INSPECTION TRAINING MANUAL BOILERS‘STEAM GENERATION BOILING AND CIRCULATION STEAM BOILERS Steam generation is the process of turning water into steam by the application of heat. When water is boiling, both water. and steam have the same temperature. This _is_ known as the saturation temperature. Although the temperature remains the same when a liquid is boiling (at constant Pressure), heat _must be added to turn the liquid into a vapor. This amount of heat is known as the Tatent heat uf vaporization. If the steam produced is free of water at the boiling tomporature, it ic said to be dry saturated steam. When the steam contains some water mist, it is said to be wet steam. If the steam is heated above its boiling temperature, it ic caid ta be superheated. There are tables which contain data on the boiling points ot steam at various pressures and also Provide information about the amount of heat contained in the steam. These tables are known as Steam Tables. Another chart that gives information on steam Properties is known ac a Mollior Chart. The object is to produce steam by boiling, and it is quite easy to visualize in a simple shell heated from below how the steam forms in bubbles at the heated area as the water begins to boil. These bubbles and hot water are displaced by colder, heavier, steam-tree water and so a circulation current is formed which brings the bubbles to the surface where the steam is released. In a water tube type boiler, water and steam flow in a large number of tubular paths. The basic idea can he Cimlified by visualizing a single circuit as shown in the diagran. One leg of the loop is heated in the firebox while the offer leg is shielded by « firebrick wall which has the effect of making the shielded leg colder in comparison. Steam bubbles form in the heated leg (known as a riser). Tnis steam-water mxture rises and is displaced by the heavier, cooler water in the unheated downcomer.FIGURE 9 SIMPLE WATERTUBE CIRCUIT STEAM. WATER MIXTURE Lo STEAM WW A SIMPLE WATERTUBE CIRCUT STEAM aA BUBBLES FORM ON THE HEATED SIDE. A ‘Te RESULTING STEAN.WATER MIXTURE ZB WEIGHS LESS THAN COOLER WATER ON Zz ‘THe UNHEATED SIDE AND IS, ACCORD. A INGLY. DISPLACED IN THE DRUM. STEAM A BUBBLES RISE TO THE WATER'S SURFACE HEATED NEATED “77 IND STEAIN is RELEASED aA Zz UNHEATED DOWNCOMER eA as ZB Z@ WATER war’ FIGURE 10 STEAM PROPERTIES cy zt « 2 are, CRITICAL ASAMEASURE OF THE EFFECTSOF «BB ! S_|PREssunE PRESSURE ON THE FORGE PRODSGING « CIRCULATION. THE CHART COMPARES. ¢ / SPECIrIG WEIGHT OF WATER AND SATU. RATED STEAM THE DFFERENTIL BETWEEN $M] 39 +t ‘THe SPEGHIG welanTs SHINS AS PRES, T ‘SURE INCREASES UNTIL. AT A PRESSURE ‘SPECIFIC WEIGHT OF 3206.2 PSIA. THE CRITICAL POINT, 20} DIFFERENTIAL. ‘THERE 13 NO MORE DIFFERENTIAL & #8 19} ream. ‘ ol ‘07 900 ToO0 T800 7060 250030003500 OP 1374834 PRESSURE PSIee Oe ee In normal operation, there is a continuous flow of water from the drum through the downcomer, up the riser, and into the drum where steam is released. While’ boilers do no operate quite as simply as this and are made up of a large number of more complex circuits, the principle is the same. This type of boiler is called a natural circulation Type. When the boiler designer designs a boiler to utilize all the heat available that can be used economically, the tubes and loop sizes are such thet there is a sufficleat Cum uf water Liruught each tube at every load to keep the metal within a safe temperature limit. In high pressure type boilers, it is normal to have forced circulation. This means the water is pumped around the various loops, In both natural and forced circulation, normally, a larger quantity of water is circulated than steam generated. ‘There are once-tnrough designs which are ydeally suited for pressures above the critical point where water turns to steam without boiling. There are, however, once-through designs at pressures below the critical point where feedwater is pumped in at one end of the tube and saturated steam comes out the other end. There are two basic types of steam generators, or boilers, as they are sometimes termed. One is called & firetube steam generator, where all of the heat transfer is effected by having the hot gases of combustion pass through tubes surrounded by water. The water and steam re contained in @ single shell housing, normally cylindrical in shape. Examples of this type of boiler are the stoam locomotive and also a ship's boiler. The other type of steam generator is known as a water tube boiler. In this type of boiler, the firebox section is surrounded by tubes that are filled with a circulating water-steam mixture. This type of boiler is more commonly used in refinery