
(TRT)

3.2 10

45

 3.3
3.4
-

(a)

(b)

(c)

3.4 (a), (b) (c)

3 15 oC


46



15 oC 60 oC

0.6 MPa 0.5 0
MPa

3.6

(Front Open) (Top Open)
(Static Vessels)
(Dynamic vessels)

3.6.1
2 3.5 -
105 110 oC -
-

3.5 --
3.6.2 (Static Retort)

3.6
(1 ) -- (3), (4)
(8) (2) (6)
47

 (10) (5)

(7)
- (Stag) (9)

2

4
7

6
8

10
6

3.6
3.6.3 (Rotary Retort)


10
2 25
60
3.7

48

 3.7
3.6.4 (Reciprocating Retort)

-

0 60 3.8

3.8

3.7

1
-
3.1

49

 3.1
1) ( (First Stop Valve))

(Shell) -

(Head Plate)
(Bottom plate) -

(Tube plate)
(Hydrostatic Test)
(Cover Plate)

(Stays)

(Bolt)

(Nut)
(Clutch)
(Radiation
Type Bars)
()

(Heating Tube)

(Casing and
Insulation)
2) (Pressure Vessel Fittings)

(Safety

Valve)

(Relief Valve)

50

2) (Pressure Vessel Fittings)

(Water relief
Pipe)

(Pressure
gauge)
(Manometer)

(Thermometer)

(Interlock)

(Liquid Level Gauge)

a)
b) (Contact Part)

c)

d) (Thin Stainless Steel Plate)

e)
(Non-Ferrous Metal)
f)
1. (Shell)
2.
g) (Lining)
h)
(Rotary Type Vessel)
i)
j) 3.6-3.8

51

 3.9

3.10

3.11
k) (Tower)
1.
2. H2S, SO2 (Head Plate)
l)

1.
2.
3. (Clamping Crutch)
4. Clamping
Radiant Arms

3.8
1.2.1, 1.2.2 1.2.6





52

/
/

/
/

.. 2505
/ ..2542 //

/
/

31

()
(

()
)

(
)
()

53

..
..

2
2.1

2.2

2.3 -

Stay

2.4

2.5
Bolt & Nut Bolt

2.6

2.7

3
3.1 (Safety Valve)

3.2

3.3
3.3.1 (Pressure Gauge)

3.3.2

3.3.3

3.3.4
4
4.1 /

54

4.2
4.3 /
4.4
4.5
5
5.1
5.2

(stay)

/ (Bolt & Nut)

)
()

55

3.9
3.9.1
.. 2549
3.9.2 http://www.acmega.co.th/thai/Knowing%20Retort%20(Thais).htm
3.9.3 http://www.batch-retort.com/autoclave-sterilizer-den-02.htm
3.9.4 http://pirun.ku.ac.th/~g4765306/thermal_proc/formula_method.htm
3.9.5 ASME Code section 2001

56

 4
(Steam Header)

4.1

4.2
4.2.1

4.2.2

4.3

4.3.1 ASME, API, ANSI , BS
, DIN , JIS
4.3.2 ASME, ASTM, API, ANSI

4.3.3
4.3.4 0.1 MPa :
50 mm

57

 4.1 ASTM 40 (Sch.40)

ASTM Schedule 40 Steel Pipe
Grade
Norminal

A-53B

Pipe

A-106B

A-53B

Size

Type : Seamless

Type : ERW

mm (in)

SE : (psi)

SE : (MPa)

SE : (psi)

SE : (MPa)

18000

124.02

15360

105.83

15 (1/2)

2222

15.31

1896

13.06

20 (3/4)

1915

13.19

1634

11.26

25 (1)

1736

11.96

1482

10.21

30 (1 1/4)

1528

10.53

1304

8.99

35 (1 1/2)

1429

9.85

1220

8.41

50 (2)

1280

8.82

1093

7.53

65 (2 1/2)

1290

8.89

1100

7.58

80 (3)

1193

8.22

1018

7.01

100 (4)

1096

7.55

935

6.44

125 (5)

1022

7.04

872

6.01

150 (6)

978

6.74

834

5.75

200 (8)

926

6.38

790

5.44

ERW (Electrical Resistance Welding)

Seamless
SE Strange Endurance
4.3.5 (Galvanized Steel Pipe)

4.3.6

4.3.7 ASME, API, ANSI 4.2

ASTM

58

 4.2 ASTM
Pipe

Weld Fitting

Screwed & Socket Fitting

Flanges

Valve

A-53

A-234 WPB

A-105

A-105

B62, A-105

API-5L

A-234 WPB

A-105

A-105

B62, A-105

A-106B

A-234 WPB

A-105

A-105

A-105

A-181 Gr.1, 2

A-216 WCB

A-182-F11

A-182-F11

A-335-P11

A-234 WP11

A-182-F11

A-217 WC6

4.4
4.4.1
4.4.1.1
15 40 m/s
4.4.1.2 25 m/s
4.4.1.3
50 100 m/s
4.4.1.4

D
v
m
s

=
=
=
=

4 m s
v

(4-1)

, m
, m/s
, kg/s
, m3/kg

4.4.1.5
(Friction Loss) 4.3

59

 4.3

4.4.1.6 30 m
4.1

60

 4.1

61

4.4.2
4.4.2.1

4.4.2.2
4.2

4.2

62

4.4.3
4.4.3.1 2

4.4.3.2 Sch.40
4.4.3.3

PD
C
2SE 2 yP

(4-2)

t
=
,mm
P
=
, MPa D
=

,mm
S
=
, MPa
E
=
= 1 ()
y
=
( A1)
C
=
( A2)

4.5
4.5.1 2 (Check Valve, Non Return
Valve) 4.3

4.3 2

4.5.2 (Gate Valve) (Globe Valve)

(Steam Header)
4.5.3 (Main Steam Valve)
4.5.4 1:100-1:250
4.4

63

 4.4 1:100-1:250 (Pocket) Condensate

4.5.5 30-50 m
4.5 4.6

(a)

(b)
4.5 (Trap Pocket)

64

 4.6

4.5.6
4.7
4.4

4.7

65

 4.4 4.7

4.5.7
Omega Loop, Expansion Loop Expansion Joint 4.8 4.9

4.8 Horseshoe or Lyre Loop

4.9 Expansion Loop

66

 Expansion Loop 4.10 4.11

Expansion from Neutral Position (mm)

4.10 Expansion Loop

4.11

67

4.5.8
4.12

4.12

4.5.9 4.3
4.4

4.13

4.5.10
4.14

68

 4.14

4.5.11
90

4.15

4.5.12
4.5

69

 4.5

4.6

4.6.1 (Orifice Plate) (Needle Valve)

4.6.1.1

4.6.1.2


(Cold start)


(Orifice Plate) (Needle valve)
4.6.1.3

70

4.6.2 (Thermostatic Group)

4.6.2.1 (Balanced Pressure Thermostatic Type)
(Thermostatic Element)

(Bellow)

(a) Balanced Pressure Steam Trap with Replaceable Capsule

(b) Operation of Balance Pressure Steam Trap Capsule

4.16

71

()

(Steam Lock)

()
(Waterhammer)
(Superheated
Steam)

()

4.6.2.2 (Liquid Expansion Thermostatic Type)

4.17

(Oil fill
element)

72

100 oC
()

(Steam lock)

()

()

73

4.6.3 (Bimetal Type)

4.18

2 2
2
2

2 2

2

4.6.3.1
(Water hammer)

4.6.3.2


74

4.6.3.3

4.6.4 (Mechanical Group)

4.6.4.1 (Free Float Type)

4.19

()

()
(Air lock)
(Automatic air vent) (Water hammer)

75

()

4.6.4.2 (Float and Lever Type)

4.20

()


()
(Air lock)
(Automatic air vent) (Water hammer)

()

76

4.6.5 (Open Top Bucket Type)

4.21

4.6.5.1

4.6.5.2
(Air lock)
(Automatic air vent)
4.6.5.3

77

4.6.6 (Inverted Bucket Type)

(a)

(c)

(b)

4.22

4.22 (a)

4.22 (b)

4.22 (c)
4.22 (b)
4.6.6.1

4.6.6.2 (Cold start)


78




( Enthapy)
4.6.6.3

4.6.7 (Thermodynamic Group)

(a)

(b)

(c)

(d)

4.23

4.23 (a)

()

4.23 (b)

79


4.23 (b)

4.23 (d)
4.6.7.1



4.6.7.2

0.25
4.6.7.3

()

4.6.8

(
)

(Automatic Air Vent) (Steam Lock Release)

4.6.8.1
4.6.8.2
4.6.8.3
4.6.8.4
4.6.8.5
4.6.8.6
4.6.8.7
4.6.8.8
4.6.8.9
80

 4.6

/
/

4.7
4.7.1 , ,
, 2549
4.7.2 American Society of Mechanical Engineers, ASME, Section , Boiler & Pressure Vessel Code, 2004
4.7.3 American Society of Mechanical Engineers, ASME, Suction , Materials, 1995.
4.7.4 Reno C. King, Piping Handbook, McGraw-Hill Book Company, Inc.,1973.
4.7.5 Spirax-Sarco, Design of fluid System: Hook-Ups, 2004

81

4.8
4.7

82

 A1 , y

A2 , C

83

5.1

5.2
5.2.1

5.2.2
(Thermal Insulator)

5.3




5.1

84

125.4

83.6
1 m2
1 oC

(kJ/m2 hr oC)
41.8

0
0

100

200

300

(oC)
5.1


60 mm 160 oC 6.3 Bar
1985.5 kJ (475 kcal/hr) 1 m

5.4

5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7

(Thermal Conductivity, k) (Thermal Resistance, R)

85

5.4.8
5.4.9
5.4.10

5.5
500 oC

5.5.1
5.5.2
5.5.3
5.5.4
5.5.5

5
Flake Insulator

Fibrous Insulation
Rock Wool, Alumina, Asbestos
Granular Insulation Calcium Silicate
Cellular Insulation
Reflective Insulation sheet Stainless Steel

5.6


5.6.1 (Glass Wool)
5.6.1.1
()
() 90%
()
() 10-48 kg/m3
56-100 kg/m3
() 4-9
150-220 mm
5.6.1.2
()
()
()
86

()
()
5.6.1.3
() 540oC
() -150oC 350oC
() 370oC
() (R) 27-32 m.K/W 25.4 mm
() (k) 0.031-0.037 W/m.K
5.6.2 (Rock Wool)
5.6.2.1
()
()
() 800oC 30
() 48-400 kg/m3
() 5-10
50-100 mm
5.6.2.2
()
() 10 ppm ASTM D-512
()
()
5.6.2.3
() 1000oC
() 100-550oC
() 100-550oC
() (k) 0.044-0.165 W/m.K

10-48 kg/m3
48-400 kg/m3
5.6.3 (Calcium Silicate)
5.6.3.1
() 650 oC
() 190-230 kg/m3
87

() 354 kN/m2
() 5.1
5.1

o
C
400
500
600

%
1.5
1.6
1.7

kN/m2
690
690
620

() (k) 5.2
5.2 (k)

o
C
50
100
150
200
250
300
350

(k)
W/m.K
0.052
0.056
0.061
0.066
0.072
0.078
0.085

650oC 1.3-1.6%
5.6.3.2
()
()
()
()
()
5.6.3.3
()

88

() 650 oC
() (k) 0.052-0.085 W/m.K
() 0.84 kJ/kg.K
5.6.4 5.3
5.3

(Asbestos)
1
2

(Rock Wool)

Diatomaceous
Earth

(Glass Wool)
1 8K-24K
2 10K-96K
3 96K

(kcal/m.hoC)

(oC)
0.053-0.056
550
0.048-0.053
350
0.055-0.065

400

400-600 0.039-0.048

250
500

0.062-0.097
0.083-0.097

300-350
0.054-0.040
0.057-0.036
0.040
0.037
0.045
650

0.053
0.065

89

 5.3 ()

Pearlite 1

(kcal/m.h oC)

(oC)
650
0.053

5.7

)
)
)
)
)

