THERMAL PERFORMANCE OF SG10 BOILER

PREPARED BY: ASHUTOSH KUMAR SINGH (AX2616) 3rd YEAR, CHEMICAL ENGINEERING

 A BOILER IS A WATER CONTAINING VESSEL WHICH TRANSFERS HEAT FROM A FUEL SORCE (OIL, GAS OR COAL) INTO STEAM WHICH IS PIPED TO A POINT WHERE IT CAN BE USED TO RUN A PRODUCTION EQUIPMENT, TO STERILIZE, TO PROVIDE HEAT, TO STEAM CLEAN, ETC. THE ENERGY GIVEN BY THE STEAM IS SUFFICIENT TO CONVERT IT BACK INTO THE FORM OF WATER. WHEN 100% OF THE STEAM PRODUCED IS RETURNED TO BE REUSED, THE SYSTEM IS CALLED CLOSED SYSTEM.

SINCE SOME PROCESSES CAN CONTAMINATE THE STEAM, SO IT IS NOT ALWAYS DESIRABLE TO FEED THE CONDENSATE BACK INTO THE BOILER.
A SYSTEM THAT DOES NOT RETURN THE CONDENSATE IS CALLED THE OPEN SYSTEM.

TYPES OF BOILERS

FIRE OR HOT GASES ARE DIRECTED THROUGH THE INSIDE OF TUBES WITHIN THE BOILER SHELL, WHICH ARE SURROUNDED BY WATER.
THE TUBES ARE ARRANGED IN BANKS SO THAT THE GASES CAN BE PASSED THROUGH THE BOILER UPTO 4 TIMES BEFORE PASSING OUT THE STACK.

WATER TUBE BOILER OR WATERTUBE-IN BOILERS IN WHICH CONDITIONS ARE REVERSED WITH THE WATER PASSING THROUGH THE TUBES AND THE HOT GASES PASSING OUTSIDE THE TUBES. THESE BOILERS CAN BE BUILT TO ANY STEAM QUALITIES AND PRESSURES AND HAVE HIGHER EFFICIENCIES THAN FIRE TUBE BOILERS.

VARIOUS TYPES OF FUELS CAN BE FIRED WITH EASE INCLUDING SOLID, LIQUID AND GASEOUS. THE WATER COOLED MEMBRANE WALL CONSTRUCTION MAKES AN EXCELLENT FURNACE.

MODE OF CIRCULATION

 NATURAL CIRCULATION UNITS DO NOT REQUIRE A PUMP FOR MAINTAINING CIRCULATION OF BOILER FEEED WATER THROUGH THE EVAPORATOR TUBES. THE CIRCULATION IS ENSURED THROUGH NATURAL GRAVITY PRINCIPLES. THE FEED WATER GETS COLLECTED OVER HERE. AS IT IS COLD WHEN COMPARED TO THE WATER STEAM MIXTURE INSIDE THE BOILER, IT COMES DOWN AND GETS COLLECTED IN THE MUD DRUM, AND THE COLD WATER THEN ENTERS, THE FURNACE, AND AS IT REACHES EVAPORATOR TUBES, IT BECOMES STEAM AND THUS IT RISES UP AND COLLECTS IN THE STEAM SPACE.

 THE USE OF CIRCULATING PUMPS IN FORCED CIRCULATION UNITS INVOLVES AN OPERATIONAL AND MAINTENANCE COST, AND THEIR FAILURE FOR SOME REASON SUCH AS POWER OUTAGE OR PUMP FAILURE COULD SHUT DOWN THE HRSG IN A FORCED CIRCULATION UNIT, ALL THE EVAPORATOR TUBES RECEIVE THE SAME STEAM WATER FLOW, IRRESPECTIVE OF THEIR LOCATION, UNLESS SPECIAL EFFORTS ARE TAKEN TO DESIGN THE ORIFICE IN EACH TUBE AS IN CONTROLLED CIRCULATION UTILITY BOILERS.

