013 - Principal Types of Boilers - RS PDF

HITACHI BOILER PLANT TRAINING COURSE
Principal Types of Boilers
PRINCIPAL TYPES OF
BOILERS
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Contents
1 Classification of Steam Generators and Regulations ........................... 6

1.1 Classification of steam generators according to different aspects ...................................... 6
1.1.1 Classification of steam generator design types according to DIN EN ................................ 6
1.1.2 Classification of steam generators according to water flow paths ...................................... 8
1.1.3 Classification of steam generators according to operation mode ..................................... 14
1.1.4 Classification of steam generators according to steam state of the produced steam ...... 14
1.1.5 Classification of steam generators according to the steam side connections .................. 16
1.1.6 Classification of steam generators according to the design configuration ........................ 22
1.1.7 Classification of steam generators for combined cycle power plants ............................... 30
1.1.8 Classification of power plants with gas turbines ............................................................... 34
1.2 Representation of steam generators in thermo-technical diagrams ................................. 40
1.2.1 Schematic representation of steam generators ................................................................ 40
1.2.2 Representation of steam generators in T, s diagram ........................................................ 42
1.2.3 Representation of the steam generator in the h, s diagram.............................................. 48
1.2.4 Representation of the steam generator in the h, p diagram. ............................................ 52
1.3 Legislative aspects of steam generators ........................................................................... 57
1.3.1 Old regulations .................................................................................................................. 57
1.3.2 New regulations ................................................................................................................ 65
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1 Classification of Steam Generators and Regulations
1.1 Classification of steam generators according to different aspects
1.1.1 Classification of steam generator design types according to DIN EN
The designs of steam generators according to DIN EN are divided into two large groups,
• shell boilers and
• water tube boilers.
Despite the distinct, traditional term “boiler” that is also used in the standards, in general usage and in
the following, the designation “steam generator” is typically used.
The shell boiler steam generator has a large water volume in relation to its vapour mass flow (e.g., 2
m³ water volume per 0.28 kg/s steam generation). The large water holding space is a tank through
which the flue gas is guided in tubes.
The water tube steam generator consists of many individual tubes with water/steam flowing through,
and a large surface circulated by flue gas.
Water tanks cannot be built arbitrarily large, and not for arbitrarily high pressure, and with good heat
transfer. Water tubes, in contrast, can be built arbitrarily long and for arbitrarily high pressure, and with
good heat transfer. Therefore, shell boiler steam generators are suitable for low steam outputs, low
pressures, and low steam temperatures.
In contrast, water tube steam generators can be built for arbitrarily large steam flows, and for very high
pressures and steam temperatures.
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1.1.2 Classification of steam generators according to water flow paths
Several shell steam generators types can be distinguished:
• flame tube boilers (single-pass boilers)
• flame tube/smoke tube boilers
– two-pass boilers
– three pass shell boilers
• smoke tube boilers (in rare cases as waste heat recovery boilers for gas turbines.)
1 Boiler body 11 Feed pump

