BOILER GENERAL OVER

VIEW
PT. ALSTOM Power Energy Systems Indonesia
 BOILER GENERAL
OVERVIEW
Steam as a Working Fluid
Steam as a working fluid had been
begun in 130 BC for driving Hero’s Engine
from Greek. This was the world’s first
Reaction Turbine.
The first commercially successful steam
engine by Thomas Savery in 1698 -->
at the beginning of Industrial Revolution

Steam is an old industrial tool,

but it will go on for the long future

The basic idea is remain the same:

GENERATE HEAT- TRANSFER THE
HEAT to WATER - PRODUCE STEAM -
CONVERSE TO ENERGY
 BOILER GENERAL
OVERVIEW
What is Steam ?

 Steam results from adding sufficient heat to water to cause

it to vaporize. This vaporization occurs in 2 steps:
– by adding heat to the water to raise it to the boiling temperature
(sensible heat)
– by continuing the addition of heat to change the state from water to
steam (latent heat)
 Saturated steam:
– steam at which boiling occurs at a constant pressure
– same temperature with the boiling water (mixed steam + water)
 Superheated steam:
– steam with temperature higher then saturated steam at the same
pressure
– close to the properties of a perfect gas
 BOILER GENERAL
OVERVIEW
Experiment #1  A Vessel contains water [ ] is heated to
boiling temperature at constant pressure
 Continuing addition of heat to change the state
of water to steam [ ]
 Result: a steam with Temperature Tp, Pressure
Pp, Volume Vp and Enthalpy Hp

Experiment #2
 The same Vessel contains water [ ] is heated
to boiling temperature at constant volume
 Continuing addition of heat to change the state
of water to steam [ ]
 Result: a steam with Temperature Tv, Pressure
Pv, Volume Vv and Enthalpy Hv.
where Pv > Pp, Tv >Tp, and Hv > Hp
Conclusion:
 With rise in the pressure, the boiling temperature will also rise
 The higher pressure and temperature of steam will increase the stored
energy in the steam (enthalpy)
 BOILER GENERAL
OVERVIEW
Why Steam ?
 Contain thermal energy (enthalpy) related to its
pressure and temperature
 Relatively easy to converse its thermal energy to
mechanical energy or other human/industrial purposes
 Easy to handle and transport it
 Easy to produce it, a lot of water resources
 Recycle process: water - steam - water - steam ….

STEAM GENERATOR IS REQUIRED !!

 BOILER GENERAL
OVERVIEW
Boiler
 By definition: generate steam at pressure above atmospheric
 Pressure Part system: converting incoming feedwater into steam
 Furnace: combustion process take place
 Fuel handling system: fuel introducing & waste removing
 Instrument and control: operation and monitoring the boiler
 BOILER GENERAL
OVERVIEW
E O-A: ICE WARMING A-O : ICE COOLING
T A-B: ICE MELTING B-A : ICE FREEZING
B-C: WATER HEATING C-B : WATER COOLING
K
C-D: WATER BOILING D’-C’: STEAM CONDENSING
P3 D-E: STEAM SUPERHEATING E-D’ : STEAM EXPANDING
THE HIGHER PRESSURE PROVIDED TO THE PROCESS
P1 WILL RESULT IN HIGHER BOILING TEMPERATURE
C
P2
D
B-E : PROCESS IN THE BOILER
E-D’ : PROCESS IN THE STEAM TURBINE
D’-C’: PROCESS IN THE CONDENSOR
C’ D’ C’-B : WATER FROM CONDENSOR BACK TO THE BOILER
K : CRITICAL POINT = 3208 Psia, STEAM & WATER
A PROPERTIES ARE IDENTICAL
B
0
0C O
S
 SATURATED STEAM AREA (MIXED WATER+STEAM) NORMALLY USED FOR HEATING/ INDUSTRIAL
PROCESS
 THE SUPERHEATED STEAM AREA NORMALLY USED FOR STEAM TURBINE
 THE ADVANTAGES OF SUPERHEATED STEAM :
 INCREASE TURBINE EFFICIENCY
 PREVENT DAMAGING AT THE LOW STEAM TURBINE BLADES DUE TO CONDENSATION
 LESS CONDESATION WHEN TRAVEL THROUGH A LONG PIPE LINE
 GENERATIVE (PREHEATED) PROCESS TO THE FEEDWATER WILL INCREASE BOILER EFFICIENCY
 BOILER GENERAL
OVERVIEW
Boiler Energy Flow
Air from FD FAN
Heated Air to Furnace

