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Feb 10, 2003

An Introduction to Boiler
Design Basics
JC Foucher
Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, Examples, and Troubles

Date of last change Reference/Name of Presentation/SN 2


Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, Examples, and Troubles

Date of last change Reference/Name of Presentation/SN 3


History : Steam as a resource
The most significant series of events
shaping today’s world is the late 17th
century industrial revolution.

However, the first steam reaction turbine,


illutrated here, has been invented in 200 BC
by Hero from Greece.

Steam Technology is an old invention its


future is still brilliant, based on the same
fundamentals :

- GENERATE HEAT
- TRANSFER THE HEAT to WATER
- PRODUCE STEAM and
- CONVERT TO ENERGY

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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History :
First Application of Steam Power

Steam Industries develop after


inventors designed safe and
efficient steam devices useful to
man activities : Alexandro Branca
from Italy invented in the 16th
century a device, illustrated here,
which marked the beginning of
Steam Turbine Development.

It was used for milling wheat grains


effortlessly.

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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Modern Use of Steam Power

z Power Generation
z Industrial Processes
z Sea and land transportation
z District Heating
z Other special uses

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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A Typical Power Station

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, Examples, and
Troubles

Date of last change Reference/Name of Presentation/SN 8


Thermodynamics for beginners - 1

z A vessel is filled with an amount of water


( ) and warmed at constant pressure
up to boiling
z a continuing supply of heat changes
water phase from liquid to gas (steam),
the temperature remains constant
z result : a steam at temp. Tp, pressure
Pp, volume Vp and energy stored as
internal heat or enthalpy Qp
z one m3 of water is transformed under
such conditions into 1700 m3 of steam

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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Thermodynamics for beginners - 2

z A vessel is filled with the same water amount


( ) and warmed at constant volume up to
boiling
z a continuing supply of heat changes water
phase from liquid to gas (steam),
z result :
– steam temperature Tv >Tp,
– pressure Pv > Pp,
– Vv =Vp volume unchanged
– energy stored as internal heat or enthalpy Qv > Qp

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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Thermodynamics for beginners - 3

z Steam generation is a phase change or water from liquid


to gas, thanks to a continuous supply of heat,
z the higher both pressure and temperature are, the higher
is the energy stored in the steam,
z the steam turbine purpose is to convert this thermal
energy into rotational mechanical energy
z the purpose of the generator is to convert this rotational
mechanical energy into electric energy

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Thermodynamics for beginners - 4

The Water-Steam Cycle inside the boiler

z From F to A to B
– liquid water warm-up
Temp. K
z B : evaporation begins
B C z B to C :
– mixture of water
(decreasing) and
steam (increasing)
A called saturated
steam
F
Entropy
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124

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Thermodynamics for beginners - 5

The Water-Steam Cycle inside the boiler (cont)

D z C : evaporation
completed, steam
Temp. K still saturated

C
z C to D
B
– steam is
superheated
z D
A – superheated
steam sent to
F turbine
Entropy
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124

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Thermodynamics for beginners - 6

The Water-Steam Cycle outside the boiler

D z D to E
– expansion in the
Temp. K steam turbine

C
z E to F
B
– steam is
condensed and
cooled in the
condenser
A
E z F
F – water available for
Entropy a new cycle
Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124

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Thermodynamics for beginners - 7

Single Rankine Reheat Steam Cycle

D
Temp. K

B C

A
E
F
Entropy

Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124

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Thermodynamics for beginners - 8

Double Reheat Steam Cycle


D K
z D to I
– expansion in the
Temp. K HP steam turbine
C z I to K
B – steam returns to
the boiler and is
I
reheated

A z K to L
L – expansion in the
F IP/LP steam
Entropy turbine

Source : J. Goalvoueden in Les Techniques de l ’Ingénieur, B 124

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Flows and Heat Exchange
in the Boiler

Source : Combustion, Fossil Power J.G. Singer 1991, ch 5 p 7 fig 2


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The Complete Water-Steam Cycle

Source : ALSTOM Indonesia Boiler Seminar, April 2002

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Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, Examples, and
Troubles

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Boiler design basics
Summary

z Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation

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Various Boiler Designs

Based on :

z Intended use industrial, power generation,


z construction shop or field assembled
z firing system grate, suspension, fluidized bed
z boiler arrangement hanged or bottom supported
z water circulation natural, controlled, forced
z fuel solid, liquid, gas, waste heat

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Boiler design basics
Summary

z Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation

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Utility plants and boilers :
three types of operation

z Base load : 100% capacity 24/7/365


– highest capacities (up to 1000 MWe), high efficiency
– no load-follow requirement
z Peak load
– ultra-fast startup time, suitable for «golden hours»
– competition with open cycle gas turbines
– a few hundred hours per year
– no high efficiency requirement
z Intermediate load
– in between, high load-follow capability

- customized design versus type of operation -


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Boiler design basics
Summary

z Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation

Note : this seminar is targeted to an area where use of coal is limited.


