BOILER DESIGN PROCEDURE AND FUNDAMENTALS

BOILER:
BOILER IS A STEAM GENERATIVE EQUIPMENT.
1.UNITS:
1. OUT PUT/ CAPACITY = t/h
2. STEAM PRESSURE = kg/cm²
3. STEAM TEMP = ºC
2.IMPORTANT:
1.DRUM OPERATING PRESSURE
2.STATIC HEAD
3.MAIN COMPONENT
1.SAFTY VALVE
2.WATER LEVEL INDICATER
3.BLOW DOWN
4.MAIN STEM STOP VALVE/ON OFF (MANUAL MOTORIZED)
5.FEED STOP VALVE
6.REGULATING VALVES
I)FEED CONTROL VALVES
II)SPRAY CONTROL VALVES
7.DRAIN VALVES – NB 25
8.VENT VALVES – NB 25
9.ISOLATED VALVES – NB 15
4.FUEL
ENERGY(THERMAL)
I) CONVENTIONAL
II) NON CONVENTIONAL

CONVENTIONAL:
1. WOOD
2. OIL (10000 kc/kg)
3. COAL
4. GAS
NON CONVENTIONAL:
1. SOLAR
2. WIND
3. HYDRO
4. GEO THERMAL
COAL: (2000 – 6000 kc/kg)
OLDEST
1.ANTHRACITE – 6000 kc/kg
2.DIMOND (CARBON)
YOUNGEST
1.PEAT
2.LIGNITE (BROWN COAL)
3.SUB BITUMINOUS – A,B,C
4.BITUMINOUS
1.MID WESTERN
2.EASTERN
THERMAL UNITS:
1.FPS – ºf POUND SECOND – BTU (BRITISH THERMAL UNIT)
2.CGS – ºc GRAM SECOND - CALLORI
3.MKS – METER KILOGRAM SECOND
4.SI – METER NEWTON SECOND - JUEL
DAY – 3 03.09.2014

FUEL:

SOURCE OF ENERGY
POINTS:
1. HEATING VALUE
2.EFFICIENCY

EFFICIENCY:
INPUT = COAL
OUTPUT = ELECTRICITY

1. EFFICIENCY = OUTPUT/INPUT
2. 1KW/H = 860 K CAL
3. 1 KW = 1000W
4. PLANT HEAT RATE
5. EFFICIENCY = 860/HEAT RATE

COST:

1 UNIT = 6 Rs

50% FUEL COST = 3 Rs

50% COST OF CAPITIAL + COST OF O&M = 3Rs
DAY – 4 04.09.2014

BOILER DIFFERENCE:
SMALL BOILER = 50 t/h
MEDIUM BOILER = 50<200 t/h
LARGE BOILER = >200 t/h

1.CYCLE EFFICIENCY = 55 – 60 %
2.SOLAR EFFICIENCY = 7 – 11 %
3.COMBINED CYCLE
I) GAS TURBINE CYCLE
II) STEAM TUR BINE CYCLE

GENERAL DATA:
1.BOILER PARAMETER
2.FUEL
3.FUEL EFFICIENCY

DUTY:
1.HEAT DUTY
2. QD = .........k cal/h
3.HEAT DUTY = OUTLET – INLET

EFFICIENCY = 100% - LOSS

TYPES OF LOSSES:
1. DRY GAS LOS
2. MOISTURE LOS
3. AIR MOISTURE
4. RADIATION LOSS
5. UN BURNED LOSS
6. UNACCOUNTED
DAY – 5 O5.09.2014

LIST OF CALCULATION PROCEDURE:

1.FUEL
2.EFFICIENCY
3.Q FIRED
4.OTHER CALLORIFIC VALUE
WEIGHT OF FUEL BURENED:
Wf = Q fired / (COAL CAL VALUE+HEAT VALUE)
Wa = COMBUTION AIR REQUIREMENT

EXCESS AIR IS IMPORTANT FACTOR IN BOILER:

5% - 10% = OIL
20% - 25% = COAL
8% - 10% = GAS