ENERGY LOSS in
Furnace
RH Econ AH STACK GASES
Walls & SH

FUEL
ENERGY
INPUT
 Fuel is primary source of heat
 The amount of heat in the
preheated air corresponds with the
exhaust gas extracted by AH
 The most of heat is absorbed as
sensible and latent heat of
vaporisation in the heating
FW to Drum surfaces of Econ, Furnace, SH and
RH --> Boiler Output
from HP
Turbine to LP Turbine  The lower energy loss in the stack
Steam to FW energy from
indicates higher boiler efficiency
HP Turbine FW Heater
 BOILER GENERAL
OVERVIEW
Water - Steam Circulation
 Circulation is the movement of water, steam, or a mixture of the
two, through heated tubes
 Circulation Ratio (Mw/Ms): the mass rate of water fed to the
steam-generating tubes divided by the mass rate of steam
generated
 Adequate circulation will result:
– The cooling fluid absorbing heat from the tube metal at a rate which
maintains the tube temperature at or below design condition
– Keep the tube within the other physical and chemical limitations
required by the inside and outside environment
 Two type of Circulation:
– Natural Circulation or Thermo-Syphonic
– Forced Circulation or Controlled Circulation
 BOILER GENERAL
OVERVIEW
NATURAL CIRCULATION
 The water/steam circulates naturally by the density different
(static head different) between the higher temperature fluid
and the lower temperature fluid
STEAM
(Ms)
Characteristic of Natural Circulation
 Circulation Ratio = Mw/Ms is bigger
 The water wall tubes normally have larger
WATER
diameter to reduce the pressure drop of
DOWNTAKE or DOWNCOMER

(Mw)
Steam +
Water
steam/water inside the tubes
 Friction factors that oppose circulation:
– friction between water and metal tube (+
any scale deposit inside the tube)
HOT SIDE
COLD SIDE

– friction in tube bent

– friction in lower drum and header
– friction around upper drum internal
 BOILER GENERAL
OVERVIEW
FORCED CIRCULATION
 The water/steam circulation assisted by circulating pump
 The circulating pump provide addition head to the existing
thermal head
Ms

Characteristic of Forced Circulation

Mw
 Circulation Ratio = Mw/Ms is smaller
COLD SIDE

 The steam produced is higher then Natural

Circulation Boiler for the same running time
 Furnished with Orifice located at the inlet of
Furnace Wall tubes to assist in obtaining an
HOT SIDE

adequate water flow of varying length and

heat absorbtion. The other functions:
– create pressure drop
– measure the water flow
– regulate the flow balance
CIRCULATING
PUMP ORIFICE
 BOILER GENERAL
OVERVIEW

What main factors will impact to the Water/Steam

Circulation ?
 Water/Steam Velocity
– The velocity relates to the force. The force is depend on the density
different and the height of boiler circuit
 Pressure
– The higher pressure of boiler will cause the water/steam density
different is smaller. At the critical pressure, there is no water/steam
different condition.
 Heat Supply
– The higher heat supply to the combustion will increase produced
steam. It will reduce the water/steam density different hence the
Circulation ratio will decrease
 Area
– Natural circulation must have tubes with larger diameter to reduce
the water/steam resistance within the tube
 BOILER GENERAL
OVERVIEW
Heat Transfer

 Heat transfer calculation in the Boiler design:

