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Thermal Engineering & Gas Dynamics

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Thermal Engineering & Gas Dynamics SAGAR INSTITUTE OF RESEARCH & TECHNOLOGY, BHOPAL DEPARTMENT OF MECHANICAL ENGINEERING THERMAL ENGINEERING & GAS DYNAMICS ME-6002 Richard Victor, Department of Mechnical 1 Engineering, SIRT Bhopal UNIT I STEAM GENERATOR SYLLABUS • Steam generators: classification, conventional boilers, high-pressure boilers-Lamont, Benson, Loeffler and Velox steam generators, performance and rating of boilers, equivalent evaporation, boiler efficiency, heat balance sheet, combustion in boilers, super critical boilers, fuel and ash handling, boiler draught, overview of boiler codes. Richard Victor, Department of Mechnical Engineering, 3 SIRT Bhopal STEAM GENERATORS • Boiler is an important equipment of the most industrial facilities and power plants. Boiler is a closed pressure vessel used to produce high pressure or low pressure steam or to produce hot water for industrial or domestic use. Richard Victor, Department of Mechnical 4 Engineering, SIRT Bhopal CLASSIFICATIONS Classification of boilers The steam boilers are classified according to the following conditions:- 1. According to the relative position of water and hot gases a. Fire tube boiler : Fire tube boilers are those boilers in which fire or flue gases are inside of the tubes and water is on shell side. Fire Tube Boilers are low capacity low pressure boilers usually used for heating, process or to produce hot water. [Cochran Boiler] b. Water tube boiler : The arrangement in the water tube boiler water is that the water is contained inside the tubes while the hot combustion gas is flows on other side of tubes. Water tubes boilers produce high pressure steam which is used for power generation purposes. Water tube boilers are more efficient and less dangerous than fire tube boilers. [Babcock – Wilcox Boiler] Richard Victor, Department of Mechnical 5 Engineering, SIRT Bhopal CLASSIFICATIONS 2. According to the axis of shell. a. If the axis of boiler is horizontal, the boiler is called horizontal Boiler [Lancashire Boiler]. b. b. If the axis is vertical then it is called vertical Boiler. [Cochran Boiler] c. If the axis is inclined then it is called inclined. Richard Victor, Department of Mechnical 6 Engineering, SIRT Bhopal CLASSIFICATIONS 3. According to the position of FURNACE a. Internally fired boiler:- In case of internally fired boilers, the furnace is located inside the boiler shell. [ all fire tube boilers] [Cochran Boilers] b. Externally fired boiler: The boiler is known as externally fired if the fire is outside the shell. [ all water tube boilers] [Babcock and Wilcox Boilers] Richard Victor, Department of Mechnical 7 Engineering, SIRT Bhopal CLASSIFICATIONS 4. According to the pressure developed a. The boiler which produce steam at pressure below 80 bar are called low pressure boiler. ex. Cochran[Pressure less than 80 bar] b. The boilers which produce steam at pressure of 80 bar and above are called high pressure boiler. ex. Velox High pressure boiler [Pressure greater than 80 bar] 5. According to the method of water circulation a. In natural circulation type of boiler the circulation of water in boiler takes place due to natural convention. ex. Lancashire, Babcock and Wilcox. [all low pressure boilers] [ Cochran Boiler] b. Forced circulation In forced circulation type of boilers the circulation of water is done by forced pumps. [all high pressure boilers] ex. Velox, Lamont Boiler Richard Victor, Department of Mechnical 8 Engineering, SIRT Bhopal CLASSIFICATIONS 6. According to the use of the boiler a. Stationary boiler [Cochran Boiler] b. Mobile boiler [Locomotive Boiler] 7. According to the number of drums a. Single Drum b. Multi Drum 8. According to the nature of draught a. Natural Draught b. Forced Draught Richard Victor, Department of Mechnical 9 Engineering, SIRT Bhopal BOILER MOUNTINGS and ACCESSORIES BOILER MOUNTINGS are the components generally mounted on the surface of the boiler to have safety during operation. These are the essential parts of the boiler, without which the boiler operation is not possible. The following are the important mountings of the boiler: 1. Safety valves [a]. Dead weight safety valve [b] Spring loaded safety valve [c] Lever safety 2. Water level indicator 3. Pressure Gauge 4. Steam stop valve 5. Feed check valve 6. Blow off cock 7. Manhole 8. Fusible plug Richard Victor, Department of Mechnical 10 Engineering, SIRT Bhopal BOILER MOUNTINGS • SAFETY VALVE: The function of the safety valve is to permit the steam in the boiler to escape to atmosphere when pressure in the s in the boiler drum raises above the working pressure. The safety valve operates in the principle that a valve is pressed against its seat through some agency such as strut, screw or spring by external weight or force, when the steam force due to boiler pressure acting under the valve exceeds the external force, the valve gets lifted off its seat and some of the steam rushes out until normal pressure is restored again. The commonly used safety valves are given below: i) Dead weight safety