Standard Design Manual For Steam Drum Internals

STANDARD DESIGN MANUAL SYM-B-1
Boiler design
201. Steam drum internals Rev. 1 1 (17)
STEAM DRUM INTERNALS
TABLE OF CONTENTS
1. STEAM DRUM INTERNALS........................................................................................................ 2

1.1 General................................................................................................................................ 2
1.2 Initial Design Information.................................................................................................... 2
1.3 Steam Separation Devices of the Steam Drum ............................................................. 4
1.3.1 Cyclone Separator ............................................................................................................. 4
1.3.2 Secondary Steam Scrubber.............................................................................................. 9
1.3.3 Perforated Plate ...............................................................................................................11
1.3.4 Water Channel..................................................................................................................12
1.4 Plugging the Vent Holes ..................................................................................................13
1.5 Pipes..................................................................................................................................14
1.5.1 Feed Water Distribution Pipe .........................................................................................14
1.5.2 Continuous Blow Down Pipe...........................................................................................16
1.5.3 Sweet Water Condenser Overflow Pipe........................................................................16
1.5.4 Water Level Lowering Pipe.............................................................................................16
1.5.5 Water Level Measuring Chamber...................................................................................17
1.6 Drawings ...........................................................................................................................17
1 2001 - 05 - 25 J. Kaikuranta 2001 - 06 - 05 M. Isoniemi 2001 - 06 - 12 K. Mäkelä

Muut. Pvm Laatinut Pvm Tarkastanut Pvm Hyväksynyt
Rev. Date Prepared by Date Reviewed by Date Approved by
This document is the exclusive intellectual property of Kvaerner Pulping Oy and is furnished for the sole purpose of operating and maintaining of the specific project, and re-use of the document for any other
project or purpose is prohibited. The document or the information shall not be reproduced or copied, or disclosed to a third party without prior written consent of Kvaerner Pulping Oy.
 Kvaerner Pulping Oy, Tampere, Finland 2001
Boiler design
1. STEAM DRUM INTERNALS
1.1 General
This section, SYM-B-1 201. Steam drum internals, replaces

corresponding section of the SYM-RB-1 –manual.
This section is also used for the drum internals design of the Power
Boilers.
The shell of the steam drum, common to all Boilers, is shown in Stan-
dard Design Manual, section 051 Steam Drum.
The internal equipment of the steam drum and water level elevations
are shown in Figure 1. Water level limits are given in Table 1.
The internal equipment is placed so that the doors can be opened

(doors open inward). The internal equipment must fit in through the
door. Internal parts should be prefabricated as far as possible to
minimize the site work.
1.2 Initial Design Information
The product engineer defines the following:
• The number of the cyclone separators. In Recovery Boilers the

number of the cyclone separators is divided as follows:
• furnace cyclones
• generating bank, II-pass side walls, load carrying rear
wall and screen tube cyclones
• The size (three sizes) and number of the secondary steam
scrubbers
• The total number of holes in the perforated plate.
• The number of holes in the feed water distribution pipe.
The process design engineer defines the size of the pipe nozzles.
Level from middle Low level High level

height of cyclone
Normal water level 0 mm
Alarm - 120 mm + 120 mm
Trip - 250 mm + 250 mm
Table 1. Water level limits
Boiler design
Figure 1. Schematic view of the steam drum internals.

When designing the steam/water mixture income chamber, it must be
checked that
• Chamber doesn’t act as a flow restrictor, check area of restriction R
• Upper circulation pipes are located so that axial velocity of the
steam/water mixture in the chamber doesn’t exceed 0.8 m/s. This
can happen for example if there are separate feed water cyclones.
Boiler design
1.3 Steam Separation Devices of the Steam Drum
The steam separation devices include a vertical cyclone separator,

primary steam scrubber, secondary scrubber (= steam purifier) and
perforated plate. The operating principle of the steam separation
devices is shown in Figure 2.
Figure 2. Operation principle of steam separation.
1.3.1 Cyclone Separator
1.3.1.1 Structure of the Cyclone
Vertical cyclone separators with corrugated plate pyramids are used

as primary steam/water separators.
The cyclone separators are made of structural steel S235JRG2.
Standard drawings 1022621 (right-handed) and 1022649 (left-handed)

