Umschlag Handbuch Dampf EN 0910 NEU.Indd
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Technical guide Steam boilers 1 Contents 7 Foreword 9 Introduction 11 A Utilising steam 12 History of steam generation 15 B What is steam? 16 Wet steam, saturated steam, superheated steam 18 B.1.2 Thermal capacity 19 B.1.3 Application areas Contents 21 C Components of a steam boiler system 24 Steam boilers 26 C.1 Steam boilers 32 C.1.1 Boiler equipment 38 C.1.2 Multi-boiler system 41 C.1.3 Steam boiler in standby mode 42 C.1.4 Waste heat boilers 44 Economiser (ECO) 46 Steam superheaters (SH) 48 Combustion system 49 C.4.1 Combustion air 49 C.4.2 Liquid fuels 50 C.4.3 Gaseous fuels 51 C.4.4 Dual fuel burner 52 C.4.5 Wood combustion 54 Water treatment 58 C.5.1 Chemical water treatment (CWT) 59 C.5.2 Osmosis systems 60 C.5.3 Thermal water treatment (TWT) 64 Condensate management / treatment 65 C.6.1 Low pressure condensate 65 C.6.2 High pressure condensate 66 C.6.3 Condensate treatment 67 C.6.4 Sampling cooler 69 C.6.5 Dosing corrective chemicals 70 Pumps 71 C.7.1 Feedwater pumps & control 73 C.7.2 Condensate pumps 74 System-dependent thermal equipment 75 C.8.1 Mixing cooler 75 C.8.2 T.D.S. expander and lye cooler 75 C.8.3 Exhaust vapour condenser 76 C.8.4 Feedwater cooler 76 C.8.5 Feedwater preheater 78 Pipework system 80 Flue system 2/3 82 Internal system demand 83 C.11.1 Internal power demand 83 C.11.2 Internal thermal power demand 84 Insulation of pipes, tanks etc. 85 C.12.1 Thermal insulation 85 C.12.2 Protection against the formation of condensate 86 Control system 87 C.13.1 Main functions 88 Rules and regulations 88 C.14.1 Legal framework 93 D Component layout 96 Steam boiler selection 96 D.1 Steam boiler selection 98 D.1.2 Selection of the boiler pressure level 99 D.1.3 Waste heat boilers 102 Product range 103 D.2.1 Steam boilers 104 D.2.2 Flame tube temperature monitoring (FTTM) 105 D.2.3 Economiser (ECO) operation 106 D.2.3.1 ECO output 108 D.2.3.2 Amortisation Economiser (AECO) 110 D.2.3.3 Utilising condensing technology 113 D.2.3.4 Superheater (SH) operation 116 D.2.3.5 Pressure / heat maintenance – steam boiler 118 Combustion systems 119 D.3.1 Variable-speed combustion air fan 120 D.3.2 O2 control 121 D.3.3 Amount of fuel / fuel demand 122 D.3.4 Combustion air, supply air ducts 125 D.3.5 Acoustic emissions from monoblock / duoblock burners 128 Water treatment 129 D.4.1 Total deaeration system 130 D.4.2 Partial deaeration system 132 D.4.3 Chemical water treatment system (CWT softening system) 136 D.4.4 Function description – reverse osmosis system (RO) 139 D.4.5 Water analysis, general explanations Contents 142 Condensate management 143 D.5.1 Function description of open vented condensate systems 144 D.5.2 Function description of sealed unvented condensate systems 150 Pumps 151 D.6.1 Feed pumps – criteria for design and operation 160 D.6.2 Condensate pumps – criteria for sizing and operation 162 Sizing the thermal equipment 163 D.7.1 Mixing cooler 168 D.7.2 T.D.S. expander 171 D.7.3 Exhaust vapour condenser 174 D.7.4 Feedwater cooler 180 D.7.5 Sampling cooler 182 Pipework 183 D.8.1 Pipework 188 D.8.2 Specifications – materials, welding work 196 D.8.3 Pipework calculations and sizing 210 D.8.4 Strength, expansion, support spans, clearances, routing / mountings 219 D.8.5 Notes on design engineering of selected pipework systems 219 D.8.5.1 Steam pipes / steam distributors 224 D.8.5.2 Condensate pipes and systems 226 D.8.5.3 Boiler lye and blow-down lines 227 D.8.5.4 Feedwater – softened water – drinking water 229 D.8.5.5 Exhaust vapour, waste steam and discharge pipes 232 D.8.5.6 Fuel lines 233 D.8.5.7 Waste water and floor drainage systems 236 Flue system 237 D.9.1 Planning and design information for connection pieces 239 D.9.2 Sizing the flue system 240 D.9.3 Chimney connection and design 242 D.9.4 Common flue system, merging of flue gas flows 244 Internal system demand 244 D.10.1 Internal electrical system demand 248 D.10.2 Internal thermal system demand 253 E Requirements and regulations 254 Basic requirements and regulations for the licensing procedure 254 E.1.1 Licensing procedure according to Section 13 of the [German] Health & Safety at Work Act 265 E.1.2 Overview of German licensing procedures 268 E.1.3 Overviews and summary of application documents and their compilation 271 E.1.4 Overviews for compiling the application documents 4/5 272 Principle requirements and regulations for the installation of steam boilers 273 E.2.1 Installation of category IV land-based steam boilers 273 E.2.2 Installation of category III land-based steam boilers (TRD 802) 274 E.2.3 Steam boiler system installation