IT COMES UNDER THE CATEGORY OF WATER TUBE BOILER IT OPERATES THROUGH NATURAL MODE OF CIRCULATION IT HAS A MAXIMUM CAPACITY OF 140 TPH BOILER LOAD. IT HAS HIGH FLUE GAS TEMPERATURES IT HAS CRITICAL TUBE SKIN TEMPERATURES, THEREFORE TST ESTIMATION AT VARIOUS STEAM LOADS IS REQUIRED. RECENTLY THERE WAS FAILURE OF SUPERHEATER TUBES IN SG10 BOILER AT HPCL, MUMBAI REFINERY. SO, THERE IS A REASON FOR THIS STUDY, WHY IT FAILED.

STEAM DRUM STEAM OUT

WATER IN

SUPERHEATER

STACK

BOILER EVAPORATOR
GT EXHAUST

MUD DRUM

ECONOMIZER

Gail gas + air

Hot flue Combustion chamber economizer gas

Cold Feed water

Mostly in the saturated form

Warm feed water

steam
Liquid water
Flows down the downcomers to the bottom of the boiler due to density difference Liquid water Heating of Water in the Tubes by radiation

Steam drum

Steam and water

Saturated steam

Primary superheater

Superheated steam

High pressure Steam turbine

Main steam

Secondary superheater

To other different units

CAUSTIC ATTACK OXYGEN PITTING HYDROGEN DAMAGE STRESS CORROSION CRACKING WATERSIDE CORROSION FATIGUE SUPERHEATER FIRE SIDE ASH CORROSION WATERWALL FIRESIDE CORROSION SHORT TIME OVERHEAT LONG TIME OVERHEAT GRAPHITIZATION EROSION MECHANICAL FATIGUE

1)

CAUSTIC ATTACK

IT OCCURS WHEN THERE IS EXCESSIVE DEPOSITION ON I.D TUBE SURFACES. THIS LEADS TO DIMINISHED COOLING WATER FLOW IN CONTACT WITH THE TUBE, WHICH IN TURN CAUSES LOCAL UNDER DEPOSIT BOILING AND CONCENTRATION OF BOILER WATER CHEMICALS. IF COMBINED WITH BOILER WATER CHEMISTRY UPSETS OF HIGH Ph, IT RESULTS IN A CAUSTIC CONDITION WHICH CORROSIVELY ATTACKS AND BREAKS DOWN PROTECTIVE MAGNETITE.

2)

STRESS CORROSION CRACKING

SCC IS MOST COMMONLY ASSOCIATED WITH SUPERHEATER MATERIALS AND CAN LEAD TO EITHER TRANSGRANULAR OR INTERGRANULAR CRACK PROPAGATION IN THE TUBE WALL. IT OCCURS WHERE A COMBINATION OF HIGH TENSILE STRESSES AND A CORROSIVE FLUID ARE PRESENT. THE DAMAGE RESULTS FROM THE CRACK THAT PROPAGATES FROM THE I.D. THE SOURCE OF CORROSIVE FLUID MAY BE CARRYOVER INTO THE SUPERHEATER FROM THE STEAM DRUM OR FROM CONTAMINATION DURING BOILER ACID CLEANING IF THE SUPERHEATER IS NOT PROPERLY PROTECTED.

BOILER TYPE LOCATION FUEL TYPE FURNACE CONFIGURATION

BI-DRUM, NATURAL CIRCULATION, FORCED DRAFT SEMI OUT DOOR GAIL GAS WIDTH DEPTH (5540 MM) (9600 MM) FUEL OIL 3.23*105 VOLUME HEATING SURFACE AREA FLAT (312 M3) PROJECTED (285 MM2) GAIL GAS 3.25*105

HEAT RELEASE BASED ON TOTAL AREA (KCAL/ HR.M2) SUPERHEATER NUMBER OF STAGES TYPE HEATING SURFACE, M2 SINGLE VERTICAL 218.8 ATTEMPERATOR NUMBER OF STAGES TYPE MEDIUM SPRAYED SINGLE SPRAY FEED WATER TOTAL HEATING BOILER ECONOMISER STEAM DRUM SUPERHEATER FURNACE TOTAL 2 SURFACE AREA, M BANK & MUD DRUM BOILER 1129.6 3975 39.4 220.8 404.2 5769 BURNERS: FRONT WALL, VERTICAL, STEAM ATOMISED FUEL BURNING EQUIPMENT FUEL CAPACITY NUMBER OF BURNERS PER LOCATION. MIN. NOR. MAX. GAIL GAS 3755 751 3129 3 3 TIER