Consequently, the information provided for coal firing is purposedly limited.

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Solid Fuels, Fossil

z Coal (from 15 to 30 MJ/Kg)

Source : Combustion, Fossil Power J.G. Singer 1991, ch 2


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Solid Fuels, Non-Fossil

z Coke
– fused solid residue from chemical processes involving
coal or oil
z Petroleum coke (petcoke)
– petrochem byproduct (32-36 MJ/Kg, 3-6% sulfur)
z Wood (20 MJ/Kg)
z Bark (mainly from paper mills)
z Food processing wastes
z Municipal and industrial refuses (7 to 15 MJ/Kg)

Source : Combustion, Fossil Power J.G. Singer 1991, ch 2


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Liquid Fuels

z Crude petroleum
– high amount of volatile compounds
z Fuel oil
Fuel Oil Grade FO n°1 FO n°2 FO n°4 FO n°5 FO n°6
Distillate Very Light Light
Type Kérosene Distillate Residual Residual Residual
Color Light Amber Black Black Black
MJ/Kg 46,4 45,5 43,4 43,4 42,5
Sulfur content,% 0,1 0,4 - 0,7 0,4 - 1,5 2.0 2.8
Atomizing temp Ambient Ambient -4°C min 50°C 93°C

- Oil fired boilers can be converted to crude firing -


1 lb/USgal x 119.8 = Kg/m3
1 BTU/Usgal x 278.72 = KJ/m3
KJ/m3 / (volumic mass Kg/m3) =KJ/Kg

Source : Combustion, Fossil Power J.G. Singer 1991, ch 2


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Gaseous Fuels

z Natural gas
z Liquefied Petroleum gas (LPG)
z Refinery and oil gas,
z Gas from steel processing : coke oven and blast
furnace gas

Gas Propane Butane Natural Gas LPG


C33H88 C44H10
10 mix mix
MJ/Kg 50 46 47 45

- Oil fired boilers can be converted to gas firing -


1 lb/USgal x 119.8 = Kg/m3
1 BTU/Usgal x 278.72 = KJ/m3
KJ/m3 / (volumic mass Kg/m3) =KJ/Kg

Source : Combustion, Fossil Power J.G. Singer 1991, ch 2


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Fuels, Typical Problems

z Degradation of fuel quality with time


z Exhaustion of fuel resource with time, leading to
fuel switching
z High quality fuel exported, low quality burned
domestically
z Cost increase, leading to fuel switching
z NOx generation properties
z Sulfur content, inducing acid dew point corrosion
z Particulates content

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Boiler design basics
Summary

z Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation

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Firing systems

z Firing on a travelling grate


– suitable to un-pulverized solid fuels
z Suspended firing
– suitable to pulverized coal, liquid and gaseous fuels
z Fluidized bed combustion
– suitable to coarse pulverized solid low grade fuels

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Firing solid fuels
on a travelling grate
Solid crushed fuel

Air Ash

Drive shaft

Air Ash

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Suspension firing

z
z Solid pulverized fuels
– solid fuel ground to the
fineness of face powder
Air + z Liquid fuels
z
pulverized
fuel z
z Gases

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Fluidized Bed Combustion,
principle

Flue Fluidized z
z Ability to burn low-grade
gas Bed fuels
z
z Fuel flexibility
z
z Immune to ash properties
Fuel & Tube z
z NOx limited production
sorbent Bundle
z
z In-situ SOx capture
Air

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Fluidized Bed Combustion,
Types
Bubbling Circulating
Fluidized Bed Fluidized Bed
gas
gas

Air
Fuel & Fuel &
sorbent sorbent

Air Ash Air Ash

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Boiler design basics
Summary

z Boiler design
– various boiler designs
– type of operation
– fuels, solid, liquid, gaseous
– firing systems
– steam water circulation

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The Natural Circulation Boiler

z No circulation pump
z circulation driven by
density differences
between water and
steam/water mixture
z pressure increase
detrimental to
circulation : low
pressure boilers only