– To determine the rate of heat to be transferred by involving
calculation of surface area and working temperature
– To determine how much heat or energy required by the
boiler
– To estimate the cost, practicability, and size of the boiler
equipment
 BOILER GENERAL
OVERVIEW
Heat Transfer Modes:

 Convection q  h As T
– tranportation and exchange of heat due to the mixing motion of
different parts of a fluid
– natural convection and forced convection
dT
 Conduction q  k Ac
dx
– heat transfer across through fixed (solid) material
 Radiation q   As T 4
– transfer radiant energy from a source to a receiver
(without medium = electromagnetic wave)
– luminous radiation and non-luminous radiation

MOST OF PRACTICAL APPLICATION IS COMBINATIONS OF THOSE TWO OR

THREE HEAT TRANSFER MODES
 BOILER GENERAL
OVERVIEW
Heat Transfer in the Boiler Pressure Parts

 Furnace
Radiant SH
Spaced SH

Evap. – radiation mode

 Radiant (Plattent) Superheater
Econ. – luminous radiation mode
– non-luminous radiation mode
– convection mode
 Convective (Spaced) Superheater
– non-luminous radiation mode
Furnace

– convection mode
 Evaporator (Boiler Bank)
– convection mode
 Economizer
– convection mode
 BOILER GENERAL
OVERVIEW
Heat Transfer Relates to Boiler Pressure

The total heat absorbed in boiler bank is reduced significantly at higher

pressure unit:
– Superheater absorbes greater heat to increase steam temperature
– Water temperature in the Boiler Bank is higher for higher pressure
– Boiler Bank will not be effective for the higher pressure boiler
 BOILER GENERAL
OVERVIEW
Metal temperature consideration
 The water/steam within the tube
exposed to furnace hot gas will
pass through a series of
resistance:
– gas film adjacent to the tube
– slag on tube surface
– tube wall
– internal scale deposite
– water & steam film

 As thermal conductivity of the water film is higher --> Tube metal

temperature of Boiler Bank and Economiser is close to the temperature of
water inside the tubes
 Tube metal temperature of Superheater, Reheater should be considered
carefully --> thermal conductivity of the steam film is low
 BOILER GENERAL
OVERVIEW
What factors will impact to heat transfer ?
 Temperature different
 Heat source
 Heating surface area
 Physical properties
– thermal conductivity
– heat transfer coefficient
– emisivity
– wall thickness
– slag or ash layer
– internal scales or sludge layer

REGULAR BOILER MAINTENANCE & INSPECTION IS REQUIRED

 BOILER GENERAL
OVERVIEW
Boiler Efficiency
Output
Heat in
the steam outlet

Input
Fuel
Preheated air
Feedwater
Losses
Unburned fuel
Hot flue gas
Radiation

 Performance Calculation follows ASME PTC 4.1

Output
Boiler efficiency = x 100%  Boiler Efficiency can be calculated based on:
Input
 Heat Loss Methode
 Input Output Methode
 BOILER GENERAL
OVERVIEW
Typical Boiler Design Parameters
 Furnace heat release rate
– maximized local absorbtion rate and avoid “hot spot”
– prevent excessive slag accumulation
– influences completeness of combustion process
 Flu gas velocities through tube banks
– limit the draft loss to control flue-gas velocity
 Tube spacing
– prevent slaging especially for residual oil, coal with low
ash-fushion temperature

BOILER DESIGN IS TAILORED TO THE FUELS & FIRING SYSTEM

 BOILER GENERAL
OVERVIEW
Boiler Type
Based on Purposes & Construction:
1. Package Boiler 4. Circulating Fluidized Bed (CFB)
2. Industrial Boiler 5. Supercritical Boiler
3. Utility Boiler 6. Marine Boiler

Based on Heating Area:

1. Fire Tube Boiler 2. Water Tube Boiler

Based on Heat Source:

1. Conventional Boiler 2. Heat Recovery Steam Generator

Based on Circulation:
1. Natural Circulation 2. Forced Cirulation

Based on Support:
1. Bottom Supported 2. Top Supported
 BOILER GENERAL
OVERVIEW
Fire Tubes Boiler
STEAM

