Steam

Circulation
System
April 21, 2020 PMI Revision 00 1
 Presentation Plan
• Steam circuit diagram
• Super Heater
• De-superheater /Attemperator
• Re-heater
• IBR
• Super Critical Boiler

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 500MW WATER AND
STEAM CIRCUIT

DRUM

CC
Pump

Bank II

Bank I
FROM BFP
DISCHARGE Economizer

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 H.
R.
M.S C.R.H H

FROM F.R.S
BOTTOM RNG HDR& Z-PANEL 1 PASS W.W
ST

1 PASS W.W O/L HDRS

ST
ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
S.H. HEADER R.H.HEADER
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2 ND
PASS ROOF O/L HDR(REAR ECONOMISER
 Types of Super Heaters
• Pendant type
• Horizontal type
• Radiant Superheater
• Convection
Superheater
• Combined
Superheater

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 SUPER HEATER
• WATER IS HEATED TO RAISE STEAM TO HIGHER TEMPERATURE

• ARRANGED IN 3 STAGES

– LTSH LOCATED ABOVE ECONAMISER

– RADIANT PENDENT TYPE (DIV PANEL)
ABOVE FURNACE
– CONVECTIVE FINAL SUPER HEATER
ABUVE FURNACE IN CONV PATH

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 Super heaters
• Super heater heats the high-pressure steam from its saturation
temperature to a higher specified temperature.
• Super heaters are often divided into more than one stage.
• The enthalpy rise of steam in a given section should not exceed
– 250 – 420 kJ/kg for High pressure. > 17 MPa
– < 280 kJ/kg for medium pressure. 7 Mpa – 17 MPa
– < 170 kJ/kg for low pressure. < 7 MPa

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 Transfer of Energy

Hot Flue Thermal Structure Steam

Gas SH

Convection & Convection HT

Radiation HT
Drop in Enthalpy Rise in Enthalpy of
of Flue Gas Steam
Mechanism of Heat Transfer

Source/Supply Thermal Structure Sink /Demand

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 Mechanism of Heat Transfer :

• Rate of heat transfer from hot gas to cold steam is

proportional to:
• Surface area of heat transfer
• Mean Temperature difference between Hot Gas and Cold
Steam.

Thot gas,in Thot gas,out

Tcold steam,out Tcold steam,in

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 Thot gas,in Thot gas,out
Tcold steam,out
Tcold steam,in

Thot gas,in

Thot gas,out

Tcold steam,out

April 21, 2020 PMI Revision 00 Tcold steam,in 10

 Platen Superheater
• Platen Superheater : Flat panels
of tubes located in the upper part
of the furnace, where the gas
temperature is high.
• The tubes of the platen SH
receive very high radiation as
well as a heavy dust burden.
• Mechanism of HT : High
Radiation & Low convection
• Thermal Structure:
– No. of platens
– No. of tubes in a platen
– Dia of a tube
– Length of a tube

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 Geometry of Thermal Structure :
Platen SH
• The outer diameter of platen SH is in the range of 32 – 42
mm.
• The platens are usually widely spaced, S1 = 500 – 900
mm.
• The tubes within a platen are closely spaced, S2/d = 1.1.
• The number of parallel tubes in a platen is in the range of
15 – 35.
• Design Constraints: Max. allowable steam flow rates.

April 21, 2020 PMI Revision 00 12

April 21, 2020 PMI Revision 00 13
 Convective Superheater
(Pendant)

• Convective super heaters are vertical

type (Pendant ) or horizontal types.
• The Pendant SH is always arranged in
the horizontal crossover duct.
• Pendant SH tubes are widely spaced
due to high temperature and ash is soft.
• Transverse pitch : S1/d > 4.5
• Longitudinal pitch : S2/d > 3.5.
• The outside tube diameter : 32 – 51mm
S1 • Tube thickness : 3 – 7mm
S2