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Controlled Circulation boiler

z circulation pump
z allow higher pressure
levels and hence,
capacities
z better load follow
capability
z more complex
z auxiliary consumption
z drum thickness
increase

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Forced Circulation Boiler

z No drum
z once-through circulation
z fast start-up/shutdown
z invented by Sulzer of
Switzerland, now within
ALSTOM
z the « tower » type boiler

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Evaporator Design

z Goal : avoid any


departure from
safe nucleate
boiling (DNB)
z as tube integrity
is therefore at
risk

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Steam - Water Separation :
The Drum
Dry saturated steam towards superheaters
Tertiary separators

Secondary Feedwater
separator inlet

Water/steam
mixture from Primary
evaporator separator
Water level

Pure Water
Downcomers
Source : Combustion, Fossil Power J.G. Singer 1991, ch 7 p 16 fig 7
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Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, , Examples,
and Troubles

Date of last change Reference/Name of Presentation/SN 42


Utility vs Industrial boilers

z Except size, no basic design difference between


both : a boiler is quite always (1) a combination of a
furnace where the combustion occurs, and,
downstream, a series of heat exchangers where
the combustion heat is transferred to the water and
steam

z Utility boilers, whose final purpose is electricity


generation, must provide high reliable service, and
show good efficiency

1 - Except HRSGs
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Utility vs Industrial boilers (+)

z Industrial boilers (whose final purpose is not


electricity generation) must often show a great
flexibility to meet quick load swings

z Both uses are mixed in combined heat-and-


power stations such as desalination plants, pulp
& paper, petrochemical, steel processing, food
industries

1 - Except HRSGs
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Shop vs site boiler construction

z Shop construction
– integrated package with preassembled auxiliaries
– shipping routes from shop to site must be carefully
investigated
– all construction by shop staff
– option limited to small boiler
z Site construction
– shop-assembled components easy to ship
– significant amount of work by local staff
– option required for large utility boilers
– strong site construction supervision

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Typical boiler specification

z Boiler
– Information related to the water and steam generating
equipment and unit designation
z Furnace
– Dimensions / Total Volume
z Superheater and reheater design
– mono/multistage, layout, pendant/panel/platen
z Air Heater
– regenerative bi/tri sectors, cold end plate material
z Economizer
– tube type, finned or plain,

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Typical boiler specification (+)

z Fuel specification
z Combustion system
– fuel preparation and handling, burners type
z Operating Conditions
– Controll point, lowest load ensuring normal steam temp
– Maximum Continuous Rating (MCR)
– Guaranteed load, base for overall unit efficiency
guarantee

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Typical boiler specification (++)

z Boiler Capacity
– steam flow rate at MCR
– control load : steam temp achieved and controlled
z Boiler Efficiency
– Efficiency of xx% means that xx% of the heat supplied
by the fuel is transferred to the water / steam mixture,
and 100 - xx% is lost
– 100% efficiency is not achievable in a cost effective way

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Boiler design basics
Summary

z History
z Thermodynamics for beginners
z Boiler design
z Utilily versus Industrial boilers
z Boiler Construction, Examples, and Troubles

Date of last change Reference/Name of Presentation/SN 49


Small / Medium size Boilers

z Bottom supported
z Can be shop
constructed (package
boilers)
z All heat furnace and
heat exchangers rest on
ground
z thermal expansion
lateral and upwards
restrained
z sensitive to earthquakes
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Small / Medium size Boilers
The ALSTOM« D » Package Boiler

– compact
– small capacity
– 100% shop assembled
– shipped on train or barges
– fast erection

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Small / Medium size Boilers

zTheALSTOM/CE
« D » type VP
package boiler
– compact size
– small capacity
– 100% shop
assembled
– shipped on train or
barges
– fast erection

Date of last change Reference/Name of Presentation/SN 52


Small / Medium size Boilers

zThe ALSTOM/CE
« VU60 » D type
package boiler
zup to 270 t/hr
(approx 90 MWe
power)

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Large size Boilers

z Large Utility boilers


z Top supported/hanged
z All heat furnace and
heat exchangers
hanged from the top
z Allow easy thermal
expansion both lateral
and downwards
z resistant to earthquakes
z footprint minimized
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Large size Boilers

z Germany
z Niederaussem K
z 1012 MWe (gross)
z lignite
z once-through forced
circulation supercritical
z operation: 2002
z Fuel: lignite
z Steam 274 bar, 580°C/600°C
z 94.4 % efficiency
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Large size Boilers

z USA z lignite
z Red Hills 2 x 250 MWe z Circulating
Fluidized Bed
z operation: 2002
z Steam 184 bar,
541°C
z Bechtel