operations than the firetube botler. Although the first water tube boiler dates back to the 18th century, designs have changed very significantly over the last 30 years. Today there is a maximum use of vertical or near- vertical tubes in hoth radiant and convection sections. In addition, there is a maximum use of, waste heat from stack gases where air heaters and economizers are utilized.Package boilers are, at the present time, the most connon form of steam generator used for refinery operation. They are called package boilers because they are built at the boiler manufacturer’s factory and shipped to the refinery site as a complete unit. The limitation on the size of these boilers is set by the vehicle to transport the boiler to the refinery. The other type of boiler is the site erected boiler, but it is much more expensive costing rouglily twice the amount of a package boiler. Boiler costs are rated on the price per pound of steam produced. Most package water tube boilers follow one of the following structural configurations, "A", "D", or "O" types as shown in the diagram. In all types of modern construction, the firebox water wall tubes, either touch - these are known as tangent tubes - ‘or are joined with a metal fin to give a gas-tight seal between each tube. This is where a boiler differs from a hydrocarbon furnace, because in the latter there is space all around the tube for heat transfer.FIGURE 11 BOILER TYPES FLUE Gases STEAM OUTLET. 3 PASS FIRETUBE BOER WATER ON OUTIDE OF TUBES— STEAM AT TOP OF DRUM BURNER’ ATYPE Was TWO suai Lowen nals 98 WEAD ER "THE UPPER ORUM 1S LARGER TO PERMIT ‘SEPARATION OF WATER AND STEAM MOST STEAM PRODUCTION OCCURS IN THE CENTER FURNACE: WALL TUBES ENTERING THE DRUM, TYPE ALLOWS MUCH FLEXIDLITY HERE THE MORE ACTIVE STEAMING RISERS ENTER THE DRUM NEAR THE WATER LINE. BURNERS ARE GENERALLY. LOCATED INTHE END WALLS STATON UMITS HEIGHT OF THE FURNACE 80” FOR EQUAL CAPACITY. A LONGER BOILER 1S OFTEN. REQUIRED FLOORS OF D AND O TYPES ARE GENER. ‘ALLY TLE-COVERED. FIGURE 12 WATERWALL TUBE DESIGNS 6OSO 3 } }zz»~o-o (TANGENT TUBE) (ownr TUBE}t le STEAM DRUM MUD DRUMS Steam drum is a drum where the water and steam soparate. It has a feed water inlet that is on Tevel control and all the risers and downcomers are attached to the drum. There is also a steam outlet gither to the process system or to a cunerheater. The steam drum will be fitted with relief valves to protect the system. ‘The method of removing the water trom the steam is basically the same in most boilers and is carried out in @ mechanical separator or cyclone separator. The steam water mixture which discharyes frum Une risers is directed to the cyclone separator by an internal baffle. The flow through the cyclone allows the bulk of the water fa drop out and the steam to escape upward where it passes through scrubbers where water droplets are trapped and returned to the water level. The relatively dry steam is then delivered to either a superheater or to the process. Mud drums are collection headers at the bottom of downconers and risers. It is from these mud drums that the blow-down is taken. Blow-down is the liquid that is taken from the boiler to keop the concentration of solids down in the boiler water. There are normally two blow-down streams; one, a continuous blow-down which is blowing down a set amount all the time and two, an intermittent blow-down. The intermittent blow-down is varied to keep the boiler water within the dissolved solids specification uf the buiter.t ly FIGURE 13 t STEAM DRUM I STEAM OUTLETS SCRUBBER ELEMENTS i I i 1 t CORRUGATED PLATES BAFFLES A CYCLONE SEPARATOR < STEAM & WATER ? FROM RISERS STEAM & WATER + DOWNCOMERS ne rasanSOOT BLOWERS FORCED DRAFT FANS First boilers are fitted with soot blowers, which are tools to keep the outside surface of the tubes clean and free from material that would have a detrimental effect on the heat transfer. The blowing fluid is generally steam and the frequency of operation depends upon the type of fuel being used. The flue gas temperature is an indicator” as to tne need for soot blowing. A higher-than-normal flue gas temperature for a given steam load at normal firing conditions indicates that the convection section tubes are becoming fouled and the proper heat transfer is not taking place. There are two types of soot blowers; fixed or stationary soot blowers and retractable soot blowers. A stationary soot blower, as the name implies, is a fixed tube with holes. The holes are positioned to blow steam between the tubes. Retractable soot blowers - the lance is operated by electric motarc. ne matar rotates tha lance at a constant speed while a two-speed motor handles