shall be used for manufacturing the cyclones.
Boiler design
Figure 3. Schematic drawing with standard dimensions of the conical type cyclone.
The vanes and bottom cover are installed according to Figure 4 to

guide the water flow.
Figure 4. Cyclone bottom cover has guide vanes that enhance the rotation of
separated water.
Boiler design
1.3.1.2 Location of the Cyclones
The furnace cyclones are normally located on the front side of the
steam drum.
The generating bank, II-pass side walls, load carrying rear wall and
screen tube cyclones are normally on the rear side.
Cyclones have to be installed so that they will not cause any water level
unbalance in heads of the steam drum. If the cyclones don’t fit in one
row, two rows in one side can be used.
Handedness of the cyclones shall be done according to following:

(examples in Figure 5)
• Handedness should be changed around downcomers,
when there are at least two pairs of downcomers along
the drum.
• Or at least every fourth cyclone has to be right handed
if others are left handed (or opposite).
Minimum distances between cyclones are presented in Figure 6.
Figure 5. Handedness of the cyclone separator
Boiler design
Figure 6. Minimum spacings of the cyclone separators
1.3.1.3 Attachment of the Cyclones
The cyclones are attached to the sockets, which can be seen in Figure
7. The cyclones are fitted to the sockets firmly and the fitted parts are
numbered so that the correct locations can be found at the erection
site.
Following model drawings for three different cases shall be used when
creating attachment drawings:
• Fastening plate A 3036413
• Fastening plate B 3036466
• Fastening plate C 3036431
Standard drawing 3036414 for setup like shown in Figure 6B shall be

used.
Boiler design
Figure 7. Attachment of the cyclone separator. If the cyclones are in two rows, the
shape of the socket (section A-A) is modified so that the sockets can be placed
side by side.
1.3.1.4 Primary Steam Scrubber
Corrugated plate pyramid (Figure 8) is used as a primary steam

scrubber (=cyclone steam cleaner).
The material of corrugated plate pyramid is cold-rolled carbon steel

CR2-11 and the perforated plate underneath it is made of stainless
steel AISI 316 or equivalent.
Standard drawing 1022622 shall be used for manufacturing the

primary steam scrubber.
Boiler design
Figure 8. Primary steam scrubber (corrugated plate pyramid).
1.3.2 Secondary Steam Scrubber
1.3.2.1 Structure of the Secondary Steam Scrubber
There are three sizes of secondary steam scrubbers (purifiers). Main

dimensions of scrubbers are shown in Table 2 and in Figure 9.
Standard drawings mentioned in Table 2 shall be used for
manufacturing.
The secondary steam scrubber consists of corrugated sheets, which

have been piled according to Figure 10. Steam flows in between the
sheets and water drops hit the curves of the sheets and fall onto the
water channel.
Size Dimensions Flow area Weight Standard

A mm B M2 kg drawing No.
A 255 180 0.0661 23 3025695
B 325 250 0.0923 29 3024173
C 354 279 0.103 31 3025696
Table 2: Main dimensions of secondary steam scrubbers
Boiler design
Figure 9. Secondary steam scrubber
Figure 10. Corrugated sheets (82 pcs/purifier, dimension B same as in figure 9)
1.3.2.2 Location of the Secondary Steam Scrubbers
The secondary steam scrubbers are normally located at both sides of

the steam drum as shown in Figure 11, and spaced evenly along the
length of the drum.
Boiler design
Figure 11. Secondary steam scrubbers located in two rows.
If cyclones are only on one side of the steam drum, one row
arrangement of secondary steam scrubbers (Figure 12) is used.
Figure 12. Secondary steam scrubbers located in one row.
1.3.3 Perforated Plate
The perforated plate is shown in Figure 13.
The perforated plates are made from standard length parts so that the
last piece is fitting to the desired total length.
Main dimensions of the plate are shown in Table 3. Dimension H

varies case by case. Model drawings mentioned in Table 3 should be
used when creating perforated plate drawing.
Boiler design
Figure 13. Perforated plate
Secondary Perforated plate dimensions [mm] Model

