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Performance Analysis of Draught System
Performance Analysis of Draught System
atm *
g
*
H
chimney
B
Essential when Natural Draft cannot generate required amount of breathing
Mechanical (Artificial)Draft : Forced Draft
H
chimney
T
atm
T
gas
A
B
p
B =
p
atm +
gas *
g
*
H
chimney
p
A =
p
fan
Mechanical (Artifical)Draft : Balanced Draft
H
chimney
T
atm
T
gas
A B
p
B =
p
fan,s
p
A =
p
fan.b
B
Resistance to Air & Gas Flow Through Steam
Generator System
+ve
-ve
Platen Super
heater
Reheater
Final Super
heater
LTSH
Economizer
Furnace
Wind Box
Coal
Pulverizer
F D Fan
Secondary
air duct
P A Fan
PA duct
APH
Flue gas
duct
Coal bunker
Coal feeder
Boiler drum
210 MW POWER PLANT SG
Pressure drop in Air and Gas Duct Systems
Bernoulli equation pressure drop across a flow passage
2
2
2
2
2
2
1
2
1
1
1
2 2
P
gZ
u P
m
W
gZ
u P A
+ + + =
A
A
+ + +
Pa
u
d
L
f p
dl
2
2
= A
Frictional resistance along flow path:
where f = coefficient of friction
L = length of the duct, m
d
dl
= equivalent diameter of the duct, m
= density of air or gas calculated at the mean gas temperature, kg/m
3
u = cross section average velocity of air or gas in the duct, m/sec
Equivalent diameter for rectangular duct is given as
( )
( )
25 . 0
625 . 0
3 . 1
b a
ab
d
dl
+
=
2
9 . 0
Re
74 . 5
7 . 3
log
0625 . 0
(
(
)
`
|
.
|
\
|
+
|
|
.
|
\
|
=
dl
d
k
f
where a and b are sides of the duct, mm.
The coefficient of friction for flow through tubes can be approximated as
shown below,
for 5000 < Re<10
8
,
10
-6
< (k/d
dl
)<0.01
Minor Losses
Calculation of Local pressure drops:
where p = local pressure drop
K = local resistance factor,
= density of air or gas at the position of the pressure drop
calculated, kg/m
3
u = velocity of air through the fittings m/s.
Pa
u
K p
l
2
2
= A
Pressure drop across a burner
pa
K = 1.5 for tangential burner
3.0 for swirl burner
2
2
u
K P
= A
Pressure drop across heating surfaces
Pressure drop across tube bundles:
Inline arrangement: K = n K
0
Where n = number of tube rows along the flow direction
K
0
= loss coefficient for one row of tubes
K
0
depends on
1
= s
1
/d
,
2
= s2/d
,
= (s
1
- d )
Where s
1
is lateral pitch & s
2
is longitudinal pitch
If
1
<=
2
:
K
0 =
1.52 (
1
1)
0.5
0.2
Re
0.2
If
1
> 2
:
K
0
= 0.32 (
1
1)
0.5
( 0.9)
0.2
Re
0.2/
Pa
u
K p
b t
2
2
= A
S
1
S
2
Staggered Arrangement
The loss coefficient is obtained as
K = K
0
(n+1)
Where K
0
is the coefficient of frictional resistance of one row of tubes
K
0
depends on
1
= s
1
/d
,
= (s
1
- d ) / (s
2
l
- d )
Where s
2
l
is the diagonal tube pitch given by
s
2
l
= ( 0.25 s
1
2
+ s
2
2
)
and K
0
can be written as,
K
0
= C
s
Re
-0.27
C
s
is design parameter of the staggered banks
S
1
S
2
For 0.17 <= <= 1.7 and
1
>= 2.0
,
C
s
= 3.2
If
1
< 2.0,then C
s
given as
C
s
= 3.2 + (4.6 2.7 )(2 -
1
)
For = 1.7 5.2, C
s
= 0.44(+1)
2
Cross-Flow over Finned Tubes
Inline arrangement
for round fins
where
1
l
= (pitch of fin, Pf / diamter of tube, d)
2
ll
= (height of fin, hf / diamter of tube, d)
Re = ( u p
f
/ )
For square fine with = 0.33
( ) | |
12 . 0
1
24 . 1
Re
1
606 . 0 ( 464 . 0 87 . 2
+ =
o
o o
n
K f
ll
f
l
| |
12 . 0
1
Re
1
75 . 2 80 . 1
+ =
o
o
n
K f
ll
f
ll
o
1) Staggered Arrangement
for round fins s
1
=s
2
=d+2h
f
for round fins s
1
=s
2
=2d
| |
24 . 0
72 . 0
Re 0 . 2
=
f
l
n K o
| |
45 . 0
24 . 0
72 . 0
Re 7 . 2
=
f
ll
f
l
n K o o
Gas side pressure drop in finned-tube economizers
Pa
u
K p
mc
2
2
= A
Pressure drop in tubular air heaters
where p
mc
is the pressure drop in the tube
K
in
and K
out
are local resistance factors at inlet and outlet
Pa
u
K K p p
out in c m mc
2
) (
2
+ + A = A
Pressure drop through rotary air heater
Corrugated plate-corrugated setting plate
Re >= 2.8 x 10
3
f = 0.78 Re
-0.25
Re < 2.8 x 10
3
f = 5.7 Re
-0.5
Pa
u
d
L
f p
dl
mc
2
2
= A
Corrugated plate- plane setting plate
Re >= 1.4 x 10
3
f = 0.6 Re
-0.25
Re < 1.4 x 10
3
f = 33 Re
-0.8
Plane plate- plane setting plate
Re >= 1.4 x 10
3
f = 0. 33 Re
-0.25
Re < 1.4 x 10
3
f = 90/ Re
Pressure drop in ducts joining air heater and dust collector
The volume flow rate of gases at the induced draft fan is determined by ,
where V
gf
= volume flow rate of gases at the exit of the duct, m
3
/s
T
g
= temperature of flue gas leaving the duct,
0
C
Ao = leakage air ratio behind the air heater
( )
|
|
.