2 Flame tube 12 Feed valve
3 Smoke tube 2nd pass 13 Steam valve
4 Smoke tube 3rd pass 14 Safety valve
5 Rear reversing chamber, water cooled 15 Water level limiter
6 Front reversing chanber 16 Blow-down valve
7 Flue gas outlet 17 Water level indicator
8 Boiler frame 18 Pressure regulator
9 Insulation 19 Manometer
10 Firing oil or gas burner
Figure 1.1: Flame tube/fire tube three-pass shell boiler
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Several water tube generators types can be distinguished:
• circulation type steam generators (drum type boilers)
– natural circulation steam generators
– forced circulation steam generators (La Mont)
Figure 1.2: Circulation type steam generators
• once through forced circulation steam generators
– without sediment bowl (classic Benson steam generator) – out-dated
– with sediment bowl
classic Sulzer steam generator – out-dated
steam generator with full load recirculation – very rare
steam generator with partial load recirculation – very rare
– once through steam generator with start-up system and low load circulating system
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Figure 1.3: Once-through steam generator
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1.1.3 Classification of steam generators according to operation mode
A classification of steam generators can be made according to their types of operation, which result
from their application conditions.
• fixed pressure operation
– drum steam generator
– steam generator in bus-bar installations
• modified sliding pressure operation
– hard coal fired steam generator
– steam generator in gas steam cycle systems
• natural sliding pressure operation
– large brown coal power plants
1.1.4 Classification of steam generators according to steam state of the produced steam
• saturated steam/wet steam
• superheated steam
– without reheat superheating
– with reheat superheating: single reheat superheater
double reheat superheater
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Figure 1.4: Operation modes
1.1.5 Classification of steam generators according to the steam side connections
• Monoblock
• Duoblock
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Figure 1.5: Systems with single reheat superheater
• Part of a range type power plant
• Part of a topping power plant
– topping steam generator
– secondary steam generator
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Figure 1.6: System without reheat superheat
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1.1.6 Classification of steam generators according to the design configuration
• tower steam generator
Figure 1.7: EVT-Sulzer-Once through steam generator with full load circulation and EVT-Natural gas
firing for a 630 MW unit
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• single-pass steam generators
Figure 1.8: “Schwarze Pumpe” power plant
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• two-pass steam generators
Figure 1.9: Wilhelmshaven power plant
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• multi-pass steam generators
Figure 1.10:
• Horizontal steam generators
– as heat recovery steam generators: for gas steam cycle power stations
for industrial heat recovery utilization
– as fired steam generators (planned)
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1.1.7 Classification of steam generators for combined cycle power plants
forced circulation steamTable 1.1 generators
– single pressure steam generators
– dual pressure steam generators
– triple pressure steam generators
• natural circulation steam generators
– single pressure steam generators
– dual pressure steam generators
– triple pressure steam generators
• once-through steam generators
– pure forced once-through circulation
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– combination of natural circulation and forced once-through circulation (multi-pressure)
– combination of forced circulation and once-through circulation (multi-pressure)
Figure 1.11: Natural circulation steam generator with single-pressure process
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Figure 1.12: Natural circulation steam generator with triple pressure process
1.1.8 Classification of power plants with gas turbines
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standing steam generator
Figure 1.13:
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• horizontal steam generator
Figure 1.14: Combination single-shaft installation
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1.2 Representation of steam generators in thermo-technical diagrams
1.2.1 Schematic representation of steam generators
Figure 1.15:
Each mass fraction of the working medium in the steam generator is supplied with the specific thermal
energy flow (heat flow) ∆q.
This way, in a subcritical steam generator, the enthalpy of the entering feed water hFW increases up to the
live steam enthalpy hLS through the following processes: (simplified to the ideal case!)
feed water is heated economiser

feed water is vaporised evaporator
steam is superheated superheater
steam is superheated reheater
Table 1.2:
If the steam, after it has performed specific technical work in a high pressure partial turbine, is directed
to the steam generator again and superheated again, the following process takes place:
steam is superheated reheater
Table 1.3:
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1.2.2 Representation of steam generators in T, s diagram
The T,s diagram has the advantage that it allows the representation of the specific enthalpies supplied
to the working medium (water steam) as areas.
Figure 1.16: Subcritical steam generator with simple reheating
Component of the steam generators and the specific enthalpy supplied to it
economiser specific liquid enthalpy ∆hl
evaporator specific enthalpy of vaporisation ∆hv
superheater (S) specific superheater enthalpy ∆hS
reheater (RS) specific superheater enthalpy ∆hRS
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Figure 1.17: Subcritical steam generator with double reheating
Component of the steam generator and the specific enthalpy supplied to it
evaporator specific enthalpy of vaporization ∆hv
superheater (S) specific superheater enthalpy ∆hS
reheater 1 (RS1) specific superheater enthalpy ∆hRS1
reheater 2 (RS2) specific superheater enthalpy ∆hIR2
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With supercritical steam generators, it is no longer possible to distinguish between the specific super-
heating enthalpy and the vaporisation enthalpy.
Figure 1.18: Supercritical steam generator with simple reheater
Component of the steam generator and the specific enthalpy supplied to it
evaporator and superheater (S) specific enthalpy ∆h
reheater (RS) specific superheater enthalpy ∆hRS
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1.2.3 Representation of the steam generator in the h, s diagram.
In general, the h, s diagram is not well suited to graphically represent the processes taking place in a
steam generator, because it was developed specifically for representing processes in steam turbines.
Figure 1.19: Subcritical steam generator without intermediate superheating
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Figure 1.20: Subcritical steam generator with simple intermediate superheating
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1.2.4 Representation of the steam generator in the h, p diagram.
The h, p diagram, specifically developed for steam generators, is well suited to graphically represent
the processes taking place in them.
Figure 1.21: Subcritical drum steam generator without reheating
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The characteristic curves for the reheaters are not shown in this representation.
Figure 1.22: Full load characteristic curves of several supercritical forced once-through steam . .
..generators with single reheating
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Supercritical forced through-flow steam generator with single intermediate superheating
IS = reheater
SH = Superheater
EK = Attemperator
Figure 1.23: Steam generator of the Wilhelmshaven Power Plant
The steam generator works in a modified sliding pressure operation. It is operated subcritical for par-
tial load operation and at full load, supercritical.
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1.3 Legislative aspects of steam generators
1.3.1 Old regulations
The old system of regulations, superseded by the Ordinance on Industrial Safety and Health, con-
sisted of:
• Trade, Commerce and Industry Regulation Act
• Regulation of the Installation and Operation of Boiler Systems (Steam Boiler Code -
DampfkV)
• General Administrative Legislation for DampfkV
• Technical Regulations for Steam Boilers (TRD)
The requirements according to § 6 of the DampfkV were considered satisfied if they corresponded to
the TRD. These were established by the "Deutschen Dampfkessel- und Druckgefäß-Ausschuß" (DDA)
[German Steam Boiler and Pressure Container Commission (DDA)], which updated the rules continu-
ously to the state of the art. The TRDs as “recognised rules of the technology” had legal force. The
Verband der Technischen Überwachungs-Vereine e.V. (VdTÜV) [Registered Association of Technical
Monitoring Associations] issued the TRD.
Steam boilers according to the steam boiler regulation are tanks and tube arrangements, in which
either of the following is created for use outside these configurations:
• water steam of higher than atmospheric pressure (steam generator) or
• Hot water at a temperature higher than the boiling point corresponding to the atmospheric
pressure (hot water generator).
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According to these regulations, the following are a part of the steam boiler:
• all equipment and lines attached to it
• the boiler steel structure
• the firing
• the fuel storage within the boiler housing
• the air preheaters
• the fans
• the flue gas ducts
• the induced draught fan
For these systems it is mandatory to:
• disclose
• obtain authorisation
• observe the technical regulations
• perform inspection by experts
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The classification of steam boilers was made according to § 4 DampfkV.
Group Volume in l Pressure in bar Temperature in °C