April 21, 2020 PMI Revision 00 14

 Convective Superheater (Horizontal)
• The horizontal SH are located in the back pass.
• The tubes are arranged in the in-line configuration.
• The outer diameter of the tube is 32 – 51 mm.
• The tube thickness of the tube is 3 – 7 mm.
• The transverse pitch : S1/d = 2 – 3.
• The longitudinal pitch :S2/d = 1.6 – 2.5.
• The tubes are arranged in multiple parallel sets.
• The desired velocity depends on the type of SH and operating steam
pressures.
• The outside tube diameter : 32 – 51mm
• Tube thickness : 3 – 7mm

S1
S2

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April 21, 2020 PMI Revision 00 16
 MS TO HPT HRH TO IPT
DRUM
ECONOMISER

PLATEN SH1

CRH FROM
PRI. SH HPT

ECONOMISER
April 21, 2020 PMI Revision 00 17
 Superheater
Temperature Control
• Basically the control of temperature is to protect the
superheater by preventing the metal temperatures reaching a
dangerously high level reducing mechanical strength and
leading to failure. Water flowing through a tube conducts heat
away much more effectively than steam due to its higher
specific heat capacity. This means that tubes carrying water
have a metal temperature much closer to the fluid passing
through it.
• For superheat temperatures alloys of chrome molybdenum
steels are used (upto 560oC), difficulties in welding means
that there use is restricted to only within the highest
temperature zone and a transition piece fitted to connect to
remaining mild steel tubing.
• Superheat temperature control is therefore fitted to ensure
superheat temperature does not exceed design limits.
April 21, 2020 PMI Revision 00 18
 Locating the desuperheater
• The preferred location of
desuperheater, especially for
temperature above 450 deg C is
between sections of superheater. The
steam is first passed through a
primary superheater where it is raised
to intermediate temperature. It is then
passed through the desuperheater and
its temperature reduction is controlled
so that, after continuing through the
secondary or final stage of the
superheater, the required constant
conditions are maintained at the outlet.

April 21, 2020 PMI Revision 00 19

 Reheater
• Purpose: RE-HEAT THE STEAM FROM HP TURBINE TO
540 DEG
– COMPOSED OF THREE SECTIONS
– RADIANT WALL REHEATER ARRANGED IN FRONT
& SIDE WATER WALLS
– REAR PENDANT SECTION ARRANGED ABOVE
GOOSE NECK
– FRONT SECTION ARRANGED BETWEEN UPER
HEATER PLATEN & REAR WATER WALL HANGER
TUBES

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 Reheater

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April 21, 2020 PMI Revision 00 22
 Procedure to Determine
Optimum Reheat Pressure
• Calculate the efficiency of Rankine cycle, Rankine.
• Calculate mean effective temperature of heat
addition, Tm,in using
Tc
 Rankine   Eq.Carnot  1
Tm ,in

• Find out pressure corresponding to Tm,in and entropy

at HP turbine inlet.
• Add reheating at this pressure and calculate
efficiency of the Reheat Cycle.
• Repeat above steps for few iterations.

April 21, 2020 PMI Revision 00 23

 Arrangement and
Construction
• The arrangement and construction of a re-
heater is similar to that of a super-heater. In
large modern boiler plant, the reheat sections
are mixed equally with super-heater sections.

April 21, 2020 PMI Revision 00 24

 Reheater

• The pressure drop inside re-heater tubes has an important adverse

effect on the efficiency of turbine.
• Pressure drop through the re-heater should be kept as low as possible.
• The tube diameter : 42 – 60mm.
• The design is similar to convective super-heaters.
• Overall Heat Transfer Coefficient : 90 – 110 W/m2 K.

