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Boilers Leture Notes VUM Steam Boilers Lecture Notes V Uma Maheshwar 11-11-11 Steam Boilers/Steam Generators Introduction: The function of a boiler is to evaporate water into steam at a pressure higher than the atmospheric pressure. Water free from impurities such as dissolved salts , gases and non soluble solids should be supplied to boilers. This is done by suitable water treatment . Steam is useful for running steam turbines in electrical power stations , ships and steam engines in railway locomotives. Boiler furnace fuel can use either solid , liquid or gaseous fuel: Wood, Charcoal, Coal, Coke, Oil, Municipal waste, industrial solid waste , refinery gas, rice husk, Paper sludge, Electric power Steam Boilers/Steam Generators Boilers are mainly classified as fire tube boilers and water tube boilers. Fire tube boilers :- hot gases from the furnace pass through the tubes which are surrounded by water. Water tube boilers :- water circulates inside the tubes which are surrounded by the hot gases from the furnace. Steam Boilers/Steam Generators Other Classifications : Based on Pressure : =>80 bar : High Pressure Boilers Babcock & Wilcox, Lamont, Benson, Velox <80 bar : Low Pressure Boilers Locomotive, Lancashire, Cornish, Cochran Steam Boilers/Steam Generators Other Classifications : Based on Pressure : =>80 bar : High Pressure Boilers Babcock & Wilcox, Lamont, Benson, Velox <80 bar : Low Pressure Boilers Locomotive, Lancashire, Cornish, Cochran Steam Boilers/Steam Generators Other Classifications : Based on Type of Circulation of water : Natural Circulation : Natural Convection Babcock & Wilcox, Stirling, Lancashire Forced Circulation : Using pumps Lamont, Benson, Velox Steam Boilers/Steam Generators Other Classifications : Based on Location of Furnace : Internally Fired: Furnace inside the shell Lancashire, Cochran Externally Fired : Furnace outside the shell Babcock & Wilcox, Stirling Steam Boilers/Steam Generators Other Classifications : Stationary/ Portable Horizontal, Vertical, Inclined (= Axis of Boiler) In FIRE TUBE : Single tube Simple Vertical Tube,Cornish Multi tube Lancashire, Locomotive 1. Fire Tube Boiler •Relatively small steam capacities (12,000 kg/hour) •Low to medium steam pressures (18 kg/cm2) •Operates with oil, gas or solid fuels 2. Water Tube Boiler •Used for high steam demand and pressure requirements •Capacity range of 4,500 – 120,000 kg/hour •Combustion efficiency enhanced by induced draft provisions •Lower tolerance for water quality and needs water treatment plant Modern Packaged Boiler •Comes in complete package To Chimney •Features •High heat transfer •Faster evaporation •Good convective heat transfer Oil •Good combustion Burner efficiency •High thermal efficiency •Classified based on number of passes Classification of Steam boilers Water Tube Boilers : Babcock and wilcox water tube boiler Stirling boiler (bent tube type water tube boiler) Fire Tube /Smoke Tube/ Shell Tube Boilers: Cornish boiler Locomotive boiler Cochran boiler Lancashire boiler High Pressure boilers: La mont boiler Benson boiler Loeffler boiler Velox boiler Comparison of Fire Tube & Water Tube Boilers Fire Tube boiler Water tube Boiler Hot gases pass through the tubes, Water passes through the water surrounds them tubes,hot gases surround them. Generally Internally Fired Generally Externally Fired Used for low pressure steam Medium to high pressure upto 165 bar. upto 25 bar Steam rate is low upto 9 TPH Steam rate is high upto 450 TPH Thermal efficiency is low Thermal efficiency is high Overall efficiency 75 % Overall efficiency with economiser 90 % Drum dia large for same Power Drum dia small for same Power Comparison of Fire Tube & Water Tube Boilers Fire Tube boiler Water tube Boiler Used to produce process steam Suitable for Large Power Plants and not suitable for Large Power Plants More Steam space, Less Steam space , more pressure fluctuation Hence, less pressure fluctuation water circulation poor better circulation of water heating surface less heating surface more For given Power, it requires For given Power, it requires Less Floor Area more Floor Area Bursting produces greater risk Bursting does not produce any destruction to boiler Comparison of Fire Tube & Water Tube Boilers Fire Tube boiler Water tube Boiler Construction is difficult Construction is Simple Transportation is Difficult Transportation is Simple Requires less Skill in Efficient & Requires more Skill and Careful Attention Economic Working Various Parts are not so easily Various parts are more accessible. accesible for Cleaning, repair and Inspection Steam boiler mountings Safety valves Dead weight safety valve Spring loaded safety valve Lever loaded safety valve High steam and low water safety valve Water level indicators Pressure gauge Attachment for inspector’s