Professional Documents
Culture Documents
gaser
bed bed
De-
filter
DM plant :
•Capacity : 300 KL , Make : Ion exchange
•Multi grade filter : for removal of impurities from ground water.
•Cation Bed : for absorption of Ca , Mg , Positive ion
•Degaser : Removal of gases in water
•Anion Bed : for absorption of Negative Ion
•Conductivity Maintains after Anion Bed is less then 30 µS
•pH 8- 9 , TDS -20-30 , Hardness -0
• Because of high consumption rate of steam ,capacity of the plant is not sufficient after
every four days (on avg 50 – 70 KL water feed into the boiler)
•Capacity require minimum 500 KL.
Demineralization
• Demineralization is the complete removal of all salts.
• This is achieved by using a “cation” resin, which exchanges the cations in the
raw water with hydrogen ions, producing hydrochloric, sulphuric and carbonic
acid.
• Carbonic acid is removed in degassing tower in which air is blown through the
acid water.
• Following this, the water passes through an “anion” resin which exchanges
anions with the mineral acid (e.g. sulphuric acid) and forms water.
• Regeneration of cations and anions is necessary at intervals using, typically,
mineral acid and caustic soda respectively. The complete removal of silica can
be achieved by correct choice of anion resin.
De-aeration
• When heated in boiler systems, carbon dioxide (CO2) and oxygen (O2) are
released as gases and combine with water (H2O) to form carbonic acid,
(H2CO3).
•Blow down Quantity varies in our plant from 0.3 ton to 1.2 ton per day.
•Feed water TDS will low as much as , blowdown % will decreases.
•TDS needs to be maintain below 10 , so conductivity of water needs to maintain Under
15. [(TDS)ppm = Conductivity µS/cm x 0.67].
Boiler Feed water
• Feed water service tank capacity : 15 KL.
• Temp. maintain between 80- 90°C by steam line given inside the tank & also Condensate
return from PMD.
• Economizer require for preheating of boiler feed water
• Amount of steam generated at 10kg/cm2(g)
Enthalpy of steam(sat) at 10 kg/cm2(g) pressure:665 K.Cal/kg
Feed water temperature : 850
• For Example :
• 4 TPH x 540 kCal/kg = 3.72 TPH
(665-85) kCal/kg
Capacity of
Engines: 800KW X 2 No
Fuel fired in
Engines: HSD
• For a boiler is operating at a pressure of 10 kg/cm2, steam saturation temperature is 180 oC, and steam enthalpy or total heat of dry
saturated steam is given by:
• hf +hfg = 182 + 663= 845 kCal/kg.
• If the same steam contains 4% moisture, the total heat of steam is given by:
• 182+ 0.96x 663 = 819 kCal/kg
• The working pressure .The distribution pressure of steam is influenced by a number of factors, but is limited by:
• The maximum safe working pressure of the boiler
• The minimum pressure required at the plant
• As steam passes through the distribution pipework, it will inevitably lose pressure due to
• Frictional resistance within the pipework
• Condensation within the pipework as heat is transferred to the environment
Steam Pipe Sizing
F = Pressure factor
P1 = Factor at inlet pressure
P2 = Factor at a distance of L metres
L = Equivalent length of pipe (m)
Steam Pipe Sizing…
The allowance for pipe fittings
The length of travel from the boiler to the unit heater is known, but an allowance must be included for the additional frictional resistance
of the fittings. This is generally expressed in terms of 'equivalent pipe length'. If the size of the pipe is known, the resistance of the fittings
can be calculated. As the pipe size is not yet known in this example, an addition to the equivalent length can be used based on
experience.
If the pipe is less than 50 metres long, add an allowance for fittings of 5%.
If the pipe is over 100 metres long and is a fairly straight run with few fittings, an allowance for fittings of 10% would be made.
A similar pipe length, but with more fittings, would increase the allowance towards 20%.
In this instance, revised length = 150 m + 10% = 165 m
Steam Pipe Sizing
Method
Select the point on the saturated steam
line at 7 bar g, and mark Point A.
From point A, draw a horizontal line to
the steam flowrate of 286 kg/h, and
mark Point B.
From point B, draw a vertical line
towards the top of the nomogram (Point
C).
Draw a horizontal line from 0.24 bar/100
m on the pressure loss scale (Line DE).
The point at which lines DE and BC cross
will indicate the pipe size required. In
this case, a 40 mm pipe is too small, and
a 50 mm pipe would be used.
Relation Between CO2 , O2and Excess Air for Fuel Oil
100
90
80
250
Excess air (% )
70
200
150 60
Excess air %
100 50
50
40
0
301 2 3 4 5 6 7 8 9 10 11 12 13 14 15
20 R e s idua l Oxyge n (%)
0
8.4 9 10 11 12 13 14 15
Carbon dioxide %
Boiler Performance Monitoring
• Boiler EVR is calculated on daily basis and it is > 13.5 Kg/Ltr. It is calculated by taking direct reading
of steam/water and FO consumption.
• Boiler Thermal efficiency can be calculated on the basis of following formula
η = M (Hs – Hw)x100/(m x CV)
η = Thermal efficiency of boiler
M: Mass of feed water/steam generated
Hs: Enthalpy of steam
Hw: Enthalpy of hot water
m : Mass of Oil
CV : Calorific Value of Oil (9600 Kcal/Kg of F.O.)
Indirect Method of Efficiency measurement
η = 100 – Losses
Losses = Flue gas loss + Blow down losses + radiation loss
Effimax is installed on 6 TPH boiler to monitor the boiler performance. We can get all the losses,
steam flow, oil flow & indirect efficiency of the boiler.
Boiler - Statuary Requirements
• Hydraulic Test : Every Boiler must be hydraulically tested every year in
presence of Boiler inspector. It is carried out by applying 1.5 times the
working pressure of boiler for 30 min. (testing water temp should be
between 20 °C to 50 ° C)
• Steam Test : Yearly, in presence of inspector, For checking whether safety
valves are working at desired pressure to relieve boilers excess steam.
• Stack Emission: This must be less than 250 mg/NM3. (This is checked by
M/s Envirochem)
Maintenance Schedule - Boiler
• Preventive Maintenance is carried out time to time as per
detail given below:
– Burner & Pumps maintenance: This is carried out on weekly basis
along with PMD maintenance day.
– De-carbonizing : Normally this is carried out on weekly basis.
– De-scaling : This is carried out as per requirement on the basis of
tube conditions.
– Yearly maintenance Jobs : Major maintenance of boiler is carried out
like lapping of all the valves, de-scaling, de-carbonizing, gauge glass
maintenance, tube inspection etc.
– The boiler maintenance job is outsourced.