DUCTS & DAM P ERS

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 .

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

COLD SECONDARY AIR DUCTING

Hot Secondary Air Duct

COLD PRIMARY AIR DUCTING

Hot Primary Air Bus to Mill & Tempering Air Duct

Economiser to Airheater Duct

Air Heaters to BOF

BOF TO AIR HEATERS BOF to EP Duct

EP to ID Fan

ID Fan to Chimney Duct

Raichur 7, 210 MW Boiler Plant

Raichur 7, 210 MW Boiler Drum area

Raichur 7, 210 MW Top View

Raichur 7, 210 MW Left side view

Raichur 7, 210 MW Right side view

Raichur 7, 210 MW Front view

Raichur 7, 210 MW Rear view

Straight duct

Circular to Rectangular duct

Transition duct

Y duct

Elbow duct

Bend duct

T duct

Anatomy of a simple straight duct

STIFFENER DUCT WITH INTERNAL TRUSS

DUCT PLATE

CORNER ANGLE

FLANGE

3D VIEW OF TUBULAR AIRPREHEATERS WITH DUCTS

COLD AIR IN FLUE GAS IN

FLUE GAS OUT

AH-I

AH-II

ELBOW DUCT

AH-III HOT AIR OUT TRANSITION DUCT

SUPPORT

FLOW METER

EXPANSION JT

HOT SECONDARY AIR DUCT

ECONOMISER DUCT AT SHOP

INTERNAL TRUSS WORK IN ECONOMISER DUCT

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.

JOINTS IN DUCTS * * * FFJ - FLANGE FIELD JOINT FJ - FIELD JOINT IFJ - INTERNAL FIELD JOINT

DUCT CORNER CONSTRUCTION

CORNER WELDING CORNERA NGLE

FIELD FLANGE JOINT-FFJ

5 50 (150)

Duct Plate

FIELD JOINT (FJ)

FJ - Plate 5 5 50(150)

Duct Plate

INSIDE FIELD JOINT (IFJ)

Duct Plate

IFJ - Plate

5 5

50(150)

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 .

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 .

TOP SUPPORT WITH HANGER AND BRACKET

TOP SUPPORT WITH HANGER AND BRACKET

TOP SUPPORT WITH HANGER AND LUG PLATE

RESTRAINT SUPPORT

RESTRAINT SUPPORT

SINGLE RESTRAINT SUPPORT

HANGER TYPE SUPPORT WITH RESTRAINT

STIFFENER

DIFFERENT TOP SUPPORTS

DUCT WITH BOTTOM SUPPORT

FLANGE WITH FITUP HOLES

DETAIL - B

SUPPORT

DETAIL - A

SUPPORT CORNER ANGLE GUSSET PLATE

STRUTTUBE WELD

RESTRAINT

BASE PLATE
WITH (BEARING)

I-BEAM SUPPORT

TOP PLATE

BEARING PLATE

BASE PLATE

BOTTOM SUPPORT WITH BASE PLATE AND BEARING PLATE

BOTTOM SUPPORT WITH STOPPERS

TOP PLATE

BEARING PLATE BASE PLATE WITH STOPPER

SHEAR TIES

TYPES OF EXPANSITION JOINTS :: TYPES OF EXPANSITION 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 .

EXPANSION JOINT ASSEMBLED IN DUCT

With metallic exp.. joint With metallic exp.. joint

With non --metallic expansion joint With non metallic expansion joint

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 .

With metallic toggle With metallic toggle

Lateral

With non-metallic EJ Axial

FIGURE --11 FIGURE CL of support

C L of support

Lateral movement to Toggle Axial movement

Movement of duct

Movement of A. H.

AIR - HEATER
Axial movement

ROUND CORNER EXPANSION JOINT --FULL ROUND CORNER EXPANSION JOINT FULL A A
DEPTH WIDTH STYLE 1 SECTION A - A

STYLE 2 STYLE 2 FULL ROUND CORNER EXPN. JOINT FULL ROUND CORNER EXPN. JOINT

216 mm

271.8

mm

STYLE 6 STYLE 6

DAD Circle / BHEL , TRICHY

DAD Circle / BHEL , TRICHY

DAD Circle / BHEL , TRICHY

Clamp Re-usable duct mating flange

Lifting lug

Bolt & NutStrut pipe

Match plate

DAD Circle / BHEL , TRICHY

PTFE SEALING LAYER

ELASTOMER COATED OUTER LAYER (silitex)

GLASS FABRIC SUPPORT LAYER

CAVITY PILLOW BOLSTER

GLASS FABRIC

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

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.

Gate with CONVENTIONAL LEAF SEAL

LEAF SEAL WHEN BLADE CLOSED

LEAK TIGHTNESS ACHIEVED FOR TALCHER COLD AIR GATE IS 96.85% WITH OUT SEAL AIR

GUILLOTINE GATES AND BIPLANE DAMPERS ARE USED WHERE 100% LEAKE TIGHTNESS IS REQUIRED.

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

P1

P2

P3

UNCHAHAR FLAP DAMPER

ACTUATOR

GEAR BOX

SEAL AIR FAN CASING BLADE

PRODUCTION OF FLAP DAMPER AT SHOP

FLAP DAMPER WITH TOGGLE LEVER ARRANGEMENT AND SINGLE ACTUATOR

ACTUATOR

TOGGLE LEVER FLAP

SIMHADRI 2x500MW

EXPANSION JOINT ACTUATO R

ECONOMISER HOPPER FLAP DAMPER WITH TOGGLELEVER To AIR-HEATER

EXPANSION JOINT

ECONOMISER HOPPER

FLAP DAMPER WITH TOGGLELEVER To AIR-HEATER

FLOWIN

FLAP WITH TOGGLELEVER

DUCT

ACTUATO R FLOWIN

DUCT FLAP WITH TOGGLELEVER

IN

OUT