)
)

)
)
)
)

)
)

(1) (2)
5.2

90

Money per year

5.2



5.7.1

Q = , W
Tv = , oC
Ta = , oC
Ts = , oC
Tj = , oC
L = , m
L1 = , m
L2 = , m
k = , W/m.K
k1 = , W/m.K
k2 = , W/m.K
L/k = R = , m2.K/W
1/hV = , m2.K/W
hV = , W/m2.K

91


5.7.1.1

Tv Ta
Q L 1

k hV

(5-1)

5.7.1.2 2
T T
Q L vL a 1
1
2
k1 k 2 h V

(5-2)

5.7.1.3

QL 1
k1

(5-3)

Q
Ta
hV

(5-4)

Tj Tv

5.7.1.4

Ts

hV

Q
Ts

Tv

Ta

k
5.3

92

L1

L2
hV

Q
Tv

Tj
k1

Ts

Ta

k2

5.4
5.7.2

Q =
Tp = , oC
Ta = , oC
Ts = , oC
Tj = , oC
k = , W/m.K
k1 = (), W/m.K
k2 = (), W/m.K
ds = , m
dp = , m
dj = , m
h = , W/m2.K
ln = 2.303 log10
= 3.1416

5.7.2.1
Q

Tp Ta
1 d s 1
ln

2 k d p h V d s

93

(5-5)

5.7.2.2 2
Q

Tp Ta
1 d j 1
ln

2 k 1 d p 2 k 2

d 1
ln s
d j hVds

(5-6)

5.7.2.3
d
Q ln j
dp
Tj Tp
2 k 1

(5-7)

5.7.2.4

Ts

Q
Ta
d s h V

(5-8)

2 Lost of heat Insulation Cost
Total Cost Total Cost

5.8

5.8.1 Diatomaceous Earth



5.8.2 2

5.8.3

94

5.9
5.9.1
5.9.1.1

5.9.1.2

5.5

5.5

5.9.1.3
16:00 .
14:00 . 16:00
. 5.6

5.6

5.9.1.4 ()
5.9.1.5
5.7
95

 5.7

5.9.1.6
5.9.1.7
5.9.2


96

5.9.2.1
5.9.2.2
5.9.2.3

5.9.2.4

5.9.2.5

5.10
5.4

0.056-0.067 W/mK
650 oC

0.045-0.055 W/mK
650 oC

0.041-0.043 W/mK
350 oC

pH 8-12.5
Cl2 120 ppm

pH 7-9
Cl2

pH 7.5-9

10-20%

97

5.11

5.11.1
5.8 5.18

1)
2)
3)
4)

5.8 Pre-Form Pipe Covering Multiple Layer Construction

1)
2)
3)
4)
5)
6)
7)
8)

5.9 Field and Factory-Applied Nom-Metal Jacketing

98

1)
2)
3)
4)
5)
6)

5.10 Field-Applied Metal Jacketing

1)
2)
3)
4)
5)
6)
7)

5.11 Pipe Shoe on Roller Support

99

1)
2)
3)

4)
5)
6)
7)

5.12 Clevis Hanger High Density Inserts

Standard Ring Hanger

1)
2)
3)
4)
5)

5.13 Standard and Split Ring Hangers

100

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

5.14 Field or Factory Fabricated Valve/Tee Insulation System

1)
2)
3)
4)
5)
6)
7)

PVC

5.15 PVC/Glass Fiber Valve/Tee Insulation System

101

1)
2)
3)
4)
5)
6)

()

5.16 Flexible Fibrous Blanket Duct Insulation Rectangular/Indoor

Process Storage Tank

1)
2)
3)
4)

High Density

5)
6)
7)

5.17 Curved Surfaces Rigid Board Insulation

102

Process Storage Tank

1)
2)
3)
4)
5)
6)
7)

5.18 Rigid Wrap Around Insulation

5.11.2

5.19 (), (), (), (), () ()

5.11.3


5.20
(), (), () ()

103

()

()

()

()

()

()

5.19 (), (), (), (), () ()

104

()

()

()

()

5.20 (), (), () ()

5.12

5.12.1
5.12.2
5.12.3

5.13
100%

105

1. ( )
2.
3.
4.
5.
6.
7.
8.
9.
10. ( )
5.13.1

.3 .10
.3
.4
.5
.6
.7
.8

.9

.10

5.13.2
1.
1.1 120oC
1.2 2 in.
10 m.
1.3
0.4 m. 1 1.2 m. 1 2 in. 1
2 in. 1 (1.2 1) (0.4 1) 1.6 m .
1.4 .3 120 oC
2 in. 0.27 kW/m.
106

1.5 3000 hr./year

1.6
kW
hr.
0.27 (10 1.6) m . 3,000
9,396.00 kWhr. / year
m
year
2.
2.1 3 (
) 64 kg/m3
2.2 120 oC 2 in.
.5 21.00 W/m
44.28 oC
2.3
.2 1.5 in. 38 mm.
2.4 3000 hr./year
2.5
W
hr. 1 kW
21 (10 1.6) m . 3,000

730.80 kWhr. / year

m
year 1000 W

9,396.00 730.80 8,665.20 kWhr . / year

:
.8 .9 .10

5.14
5.14.1 Incropera, F.P. and DeWitt, D.P., Introduction to Heat Transfer, Third Edition, Wiley, 1996.
5.14.2 , , , 5, 2538

5.14.3 ,
, 2547
5.14.4 , ,
1, 2550

107

.1

.2

108

 .3 (kW/m)

109

 .4 (kW/m)

110

 .5 (kW/m)

111

 .6 (kW/m)

112

 .7 (kW/m)

113

 .8 (kW/m)

114

 .9 (kW/m)

115

 .10 (kW/m)

116

6.1

6.2
6.2.1
(Blow Down)


6.2.2
6.2.2.1 (pH) 7
7 7
6.2.2.2 (Hardness)
ppm
6.2.2.3 (Dissolved Oxygen)
7 ppm 35 oC

6.2.2.4 (Scale)

(Sludge)
6.2.2.5 (Alkalinity)

ppm
6.2.2.6 M-Alkalinity Methyl Orange (pH 4.8) Total
Alkalinity = M-Alkalinity + P-Alkalinity
6.2.2.7 P-Alkalinity P-Alkalinity

Phenolphthalein (pH 9.0)
117

6.2.2.8 (Total Dissolved Solid)

(Total Solid)
(Dissolved Solid)
(Suspended
Solid)
6.2.2.9 (Chloride Ion)

6.2.2.10 (Silica) 2

6.2.3

6.2.4

6.2.4.1 2

6.3
6.2.4.2 (Pitting)

6.2.4.3 (Stress Corrosion)

6.2.4.4 (Impingement Corrosion)

118

6.2.4.5 (Condensate Grooving)

6.2.4.6 (Caustic Embitterment)

6.1

1.

2. ( 7)
3.
4. ()
5.

6.

7.
8.

Hydrogen overvoltage
X0
X+a + ae 2H+ + 2eH2

119

 6.2

Magnesium alloy
Zine
Beryllium
Aluminum alloy
Cadmuim
Mild steel, Wrought Iron
Cast Iron, Flake or Ductile
Low-alloy high- strength steel
Nickel-resist,type 1&2
Naval bronze (CA 464),yellow bronze (CA268),Aluminum bronze(CA687)
Red bronze (CA230),Admiralty bronze (CA443),Manganese bronze
Tin
Copper (CA102,110),Silicon bronze (CA655)
Lead-Tin solder
Tin bronze (G&M)
Stainless steel,12-14 % chromium (AISI Type 410,416)
Nickel silver (CA732,735,745,752,764,770,794)
90/10 Copper-nickel (CA706)
80/20 Copper-nickel (CA710)
Stainless steel,16-18 % chromium (AISI Type 430)
Lead
70/30 Copper-nickel (CA715)
Nickel-aluminum bronze
Inconel alloy 600
Silver braze alloys
Nickel 200
Silver
Stainless steel,18 chomium,8 nickel (AISI Type302,304,321,347)
Monel alloys 400,K-500
Stainless steel,18 chomuim,12 nickel-molybdenum (AISI Type 316,317)
Carpenter 20 stainless steel, Incoloy alloy 825
Titanium, Hastelloy alloys C&C276,Inconel alloy 625
Graphite, graphitized cast iron

120

6.2.5

6.3

CaCO3
Ca(HCO3)2
CaSO4
MgCO3
MgSO4
SiO2
CaCl2
Mg(HCO3)2
MgCl2
NaCl
Na2CO3
Na(HCO3)2
NaOH
Na2SO4

,
,

Epsom Salt

Glaubers Salt

Electrolysis

6.2.6 (Priming) (Foaming)

6.2.7

121

6.3
(Polarization)

6.4

6.4.1
6.4.2

6.5

122

 6.4
1. STEAM BOILER
1
Boiler type

Operating pressure

bar.g

2
3
4
Combined flue and smoke-tube
boiler

>1
22

Water chemical operation

> 22 * 44

5
Quick
steam
generator
36

Saline 1)

Combined flue and

smoke-tube boiler and
quick steam generator
44

>44

Low-salt
2)

Salt-free
3)

2. BOILER FEED WATER

General requirements

colorless clear free of undissolved matter

pH value at 25 0C

pH value

>9

>9

>9

8.5 - 9.5

>9

>9

Ks8,2 p-value

mmol / l

> 0.1

> 0.1

> 0.1

> 0.1

> 0.1

Ks4,3 m - value

mmol / l

Earth alkalincs (total hardness)

Oxygen (O2)

mg / l

see legend
< 0.015

< 0.01

< 0.01

< 0.01

< 0.01

< 0.005

< 0.1

< 0.05

< 0.05

< 0.05

< 0.05

< 0.03

< 0.1

< 0.2

0.2

< 0.1

< 0.2

< 0.1

5 - 50

<5

Oxygen binding agents

see legend

Electr. conductivity at 250c (original)

ms/cm

Carbon dioxide , comnined (CO2)

mg / l

< 25

< 25

< 25

< 50

< 10

<1

Iron , total (Fe)

mg / l

< 0.05

< 0.03

< 0.03

< 0.03

Copper , total (Cu)

mg / l

< 0.01

< 0.05

< 0.005

< 0.005

Oil , grease

mg / l

<3

<1

<1

<1

<1

<1

KMnO4 Consumption as much

mg / l

< 10

< 10

< 10

< 20

<5

<3

Sillicic acid (SiO2)

mg / l

<2

< 0.05

<. 500

Only limit values for boiler water apply

123

 6.4 ()
3. BOILER WATER

in the case of quick steam generators : See reverse

General requirements

colorless , clear , free of undissolved matter

10.5 12
10-11.8
10.5-12 10.5-11.5

pH value at 250C

pH value

10.5 12

Ks (o-value)

mmol / l

1-8

1-12

0.5-6

1-8

0.5-3

0.1-1

Earth alkalines (total hardness)

mmol / l

< 0.015

< 0.01

< 0.01

< 0.01

< 0.01

< 0.01

< 0.1

< 0.05

< 0.05

< 0.05

< 0.05

< 0.05

dH

9.8-10.8

If using oxygen binding agents

Hydrazine (N2H4) or

mg / l

see legend

Sodium sulphite (Na2SO3)

mg / l

Electr. conductivity at 250c (original)

ms/cm

Phosphate (PO4)

mg / l

10-20

KMnO4 Consumption as much

mg / l

Sillicic acid (SiO2)

mg / l

10-30

10-30

10-20

10-20

30-5000 30-7500

30-5000

30-5000

30-2000

30-300

10-20

5-15

5-10

10-30

10-20

< 100

< 150

< 100

< 50

< 30

< 150

< 50

< 40

<4

ALL VALUES ARE BASED O N GERMAN STANDARD

* IN CASE BOILERS WITH SUPERHEATER ALSO LOWER OPERATING PRESSURE POSSIBLE
6.5.1

6.5.2
2
6.5.2.1

6.5.2.2
124

6.5.3

6.6

6.6.1 (Water Softener)