Date of last change


- Largest lignite-fired CFB in the world -
Reference/Name of Presentation/SN 56
Large size Boilers

z Shoaiba, 3 x 350
MWe in Saudi Arabia
z Oil-fired
z 2 pass - subcritical

Controlled Circulation
z Operation: 2002
z Fuel: Oil & gas
z Steam 182 bar,
540°C/540°C

Menu Sub
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Large size Boilers

z Egypt
z Suez 3 & 4 (and Aboukir)
z 2 x 325 MWe
z Oil or gas-fired
z drum boiler, 2 coupled
pass Controlled
Circulation
z Operation: 1987
z Fuel: Oil & gas
z Steam 181 bar,
541°C/541°C

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Large size Boilers

Heat Exchangers Arrangement

RH
RH
SH
RH
SH
EC0

Vaporizer

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Large size boiler
Glossary, top
Furnace Structural Pressure-part
steam-cooled steel framing support steel
Hanger rods
roof
Rear
pass
Drum U bolts steam-
cooled
Riser tubes roof
Steam drum
Finishing
(High temp)
Superheater Superheater
panels or reheater
Superheater
or reheater Buckstays
platens
Radiant wall
reheater Convection
Superheater
or reheater
Reheater
inlet header
Source : Combustion, Fossil Power J.G. Singer 1991, ch 7 p 21 fig 11
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Large size boiler
Glossary, middle

Radiant wall
reheater Convection
Superheater
Reheater or reheater
inlet header
Furnace Economiser
side wall
Furnace Furnace rear
front wall wall
Economiser
Downcomers inlet
Windbox
Burners Economiser
ash hoppers

Boiler water Ljungstrom®


circulating Regenerative
pump Air heater
Source : Combustion, Fossil Power J.G. Singer 1991, ch 7 p 21 fig 11
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Large size boiler
Glossary, bottom

Boiler water
circulating Ljungstrom®
pump Regenerative
Air heater

Lower waterwall Bottom-ash Primary Forced


ring header hopper air fans draft fans

Source : Combustion, Fossil Power J.G. Singer 1991, ch 7 p 21 fig 11


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Boiler Construction : furnace
Tube wall (membrane)
Insulation

Mineral Ribbed
liner fibre outer casing
double
layer Galvanized
lagging hex mesh
Insulation
pins Tube wall

Horizontal
Pourable Buckstay
Insulation
Corner closure plate
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Boiler Construction :
Combustion Area
z Two firing types
– tangential firing

– Front/wall firing

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Boiler Furnace : T / front firing

Tangential firing

Burners are located in the furnace angles


No individual flames but a rotating fireball
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Boiler furnace : T / front firing

Front firing
Burners are located on
one furnace wall or two
facing walls.

Flames stay individual

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Tangential and wall fired
VU 60 industrial boilers

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Combustion System Issues

z Incomplete/bad combustion : yellow flame, black


smoke
z Lack of combustion air, insufficient excess air
z Flame too long (front firing)
z Flame too close from the wall (T firing)
z Flame instability at low loads
z Poor fuel oil pulverization
z Superheater / reheater burned on gas firing
z Emissions of NOx, SOx and particulates

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Boiler Tube issues

z Tube cleanliness
z Tube corrosion by combustion
byproducts
z Tube overheating
z Tube pitting
z Hydrogen-induced tube
embrittlement
z Tube ductile gouging

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Heat Transfer and Tube Cleanliness

Energy Loss, clean tube


• Loss in the tube wall only

Energy Loss, fouled tube

• Loss in external deposits


• Loss in the tube wall
• Loss in internal deposits

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Heat Transfer and Tube Cleanliness

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Heat Transfer and Tube Cleanliness

Remove external Avoid internal deposits by


deposits water treatment; remove
by sootblowing by acid cleaning

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Corrosion of Heat Exchangers
by Combustion Byproducts

z High temperature corrosion in superheaters and


reheaters
– promoted by sodium and vanadium compounds
– sensitive if metal temp. above 600°C
z Medium temp. Corrosion in evaporators
– fixed through combustion system adjustment
z Low temp. Corrosion in cold areas
– promoted by sulfur, which turns into sulfuric acid
below dew point : keep temperature above 150°C