FIRETUBES
 Application: hotel, heater,
small industrial process
 Fuel: Oil, Gas
 Typical steam capacity up
to 5 Ton/h
BURNER
 Saturated temperature
 Typical design pressure up
to 2.5 Barg
 Fully shop assembly
 BOILER GENERAL
OVERVIEW
Package Boiler

 Application: Auxiliary boiler, industrial process

 Fuel: Oil and Gas only
 Steam Capacity up to 220 Ton/hr
 Design Pressure up to 110 Bar
 Design Temperature up to 500o C
 Mainly shop assembly, very minimum site works
 AP ESI has full capability on design, manufacture, commissioning
 BOILER GENERAL
OVERVIEW
Heat Recovery Steam Generator (HRSG)

 Application: Cogeneration, Combined Cycle

 Type: Horizontal (Natural Ciculation), Vertical (Forced Circ.)
 Steam Capacity up to 400 Ton/hr (GT 9 FA size) depend on GT type
 Single, Dual or Triple Pressures up to 120 Bar
 Design Temperature up to 450o C
 Site assembly
 AP ESI has full capability on design, manufacture, commissioning
 BOILER GENERAL
OVERVIEW
Industrial Boiler
 Application: Industrial Process,
Power Generation (< 50 MW)
 Multi Fuels: Oil, Gas and Solid
 Steam Capacity up to 200 Ton/hr
 Design Pressure up to 120 Bar
 Design Temperature up to 500o C
 Site assembly
 AP ESI has capability on design,
manufacture, commissioning

Consideration of Industrial Boiler:

– Multifuels Burning capability
– Waste Fuel Utilisation (biomass,
waste acid, sludge, etc.)
– Cogeneration Potential to
maximize heat from their fuel
 BOILER GENERAL
OVERVIEW
Utility Boiler
 Application: Power Generation
(above 50 MW)
1  Main Fuel: Coal
6
 Typical Steam Capacity up to
1,850 Ton/hr (600 MW)
7  Design Pressure up to 173 Bar
 Design Temperature up to 538o
2 C
5  Site assembly
8
 AP ESI has capability on
9
3 Pressure Parts Detailing,
Manufacturing
4
 BOILER GENERAL
OVERVIEW
CFB Boiler
+ 50.0 m

 Application: Industrial process,

SH 3
SH
1/2
SH
1/1
Power Generation
Evaporator Wings
 Fuel: Flexible Solid fuels
 Emission: Low, environmental
ECO
friendly
SH 2 ECO

Coal Bunker
 Typical Steam Capacity up to 800
Prim. Air
Sec. Air Ton/hr
TAPH  Design Pressure up to 120 Bar
 Design Temperature up to 500o C
 Site assembly
 AP ESI has capability on Pressure
Ash Cooler
± 0.0 m
- 1.5 m
Parts Detailing, Manufacturing
 BOILER GENERAL
OVERVIEW
“FI Circ” Boiler (Small CFB)
 Application: Industrial process,
Power Generation
 Fuel: Flexible Solid fuels
 Emission: Low, environmental
friendly
 Typical Steam Capacity up to
265 Ton/hr
 Design Pressure up to 100 Bar
 Design Temperature up to 500o
C
 Modularized concept
 AP ESI has capability on
Pressure Parts Detailing,
Manufacturing
 BOILER GENERAL
OVERVIEW
Super Critical Boiler
 Application: Power Generation
 Fuels: Pulverized Coal
 Typical Steam Capacity up to
2,500 Ton/hr (800 MW)
 Design Pressure up to 253 Bar
 Design Temperature up to 538o
C
 Higher efficiency (no steam
drum, no blow-down system)
 Feedwater quality is major
concern
 Site assembly
 AP ESI has capability on
Pressure Parts Detailing,
Manufacturing
 BOILER GENERAL
OVERVIEW
Marine Boiler