Ion Exchange Resin ()

(Regeneration)
Regeneration


6. 1

125

 6.1
6.6.2 (Demonetization system)
3 CATION FILTER,
ANION FILTER MIXED BED FILTER
6.6.2.1 CATION FILTER

Strong Cation Exchange Resin

Resin Resin
( Regeneration) Resin
Demineralize
Resin H+
H+
H+

(98%)

1-5% H+
H2SO4
H+ SO4 SO4
(HCL)

126

6.6.2.2 ANION FILTER

STRONG ANION EXCHANGE RESIN
CATION FILTER (NaOH)
4% OH-
OH- ANION FILTER
CATION FILTER CATION FILTER H+
H+ OH- H2O
6.6.2.3 MIXED BED
Demineralization 2
Cation Anion Resin Cation
Anion Filter
1
Cation Anion Filter

2 Anion
Resin () Cation Resin
2

6.2
127

6.6.3 Reverse Osmosis (RO) system

(Osmosis)
(Semi Permeable Membrane)


()

(Osmotic Pressure)
(Vapor Pressure)


Reverse Osmosis (RO)
RO 2
(Membrane Processes) (SemiPermeable Membrane) 3
Electro dialysis (ED), Reverse Osmosis (RO) Ultra Filtration (UF)

Electro Dialysis (ED)
Reverse Osmosis
( Hyper Filtration) Ultra Filtration (UF)
Reverse Osmosis (RO)
UF RO UF
7 RO 20-70
RO
UF
500 ED 2

ED, RO, UF

128

 6.5 Reverse Osmosis (RO) system

RO

20-70

, , ,
200 ( )

UF
ED

500

RO UF ED RO

6.3 Reverse Osmosis (RO)

6.6.4 ()

129


0.005
0.005
100 %

6.3
82 93 oC (180 200 oF) 2 1
102 oC (215 oF)

20

40

70

90
o

110

6.4
6.4

82 - 93 oC (180 - 200 oF) Cavitation Steam Shock

6.4

130

 6.5

6.6

131

6.7
6.7.1 .. , ,
, 2524
6.7.2 ,,
(-), 2525
6.7.3 PK NAG ,Power Plant Engineering Second Edition, McGraw-Hill Publishing Company Limited, 2001

132

7.1

7.2
7.2.1

7.2.2
7.2.2.1
7.2.2.2

kJ/kg kJ/m3
7.2.2.3

7.2.2.4

7.2.2.5 (Stoichiometry)

133

7.2.2.6 (Stoichiometric Mixture)

7.2.2.7 (A/F)stoi

7.2.2.8 (Equivalence Ratio;)

7.2.2.9 (Percent Theoretical Air)

(Air ratio)

7.2.2.10 (Percent Excess Air)

100
7.2.2.11

7.3


(Hydrocarbon Fuels)
3

7.3.1 (Solid Fuels)
7.3.1.1 (Natural Solid Fuels )
() (Wood) C41 H63 O27 N0.8

() (Peat)

() ( Lignite) C61 H47 O12 N0.7 S0.6
40% 60%

() (Bituminous) 4-6 %
75-90%

134

() (Anthracite Coal)
90%

7.3.1.2 (Prepared Solid Fuels)

() (Wood Charcoal)
280 oC
() (Coke)
85-90 %
() (Briquette Coal )

() (Pulverized Coal)

(Cement Kiln)
7.3.1.3

() (Paddy Husk) 13.4-14.65 MJ/kg (3,200-3,500
kcal/kg) 9-11% 18-19%

() (Sawdust) 7.5% 14.65 MJ/kg (4,630 kcal/kg)
6.2 %
() (Bagasse) 50% 9.42 MJ/kg (2,250
kcal/kg) 7.53 MJ/kg (1,800 kcal/kg)
()

()

7.3.2 (Liquid Fuels)

(Crude Oil) 3
7.3.2.1
689-1379 kPa (100-200 psi)
(Liquefied Petroleum Gas LPG)
7.3.2.2
(Distillate)
135

() 35-180 oC
() 150-275 oC
() 225-350 oC
7.3.2.3 350 oC
(Residual)
()

7.3.3 (Gas Fuels)

7.3.3.1 (Natural Gaseous Fuels)
(Gas Field Gas) (Associated
Gas) (CH4)

() (Natural Gas) -161

o
C


() (LNG : Liquefied Natural Gas)
164 oC
600

() ( CNG : Compressed Natural Gas)

1 xx kPa (3,000 psi)
140 kg/m3
() (LPG : Liquefied Petroleum Gas) (C3H8)
(C4H10)
70% 30%
0.51-0.55 kg/liter
() (NGL = Natural Gasoline Liquid)
(C5H12)

(Solvent)

136

7.3.4 (Prepared Gaseous Fuels)

7.3.4.1 (Bio-Gas)
Anaerobic Digestion
55% 45%
3 7.1
7.1 3

-
-

7.4 (Heating Value)

kJ/kg kJ/m3
(HHV) (LHV)


137

LHV
LHV

=
=

HHV - m w h fg
HHV 9m H2 h fg

(7-1)
(7-2)

m w 1

1 kg
%C, %H, %O, %N, %S %)
9 (H2O/H2)
h fg

(C, H, O S) HHV
(Dulongs equation) MJ/kg
m H2

HHV

33.917C + 143( H O ) + 9.094S

8

(7-3)

3 7.2-7.4
.2 .6

7.2 (HHV)

(MJ/kg)

(brown coal)

18
21
29
29

(metal compound)

138

 7.3 (HHV)

..

(MJ/kg)

0.74
0.79
0.84
0.90
0.98
0.79

46.5
46.4
45.7
44.5
42.9
27.2

7.4 (HHV)

(CH4)

LPG

(C3H6)
(C4H10)
H2

MJ/m3
MJ/kg
37.5
49.3
94

50

12.2

144

7.5




(SOX) (NOX) 7.1

NOX

139

(C)
(S)

(H2)
(N2)

(CO2)
(H2O)
(CO)

1.
2.
3.

(O2)
(N2)

(NO)
(NO2 )
(SO2)

7.1
(CH4)



7.2

CH4 + 2O2
Reactants

(Heat)

(Products)

(Reactants)
=>
=>

CO2 + 2H2O
Products

+
+

Energy
Heat

7.2



140




7.5



7.6
.1
7.5

A
C
C
C
C

1
(St)

0.12-0.17
0.12-0.20
0.20-0.40
0.30-0.60

1 (C)

105-120
100-120
80-100
70-90

1 : Esso
7.5.1

7.3

7.4

141

 7.6

142

 7.3

7.4

7.5
100%

7.5

143

100%
( > 100%)

7.5.2 (Burner)

()
()

()

7.5.2.1 2 7.6
1. pre-mix burner

2. nozzle mix burner

144

 7.6 ) )
7.5.2.2 3
7.7 7.7

1. (Twin-Fluid Atomizer)

1.1) (Low Pressure Burner)

1.08 25-40%

145

1.2) (Medium Pressure Burner)

1.25-2.0
3-5%

1.3) (High Pressure Burner)

2.00-4.45

2. (Pressure Atomizer)
(Oil Pressure Burner)

(70-300 PSI) 50-120
sec Redwood No.1 (
)
Swirl Chamber
(Rotational velocity)

146

)
7.7 ) ) )

3. (Rotary Cup Burner)

1. Filming
147

2. Disintegration (Oil film)

7.7
/

1.5 180
10 5,000
(L/h)
/
/

0.1 1
0.2 9.0
(barg)
0.4 2.0
2 10
(barg)

50 10,000

10 300

14 18
-

0.5 10
13

7.5.2.3
3
1. (on off control)

2. (step control)
2 3
3. (modulating control)

3
7.8

148

 7.8 ) - ) )

.
7.5.2.4

3 7.9

1. (grate stoker)

2.
50

3.

149

 7.9 ) ) )
7.5.2.5





(Burner tile)


7.8
7.8

150

1.2
O2
3.5 CO2 12.5

7.5.3

(tune-up)

(O2)
(CO) (CO2)
(draft) (NO) (NO2)
(SO2)

7.10 7.11

7.10

151

 7.11
7.5.4 (Combustion Stoichiometry Theory)

C, H, O, N S
CHONS () -
(7-4)
v w
v

C u H v O w N x S y u y O 2 3.76 N 2 uCO 2 H 2 O ySO2

4 2
2

v w

x
3.76 u y N 2
4 2

(7-4)

152

 u, v, w, x y
3.76
0.79/0.21
C
12, H 1, O 16, N 14 S
32 (7-5)
m f (12 u ) (1 v) (16 w ) (14 x ) (32 y) 12u v 16 w 14 x

(7-5)

(7-6)

m f

v w

m a 137.28 u y
4 2

(7-6)

m a

(7-4) 21%
79%
7.5.5
7.5.5.1 (Stoichiometric mixture)

(7-7)
;
mf
mr

Ym

Ym

Ym

(7-7)

m r ()

7.5.5.2 (A/F)stoi
(7-8)
(A / F)stoi.

153

ma
mf

(7-8)

7.5.5.3 (Equivalence ratio; )

(Fuel equivalence ratio; f ) (7-9)
f

m f
m f

m a actual n f n a actual

n f n a stoi.
m a stoi.

(7-9)

(Oxidizer equivalence ratio; o )

(7-10)
o

1
f

(7-10)

f < 1
o > 1 (Fuel-lean Mixture)
f > 1
o < 1 (Fuel-rich Mixture)

f = o = 1

(Stoichiometry)
7.5.5.4 (Percent Theoretical Air)
(Air ratio)

(7-11)
(%TA)

%TA

100
100o
f

(7-11)

f = 0.8 o = 1.25 125

100
7.5.5.5 (Percent Excess Air)
100
(7-12)

154

 (%EA)
%EA

100
100 100o 100
f

(7-12)

(7-13)
% Excess Air

% O 2 measured
100
20.9 % O 2 measured

(7-13)

CO (7-14)
%CO
2
% Excess Air
%CO

20.9 % O 2
2

% O2

100

(7-14)

()
(7-15)

% Excess Air
1
100

155

(7-15)

7.6
7.6.1

7.12

7.12

7.6.1.1
O2, CO
7.6.1.2

7.6.1.3
(P)
7.6.1.4

7.6.1.5
CO 0-10,000 ppm
7.6.1.6
CO2, ,

7.6.1.7

7.6.1.8
LCD
7.6.2

Stack Loss

7.6.2.1

156

7.6.2.2 %CO2

%CO2 %O2
7.6.2.3

7.6.3
CO2

7.6.3.1 CO2 O2
7.6.3.2
7.6.3.3
7.6.3.4
.7- .12
7.6.3.5
(RADIATION & CONVECTION)
7.6.3.6
)

)

7.10
)
7.11
) .7-.12

7.6.3.7
10 ton/hr C
9%
260 oC 35 oC
157


200 oC
5%

.7 9%
260 oC 14.37
.7
5% 200 oC
7.91
14.37 7.91 = 6.46

7.7


7.7.1
7.7.2
(Atomization)
Primary Air
Secondary Air Primary Air Secondary Air
(Low Excess Air,
LEA)
7.7.3
Full Rated Capacity

7.9

7.9
158

:
:
:

:
:

7.8
7.8.1

10 1 (Air Change per Hour)

20,000
7.8.2
7.8.3

7.8.4 2,500

2,500
23
2
7.8.5
7.8.6 ,
7.8.7

159

7.8.8 ,

7.8.9 1
2.50-3.00
7.8.10 5
15

7.9
7.9.1 20,000 ( .)
7.9.2 100,000
7.9.3 12,000 , 15,000 30,000

7.10
7.10.1 , ,
1, 2540
7.10.2 P.K. Nag, Power Plant engineering steam and nuclear, Tata McGraw-Hill Publishing Company
Limited, New Delhi, 1998.
7.10.3 , , , 1, 2547
7.10.4 , , , 3,
2547
7.10.5 ,
, 2547
7.10.6 ,
, 1, 2550
7.10.7 .. 2547 - 2548

160


.1 (oC)

.2

161

 .3

162

(MJ)

 .4 (1)

.5

(2)

42.72
40.11 MJ/lit

41.18
38.67 MJ/lit

38.60
36.24 MJ/lit

34.48
32.38 MJ/lit

26.50
23.67 MJ/lit

38.45
34.33 MJ/m3

33.50
31.10 MJ/kg

3.60
3.60 MJ/kW hr
:
(1)
(2) 5.5

0.96 kg/lit
0.84 kg/lit
0.74 kg/lit
0.53 kg/lit
0.75 kg/m3

.6

(c)
(kJ/kg K)
4.19
2.09(1)
1.004(2)
0.477
0.385
0.9
0.128
0.235
4.8

()
(kg/m3)
1000
1.293(3)
7850
8930
2700
11300
10470
602

: (1) 1 bar
18 kJ/kg K
(2) 273.15 (K) (T) C = a + bT +
cT2 + dT3 A = 28.11, b = 0.1967 x 10-2, c = 0.4802 x 10-5, d = -1.966 x 10-9
1.005(300K), 1.013(400K), 1.029(500K), 1.051(600K), 1.075(700K), 1.099(800K),
1.121(900K), 1.142(1000K)

163

(3) 273.15 (K) (T)

1.293 273.15
T
.7

164

 .8 ()

165

 .9

166

 .10 ()

167

 .11

168

 .12 ()

169

170


(.. 2547-2548)

.1 ( 2) .. 2547

1
2

(Sulphur Content, %wt.)

