Steam Power Plant

POWER PLANT TECHNOLOGY STEAM POWER PLANT
STEAM POWER PLANT
INTRODUCTION
Steam usage
1. Power generation
2. Sterilizing – surgery equipment, dish wash
3. High pressure cooking – oil palm industries
4. Drying – Palm oil kernel, concrete
5. Pressing – Furniture industry
6. Engine – Locomotive, ship engine
Steam power plant basic layout and equipment
Steam power plant

cycle
Water filled into boiler and

heat was supplied by
furnace/burner that generate
by fuel and air. The fuel can
be coal, diesel, agricultural
rubbish and gas turbine
exhaust. The heated water
change into steam phase and
it supply to turbine.
Meanwhile, the combustion
exhausts realaese through
chimney.
Boiler actually is such as closed

vessel that filled with water so
it can change to steam phase
when heat is applied to the
boiler. Boiler can be classified by it structure, i.e:
1. Water Tube
2. Fire Tube
ROSHAIZUL NIZAM BIN MOHD SANI

Steam
turbine
Steam turbine consists of a series of blade. The blades were connected to the shaft that wound with
cuprum wire. When a high velocity turbine strike the tubine blades, the blades spinning and so with the
wire cuprum wounded shaft. The spinning will create electromagnetic field that generate electricity
Condenser
The steam that rotate the

turbine will pass by to
condenser. The condenser
will change steam to water.
With heat transfer
application, the heat from
steam will transfer to a
duct contains cold water.
The cold water become hot
and steam will change to
water. The hot water
cooled by sea water, river
or cooling tower. Next, the
water from that source will
supply again to condenser
and the cooling proses will
repeated again and again.

The water that condenses by the condenser will supply to the boiler using water pump. The cycle
repeated until the plant was shut down.
Wout
3
2
Qout
Qin
1 4
Win
s
Steam power plant T-s diagram (Carnot cycle)
The figure above shown Carnot cycle (T-s) that equivalent with a basic steam power plant.
1-2: Boiler - Heat in
2-3: Turbine - Work out
3-4: Condenser -Heat out
4-1: Water pump - Work in
Fuel and handling system
Coal
Coal is one of many variety of steam power plant fuel. It considered cheap. Once harvested, coal is
shipped to power plants primarily by train, river barge, or ship. Its journey can cover thousands of miles.
It culminates in delivery to a power plant, where it is unloaded by means of a huge piece of machinery
called a rotary dumper.
This machine is capable of grabbing onto 100 ton railcars and turning them upside down. The coal spills
into a large collection hopper positioned next to the railroad track
Collection hoppers and have slanted bottoms which allow coal to easily spill out onto a conveyor belt.
Within the plant coal is transported by means of conveyors into what’s known as a “breaker building.”
This building lives up to its name because it contains a very large machine whose job it is to break the
chunks of raw coal that have been harvested from mines into smaller chunks which the boiler can work
with.

The “journey” of
coal
Once broken down,

the coal will go to
one of two places,
either directly into
silos or coal
bunkers in the
power plant
building for short
term storage, or
into an outside
storage pile,
usually a
prominent feature
of a power plant
due to its
formidable size.
The coal pile can

be several stories
tall and much
larger than a
football field. It
acts as a reserve supply should the regular delivery of coal be interrupted by labor strike, natural
disaster, or equipment failure. When necessary, the coal is removed from the pile and sent into the plant
to fill the coal silos. Coal from the silos is used to feed the power plant boilers.
Coal combustion
system
Bagasse
Waste and others
Basic Boiler
Engineering
Function of
Boiler
Boiler is an
apparatus to
produce steam.
Thermal energy
released by
combustion of
fuel is transferred
to water, which vaporizes and gets converted into steam at the desired temperature and pressure.
Boiler is a closed vessel in which water is converted into steam by the application of heat.
High Pressure vs Low Pressure Boiler
Low-Pressure Boiler Definition

In a low-pressure boiler the pressure does not exceed 1 bar (15 psi), and hot water heating boilers are not
designed to exceed over 18 bar (260 psig). The temperature in a low-pressure boiler will not rise above
394 K (250 degrees F). Because these types of boilers operate at lower pressures, they don't need to be
monitored regularly and only have to be checked when the appliance begins to break down.
Low-Pressure Boiler Uses

Low-pressure boilers are often used in buildings and designed to heat rooms through radiators. Types of
buildings may include restaurants, hospitals, office buildings and schools. The boilers are able to heat
the water used in bathrooms and use steam to heat the different rooms throughout the building, allowing
them to become warm.
High-Pressure Boiler Definition

