03/27/2021 Gyanendra Sharma, NPTI Delhi

DUCTS & DAMPERS

Duct is a closed path for the flow of cold air , hot air
and gases from one point to another point in a
system . This can be of any shape like Circular ,Elbow
, Straight , Square, Rectangular or some other shape.

There are eleven duct systems in Boiler :

1 . Cold air duct - FD fan to air heater.
- PA fan to air heater.
2 . Tempering Air system .

03/27/2021 Gyanendra Sharma, NPTI Delhi

 HOT AIR DUCTS :

* Hot air To Wind box

* Hot air To Bus duct
* Hot air to Mills
GAS DUCTS :
* Gas To Economizer
* Gas To Boiler Outlet
* Gas To Electro statics precipitator
* Gas To ID Fan
* Gas To Chimney
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 COLD SECONDARY AIR DUCTING
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Hot Secondary Air Duct

03/27/2021 Gyanendra Sharma, NPTI Delhi

COLD PRIMARY AIR DUCTING
03/27/2021 Gyanendra Sharma, NPTI Delhi
Hot Primary Air Bus to Mill &
Tempering Air Duct
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Economiser to Airheater Duct

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Air Heaters to BOF

03/27/2021 Gyanendra Sharma, NPTI Delhi

 BOF TO AIR HEATERS
BOF to EP Duct

03/27/2021 Gyanendra Sharma, NPTI Delhi

 EP to ID Fan

03/27/2021 Gyanendra Sharma, NPTI Delhi

ID Fan to Chimney Duct
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Raichur 7, 210 MW
Gyanendra Boiler
Sharma, NPTI DelhiPlant
03/27/2021 Raichur 7, 210 MWSharma,
Gyanendra Boiler
NPTI Drum
Delhi area
03/27/2021 Raichur 7, 210 MW
Gyanendra Sharma,–NPTI
Top View
Delhi
03/27/2021 Raichur 7, 210 MW
Gyanendra Sharma,–NPTI
LeftDelhiside view
03/27/2021 Raichur 7, 210 MWSharma,
Gyanendra – Right side view
NPTI Delhi
03/27/2021 Raichur 7,Gyanendra
210 MW – NPTI
Sharma, Front
Delhi view
03/27/2021 Raichur 7, 210 MW
Gyanendra –NPTI
Sharma, RearDelhi view
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Circular to Y duct
Straight duct Rectangular duct Transition duct

Elbow duct Bend duct

T duct

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Anatomy of a simple straight duct

STIFFENER

DUCT WITH
INTERNAL
TRUSS
DUCT
PLATE

CORNER
ANGLE

FLANGE

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FLUE
3D VIEW OF TUBULAR GAS
OUT
AIRPREHEATERS WITH
DUCTS

COLD
AH-I
AIR IN

FLUE
GAS IN

AH-II ELBOW DUCT

AH-III
HOT AIR TRANSITION
OUT DUCT

03/27/2021 Gyanendra Sharma, NPTI Delhi

SUPPORT
FLOW METER

EXPANSION JT

HOT SECONDARY AIR DUCT

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 ECONOMISER DUCT AT SHOP
03/27/2021 Gyanendra Sharma, NPTI Delhi
 INTERNAL TRUSS WORK IN
ECONOMISER DUCT

03/27/2021 Gyanendra Sharma, NPTI Delhi

GUSSET PLATE :

This is a plate for welding cross bracing (ex. Strut tube)

inside the duct.

Strut tube

Gusset plate
Welding

STRUT TUBE :
This is used for load transfer and retain the shape of
duct.
03/27/2021 Gyanendra Sharma, NPTI Delhi
 JOINTS IN DUCTS

* FFJ - FLANGE FIELD JOINT

* FJ - FIELD JOINT
* IFJ - INTERNAL FIELD JOINT

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DUCT CORNER CONSTRUCTION

CORNER
WELDING

CORNERA
NGLE

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FIELD FLANGE JOINT-FFJ

5
50 (150)

Duct Plate

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FIELD JOINT (FJ)

FJ - Plate 5
5
50(150)

Duct Plate

03/27/2021 Gyanendra Sharma, NPTI Delhi

 INSIDE FIELD JOINT (IFJ)

Duct Plate

5 50(150)
IFJ - Plate
5

03/27/2021 Gyanendra Sharma, NPTI Delhi

 TYPE OF SUPPORTS IN DUCT
1 * TOP SUPPORT
a . Hanger support .
2 * BOTTOM SUPPORT
a . Fixed Type .
b . Sliding Type .
Normally hot air ducts will be provided with sliding bottom
supporting .
HANGER SUPPORTS:
a . Fixed hanger supports :
Where the downward movement of the duct need not be
allowed .