15.6/15.6 oC
(Specific Gravity at 15.6/15.6 oC)

(Viscosity, cSt)
50 oC
100 oC

oC
(Flash Point, oC)

1
2.0

0.985

2
2.0

3
2.0

4
2.0

5
0.5

ASTM D 4294

0.990

0.995

0.995

0.995

ASTM D 1298

ASTM D 445

7
80
60

81
180
60

171

181
230
60

231
280
60

3
30
60

ASTM D 93


5
6
7
8
9

oC
(Pour Point , oC)
/
(Gross Heat of Combustion, Cal/g)

(Ash Content, %wt.)

(Water and Sediment, %vol.)
(Colour)

1
24

2
24

3
30

4
30

5
57

9,900

9,900

9,900

9,900

ASTM D 97

10,000

0.1

0.1

0.1

0.1

0.1

ASTM D 482

1.0

1.0

1.0

1.0

1.0

ASTM D 1796

8.0

ASTM D 1500

172

ASTM D 240

.2 .. 2547

37.8 C

1,380
ASTM D 1267
o
(Vapour Pressure @ 37.8 C kPA)
2
oC

2.2
ASTM D 1837
(Distillation, oC)

95
(95% Evaporated)
3

2.0
ASTM D 2163

(Pentane and Composition Content, %vol.)

4
(Corrosion)

1
ASTM D 1838
5

140
ASTM D 2784
(Sulphur Content, ppm by wt.)
6

0.05
ASTM D 2158
100 .

(Residue, ml)
7
(Water Content)

8
(Odorant)

173

.3 .. 2547

2
3

4
5
6

15.6/15.6 oC
(Specific Gravity at 15.6/15.6 oC)

(Smoke Point, mm.)
oC
(Flash Point, oC)

(Sulphur Content, %wt.)

(Corrosion)
oC
(Didtillation, oC)
(1) 10

(10% Envporated)
(2)
(End Point)

(Saybolt Colour)

0.84

ASTM D
1298

22

ASTM D
1322

38

ASTM D 56

0.20

ASTM D
4294

1 ASTM D 130
ASTM D 86

205

300

+16

ASTM D 156

174

.4 ( 3) .. 2548

2
3

15.6/15.6
(Specific Gravity at 15.6/15.6 oC)
(Cetane Number)
(Calculated Cetane Index)

(Viscosity, cSt)
3.1 40
(at 40 oC)

3.2 50
(at 50 oC)

o
(Pour Point ,
C)

5
0.81
0.81

ASTM D 1298
ASTM D 613
ASTM D 976
ASTM D 445

0.87
47

0.87
47

0.920
45

1.8

1.8

4.1

4.1

8.0

6.0

10

10

16

175

ASTM D 976

5
6
7
8
9
10
11
12

(Sulphur, %wt.)

(Copper Strip Corrosion)

/
(Oxidation Stability,
g/m3)

(Carbon Residue, %wt.)

(Water and Sediment, %vol.)

(Ash,
%wt.)

(Flash Point, oC)

(Distillation, oC)

(90% recovered)

5
0.035
0.035

1.5

ASTM D 4294

ASTM D 130

25

ASTM D 2274

0.05

0.05

ASTM D 189

0.05

0.05

0.3

ASTM D 2709

0.01

0.01

0.02

ASTM D 482

52

52

52

ASTM D 93

357

357

ASTM D 86

176

13

(Colour)
12.1 (Hue)
12.2 /
(Dye,
mg/l)

177

7.0

(1)

ASTM D
1500

(2)ASTMD 2392

12.3 (Intensity)

14

15
16

(Methyl Ester of Fatty Acid, %vol.)

(Lubricity,
um)
()
(Additive)

5
-

4.0

4.5

ASTM D 1500

7.5
4

460

5
460

EN 14078

CEC F-06-A-96

1)

2) 1,4 dialkylamino anthraquinone (1) (2)

178

.5 .. 2548

(Ethanol plus higher saturated alcohols, %vol.)
2

3-5
(Higher saturated (C3-C5) mono alcohols, %vol.)
3

(Methanol, %vol.)
4

/100
(Solvent Washed Gum, mg/100mL)
5

(Water, %wt)
6
/
(Inorganic chloride, mg/L)
7
/
(Copper,
mg/kg)
8
/
(Acidity as acetic acid,
mg/kg)

179

EN 2870
Appendix 2
Method B
EN 2870
Method III

99.0

2.0

0.5

5.0

EN 2870
Method III
ASTM D 381

0.3

ASTM D 203

20

ASTM D 512

0.07

ASTM D 1688

30

ASTM D 1613


9
-
(pHe)

10
11

12

/
(Electrical conductivity US/m)

()
(Additive)

6.5

ASTM D 6423

9.0
500

ASTM D 1125

1)

180

.6 .. 2548

1.1 (Research Octane Number ; RON

-
1.2 (Motor Octane Number ; MON
-
1.3

()

1
2

ASTM D 2699

87

89
ASTM D 2700

181

76

78

2
3
4
5
6
7
8

/
(Lead,
g/L)

(Sulphur,
%wt.)
/
(Phosphours, g/L)

(Copper Strip Corrosion)

(Oxidation Stability
minutes)

/100
(Solvent Washed Gum,
mg/100mL)

(Distillation, oC)
8.1
(1) 10
(10% Evaporated)

182

1
2

0.013

0.013

ASTM D 5059

0.05

0.05

ASTM D 4294

0.0013

0.0013

ASTM D 3231

ASTM D 130

360

360

ASTM D 525

ASTM D 381

70

70

ASTM D 86

(2) 50
(50% Evaporated)

9
10
11

12

(3) 90
(90% Evaporated)
(4)
(End Point)
8.2

(Residue,
% vol.)
37.8
(Vlpour Pressure @ 37.8 oC, kPa)

(Benzene,
% vol.)

(Aromatic,
% vol.)
1 2551

(Colour)
12.1

1
2
90
90

110
170

110
170

200

200

2.0

2.0

54.5

54.5

ASTM D 4953

3.8

3.8

ASTM D 5580

38

46

ASTM D 5580

38

38

183

(1)

(Hue)
12.2 /
(Dye,
mg/L)

13
14
15

(Water,
%wt.)

(Appearance
()
(Additive)

1
2

4.0

10.0

0.7

0.7

ASTM D 1500

(2) ASTM D 2392
ASTM D 203

1)

184

2) (Additive)
3) ASTM D 1500 0.5 1,4 -dialkylamino anthraquinone
1,3 benzenediol, 2,4-bis (alkylphenyl)azo 9 : 4
(1) (2)
4) ASTM D 1500 0.5 2-naphthalenol (Phenylaze) phenyl
azo alkyl derivatives 1,3-benzenediol, 2,4-bis (alkylphenyl) azo-) 1 : 3
(1) (2)

185

.7 .. 2548

(Methyl Ester,
% wt.)
2
15% oC /
(Density at 15 oC,
kg/m3)

40 oC
(Viscosity at 40 oC,

o
(Flash Point,
C)

(Sulphur,
% wt.)

( 10
(Carbon Residue, on 10% distillation residue, %wt.)

(Cetane Number)

(Sulfated Ash,
%wt.)

(Water,
%wt.)

(Total Contaminate, %wt.)

(Copper Strip Corrosion)

110

(Oxidation Stability at 110 oC hours)

/
(Acid Value, mg KOH/g)

/100
(Iodine Value,
g lodine/100

5
6

7
8
9
10
11
12

13
14

cSt)

186

96.5

EN 14103

860

ASTM D 1298

3.5

ASTM D 445

120

ASTM D 93

0.0010

ASTM D 2622

0.30

ASTM D 4530

51

ASTM D 613

0.02

ASTM D 874

0.050

ASTM D 2709

0.0024

ASTM D 5452

1 ASTM D 130

EN 14112

0.50

ASTM D 664

120

EN 14111

15

(Linolenic Acid Methyl Ester, %wt.)
16

(Methanol,
%wt.)
17

(Monoglyceride,
%wt.)
18

(Diglyceride,
%wt.)
19

(Triglyceride,
%wt.)
20

(Free glycerin,
%wt.)
21

(Total glycerine,
%wt.)
22
1 () /
(Group/metals (Na+K)
mg/kg)
2 () /
(Group/metals (Ca+Mg
mg/kg)
23

(Phosphorus,
%wt.)
24
()
(Additive)

12.0

EN 14103

0.20

EN 14110

0.80

EN 14105

0.20

EN 14105

0.20

EN 14105

0.20

EN 14105

0.25

EN 14105

5.0

5.0

EN 14108
EN 14109
prEN 14538

0.0010

ASTM D 4951

1)

187

.1

.2

188

.3

189

8.1

8.2


8.2.1


8.2.2
8.2.2.1 Maximum Continuous Rating (MCR)

8.2.2.2 Boiler Rating
(kg/hr) (Ton/hr)
8.2.2.3 Efficiency 4
() (Combustion Efficiency)


15-20

() (Thermal Efficiency)


190

() Boiler Efficiency

() Fuel to Steam Efficiency

(PTC 4.1)
ASME (American Society for Mechanical Engineers)
(Input Output Method)
(Heat Loss Method)
8.2.2.4 Boiler Turndown
4 1

25%
20%
8.2.2.5 Primary Air

8.2.2.6 Secondary Air

Primary Air

8.2.2.7 Tertiary Air

Secondary Air

8.2.2.8 Stoichiometric Stoichiometric

Substoichiometric

8.2.2.9 Balanced Draught

8.2.2.10 Gross Calorific Value (GCV)

191


(Latent Heat) (Sensible Heat)
8.2.2.11 Net Calorific Value (NCV)

(Vapors)
8.2.2.12 Absolute Pressure
9 bars (Absolute Pressure)
90.03 bars
8.2.2.13 Atmospheric Pressure
lb/in2 in-Hg kg/cm2 760 mm-Hg
101.325 kPa 1.013 bars
8.2.2.14 Carbon Monoxide (CO)

8.2.2.15 Blow Down

8.2.2.16 Complete Combustion

() (Stoichiometric)
8.2.2.17 Perfect Combustion
() (Stoichiometric)
8.2.2.18 Saturated Steam
8.2.2.19 Wet Steam (Saturated Steam)
8.2.2.20 Dry Steam (Saturated Steam) (Superheated Steam)

8.2.2.21 Superheated Steam

(Saturation Temperature)
192

8.2.2.22 Oxygen trim

()

(Oxygen Trim)
(Excess Air)
(Low and High Fire)

