STEAM GENERATING UNIT

PRESENTED BY:
Garrido, Francis Collens
Mangkit, Vencent
Resabal, Marion Vincent
What is Steam?
 Steam is the gas formed when water passes from the liquid
to the gaseous state.

 The uses for steam are many and varied like:

1. Power Generation
2. Industrial Process
3. Heating
What is a boiler?
 A boiler is an enclosed
vessel that provides a means
for combustion heat to be
transferred to water until it
becomes heated water or
steam.
Classification of Steam
 According to the contains of the tube:
 Fire tube boiler
 Water tube boiler.

 ACCORDING TO POSITION OF FURNACE:

 Internally fired boilers
 Externally fired boilers
Classification of Steam
 ACCORDING TO METHOD OF CIRCULATION OF WATER:
 Natural circulation boilers
 Forced circulation boilers

 ACCORDING TO PRESSURE OF STEAM:

 High pressure boiler (> 80 bar)
 Low pressure boiler (≤ 80 bar)
Types of Boilers
1. Fire Tube Boilers
2. Water Tube Boilers
3. Packaged Boiler
4. Fluidized Bed (FBC) Boiler
5. Stoker Fired Boiler
6. Pulverized Fuel Boiler
7. Waste Heat Boiler
8. Nuclear Steam Generating System
Types of Boilers
 Fire tube boiler
 Flames and hot gases
(flue gases: products of
combustion) pass
through the tubes, and
Tubes are surrounded by
water.
Example of Fire Tube Boilers:

1. SIMPLE VERTICAL BOILER

 Is one whose axis of

orientation is vertical with
respect to the ground.
Example of Fire Tube Boilers:
2. COCHRAN BOILER
 Is a fire tube boiler which
is just like the simple
vertical boiler with some
changes to increase the
efficiency of the boiler by
increase maximum
heating area of the
boiler.
Example of Fire Tube Boilers:
3. LOCOMOTIVE BOILER
They are the horizontal boiler and belong from the fire
tube class of boilers. Locomotives boiler are divided into
three main parts smoke box, shell box and fire box.
Example of Fire Tube Boilers:
4. LANCASHIRE BOILER

 Isa simple horizontal boiler and belong from the shell and
tube types of boilers.
LANCASHIRE BOILER
Example of Fire Tube Boilers:
5. CORNISH BOILER

 Isa simple horizontal boiler which belong to the shell and

tube class of boilers. Cornish boiler is much like the
Lancashire boiler.
CORNISH BOILER
Types of Boilers

 Water tube boiler

 Water passes through the

tube, and Flames and hot
gases pass outside the
tubes.
Example of Water Tube Boilers:
1. LA-MONT BOILER
 is a type of forced
circulation water-tube
boiler in which the boiler
water is circulated
through an external
pump through long
closely spaced tubes of
small diameter.
Example of Water Tube Boilers:
2. LOEFFLER BOILER
 This is also a modern
high pressure water
tube boiler using the
forced circulation
principle and named
after Prof.Loeffler.
Example of Water Tube Boilers:
3. BENSON BOILER
 The first modern high
pressure drumless boiler
developed by benson
was put into operation in
1927 in west Germany
power station.
Example of Water Tube Boilers:
4. BOBCOCK AND WILCOX BOILER
 It is a water tube boiler
used in steam power
plants. In this, water is
circulated inside the
tubes and hot gases flow
over the tubes.
Types of Boilers

 Packaged Boiler

 Isa factory-made boiler

that consists of a range
of standard designs.
Example of Packaged Boilers:

1. D-type Package Boiler

 TheD-type boiler has a

water drum, steam drum,
and generating tubes.
Example of Packaged Boilers:

2. A-type Package Boiler

 Has two water drums and

one steam drum
compared to the D-type
package boiler.
Example of Packaged Boilers:

3. O-type Package Boiler

 Area little more simple

compared to D-type and
A-type. are a little more
simple compared to D-
type and A-type.
Types of Boilers
 Fluidized Bed (FBC) Boiler

 Rapid mixing ensures

uniformity of
temperature.
A fluidized bed may be
defined as the bed of
solid particles behaving
as a fluid.
Types of Fluidized Bed Combustion (FBC)
1. Vertical type FBC
 Theirvertical shape
reduces the overall
dimension of the
steam boiler, and is
extremely efficient in
plants, where space
provision is limited.
Types of Fluidized Bed Combustion (FBC)

2. Horizontal type FBC

 The high capacity of the
horizontal type Fluidized
boilers coupled with their
high efficiency, makes them
an extremely desirable
choice for the coal fired
thermal power generating
station.
Types of Boilers

 Stoker Firing
 Proper and sufficient
supply of air and proper
mixing of air with fuel are
primary requirements.
Adequate supply of fuel
particles for proper
burning of particles also
to be maintained.
Types of Stoker Firing