03/27/2021 Gyanendra Sharma, NPTI Delhi

 b . Spring hanger supports:
Duct is allowed to move in the down ward direction .
* Variable load hangers ( VLH ) .
Used where the difference between the cold loads and hot loads
is very small .
* Constant load hangers ( CLH ) .
Used where the difference between the cold loads and hot loads
is very large .
3 * RESTRAINTS : (STOPS & TIES )
Used to take the horizontal loads on the ducts like
1 . Wind loads
2 . Seismic loads
3 . Expansion joint loads &
4 . Unbalanced pressure loads .
SHEAR TIES & PIN TIES :
These are used to support the toggle section inside the duct itself .
03/27/2021 Gyanendra Sharma, NPTI Delhi
 TOP SUPPORT WITH HANGER
AND BRACKET

03/27/2021 Gyanendra Sharma, NPTI Delhi

 TOP SUPPORT WITH HANGER AND BRACKET

03/27/2021 Gyanendra Sharma, NPTI Delhi

TOP SUPPORT WITH
HANGER AND LUG PLATE

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
RESTRAINT SUPPORT

03/27/2021 Gyanendra Sharma, NPTI Delhi

RESTRAINT SUPPORT

03/27/2021 Gyanendra Sharma, NPTI Delhi

 SINGLE RESTRAINT SUPPORT

03/27/2021 Gyanendra Sharma, NPTI Delhi

 HANGER TYPE
SUPPORT WITH
RESTRAINT

03/27/2021 Gyanendra Sharma, NPTI Delhi

 STIFFENER

DIFFERENT TOP SUPPORTS

03/27/2021 Gyanendra Sharma, NPTI Delhi

 DUCT WITH BOTTOM SUPPORT

FLANGE WITH
FITUP HOLES

DETAIL - B

SUPPORT

DETAIL - A

03/27/2021 Gyanendra Sharma, NPTI Delhi

 SUPPORT
CORNER GUSSET
ANGLE PLATE

STRUTTUBE WELD

RESTRAINT BASE PLATE

WITH (BEARING)
03/27/2021 Gyanendra Sharma, NPTI Delhi
 I-BEAM
SUPPORT

TOP PLATE

BEARING PLATE

BASE PLATE

BOTTOM SUPPORT WITH BASE

PLATE AND BEARING PLATE
03/27/2021 Gyanendra Sharma, NPTI Delhi
 BOTTOM SUPPORT
WITH STOPPERS

TOP PLATE

BEARING PLATE

BASE PLATE
WITH STOPPER

03/27/2021 Gyanendra Sharma, NPTI Delhi

SHEAR TIES

03/27/2021 Gyanendra Sharma, NPTI Delhi

 TYPES
TYPES OF
OF EXPANSITION
EXPANSITION JOINTS
JOINTS ::

1 * Non - metallic expansion joints .

2 * Metallic expansion joints.
Round corner expansion joint - Full .
Round corner expansion joint - Half .
Square corner expansion joint .
Omega type expansion joint .
Full size round corner expansion joints have 8.5 inches height and are
made from 2.5 mm thick sheet .Half size round corner expansion joints
have 4.25 inches height and are made from 1.6mm thick sheet .

03/27/2021 Gyanendra Sharma, NPTI Delhi

 EXPANSION JOINT
ASSEMBLED IN DUCT
03/27/2021 Gyanendra Sharma, NPTI Delhi
 With
With metallic
metallicexp..
exp..joint
joint

With
With non
non--metallic
metallicexpansion
expansionjoint
joint

03/27/2021 Gyanendra Sharma, NPTI Delhi

 TOGGLE SECTION :
A small piece of duct having expansion pieces on
either
ends . It may be floating or pinned at one end
or pinned at both
ends. The duct piece may be straight or tapered .
A toggle section
which is floating can take expansion in all the
directions at both the
expansion joints .

03/27/2021 Gyanendra Sharma, NPTI Delhi

 With
With metallic
metallic toggle
toggle

Lateral

With non-metallic EJ
Axial

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FIGURE
FIGURE--11

CL of support C L of support
Movement
Lateral movement to Toggle of duct

Axial movement

Movement
of A. H.