8.2.2.23 Heat Transfer Mediums

8.2.2.24 Thermic Fluid

8.2.2.25 Hot water

70-90 oC

8.2.2.26 Steam
(Sensible Heat) (Enthalpy)
0 oC

(Latent heat of Evaporation)

(Equilibrium)
(Saturation Conditions)

(Superheated Steam)

193

8.3
8.3.1 (British Standard, BS845: 1987)
(BS845: 1987)

(Load) (Full Load)

%

(Gross Calorific Value: GCV) 2
8.3.1.1
8.3.1.2

8.3.2 2 ASME: PTC-4-1 ()

8.3.2.1 : ( Input-output Method)
8.3.2.2 : ( Heat Loss Method)
8.3.3 IS 8753:
IS 8753 BS845

(Blow Down)

8.3.3.1
()
Input-out Method
()
( )

= x 100

194

(8-1)

100%
+

8.1

x 100

= x ( ) x 100
x (GCV)

(8-2)

(8-3)

()
(Heat Input) :


:

195

 :




(Hopper) (Load Cell)

(Heat output)

Orifice Venturi

Variable-orifice Vortex-shedding

() :

(Steam
generation)

196

 8.1 :
(Heat Output Data)

: 8 ton/hr
/
: 10 kg/cm2/180 oC
() : 2784 kJ/kg
10 kg/cm2

: 85 oC

: 356 kJ/kg
(Heat Input Data)

1.6 ton/hr
(GCV)
16743 kJ/kg

() = Q x (H-h) x 100
q x GCV

Q
=
(kg/hr)
q
=
(kg/hr)
GCV
=
(kJ/kg)
H
=
(kJ/kg)
h
=
(kJ/kg)
()
= 8 (ton/hr) x 1000 (kg/ton) (2784-356) x 100
1.6 (ton/hr) x 1000 (kg/ton) x 16743 (kJ/kg)
= 72.5%
= 8 ton ()/1.6 ton ()
=5
8.3.3.2

100
(Error)
197

 90% 1%
90 + 0.9 = 89.1 90.9%
1%
= 100-(10 + 0.1) = 90 + 0.1 = 89.9 90.1%

1.
2. H2
3.
4.
5. CO

6.

100%

7.

8.

8.1
= 100 (1+2+3+4+5+6+7+8) ()

L1- ()
L2- (H2)
L3- (H2O)
L4- (H2O)
L5- (CO)
L6- *
198

L7- ()
L8- ()
= 100 (L1+L2+L3+L4+L5+L6+L7+L8)
8.3.3.3

a)
1. CO2 O2
2. CO
3.
b)
1.
2.
3.
4.
5.
c)
1.
2.
3.
4.
5.
6.
7.
d)
1.
2.
3.
4.
e)
1. (TDS)
2. - (pH)
3.
199

 8.1
8.2

(Draft Gauge)

(TDS Meter)

(Thermocouple)

% CO2 O2 CO



(Manometer)
(Differential
Pressure)

(Conductivity)

(Make-up Water)

8.3.3.4
A)
(Standby Losses)

(Steady Load)

(Blown Down Loss)

(Soot Blower Steam)

(Auxiliary Equipment Energy

Consumption)

B)

(Steady Load)

200







C)

D)
(Oxygen Test)
(Carbon Dioxide Test)







(Negative Pressure)

E)
4-8

201



(Psychometric Chart)

8.3.3.5

8.3

%C
=
0.97C+ 0.7(VM+0.1A) - M(0.6-0.01M)
%H2
=
0.036C + 0.086 (VM -0.1xA) - 0.0035M(1-0.02M)
%N2
=
2.10 -0.020 VM
C
=
%
A
=
%
VM
=
%
M
=
%

(Stoichiometric)

8.4
8.4 (Stoichiometric)
a)

[(11.6 x C) + {34.8 x (H2- O2/8)} + (4.35 x S)]/100

= kg/kg [ ]
C H2 O2 S

202

b) %
(EA)

O2 %
x100 []
21 O 2 %

CO2
7900x[(CO 2 %) t (CO 2 %)a ]
[]
(CO 2 )a %x[100 (CO 2 %) t ]

(CO2%)t = CO2
(CO2%)a = CO2%
C
( CO2 )t =
N 2 C
N2 = N2 + N2
N2
C = C
C
c) = {1 + EA/100} x
/ kg (AAS)

1)

(8-4)

L1
m

=
=

Cp
Tf
Ta

=
=
=

%
(kg/kg)
: CO2+ SO2+ N2 + N2 +O2
()
(kJ/kg)
(oC)
(Ambient) (oC)

203

2) H2 (%)

(8-5)

H2
Cp
Tf
Ta
2445

=
=
=
=
=

(kg) 1 kg
(kJ/kgoC)
(oC)
(oC)

3)

(Sensible Heat)

(8-6)

M
Cp
Tf
Ta
2445

=
=
=
=
=

(kg) 1 kg
(kJ/kgoC)
(oC)
(oC)

4)

204

 Psychrometric
8.4
8.5

(oC)
20
20
30
40

(oC)
20
14
22
30

(%)
100
50
50
50

(kg) (kg)
(Humidity factor)
0.016
0.008
0.014
0.024

(8-7)

AAS
Humidity Factor
Cp
Tf
Ta

=
=
=
=
=

1 kg
(kg) (kg)
(kJ/kgoC)
(oC)
(oC)

5)

CO, H2

(8-8)

L5
CO
CO2
C

=
=
=
=

% C CO
CO Economizer (%)
CO2 (%)
(kg)/ (kg)

205

 CO ppm
= CO (ppm) x 10-6 x Mf x 28 (MCO)
CO (Mco)
Mf = (kg/hr)
L5 = Mco x 24043*
*
6)

/ packaged = 1.5-2.5%
= 2-3%
Power station = 0.4-1%

(8-9)

L6
Vm
Ts
Ta

=
=
=
=

(W/m2)
(m/s)
(K)
(K)

7) (%)

L7 = /kg x GCV x 100

GCV
8) (%)

206

(8-10)

L8 = /kg x GCV x 100

GCV

(8-11)

8.4

8.4.1
8.6
(Input/ Output parameter)
kJ/kg

1.
=
2.
=
3.
=
4.
=
5. C CO
=
6.
=
7.
=
8. =

=
= 100 - (1+2+3+4+5+6+7+8)

%
100

8.4.2
8.4.2.1

207

 8.7

%CO2
%CO

GCV
GCV

(%)

GCV

=
=
=
=
=
=
=
=
=
=
=
=
=
=
=

5599.17 kg/hr
21937.5 kg/hr
43 kg/cm2
377 OC
96 OC
14
0.55
190 OC
31 OC
0.0204 kg/kg
70 OC
3.5 m/s
90 m2
3349 kJ/kg
1894 kJ/kg

= 90:10
=
=
=
=
=
=
=

8.63
31.6
41.65
2.0413
1.6
14.48
14654 kJ/kg

1-

= [(11.6 x C) + {34.8 x (H2- O2/8)} + (4.35 x S)]/100

kg/kg
= [(11.6 x 41.65) + {34.8 x (2.4013- 14.48/8)} + (4.35 x
0)]/100
= 4.91 kg/kg

208

 2- CO2%
% CO2 (CO2)t
=
N2

=
=

C
(CO2)t

=
=

C
N 2 C
N2 + N2
N2
[4.91 x (77/100)] + 0.016
= 0.1356
28
0.4165/12 = 0.0347
0.0347
= 20.37%
0.1356 + 0.0347

3-
CO2 = 14.0%

% (EA)
= 7900x[(CO 2 %) t (CO 2 %)a ]
(CO 2 )a %x[100 (CO 2 %) t ]
7900x[20.37-14]
= 14x[100-20.37]
= 45.17%
4-

= {1 + EA/100} x

= {1 + 45.17/100} x 4.91
= 7.13 kg/kg
5-
= CO2 + N2 + N2
+ O2

= 0.4165x44 0.016 7.13x77 (7.13 4.91)x23

12
100
100
= 7.54 kg/kg

209

 6-
6.1 % =
(L1)
=
L1 =

7.88%

6.2 % =
H2
=
(L2)
L2 =

3.44%

6.3 % =

(L3)
=
L3 =
6.4 %

(L4)

=
=

L4 =
6.5 %
CO 2
CO (L5)

5.91%

0.29%

=
=

L5 =

2.58%

6.6 % =

(L6)
=
=
=
=
=

633.3 W/m2
633.3 x 3.6
2279.88 kJ/m2 hr
2279.88 x 90
210

=
% =

L6 =

205189.2 kJ/hr

0.25%

6.7 % (L7)
%
= 8.63
= 90:10

GCV
= 1894 kJ/kg
= 0.1 x 0.0863 = 0.00863 kg
1 kg

= 0.00863 x 1894 = 16.345 kJ/kg

% = 16.345 x 100 / 14654

L7 = 0.11%
6.8 % (L8)
GCV
= 3349 kJ/kg
= 0.9 x 0.0863 = 0.077 kg
1 kg
= 0.077 x 3349 = 257.85 kJ/kg

% = 257.85 x 100 / 14654

L8 = 1.77%

=
=
=
=

100 (L1+L2+L3+L4+L5+L6+L7+L8)
100 (7.88+3.44+5.91+0.29+2.58+0.25+0.11+1.77)
100-22.23
77.77%

211


(Input/ Output parameter)
kJ/kg
14654

1.
1154.78
=
2.
540.10
=
3.
866.08
=
4.
42.49
=
5. C CO
378.06
=
6.
36.63
=
7.
3.85
=
8. =
257.85
= 100 - (L1+L2+L3+L4+L5+L6+L7+L8) = 77.77%

%
100

7.88
3.44
5.91
0.29
2.58
0.25
0.11
1.77

8.4.2.2

(%)

GCV

(%)

=
=
=
=
=
=
=
=
=
=
=
=

84
12
0.5
1.5
1.5
0.5
41858 kJ/kg
2648.125 kg/hr
80 oC
90 m2
0.025 kg/kg
3.8 m/s

=
=

190 oC
30 oC
212

% CO2
% O2
a)

b) % (EA)

c)
(AAS)

d)

e) %

=
=

10.8
7.4
[(11.6 x C) + {34.8 x (H2- O2/8)} + (4.35 x S)]/100
kg/kg
= [(11.6 x 84) + {34.8 x (12- 1.5/8)} + (4.35 x 1.5)]/100
= 13.92 kg/kg
O2 %
=
x100 []

21 O 2 %

7.4
x100
21 7.4
= 54.4%
= {1 + EA/100} x
= {1 + 54.4/100} x 13.92
= 21.49 kg/kg
= (CO2 + SO2+ N2 + O2) +
N2
= 0.84x44 0.015x64 0.005 7.4x23 21.49x77
12
32
100
100
= 21.36 kg/kg
=

=
L1 = 7.86%
f)
% =
H2
= 9x0.12x{584 0.45(190 30)} x100
10000
L2 = 7.08%
g) % =

=
L3 = 0.033%

213

h) % =

=
L4 = 0.38%
i) =
(L6)
=
= 1303 W/m2
= 1303x3.6
= 4690.8 kJ/m2 hr
= 4690.8 x 90 m2

= 422172 kJ/hr
% =

L6 = 0.38%
0.5-1.0%

=
=
=
=

100 (L1+L2+L3+L4+L6)
100 (7.86+7.08+0.033+0.38+0.38)
100-15.73
84.27%

214


(Input/ Output parameter)
kJ/kg
41858

1.
3290.04
=
2.
2963.55
=
3.
13.81
=
4.
159.06
=
5. C CO
0
=
6.
159.06
=
= 100 - (L1+L2+L3+L4+L6) = 84.27%

%
100

7.86
7.08
0.033
0.38
0
0.38

8.4.3

8.4.4
1.
1. (Boiler ID Code and Make)
2. (Year of Make)
3. (Boiler Capacity Rating)
4. (Type of Boiler)
5. (Type of Fuel Used)
6. (Maximum Fuel Flow Rate)
7. (Efficiency by GCV)
8. (Steam generation pressure & superheat temperature)

215

9.
10.
11.
12.

