STEAM GENERATORS

STEAM GENERATORS
Generates steam at desired rate, desired pressure, and temperature by burning fuel It is a complex integration of furnace, superheater, reheater, evaporator, economizer, air pre-heater, along with various auxiliaries such as pulverizes, burners, stokers, dust collectors, ash-handling equipment, chimney or stack Boiler is part of steam generator where phase change occurs from liquid to vapor at constant pressure and temperature

Classification of boilers
1. Horizontal, vertical or inclined Axis horizontal, vertical or inclined Horizontal boiler occupies more space But the inspection & maintenance are easy

2. Fire tube and water tube Hot gases inside the tube & water surrounds it (Cochran, Lancashire, and locomotive boilers ) Water inside the tube & fire surrounds it (Babcock and Wilcox, Stirling )

Classification of boilers
3.
Externally fired and internally fired

Fire is outside (external) the boiler shell (Babcock and Wilcox, Stirling ) Fire is inside the boiler shell (Cochran, Lancashire) 4. Forced circulation & Natural circulation Circulation of water by a forced pump ( Velox,Lamont,Benson) Circulation of water by natural convection(Lancashire, Babcock and Wilcox)

Classification of boilers
5. High pressure & low pressure boilers.
Pressure 80 bar &above (Velox,Lamont,Benson , Babcock and Wilcox) Pressure below 80 bar(Cochran, Lancashire, and locomotive boilers ) 6. Stationary & portable Used for power plant steam Locomotive type 7. Single tube and multi tube boilers

Fire tube boiler

Water tube boiler

Comparison between Fire-tube & Water-tube boilers

Particulars Fire tube boilers Water tube boilers Position of water and Hot gases inside the Water inside the tube hot gases tube and water outside and hot gases outside the tube the tube Mode of firing Operating Pressure Rate of steam production Internally fired Limited to 16 bar Externally fired Can work under as high pressure as 100 bar Higher

Lower

Suitability

Not for large power plants

Suitable for large power plants

Comparison between Fire-tube & Water-tube boilers

Particulars Fire tube boilers Water tube boilers

Risk on bursting

Less due to low pressure Chances of explosion Less Construction Transportation Floor area required Treatment of water Difficult Difficult More Not so necessary

More More Simple Simple less More necessary

Lancashire boiler
Fire tube boiler Internally fired Low pressure Specifications Diameter of shell : 2 to 3 m Length of the shell : 7 to 9 m Maximum working pressure: 16 bar Steam capacity : 9000 kg/h Efficiency : 50-70 %

Lancashire Boiler

Lancashire Boiler

Lancashire Boiler

Babcock and Wilcox boiler

water tube boiler externally fired high pressure Specifications Diameter of the drum : 1.22 to 1.833 m Length : 6.096 to 9.144 m Maximum working pressure: 40 bar Steam capacity : 40000 kg/h Efficiency : 60-80 %

Babcock and Wilcox boiler

Babcock and Wilcox boiler

Babcock and Wilcox boiler

High pressure boilers

Steam capacities 30-650 t/hr Pressure up to 160 bar, max . Temp. 5400C Features : Method of water circulation-forced circulation with the help of a pump Type of tubing parallel system of tubing reduce the pressure loss and better control over the quality of steam Improved method of heating- saving of latent heat by evaporation of water above critical pressure of steam

Advantages of high pressure boilers

The tendency of scale formation is eliminated due to high velocity of water through the tubes Light weight tubes with better heating surface arrangement can be used. Space required is less Danger of overheating is reduced because of uniform heating Variable load requirement can be met quickly The efficiency of plant is increased upto 40-42%

LaMont boiler
Capacity : 40-50 tones (super heated steam) Pressure : 130 bar Temp : 5000C

LaMont boiler

Benson Boiler
Capacity : 150 tones/h (super heated steam) Pressure : 500atm Temp : max 6500C

Benson Boiler

Once through boiler

A boiler in which water flows, without recirculation, sequentially through the economizer, furnace wall, and evaporating and superheating tubes. The once through boiler has high load response characteristics due to the fact that it does not have a drum Once through boilers of super-critical pressure boilers have higher efficiency

Boiler mountings
Boiler mountings that are fitted on the boiler body itself for a safe and efficient running of the boiler Safety Valves -to protect the boiler from overpressure Main Steam Valve-Main steam stop valve is a non return valve, fitted on the main steam line just near to the boiler Auxiliary Steam Stop valve-back up valve to the main steam stop valve Feed Check or Control valve Water level gauges

Boiler mountings
Air release Cock Blow Down Valve-Used for emptying the boiler water Scum Valve-removal of impurities from the boiler water Additional mountings on Water Tube boiler Automatic feed water regulator Low alarm level High alarm level Soot blowers-use pressurized steam or compressed air to blow off the soot and other combustion products deposits from the surface of the tube.

Boiler Accessories
1. Economiser A device in which waste heat of flue gas is utilized for heating the feed water. Independent type- installed in chamber apart from boiler setting Integral type- installed within the boiler. Advantages Temperature range b/w various parts of the boiler reduced-results in reduction of stress due to unequal expansion Cold water may chill the boiler metal hot feed water checks it Evaporative capacity of the boiler increased Overall efficiency of the plant increased

Economiser
Independent type Vertical tube ( Greens Economiser)

Economiser
By-pass arrangement of flues

Air Preheater
To increase the temperature of air before it enters the furnace. Preheated air accelerates the combustion and facilitates the burning of coal. Placed after the economiser Three types Tubular type Plate type Storage type

Tubular type air preheater

Storage type air preheater

Storage type air preheater

Storage type air preheater( Stationary type)

Superheater
To increase the temperature of steam above its saturation point Avoids too much of condensation in the last stages of turbine. Eliminates turbine blade erosion Overall efficiency increased Two types Convective superheater Radiant superheater

Sugdens superheater

Steam power plant Layout

Boiler mountings and accessories: Boilers are equipped with two categories of components: boiler mountings andboiler accessories. Boiler mountings are the machine components that are mounted over thebody of the boiler itself for the safety of the boiler and for complete control of theprocess of steam generation. Various boiler mountings are as under: 1) Pressure gauge. 2) Fusible plug. 3) Steam stop valve 4) Feed check valve 5) Blow off cock 6) Man and mud hole