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Boiler Thumb Rules

This document provides guidelines for sizing and operating parameters for boiler systems. It includes recommendations for: 1) Calculating boiler heating surface area and flue gas ducting size based on boiler capacity; 2) Determining the number of open tubes in the steam drum and deaerator venting capacity; 3) Calculating safety valve relieving capacities as a percentage of boiler maximum continuous rating (MCR). 4) Setting safety valve pop-up pressures as a percentage above operating pressure.

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Mahimmay paul
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963 views1 page

Boiler Thumb Rules

This document provides guidelines for sizing and operating parameters for boiler systems. It includes recommendations for: 1) Calculating boiler heating surface area and flue gas ducting size based on boiler capacity; 2) Determining the number of open tubes in the steam drum and deaerator venting capacity; 3) Calculating safety valve relieving capacities as a percentage of boiler maximum continuous rating (MCR). 4) Setting safety valve pop-up pressures as a percentage above operating pressure.

Uploaded by

Mahimmay paul
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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1. Boiler heating surface (M2) = Boiler capacity in kg/hr/(17–18)..

Ex: 115 TPH boiler will have heating surface =


(115 X 1000/17 or 18) = 6390 to 6750 M2 (Appx.)......
2. Boiler flue gas ducting size (M2) = Boiler capacity in TPH/15.
3. No. of open tubes in steam drum for water recirculation = 30–31% of total no. of tubes present.
4. Deaerator steam venting capacity = Deaeration capacity X 0.1%.
5. Super heater safety valve relieving capacity at full open condition in TPH = Boiler MCR X 36–38%.......Ex: 125
TPH Boiler has SH safety valve of relieving capacity = (125 X 36/100) = 45 TPH.
6. Drum safety valve (1 no.) relieving capacity at full open condition in TPH = Boiler MCR X 46–48%.
7. All boiler safety valves (super heater and drum safety valves) relieving capacity at full open condition= Boiler
MCR X 125–130%.
8. Safety valves pop up pressure = Operating pressure X 106–107%.Ex: A boiler operating pressure of 110
kg/cm2 has safety valve set at 110 X 106/100 =116.6 kg/cm2.
9. Boiler start up vent steam blow capacity 30–35% of boiler MCR on full open condition.
10. Boiler CBD water flow is 0.8 to 2% of steam generating capacity of the boiler.
11. Drum man hole door size 410 mm X 310 mm (Elliptical).
12. Boiler drum hold up capacity is 2–4 minutes at MCR operation.
13. Feed water velocity in Economiser coils 0.6 to 1 meter/sec.
14. Pressure drop in Economiser coils 0.5 to 1 kg/cm2.
15. Flue gas Pressure drop in ESP 25 to 30 mmwc.
16. Mass of flue gas generated = Mass of air per kg of fuel to be burned + 1.
17. Boiler fans power consumption = Total plant auxiliary consumption X 35–38%.
18.Boiler feed pumps power consumption = Total plant auxiliary consumption X 35–38%.
19. Turbine auxiliary power consumption = Total plant auxiliary consumption X 10–12%.
20. Fuel handling power consumption = Total plant auxiliary consumption X 4%.
21. For every 1% increase in fuel moisture, boiler efficiency reduces by 0.27% and vice versa.
22. For every 5% increase in excess air for fuel, boiler efficiency decreases by 0.18% and vice versa.
23. For every 100 kcal/kg increase in fuel GCV, boiler efficiency increases by 1.2% and vice versa.
24. For every 0.5% increase of Hydrogen in fuel, boiler efficiency decreases by 0.8–1% and vice versa.
25. For every 10 °C increase in flue gas temperature, boiler efficiency decreases by 0.45% and vice versa.
26. For every 100 kcal/kg increase in GCV of coal, boiler (TG) efficiency increases by 0.36% and vice versa.
27. Boiler peak load = Boiler MCR X 110%. Minimum possible duration of boiler peak load is 30 minutes/shift.
28. Minimum stable operating load on the boiler is around 30% of boiler MCR.

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