scrubber size drawing No.
Dim. A Dim. B Dim. C
A 160 120 103 3025698
B 90 64 82 3025697
C 60 40 72 3025699
Table 3: Main dimensions of perforated plate
1.3.4 Water Channel
Water channel is made from 1500 mm or 2500 mm long parts. The last
piece is cut to a required length. Standard drawings mentioned in
Figure 14 and in Table 3 should be used for manufacturing the water
channels.
There are two different types of water channels. Type 1 (Figure 14) is
used when secondary steam scrubbers are located in one row.
Water channel type 2 is used in drums where secondary steam

scrubbers are installed in two rows. Type 2 channel is shown in Table 4
and Figure 15.
Boiler design
Figure 14. Water channel type 1. Standard drawing 3036986 shall be used for
manufacturing the channel.
Figure 15. Water channel type 2. Drainpipes shall be bent between the cyclones
so that they don’t block the way during drum inspections. The spacing of the
drainpipes is 1250 mm.
Water channel type 2 dimensions [mm]

Water channel Secondary Standard A B
size scrubber size drawing No.
2A A 3025700 410 71
2B B 3025701 340 62
2C C 3025702 310 58
Table 4: Main dimensions of water channel type 2 for different secondary steam
scrubbers.
1.4 Plugging the Vent Holes
Air holes in the end plates of the fastening plates of the cyclones and
the secondary steam scrubbers have to be blocked after pickling with
a tight round bar plugs.
Boiler design
Blocking the holes must be shown in the assembly drawing of the

steam drum internals.
1.5 Pipes
1.5.1 Feed Water Distribution Pipe
When the feed water temperature is below saturation, the feed water is
discharged straight trough the perforated feed water distribution pipe
(Figure 16).
Figure 16. Feed water discharge without cyclones.
When a steaming economizer (saturated feed to drum) is used, steam

bubbles will be formed in the feed water pipes. Then the feed water is
discharged through separate feed water cyclone(s) to the perforated
feed water pipe. Figure 17 shows an example of a separate feed
water cyclone. The cyclone is similar to the one used for the upper
circulation pipes.
Figure 17. Separate feed water cyclone in the drum.
The feed water is brought into the steam drum either from one or both
ends (see feed water flow sheet). If the feed water is brought from both
Boiler design
ends, the pipes are connected inside the drum. Usually the distribution
pipe consists of several parts. This is done to make the handling and
installation easier. There is a connecting sleeve between pipe parts,
which also helps the installation by adjusting the length of distribution
pipe. The other end of this sleeve is not welded to pipe to allow thermal
movements. One part of the distribution pipe is presented in Figure 18.
Model drawing 3025704 shall be used when creating distribution pipe
drawings. There is also a model drawing 3025734 for the support of
distribution pipe.
The feed water is distributed into the steam drum through the holes in
the pipe. The feed water may have lower temperature than the
saturated water in the drum. Variations in temperature lead into
variations in metal tension, which might lead into material fatigue and
cracking. It must be checked that the water jet does not hit the drum
shell. Also magnetite layer problems may occur if the water is
constantly sprayed to the shell. The feed water must not be sprayed
above the water surface, to avoid drops in the steam.
Minimum angle and size of the spraying holes is presented in Figure

18 (section A-A).
Product engineer defines the size and the number of the spraying
holes.
Figure 18. Spraying holes in a part of the feed water distribution pipe
Boiler design
1.5.2 Continuous Blow Down Pipe
For low-pressure boilers (p<40 bar), the continuous blow down pipe
should be located in the middle of the steam drum. The level of the pipe
compared with the minimum water level and the location and the size of
the holes are shown in Figure 19.
Figure 19. Continuous blow down pipe.
For high-pressure boilers (p>40 bar), the continuous blow down pipe
should be located under the cyclone separators.
Model drawing 3025703 shall be used when creating continuous

blowdown pipe drawings.
1.5.3 Sweet Water Condenser Overflow Pipe
The lower end of the sweet water condenser (dolezal) overflow pipe
shall be 150 mm below the minimum water limit of the steam drum. If
the lower end of the pipe is above the water surface, a reverse flow of
steam and dirty boiler water droplets may enter the sweet water
condenser through the overflow pipe.
1.5.4 Water Level Lowering Pipe
The water level lowering pipe is used to control the steam drum water
level during start-up when the boiler water expands. If the water level
rises too much water is blown out from the steam drum through the
level-lowering pipe (Figure 1).
The end of the pipe inside the drum has to be above the low-level trip.
Boiler design
1.5.5 Water Level Measuring Chamber
Two chambers for water level measurements shall be placed in both