() (Heat Transfer Area in m2)

(Is there any waste heat recovery device installed?)

(Type of Draft)
() (Chimney Height in Metre)

2.

GCV
()
()

:
1.
2.
3.
4.

%
%
%
%

1.
2.
3.
4.
5.
6.
7.

%
%
%
%
%
%
%

:
1. (TDS)
2. (TDS)
3. - (pH)
4. - (pH)

216

ppm
ppm


1. CO2
2. O2
3. CO
4.

%
%
%
o
C

217

 3.
:..

0
0
2

(0C)

( C)
(kg/cm )
( C)
(m3/hr)
(m3/hr)

(kg/hr)

(0C)
(0C)

%
O2

% %
CO2 CO (0C)

1.
2.
3.
4.
5.
6.
7.
8.

(Boiler Supervisor)

(Energy Manager)

218

(Energy Auditor)

(0C)

8.5
8.5.1

1. a) (Shell),

(End plate),
(Flue
Gas)
(Cast iron
section)
b)

2. (Water

tube), (Fire
tube) (Stay)

3.
a) (Casing)
i)

(Refractory)

ii)

b) (Insulation)
4.
a)

( Foundation

bolt)

b)
i)
(Concrete foundation)
ii)

c)

(Boiler body)

219

i)

ii)

i)
ii)

8.5.2

1. a)
(Temperature controller)

2.

3.

i)

ii)


(Electrical contact)

i)

ii)

b) (Control

valve)

c)
(Steam trap)

d)

a) (Sealing

part and pipes)

b) (Gland
packing)

c) (Bearing)

d) (Rotor)

e)

(Pressure gauge)

a) (Nozzle),

(Stabilizer)
(Atomizing
cup)
b) (Nozzle
tip)

220


c)

4.

d) i)
(A/F ration

mechanism)

ii)

e) (Electrode)
i)

ii)

iii)

iv)

i)
(Wire net)
ii)
iii)

iv)

(Refractory material
and burner tile)

5.

6.
a)

(Stoker)

b) (Fire grate)

i)
ii)

i)

ii)

iii)
iv)

i)
ii)
iii)
iv)

221


7.
a) (Bearing)

b)
(Vane and damper)
c)
(Air duct and wind
box)

d)
(Wire net and suction
port)

8. a) i)

ii)

iii)

iv)

(draft
gauge)
b)
(Lightning rod)

c) (Foundation)

9. a)
i)
(Plate and frame)

(Explosion
ii)
door)

b)

10.
a)

222

i)
ii)

iii)

iv)

i)

ii)

b)

c)

(Bottom part)

d) (Foundation)

e)
i)
(Oil level

controller)
ii)

iii)
(Bellow)

f)

(Oil level gauge)

i)
ii)
iii)

8.5.3.

1.
a) (Parts)

i)
ii)

b)
(Terminal)

2.

3.
a)

(Case and cover)

223

i)
ii)


b)

i) i)

ii)
ii)

c)

4. a)

(Protect and shielding

glass)
b) UV (Ultra

violet photo-electric

tube)

(Flame rod)
(Flame detector)

(Primary safety
controller)
5.
5.i
a) (Coil)

b)

c)

5.ii a) (Driving

source)

b)

224

c) (Fixing)

d)

6. a)

(
b)

c)

)
d) i)

ii)

i)
ii)

8.5.4

1. i)
(Super heater)

ii)

( Superheated
steam)
2. i)
(Economizer)

ii)

225

i)


ii)

i)

3.

(Air
preheater)

3.i

3.ii a) (Rotor)

(Regenerative
air-preheater)
b) (Bearing)

c)
(Driving motor)
d) (Element)

e) (Sealing part)

4. (Feed water
pump)

a) (Rotor)

i)

ii)

iii)

(Load)

226

i)

ii)

iii)

b) (Gland)
i)

ii)

c)

(Bearing)

d) (Shaft)

5.
(Feed water tank)

(Eccentricity)
(Run out)
a)

b)

c)

d)
i)

ii)

e) (Piping)

f)
227

i)

ii)

i)

ii)

6. a)
(Safety valve)

b)

c)

d)

e)

8.5.5

1.

1.i a)

b)
(Expansion joint)

(Pipe supporter)
c)

(Steam trap)
d)

e)
228

1.ii

2. (Soot blower)

3.
a)

(Detecting part)

b)
(Measuring part)

8.6




8.6.1
8.6.1.1

8.6.1.2

8.6.1.3

8.6.1.4

8.6.1.5

229

8.6.1.6

8.6.1.7


8.6.1.8

8.6.1.9

8.6.1.10
:
8.6.1.11

8.6.2
8.6.2.1 (Inspection)

8.6.2.2 (Advice)



8.6.2.3 (Visual Inspection)

8.6.2.4 (Verification)

8.6.2.5 (Outside Surface)

()
() (Biased Flow)
(Flame by-pass)
()
230

()
8.6.2.6 (Cracks)

()
()
()
8.6.2.7 (Corrosion)

()
1.
2.
3.
()
1. (Head Plate)
(Flue)
2. (Stay)
3. (Manhole)
4. (T-type Joint)
5. (Refractory)
(Casing)

8.6.2.8 (Leakage)

()
(Hydrostatic test)

()
(Joint)
(Hole)
(Tube Attachment)

8.6.2.9 (Lamination, Blister and Peeling)

1.
2.
3.
4.

231



8.6.2.10 (Flue) (Fire Tube)
() (Water Side)
1. (Flue) (Tube Plate) (Fire Tube)

2. (Flue) (Tube Plate) (Fire Tube)

3.
4.
5. (Stay)
6.
7. (Feedwater Pipe)
8. (Feedwater Pipe)
9.
10.
11. (Drain Separator)
12. (Fusible Plug)
13.

() (Fire Side)
1.
(Stay Tube)
2.
3. (Flue)
4.

5. (Water Side)
6. (Separation Plate) (Smoke Box)
7. (Explosion Door)
8.
8.6.2.11 (Sectional Cast Iron
Boiler)
()
(Water Side)

232

() (Hydrostatic Test)

1.
2.
3.
4.
5.
6.
7.
8.

(Nipple)
(Bracket)

8.6.2.12 (Vertical Boiler)

()
(Stay)
()
()
() (Water Leg)
1.
2.
3.
() (Crown Plate)

()
(Upper Tube Plate)
(Tube Stay) (Smoke Tube)

()
(Narrow Water Portion) (Fire Hole)
() (Water Tube) (Crosstube)
8.6.2.13 (Water Tube Boiler)
() (Caustic Embrittlement, Alkaline Corrosion)
(Rivet)
() (Stub Tube)
() (Header)
233

()
() (Drum)
()
1. (Soot Blower)
2. (Tube leaner)
3.
4. (Inspection Hole)
()

8.6.2.14 (Once-through Boiler)

() (Hydrostatic Test)

()
()
()

() (Multitube Type Once-through Boiler)

1.
(Upper and Lower Header)
2.
3.

234

--

235

236

237

238

8.7
8.7.1
.. 2549
8.7.2 Boiler & Pressure Vessel Inspection, , 2541
8.7.3 Energy audit Reports of National Productivity Council
8.7.4 Energy Hand book, Second edition, Von Nostrand Reinhold Company - Robert L.Loftness
8.7.5 Industrial boilers, Longman Scientific Technical 1999
8.7.6 www.boiler.com
8.7.7 www.eng-tips.com
8.7.8 www.worldenergy.org
8.7.9 Japanese Industrial Standards (JIS) Standard

239

9.1

9.2
9.2.1

9.2.2
9.2.2.1 (Air Pollution)
(Pollution)


3
,
9.2.2.2 (Particulates)
0.1 m
200 m , , , , ,

9.2.2.3
, ,
, , ,
, ,

9.2.2.4

240

9.3


(Air Quality Standards) (Emission
Standards)
9.3.1
1
, 8 , 24 1

, 9.1
CO, O3, NO2 SO2
50-75 g/m3
1,500 g/m3 1-20
mg/m3 9.1
9.1
Pollutant

Average Density

Standard

Carbon Monoxide

1 hr.

30 ppm (34.2 mg/cu m)

(CO)

8 hrs.

9 ppm (10.26 mg/cu m)

Lead

24 hrs.

(Pb)

30 days

1.5 microgram/cu m

Total Suspended Particulate

24 hrs.

0.33 mg/cu m

Matter (TSP)

1 Year

0.10 mg/cu m

Suspended Particulate Mater

24 hrs.

120 micro g/cu m

(PM-10)

1 Year

50 micro g/cu m

Ozone (O3)

1 hr.

0.10 ppm (0.20 mg/cu m)

1 hr.

0.3 ppm (0.78 mg/cu m)

Nitrogen Dioxide (NO2)

Sulfur Dioxide (SO2)
: http://www.pcd.go.th

241

9.3.2


NO2 SO2
9.2
9.2
Substance

Source

Standard (mg/m3)

Boiler and furnace (oil)

300

Boiler and furnace (coal)

400

Boiler and furnace (other fuel)

400

Steel and aluminum mfg.

300

Other source

400

Antimony

Any source

20

Arsenic

Any source

20

Copper

Furnace or smelter

30

Lead

Any source

30

Chlorine
Hydrogen Chloride
Mercury
Carbon monoxide
Sulfuric Acid
Hydrogen Sulfide
Sulfur dioxide
Oxides of nitrogen

Any source

30
200
3
1000 (870 ppm)
100 (25 ppm)
140 (100 ppm)
1300 (500 ppm)
940 (500 ppm)
470 (250 ppm)
870 (200 ppm)

Particulate

Any source
Any source
Any source
Any source
Any source
Sulfuric acid production
Boiler and furnace (coal)
Boiler and furnace (other fuel)

Xylene
: http://www.pcd.go.th

300 MW SO2 640 ppm
120 mm/m3

242

 1,000 MW
9.3

9.3 1,000 MW
, 106 kg
Gas

Fuel oil

Coal

Ash content (%)

0.05

Sulfur content (%)

1.6

3.5

Particulates

0.46

0.73

4.49

SOX

0.012

52.66

139.00

NOX

12.08

21.70

20.88

Carbon monoxide

negligible

0.008

0.21

Hydrocarbons

negligible

0.67

0.52

Based on the assumption that the plant burns 1.9x109 m3 gas/year

Assuming that the plant burns 1.57x106 tons oil/year
Assuming that the plant burns with 3.5% sulfur, of which 15% remain in the ash.

The fly ash collection efficiency is 97.5%

243

9.3.3
9.4

() CO2, SO2 SO3
(Sintering) 1,100 oC

244

() 1,650 oC () 2,200 oC
9.1
(Organically-Bound)
750 oC NaOH

(Fire-Side Deposits)

(Fouling) (Slagging)
(High Temperature Corrosion)

9.1
9.3.4

9.3.4.1


10 m
9.3.4.2 ( 1%)
(Volatile Species)

(Refractory Species)

( 0.01-0.1 m)
245

Cao, MgO, Na2O, K2O
SiO2, Aio2, Ai2O3 Fe2O3

9.4

70-100
10-30

30-50
300 m
( 100 m)

9.4.1 (Gravity)
9.4.2 (Inertia)
9.4.3 (Electrostatic)
9.4.4 (Filtration)
9.4.5 (Scrubbing)
9.4.1

(Settling Chamber)
100 m 9.2 () 80 m
9.2 ()
9.2 ()

nWLVt

100%
Q
246

(9-1)


n
W
L
Vt

=
=
=
=

, m
, m
Terminal velocity , m/s
( Vt
Vt )
, m3/s

()

()

()

9.2
9.4.2
(Centrifugal Force)

247

 (Cyclone)



9.3

9.3 g[nhv9ho

(1 n ) p D 2 1

1 exp

1 n
1 n
n
18W ( R 2 R 1 )R 2 ( R 2 R 1 )

p
Q
D
1 (12 )
R 2 ()
R 1 ()
n (0.5-0.7)
248

(9-2)

W

5 m

9.5

, in (mm)

, %

6 (150)
9 (225)
12 (300)
24 (600)

90
83

, %
, ,
m
m
-5 66
+5 98
-10 60
+10 99

-20 47

70

+20 98

(Multiple Cyclones)
5 cm 30 cm 9.4

9.4 (Multiple Cyclones)

249

9.4.3
(Ionize)

9.5

9.5

(Electrostatic Precipitator) ESP

95-450 oC
600 mm, H2O 15-30 mm, H2O ESP
100 g/m3

1 exp(

AVM
)
V

(9-3)

VM

R1 2
2

R
1
2

V
A

250


( 0.01 m)

9.4.3.1
()
()
()
()
()
()
9.4.3.2
()
()
()
()

9.6 ESP

9.7
(0.4-0.8%S)


251

 ESP

ESP

9.7 () ESP

9.7 () ESP
9.4.4

2 (Packed Filter)

252

 (Single-Layer Filter)

(Bag Filter)
125 300 mm
1.80 6.0 m 20: 1 9.8

Baghouse

9.9

9.8

253

()

()

()
9.9 (Baghouse)
() () ()

1 ESP

9.4.5 (wet scrubbing)

( )

4
9.4.5.1 10-1,000
9.4.5.2 (Impinge) (Impact) Brownian
Motion

254

9.4.5.3

9.4.5.4

(Spray Tower ) (Cyclone Spray Tower)
(Impingement Scrubber)
(Venture Scrubber) 9.10

ESP 2.5-10 m
80%
()
1.
2.
3.

