Steam Boiler

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Design Buckstay in the Steam Boiler

Fig. 1: Design Buckstay in the Steam Boiler

The furnace of steam boiler has internal pressure which is usually designed 200 mm wg. The internal
pressure is resisted by attaching buckstay in every approximately 2-3 m along the height of furnace
wall. Buckstay is support that consist of four girder which be installed in the four sides of furnace
wall; right side wall, left side wall, front side wall and rear side wall. At the corner design buckstay
is hinged to permit expansion on the furnace wall of steam boiler.

Bucstay is designed to resist longitudinal load such as internal and external pressure, normal load
such as internal pressure, moment bending because of support bracket of pressure part, and
temporary load such as explosion, wind and seismic forces. Buckstay has important roles to keep the
furnace remain in its position and no bending occurs when the steam boiler operates continuously.

Spacing of buckstay a long the height of furnace is calculated to avoid wall tubes deflection and
prevent vibration on tubes which has same frequency same with natural frequency of furnace wall
tubes. Deflection of buckstay is usually calculated as L/360. At the time of application buckstay is
attached to tie bar with slip connection to give limitation of deflection inward and outward of furnace
wall tubes. Tie bar is rectangular bar and form continuous band around the furnace wall tubes (see
figure 1).

For more details about calculation of design buckstay, please look this spreadsheet: "Calculation of
Design Buckstay"

Steam Boiler
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Requirement Design of Tubes

Requirement design of tubes is made to make sure design tube can be used in certain temperature
and pressure in steam boiler. Tubes are one pressure parts. These provisions should apply to any
tubular pressure part that is either exposed over much of its length to hot gases for purposes of heat
transfer or is directly butt welded to such a tubular pressure part.
Requirement design of tubes should comply with the requirements of the ASME Boiler and Pressure
Vessel Code, Section I, Power Boilers. The calculation of tube thickness should be based on ASME BPV
Section I.

The requirement design of tubes should describe the design basis for controlling mechanical wastage
(eq. grit and soot blower erosion) and chemical wastage (e.g. fireside corrosion, dew point corrosion)
of tubing. During the design phase, the requirement design of tubes should supply details of the
wastage provision for each tube design.

Membrane panel construction should be either by a fusion welded fin or integral fin method.
Resistance welded fin construction will not be allowed. No tube bend should contain a circumferential
weld. Parallel down-flow circuits subject to significant variations in heat absorption and/or resistance
to flow between these circuits should be avoided. A staggered arrangement of tubes in the gas pass
should not be used.

Durable caps suitable for transportation should be provided on each end of the tubes to prevent
damage and rust on inside surface of tube and to prevent entry of debris. Corrosion or erosion margin
of tube thickness should be provided for the boiler tubes.

Steam Boiler
All of About Steam Boiler, Heat Exchanger, Energy and Power Generation

Can You Calculate Tube thickness?

Can you calculate tube thickness is one of question must be answered by mechanical engineer
who involve in design steam boiler. Basically the calculation of tube thickness is really simple
but if we dont know, it will be difficult off course.

Basically you only need knowledge about the theory of longitudinal stress in cylindrical part
and circumferential stress cylindrical part as my previous post. The following below is formula
to calculate tube thickness because of these stresses:

tL = P D / 2 SL (equation 1)
tC = P D / 4 SC (equation 2)

where:
tL = tube thickness because of longitudinal stress
tC = tube thickness because of circumferential stress
P = design pressure
D = inside diameter
SC = circumferential stress
SL = longitudinal stress

From the equation above, thickness because of longitudinal stress is always greater than
thickness because of circumferential stress. Therefore you can simply choose the equation 1
to calculate tube thickness.

However, if the tube is used in boiler plant, the calculation should refer to ASME BPV Code
Section I Part PG 27.2.1 as following formula:

t = (P D / 2 S) + 0.005D + e + Ca

where:
t = minimum required tube thickness
P = maximum allowable working pressure
D = outside diameter
S = maximum allowable stress value at certain temperature in each material, the table can be
found in ASME BPV Code Section IID.
e = thickness factor for expanded tube ends
Ca = Corrosion allowance.

To make easy to calculate tube thickness, I had made a spreadsheet of tubethickness

calculation, you just enter input data such as pressure, outside diameter, e, Ca and S value.