test gauge Steam stop valve Feed check valve Blow-off cock Manhole Fusible plug Steam boiler accessories Economizers Air pre-heaters Superheaters Smooth tube hairpin type superheater Multiple loop superheaters Feed pumps Steam drier or separator Steam trap Expansion trap Duplex feed pump Steam drier or separator Steam trap Expansion trap Bucket or float trap Injectors Pressure reducing valve About Units of Power used in Automobiles and Steam Boilers Metric horsepower — 1 HP(metric)= 1 PS = 75 kgf-m/sec= 0.73549875 kW/hp (735.5 watts/hp)= (German: PS= Pferdestärke = horse strength) Mechanical horsepower — 0.74569987158227022 kW/hp (745.7 watts/hp) (33,000 ft-lbs/min) (550 ft-lbs/sec) Electrical horsepower — 0.746 kW/hp (746 watts/hp) Boiler horsepower — 9.8095 kW/hp (9810 watts/hp) boiler horsepower unit is used for boilers in power plants. It is the energy rate needed to evaporate 34 .5 lb (15.65 kg) of water at 212 °F (100 °C) in one hour. Natural water circulation in a Heat transfer in the convection water-tube boiler section Modes of Heat Transfer in Boiler tubes Heat transfer in the furnace or radiant section Water Tube BOILERS Babcock & Wilcox Stirling Water Tube Boiler Longitudinal drum boiler Water Tube Boiler Cross drum boiler 1 1 1 1 Bent tube or Stirling Boiler A water tube boiler with a superheater Stirling Water Tube Boiler Fire tube BOILERS Simple vertical tube Cochran Locomotive Cornish Lancashire 1 1 1 1 1 1 Lancashire Boiler The hot gaseous products of combustion passes from the furnace through the large-bore corrugated flues. Heat from the hot flue gases is transferred into the water surrounding these flues. The boiler is in a brickwork setting which is arranged to duct the hot gases emerging from the flues downwards and beneath the boiler, transferring heat through the bottom of the boiler shell, and secondly back along the sides of the boiler before exiting through the stack. These two side ducts meet at the back of the boiler and fed into the chimney. These passes were an attempt to extract the maximum amount of energy from the hot product gases before they are released to atmosphere. 1 1 Pressur Steam Temp Remarks e bar Rate OC TPH Water Tube Boilers Babcock and wilcox 12-18 20-40 Stirling boiler 60 50 450 Fire Tube Boilers Cornish boiler Locomotive boiler 15-20 8.5 370 Cochran boiler Upto 20 0.15 o 3.0 Lancashire boiler 16 8 High Pressure >80 boilers La mont boiler 120 45-50 500 Benson boiler 500 150 650 Loeffler boiler 140 100 Velox boiler 100 HIGH PRESSURE BOILERS La mont Benson Loeffler Velox A forced circulation water-tube boiler Forced Circulation Boiler Rate~ 50 TPH Pressure~130 bar Temp~ 500 o C 1 La Mont Boiler 1 A forced Circulation boiler A pump circulates water at a rate of 8-10 times of mass of steam evaporated to prevent tubes from over heating Water from Drum is passed through a nozzle into evaporator Problem : Formation and attachment of bubbles on the inner surfaces of the heating tubes They offer higher thermal resistance compared to water film Benson Boiler A forced Circulation Supercritical boiler Boiler Pressure is raised above Critical pressure where density of water & steam are same. Hence formation of bubbles is eliminated on surfaces of heating tubes. Very insensitive to load fluctuations. Hence suitable for grid power station. No water drum is required. Small dia. Tubes are used. Superheater is an integral part of forced circulation system Problem : Deposition of salt 1 and sediments on tubes surfaces increases thermal resistance Loeffler Boiler A forced Circulation boiler Problem of Deposition of salt and sediments on tubes is solved by preventing flow of water into tubes. By Pass 65 % of steam generated to evaporating drum to generate steam from feed water supplied. Circulate the steam only through tubes using STEAM PUMP ! Evaporator water drum is required Superheater is an integral part of forced circulation system. Nozzles which distribute the superheated steam through water into evaporator drum are 1 of special design to avoid noise and priming. Very Compact boiler Used for land and sea transport power generation Velox Boiler A forced Circulation boiler Air is compressed to 2.5 bar with the help of a compressor run by gas turbine before supplying to combustion chamber to get supersonic velocity of gases passing through gas tubes. Heat is transferred at a higher rate due to supersonic velocity of Gases. Flue gases coming out of superheater at high velocity are used to run a gas turbine which in turn runs the compressor. Some extra power required to run Compressor is supplied from electric motor. A pump circulates water at a rate of 10-20 times of mass of steam evaporated to prevent tubes from over heating 1 Oil fired boiler to gas and electricity, Which are all vertical
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