()
1.
2.
(erosion)
3.

255

()

()

()

()

9.10
() , () , () ()

9.5
SOX
9.5.1 (Pre-Combustion)
H2S,
SOX
9.5.2 (Combustion) SOX

256

9.5.3 (Post-Combustion)
Flue Gas Desulfurization FGD
SOX (Wet FDG Process)
(Dry FDG Process) 9.11 9.12

9.11 SOX

9.12 SOX

257

9.5.4
( 2,000 K)
Thermal NOX
(NOX )
NO
NO2 (
30 %)

CO NO2
(photochemical pollutants)
NO2 + h V
O + O2 +M

NO + O
O3 + M

(9-4)
(9-5)

NOX 100
1,000 200-500
NOX 100
500
350
NOX NO
NO
NOX
9.5.4.1
9.5.4.2 (Off - Stoichiometric Staged Combustion)
9.5.4.3 (Flue Gas Recirculation)
9.5.4.1
No NO2
NO2
NOX
NOX
NOX
NOX 20-30%
258

9.5.4.2
Thermal NOX
NOX (Low NOX Burners)
9.13
(Axial Swirl)
NOX
9.14.
(Corner Firing)
NOX
9.15
9.5.4.3

9.14 9.16

NOX 50% 9.17

9.13 NOX

259

 9.14 NOX

9.15 NOX

9.16

260

 9.17 NOX

9.6
1. , ,
2. J.A. Barnard and J.N. Bradley, Flame and Combustion, Second edition, Chapman and Hall,1985.
3. R.W. Bryers, Fireside slagging. fouling and high-temperature corrosion of heat-transfer surface due to
impurities in steam-raising fuels, Prog. Energy Combust.Sci,22,29-120,1996.
4. P. Chattopadhyay, Boiler Operation Engineering: Questions and Answers, Tata McGraw-Hill Publishing
Co.Ltd., 1994, ISBN 0-07-460296-9.
5. N. Chigier, Energy, Combustion and Environment, McGraw Hill, 1981, 496 pp. ISBN 0 07 010766 1.
6. M. Crawford, Air Pollution Control Theory, McGraw-Hill Inc., 1976.
volume, John Wiley and
7. M.A. Elliott, ed. in chief, Chemistry of Coal Utilization, second supplementary
Sons, 1981.
8. J.C. Jones. Combustion Science: Principles and Practice, Millennium Book, 1993.
9. K.E. Noll, W.T. Davis and J.R. Duncan, ed., Air Pollution Control and Industrial Energy Production, Ann Arbor
Science, 1975.
10. S.R. Turn, An Introduction to Combustion, Second edition, McGraw-Hill International Edition,2000,676 pp,
ISBN 0 07 235044 x.
261

 10

10.1

10.2



10.2.1
10.2.1.1

10.2.2
10.2.2.1

20

262

10.3

10.4
10.4.1 (.)
ASME, JIS, EN

10.4.2
(.) ASME, JIS, EN


10.4.2.1

10.4.2.2

10.4.2.3

10.4.2.4

10.4.2.5

10.4.2.6

10.4.3
(.)

10.5




10.5.1
.. 2549

263

 20

10.5.2


.. 2549

10.5.3
10.5.3.1

10.5.3.2

10.5.3.3

10.5.3.4

10.5.3.5

1.
2
2549
2.


9
10.5.4
10.5.4.1

264

10.5.4.2

10.5.4.3
10.5.4.4
10.5.4.5
10.5.4.6

1.

2.
3

10.5.5
10.5.5.1

10.5.5.2

3

10.5.5.3

10.5.5.4


1.

2.
3

265

10.5.6
10.5.6.1



(Model)

10.5.6.2

.

.

.
10.5.6.3

10.5.6.4

10.5.6.5

(1) (3)
6 (1)

1.

2.
3

266

10.5.7
10.5.7.1



(Model)

10.5.7.2

.

.
10.5.7.3

10.5.7.4

10.5.7.5

10.5.7.6

10.5.7.7

10.5.7.8

(1)(3)
6 (1)

267



1. 1

2.

3. 1
4.

5.
3
6.

1
7.
.
.
.
.
.
8.
9.
3
10.
3

11.

10.6

..
2549 6

10.7

268

10.7.1

10.7.2 4
2549 12
10.7.3


10.7.4

10.7.5

10.8


2
. (fire Side)

. (Water Side)

269

10.8.1
3 6


10.1
10.1

1. 1.

Ca, Mg,
CaCo3, MgCo3, CaSo4
2. Softenner

2. , , 1.

3. 1. PH 7 HCl,
H2SO4
2. CO2
3. O2
4.

4.

5.

1. NaCO3,
Na(HCO3), Na(HO3)
2.
1.

270

-
1. ,
, Condensate
,
(
Armohib)
2. Softenner

1.(
5 8 ../)
,
,,
, Demineralization
condensate
1.
PH 9-11
2. Deaeration

Ammonia
3. Deaeration
Hydrasine
4. Aeration,
Cation
exchange,

1.Lime-Soda Softening, Demineralization, Anion exchange

2.
1.,

-
2.

3.
2.
3. 4., Steam Trap
5.

4.
6.
5.

6. 7.,

,
7.

1.
6. 1.

()
2.
3. 2.,

3. ( 5
4.
8 ../)
4.

(Carry - over) 10.1
(Scaling)

(Sludge)

271

10.8.1.1

(Corrosion)

()
OH-
Electrolytic Dissociation Fe2+
Fe(OH)2 pH Fe(OH)2
Fe(OH)3
Fe(OH)2 Fe2O4
Fe2O4 Fe(HCO)3
pH

() (Pitting Corrosion)


Local Galvanic Action OH Fe(OH)2

Local Galvanic Action

()

Fe(OH)2

10.8.1.2

(Caustic Embitterment)
(NaOH)

(Intercrystalline)
(Stress)
() pH

272



(Super Heater)

pH
pH

pH

pH

10.8.1.3

(Carry-over)


(Priming) ( )
(Foaming) ()
() (Priming)




() (Foaming)

273

()

10.9





, ,

10.9.1
10.9.1.1

10.9.1.2

274

10.9.2
, ,

10.9.2.1
10.9.2.2
10.9.2.3
10.9.2.4
10.9.2.5
10.9.2.6
10.9.2.7

(Electrode Holder)

10.9.3
10.9.3.1
()

()

10.9.3.2
()

()

1.


1. 2.

2.

275

10.9.3.3

10.9.3.4

2
() (photo cell)

()

(Photo cell)
12

10.9.3.5

() 6

() , 4-6

() Package Boiler 4-6

10.9.3.6

() 1

276

() 1

()




10.9.3.7

1.1
(Maximum Allowable Working Pressure : MAWP)

.. 2549

10.10

3 1

277



160C 250C
1/32
6.25 %
80C

10.10.1
2
10.10.1.1 Convection Section

10.10.1.2 Radiant Section

( 540-590 oC)





10.10.2

10.10.2.1
()

()
()

278

()

10.10.2.2
()

() / /

()

10.10.2.3
()
()
()
()
10.10.3
()
()
()
()
()
()
()
()

10.11

10.11.1
6 1%

279

10.11.2 250C

Pass 1 Pass3 Pass 2 Pass 4

,

10.11.2.1

10.11.2.2 ()
10.11.2.3 ()
10.11.2.4 ()
10.11.2.5
10.11.3
10.2

A
10% CO2
B
9% CO2
C
8.5 % CO2
D
8%
A= B= C= D=

12.8% CO2
11.5% CO2
10% CO2
9%

13.8%CO2
13% CO2
12.5% CO2
12%

10.12


10.12.1
10.12.2
10.12.3
10.12.4
10.12.5
10.12.6

280

10.13

10.13.1
10.13.2
10.13.3
10.13.4
10.13.5

10.14

10.14.1

10.14.2 2
10.14.2.1
3 -
(quick lime) (Silica
gel) (Activated alumina)

(N2)
Blow down valve
Blow down valve
5
1

10.14.2.2
3

(Na2So3) (N2H4) 100 ppm (1.5
Na2So3 N2H4 100 ) (NaOH)
281

 400 ppm (3 1000

)

282

 10.3

()

1
2

O / ..
O

()
(

O / ..
O

. /

(Blow Down)
1

283

O O
O
O O

31..

 10.4

()

(Pressure)

(Blow Down)

O O

()
(

31.. )

284

10.15

,
10.6

, , , ,


10. 5
(Steam Explosion) ( : )
...

27 .21
15 .21

/.
/.

19 .23

/.

11 .24
20 .24
25 .24
29 .24
7 .25
7 .25
8 .26
27 .26
27 .29
15 .31
19 .32
20 .32
.2533
.2533
.2533
31 .35

/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.

()

>10

53

>10

10

30

16

40
Package
35

40
Package
1

11

11
Package
9
Package
7

15
285

24/20
2/8

10
1

1/3

0/2
5/4
1/8
0/1
2/3
0/2
3/14
1/9
4/2
2/5
1/4
0/4
0/1
0/0
1/0
0/1

1
5
1
5.1
2
5
4
2
1
9
6
2
1.2
6
2
1.5

...

6 .35
11 .35
4 .38
..2538
24 .40
13 .41
.2543
.2543
..2543
28 ..44
..2544
..2544
23 .44
19 .45
7 .46
15 .46
..2546
..2546
..2546

/.
/.
/.
/.
/.
/.
/.
/.
/
/.
/.
/.
/.
/.
/.
/.
/.
/.
/.

..2547

/.

2547
..2547
12 .48
13 .. 49
29 .. 49
28 .. 49
26 .48
21 .. 49

/.
/.
/.

/.

()

17

14

8
Package
12
Package
10
Package
>10
Package
8
Package
10

30 .
Package
12
Glove Valve 8
3
Package
3
Condensate
25
Package
9
Package
6
Package
7

1 .

