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WHAT IS BOILER ??
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BOILER
- IBR
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STEAM
STEAM PIPE
- IBR
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BOILER CODES
Boiler Codes have been written by various nations in the
past century to ensure safety of personnel and to avoid loss
of property. Boiler codes cover the whole gamut of
activities including Design, Fabrication, Testing,
Construction and Operation. The various aspects of IBR
Regulations are called out and consolidated against major
items like drum, headers, lines & links, etc. The following
codes have been used widely.
1. IBR 1950
2. ASME Section-I
3. BS 1113
4. DIN TRD 300.
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THERMODYNAMICS OF
POWER PLANT
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SENSIBLE HEAT
The Heat required to bring the water from 00c to
boiling point is the enthalpy or heat content of the
liquid measured in Kcal/Kg.
OR
The sensible heat of a thermodynamic process may be
calculated as the product of the body's mass (m) with
its specific heat capacity (c) and the change in
temperature ( T):
Q=mc T
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LATENT HEAT
Latent heat is the amount of energy in the form of heat
released or absorbed by a substance during a change of
phase (i.e. solid, liquid, or gas), also called a phase
transition
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SUPERHEAT
When the steam is heated out of contact with water ,
the steam temperature increases above saturation
temperature .Such a heating is known as super
Heating
OR
In physics, superheating (sometimes referred to
as boiling retardation, or boiling delay) is the
phenomenon in which a liquid is heated to
a temperature higher than its boiling point, without
boiling
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B C
C)
24 deg C E
F
A
-273
0 Entropy KJ / Kg K
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DIFFRENCE BETWEEN
POWER AND ENERGY ??
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MEANING OF 1 MW POWER
If 10 bulbs of 100 Watt glows at a time in one home.
It will consumes 1 kilo-watt of power.
Let us assume, load of one home is 1 kilo watt
1 MW = 1000 kW
= 1000 X 1000 W
= 1000 X (load of one home)
= load of 1,000 homes
Hence, 500 mw plant will benefit 5,00,000 homes (provided each home uses 1kw
power at a time)
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MEANING OF 1 UNIT OF
ELECTRICITY
if 10 bulbs of 100 watt glows at a time in one home for one hour. it will consumes 1
kilo watt hour (1kwhr) of power. this is called as 1 unit in our electricity bills.
If 500 MW plant, when run for one full day, it will produces
500 mw = 500 mw x 24 hr = 12,000 mw hr
= 12,000 x 1,000 kW- hr
= 1,20,00,000 units of electricity
(12 million units per day)
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EFFICIENCY
Mathematically,
HEAT RATE
Heat rate is the ratio of heat added to steam in boiler (in Kcal) to the Electrical
energy sent out (in kWh)
Efficiency and Heat Rate are related terms. Lower the heat rate more efficient is
the plant.
Heat rate for thermal project is in the range of 2200 to 1950 Kcal / kW-hr
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TYPE EFFICIENCY
BOILER (1) 84-92 %
CRITICAL POINT
SUB CRITICAL
&
SUPERCRITICAL BOILERS
Boiler operating below the critical point range and
have some amount of latent heat addition in steam
during phase conversion from liquid to Gaseous
state are termed as Sub Critical Boilers.
BOILER CLASSIFICATION
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TYPES OF BOILERS
(A) BASED ON APPLICATION :
Types Of Boilers.contd
(B) BASED ON CONSTRUCTION:
1. Vertical Recovery-V2R
2. Vertical Unit 40-VU40
3. Vertical Unit 60-VU60
4. Modular Unit-MU
5. 2 Pass Single Arch
6. 2 Pass Double Arch
7. Close couple
8. Box Type
9. Tower Type
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Types Of Boilers.contd
Types Of Boilers.contd
Top Suspended Boiler:
Types Of Boilers.contd
Types Of Boilers.contd
Types Of Boilers.contd
Corner Tangential Fired Boiler
Types Of Boilers.contd
1. SINGLE DRUM
2. BI- DRUM
3. NO DRUM (Vertical Separator)
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Types Of Boilers.contd
1. NATURAL
2. CONTROLLED
2.1 FORCED Circulation (Pump)
2.2 CONTROLLED Circulation (+Orifice)
2.3 CC+ (Pump + Orifice + Rifled Tubing)
3. ONCE THROUGH
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Boiling Mechanism
Circulation refers to flow of steam and water mixture
generated in water walls to drum.