April 21, 2020 PMI Revision 00 25

 Safety Valves

Device attached to a boiler for

automatically relieving the pressure
of steam before it becomes great
enough to cause bursting. The
common spring-loaded type is held
closed by a spring designed to open
the valve when the internal
pressure reaches a point in excess
of the calculated safe load of the
boiler. Safety valves are installed on
boilers according to strict safety
norms and IBR recommendation

April 21, 2020 PMI Revision 00 26

 Safety Valve Settings of a
Typical 200 MW Boiler

Locacation Set Reliving

Pressure Capacity
(Kg/sq cm T/Hr

Drum 175.8 177.1

179.3 180.6
181.1 182.5
Super Heater 163.3 154.0

Re-heater – 45.0  
inlet
45.5
46.3
Re-heater 42.70  
outlet

April 21, 2020 PMI Revision 00 27

 Indian Boiler Regulations
• History
• Scope (cover regulations on):
– Electric-Resistance-Welded Steel Boiler And Super-
Heater Tubes
– Boiler Tubes Subject To External Pressure
– The Working Pressure To Be Allowed On Various Parts
Of Boilers
– Welded And Seamless Forged Drums For Water Tube
Boilers And Super Heaters
– Requisite Mountings, Fittings and Auxiliaries

April 21, 2020 PMI Revision 00 28

 Indian Boiler Regulations
(Continued)
– Boiler And Super Heater Tubes, Headers
And Other Pressure Parts Tubes
– Steam-Pipes And Fittings
– Registration Of Boilers And Inspection Of
Boilers
– Safety Of Persons Inside Boilers
– Qualification Tests For Welders Engaged In
Welding Of Boilers
– Feed Water For Boiler

April 21, 2020 PMI Revision 00 29

 WHY SUPERCRITICAL
PRESSURE
 Increasing the pressure will mean increase in saturation
temperature at which steam evaporates thus increasing
the average temperature of heat addition.
 A Boiler operating at a pressure above critical point is
called ‘SUPERCRITICAL BOILER’
 A point where boiling water and dry saturated lines
meet so that associated latent heat is zero, this point
is called Critical Point.

April 21, 2020 PMI Revision 00 30

 CRITICAL CONDITION
Definition
“CRITICAL” is a thermodynamic expression
describing the state of a substance beyond
which there is no clear distinction between the
liquid and gaseous phase.
• The critical pressure & temperature for water are
• Pressure = 225.56 Kg / cm2
• Temperature = 374.15 C

April 21, 2020 PMI Revision 00 31

 T S DIAGRAM
Basic Rankine Cycle
OUTPUT INCREASE D
Temperature (0 C )

Dr
yS
at
er

ur
at

at
W

B C

ed
g
ilin

St
Bo

ea
m
E
24’0c
F
A

-273
0
April 21, 2020 Entropy
PMI Revision 00 KJ / Kg K 32
TEMP 568’C
540’C SUPER CRITICAL
600 BOILER CYCLE WITH
c m2
Kg
/ SH, RH & Regeneration
6
500 25
400 of SIPAT 3 x 660 MW
Steam flow :2225 T/Hr
Steam temp : 540 ‘c
300 Steam Pres : 256 kg/cm2
RH pre : 51.6 Kg/cm2
200 RH Temp : 568’c
Feed water Temp : 291’c

100

0
April 21, 2020 PMI Revision 00 33
ENTROPY
 SUPERCRITICAL BOILER

• Supercritical pressure boiler has no drum and heat absorbing

surface being, in effect, one continuous tube, hence called
‘once through Supercritical pressure boilers.’
• The water in boiler is pressurized by Boiler Feed Pump, sensible
heat is added in feed heaters, economizer and furnace tubes,
until water attains saturation temperature and flashes
instantaneously to dry saturated steam and super heating
commences.

April 21, 2020 PMI Revision 00 34

 Pressure Parts Material

Material Oxidation Criteria,

Section SIPAT 500 MW Plant ℃

Economizer Tube SA210C

SA-210C 454
Evaporator Spiral SA213T22
Tube/Water
SA-213T2 482
Wall Vertical SA213T22
Primary SA213T23, T91 SA-213T12 552
Superheater
Tube Secondary SA213T12, T23, T91
SA-213T22 593
Final SA213T23, T91, T92
SA-213T23 593
Reheater Primary SA210C, T12, T23
Tube Final SA213T23, T91 SA-213T91 649
SUPER304H
Separator SA302C SA-T92 649
SH outlet SA335P91
Header
RH outlet SA335P91 SUPER304H 760

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 THANK YOU

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