So if you get question can you calculate tube thickness? just answer it, I can do it for 5
minutes only, he..he.. but if you have already ASME BPV Code Section IID to find S value.

Steam Boiler
All of About Steam Boiler, Heat Exchanger, Energy and Power Generation

Design Deaerator or Feed Water Storage Vessel

The design daerator should consist of the dearating unit and a feed water storage vessel. A feed
water storage vessel should be provided within the feed water heating system. The dissolved oxygen
content in the feed water effluent from the heater should not be more than 0.007 mg/liter at any
load condition, measured in accordance with the "Method and Procedure for the Determination of
Dissolved Oxygen" of the Standards of the Heat Exchange Institute. The feed water storage vessel
should be integrated with a deaerating unit to fully de-aerate the feed water, if an alternative water
chemistry regime is proposed the design should substantiate his provisions for control of dissolved
oxygen in the feed water system.

The main functions of the feed water vessel should be to:

Condition feed water for start-up

Provide a reserve to compensate for fluctuating feed flows
Ensure boiler feed pump suction requirements are met at all times
Removal of oxygen via a steam heating/de-aerating process

Whichever arrangement of feed water / deaeration vessel in the design deaerator or feed water
storage vessel to provide a full description of the normal function, including:

Level indication and level control

Conditioning of feedwater prior to start-up (cold start)
Flows of condensate, bled steam, auxiliary heating steam
System responses to transient conditions
Any specific arrangements proposed for part load operation
Disposal of scrubbed or vented non condensable gases
The design deaerator or feed water storage vessel should state the provision for deaeration and
heating the stored water on plant starts when the LP heater is out of service. The description should
also describe the provision included to monitor and control the condensate level within the storage
tank and any recirculation system if necessary to ensure homogenous conditions in the stored water.

The feed water storage vessel should be located at or as close to the turbine operating floor level as
possible, consistent with satisfying the feed pump net positive suction head (NPSH) requirements.
The tank should store a minimum quantity of feed water corresponding to 7 minutes of rated (MCR)
feed water flow or that quantity of feed water which should permit a controlled and safe shut down
of the boiler, whichever is greater and assuming that the condensate is initially at the normal working
level.

The feed water storage vessel should be designed to operate with freedom from condensate surging
and vessel vibration. The freeboard above the top of the working level range should be sufficient to
accommodate the total condenser hot well content with margin.

Boiler feed pump leak-off returns should be introduced into the feed water storage tank in a
controlled manner to prevent damage from high velocity evolved steam or water impingement. At
all other points when steam or water enters the deaerator / feed water storage vessel, suitable
precautions such as baffles or diffusers should be provided to prevent direct impingement on the tank
plates, internals or water surface, internal baffles should be arranged within the feed water storage
tank to prevent surging of the condensate.

Provisions to protect the steam turbine from the risk water induction arising from any bled steam
pipe work connecting the deaerator / feed water storage vessel should be as stated in Section "Bled
Steam supply Lines".

The deaerator should be of the spray/tray type and should include storage tank, supports, vent
condenser and fittings. The design should be to the Heat Exchange Institute standard and suitable for
full vacuum.

The deaerator should be designed and arranged for the efficient removal of non-condensable gases
from the feed water under all conditions of operation, including the admission of auxiliary steam
during starting and low temperature condensate under fault or restart conditions.

If a part load deaerator is offered then the design should include a full description of the start-up
and operation with increasing load up to full load on the steam turbine-generator.

The design deaerator or feed water storage vessel should describe features of the deaerator head
which facilitate the removal of non-condensable gases from the circulating feed water and the
provision if any, for recovering heat from the vented gases and vapor. Deaerator level indicators and
alarms should be provided in the CCR, these alarms should be fully functional at all times when the
plant is available for operation, including periods when the plant is on standby duty.

Safety valves should be provided to protect the deaerator and feed water storage vessel from over
pressure from any source. All parts of the deaerator exposed to oxygen or corrosive gases should have
an adequate corrosion allowance or be of corrosion resistant materials.