Steam generated forms bubbles which in any case
should immediately flow and should not stick to water
wall surface, which is termed as Nucleate Boiling.
y
lit
Generated Q
ua
Q
ty
30%
le
uali
ab
w
ed Q
lo
Al
erat
Gen
10%
Elevation
Elevation
DNB
y
Qualit
DNB Region
Region
able
Allow
Quality Quality
Minimum Safety Margin Minimum Safety Margin
~10% ~30%
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Circulation in Boiler
The ratio of the weight of water to the weight of steam in
the mixture leaving the heat absorption surfaces is called
Circulation Ratio.
Natural Circulation
At lower drum operating pressure (below 175 kg/cm2),
there is a considerable difference in densities of water
and steam.
Drum and down comers are full of relatively cold water
whereas upper portion of water walls and risers tubes
are full of wet steam. The circulation in furnace, in this
case, takes place due to Thermo-Siphon principle.
The density difference is the driving force and this
balances the frictional losses, establishes a rate of
circulation. The furnace is called Natural Circulated.
Thus Natural circulation is the ability of water to circulate
continuously, with gravity and changes in temperature
being the only driving force known as "thermal head.
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Forced Circulation
Diff in Density
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Types Of Boilers.contd
1. Forced draft
2. Induced Draft
3. Balanced Draft
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Types Of Boilers.contd
PRESSURE PARTS
WATER WALLS
LOOKING FROM
OUTSIDE
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Downcomers
There are down comers in boiler ( 6 no. in 270 MW) which
carry water from boiler drum to the bottom ring header.
WATER
WALLS
HEATING AND EVAPORATING THE FEED WATER SUPPLIED TO
THE BOILER FROM THE ECONOMISERS.
8. Risers
9. Drum
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bottom ring
Via Downcomers
headers
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Boilersinfo.com SH STEAM OUTLET
DRUM
LTSH
EXTENDED
WW
Economiser
WATER INLET
SH steam
LTSH TO SH SH outlet
cooled rear Platen HDR
wall tubes headers
LTSH steam
cooled rear LTSH outlet Main Steam
wall tubes inlet headers (MS) line
header
LTSH
LTSH coil
horizontal
terminals
spaced coils
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Transfer of Energy in SH
Super heater heats the high-pressure steam from its
saturation temperature to a higher specified temperature.
Platen Superheater
Flat panels of tubes located in the
upper part of the furnace, where
the gas temperature is high.
The tubes of the platen SH
receive very high radiation as well
as a heavy dust burden.
Mechanism of HT : High
Radiation & Low convection
Thermal Structure:
No. of platens
No. of tubes in a platen
Dia of a tube
Length of a tube
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S1
S2
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76
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Reheater
CRH to HRH
HRH line
CRH line
Reheater
vertically
placed rear
DeSH
outlet header
Reheater Reheater
Vertical platen vertical spaced
inlet header coil
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Economizer
Economiser are feed-water heaters in which the heat from
waste gases is recovered to raise the temperature of feed-
water supplied to the boiler.
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Economizer
The economizer preheats the feed water by utilizing the residual heat of the
flue gas.
It reduces the exhaust gas temperature and saves the fuel.
Modern power plants use steel-tube-type economizers.
Design Configuration: divided into several sections : 0.6 0.8 m gap
Advantages of Economizer
Type of Construction
Plain Tube : Several banks of tubes with either-in-line or
staggered type formation. Staggered arrangement induces
more turbulence than the in-line arrangement. This gives a
higher rate of heat transfer and requires less surface but at
the expense of higher draught loss.
Welded Fin-tube : Fin welded design is used for
improving the heat transfer.
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Finned Economizers
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Circulating System
S. Design
Description Material
No. Temp.
1. Drum SA 299 368
Tubes SA210 Gr C 398
Water
2. SA 299, SA106
Walls Headers 370
Gr C
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Sl.
Description Material Design Temp.
No.
S.
Description Material Temp. Range
No.
T11, T22,
Coils 351 - 589
T91, TP347H,
1. RH
Headers SA106 Gr C
361 - 590
SA335 P22
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