CHAPTER 2:

STEAM POWER
PLANT
 INTRODUCTION
 The purposes of steam generated:

 POWER - steam engines, steam

turbine,steam pumps

 DRYING – bleaching, palm kernel,

ironing, curing concrete
 STERILIZING – operation theater
equipment, palm oil

 HEATING – buildings, bulk

storage
 COOKING – pressure cooking,
steam jackets
 INTRODUCTION
 Steam power plant:
CHEMICAL MECHANICAL/ELECTRICAL
ENERGY ENERGY

Mechanical Electrical
Energy Energy
Steam
Turbine Grid
System
Generator

Water
Boiler Waste gases

Fuel
 INTRODUCTION
 The purposes of steam power plant:
To produce electric power

To produce steam for

industrial purposes (textiles, paper
mills, sugar mills, etc)
LAYOUT OF STEAM POWER PLANT
To chimney
Coal
storage
Flue gases
Air
Air
preheater
Coal handling
plant
Flue gases

Economiser
Feed water
Air
Main
Super heated valve
Ash storage Ash handling Super steam Turbine
plant Boiler heater Generator
Flue
gases

High pressure Exhaust

heater steam
Condensate
Steam extraction
Boiler feed
pump
pump Condenser
Low pressure heater

Circulating
water
pump

Cooling tower
COAL AND ASH CIRCUIT

Coal storage

Coal and
handling plant

Ash handling
Ash storage plant Boiler
ASH AND GAS CIRCUIT
To chimney

Flue gases
Air
Air preheater

Flue gases

Economiser

Boiler Superheater

Flue gases
FEED WATER AND STEAM FLOW
CIRCUIT

Economiser Feed water

Main
valve
Superheated Turbine
Boiler Superheater steam

High pressure Exhaust steam

heater

steam Condensate
Boiler feed pump extracting pump

Condenser
Low pressure
heater
 COOLING WATER CIRCUIT

Cold Condenser
water

Circulating Hot water

water pump

Cooling tower
 COMPONENTS OF STEAM
POWER PLANT
1. Boiler 10. Coal mill
2. Steam turbine 11. Induced draught fan
3. Generator 12. Ash precipitators
4. Condenser 13. Boiler chimney
5. Cooling tower 14. Forced draught fan
6. Circulating water pump 15. Water treatment plant
7. Boiler feed water pump 16. Control room
8. Wagon tippler 17. Switch yard
9. Crusher house
 BOILER
 Definition: closed vessel in which steam
is produced from water by
combustion of fuel

 Function of the steam boiler:

 Generate steam
 Supply steam at required pressure and quality.

 Classification of boiler:
1. Axis
2. Relative position of water and hot gases
3. Method of furnace
4. Method of water circulation
5. Pressure
6. Purpose
 BOILER
1. Axis
 Horizontal boiler can be inspected easily, but it occupies
more space.
 The vertical boiler occupies less area.

2. Relative position of water and hot gases

 Fire tube- hot gases inside the
tubes, water surrounds the tubes

Water tube- the water inside the tubes and

 gases surround them
 BOILER
3. Method of furnace
 Externally fired
- the furnace placed outside the boiler shell.
- Eg: water tube boiler
 Internally fired
– the furnace located inside the boiler shell.
- Eg: fire tube boiler

4. Method of water circulation

 Forced circulation
- the circulation water is done by a forced pump.
- Suitable for high pressure and high capacity boiler.
 Natural circulation
–the circulation of water is due to natural convection current
- for low capacity boiler
 BOILER
5.Pressure
 High pressure – produced steam at 80bar or above
 Low pressure – produced steam below 80bar

6. Purpose
 Stationary boiler (land)
– used for power plant steam, for central station utility or
for plant process steam
 Mobile boiler (portable)
– small units boiler for temporary use
Choice of Fuel / Heating Medium :
 Gas : Natural gas, LPG
 Liquid : Diesel, kerosene, light fuel oil, medium fuel oil,
heavy fuel oil
 Solid : Coal, wood, fibre and shell, other agricultural
waste such as bagasse.
 Waste heat : from gas turbine, diesel engine exhaust,
reactors
 Electricity
 Hot oil
 BOILER HORSEPOWER
 Steam engine - Boiler horsepower is used rating a boiler's
capacity to deliver steam to a steam engine

 Power plant - The amount of energy needed to produce 34.5

pounds (15.65 kg) of steam at temperature 212oF (100oC) in
one hour.

 One boiler horsepower is about 33,479 Btu per hour (about

9,810 watts, 8430 Kcal/Hr).

 Boiler horsepower can be determined from the heat transfer

area
PBoHP = A / 17 (1)
where
PBoHP = boiler horsepower
A = heat transfer area (ft2)
UNITS
 SELECTION OF BOILER
While selecting a boiler the following factors should be
considered:

 The working pressure and quality of steam required

 Steam generation rate
 Floor area available
 Accessibility for repair and inspection
 Comparative initial cost
 Erection facilities
 The probable load factor
 The fuel and water available
 Operating and maintenance costs
 ESSENTIALS OF A GOOD STEAM
BOILER
A good boiler should posses the following features:

1) Produce the maximum weight of steam .

