Boiler Circulation System
PMI Revision 01 1
Types of boilers
Drum type
Once-through type
PMI Revision 01 2
Drum type boiler
Steam generation takes place in furnace
water walls
Fixed evaporation end point - the drum
Steam -water separation takes place in
the drum
Separated water mixed with incoming
feed water
PMI Revision 01 3
Boiler Water Circulating Systems
Choice of Circulating system depends on
Operating Pressure
The density difference between water and steam
provides the driving force for the Circulating fluid
Higher pressures units warrant pumps to ensure
circulation (Natural circulation not adequate)
PMI Revision 01 4
Boiling
• Difference Between Boiling
and evaporation
– Evaporation occurs at liquid-
vapour interface, when
vapour pressure is less than
the saturation pressure. Evaporation
– Boiling, on the other hand,
occurs at the solid–liquid
interface when a liquid is
brought into contact with a
surface maintained at a
temperature sufficiently
above the saturation
temperature of the liquid
PMI Revision 01 5
Boiling
• The boiling process is characterized by the rapid
formation of vapor bubbles at the solid–liquid
interface that detach from the surface when they
reach a certain size and attempt to rise to the
free surface of the liquid.
• Boiling is a complicated phenomenon because of
the large number of variables involved in the
process and the complex fluid motion patterns
caused by the bubble formation and growth.
PMI Revision 01 6
Pool and Flow Boiling
• In pool boiling, the fluid
is stationary, and any
motion of the fluid is due
to natural convection
currents and the motion
of the bubbles under the
influence of buoyancy.
PMI Revision 01 7
Sub-cooled and saturated boiling
• Boiling is said to be
subcooled (or local) when
the temperature of the
main body of the liquid is
below the saturation
temperature (i.e., the bulk
of the liquid is subcooled)
and saturated (or bulk)
when the temperature of
the liquid is equal to
saturation temperature
(i.e., the bulk of the liquid is
saturated).
PMI Revision 01 8
Boiling Regimes and the Boiling Curve
• Four different boiling
regimes are observed:
– natural convection
boiling,
– nucleate boiling,
– Transition boiling, and
– film boiling
• These regimes are
illustrated on the boiling
curve which is a plot of
boiling heat flux versus
the excess temperature.
PMI Revision 01 9
Boiling Regimes In Pictures
PMI Revision 01 10
Boiling Regimes Photographs
Film Boiling
PMI Revision 01 11
Critical Heat Flux
• Critical heat flux describes the thermal limit of a
phenomenon where a phase change occurs during
heating (such as bubbles forming on a metal surface
used to heat water), which suddenly decreases the
efficiency of heat transfer, thus causing localized
overheating of the heating surface.
PMI Revision 01 12
CHF Enhancement
• When the flow in a tube is directed
by twisted tape, a helical coil or a
grooved surface (rifled tube), a swirl
flow can be generated. By the
centrifugal force generated by the
swirling motion of the fluid, liquid is
forced to flow on the tube surface
and vapor is forced to flow along
center line of the tube. Consequently,
local velocity of the flow is increased
compared to that in a smooth tube
under the same mass flux. Therefore,
the swirl motion of the flow can
contribute to enhancement of the
CHF. Several methods to this end
have been developed. Among these
are insertion of twisted tape,
insertion of a helical coil, and
grooving the tube surface.
PMI Revision 01 13
PMI Revision 01 14
PMI Revision 01 15
Types of Circulation
PMI Revision 01 16
Controlled Circulation (Vs) Once Thru’
CC OT
PMI Revision 01 17
The Concept
The mass flow rate thru’ all heat transfer
circuits from Eco. inlet to SH outlet is kept
same except at low loads wherein recirculation
is resorted to protect the water wall system
PMI Revision 01 18
Circulating System
PMI Revision 01 19
Boiler Capacity
Growth of Unit Increase - Indian Scenerio
Size in India
600
500 MW
Controlled 500 MW
Circulation Once Thro'
500
400
Boiler Capacity in MW
300
250 MW
210 MW 210 MW
200
200 MW Tower Type
110 MW
Tangential Firing 120 MW
100
60 MW
Wall Firing
0
1960 1970 1980 1990 2000 2010
Year
PMI Revision 01 20
Growth Of Unit Sizes In India(contd..)