 Application: Steam turbine drive (turbine

propulsion) in the shipboard
 Multi Fuels: Oil, Gas and Solid
 Typical Steam Capacity up to 70 Ton/hr
 Design Pressure up to 58 Bar
 Design Temperature up to 500o C
 Limited spaces, compact arrangement
 Dynamic behavior

Note:
Alstom has no longer developed this product
 BOILER GENERAL
OVERVIEW
Boiler Main Component
 Pressure Parts
– Steam and Water Drums
– Superheater, Reheater
– Risers, Down Comer
– Boiler Bank (Evaporator)
– Water wall
– Economiser
 Auxiliary Equipment
– Burner
– Force and Induce Draft Fans
– Valves, Controls and Instrument
 Balance of Boiler island
– Deaerator
– Feedwater Heater
– Blowdown System
 BOILER GENERAL
OVERVIEW
STEAM OUTLET
Steam Drum FEED WATER
DRYER INLET
SECONDARY
SEPARATOR

RISER
TUBES

BAFFLE
PRIMARYY
PLATES
SEPARATOR
DOWNCOMER
 Function of Steam Drum
– Collect and separate steam from water
– Supply and distribute the boiler water to evaporator section
 Drum Internals
– Primary & Secondary Separator: to reduce water content in the steam from
boiler water circuit
– Baffle Plates: to direct a flow pattern to assist gravity separation in the drum
– Dryer: to remove residual moisture of the steam
 BOILER GENERAL
OVERVIEW
Turbo (Centrifugal) Separator
STEAM

DISCHARGE WATER

STEAM

WATER WATER

 It works based on the Principe of Centrifugal

 Water has higher density then steam. The water
will move up caused by spinner blades in the
peripheral and turndown by separator top cover
 Steam has lower density. The steam will move up
leaving the separator and flow through the screen
dryer
 BOILER GENERAL
OVERVIEW
Superheater
 BOILER GENERAL
OVERVIEW
Deaerator
 Why we need Deaerator ?
– The present of O2 and CO2 in
the feedwater is the main
cause of corrosion and
gradually creating a pit to the
inner surface of pressure parts
– CO2 is mainly formed in the
condensate system

 Function of Deaerator:
– To remove Oxygen and CO2 in the feedwater
– For feedwater heating
– For storage of deaerated feedwater
 BOILER GENERAL
OVERVIEW
How Deaerator works ?
DEMIN. WATER

Demin. water is sprayed into Deaerator

At the same time steam is also supplied into
Deaerator
The water and steam become integrally mixed
As steam molecules hit water molecules (Partial
Pressure Henry’s Law), the dissolved Oxygen
and CO2 in the water is separated the releases
STEAM
to atmosphere (vented)
The deaerated water and the condensing steam
flow down to the feedwater storage thank
STORAGE
TANK

TO FW SYSTEM
 BOILER GENERAL
OVERVIEW
Type of Deaerator WATER

WATER
VENT

VENT

STEAM
DRAIN STEAM

VENT

SPRAY TRAY TYPE

TYPE WATER

STEAM
SPRAY

SCRUBER
SCRUBER
TYPE
 BOILER GENERAL
OVERVIEW
GAS AND OIL BURNERS
 BOILER GENERAL
OVERVIEW
SUSPENSION FIRING (Cont’d)
 BOILER GENERAL
OVERVIEW
FORCED DRAFT FAN

AIRFOIL BLADE
CETRIFUGAL FAN
 BOILER GENERAL
OVERVIEW

SV
TT FT PT

MAIN STEAM
PRODUCT
TT PG TG
SPRAY WATER

ATM
O2
SV
PT
TT

FEED WATER
FDF W LT TG PT FT SUPPLLY
C

STACK TG

PT

FL
TG PT TG PT
BLODOWN
SH-2 TANK
IDF
AH SH-1
BMS
TT

TG PT

TT PT FT
PT

FUEL
SUPPLLY
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