BOILER FIXTURE/FITTINGS

1.0 Introduction -Boiler fixtures are additional equipment.Without it,the boiler may function but it is always a concern about efficiency and safety.Steam boilers play a very important part in the efficient operation of the boilers in a Power Station. These are contained within different systems such as the boiler feed, fuel oil, and combustion air systems. These systems are automatically regulated by a control board. The boiler generates high pressure steam by transfering the heat of Combustion in various heat transfer sections. This part of the article series briefly describes the flow and arrangement of the heat transfer sections in a boiler. In line diagrams help make the concept clear. 1.1 Safety Valves 1.1.1 Function -Its function is to protect the boiler shell from over pressure and subsequent explosion. 1.1.2 Operation Many different types of safety valves are fitted to steam boiler plant, but generally they must all meet the following criteria:-The total discharge capacity of the safety valve(s) must be at least equal to the 'from and at 100C' capacity of the boiler. If the 'from and at' evaporation is used to size the safety valve, the safety valve capacity will always be higher than the actual maximum evaporative boiler capacity. -The full rated discharge capacity of the safety valve(s) must be achieved within 110% of the boiler design pressure. -The minimum inlet bore of a safety valve connected to a boiler shall be 20 mm. -The maximum set pressure of the safety valve shall be the design (or maximum permissible working pressure) of the boiler. -There must be an adequate margin between the normal operating pressure of the boiler and the set pressure of the safety valve.

1.1.3 Diagram

1.1.4 Safety and Efficiency -Safety relief equipment is provided in any pressurized system, and boilers are no exception. Boilers have safety valves can relieve the entire generating capacity of the boiler if the pressure goes above a limit and are provided in the drum, superheater, and reheater. If, due to any reason of operation or malfunction in equipment or controls, the operating pressure in the system goes above the safe limit of the material of construction, it can cause catastrophe. To prevent such catastrophes, safety valves are provided in the boiler at various locations.

1.2 Meltable Plug 1.2.1 Function - A meltable plug radiation switch comprising a case, a spring in the form of an annular split ring fixedly secured to said case, a pair of contacts located adjacent said spring, said spring being biased into contact with said pair of contacts by a meltable plug, whereby melting of said plug allows said spring to move out of contact with said pair of contacts. 1.2.2 Operation - Referring now to the drawing, it can be seen that in the inoperative position the snap ring 20 engages the spring contacts 24 and 26 forming a complete circuit, i.e., in the inoperative position the meltable plug 28 is in place. - Upon subjection of the switch 10 to an environment wherein the neutron exposure exceeds a predetermined damage threshold established by the meltable plug alloy composition, the plug 28 of switch 10 melts allowing the snap ring 20 to snap to its original position wherein the ring does not touch the contacts and thereby breaks the circuit. The breaking of the circuit in turn activates any device attached there. 1.2.3 Diagram

1.2.4 Safety and Efficiency -It is a further object of this invention to provide a radiation switch whose percentage of failure is at a minimum. -It is still another object of this invention to provide a radiation switch which will survive a non-lethal encounter just prior to a lethal one. -It is still a further object of this invention to provide a radiation switch which is economical to produce and which utilizes conventional, currently available components that lend themselves to standard mass production manufacturing techniques.

1.3 Water Gauge 1.3.1 Function -The task of any steam boiler is to provide the correct amount of high quality steam: safely, efficiently, and at the correct pressure.Steam is generated by heat from the combustion of fuel in a furnace, or by waste heat from a process. The heat is transferred to water in the boiler shell, which then evaporates to produce steam under pressure. 1.3.2 Operation -In horizontal shell boilers, the water level rises with increasing load (due to the presence of more steam being below the water level in the boiler). As it does so, the water surface area (steam release area) will decrease because, as the water level is above the centre line of the boiler, the sides of the containing shell converge. -The boilermaker will have designed the boiler to ensure that the area of the normal water level (NWL) is such that steam will be released at an acceptable velocity. The design will also allow a specific minimum height of the steam off-take above the NWL. -Clearly, as steam is generated, the water in the boiler evaporates, and the boiler must receive a supply of water to maintain the level. Because of the factors outlined above, water must be maintained at the correct level.