1. Hand firing
 Here, coal chips are put
into the furnace
frequently by shovels.
Types of Stoker Firing

2. Mechanical stroke firing

 Under Feed Mechanical

Stoker Firing
 Travel Grate Stoker Solid
Coal Firing
Types of Boiler
Pulvarized Fuel Firing
For getting most calorific value of coal, the coal is
pulvarized in fine powder and then mixed with sufficient air.
Types of Boilers

 Waste Heat Boiler

 Auxiliary fuel burners
used if steam demand is
more than the waste heat
can generate.
 Used in heat recovery
from exhaust gases from
gas turbines and diesel
engines.
Types of Boilers
 Nuclear Steam Generating
System
 Steam generators are heat
exchangers used to convert
water into steam from heat
produced in a nuclear reactor
core. They are used
in pressurized water reactors
(PWR) between the primary
and secondary coolant loops.
BOILER DRUM AND ITS INTERNALS
Function

 Boiler Drum is a pressure vessel it is used to Separate steam

and water mixture
 Mixing feed water with water separated from steam-water
mixture and re-circulate through the evaporating tubes.
 Reduce dissolved solid contents of the steam ( Blow down)
 Storage of water
Types of steam separators:
 Baffle Separator - are used to reverse flow direction of the
mixture and acts as impact plate.

 Centrifugal Separator - Mixture passes through the Turbo

separator.

 Mechanical Coalescing/Centrifugal Separator - To arrest

the residual moisture if any steam is passed through the
screen dryer before leaving the drum
Drum Internal
Arrangement Of Drum Internals
Seperation Procedure

 Wet steam entering the drum from the riser tubes is collected
in a compartment called separating chamber.

 From this compartment the steam is first led through two

rows of turbo separators.

 Each turbo-separator consists of a primary stage and a

secondary stage
Boiler Drum
Objectives of boiler drum:
 The main purpose of the boiler drum is to provide necessary
space for separating steam from steam-water mixture at a
certain pressure.
 It provides a point for chemical dosing in order to maintain
the concentration of the impurities and the ph of the water
 It provides a point for blow down to maintain the
concentration of the impurities as well as in case of
emergencies like high drum level; it helps to drain out the
excess water.
 It provides necessary space for housing the drum internals.
 MAIN CONNECTIONS  AUXILLARY
1. Feed Lines CONNECTIONS

2. Down Comers 1. Blow Down Lines

3. Risers 2. Chemical Dosing Lines

4. Super heater supply tubes 3. Instrumentation Tappings

4. Air Vents
5. Safety valves
6. Nitrogen Filling Line
7. High & Low level trips
Main Connections

 Feed Lines
 Feed water from
economiser outlet is
supplied to drum through
feed lines and connected to
the feed nozzles mounted
with the drum. Feed nozzles
in turn are connected to the
feed header provided inside
the drum.
Main Connections

 Downcomers
 The downcomer pipe are
connected to the bottom of
the drum.
 The water from drum is
circulated to the
evaporating tubes through
the downcomers which are
kept external to the heating
zone of the boiler.
Main Connections

 Riser Tubes
 The water steam mixtures
formed inside the
evaporating tubes is
collected in the top headers
from where water steam
mixture enters the drum
through risers tubes.
Main Connections

 Super Heater Supply Tubes

 The dry saturated steam
separated inside the drum is
circulated to Superheaters
through these tubes
connected at the top of the
drum.
Anti Vortex Spider

 The water entry from drum to down comers connected at the

bottom leads to the formation of vortex at the inlet. This may
cause drawl of steam into down comers and water
hammering. To prevent this vortex formation anti-vortex
spider in the form of cruciform are located at the down
comers inlet.
Auxiliary Connections
 Air Vents
 Vent pipes fitted with valves and open to atmosphere are
mounted on the top of the drum. The vents are required to
evacuate the air while filling water in drum and to kill the
vacuum during shutdown due to condensing of steam in
drum.

 Nitrogen filling line:

 To charge nitrogen into drum when boiler is under shut down
for preservation purpose.
Auxiliary Connections

 Safety Valve
 To prevent drum explosion from excessive pressure, drum
is provided with spring loaded safety valve.

 Constructions & Location

 Boilerdrum is a heavy wall pressure vessel having
hemispherical ends
 Heavy thickness plate are rolled/pressed and welded to
construct the drum
 It consists of cylindrical portion with two hemispherical end
Important Aspects
 The fitting and alignment of drum internals are very important
for its efficient performance.
 Any misalignment with gap will lead to heavy carry-over of
impurities into steam which will get deposited in the super
heater.
 The alignment should be checked and drum internals should
be set right at every annual overhaul.
 In between also, it is desirable to check the drum internals fit
up during any shut down for a few days.
Mud Drum

 A drum beneath a boiler,

into which sediment and
mud in the water can settle
for removal.
 It is related with “bottom”
blow down which reduces
the quantity of un-dissolved
solids (sludge) which collect
in the lower parts of the
boiler (mud drum)
Superheater Coils

