Presented by:

Naresh Boddu

Shivaji Banoth

1
  Theory of circulation
 Types of circulation
 Boiling fundamentals
 Economizer
 Water walls
 Drum and its internals

December 9, 2021 2
The steam generator has to produce steam at highest purity,
and at high pressure and temperature required for the
turbine. Water must flow through the heat absorption surface
of the boiler in order that it be evaporated into steam Natural
circulation is the ability of water to circulate continuously,
with gravity and changes in temperature being the only
driving force known as "thermal head“.

The ratio of the weight of water to the weight of steam in

the mixture leaving the heat absorption surfaces is called
Circulation Ratio.

Cold feedwater is introduced into the steam drum where, because the density of
the cold water is greater, it descends in the 'downcomer' towards the lower
bottom ring header, displacing the warmer water up into the front tubes.
Continued heating creates steam bubbles in the front tubes, which are naturally
separated from the hot water in the steam drum, and are taken off.
December 9, 2021 3
  Boiler drum level control is critical for both plant
protection and equipment safety and applies equally to
high and low levels of water within the boiler
drum.The purpose of the drum level controller is to
bring the drum up to level at boiler start-up and
maintain the level at constant steam load. A dramatic
decrease in this level at constant steam load. A
dramatic decrease in this level may uncover boiler
tubes, allowing them to become overheated and
damaged. An increase in this level may interfere with
the process of separating moisture from steam within
the drum,

December 9, 2021 4
  The Three main options available for drum
level control are Single element drum level
control
 Two element drum level control
 Three-element drum level control

December 9, 2021 5
 However, when the pressure in the
water-tube boiler is increased, the
difference between the densities of the
water and saturated steam falls,
consequently less circulation occurs.
To keep the same level of steam
output at higher design pressures, the
distance between the Bottom ring
header and the steam drum must be
increased, or some means of forced
circulation must be introduced.

Therefore natural circulation is limited

to boiler with drum operating pressure
around 175 Kg/cm2.

December 9, 2021 6
Natural Circulation
 The downcomer contain
relatively cold water, whereas
the riser tube contain steam
water mixture ,whose density is
comparitively less .this density
difference is the driving force
,for the mixture. (thermo-siphon
principle)
 Circulation takes place at such a
high rate that the driving force
and frictional resisitance in water
wall are balanced.
Natural Circulation Forced Circulation

Forced Circulation
 Beyond 180 Kg/cm2 of pressure, circulation is to be assisted with
mechanical pumps, to overcome frictional losses. To regulate the flow
through various tubes, orifice plates are used. This system is applicable in
the high sub-critical regions (say 200 Kg/cm2).
December 9, 2021 7
 AS THE PRESSURE
INCREASES,THE
DIFFERENCE IN DENSITY
BETWEEN WATER AND
STEAM REDUCES .
 THUS THE HYDROSTATIC
HEAD AVAILABLE WILL
NOT BE ABLE TO
OVERCOME THE
FRICTIONAL RESISITANCE
FOR A FLOW
CORRESPONDING TO THE
MINIMUM REQUIREMENT
OF COOLING OF WATER
WALL TUBES.
 NATURAL CIRCULATION IS
LIMITED TO 175KSC

Diff in Density

December 9, 2021 8
 2.Controlled circulation system:
• use of controlled circulation pump
• used for pressure up to 194kg/cm2 (sub critical pr.)
• circulation ratio=6-9

December 9, 2021 9
 Circulation ratio=2
No use of drum
Use of controlled circulation pump
Use for pressure above 200kg/cm2.

December 9, 2021 10
  Boiling is the formation of
vapor bubbles at the heating
surface. These bubbles form
at nucleation sites whose
number and location
depend upon the surface
roughness or cavities, fluid
properties, and operating
conditions. The boiling heat
transfer coefficient is very
sensitive to the temperature
difference.

December 9, 2021 11
Boiler Economiser are feed-water heaters in which the heat
from waste gases is recovered to raise the temperature of
feed-water supplied to the boiler.

December 9, 2021 12
 The economizer preheats the feed water by utilizing the residual heat of
the flue gas.
 It reduces the exhaust gas temperature and saves the fuel.
 Modern power plants use steel-tube-type economizers.
 Design Configuration: divided into several sections : 0.6 – 0.8 m gap

December 9, 2021 13
December 9, 2021 14
December 9, 2021 15
  Out side diameter : 25 – 38 mm.
 Tube thinckness: 3 – 5 mm
 Transverse spacing : 2.5 – 3.0
 Longitudinal spacing : 1.5 – 2.0
 The water flow velocity : 600 – 800 kg/m2 s
 The waterside resistance should not exceed 5 – 8 %.
Of drum pressure.
 Flue gas velocity : 7 – 13 m/s.