1.3.3 Diagram

1.3.4 Safety and Efficiency -Safety is also of paramount importance. If the boiler operates with insufficient water, severe damage could occur and there is ultimately the risk of explosion. -For this reason, controls are required which will:

Monitor and control the water level. Detect if a low water level point is reached, and take appropriate action.

-This action may include: Sounding an alarm, shutting down the feedwater supply and shutting down the burner(s). -It is also essential to provide an external indication of the water level.

1.4 External level control chamber 1.4.1 Function -Level control chambers are fitted externally to boilers for the installation of level controls or alarms 1.4.2 Operation The following is a typical procedure that may be used to test the controls when the boiler is under pressure, and the burner is firing:

Slowly turn the handwheel clockwise until the indicating pointer is at the first 'pause' position. The float chamber connection is baffled, the drain connection is opened, and the water connection is blown through. Pause for 5 to 8 seconds. Slowly turn the handwheel fully anticlockwise to shut-off against the back seating in the 'normal working' position.

Sequencing purge valves are provided by a number of different manufacturers. Each may differ in operating procedure. It is essential that the manufacturer's instructions be followed regarding this operation.

1.4.3 Diagram

1.4.4 Safety and Efficiency - Sequencing purge valves are provided by a number of different manufacturers. Each may differ in operating procedure. It is essential that the manufacturer's instructions be followed regarding this operation.

1.5 Air Pre-Heater 1.5.1 Function - An air preheater (APH) is a general term to describe any device designed to heat air before another process (for example, combustion in a boiler) with the primary objective of increasing the thermal efficiency of the process. They may be used alone or to replace a recuperative heat system or to replace a steam coil. 1.5.2 Operation - In particular, this article describes the combustion air preheaters used in large boilers found in thermal power stations producing electric power from e.g. fossil fuels, biomasses or waste. - The purpose of the air preheater is to recover the heat from the boiler flue gas which increases the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. - As a consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower temperature, allowing simplified design of the ducting and the flue gas stack. - It also allows control over the temperature of gases leaving the stack (to meet emissions regulations, for example. 1.5.3 Diagram

1.5.4 Safety and Efficiency - The boiler flue gas contains many dust particles (due to high ash content) not contributing towards combustion, such as silica, which cause abrasive wear of the baskets, and may also contain corrosive gases depending on the composition of the fuel. - In this RAPH, the dust laden, corrosive boiler gases have to pass between the elements of air preheater baskets. The elements are made up of zig zag corrugated plates pressed into a steel basket giving sufficient annular space in between for the gas to pass through. - These plates are corrugated to give more surface area for the heat to be absorbed and also to give it the rigidity for stacking them into the baskets.

1.6 Blowdown Valve 1.6.1 Function -The blow down valves are needle valves designed for operation in open position. Their function is mainly to control a continuous flow of steam and/or water under high differential pressure. -For that reason the design and materials must be such as to minimize the effects of a fluid stream in condition of flashing or made of water containing sometimes abrasive particles. 1.6.2 Operation -Blowdown should be done with the boiler under a light load. Open the blowdown valve nearest the boiler first. This should be a quick opening valve. -Crack open the downstream valve until the line is warm. Then open the valve at a steady rate to drop the water level in the sight glass inch. -Then close it quickly being sure that the hand wheel is backed off slightly from full close to relieve strain on the valve packing. Close the valve nearest the boiler. -Repeat the above steps if the boiler has a second blowdown tapping.

1.6.3 Diagram

1.6.4 Safety and Efficiency -Care should be taken to prevent low water shutdown if this will affect process load. -Water columns should be blown down at least once a shift to keep the bowls clean. -All blowdown piping should be checked once a year for obstructions