STEAM CIRCULATION SYSTEM

Steam circuit diagram Super Heater De-super heater / Attemperator Re-heater IBR Super Critical Boiler

Types of Super Heaters

Pendant type Horizontal type Radiant Superheater Convection Superheater Combined Superheater

M.S

FROM F.R.S

Sh 1

M.S

FROM F.R.S

SH 2

M.S

FRM F.R.S

LTSH

M.S

FROM F.R.S

Final SH

M.S

C.R.H

H. R. H

FROM F.R.S

Super heaters

Super heater heats the Super heater heats the high-pressure steam high-pressure the highSuper its heatsheats Super heater saturation the Super heater heats the highfrom heater steam pressureits saturation pressure steam from its from steam from a high-pressure toits temperature steam saturation temperature to a saturation temperature to a temperature to a higher from specified temperature. its saturation higher specified higher specified temperature. higher specified temperature. temperature to a temperature. Super heaters are often divided Super heaters are often divided higher specified into more than one stage. into moreheaters stage.often Super than one are temperature. are often Super heaters divided into more than divided into more than one stage. Super heaters are often one stage. divided into more than

Transfer of Energy

Hot Flue Gas

Thermal Structure SH

Steam

Convection & Radiation HT Drop in Enthalpy of Flue Gas

Convection HT Rise in Enthalpy of Steam

Mechanism of Heat Transfer Source/Supply Thermal Structure Sink /Demand

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,out Tcold steam,in

Thot gas,in Tcold steam,out

Tcold steam,out

Thot gas,in

Thot gas,out Tcold steam,in

Thot gas,in

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

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,out Tcold steam,in

Thot gas,in Tcold steam,out

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

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 number of parallel tubes in a platen is in the range of 15 35. Design Constraints: Max. allowable steam flow rates.

WAYS TO IMPROVE EFFICIENCY

SUPERHEATING REHEATING REGENERATION

REHEATING

Rankine Cycle Efficiency net work n = -------------Qin Cycle thermal efficiency is improved by increasing the mean temperature of heat addition process. This temperature is increased because the boiler inlet pressure sets the saturation temperature in Rankine cycle. Total fuel input Heat Rate =-----------------Electrical generation (KW)

It effects improvement and economy in the following ways

It increases capacity of plant. It eliminates errosion of the last stage of the turbine. It reduces the steam consumption of the turbine.

Horizontal Superheater

How it increases efficiency?

Rankine Cycle Efficiency net work n = -------------Qin Cycle thermal efficiency is improved by increasing the mean temperature of heat addition process. This temperature is increased because the boiler inlet pressure sets the saturation temperature in Rankine cycle. Total fuel input Heat Rate =-----------------Electrical generation (KW)

Superheated cycle

Based on the position of header

1.Vertical superheater. 2.Horizontal superheater.

Based on heat receiving capacity

Convective

superheater Radiant superheater

STEAM OUTLET TEMPERATURE RESPONSE OF DIFFERENT SUPRHEATERS

Radiant SH & Convective SH each has different steam outlet temp response. As demand for steam increases with increase in load, fuel and airflow and hence combustion gas flow are increased.

Load response of SH

In CSH heat transfer co-efficient (Hi&Ho) increases both outside & inside due to increase in gas flow rate and increase in steam flow rate respectively. In case of RSH since furnace temperature and hence the amount of available heat from radiation does not rise as rapidly as the steam flow rate it has falling characteristic.

In CSH steam O/T Temp. increases with incease in steam flow rate while in RSH it decreases with steam flow rate. Hence combination of RSH &CSH is used in series which gives a relatevely flat curve for steam O/T temp. and is thus insensetive to load change.

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) Superheat temperature control is therefore fitted to ensure superheat temperature does not exceed design limits

Reheater and Desuperheater

Reheat pressure for optimum efficiency

Reheater in 500 MW plant

M.S

FROM F.R.S

RH

CRH pressure 43.5 KSC temperature 340 C

HRH pressure 41.5 KSC temperature 535 C

ATTEMPERATION

What is the purpose of attemperation and its location in power plant?

Direct contact Desuperheater

EFFECT OF SUPERCRITICAL PARAMETERS

538

240 kg/cm2

Expansion Line
170 kg/cm2

Critical Point 225 kg/cm2

Condensation

Enthalpy

SUPERCRITICAL ADVANTAGES Enhancements Plant efficiency Fuel tolerance coal quality changes Reductions Coal Consumption Ash production CO2 SO2 Nox Improvements Startup time Sliding Pressure Operation Load following capability

0.69% to 1.64% More tolerant to

SELECTED PARAMETERS MSP 246 kg/cm2 MST 538 0C RST 566 0C

Sliding pressure V/s Constant pressure In sliding operation, turbine inlet valves remains fully open during normal operation. As a result the live. Advatages lower thermal stresses The control range of the reheater final steam is extended. Reduce pressure level at low loads prolong the life span of plant components. Overall reduction in power consumption

Salient Features of the Steam Generator

Type Rating
At SH Outlet At RH Outlet
Flue Supercritical,

suitable for variable pressure or rifled/plain water wall tubing Tower type or two pass type Flow (T/Hr) 2225 1740

operation with spiral

Temperature Deg CPressure Kg/Cm2(a) 540 568 256 52.0

gas temperature at air-heater outlet- 125 Deg C

Fuel Start up system

GCV range 3000 to 4000 Kcal/kg with 10-16% moisture and 32 to 48% ash Start up system with one no. circulating pump is with alternate drain flow to condenser through flash tank .

Indian Boiler Regulations

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

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