LOAD (%) LOAD (TPH) EXCESS AIR LEAVING FROM BOILER (%) DRUM DESIGN PRESSURE (Kg/ cm2) DRUM OPERATING PRESSURE (Kg/ cm2) SUPERHEATER OUTLET PRESSURE (Kg/ cm2) FEED WATER TEMPERATURE AT ECONOMIZER INLET (0C) STEAM TEMPERATURE AT DRUM (0C) STEAM TEMPERATURE AT SUPERHEATER OUTLET (0C) FLUE GAS LEAVING FURNACE (0C) FLUE GAS LEAVING SUPERHEATER OUTLET (0C) FLUE GAS LEAVING BOILER BANK (0C) FLUE GAS LEAVING ECONOMIZER (0C) BOILER EFFICIENCY (LHV BASIS) (%)

25.0 40.0 35.05 56.08 40 30.0 52.0 52.0 40.4 41.0 40.2 40.6 120 120 251 252 346 392 794 96 585 717 265 28 123 16 85.87 85.57

60 84.12 20.0 52.0 42.3 41.4 120 254 397 1095 833 311 130 85.24

100 140 10 52.0 46.4 43.9 120 260 398 1277 1003 366 140 84.08

 STEP (1): 1) FLUE GAS FLOW CALCULATION:

Feed water (120 0C) (40.77 bar) Superheat steam (345.960 C) (40.42 bar)

economizer

evaporator

superheater

FUEL TOTAL ENERGY INPUT = mCP dT + mHfg + m(H2 - Hg) ACTUAL ENERGY INPUT= (TOTAL ENERGY INPUT/ BOILER EFFICIENCY ON LHV BASIS) FUEL REQUIRED= (ACTUAL ENERGY INPUT/ CALORIFIC VALUE OF FUEL) FLUE GAS FLOW= (AIR FLOW + FUEL REQUIRED)

Step (2): OUTSIDE HEAT TRANSFER COEFFICIENT

1) GAS MASS VELOCITY:

2) REYNOLDS NUMBER: 3) PRANDTL NUMBER: 4) NUSSELT NUMBER : ( 0.33*(REYNOLDS NUMBER0.6) *(PRANDTL NUMBER0.33))

5) CONVECTIVE HEAT TRANSFER COEFFICIENT:

6) K: 7) g = 0.9(1- e-(BEAM LENGTH*K) ) 8) NON LUMINOUS HEAT TRANSFER COEFFICIENT:

 OUTSIDE HEAT TRANSFER COEFFICIENT= hc + hn STEP (3): INSIDE HEAT TRANSFER COEFFICIENT
1) STEAM VELOCITY

2) REYNOLDS NUMBER

3) PRANDTL NUMBER=

4) NUSSELT NUMBER = (0.023*(NRe0.8)*(NPr0.4)) 5) INSIDE HEAT TRANSFER COEFFICIENT =

 STEP (4): RESISTANCES ESTIMATION

1) OUTSIDE RESISTANCE (RO) =(1/ho) 2) INSIDE RESISTANCE (RI) = (1/hi) 3) METAL WALL RESISTANCE (Rm)
(WALL THICKNESS*O.D)/(THERMAL CONDUCTIVITY*MEAN WALL DIAMETER)

4) SCALE RESISTANCE (RS)

(THICKNESS OF SCALE FILM / THERMAL CONDUCTIVITY OF SCALE FILM)

5) TOTAL RESISTANCE INCLUDING SCALE = (RO + RI + RS + Rm )

6) TOTAL RESISTANCE EXCLUDING SCALE = (RO + RI + Rm )

 STEP (5) : CRITICAL TST ESTIMATION

a) HEAT FLUX:
(MAX GAS TEMPERATURE- MAX STEAM TEMPERATURE)/ (TOTAL RESISTANCE)

b) TEMPERATURE DROP ACROSS GAS FILM c)

