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Piping Model
Types of Boiler:
There are two major types of boiler which are as under:
( a ) F i r e T u b e B o i l e r
(b) Water Tube Boiler
Boiler Characteristics:
Capacity:
Capacity refers to the steam or heat output of a boiler .
The term used to express capacity depends on the size of the boiler.
Boiler manufacture indicates the capacities of medium and large boilers
in pounds of steam per hour (at a specified temperature and pressure).
Capacity of small boilers is expand in term of total square feet of
heating. One boiler horse power equals to a heat output of 33475 Btu/hr.
If a boiler produces more steam than the rated capacity can be given as
percentage of rating percentage equals the actual capacity divided by
rated capacity
produces more steam than the rated capacity can be given as percentage
of rating percentage equals the actual capacity divided by rated capacity.
Pressure:
A boiler is classified by the pressure at which it operates. Fire tube
boilers pressure generally ranges between 50-250Psi.Water tube boiler
pressures can be as high as 5000 Psi
Duty:
Duty is the steam demand made on a boiler by the heating process.
The duty required of a boiler determines the load it carries according to
design capacity. A boiler can operate at minimum normal or maximum
load.
Economizers and Preheaters:
The devices increase the capacity and efficiency of a boiler by
recovering heat from flue gases. An economizer to a nest of small tubes
placed at the flue gases outlet of the boiler. Feed water at low
temperature of the boiler flows through the tube sand gases and absorb
heat from the hot gases passing around the outside of the tubes. Thus an
economizer lowers steam cost because less fuel is needed to heat feed
water to its boiling point .An air pre heater uses the heat from the flue
gases to warm incoming air that will support combustion. A pre heater is
usually placed between the economizer at the stack.
Why Steam is Ideal for Carrying Heat Energy:
In heating water it takes 1 Kilocalorie to rise the temperature of 1 kg
of water through it. It takes an additional of 539 kilocalorie to change 1
kg of water to steam. This amount of heat is then stored in the steam.
When steam condenses the heat energy is given off. Water is also used
to carry heat energy because of following reasons:
1.It is easily available.
2.It is cheaper.
3.It has an ideal behavior.
4 . It is foun d on earth in ev ery state.
Sensible Heat:
The heat required to bring change in water is known as Sensible
heat.
Latent Heat:
The heat which does not rise the temperature but bring a
change inthe state of water is known as Latent Heat
The heat which does not rise the temperature but bring a change inthe
state of water is known as Latent Heat
Scaling:
The impurities in water which it contains cause corrosion and stop
the boiler efficiency to work properly. It causes due to dissolved salts in
water.Scaling is due to following factors:
1 .Process with un treated water.
2.Incomplete Composition due to imbalance ratio of fuel and air.
3.No preheat of air.
4 .Ov erheatin g wh ich melts the tub es of b oiler.
Temporary Hardness:
Presence of bicarbonates of calcium and magnesiumcauses the
hardness of water which is known as temporary hardness. It can
beremoved by heating the hard water.
Ca(HCO3) CaCO3 + H2O + CO2
Mg(HCO3) MgCO3 + H2O + CO2
Permanent Hardness:
Presence of chlorides and sulphates of Calcium (Ca)and
Magnesium (Mg) causes the permanent hardness of under processed
water. Thishardness can not be removed by heating.
Treatment Methods:
The treatment of water can be done by the following
methods:
1.Lime Soda Method
2 .Zeolite Method Ion Ex ch ange Method Ion Exchange Method
3.Demin Process
4 . R e v e r s e O s m o s i s Zeolite method is used in the Miniature Plant
for the treatment of water
Zeolite Method:
This method is a type of Ion Exchange Method. In this method
softening material mostly used is called resins.
Formula of Zeolite is as under:
Zeolite: Na2O3.Al2O3.2SiO2.H2O
The reactions taking place in the Sodium Zeolite chamber is as under:
Ca(HCO3) + Na2Ze CaZe + 2NaHCO3
MgCl2 + Na2Ze MgZe+ 2 NaCl
After the reaction Sodium Zeolite (NaZe) is regenerated due to
following reactions:
CaZe + 2NaCl Na2Ze + CaCl2
MgZe + 2NaCl Na2Ze + MgCl2
Condensative Recovery:
It is a good energy conservation method whichimproves the
system efficiency and reduces the fuel and water cost. A condensate
recovery system returns condensed steam to the boiler to become a
portion steam tothe boiler of the feed water supply. The rest of the feed
water supply comes frommake up water replaces water loss through
blow down. High quality water containingfew minerals and treated with
chemicals thus condensate requires less treatment thanraw make up
water to make it pure to use it as feed water. In this way energy is saved
through this process.