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Requirement Design of Economizer

Requirement design of economizer is made to ensure that steam boiler can be performed
efficiently. The requirement design of economizer should describe the provisions for preventing
thermal fatigue damage to the economizer inlet manifolds, headers and tubing due to feed
temperature cycling during hot banked conditions and start up. The economizer and its circulating
system should be designed so as to avoid any serious water hammer caused due to steaming in the
economizer tubes.

The economizer tubes can be seamless material. The economizer should be of a continuous loop
drainable type and arranged for the upward flow of water and downward flow of flue gas. Staggered
spacing and extended fins or studs will not be accepted. The minimum tube spacing should be not
less than the spacing of the horizontal tubes which are located above economizer.

The economizer heating surface should be of effective heat transfer design, consistent with the
minimum cross sectional free flow area in the tube bundle. The entire tube arrangement should be
drainable.

Thermocouples with protection wells should be provided in the requirement design of economizer.
Where required for access and inspection, doors should be provided with tight gasket joints.

All headers should be external to the gas stream except economizer inlet and junction headers which
are located at low gas temperature area, and should be provided with welded inspection hole covers
as required for inspection. The header in the gas stream should be shielded to avoid header damage
caused by the flue gas. Inlet and outlet headers and/or lead pipes should have thermo wells with
thermocouples and connections for pressure gauge and test gauge furnished in the requirement
design of economizer.

Feedwater connection at the terminal point should be welded type and material to match Power
piping. Double drain valves should be provided in the requirement design of economizer. In the case
of extended surface type finned tube, a special consideration should be made in order to avoid undue
fouling or plugging with ash.
The economizer tubes should be arranged to permit the installation and easy replacement of soot
blowers and to permit future installation of additional soot blowers. The economizer support should
be designed to permit free expansion of all pressure parts and to prevent excessive expansion stresses
on the boiler.

The tube spacing of the economizer should be designed to minimize bridging and to avoid tube
erosion. Sufficient numbers of baffle plates should be installed at convection zone, including
economizer. Manholes installed on the baffle plates of economizer should be of the sliding door type.
The casing should be gas tight, and sufficient access door for entrance should be provided at each
section of the requirement design of economizer.

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Design Header in Steam Boiler

Design header in steam boiler should comply to ASME Boiler & Pressure Vessel Section I (ASME BPV).
Header shells can be manufactured by a seamless process. Feed water connections to drums should
be of a thermal sleeve design unless an alternative design is agreed with the owner.

Headers should be provided with access arrangements to allow full internal visual inspection and
cleaning. Wherever possible, the access openings should be through header ends and should be
arranged in order that the numbers of inspection openings are minimized. The openings shall have
an internal diameter of at least 75mm in order to allow televisual inspection of the complete header.

The closure of these openings should be of a permanent type, fixed by means of fully penetrating
butt welds with suitable length allowance for future cutting and re-welding.

All headers which are designed on a time dependent basis should be fitted with creep pips or other
means, to allow periodic measurement of diametric creep distension.

All nozzles, branches and tube stubs should be attached by welding and should be of the set on type.
The weld preparations and welding procedures should ensure fully penetrating welds. Reinforcing
pads should not be used.

No nozzle, branch or tube stub weld shall encroach over the heat affected zone of main seam welds.
Any specific instances where these requirements cannot be complied with should be submitted to
the Purchaser for approval during the design phase.

All nozzles, branches and tube stubs shall be of a sufficient length to ensure adequate access for
welding on the adjoining tubes or pipes and to permit effective post weld heat treatment of these
butt welds so as not to affect the integrity of the drum / headers.
Design header in steam boiler should be performed to ensure safety during operation. Diameter,
thickness and material to be used should be calculated as per design

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Design Steam Drum and Water Drum

Design steam drum and water drum is important step in design steam boiler due to mechanical
design and performance design. Steam drum and water drum are two of pressure part in boiler. The
steam drum should be furnished with internals which at least include hydraulic baffle, mesh dryer
screens to meet the required steam purity, and blowdown connection. Also, the drum internals are
protected from any possible attack by the chemicals and there is no chance of chemicals short-
circuiting and being discharged through the continuous blowdown system.

The water drum size is dependent on the number of tubes deep in the boiler bank. The chemical feed
connection could be located on the water drum. By placing the chemical feed on the water drum the
chemicals combine with the circulating water and are better mixed before entering the steam drum.