 Super heater coils are used

in a boiler to generate
saturated steam. The super
heater coils are specially
used in Boilers of Power
plant.
Re-heaters

 They are the same as the

supera-heaters but as their
exit temperature is a little bit
less than super-heaters and
their pressure is 20%-25%
less than the super-heater,
they can stand less quality
material alloys.
Economiser Coils

 Economizer coils are used

in downstream of Boiler
bank to preheat the feed
water absorbing heat from
hot exhaust gases.
Economizers are always
water tube type.
Headers

 Form an important part of

all types of boilers. Steam
from the generating tubes is
collected in headers which
are therefore always under
pressure.
WATER WALL PANEL

 Water wall panels are used

in Waste Heat recovery
boilers.
 These are tubes in the boiler
where water is evaporated
to steam and are also called
steam generating tubes.
Air Preheater

 An air preheater (APH) is a

general term used 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.
Soot Blower
 Is a device for removing
the soot that is deposited
on the furnace tubes of a
boiler during combustion.
Classification of Soot Blower
 Long Retractable Soot
Blower
 This type of soot blower is
located in area superheater
and reheater.
Classification of Soot Blower
 Wall / Short Retractable
Soot Blower.
 This type of soot blower is
located in area furnace.
There is not temperature
limitation in its use
Classification of Soot Blower

 Rotary Soot Blower

 This type of soot blower is
located in area boiler bank,
economizer, and air heater.
Classification of Soot Blower

 Rake Soot Blower

 This type of soot blower is
located in area fin tube
economizer and vertical
tubular air heater.
Furnace

 Is a device used for high-

temperature heating. The
name derives
from Greek word fornax,
which means oven.
Burners

 The burner is the device that permits

controlled burning of fue inside the
furnace.
 The burner mixes the fuel with the
required amount of air and directs the
flame into the combustion area.
 The burner comprises of gas burner
and oil burner with atomizing steam
connection.
Burner consists of:

 Air Register
 Used to given an enough quantity of air to the burner for
good combustion.
 Ignition Gun
 Used to give ignition spark to the burner for firing.
 Flame Detector
 Used to monitor the flame.
Oil Burners

 Pressure Jet Burners - These

burners consist of an orifice
at the end of the pressurised
tube. The pressure of the
fuel oil ranges from 7 to 15
bar. These burners are easy
to maintain and have less
cost.
Oil Burners

 Swirl oil burner

 In swirl oil burner, oil is
pressurized to about 7-10
bar. This pressurized fuel
enters tangentially through
the slot at a high velocity in
the oil swirl chamber. It
flows in the form of vortex
and escapes through a
nozzle at the other end of
the chamber.
Oil Burners

 Rotary cup Burner

 This burner has a rotary cup
and a fan. The cup and the
fan are rotated by an electric
motor with a shaft. Oil is
feed to the oil distributer to
throw at the inner surface of
the cup.
Oil Burners

 Dual fuel burners

 These are burners designed
with gas as main fuel and
have additional facility for
burning fuel oil.
Boiler Draft System
Boiler Draft System
Boiler Draft System
 Natural draft: When air or flue gases flow due to the
difference in density of the hot flue gases and cooler ambient
gases.
 Forced draft: When air or flue gases are maintained above
atmospheric pressure.
 Induced draft: When air or flue gases flow under the effect of
a gradually decreasing pressure below atmospheric pressure.
 Balanced draft: When the static pressure is equal to the
atmospheric pressure, the system is referred to as balanced
draft. Draft is said to be zero in this system.
Boiler Drains & Vents System
Boiler Drains & Vents System

 Vents are provided on different pressure parts of the Boiler.

They are used during depressurizing, filling and charging the
system. All drains and vents are manual operated and are
used during startup and shutdown.
 The purpose of this system is to vent and drain the
superheater, Reheater, Boiler drum, Economizer, Deaerator
and Boiler convection pass during startup and shutdown
activities of the Boiler as required.
 The cool down the high temperature drains in the Blowdown
Tank before sending the water to the waste water system.
Use of drains:

 Superheater Drains – During shutdown, these drain valves are

usually opened to depressurize during shutdown.
 Reheater drains – These drains are usually opened for
depressurizing the Reheaters during shutdown.
 Drum level gauge drain – This drains is usually opened when
the gauge is required to place in service.
 Economizer inlet drain – these drains are used for draining the
boiler after shutdown.
Use of drains:
 Lower convection pass header drain – These drains are used
for draining the boiler after shutdown.
 Downcomer header drains – These drains are used for
draining the boiler adter shutdown or cycling the feedwater
system during normal operation.
 Continous Blowdown – This arrangement is used to remove
the silica & another impurities fro the steam drum water.
 Drum Vent – During depressurizing the boiler, open the vent
at 2kg pressure
 Superheater vents – Keep these vents open until steam comes
out of those during startup.