ends of the steam drum. They are connected to the steam drum by DN
80 nozzle. One chamber is connected to steam space and the other to
water space. The water gauge and instrumentation are joined to the
chambers by smaller nozzles. The measurement chambers can be
pointed horizontally to any direction that allow a good layout, Figure 20.
Figure 20. Water level measuring chambers
1.6 Drawings
In every project, an assembly drawing of the drum internals with list of

parts is prepared. Several detail drawings are also needed. Standard
and model drawings mentioned in this document shall be used as
detail drawings or as a basic for the detail drawing.
The following matters should be mentioned in the assembly drawing:
• use of galvanized or painted parts is not allowed

• welding to the steam drum shell is not allowed
• parts are pickled during the pickling of the boiler
• cyclones are fitted to the sockets, and the fitted parts will be
numbered

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STANDARD DESIGN MANUAL SYM-B-1

STEAM DRUM INTERNALS

1. STEAM DRUM INTERNALS........................................................................................................ 2

1 2001 - 05 - 25 J. Kaikuranta 2001 - 06 - 05 M. Isoniemi 2001 - 06 - 12 K. Mäkelä

1. STEAM DRUM INTERNALS

This section, SYM-B-1 201. Steam drum internals, replaces

The internal equipment is placed so that the doors can be opened

1.2 Initial Design Information

The product engineer defines the following:

• The number of the cyclone separators. In Recovery Boilers the

Level from middle Low level High level

Table 1. Water level limits

Figure 1. Schematic view of the steam drum internals.

1.3 Steam Separation Devices of the Steam Drum

The steam separation devices include a vertical cyclone separator,

Figure 2. Operation principle of steam separation.

1.3.1 Cyclone Separator

1.3.1.1 Structure of the Cyclone

Vertical cyclone separators with corrugated plate pyramids are used

The cyclone separators are made of structural steel S235JRG2.

Standard drawings 1022621 (right-handed) and 1022649 (left-handed)

The vanes and bottom cover are installed according to Figure 4 to

1.3.1.2 Location of the Cyclones

Handedness of the cyclones shall be done according to following:

Minimum distances between cyclones are presented in Figure 6.

Figure 5. Handedness of the cyclone separator

Figure 6. Minimum spacings of the cyclone separators

1.3.1.3 Attachment of the Cyclones

Standard drawing 3036414 for setup like shown in Figure 6B shall be

1.3.1.4 Primary Steam Scrubber

Corrugated plate pyramid (Figure 8) is used as a primary steam

The material of corrugated plate pyramid is cold-rolled carbon steel

Standard drawing 1022622 shall be used for manufacturing the

Figure 8. Primary steam scrubber (corrugated plate pyramid).

1.3.2 Secondary Steam Scrubber

1.3.2.1 Structure of the Secondary Steam Scrubber

There are three sizes of secondary steam scrubbers (purifiers). Main

The secondary steam scrubber consists of corrugated sheets, which

Size Dimensions Flow area Weight Standard

Table 2: Main dimensions of secondary steam scrubbers

Figure 9. Secondary steam scrubber

Figure 10. Corrugated sheets (82 pcs/purifier, dimension B same as in figure 9)

1.3.2.2 Location of the Secondary Steam Scrubbers

The secondary steam scrubbers are normally located at both sides of

Figure 11. Secondary steam scrubbers located in two rows.

Figure 12. Secondary steam scrubbers located in one row.

1.3.3 Perforated Plate

The perforated plate is shown in Figure 13.

Main dimensions of the plate are shown in Table 3. Dimension H

Figure 13. Perforated plate

Secondary Perforated plate dimensions [mm] Model

Table 3: Main dimensions of perforated plate

1.3.4 Water Channel

Water channel type 2 is used in drums where secondary steam

Water channel type 2 dimensions [mm]

1.4 Plugging the Vent Holes

Blocking the holes must be shown in the assembly drawing of the

1.5.1 Feed Water Distribution Pipe

Figure 16. Feed water discharge without cyclones.

When a steaming economizer (saturated feed to drum) is used, steam

Figure 17. Separate feed water cyclone in the drum.

Minimum angle and size of the spraying holes is presented in Figure

1.5.2 Continuous Blow Down Pipe