Boiler Circulation System

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Types of
boilers
Drum type

Once-through type

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 Drum type
boiler
Steam generation takes place in
furnace water walls
Fixed evaporation end point - the drum
Steam -water separation takes place
in the drum
Separated water mixed with
incoming feed water

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 Boiler Water Circulating
Systems
Choice of Circulating system depends on

Operating Pressure

The density difference between water and

steam provides the driving force for the

Circulating fluid Higherpressures units warrant

pumps to ensure

circulation (Natural circulation not adequate)

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Controlled Circulation (Vs) Once Thru’

CC OT

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 The
Concept
The mass flow rate thru’ all heat transfer

circuits from Eco. inlet to SH outlet is kept same

except at low loads wherein recirculation is

resorted to protect the water wall system

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Circulating System

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 Growth of Unit Size in India
600
500 M W
C o n t ro ll ed 500 M W
C i rc u la tion O n c e Thro'
500

400
Boiler Capacity

300

250 M W
in MW

210 M W 210 M W
200
200 M W Tower T y p e
110 M W
Tangential Firing 120 M W
100
60 M W
Wall Firing
0

1960 1970 1980 1990 2000 2010

Year

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Growth Of Unit Sizes In India(contd..)

Unit Year of Steam Parameters

Size Introduction
Steam SHO SHO/RHO
Flow Pressure Temperature
(t/h.) (kg/cm2) (Deg. C)

30MW 1969 150 63 490

60/70MW 1965 260 96 540
110/120MW 1966 375 139 540/540
200/210MW 1972 690 137/156 540/540
250MW 1991 805 156 540/540
500MW 1979 1670 179 540/540
660MW 2004 2245 256 540/568

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200 MW NTPC Korba

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500 MW NTPC Singrauli

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 General Arrangement of SG

Reheater Chimney
Boiler
Drum Final Super
Heater
Platen Super LTSH
Heater
Economizer
Coal
Secondary
Bunker
Win Air PA
d Duct duct
Box Furnace
Flue Gas
APH Duct
Coal Feeder

Coal Mill

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Fan
 Major Components

• Furnace
- Four sides surrounded by water wall tubes
- First pass of the boiler
- Where combustion takes place.
• Boiler drum
-Separates steam from steam water mixture.
• Down comers
-The pipes to transport water fromboiler drum to
all the four sides of water wall tubes.

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 Major Boiler Components
• Water wall
– Bundles of boiler tubing located in the first pass of the
boiler forming four sides of furnace
– Heat is transferred mainly by radiation to the water wall
tubes to convert water into steam water mixture.
• Economizer
– Section of boiler in which FW is first introduced into and
flue gas is used to raise the temp. of FW.

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 Major Boiler Components
• Super heaters
– Bundles of boiler tubing located in the flow path
of the hot flue gases.
– Heat is transferred from flue gases to the
steam in super heater tubes
• Re-heater
– Bundles of tubes exposed to combustion gases in
the same manner as super heater

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 Major Boiler Components
• Steam Cooled Wall
-Steam cooled wall is part of super heater that forms the
closed space of second pass of boiler
• Spray attemperators
– Are spray nozzles in the boiler tubes between two super
heaters and two reheaters.
– The spray nozzles supply a fine mist of pure water into
steam to prevent damage from overheating

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 Circulation in Boiler
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.
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 Types of Drum Level Control
• 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

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

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 Economize
r
Boiler Economizer are feed-water heaters in which the heat from
waste gases is recovered to raise the temperature of feed-water
supplied to the boiler.

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 Economize
•
r
The economizer preheats the
gas.
feed water by utilizing the residual heat of the flue

• 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

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

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 Boiler Drum
• 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

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BOILER DRUM

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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
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 SPECIFICATION
- 500MW
MATERIA - CARBON STEEL
L LENGTH - 22070 MM
OD - 2130 MM
ID - 1778 MM
DESIGN.PR - 204 KSC
WEIGHT(INT) -246 TONNES
WITHOUT(INT) –224 TONNES

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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.

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 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
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 Drum Internals

Steam
Separator

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 Downcomers
• 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.

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 WATE
R
• HEATING WALLS
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.

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 Hydro Testing
• Need:
• Method:
– Ensure pressure instrumentation is ready.
– Water Filling(10ppm Ammonia, 200 ppm Hydrazine, pH 10)
– Drainable parts (economizer, water wall and drum)
– Non Drainable portions filling
– First pressurization through boiler Fill pump
– Later pressurization through special purpose pumps.
– Test pressure and rate of pressure rise and rate of pressure
drop as per IBR.
– After completion system drained and kept under
wet
preservation.

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