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Chapter 4 Introduction

The document discusses steam generation, outlining the process of converting water into steam and the historical development of steam generators, which include shell type, fire/smoke tube, and water tube boilers. It also describes different types of boiling, such as nucleate and film boiling, and various circulation methods including natural, forced, and assisted circulation. Additionally, it emphasizes the importance of expansion and sealing in boilers to prevent stress and maintain efficiency.

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2 views

Chapter 4 Introduction

The document discusses steam generation, outlining the process of converting water into steam and the historical development of steam generators, which include shell type, fire/smoke tube, and water tube boilers. It also describes different types of boiling, such as nucleate and film boiling, and various circulation methods including natural, forced, and assisted circulation. Additionally, it emphasizes the importance of expansion and sealing in boilers to prevent stress and maintain efficiency.

Uploaded by

sureshpv36
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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BOILER AND AUXILIARIES INTRODUCTION

CHAPTER 4
INTRODUCTION

4.1 STEAM GENERATION


Steam generation is the process of converting water into steam, a vapour exhibiting the
properties of a gas by application of heat. Heating water at any pressure eventually will
cause it to boil and steam will be released.

4.2 HISTORY OF STEAM GENERATORS


Steam generator is equipment used to generate the steam. Over the pas three centuries
developments in steam generators are oriented towards increased steam generating
capability, efficiency, safety, etc. And trouble free operation. There are three main
generations are developed which are:
1. First generation – shell type boilers
2. Second generation – fire/smoke tube boilers
3. Third generation – water tube boilers

4.3 TYPE OF BOILING


1. NUCLEATE BOILING
2. FILM BOILING

Fig. Boiling Characteristic Curve

ET – ’08 29
BOILER AND AUXILIARIES INTRODUCTION

1. NUCLEATE BOILING
When the water droplets, adhered to the inner surface of a container heated upon,
receive the heat from the inner wall and the droplets are individually converted into
steam bubbles.

Other water droplets occupy their space and this process continues as long as the
container is heated. This process of individual bubble formation is termed as nucleate
boiling. Under this condition the inner walls are always in contact with water droplets
and so the inner wall temperature normally remain around the saturation temperature
corresponding to the pressure.

2. FILM BOILING
If the heat flux to the container is greatly increased before individual bubbles detach
from the wall more steam bubbles adjacent to each other will be formed. These adjacent
bubbles of steam coalesce to form a steam film on the inner wall of the heating surface.
That is between the inner wall and water body a steam film, which is a poor conductor
of heat will be formed.

The deviation of boiling process from nucleate boiling condition to film boiling is
termed as departure from nucleate boiling (DNB), which leads to overheating of metal.

4.4 TYPE OF CIRCULATION


1. NATURAL CIRCULATION
2. FORCED CIRCULATION
3. ASSISTED CIRCULATION

Ratio of the quantity of the water-steam mixture flowing through the circuit to the
quantity of steam produced in the circuit is known as circulation number. Higher
circulation number reduces the chance of scale formation in evaporating tubes and
DNB but needs more evaporating surface.

ET – ’08 30
BOILER AND AUXILIARIES INTRODUCTION

1. NATURAL CIRCULATION
This is adopted in recirculation systems. In the fig water from the economiser circuit
enters a drum and joins the circulation system. The circulation in this case takes place
on the thermo-siphon principle.

Industrial boilers are having circulation number from 10 to 15.


Utility boilers are having circulation number from 7 to 9.

Fig. Natural Circulation

It serves two functions as described below:


a. Prevent the dissolved salts in water, precipitating and depositing scale on the
surface of tubes when all the water in the tube is evaporated to steam.
b. Ensure the inner walls of the tubes are continuously wetted with water and to
have nucleate boiling throughout the tubes.

2. ASSISTED CIRCULATION
Beyond 175 kg/cm2 of pressure in a recirculation system, circulation through the
evaporator is to be assisted with mechanical pumps to overcome frictional losses in the

ET – ’08 31
BOILER AND AUXILIARIES INTRODUCTION

tubes. A pump called boiler circulation pump will be placed between the drum and
water wall tubes inlet to do this function.

Circulation number for this type of boiler is from 2 to 4.

Fig. Assisted Circulation

3. FORCED CIRCULATION
In the once through systems of sub critical pressure or in boilers operating above
critical pressure, the water from the feed supply is pumped to the inlet end or ends of
the heat absorbing circuits. This is called forced circulation.
Circulation number for this type of boiler is 1.

4.5 EXPANSION AND SEALING OF BOILER


The provision for free expiation for all parts of the boiler is important but in the case of
furnace water wall tubes it is vital. Since the boiler is suspended from the boiler house
steelwork the expansion is wholly in downward direction. Total expansion from cold to
full load can be varied from 220 to 400 depends upon rating of boiler. As any
restriction to free expansion of the water wall tubes will induce stress in the tubes and
their ultimate failure sufficient spacing will be provided in the bottom of the furnace to
allow free expansion of the water wall system.

ET – ’08 32
BOILER AND AUXILIARIES INTRODUCTION

Sine a significant suction (up to – 20 mm wc) is present at the bottom of the furnace
during normal operation it is obviously imperative that a sealing arrangement is
provided to prevent the ingress of unmetered excess air into the furnace.

These seals normally consist of water filled trough attached to the ash hopper, which
itself rigidly mounted on the boiler house basement floor. A dipper plate is secured to
the bottom of the furnace water walls and when boiler is cold, part of this plate is
immersed in the water. As the boiler warms up, downward expansion of the water walls
because the plate further submerged until, at full load their bottom edges are well below
the surface of water. As the water in this seat trough is exposed to furnace radiation, it
will evaporate and the sealing will be lost. To prevent this there will be a continuous
flow of water to the seal rough and the water from the seal trough will be drained to the
bottom ash hopper. Screen plates also will be welded to the water wall section parallel
to seal plate but outside the seal trough to prevent the slag/ash particles falling into the
seal trough.

ET – ’08 33

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