Professional Documents
Culture Documents
PART-II
A presentation by,
B.K.Patnaik
Indian Institute for Production Management
H2O
1
Water
z
z
z
z
Water
z
a)
z b)
z
Suspended Impurities
Dissolved Impurities
Impurities of Water
Chemical name
Symbol
Calcium Carbonate
CaCo3
Calcium Bicarbonates
Ca(Hco3)2
Calcium Sulphate.
CaSo4
Calcium Chloride
CaCl2
Magnesium Carbonate
MgCo3
Magnesium Sulphate.
MgSo4
Magnesium Chloride
MgCl2
Common
name
Chalk
Effect
Soft scale
Soft scale
Gypsum
Hard scale
Corrosion
Chemical name
Symbol
Sodium Carbonate
Na2Co3
10
11
Common name
Effect
Washing Soda
Alkalinity
Baking Soda
Priming
Sodium Sulphate.
Na2So4
Glauber Salt
Alkalinity
12
Sodium Chloride
NaCl
Common Salt
Electrolysis
13
Sodium Hydroxide
NaOH
Caustic Soda
Embrittlemen
14
Silicon Oxide
Sio2
Silica
Hard scale
External Treatment
Water Softning
SOFT WATER
z Water is called SOFT when it produce
enough lather with soap. It contains
little or no Scale forming impurities.
impurities
Soft water is suitable to be used as
Boiler feed.
z
HARD WATER
z Water is said to be HARD when it does
not produce lather with soap solution
easily. It contains excessive scale
forming impurities such as Carbonates
of Calcium and Magnesium.
z
10
Water Softning
z
1
z1
z
11
Water Softning
TEMPORARY HARDNESS
z Water containing Bicarbonate hardness
is said to have Temporary hardness, as
this can be removed by heating. When
water is heated to its boiling point,
Bicarbonate hardness is separated out
and is precipitated.
PERMANENT HARDNESS
z Water
containing soluble salts of
Calcium and Magnesium (Other than
Bicarbonates)
is
said
to
have
permanent hardness. These impurities
cannot be removed just by heating. But
they form scale deposits when heated
Institute for Production
to more than Indian
300F
in the Boiler.
12
Management
Removal of Permanent
Hardness
1) CLARKS METHOD : By adding Washing Soda
14
Gravel
Gravel
filter
filter
BASE
Exchan
ger
BASE
Exchan
ger
SOFT
WATER
TANK
15
BASE EXCHANGER
CHEMICAL REACTIONS
z
Cl2
16
tank
DM
WATER
TANK
Gravel
Gravel
filter
filter
Mixed
Mixed
bed
bed
filter
filter
Cat ion
Cat-ion
Cat ion
Cat-ion
filter
filter
Degasifier
Anion
Anion
filter
filter
17
18
19
20
10
De Mineralized water
21
Internal Treatment
22
11
Internal Treatment
23
12
25
26
13
C
z
z
z
z
z
28
14
Boiler operation
z
z
z
z
z
z
z
z
z
z
z
z
Parts
Pre start checks
Preparation for starting
Firing
Pressure build up
Circulation
Charging
Running
Emergency handling
Shutdown
Cooling
Preservation
Indian Institute for Production
Management
30
15
STEAM STOP
VALVE
SPH 3
SPH 1
APH
SPH 2
FUEL
ESP
AIR
THROUGH
APH
FD
ID
32
16
Check furnace
Clear furnace of all unwanted substances, Close
drums
Check all drives
Close drain valves
Open all vents
Fill Feed tank with D M water
Start feed pump and fill boiler upto minimum level.
Ch
Charge
gauge glass
l
Start I D Fan and then F D Fan
Make control panel ready
Indian Institute for Production
Management
34
17
35
36
18
Boiler Drum
Turbo Generator
Feed Tank
Super Heater
E
Economiser
i
Boiler Furnace
Condensor
Fuel+Air
Feed Pump
Flue gas
Condensate Pump
Boiler Furnace
E
i
Economiser
FUEL
Burner
Flue Gas
ESP
CHIMNEY
Air Preheater
F D FAN
I D FAN
19
39
Natural circulation.
Natural circulation of water inside the boiler is
the circulation due to the density differences of
steam and water.
Inside the furnace, when water is heated and is
converted to partly steam, it moves up and
comparatively cold water from the drum moves
down to fill the space and thus water circulates
from top drum to mud drum and back to the
top drum. This process is termed as Natural
circulation.
40
20
WATER &
STEAM
WATER
NATURAL CIRCULATION
42
21
43
FORCED CIRCULATION
WATER &
STEAM
Pump
WATER
MUD
DRUM
22
LTSH
Final SH.
Platen SH.
330-375C
500-540C
375C-425C
Economizer
Water Wall
240-310C
310C
DRUM
SUPERHEATER-1
SUPERHEATER
1
SUPERHEATER-3
SUPERHEATER-2
DOWNCOMER
RISER TUBES
BURNERS
ECONOMIZER
FORCE
CIRCULATIO
N PUMP
23
47
48
24
STEAM PRESSURE
FEED WATER
I.D.FAN
49
50
25
51
52
26
z
z
z
z
z
53
54
27
55
56
28
DRUM
SUPERHEATER-1
SUPERHEATER
1
SUPERHEATER-3
SUPERHEATER-2
DOWNCOMER
RISER TUBES
BURNERS
ECONOMIZER
29
Heat Balance
Heat input to boiler
Energy in fuel
w*C
Heat in air
Ta*Sp.heat
Boiler efficiency
Boiler Eff. = Heat output/ Heat input
[(
)
cp(T2-T1)]
p(
)]
W[(h-h1)+L+
w*C
W= weight of steam generated in a given period
h = Sensible heat.
h1 = heat in feed water.
L = Latent heat of steam.
cp = Specific heat of steam.
T2 = absolute temperature of superheated steam.
T1 =absolute temperature of saturated steam.
w = weight of fuel burnt in the same period.
C = calorific value of fuel.
Indian Institute for Production
Management
60
30
Boiler Trial
v
31
Boiler Availability
Boiler availability depends upon:
z
z
z
z
z
z
z
z
z
z
z
z
z
z
63
64
32
MAINTENANCE is a system
y
by
y
which the Machinery Assets are
kept in GOOD working condition
and maintain in the same
condition by preventing from
deterioration.
33
WHY MAINTENANCE ?
RELATIVE MOTION
Motion
One
Stationary &
other Moving
Both moving
but in
opposite
direction
Both moving in
same direction
But at diff. speeds
34
Case -1
Case -2
Surface contact
Point contact
SLIDING FRICTION
ROLLING FRICTION
35
TO PREVENT FRICTION
zLUBRICATION
36
OIL
FILM
37
MACHINE
A LWAYS
IN
N EW
T OPCLASS
E FFICIENT
N EAT
A ND
N ICE
C ONDITION
E VERYWHERE
MAINTENANCE
STRATEGIES
38
Boiler Maintenance
MAINTENANCE STRATERGIES:
ON FAILURE MAINTENANCE.
2 FIXED TIME MAINTENANCE
2.
1.
z
z
z
3.
PREDICTIVE MAINTENANCE
z
z
z
4.
ONLINE
SHUTDOWN
OVERHAULING
Vibration
Thermography
Wear Debris Analysis
77
BOILER VIDEO
78
39