Disediakan Oleh:MOHD ZULHAIRI BIN ZULKIPLI

Pensyarah,
Politeknik Ungku Omar
JJ618-Engineering Plant Technology

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For the production of paper and other wood

products
For the preparation and serving of foods
For the cooling and heating of large buildings
For driving equipment such as pumps and
compressors, and
For powering ships

However, its most important priority remains as

the primary source of power for the production of
electricity
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STEAM

WATER

Steam is basically recycled, from steam

to water and then back to steam again
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3
1
4

Figure 1a : Schematic diagram for a Rankine cycle.

The simplest steam cycle of practical value is called the Rankine

cycle, which originated around the performance of the steam engine.
The steam cycle is important because it connects processes that allow
heat to be converted to work on a continuous basis.
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Coal
Oil
Gas
Bagasses

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A boiler is closed vessel in which water, under

pressure, is transformed into steam by the
application of heat.
Open vessels and those generating steam at
atmospheric pressure are not considered to be
boiler

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The M.A.W.P or Maximum Allowable Working Pressure is the

highest amount of pressure that the vessel is designed to
withstand. Pressure is measured in terms of pounds per square
inch or psi. Psig (gauge) indicates gauge pressure, which ignores
the atmospheric pressure. Psia (absolute) is the sum of gauge
pressure plus the atmospheric pressure at that location, which
varies based on altitude. A compound gauge measures indicates
pressure and vacuum.
Low-pressure boilers are designed to withstand
a maximum of 15 psig steam or a M.A.W.P. 160
psig water
High-pressure boilers are designed to withstand
pressure above 15 psig steam and/or a M.A.W.P.
160 psig water

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Safety. The boiler should be safe under operating conditions.

Accessibility. The various parts of the boiler should be accessible for repair and
maintenance.

Capacity. The boiler should be capable of supplying steam according to the

requirements.

Efficiency. To permit efficient operation, the boiler should be able to absorb a

maximum amount of heat produced due to burning of fuel in the furnace.

It should be simple in construction.

Its initial cost should and its maintenance cost should be low.

The boiler should have no joints exposed to flames.

The boiler should be capable of quick starting and loading.

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According to
what flows in the
TUBE

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Less liable to explosion, produce higher pressure,

accessible and can response quickly to change in
steam demand

Tubes and drums of water-tube boilers are smaller

than that of fire-tube boilers and due to smaller size of
drum higher pressure can be used easily

The efficiency of water-tube boilers is more compare

to fire tube boiler

Water tube boilers require less weight of metal for a

given size

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Require careful attention. The maintenance

costs are higher

Failure in feed water supply even for short

period is liable to make the boiler over-heated

Less suitable for impure and sedimentary water,

as a small deposit of scale may cause the
overheating and bursting of tube

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Fire tube boilers have low initial cost (cheaper than water tube boiler)

Easy to use, operate, clean and maintain.

More compacts can be use in small scale industries (refer to small size boiler)

More likely to explosion

Water volume is large and due to poor circulation they cannot meet quickly the
change in steam demand.

For the same output the outer shell of fire tube boilers is much larger than the
shell of water-tube boiler.

Capacity of generated steam is limited

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Boiler are equipped with two categories of components : boiler mounting

& boiler accessories.

Boiler mounting are the machine

components that are mounted over the
body of the boiler itself for the safety of
the boiler & for complete control of the
process of steam generation

Pressure gauge
Fusible plug
Steam stop valve
Feed check valve
Safety valve
Blow off valve
Man & mud holes
Water gauge
Water column

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Boiler accessories are those components

which are installed either inside or
outside the boiler to increase the
efficiency of the plant and to help in the
proper working of the plant

Steam purifier
Air Pre-heater
Economizer
Superheater
Feed water heater

Pressure Gauge
Function : To record the steam pressure at which

the steam generated in the boiler.

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Fusible Plug
Function : To extinguish fire in the event of water

level in the boiler shell falling below a certain

specified limit.

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Steam Stop Valve

Function : To shut off or regulate the flow of

steam from the boiler to the steam pipe or steam

from the steam pipe to the engine.

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Feed Check Valve

Function : To allow the

feed water to pass into

the boiler.
To prevent the back
flow of water from the
boiler in the event of
the failure of the feed
pump.
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Safety Valve
Function : A safety valve is a

valve mechanism which

automatically releases a
substance from a boiler,
pressure vessel, or other
system, when the pressure
or temperature exceeds
preset limits
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Blow off Valve

Function : To drain

out the water from

the boiler for internal
cleaning, inspection
or other purposes.
Blowoff valves. (a) Flanged angle valveopen
position for full and free
discharge. (b) Flanged angle valveclosed
position for drop-tight shutoff. (Yarway.)
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Man & Mud Holes

Function : To allow man to enter inside the boiler

for service and maintenance, e.g., properly

inspect, clean, and repair the inside of the drum
and/or its internals.

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Water Gauge
Function : A water gauge

is a device that allows

the liquid level in a vessel
to be visually inspected.
Water gauges are
required by the ASMW
Boiler and Pressure Code
on steam boiler, and are
also useful in many other
monitoring the amount
of oil in an oil tank.
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Water Column
Function : A water

column is used on a
steam boiler to reduce
the turbulence and
fluctuation of the
water level so the
gauge glass can
provide a steady
accurate water level
reading.
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Water column and gauge arrangement for

connection to steam drum. (ClarkReliance Corp.)

Steam Purifier
Precise system control is required

for the operation of modern

superheated steam turbines.
Solids in the steam leaving a boiler
can deposit in the superheater and
turbines, causing costly damage.
For this reason, close control of
steam purity is critical.
Steam purity refers to the amount
of solid, liquid, or vaporous
contamination in the steam. Highpurity steam contains very little
contamination. Normally, steam
purity is reported as the solids
content.