14

Water Tube
>5
Package
5
Package
3
Package
1/2
Water Tube Boiler 30

1
Package
5

286

3/0
1/10
0/1
1/0
1/0
0/2
1/0
0/1
0/1
1/1
0/1
1/0
1/2
1/9
5/12
0/0
0/0
0/0
1/1

2
3
6
5
1
1
1
>1
>3
>5
>6
>5
>1
>5
>2
>2
1
>2
5

0/0

0/0
0/0
0/7
0/0
0/2
0/7
1/2

>50
6
22
3.5
70
1
30
0.3

 10.6

3-6

o
o
o
o
o

o
o

o
o
o

o
o
o

(Photo Cell)

o
o

o
o
o
o
o

, ,
,

287

3-6

o
o
o

Steam Trap

O , ,
, ,

10.16

10.16.1
10.16.2
10.16.3
10.16.4
10.16.1

10.16.1.1
10.16.1.2
10.16.1.3 (Blowdown)
10.16.1.4 ()
10.16.1.5
10.16.1.6
10.16.2

10.16.2.1
10.16.2.2
10.16.2.3
10.16.2.4
288

10.16.2.5

10.16.2.6
10.16.2.7
10.16.2.8
-
-
10.16.2.9 ()
10.16.2.10
10.16.3
10.16.3.1
10.16.3.2
10.16.3.3 ()
10.16.3.4
10.16.3.5 ()

10.16.3.6
10.16.3.7
10.16.3.8
10.16.3.9
10.16.3.10
10.16.4
10.16.4.1

10.16.4.2
10.16.4.3
10.16.4.4 ()

10.17


10.17.1

289

10.17.2
10.17.3
10.17.4
10.17.5
10.17.6
10.17.7

10.17.8

10.18
10.18.1 , ,
, 2535
10.18.2 Mr.Yoshihiko Takamura , ,
(-) , 2525
10.18.3 Boiler and Pressure Vessel Inspection Technology and Approve System in
Japan , .. 1998
10.18.4 Professional Boiler In Section march , 1999
10.18.5
.. 2549

290

 11

11.1

11.2
11.2.1

11.2.2

11.3

11.3.1 (Overhaul Procedures)
11.3.2 (Overhaul Scheduling)
11.3.3
11.3.4
11.3.5
11.3.1

.
.
.

291

11.3.2

11.3.3

11.3.4




11.3.5

11.4


11.4.1
(field erected)
(package) 11.1

292

 11.1

Drums, Headers Tubes ( 1) (corrosion) (scale) (pitting)

)
2) (Manhole)

3)
() Drum
4) Line Blow Down

5) Drum Headers
6)

7) (Hand hole)
(Stud Threads)
8)

Drums, Headers Tubes ( 1) Drum Header
Overheat
)
2) Drum
3) Seal Drum
Header
4) Drum Header

5) Blow down
Drum Header
6) Tube Fin
Soot Blower
1) Super Heater Header Tubes
Super heater
Overheat
2) Soot
3) Headers Tubes
4) Vent Drain
5) Header Tube

293


Economizer

(Soot Blowers)

1) Oxygen Pitting Scale

Headers Tubes
2)
Headers Tubes Soot
3) Vent Drain
4) Flue Gas
Economizer
5)
6) Header Tube
1)

2)

3) -
()
4)
5)

6)

1)

2)
1) Soot Blower
2) Soot Blower Hanger Bearing, Soot
Blower Nozzle, Soot,
, Soot
3)
4)
5) Steam
6)
7)

8) Overheat

294

(Drain)

Safety Valve

Valve Nozzle Disk Seat

Valve Springs
Spring

Drain


% Blow Down
1) (Air Damper)

2)
3)
Wind box

1) ()

(Pulverized Coal Firing)

(Shaft and Roll)
(Feeder
Housing)

2) 4 Ball-race mills, Bowl mills,
Impact Attrition mills Ball mills

Housing

295

1)
2)
(Exhauster)
3)
4)

1)

Stoker Coal Firing

2)
3)
1)

2)

(Adjusting Mechanism)

(Grinding Surface)
Spring Grinder
Bearing, Shaft Journals


(Scrapers)
Alignment
Bearing

Housing Exhauster Liner
Leak
(Coal Nozzle)
Burner
Coal Nozzle (Refractory Throat)

Underfeed Stoker Underfeed Stoker

(Main Ram and

Distribution Ram)
(Tuyeres)
(Wind box
and Damper)
(Clinker and Ash
Grinding Mechanism) (Rams)
(Wind box damper)
Spreader Stoker Spreaders Stoker

Distributor Blades Distributor Tray

Feeder Lining
(Alignment)

Over Fire Air Fan distribution Nozzles

296

Traveling Grates

3) (Damp Grates)
Grate Bars

Dampers and Frames
Fire Door Liners Over Fire

Air Seals

Wind box
Air Dampers
Damper

Shear Pin
(Grate Drive)

1) Turbine Drive
(Clearances)
Clearances


2) (Steam Driven
Reciprocating Pump)

297


1)
2)

3)
4)
5)
6)
1)
2)
3)
4)
5)
6)
7)
8)

9)
1)
2)
3)
4)
1)

2)

Oil Heater

Vent Drain

Setting Relief Vale

Setting
Relief Valve

Oil
Heater

(Calibrate)
Trap Drain Valve
Shut off ( )

Burner Nozzle

(Gas Nozzles)
Damper

Hydraulic

298

1)

2)

1)

2)

Regenerative Ljungstrom Type

Cold End
Seal

(Gear Drive)
(Soot Blower)
(
)

Forced Draft Primary Air
(Fan Housing) (Rotor)

(Coupling Alignment)

Induced Draft
(Housing) (Housing Liners)
Fly Ash

(Fan Rotor) (Liners)

Fly Ash

299

(Damper)

(Shaft Seals)
-

(Coupling Alignment)

1) Blade
2) Blade

3)

4) Damper

5) (Seal Strips) Damper

6) blades

7)
8)
9)

10) Damper

11) Dampers Induced Draft
Fan Forced Draft Fan Purge
Damper

()

(Super heater Headers and Tube Joint)
(Doors) (Seals)
300

() (Refractory)
Burner Throat
(Slag)
Drum,
Header
() (Burners)


Burner Vanes

() (Super heater Tubes)

(Pressure Drop)

() Steam Drums

Drum
Drums
Drums
() (Soot Blowers)

Blower


() (Economizers and Air Pre heater)
Load

()
(Pressure Drop)

(Pressure Drop)

()

301

 (Header Support Hangers)

11.4.2

3
1.
2.
3. ()
11.4.2.1
()
1.

2.
3. (Tube Sheet)
()
1.

2. Overheat
3.
4.
5. Hot
Spot
6.
7. (Crack)
() ()
1.

2.

3. Hot Spot
Overheat

302

11.4.2.2
() (Pressure Drop)

()
()

() (Hot Spots)

() Boiler Drum
()

11.5
11.5.1 National Board Inspection Code ( NBIC ) , 2001 Edition,
11.5.2 RECOMMENDED GUIDELINES FOR THE CARE OF POWER BOILERS ASME VII , THE
AMERICAN SOCIETY OF MECHANICAL ENGINEERS NEW YORK, NEW YORK
11.5.3 Combustion Fossil Power A Reference Book on Fuel Burning and Steam Generation Editor; Joseph
G.Singer, P.E. Forth Edition Published by Combustion Engineering, INC. 1000 Prospect Hill Road
Winsor, Connecticut 06095, 1991

303



1)

Rotary Oil

(Atomizing Oil)
(Cup)
Atomizing Cup Air Nozzle
Cup

Stuffing

2)


3)
3.1

3.2

4)
4.1
4.2

4.3
4.4
4.5
4.6
4.7

304

4.8

305

1)
1.1
1.2
1.3
2)
2.1
2.2
2.3
3)
3.1 (
)
3.2
4) (Superheater Tubes)
4.1 (
)
5) (Drum)
5.1
(Steam Scrubbers & Separator)
5.2 -
6) (Soot Blowers)
6.1
6.2

6.3

7)
7.1

306

8)
8.1

8.2

9) (Furnace & Casing)

9.1
9.2 (Support Hanger)

307

1)
1.1

1.2
1.3
2)
2.1
(Soot)
2.2 Overheat
2.3
2.4
2.5

2.6
2.7
3) ()
3.1
3.2 (Tube Sheet)
3.3
3.4

3.5

308

1)

2)
3)

4)
5)
6)

309

 12

(Saturated Steam) (Superheat Steam)
, (Water Wall Tube),
(Super Heat Tube),

3 (Corrosion)
(Erosion) (Material Degradation)
(Creep)
(Fatigue) (Cyclic Load)

12.1

12.2
12.2.1
(, )

12.2.2
12.2.2.1
12.2.2.2

12.2.2.3

(Tubular
Products)
(Verification)
(Flue Gas Path)
310

12.3
12.3.1

()
, ,
()
()
() ,
(Measuring Point Diagram)

() ()

() ()

() (Nondestructive)

() (Geometry) (Out-ofroundness)
()
()
() (Exhaustion)

12.4

311

12.5

12.6




12.6.1


12.6.2

12 21 mm.
17 mm.()
0.2 mm. (21 17) / 0.2 20
12.6.3
2
Lifetime

12.6.3.1

Lifetime
Component Lifetime
(
)
2.1 ZO ZB
12.1 ZB (Working stress, gB)
(Lower limit curve) 0.8 (Scatter band)

312

 (Creep rupture strength)

(0,8

2.1 Zo ZB

(
)

z,k
lifetime)

B/ /p

/p

(Component design

((Data processing system)

)
(Full load working
pressure) z B/ /p

(12-2)
313

 (Linear damage rule)

z,k 12-3
(12-3)

12.1
12.1
Class assign

Temperature ranking

Operation
Pressure
100 % (35 bar)

20 < T < 400

400 < T < 500

500 < T < 510

510 < T < 550

2500 hr

6500 hr

2800 hr

123000 hr

80% (28 bar)

3000 hr

600 hr

1000 hr

20000 hr

0%

Remark

100% 35 bar 540 oC, (operation time) = 123,000

hr. 35

21.9 N/mm2
12.2

314

Material 13 CrMo44
1000

Stress (N/mm2)

450 C
500 C
100

450 C

550 C

500 C
550 C

10

550 C
500 C
450 C

1
1

10

100

1000

10000

100000

1000000

Time (hr)

12.2 Life Time Curve 13 CrMo44

: 500 oC
=21.9 N/mm2 550 oC (allowance operation time
1,000,000 hr 12-2 ez =
operation time / allowance hour 123000x100/1000000 (12.3 %
510 - 550 oC)
12.2
12.2 13 CrMo44
Class assign
Temperature ranking
Operation Pressure 20 < T < 400
400 < T < 500
100 % 35 bar
80% 28 bar

0%

0
0

0
0

500 < T < 510

510 < T < 550

Time

2.3 %
1.2 %

12.3 %
2.3 %

14.6 %
3.5 %

Total ez

315

18.1 %

 18.1
18.1 100
200,000 ( 200,000 )
163,800
12.6.3.2

(Stage)
12.3

12.3 Strain & Time Curve Creep Test (Creep Curve)

Creep Curve
Curve Curve Rate (d/dt)
(Initial State) (Plastic Strain)
Curve
(Creep Resistance)
Curve Creep Strain Rate
Secondary State (Steady State) : (Work
Hardening) (Strength)
(Recovery Processes)
Creep Rate
Creep Rate (Cavities)

316

 12.3

0
1
2a
2b
3a
3b
4
5

VGB Standard
Assessment Class
Structure and Damage Condition
as received without thermal service
creep expose, without cavities
advance creep exposure, isolated cavities
advance creep exposure, numerous cavities
without preferred orientation
creep damage, numerous orientated cavities
advance creep damage, chains of cavities and/or
grain boundary separation
advance creep damage, micro crack
Large creep damage, macro crack

ASTM Standard
Damage Parameter :
Structure and Damage Condition : Action Required

A Isolated cavities :

None until major maintenance

B Oriented cavities :

Replica test at specified interval

C Micro-crack :
Limit service until repair
D Macro-crack : Immediate repair

12.4 12.3

317

12.7
12.7.1 TRD, Technical rules for steam boilers
12.7.2 API STANDARD, Tank Inspection, Repair, Alteration, and Reconstruction
12.7.3 VGB standard for the technique and operation of power plants
12.7.4 ASTM E139 - 06 Standard Test Methods for Conducting Creep, Creep-Rupture, and StressRupture Tests of Metallic Materials

318

319

319

 ()

320


.1

321

 .1 ()

322

 .1 ()

323

 .1 ()

324

 .2

325

 .2 ()

326

 .2 ()

327

 .2 ()

328

 .3

329