2) Reliable.
3) Occupy minimum space.
4) Light in weight.
5) Quick starting.
6) Simple installation
7) Easy for repairs and inspection.
8) The boiler components should be transportable
without difficulty.
9) The tubes of the boiler should not accumulate soot
or water deposits and should be sufficiently strong
to allow for wear and corrosion.
 DESIGN APPROVALS
 “SteamBoiler”:closed vessel in which steam is generated
under pressure greater than atmospheric pressure, and
includes economizer and superheater.
 Section 18 FMA :
1)No person shall manufacture, repair or install
machinery in such a manner that it does not
comply with the provisions of this Act and
regulations
2)No person shall importany machinery other than
transmission machinery which does not comply
with any regulations made under this Act.
BOILER FABRICATION
BOILER FABRICATION
•A boiler stay is an internal strengthener
inside a steam boiler.

•Their function is to support the flat walls of

a boiler against the internal steam pressure.

• In many cases the boiler can be given a

domed shape that is self-supporting: stays
are required where this is not possible.

•There are several forms of stay, according

to the forces they must resist.
 WELDING
 Welding Procedure Specification (WPS)
 Welder Performance Qualification Test (WQT)
 Different types of welding
-TIG, SMAW, ElectricResistance, Gas Welding
 Welding defects :
-Cracks
- Cavities, Gas Porosity
- Slag inclusion
-Lack of penetration
-Lack of fusion
-Undercut
-Excessive capping
-Wrong specifications
TYPES OF JOINT
POSITIONS
INSTALLATION AND CERTIFICATION
 No person shall buy, install, repair, modifyor sell any boiler without
approval of DOSH.(Section 17, FMA 1967).

 No person shall operate a boiler without a valid certificate of

fitness(Section 19, FMA 1967)and boiler attendantand steam
engineeras required.(Section 29, FMA 1967).

 All boilers have to be opened up for inspection before the certificate

of fitnesscan be renewed.(Regn 10&14, Notification, Certificate of
Fitness and Inspection Regn, 1970)

 Boilers can only be repaired by approved Boiler Repaircompanies

after the repair procedure has been approved by DOSH.
 INSTALLATION & TESTING
 Application to local DOSH office for permission to install any steam boiler.
–Form JKJ 105
–Layout plan,and
–Copy oft he design approval.

 Hydrostatic Test (Regulation 72 Steam Boiler and UPV Regulation):

 Purpose : To check leakage
 1st service during installation at site
 Every 7 years
 After repair
 1.5 x authorised safe working pressure and hold for 20 min.

 Steam test
 Purpose : To check functioning of boiler equipment and safety features
e.g : water alarm, blowdown, relief valve etc
 1st time service during commissioning after hydrostatic test
 When the authorised safe working pressure has been altered or safety
valve change
 HYDROSTATIC TEST
 Spading (isolating) the boiler attachments e.g. safety valves and
water gauge, except for the feed water inlet and blowdown valves
 Use appropriate pressure gauge
 Leave one vent open at the top to ensure water pumped in
completely fills the boiler
 Raise pressure to design pressure. Check.
 Raise pressure to 1.5 x design pressure, maintain for at least 20
mins. Check for leaks.
 Slight weeping is acceptable (expanded tubes only).
 Fill in the hydrostatic test FormJKJ 127 (newboiler).
 STEAM TEST
 Warm up the boiler.
 Fire the boiler –adequate slow firing.Check.
 Raise the pressure to the operating pressure; Check. Increase the
pressure;
 Bypass thefire cut-off if necessary, to test the pressure relief valves.
The highest pressure setting should not exceed the design
pressure. Note the seating pressure.
 If provided with superheater, test the superheater relief valvefirst; it
should have the lowest setting.
 Test the high water and low water alarms.
 Ensure safe blowdown; check blowdown pit or tank
ANNUAL INSPECTION
 The boiler has to be shut down and allowed to cool.
 Water is drained and all the fittings including caps in headers
and mud drums are dismantled.
 The boiler is effectively disconnected from any other steam
boiler or source of steam.
 The fireside is thoroughly cleaned
 The internals are cleaned as necessary -by hydrojet, and
wirebrushed clear of scales and deposits
 Fittings such as cocks and valves, floats and gauge glasses
are cleaned and serviced
 Temporary scaffolds or ladders must be provided if permanent
ones are not available -for inspection of remote areas
 The boiler is empty, cool and dry
Statutory Inspection

 􀁺What the DOSH inspectors look for:

 –Signs of shell wall thinning.
 –Cracks at welds and at connections.
 –Damage to the shell by impact.
 –Leaking gaskets and seals.
 –Soundness of foundation.
 –Protective coatings.
 –Safety relief valve functions.
 –Alarm functions
 –Pressure gauge calibration

 –Hazards such as sumps and blowdowns .