The drums should be of fusion welded construction fabricated from carbon steel plate and should be
equipped with 450 mm diameter manholes on both end plates of the drum to permit access into the
drum interior. All faces between manholes and drum plates should be fabricated and machined so as
to obtain a perfect seal.

Necessary welding end inlet and outlet connections and nozzles are provided to accommodate the
required valves and accessories. Steam drum should be provided with the necessary connections,
such as safety valves, continuous bIowdown, water level and pressure measuring instruments, vents,
etc.

Sufficient thermocouples should be provided on the drum shell. The metal temperature should be
measured as input data to the plant computer which should be furnished in the computer room.

All connection openings should be protected with caps before shipment. Drum should be capable of
complete drainage so as to assure the dry preservation of boiler when not in service. Pipes carrying
the saturated steam from the boiler drum to the superheater should be evenly spaced on the drum
and designed so that an adequate distribution of steam will be obtained for the superheater.

Necessary drum supports, such as U-bolts and nuts, should be furnished. Continuous steel rings for
insulation support around manholes should be welded on the drum. Two (2) multiple port type drum
water level assemblies, two (2) level transmitter pressure gauges and other necessary accessories
should be provided on the drum. Boiler water level should be indicated on operator monitor in the
central control room.
Insulation and jacketing should be installed on boiler drum and necessary fittings should be assembled
and welded in the manufacturer's shop before shipment. Field welding of parts or fittings should be
minimized. A single pass - cross flow or multiple passes generating bank design should be furnished.
The generating bank should employ a 400 mm central access cavity for maintenance.

The tubes are rolled during erection into the steam and water drums without any butt welds. The
entire generating bank sidewall construction features finned tubes will eliminates the need for an
inner casing. Where header/drum ends are attached by welding this should be by using a fully
penetrating plain butt weld joint.

Drums and headers should be self draining and provided with drain valves. Design headers / design
steam drum and water drum material should be in accordance with ASME Boiler & PV SectionII D.

Steam Boiler
All of About Steam Boiler, Heat Exchanger, Energy and Power Generation

Requirement Design of Superheater

The requirement design of superheater will be better to establish before manufacturing process
will be performed. The design superheater should provide uniform distribution of steam and
temperature at all loads, and provides thermal expansion of headers, tubes, spacers and supports,
and should be accessible for cleaning, examination and removal of elements.

The designer of steam boiler should arrange the superheater tube banks as conveniently as possible
to perform maintenance and periodic inspection. The requirement should describe what programs
are being undertaken, if any, to resolve problems of gas side corrosion and erosion of superheater
tube materials at elevated temperatures.

Horizontal tube sections of superheater should be arranged with sufficient clear spacing between
tubes in the gas flow at least equal to tube diameter and such as to avoid slag formation. Tubes
should be arranged in parallel rows. Horizontal tube banks in the convective pass may have minimum
baffles installed for the prevention of acoustical standing wave formation.

The wall thickness for superheater tubes, at least, should have a corrosion and/or erosion allowance
of not less than 0.5 mm. All superheater tube joints including connection to headers should be of
welded construction in accordance with ASME BPV Section l.

Superheater tubes should be arranged and terminated in outlet headers in a manner which will yield
through mixing of the steam, thereby resulting in the same temperature at each of the main steam
outlets. The superheater arrangements should be provided so that by the arrangement of the
connecting tubes and by the mixing points a uniform flow admission and sufficient temperature
balance are insured.
Tube connections should be shop-welded stub ends on headers. Stub ends should be prepared for
field welding of superheater tubes. Any welding of ferritic to austenitic stainless metals should be
done in work shop.

Spacers and hangers for superheater tubes should be designed to provide for appropriate sliding
expansion, and should be of material suitable for temperature encountered. All headers should be
external to the gas stream and should be provided with welded inspection hole covers as required for
inspection. The header in the gas stream should be shield to avoid header damage caused by the flue
gas. Inlet and outlet headers and/or lead pipes should have thermo wells with thermocouples and
connections for pressure gauge, lest gauge and transmitter should be furnished. The design
superheater must be equipped also with desuperheater and safety valve to control pressure and
temperature.

Based on description above, requirement design of superheater is a must to be performed prior to

begin manufacturing process to get high performance and efficiency.