December 9, 2021 16
 6oC raise in feed water
temperature, by economizers
corresponds to a
1% saving in fuel consumption

220 C reduction in flue gas

temperature increases boiler
efficiency by 1%

December 9, 2021 17
 6oC raise in feed water temperature,
by economizers corresponds to a
1% saving in fuel consumption

December 9, 2021 18
  Ahead of air-heaters
 Following the primary super-heater or re-heater
 Counter-flow arrangement
 Horizontal placement (facilitate draining)
 Supported to prevent sagging, undue deflection and
expansion .
 Stop valve and non-return valve incorporated to ensure
recirculation in case of no feed-flow
 Ash hopper below as flue gas takes a turn

December 9, 2021 19
  Plain Tube : Several banks of tubes with either-in-line
or staggered type formation. Staggered arrangement
induces more turbulence than the in-line arrangement.
This gives a higher rate of heat transfer and requires
less surface but at the expense of higher draught loss.
 Welded Fin-tube : Fin welded design is used for
improving the heat transfer.

December 9, 2021 20
  It is an enclosed Pressure
Vessel
 Heat generated by
Combustion of Fuel is
transferred to water to
become steam
 Process: Evaporation

Steam volume increases to

1,600 times from water and
produces tremendous force

December 9, 2021 21
 DRUM Lifting in progress

December 9, 2021 22
 DRUM SERVES TWO MAIN
FUNCTIONS

 SEPERATING STEAM FROM THE

MIXTURE OF WATER AND STEAM

 2. IT HOUSES ALL EQUIPMENTS USED

FOR PURIFICATION OF THE STEAM
AFTER BEING SEPERATED FROM THE
WATER
December 9, 2021 23
MATERIAL - CARBON STEEL
LENGTH - 22070 MM
OD - 2130 MM
ID - 1778 MM
DESIGN.PR - 204 KSC
WEIGHT(INT) -246 TONNES
WITHOUT(INT) –224 TONNES

December 9, 2021 24
 Drum Internals

The steam drum

contains steam
separating
equipment and
internal piping for
distribution of
chemicals to the
water, for distribution
of feedwater and for
blowdown of the
water to reduce
solids concentration.

December 9, 2021 25
 DRUM INTERNALS

1. PRIMARY SEPERATORS

CONSISTS OF BAFFLE ARRANGEMENT

DEVICES WHICH CHANGE THE
DIRECTION OF FLOW
OF STEAM AND WATER MIXTURE

2. SECONDARY SEPERATORS

SEPERATORS EMPLOYING SPINNING

ACTION

3. SCREENING DRYERS

December 9, 2021 26
 Steam
Separator

December 9, 2021 27
  There are six down comers in (500 MW) which
carry water from boiler drum to the ring
header.
 They are installed from outside the furnace to
keep density difference for natural circulation
of water & steam.

December 9, 2021 28
  HEATING AND EVAPORATING THE FEED WATER SUPPLIED
TO THE BOILER FROM THE ECONOMISERS.

 THESE ARE VERTICAL TUBES CONNECTED AT THE TOP

AND BOTTOM TO THE HEADERS.

 THESE TUBES RECEIVE WATER FROM THE BOILER DRUM BY

MEANS OF DOWNCOMERS CONNECTED BETWEEN DRUM
AND WATER WALLS LOWER HEADER.

 APPROXIMATELY 50% OF THE HEAT RELEASED BY THE

COMBUSTION OF THE FUEL IN THE FURNACE IS ABSORBED
BY THE WATER WALLS.

December 9, 2021 29
 
Tangent tube The
construction consists of
water wall placed side
by side nearly touching
each other. An
envelope of thin sheet
of steel called "SKIN
CASING" is placed in
contact with the tubes,
which provides a seal
against furnace
leakage.

December 9, 2021 30
 Membrance Wall A number of tubes
are joined by a process of fusion
welding or by means of steel strips
called 'fins pressurised furnace is
possible with the related Advantages
•Increase in efficiency
•Better load response simpler
combustion control.
•Quicker starting and stopping
•Increased availability of boiler.
•Heat transfer is better
•Weight is saved in refractory and
structure
•Erection is made easy and quick

December 9, 2021 31
 WATER WALL
SPECIFICATION

NO OD(MM)

FRONTWALL 283 51

SIDEWALLS 444 51

REAR WALLS 283 51

ROOF 142 57

December 9, 2021 32
December 9, 2021 33