valve ii) Lever safety valve iii) Spring loaded safety valve iv) High steam-low water safety valve Richard Victor, Department of Mechnical 11 Engineering, SIRT Bhopal Richard Victor, Department of Mechnical 12 Engineering, SIRT Bhopal BOILER MOUNTINGS • Water level indicator: the function of the water level indicator is to show the level of water in the boiler. Richard Victor, Department of Mechnical 13 Engineering, SIRT Bhopal BOILER MOUNTINGS • FUSIBLE PLUG: The function of the fusible plug is to extinguish the fire in the event of the boiler shell failing below a certain specified limit. We know that when the water on heating transforms into steam, the level of water in the boiler falls down. If the water is not replenished and the steam generation continues then the parts, which have been uncovered by water uncovered by water may get overheated and subsequently are melted. To safeguard against this eventuality we use fusible plug. The fusible plug is inserted at the box crown or cover the combustion chamber at the lowest permissible water level. Richard Victor, Department of Mechnical 14 Engineering, SIRT Bhopal Richard Victor, Department of Mechnical 15 Engineering, SIRT Bhopal BOILER MOUNTINGS • PRESSURE GAUGE: Each boiler has to be provided with a pressure gauge, which record the pressure at which the steam is being generated in the boiler. Richard Victor, Department of Mechnical 16 Engineering, SIRT Bhopal BOILER MOUNTINGS • BLOW OFF COCK: The blow of cock serves to drain out the water from the boiler periodically for any one of the following reasons: 1) To discharge mud, scale and other impurities which settle down at the bottom of the boiler? 2) To empty the boiler for internal cleaning and inspection. 3) To lower the water level rapidly if the level becomes too high. The unit is fitted at the lowest portion of the boiler. It may be mounted directly to the boiler shell or through an boiler elbow pipe, which is fitted to the boiler shell. Richard Victor, Department of Mechnical 17 Engineering, SIRT Bhopal BOILER MOUNTINGS • FEED CHECK VALVE: The feed check valve has the following two functions to perform: 1. To allow the feed water to pass into the boiler. 2. To prevent the back flow of water from the boiler in the events of the failure of the feed pump. Richard Victor, Department of Mechnical 18 Engineering, SIRT Bhopal Richard Victor, Department of Mechnical 19 Engineering, SIRT Bhopal Richard Victor, Department of Mechnical 20 Engineering, SIRT Bhopal BOILER MOUNTINGS • STOP VALVE: The function of the steam stop valve is to shut off or regulate the flow of steam from the boiler to the steam pipe or from the steam pipe to the engine. When used for the former purpose, it is called junction valve. Usually the junction valve means a regulating valve of larger size and a stop valve refers to a regulating valve of smaller size. The junction valve is mounted on the highest part of the steam space of the boiler and is connected to the steam pipe, which carries the steam to the engine. Richard Victor, Department of Mechnical 21 Engineering, SIRT Bhopal Richard Victor, Department of Mechnical 22 Engineering, SIRT Bhopal BOILER MOUNTINGS • MAN HOLES: These are door to allow men to enter inside the boiler for the inspection and repair. Richard Victor, Department of Mechnical 23 Engineering, SIRT Bhopal BOILER MOUNTINGS and ACCESSORIES Boiler Accessories: These are those devices which are installed with a boiler and its neighbouring area to increase the efficiency of the boiler. These are not the essential part of the boiler and thus without installing these devices, the boiler operation can be accomplished though at a lower efficiency. The following are the important accessories of the boiler are: 1. Economiser 2. Air pre-heater 3. Super heater 4. Feed pumps Richard Victor, Department of Mechnical 24 Engineering, SIRT Bhopal BOILER ACCESSORIES • AIR PREHEATER: Air heater or air pre-heater is waste heat recovery device in which the air on its way to the furnace is raised in temperature by utilizing the heat of the exhaust gases. Air pre-heater are classified into the following two categories. • Recuperative Air heater • Regenerative Air heater Richard Victor, Department of Mechnical 25 Engineering, SIRT Bhopal BOILER ACCESSORIES Richard Victor, Department of Mechnical 26 Engineering, SIRT Bhopal BOILER ACCESSORIES • ECONOMISER: The economizer is a device, which serves to recover some of the heat being carried by exhaust flue gases. The heat thus recovered is utilized in raised temperature in feed water being supplied to the boiler. If the water is raised and thus there is a saving in the consumption of fuel. • The economizer unit is installed in the path of the flue gases between the boiler and the chimney. Richard Victor, Department of Mechnical 27 Engineering, SIRT Bhopal BOILER ACCESSORIES Richard Victor, Department of Mechnical 28 Engineering, SIRT Bhopal BOILER ACCESSORIES Richard Victor, Department of Mechnical 29 Engineering, SIRT Bhopal BOILER ACCESSORIES • SUPER HEATER:- The steam generated by a simple boiler in generally wet or at the most dry saturated.
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