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Contents of Presentation
Theory of circulation Types of circulation Boiling fundamentals Economizer Water walls Drum and its internals
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Circulation in Boiler
The steam generator has to produce steam at highest purity, and at high pressure and temperature required for the turbine. Water must flow through the heat absorption surface of the boiler in order that it be evaporated into steam 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. The ratio of the weight of water to the weight of steam in the mixture leaving the heat absorption surfaces is called Circulation Ratio.
Cold feedwater is introduced into the steam drum where, because the density of the cold water is greater, it descends in the 'downcomer' towards the lower bottom ring header, displacing the warmer water up into the front tubes. Continued heating creates steam bubbles in the front tubes, which are naturally separated from the hot water in the steam drum, and are taken off.
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Forced Circulation
However, when the pressure in the water-tube boiler is increased, the difference between the densities of the water and saturated steam falls, consequently less circulation occurs. To keep the same level of steam output at higher design pressures, the distance between the Bottom ring header and the steam drum must be increased, or some means of forced circulation must be introduced. Therefore natural circulation is limited to boiler with drum operating pressure around 175 Kg/cm2.
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Natural Circulation
Forced Circulation
Forced Circulation Beyond 180 Kg/cm2 of pressure, circulation is to be assisted with mechanical pumps, to overcome frictional losses. To regulate the flow through various tubes, orifice plates are used. This system is applicable in the high sub-critical regions (say 200 Kg/cm2).
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Diff in Density
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Economiser
Boiler 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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Economiser
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
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Finned Economizers
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Advantages of Economiser
6oC raise in feed water temperature, by economizers corresponds to a 1% saving in fuel consumption
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6oC raise in feed water temperature, by economizers corresponds to a 1% saving in fuel consumption
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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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Boiler Drum
It is an enclosed Pressure Vessel Heat generated by Combustion of Fuel is transferred to water to become steam Process: Evaporation
Steam volume increases to 1,600 times from water and produces tremendous force
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SEPERATING STEAM FROM THE MIXTURE OF WATER AND STEAM 2. IT HOUSES ALL EQUIPMENTS USED FOR PURIFICATION OF THE STEAM AFTER BEING SEPERATED FROM THE WATER
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SPECIFICATION500MW
MATERIAL - CARBON STEEL LENGTH - 22070 MM OD - 2130 MM ID - 1778 MM DESIGN.PR - 204 KSC WEIGHT(INT) -246 TONNES WITHOUT(INT) 224 TONNES
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Drum Internals
The steam drum contains steam separating equipment and internal piping for distribution of chemicals to the water, for distribution of feedwater and for blowdown of the water to reduce solids concentration.
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DRUM INTERNALS
1. PRIMARY SEPERATORS
CONSISTS OF BAFFLE ARRANGEMENT DEVICES WHICH CHANGE THE DIRECTION OF FLOW OF STEAM AND WATER MIXTURE 2. SECONDARY SEPERATORS SEPERATORS EMPLOYING SPINNING ACTION 3. SCREENING DRYERS
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Drum Internals
Steam Separator
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Downcomers
There are six down comers in (500 MW) which carry water from boiler drum to the ring header. They are installed from outside the furnace to keep density difference for natural circulation of water & steam.
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WATER WALLS
HEATING AND EVAPORATING THE FEED WATER SUPPLIED TO THE BOILER FROM THE ECONOMISERS. THESE ARE VERTICAL TUBES CONNECTED AT THE TOP AND BOTTOM TO THE HEADERS. THESE TUBES RECEIVE WATER FROM THE BOILER DRUM BY MEANS OF DOWNCOMERS CONNECTED BETWEEN DRUM AND WATER WALLS LOWER HEADER. APPROXIMATELY 50% OF THE HEAT RELEASED BY THE COMBUSTION OF THE FUEL IN THE FURNACE IS ABSORBED BY THE WATER WALLS.
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Hydro Testing
Need: Method: Ensure pressure instrumentation is ready. Water Filling(10ppm Ammonia, 200 ppm Hydrazine, pH 10) Drainable parts (economizer, water wall and drum) Non Drainable portions filling First pressurization through boiler Fill pump Later pressurization through special purpose pumps. Test pressure and rate of pressure rise and rate of pressure drop as per IBR. After completion system drained and kept under wet preservation.
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THANK YOU
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