|
\
|
+
A + =
273
273
0
g
g f g
T
V V B V o
B = fuel firing rate, kg/s
where oe is the excess air ratio in the flue gas at the duct exit
T
0
is the cold air temperature,
0
C
o o
o o
A +
A +
=
e
g e
f g
T T
T
0
Pressure drop through convective section
Mass conservation for unchanged density,
u A = u
1
A
1
= u
2
A
2
local pressure loss, Ap
1
=
total loss, Ap = Ap
1 + A
p
2 + .+A
p
n
= (k
1
1
+ k
2
2
..+ k
n
n
)
where k
1
1
= k
1
(A/A
1
)
2
,
k
1
2
= k
2
(A/A
1
)
2
2 2 2
2
1
1
2
1
2
1
2
1
1 1
u
K
u
A
A
K
u
K p = = = A
2
2
u
Ash Collectors
Following Table is used to estimate the pressure drop in Ash
collectors.
Cyclone: 15 20 m/s 70 90% 500 1000 Pa
ESP: 1 2 m/s 99% 100 200 Pa
Pressure Drop through Stack
where Ap
st
= stack pressure drop, Pa
f = friction factor
L
st
= height of the chimney, m
D= diamter of the chimney , m
K
c
= resistance factor at the stack outlet
= gas density in the stack, kg/m
3
u
c
= gas velocity at the chimney outlet, m/s
2
2
c
c
st
sy
u
K
D
L f
p
|
|
.
|
\
|
+
+
= A
Total gas side pressure drop
Pa
where EAp
1
= total pressure drop from the furnace outlet to the
dust collector, Pa
EAp
2
= pressure drop after the dust collector, Pa
= ash content in the glue gas, kg/kg
p
a v
= average pressure of the gas, Pa
p
g o
= flue gas density at standard conditions, kg/Nm
3
| |
(
EA + + EA = A
av
o g
sy
P
p p p
101325
293 . 1
) 1 (
2 1
100
=
The pressure drop from the balance point of the furnace to the chimney
base is
Ap
rest
= Ap
exit
+ Ap
gas
Ap
nd
where Ap
exit
= pressure drop up to the boiler outlet
Total losses
Ap
Percent Boiler Rating
Burner Losses
APH Losses
Ducts & dampers losses
Air Pressure Losses
Total losses
Ap
Percent Boiler Rating
Furnace, SH & RH Losses
Economizer Losses
Ducts & dampers losses
Draught Losses
FD
Fan
Duct APH Duct Furnace Duct APH
Back
pass
ESP
ID
Fan
Chimney
D
u
c
t
D
u
c
t
Modeling of 210 MW Draught System
Pressure drop calculation in air & gas path and its
comparison with design value.
Assessment of ID and FD fan power as a function of
furnace pressure.
Assessment of effective kinetic rate coefficient as a
function of furnace pressure.
Pressure Variation
Pressure Variation in Air & Gas Path at Full Load
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
3000
1 2 3 4 5 6 7 8 9 10 11 12
Path Element
P
r
e
s
s
u
r
e
(
P
a
)
Calculated (215 MW) Design (210 MW)
Duct FD Fan Duct SCAPH APH Duct
Wind
Box
Boiler APH ESP ID Fan
Off Design Pressure Variation
Pressure Variation in Air & Gas Path at Part Load
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
1 2 3 4 5 6 7 8 9 10 11 12
Path Element
P
r
e
s
s
u
r
e
(
P
a
)
Calculated (168 MW) Design (168 MW)
ID Fan ESP Boiler APH
Wind
Box
Duct APH Duct SCAPH Duct FD Fan
Draught Control
Windbox Pressure Control
Combustion Prediction & Control
Combustion and Draught Control
The control of combustion in a steam generator is extremely critical.
Maximization of operational efficiency requires accurate combustion.
Fuel consumption rate should exactly match the demand for steam.
The variation of fuel flow rate should be executed safely.
The rate of energy release should occur without any risk to the plant,
personal or environment.
The Model for Combustion Control
Parallel Control of Fuel & Air Flow Rate
Flow Ratio Control : Fuel Lead
Flow Ratio Control : Fuel Lead
X
E
Cross-limited Control System
Oxygen Trimming of Fuel/air ratio Control
Combined CO & O
2
Trimming of Fuel/Air Ratio Control