the travel. A slow speed is used when the lance is going in and a much faster speed is used as it retracts. This is to save time and steam. One method of operation of the retractable soot blower is on_aulumatic control uf flue gas temperature. There is a disadvantage to this in that during soot blowing, a temperature reduction occurs because the steam used for soot blowing cools the tubes and therefore the blowing could cause quite a drop in steam production at an inconvenient time. It must be emphasized that the steam traps on the lines to the soot blowers must be operational so that condensate is nut blown onto the tubes. Soot blowing must not be carried out at low steaming rates to avoid tho possibility of putting out the fires. Most steam boilers are of the forced draft design. ‘This means that the air to the burner is supplied by a forced draft fan. This fan may be a steam or air turbine driven fan or electrically driven fan. The fan keeps a positive pressure in the firebox.BOILER INSPECTOR To keep a controlled fuel/air ratio in the firebox, the steam or air uriven turbine speed 15 varied; oF in case of an electric motor, dampers are fitted which are varied accordingly. As with any major turnaround, the inspector should Plan to check all boiler shells, drums, tubes, furnaces, flue and air ducts, piping and refractories, as well as associated auxiliary equipment as the need arises. Although this section of the refinery processes essentially water in its several forms, serious corrosion, erosion and deterioration of equipment can occur, not only ‘on the inside of vessels and piping but also on the 0D cide of tubes end furnace walls: In service inspection of boilers may have to be Performed hy special state or insurance company inspectors in addition to the inspection carried out by the plant inspector. In fact, the plant inspector may have to be qualified by written examination before he is considered able to inspect a boiler. Local laws and codes governing boilers will dictate just what the inspector qualifications need Lu be. As pointed out in the API Guide, one of the most serious caucce of boiler deterioration is over heating. Results can be oxidation and deformation of pressure parts and possible rupture. Also, corrosion of tubes can take place from either cide as a result of flue gas contaminants or poor feed- water treating systems. Caustic embrittlement can occur, but due to present day stress relieving guidelines, this form of corrosion is being found Jess often. Refractories need to be checked closely to ensure they are maintaining their insulating properties: — spalling, cracking and fluxing can all be detrimental to good refractory performance. In summary, boiler systems are subject not only to harsh internal corrosive environments but also to severe mechanical environments. The boiler undergoes repeated expansion and contraction cycles asa result of rapid temperature changes. Inspection of these systems should be thorough.FIGURE 14 SOOT BLOWERSFigure 15 TYPICAL “D” TYPE PACKAGE BOILER TOP VIEW OF FIRE BOX ("ateecawun 1 MaNaRNeT wareRALL eeFIGURE 16 TYPICAL “D” TYPE PACKAGE BOILER END ELEVATION _ \ BLOW DOWN CONNECTION oP 13748:16FIGURE 17 Vent tor gases SPRAY TYPE overtiowSTEAM DEAERATORS ‘SPRAY TRAY TRAY COMBINATION TYPE DEAERATION Dissolved gases in the boiler water supply can Produce corrosion and pitting and must be removed to protect the hailer, piping, pumps, and Condensate lines. The predominant gases are oxygen and carbon dioxide. Their removal is based on raising the water temperature thereby lowering the Saturation level of the gases and then stripping the incoming water with steam. Oxygen and CO> may be removed in deaerators by one of two methods: under pressure with steam, or by use of vacuum. In boiler service it is normal to use steam and this is the method discussed. Steam deaerators break up boiler feed water into a spray, then sweep steam across and through the water to strip out the diccalved gases. Bocigns fall into two types: spray and tray combination. Spray Type - Feed water sprays into a steam-filled primary area where it is heated and scrubbed. It ‘is then scrubbed by oxygen-free steam in the secondary deaeration zone to remove the last traces of gas before it enters the storage area which 1s normally designed to hold sufficient water for 10 minutes residence time at rated boiler capacity. The feed water first sprays into a steam-filled space, then rains down through a series of trays contacting cross current steam to remove gas and heat the water.FIGURE 18 Vent Anternal vent condenser Heating and ‘deaerating trays Deserated-water storage To boiler-teed pump COMBINATION TYPE