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Superheater
Function : To superheat the

steam generated by boiler.

Super heater are heat
exchangers in which heat is
transferred to the saturated
steam to increase its
temperature. Superheat refers
to the process of increasing the
temperature of steam above
about 400F/204C and 100
psi/6.89 bar to produce a very
"dry" steam with absolutely no
water vapor. This feature is most
common in very large power
plant boilers of watertube
construction.

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There are three basic methods to obtain

constant steam temperature:

Attemperation i) Drum-type attemperator

ii) Spray-type attemperator

Flue gas bypass (or flue gas proportioning)

Flue gas recirculation

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 Feed Water Heater

Function : To increasing

feedwater temperature
& to minimize the
thermal effect.
1
2

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Closed Feedwater
Heater
Open Feedwater Heater

Air Pre-Heater
Function : A waste recovery

device in which the air to

on its way to the furnace is
heated utilizing the heat of
exhaust gases.

What is Baffle :- a flow-directing vane or panel in some vessels such as

shell and
tube heat exchanger, chemical reactor, or static mixers
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2:44 PM

 Economiser
Function : To recover

some of the heat being

carried over by exhaust
gases. (This heat is
used to raise the
temperature of
feedwater supplied to
the boiler)

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A soot blower is a system for removing the soot that is

deposited on the furnace tubes of a boiler during combustion.
Types of soot blowers:
Wall Blower.
Long Retractable Soot Blower (LRSB)
Air Heater Blower.
Long Retractable Soot Blower (LRSB) with
blowing medium steam

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A steam trap is a device used to discharge condensate and non

condensable gases with a negligible consumption or loss of live steam.
Most steam traps are nothing more than automatic valves. They open,
close or modulate automatically. Others, like venturi traps, are based
on turbulent 2-phase flows to obstruct the steam flow.
The three important functions
of steam traps are:
i. Discharge condensate as
soon as it is formed.
ii. Have a negligible steam
consumption.
iii. Have the capability of
discharging air and other
non-condensable gases.

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Water-wall a furnace or other wall within a

boiler enclosure that is composed of
numerous closely set water-tube. These
tubes maybe either bare, or covered by a
mineral cement.

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History
De Laval, Parsons and Curtis developed the concept for the steam
turbine in the 1880s. Modern steam turbines use essentially the same
concept but many detailed improvements have been made in the
intervening years mainly to improve turbine efficiency.
Steam turbines are used in all of our major coal fired power
stations to drive the generators or alternators, which produce
electricity.
The turbines themselves are driven by steam generated in Boilers
or Steam Generators as they are sometimes called.

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Energy Transfer
Coal, Natural Gas, Nuclear,
Biofuel, Waste Fuel
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How Steam Turbine Function?

Energy in the steam after it leaves the boiler is converted into

rotational energy as it passes through the turbine.
The turbine normally consists of several stages with each stage
consisting of a stationary blade (or nozzle) and a rotating blade.
Stationary blades convert the potential energy of the steam
(temperature and pressure) into kinetic energy (velocity) and direct the
flow onto the rotating blades.
The rotating blades convert the kinetic energy
into forces, caused by pressure drop, which
results in the rotation of the turbine shaft (Fig. 1).
The turbine shaft is connected to a generator,
which produces the electrical energy. The
rotational speed is 3000 rpm for Australian (50
Hz) systems and 3600 for American (60 Hz)
Figure 1
systems.

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 Steam under pressure contains energy.

Turbines convert the energy in steam into
rotating mechanical energy.
Impulse turbines convert the kinetic energy
of a jet of steam to mechanical energy.
Reaction turbines convert potential energy
in pressurized steam to
mechanical energy.

L
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An Impulse Turbine the potential energy, or the head of water, is first

converted into kinetic energy by discharging water through a carefully
shaped nozzle. The jet, discharged into air, is directed onto curved buckets
fixed on the periphery of the runner to extract the water energy and convert
it to useful work

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Compounding is a method for

reducing the rotational speed of the
impulse turbine to practical limits
High velocity of steam is allowed to flow through one row
of moving blades, it produces a rotor speed of about
30,000 r.p.m. which is too high for practical use
The leaving loss is also very high.

Some improvements in the simple impulse

turbine have been made for practical use and
also to achieve high performance
There are three main types
(a) Pressure-compounded impulse turbine.
(b) Velocity-compounded impulse turbine.
(c) Pressure and velocity compounded impulse
turbine (Impulse-Reaction Turbine).
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In a Reaction Turbine, forces

driving the rotor are achieved by
the reaction of an accelerating
water flow in the runner while the
pressure drops. The reaction
principle can be observed in a
rotary lawn sprinkler where the
emerging jet drives the rotor in
the opposite direction. Due to the
great variety of possible runner
designs, reaction turbines can be
used over a much larger range of
heads.

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Impulse

Reaction

o Pressure drops in nozzles and not in moving

blade channels
o Constant blade channel area
o Profile type blades

o Pressure drops in fixed blade as well as moving

blades
o Varying blade channel area
o Aerofoil type blades

o Restricted round or incomplete admission of

steam
o Diaphragm contains nozzles

o All round or complete admission

o Occupies less space for same power

o Higher efficiency in initial stage
o Suittable for small power requirements
o Blade manufacturing is not difficul and thus not
cosly
o Velocity
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2:44steam
PM
is high

o Fixed blades similar to moving blades attached

to casing act as nozzles and guide the steam
o Occupies more space for same power
o Higher efficiency in final (low pr) stages
o Suittabel for medium or high power
requirements
o Blade manufacturing process is dificult compare
to impulse and hence costly
o Velocity of steam is less

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