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Tube failures - Overheating

Cross section of a tube exposed


to short time overheating
Cause : often DNB excursion

Short time overheating failure

Long time overheating failure

Long time overheating failure

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Tube failures - Pitting

Electromechanical corrosion

Fix : appropriate water chemistry

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Tube failures - Others

Hydrogen-induced
tube burst : occurs
beneath a relatively
dense deposit
Fix : appropriate water
chemistry

Ductile gouging :
irregular wastage of the tube
meteal beneath a porous deposit

Fix : appropriate water chemistry

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Boiler Construction : Drum
Dry saturated steam towards superheaters
Feedwater

Water/steam
mixture from
evaporator

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Troubles associated to drums

z Loss of level gauges


z water level controllers out of service
z corrosion
z moisture carry-over in the steam
z safety valves leaking
z leaks of roll-expanded evaporator
tubes
z plugging of evaporator tubes

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Boiler Auxiliary : Ljungstrom®
Regenerative Air Heater

Hot flue gas


from boiler Hot Air to
Burners

Cold flue gas


to stack Cold Air
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Ljungstrom® Regenerative
Air Heater, Glossary
Hot Air
to burners Radial seals
Hot flue gas
from boiler
Heat transfer
Elements

Rotor Housing

Pin rack tor


Ro Hot End

Intermediate
So
otb
low Cold End
Axial seals er
Cold flue gas s
Cold air
to chimney Source : Combustion, Fossil Power J.G. Singer 1991, ch 14 p 29 fig 27
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Ljungstrom® Regenerative
Air Heater Issues

z Leakages due to damaged axial or


circumferential seals
z Cold end baskets damaged by acid corrosion,
z Poor sootblowing, triggering fires
z Standby pneumatic or DC motor not working or
absent
z Broken / missing pins on the pin rack

- Heavy impact on boiler efficiency -


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Boiler auxiliary : Sootblowers

Source : Combustion, Fossil Power J.G. Singer 1991, ch 14 p 39 fig 34


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Sootblowers Issues

z Locked, unable to travel in the furnace


z Auxiliary steam not available
z Insufficient number of sootblowers
z Wear and tear of the steam nozzles
z etc.

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Boiler Auxiliary : fans

Discharge

Inlet
vanes

Inlet (Suction)

Inlet (Suction)

Source : Combustion, Fossil Power J.G. Singer 1991, ch 14 p 8 fig 5


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Boiler Auxiliary : fans

Source : Combustion, Fossil Power J.G. Singer 1991, ch 14 p 8 fig 6

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Boiler Auxiliary :
Circulation Pump
Inlet (Suction)

Discharge Discharge
Pump-End
Impeller Bearing Housing
Pump-End Heat-Exchanger
Journal Bearing Inlet Connection
Rotor Stator Windings
Motor Casing Stator laminations
Cover-End
Thrust Bearing Journal Bearing
Terminal Gland Thrust Disc and
Auxiliary Impeller
Electrical Heat-Exchanger
Terminal Box Outlet Connection
Source : Combustion, Fossil Power J.G. Singer 1991, ch 14 p 43 fig 37
Filter Reverse Thrust Bearing
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Boiler Operation Improvement :
Training

Source : Combustion, Fossil Power


J.G. Singer 1991, ch 21 p 32

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Safe Operation of Large Boilers

z Protection against pressure surges


– safety relief valves on drum, reheaters and
superheaters
z Lack of water in the drum
– automatic trip if level comes too low to avoid operation
of boiler without water
z Protection against explosions in furnaces
– boilers on-off safeties : burner management system
– flame scanners
z Environmental issues

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Power Generation Glossary

z Capacity Factor
– energy generated by the unit during the reference period
divided by the energy that could have been generated
had the unit run at its full rating over the entire period

z Net Plant Heat Rate [ NPHR ]


– the fuel-heat input required to generate one KWhr of
energy delivered to the grid

z Auxiliary Power Charges


– in-house power requirement of the installation (pumps,
fans, motors, etc.)

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Power Generation Glossary (+)

z Gross Plant Heat Rate


– net plant heat rate plus the fuel-heat input needed to
cover the auxiliary power charges
z Replacement Power Cost
– the cost of purchasing the replacement energy if the
concerned installation is not operating, due to a
scheduled or forced outage
z Black Start Capability
– in-house auxiliary generating station (diesel, generally)
to cover the auxiliary power charges necessary to start
the plant

Date of last change Reference/Name of Presentation/SN 91


A introduction to Boiler Design
Basics

Boiler Design
Basics
Introduced !

Thank you for your attention

Date of last change Reference/Name of Presentation/SN 92


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