Blow Down:
As the boiler generates steam, the condensation method that improves
system of minerals and treatment chemicals that remain in the boiler
water increases large amount of minerals which cause corrosion, boiler
tube blockage and scaling.It is actually a process which water is
removed todecrease the concentration of salts. It is mainly of two types:
1.Periodic Blow down
2.Continuous Blow down
Periodic blow down of a boiler involves opening the main blow of
valve regularly usually when steam demand is low and when the solid
concentration is so high.
Continuous blow down removes a small amount of water from a
boiler continuously. Water drains through a pipe beneath the water
surface where the levelsof impurities are highest. This type of blow
down is used in most of the plants. Itmakes a uniform level of solids in
the under processed water.
Boiler Efficiency:
The main factors that reduce the efficiency of boiler are thegreatest
loss of heat in boiler operation. There are two causes of abnormal stack
losswhish are as under:
1 .Ex cess Air in Co mb ustion Area
2 .High ex it temp eratu re of Flue Gases
Every fuel requires some excess air to burn completely. High
flue gas exittemperature reduces the efficiency of boiler because the heat
released through thestack is wasted heat. Economizer and air pre-heater
can recover some of the heat toimprove its efficiency and it also lowers
fuel cost. Radiation loss is the heat loss fromthe boiler and high
temperature piping through radiation to the surrounding air.
Use of Steam:
Steam is of two types:
1 .Satu rated Stea m(Hea ting p u rpo se)
2 .Sup erheated Steam(tu rbin e op eration )
Steam is mainly used in the power generation purposes.Superheated
steam carries vapors in it. Thats why it is used to runTurbines
Definition:
The Instrument air compressor is the fourth important part of the
Miniature Plant. The basic work of an air compressor is to deliver air at
a maximum pressure
Diagram:
Function of Air Compressor:
The function of compressor is to provide air at the pressure required
for various plant applications. In many plants compressed air is used as a
power source. Some typical uses of compressed air are as under:
1 .To p rov id e po wer fo r p neumatic in stru me n ts.
2 .To p rov id e air fo r b reathin g app aratus.
3 .To p rov id e air fo r pn eu matic contro l.
In reciprocating air compressor the air is compressed by themovement of
a piston inside a cylinder. Air enters the cylinder through a suctionvalve
that is designed to allow air to flow in only one direction.This section
increases the pressure of the air. Compression takes place in the
cylinder. The compressed air leaves the cylinder through a
dischargevalve. This valve is also designed to permit air to flow in only
one direction out of thecylinder. The power required to move the piston
is usually supplied by a motor. The motor moves a crank shaft. There are
two types of reciprocating air compressor:
1.Single Acting Compressor
2.Double Acting Compressor
Valves:
Valves are the devices used to control the rate of flow of fluids in a
pipeline. Several valves are provided in the piping model valves are
classified as given below:
Gate Valve:
Gate valves are mostly used in plants. These valves are used to cut
the flow of liquids or to control its flow rate. In a gatevalve diameter of
the opening through which the fluid passes is nearly thesame as that of
pipe. These valves are usually used to complete cut of the pipeline
liquid. The other end of the stem extends through the stuffing boxin the
valve bonnets connects to the hand wheel. In a rising stem, gatevalve is
not connected with the stem directly to its wheel. Instead of the stem is
threaded through a fitting called stem bashing. In a non-rising stemgate
valve the stem is directly attached to the hand wheel.
Globe Valve:
So called because in the earliest design the body of the valve was
spherical. The globe valve is mainly used for flow rate control.
Theopening increases almost linearly with stem position and wear
distributed around the disc. The fluid passes through a restricted opening
and changes direction several times. As a result the pressure drop in this
kind of valveis large.
Check Valves:
Check valves are used when unidirectional flow is desired.They are
automatic in operation. It is opened by the pressure of the fluid inthe
desired direction, automatically closes by gravity or by a spring pressing
against a disk. Common types of check valves are:
1.Lift Check
2.Swing Check