EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

Overview in general
Heat Ventilation and Air Condition (HVAC)
Part 1: Steam technology
Part 2: Refrigeration-, Air conditioning technology

Topic overview part Steam technology (Lecture Concept)

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Introduction
Steam pressure generation systems
Heat exchangers
Firing systems and combustion
Supply systems of boilers
The water-steam-circuit
Condensate management
Safety-, regulation- and warning systems of boilers
Commissioning and decommissioning of boilers
Boiler damages

References

Mayr F.: Kesselbetriebstechnik, Verlag Dr. Ingo Resch GmbH, 12. Edition 2009
Effenberger, Helmut; Dampferzeuger; Deutscher Verlag fr Grundstoffindustrie; 1989; 374 S.
Repetitorium Dampferzeuger; Energie & Management Verlagsgesellschaft mbH; 1996;227 S.
Brandt, Fritz; Wrmebertragung in Dampferzeuger und Wrmeaustauschern; VULKAN;
1995; 307 S.
Steinmller; Taschenbuch Dampferzeugertechnik; Vulkan 1999; 278 S.

Introduction

Historical Development
History of steam-use goes back to 1st century
1712 first operational steam machine by Thomas Newcomen =0,5%
1769 James Watts steam engine was patented =3%
First steam turbine by Carl Gustav Patrik de Laval-1883 acting on action principle, almost at
once (1884) reaction turbine Charles Parsons
Utilization of steam was essential precondition for industrialization
Steam today
Steam as heat transfer medium Heating- and process steam
Steam power plant with unit outputs up to 1300 MWel
Steam generation by:
combustion of fossil fuels
nuclear fission
geothermal energy
sun energy
waste heat (chemical processes, production processes .)
History of steam in power plant technology
Striving for increase of efficiency leads inevitable to:
pS 250 bar 300 350 bar,
S 550C 600 - 750C
changed boiler constructions

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

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new boiler steels (creep-resistant steel with high load cycle number)
Todays efficiency of power plants up to app. 50 %
Efficiency can drop in future ( Exhaust-after treatment plants)

Characteristic Boiler
Steam boilers are heat transmitter, which have on the one hand exhaust gas- and radiant
heat as source of energy and on the other hand water or steam as process medium.
Exhaust gas and water or steam are divided by a solid barrier (steal tubes or steal pates)
Supply systems of boilers
For the continuous operation important supply systems are:
boiler feeding water system including water treatment
fuel supply system
combustion air supply system
combustion support systems (e.g. ash drain)
regulation- and control systems
safety systems
Demands on Boilers
High operating safety
Simple operation
Quick adjustment on changing of loads
Small required space
Low weight
Low noise emission
Additional for ship boilers:
save operation at rolling and pitching of the ship
adequate cooling of heated surfaces at extreme trim- and stern positions

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Steam pressure generation systems

Classification of Boilers to Physical Active Principle

Boiler

Natural
Circulation Boiler

Forced
Circulation Boiler

Forced
Once-through
Boiler

EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

1.1 Natural Circulation Boiler

Picture 1: Construction Nature Circulation Boiler in Principle

Picture 2: Formation of Nature Circulation

Formation of Nature Circulation (Circulation Pressure p)

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

Picture 3: Nature Circulation in Different Boiler Type

Characteristics Nature Circulation

Low operation pressure, depending on steam content

starting up on low load (p=f(p H2O)
after start of evaporation firing capacity can be increased
low heating surfaces load
Downpipes and heating tubes are to be filled always with water
down-pipes and heating tubes enter the steam drum under the min. water level
Cooling of heat exchanging surfaces decreases with rising steam content
low heat surface load
max. steam content in heating tubes at x=0,15

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

Picture 4: Smoke Tube Boiler

Picture 5: Water Tube Boiler

Picture 6: Flue Tube Smoke Tube Boiler (two passed with reversing chambers)

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

1.2 Forced Circulation Boiler

Picture 7: Construction Forced Circulation Boiler in principle

Characteristics Forced Circulation Boiler

Operating pressure is sustained by circulating pump

Starting up on medium load
After warming up firing capacity can be increased
High heating surfaces load possible
Water has to run towards the circulating pump
minimum total suction height to avoid cavitations
steam drum is to be filled with water sufficiently
Cooling of heat transmission surfaces decreases with rising steam content
high circulating water quantities
max. steam content in heating tubes at x= 0,3 - 0,35
Operation Forced Circulation Boiler

Problem:

Tube lengths in parallel vaporizer tubes are different

Different flow resistances
Different circulating quantities
Different cooling of tubes
(Influence to steam content and surface temperatures)
Solution:
Matching of flow conditions
installation of dominating flow resistances
increasing pump power

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

Picture 8: La-Mont-Boiler (Forced-Circulation-Boiler)

Picture 9: Throttle Insert La-Mont-Boiler

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EM 12 Heat Ventilation and Air Condition

Lesson 1 Steam pressure generation systems

Prof. Dr. Ing. M. Rachow / Dr. Sutopo Purwono Fitri

1.3 Once-Through-Boiler

Picture: 10 Construction Once-Through-Boiler in principle

Characteristics Once-Through-Boiler
Feeding pressure is generated by feed water pump
high feed water pump power
spare pumps essential for boiler cooling in case of pump failure
very high heating surfaces load possible
Feed water evaporates in one pass through
accompanying substances remain in evaporator
high requirements on purity of feeding water
No storage capability
high inertia of boiler (limited control dynamics)

Picture: 11 Benson Boiler with Partly Forced Circulation

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