I V ≤ 10
II V > 10 and p = 1 or ϑ = 120
III 10 < V ≤ 50 and p > 1 or ϑ > 120
and p × V ≤ 1.000
IV p>1 ϑ > 120
if not belonging to Groups I to III
Table 1.4: The classification of steam boilers
The TRD specified the state of the safety requirements for the:
• materials
• production
• calculation
• equipment
• installation
• inspection
• operation
of the steam boiler.
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TRD Name Content

Design and Use
001 General
Summary and Overview
Fundamentals, sheeting, tubes, steel casting, cast iron, drums,
100 to 110 materials
screws, nuts, fittings
201 to 203 production welding, inspection
Strength calculations, cylindrical shells, elbows, spherical shells,
300 to 320 calculation
flame tube bottoms
equipment oil firing, gas firing, dust firing, wood firing, fuel storage, safety
401 to 460
calculation valves
500 to 520 inspection inspections, recurring inspections

operation, air monitoring, supervision, feed water, boiler water,
601 to 611 operation
maintenance
701 to 721 ND boiler Steam boilers and hot water generators of Group II
801 Small boiler Steam boilers of Group I
802 Small boiler Steam boilers of Group III
Table 1.5: The numbering of the application areas of the TRD
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The DIN standards given in the TRD specify examples of how the defined requirements could be sat-
isfied.
1.3.2 New regulations
The new applicable regulation system, harmonised in Europe, is:
• the Ordinance on Industrial Safety and Health (BetrSichV)
• with the associated Technical Rules for Operational Safety (TRBS).
As not all corresponding TRBS are not yet established and passed, every system manufacturer and
operator is well advised to consult the old regulations.
For steam generators, the already enacted TRBS are especially important:
1001 Structure and application of the TRBS
1111 Risk assessment and safety related evaluation
1201 ff Inspection of work equipment and systems requiring special monitoring
1203 ff Qualified people
2141 ff Hazards due to steam and pressure
2152 ff Hazardous, potentially explosive atmospheres
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In the field of production, the TRD has been replaced by DIN EN 12952 ff for water tube boilers, and
DIN EN 12953 ff for shell boilers.
Standard Issue Title