room 277 E.2.4 Acoustic emissions 278 E.2.5 Transportation and handling 279 E.2.6 Earthquake protection 283 F Operation 284 Operating modes 284 F.1.1 Operating modes 286 F.1.2 Standards and regulations governing operation 287 F.1.3 Inspection intervals for boilers according to the Pressure Equipment Directive 293 G Appendix Technical data collection and tables 294 [A 1] Standard circuit diagram; other diagrams can be found in the cover inside pocket 296 [A 2.1] Thermal insulation of pipes 297 [A 2.2] Contact protection insulation 298 [A 3] Technical Guide on water quality – extract 302 [A 4] Sketch of steam boiler container system 304 [Tb. 1.0] SI units / conversion table 305 [Tb. 1.1] 1. Conversion table – BTU / BHP / KW / t/h 306 [Tb. 2.0] Steam table (saturation state) 309 [Tb. 2.1] Properties of superheated steam 313 [Tb. 2.2] Properties of saturated steam 314 [Tb. 2.3] Enthalpy/Entropy 315 [Tb. 3.0] Internal pipe roughness 316 [Tb. 3.1] Pipe friction factor / Reynolds number 317 [Tb. 4.0] Pressure drop in steam pipes 318 [Tb. 4.1] Pressure drop in steam pipes – example 319 [Tb. 5] Conversion for the units of water hardness 320 [Tb. 6] Re-evaporation in condensate expansion 311 [Tb. 7] Pipe cross section for given steam parameters – example 322 [Tb. 8] Pressure drop in water pipes for a particular flow rate – example 323 [Tb. 9] Flow velocities (standard values) 324 [Tb. 10] Steam boiler inspection checklist 325 Literature references 326 Keyword index 336 Imprint Introduction 6/7 Foreword The global energy situation is characterised In selecting the subjects to be covered, we by finite natural gas and mineral oil reserves, have given priority to planning and engineering simultaneously increasing consumption and reliability in the layout of steam boilers and significant price increases. Furthermore, ever their components. After all, proper planning increasing CO2 emissions are heating up the and professional design are fundamental atmosphere, leading to dangerous climate prerequisites, not only for the trouble-free change. This forces us to handle energy and efficient operation of a steam boiler responsibly. We need greater efficiency system, but also for the safety of people and and increased use of renewable energy the environment. sources. As the largest consumer of energy, the industrial sector can make a significant I am convinced that this planning manual contribution towards essential energy will be of welcome assistance to everyone savings and CO2 reduction through the use of involved in the design of industrial steam innovative and efficient heating technology. generation systems. I wish every success to all those who use it. The comprehensive product range from Viessmann includes system solutions for Dr Martin Viessmann every type of energy source, which minimise consumption of resources for convenient heat provision and reliable steam supply, and help protect the environment by reducing CO2 emissions. Whether it be steam boilers with integrated economisers and downstream condensing heat exchangers for oil or gas combustion, or wood-burning (biomass) steam boilers for generating process steam with downstream economisers, Viessmann has the suitable solution. The integration of heat recovery systems requires precisely coordinated individual components to achieve maximum efficiency and to keep costs under control. This must be based on proper system planning. Viessmann began with the development and production of powerful boilers for generating steam several decades ago and can therefore call on extensive experience. We would like you to benefit from this experience through this compact planning manual. Introduction Vitomax production plant, Mittenwalde 8/9 Introduction This steam manual is intended as a supplement to such literature as the "steam" technical series and the sales folder for steam industrial systems, with a focus on the design and sizing of steam generation systems powered by the fuels oil, gas and wood (biomass), as well as waste heat boilers up to a generator output of 75 t/h. The manual must therefore be considered In spite of thorough checking, we cannot as a "guideline" for the approach to be taken completely rule out errors in the content or in seeking a conclusive generator concept printing errors that have been overlooked. on the basis of Viessmann-specific "main Viessmann expressly accepts no liability for components". System and heating engineers, such mistakes. As a consequence, Viessmann planners and production engineers will be accepts no responsibility for the correctness of able to use this manual in conjunction with statements made in this publication.