HEAT FLUX * RO HEAT FLUX * RI HEAT FLUX* Rm

TEMPERATURE DROP ACROSS STEAM FILM =

=

d) TEMPERATURE DROP ACROSS WALL FILM

e) CRITICAL TUBE SKIN TEMPERATURE

BOILER LOAD 30 40 50 60 70 80 90 100 120 130 140

CRITICAL TST (WITH SCALE) (IN 0C) 476.42 545.79 604.30 653.75 687.04 716.10 741.5 0 739.94 783.50 800.50 837.30

CRITICAL TST (WITHOUT SCALE) (IN 0C) 382 413 440 462 465 467 468 469 468.8 468.3 467.33

THE GRAPH SHOWN DEPICTS THE VARIATION OF TUBE SKIN TEMPERATURE VALUES ON VARYING THE BOILER LOAD, WHEN THE SCALE RESISTANCE IS EXCLUDED. UPTO 60 TPH BOILER LOAD, THERE IS A DRASTIC INCREASE IN TST VALUE, BECAUSE OF LARGE INCREASE IN TEMPERATURE DROP ACROSS STEAM FILM. FROM 60 TO 110 TPH, THERE IS VERY SMALL INCREASE IN TST VALUE, AND THEN UPTO 140 TPH, THERE IS VERY-VERY SMALL DECREASE IN TST, B/C OF THE VERY SLIGHT DECREASE IN TEMP. DROP ACROSS STEAM FILM.

STEAM FLOW V/S TUBE SKIN TEMPERATURE EXCLUDING SCALE 500

450

400

350

300
0 50 100 150

 THE GRAPH SHOWS THE VARIATION OF TUBE SKIN TEMPERATURE ON VARYING THE BOILER LOAD WHEN THE SCALE RESISTANCE IS INCLUDED. THERE IS A CONTINUOUS INCREASE IN TST VALUE BECAUSE OF CONTINUOUS LARGE INCREASE IN TEMPERATURE DROP ACROSS THE STEAM FILM THIS TYPE OF GRAPH IS OBTAINED WHEN THE BOILER IS OLD, MEANS THE FOULING FACTOR IS TAKEN INTO ACCOUNT.

STEAM FLOW V/S TUBE SKIN TEMPERATURE (INCLUDING SCALE

900 800 700 600 500 400 300 200 100 0 0 50 100 150

1)

NON DESTRUCTIVE OXIDE THICKNESS INSPECTION SERVICE:

AN ULTRASONIC TEST NDE COUPLED TO A COMPUTER MODEL ENABLES THE CALCULATION OF REMAINING CREEP LIFE OF SUPERHEATER TUBES

2) FURNACE WALL HYDROGEN DAMAGE NON DESTRUCTIVE EXAMINATION SERVICE

THIS ULTRASONIC TEST UTILIZES MULTIPLE TRANSDUCERS TO SCAN TUBES FOR ATTENUATION DUE TO HYDROGEN DAMAGE

3) FAST SCANNING THICKNESS GAGE

IT IS AN ELECTROMAGNETIC ACCOUSTIC TRANSDUCER BASED NON DESTRUCTIVE EXAMINATION TECHNIQUE THAT ENABLES RAPID SCANNING OF BOILER TUBES TO DETECT WALL LOSS AND INTERNAL TUBE DAMAGE

 THIS PROJECT DEALS WITH THE BASICS OF SG10 BOILER, ITS WORKING PRINCIPLE, CAUSES OF BOILER TUBE FAILURES, THEN THE METHOD OF ESTIMATING CRITICAL TUBE SKIN TEMPERATURE AT VARIOUS LOADS (INCLUDING SCALE AND EXCLUCING SCALE), FINALLY SOME TECHNIQUES HAVE BEEN DEVELOPED WHICH MAY IDENTIFY THE TUBES THAT MAY LEAD TO FAILURE. THIS PROJECT IS BENEFICIARY TO THE REFINERIES WHERE STEAM IS GENERATED, BECAUSE IN THIS PROJECT AN EXCEL SPREAD SHEET HAS BEEN PREPARED WHICH WILL GIVE THE CRITICAL TST VALUE AT DIFFERENT LOADS.

 1) SG10 BOILER MANUAL, HPCL, MUMBAI REFINERY,B.D PATIL MARG, MAHUL MUMBAI. 2) ALLIANCE RESEARCH CENTRE, BABCOCK AND WILKOX COMPANY, BARBERTON, OHIO,USA. 3)V. GANAPATHY, STEAM PLANT CALCULATIONS MANUAL, MARCEL DEKKER, NEW YORK, 1994, S. GANAPATHY,V, WASTE HEAT BOILER DESKBOOK, FAIRMONT PRESS, ATLANTA, 1991.

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