Water tube boiler
DIN EN 12952-1 2002-05 Water tube boiler and system component
Part 1 : general
German vision EN 12952-1 : 2001
Part 2 : materials for pressure bearing boiler parts and fixtures
Part 3 : design and calculation for pressure bearing parts
Part 4 : calculations for the service life expectation, throughout the operation
Part 5 : processing and design of pressure bearing boiler parts
Part 6 : inspection during manufacture, documentation and labelling for pressure
bearing boiler parts
Part 7 : boiler equipment requirements
Part 8 : firing system requirements for liquid and gaseous fuels for the boiler
Part 9 : dust firing system requirements for the boiler
Part 10 : safety related requirements to prevent excess pressure
Part 12 : feed water and boiler water quality requirements
Part 13 : flue gas treatment system requirements
Part 15 : acceptance tests
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Part 16 : grate fired and fluidised bed firing system requirements for
solid fuels for the boiler
DIN EN 12952- 2002-08 Water tube boiler and system component
supplementary sheet 1 Part 17 : guideline for involving a manufacturer independent inspection organisation
Table 1.6: DIN EN 12952 ff for water tube boilers
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Standard Issue Title

Shell boiler
DIN EN 12953-1 2002-08 Shell boiler
Part 1 : general
Part 2 : materials for pressure bearing boiler parts parts and fixtures
Part 3 : design and calculation for pressure bearing parts
Part 4 : processing and design of pressure bearing boiler parts
Part 5 : inspection during manufacture, documentation and labeling for pressure
bearing boiler parts
Part 6 : boiler equipment requirements
Part 7 : firing system requirements for liquid and gaseous fuel for the boiler
Part 8 : safety related requirements to prevent excess pressure
Part 9 : feed water and boiler water quality requirements
Part 10 : acceptance tests
Part 12 : grate fired and fluidised bed firing system requirements for
solid fuels for the boiler
Part 12 : operation instruction
German vision prEN 12953-13 : 2003
DIN EN 12953 - 2003-08 Shell boiler
supplementary sheet 1 Part 12 : guideline for involving a manufacturer independent inspection or-
ganisation
German vision CEN/CR 12953-14 : 2002
DIN EN 14222 2003-09 Stainless steel shell boiler
German vision EN 14222.2003
Table 1.7: DIN EN 12953 ff for shell boilers
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In addition, prior existing regulations are:
• Government safety organisation rules for safety and health at work (BGR)
• Accident prevention and insurance regulations (BGV)
the applicable standards, rules, guidelines, recommendations and bulletins (EN, DIN, ISO, VDI,
AD, VGB, ...)
Here, a quick reference is made to the applicable associations VGB, FDBR, TÜV, on whose Web sites
information can be obtained about current developments.
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HITACHI BOILER PLANT TRAINING COURSE

Principal Types of Boilers

Principal Types of Boilers

Principal Types of Boilers

Principal Types of Boilers

1 Classification of Steam Generators and Regulations ........................... 6

Principal Types of Boilers

Principal Types of Boilers

1 Classification of Steam Generators and Regulations

1.1 Classification of steam generators according to different aspects

1.1.1 Classification of steam generator design types according to DIN EN

• shell boilers and

• water tube boilers.

Principal Types of Boilers

Principal Types of Boilers

1.1.2 Classification of steam generators according to water flow paths

Several shell steam generators types can be distinguished:

• flame tube boilers (single-pass boilers)

• flame tube/smoke tube boilers

– three pass shell boilers

1 Boiler body 11 Feed pump

Figure 1.1: Flame tube/fire tube three-pass shell boiler

Principal Types of Boilers

Principal Types of Boilers

Several water tube generators types can be distinguished:

• circulation type steam generators (drum type boilers)

– natural circulation steam generators

– forced circulation steam generators (La Mont)

Figure 1.2: Circulation type steam generators

• once through forced circulation steam generators

– without sediment bowl (classic Benson steam generator) – out-dated

– with sediment bowl

classic Sulzer steam generator – out-dated

steam generator with full load recirculation – very rare

steam generator with partial load recirculation – very rare

Principal Types of Boilers

Principal Types of Boilers

Figure 1.3: Once-through steam generator

Principal Types of Boilers

Principal Types of Boilers

1.1.3 Classification of steam generators according to operation mode

• fixed pressure operation

– drum steam generator

– steam generator in bus-bar installations

• modified sliding pressure operation

– hard coal fired steam generator

– steam generator in gas steam cycle systems

• natural sliding pressure operation

– large brown coal power plants

• saturated steam/wet steam

– without reheat superheating

– with reheat superheating: single reheat superheater

double reheat superheater

Principal Types of Boilers

Principal Types of Boilers

Figure 1.4: Operation modes

1.1.5 Classification of steam generators according to the steam side connections

Principal Types of Boilers

Principal Types of Boilers

Figure 1.5: Systems with single reheat superheater

• Part of a range type power plant

• Part of a topping power plant