Unit Year of Steam Parameters
Size Introduction
Steam SHO SHO/RHO
Flow Pressure Temperature
(t/h.) (kg/cm2) (Deg. C)
30MW 1969 150 63 490
60/70MW 1965 260 96 540
110/120MW 1966 375 139 540/540
200/210MW 1972 690 137/156 540/540
250MW 1991 805 156 540/540
500MW 1979 1670 179 540/540
660MW 2004 2245 256 540/568
PMI Revision 01 21
200 MW NTPC Korba
PMI Revision 01 22
500 MW NTPC Singrauli
PMI Revision 01 23
General Arrangement of SG
Reheater Chimney
Boiler
Drum Final Super
Heater
Platen Super LTSH
Heater
Economizer
Coal
Secondary Air
Bunker
Wind Duct PA duct
Box
Furnace
Flue Gas
APH Duct
Coal Feeder
Coal Mill
F D Fan
PMI Revision 01 P A Fan 24
Major Components
• Furnace
- Four sides surrounded by water wall tubes
- First pass of the boiler
- Where combustion takes place.
• Boiler drum
-Separates steam from steam water mixture.
• Down comers
-The pipes to transport water from boiler drum to
all the four sides of water wall tubes.
PMI Revision 01 25
Major Boiler Components
• Water wall
– Bundles of boiler tubing located in the first pass of the
boiler forming four sides of furnace
– Heat is transferred mainly by radiation to the water wall
tubes to convert water into steam water mixture.
• Economizer
– Section of boiler in which FW is first introduced into and
flue gas is used to raise the temp. of FW.
PMI Revision 01 26
Major Boiler Components
• Super heaters
– Bundles of boiler tubing located in the flow path
of the hot flue gases.
– Heat is transferred from flue gases to the steam in
super heater tubes
• Re-heater
– Bundles of tubes exposed to combustion gases in
the same manner as super heater
PMI Revision 01 27
Major Boiler Components
• Steam Cooled Wall
-Steam cooled wall is part of super heater that forms the
closed space of second pass of boiler
• Spray attemperators
– Are spray nozzles in the boiler tubes between two super
heaters and two reheaters.
– The spray nozzles supply a fine mist of pure water into
steam to prevent damage from overheating
PMI Revision 01 28
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.
PMI Revision 01 29
Types of Drum Level Control
• The Three main options available for drum
level control are Single element drum level
control
• Two element drum level control
• Three-element drum level control
PMI Revision 01 30
Why controlled circulation is
required?
• AS THE PRESSURE
INCREASES,THE DIFFERENCE IN
DENSITY BETWEEN WATER AND
STEAM REDUCES .
• THUS THE HYDROSTATIC HEAD
AVAILABLE WILL NOT BE ABLE
TO OVERCOME THE
FRICTIONAL RESISITANCE FOR A
FLOW CORRESPONDING TO THE
MINIMUM REQUIREMENT OF
COOLING OF WATER WALL
TUBES.
• NATURAL CIRCULATION IS
LIMITED TO 175KSC
Diff in Density
PMI Revision 01 31
2.Controlled circulation system:
• use of controlled circulation pump
• used for pressure up to 194kg/cm2 (sub critical pr.)
• circulation ratio=6-9
PMI Revision 01 32
3.Combined circulation system:
Circulation ratio=2
No use of drum
Use of controlled circulation pump
Use for pressure above 200kg/cm2.
PMI Revision 01 33
Economizer
Boiler Economizer are feed-water heaters in which the heat
from waste gases is recovered to raise the temperature of
feed-water supplied to the boiler.
PMI Revision 01 34
Economizer
• 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
PMI Revision 01 35
Tube Bank Arrangement
PMI Revision 01 36
Finned Economizers
PMI Revision 01 37
Thermal Parameters of Economizer
• Out side diameter : 25 – 38 mm.