AIR - HEATER
Axial movement

03/27/2021 Gyanendra Sharma, NPTI Delhi

ROUND
ROUNDCORNER
CORNEREXPANSION
EXPANSIONJOINT
JOINT--FULL
FULL

SECTION A - A
A
DEPTH

WIDTH

STYLE 1

03/27/2021 Gyanendra Sharma, NPTI Delhi

 STYLE
STYLE22
FULL
FULLROUND
ROUNDCORNER
CORNEREXPN.
EXPN.JOINT
JOINT

216 mm

271.8 mm

03/27/2021 Gyanendra Sharma, NPTI Delhi

 STYLE
STYLE66

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 DAD Circle / BHEL , TRICHY
Gyanendra Sharma, NPTI Delhi
03/27/2021 DAD Circle / BHEL , TRICHY
Gyanendra Sharma, NPTI Delhi
03/27/2021 DAD Circle / BHEL , TRICHY
Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Clamp

Re-usable duct
mating flange

Lifting lug
Bolt & Strut pipe
Nut

03/27/2021 Gyanendra Sharma, NPTI Delhi

 Match plate

03/27/2021 DAD Circle / BHEL , TRICHY

Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 PTFE SEALING ELASTOMER COATED GLASS FABRIC
LAYER OUTER LAYER (silitex) SUPPORT LAYER

CAVITY
PILLOW
GLASS FABRIC
BOLSTER

DUCT S.S WIREMESH

FABRIC DETAILS FOR N.M.E.J

• Supplied SILITEX coated outer layer is inadequate for the intended

application
• FLUORO polymer based outer layer is recommended
03/27/2021 Gyanendra Sharma, NPTI Delhi
 What is guillotine gate ?

GATE Guillotine gates are

used in boilers to
isolate the flow in duct
for online maintenance
of auxiliary equipment
of boilers and for part
load operations.

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 Gate with CONVENTIONAL LEAF SEAL

LEAF SEAL WHEN

BLADE CLOSED

LEAK TIGHTNESS ACHIEVED FOR TALCHER COLD

AIR GATE IS 96.85% WITH OUT
03/27/2021
SEAL AIR
Gyanendra Sharma, NPTI Delhi
GUILLOTINE
GATES AND
BIPLANE
DAMPERS ARE
USED WHERE
100% LEAKE
TIGHTNESS IS
REQUIRED.

03/27/2021 Gyanendra Sharma, NPTI Delhi

100% LEAK TIGHTNESS
The seal air is admitted inside the
seal air chamber with a pressure of
125 mm WC more than the system
pressure.

P2>P1&P2

PLENUM DUCT

BLOWER TESTING TUBE

FLOW

COLD AIR GATE IN TESTING P3

P1 P2

03/27/2021 Gyanendra Sharma, NPTI Delhi

 UNCHAHAR FLAP DAMPER

ACTUATOR

GEAR BOX

SEAL AIR FAN

CASING

BLADE
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
 PRODUCTION OF FLAP DAMPER AT SHOP

03/27/2021 Gyanendra Sharma, NPTI Delhi

 FLAP DAMPER WITH TOGGLE
LEVER ARRANGEMENT AND
SINGLE ACTUATOR

ACTUATOR

TOGGLE
LEVER FLAP

03/27/2021 SIMHADRI 2x500MW

Gyanendra Sharma, NPTI Delhi
 EXPANSION JOINT

ACTUATOR

ECONOMISER
HOPPER

FLAP DAMPER
WITH TOGGLE-
To AIR-HEATER
LEVER
03/27/2021 Gyanendra Sharma, NPTI Delhi
 EXPANSION JOINT

ECONOMISER
HOPPER

FLAP DAMPER
WITH TOGGLE-
LEVER To AIR-HEATER
03/27/2021 Gyanendra Sharma, NPTI Delhi
FLOW-IN

DUCT
FLAP WITH
TOGGLE-
LEVER
03/27/2021 Gyanendra Sharma, NPTI Delhi
 ACTUATOR

FLOW-IN

DUCT
FLAP WITH
TOGGLE-
LEVER
03/27/2021 Gyanendra Sharma, NPTI Delhi
 IN

OUT

03/27/2021 Gyanendra Sharma, NPTI Delhi

03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi
03/27/2021 Gyanendra Sharma, NPTI Delhi