• Tube thickness: 3 – 5 mm
• Transverse spacing : 2.5 – 3.0
• Longitudinal spacing : 1.5 – 2.0
• The water flow velocity : 600 – 800 kg/m2 s
• The waterside resistance should not exceed 5 – 8 %. Of
drum pressure.
• Flue gas velocity : 7 – 13 m/s.
PMI Revision 01 38
Advantages of Economizer
6oC raise in feed water
temperature, by economizers
corresponds to a
1% saving in fuel consumption
220 C reduction in flue gas
temperature increases boiler
efficiency by 1%
PMI Revision 01 39
6oC raise in feed water temperature, by
economizers corresponds to a
1% saving in fuel consumption
PMI Revision 01 40
Location and Arrangement
• Ahead of air-heaters
• Following the primary super-heater or re-heater
• Counter-flow arrangement
• Horizontal placement (facilitate draining)
• Supported to prevent sagging, undue deflection and
expansion .
• Stop valve and non-return valve incorporated to ensure
recirculation in case of no feed-flow
• Ash hopper below as flue gas takes a turn
PMI Revision 01 41
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.
PMI Revision 01 42
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
PMI Revision 01 43
BOILER DRUM
PMI Revision 01 44
DRUM SERVES TWO MAIN
FUNCTIONS
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
PMI Revision 01 45
SPECIFICATION-
500MW
MATERIAL - CARBON STEEL
LENGTH - 22070 MM
OD - 2130 MM
ID - 1778 MM
DESIGN.PR - 204 KSC
WEIGHT(INT) -246 TONNES
WITHOUT(INT) –224 TONNES
PMI Revision 01 46
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.
PMI Revision 01 47
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
PMI Revision 01 48
Drum Internals
Steam
Separator
PMI Revision 01 49
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.
PMI Revision 01 50
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.
PMI Revision 01 51
Construction of Water Walls
• Tangent tube The
construction consists of
water wall placed side by
side nearly touching each
other. An envelope of thin
sheet of steel called "SKIN
CASING" is placed in
contact with the tubes,
which provides a seal
against furnace leakage.
PMI Revision 01 52
Construction of Water Walls
Membrane Wall A number of tubes are
joined by a process of fusion welding or
by means of steel strips called 'fins
pressurized furnace is possible with the
related Advantages
•Increase in efficiency
•Better load response simpler
combustion control.
•Quicker starting and stopping
•Increased availability of boiler.
•Heat transfer is better
•Weight is saved in refractory and
structure
•Erection is made easy and quick
PMI Revision 01 53
WATER WALL
SPECIFICATION
NO OD(MM)
FRONTWALL 283 51
SIDEWALLS 444 51
REAR WALLS 283 51
ROOF 142 57
PMI Revision 01 54
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.
PMI Revision 01 55
IBR Requirement for Hydraulic test
• Every boiler shall be hydraulically tested after erection at site in
presence of the Inspector to 1¼ times the maximum working
pressure as certified by the Inspecting Authority, to be stamped on
the boiler, as free from any indication of weakness or defects.
• The test pressure shall be raised gradually under proper control at all
times so that it never exceeds by more than 6% of the required
pressure and maintained for 30 minutes whereupon the pressure
shall be reduced to maximum allowable working pressure and
maintained for sufficient time to permit close visual inspection for
leakage of pressure parts.
• The boiler shall satisfactorily withstand such pressure without
appreciable leakage or undue deflection or distortion of its parts for
at least ten consecutive minutes.
PMI Revision 01 56
IBR Requirement for Hydraulic test
• At the first hydraulic test of a boiler prior to
the issue of an original certificate
deflection measurements shall be made
before, during and after test of each
furnace length, fire-box and flat end or
other plates.
• After the application of the hydraulic test
the Inspector shall carefully examine the
boiler inside and outside and satisfy
himself that it has satisfactorily withstood
the test. PMI Revision 01 57
Thanks
PMI Revision 01 58