High-pressure boilers will heat steam above 1 bar (15 psi) and water at pressures that exceed 11 bar (160
psig). Temperatures in high-pressure boilers will exceed 394 K (250 degrees F). Because of the elevated
pressure at which these boilers operate, they need to be monitored to ensure safety at all times. High-
pressure boiler operators must inspect switches, valves, safety devices and leaks on a regular basis. Any
malfunctions need to be fixed immediately to prevent further damage from occurring.
High-Pressure Boiler Uses

High-pressure boilers are used in industries and designed to generate the steam found in power plants,
dry cleaners and laundromats. These boilers were also used in locomotive steam engines to give them
the necessary power to run. Individuals who maintain these boilers need to follow certain precautions to
avoid burns, shocks and other hazardous conditions.
Boiler Mounting and Fittings
Safety Valve
Safety valve is a valve mechanism for automatic release to reduce a pressure inside the boiler so it can’t
exceed its pressure limits. This is to ensure the boilers did not explode and maintain the components in
the boiler itself. To reduce the pressure, safety valve will automatic release a steam to atmosphere.
Safety valve was installed in uppermost steam production line tube.
Figure below show cross-sectional for safety valve. The inlet is a part where safety valve was attached to
the boiler. Meanwhile, the outlet has a by-pass line to release excessive steam pressure. Safety valve was
controlled by a spring that has a equivalent spring force with maximum boiler pressure. When a boiler
pressure exceed allowable working pressure, steam from boiler will push a disc and compressed a
spring. Then, the excessive steams will realease. Stop valve will close and spring back to original
condition when boiler pressure is within allowable working pressure.

Steam pressure from boiler
Cross-sectional of
safety valve
Besides boiler,
safety valve can be
installing to heat
exchanger or another
system/equipmet
that handlingDisc
with Excessice steam pressure outlet
high pressure steam
or air.
Relief valve
Relief valve has a

same function as
safety valve. The
different is, safety
valve was use for a
system/equipment
that handling steam
and air, meanwhile
relief valve was use
for a
system/equipmet
that handling liquid
such as hot water
boiler and high
pressure pump.
Relief valve
Water gauge

Water gage was use to see water level inside the boiler. It was build from glass to ease boiler operator to
see boiler water level.
Refer to the figure above. Upper part of glass tube was attached to steam space in the boiler.
Meanwhile, the bottom part of glass tube was attached at 2 inci above the lowest water space in the
boiler. Upper tube (steam) and bottom tube (water) was attached to the glass tube called by G-tube. The
G-tube was marked with 3 lines that represent minima, medium and maximum water lavel in the boiler.
G-tube was covered by a glass/transparent plastic (marked by F in the figure). These prevent G-tube
from hit accidentally by boiler operator.
As safety precaution, there has a locking lever (marked as D and E in the figure). This lever will use to
closed steam and water tube if the G-tube broken.


Water gauge
Water coloum
Practically it difficult to attached water gauge directly to the boiler. This is because of a high pressure of
boiler that can cause water gauge broken or damage. In addition, it has a worried that the water gauge
clogged by sediment derived from the boiler. This will cause water gauge reading not accurate as
expected. Therefore, it is important a device called water coloum placed between boiler and water
gauge.
The purpose of water coloum is to stabilize water level on water gauge. Besides, water coloum made for
create a space for deposition. The deposition may occur as result from reaction between water and boiler
component. Water coloum easy to detached and cleaned.
Water coloum placed on outside of boiler shell. As water gauge, the upper part of the coloum was
attached to a part that contains steam. Meanwhile, the lower part was attached to lower part of boiler that
filled with water.
Water coloum
Steam Pressure gauge

All boilers must be fitted
with at least one pressure
indicator.
The dial should be at least

150 mm in diameter and of
the Bourdon tube type, it
should be marked to
indicate the normal working
pressure and the maximum
permissible working
pressure / design pressure.
Pressure gauges are

connected to the steam space of the boiler and usually have a ring type siphon tube which fills with
condensed steam and protects the dial mechanism from high temperatures.
Pressure gauges may be fitted to other pressure containers such as blowdown vessels, and will usually
have smaller dials.

Typical pressure
gauge with ring siphon
Blow down valve
Blow down valve was

use to drain all boiler
water for overhauling
purpose. Or, it was use
to just drain the
precipitate of mud and
slut that at the bottom
of boiler.
Blowdown of steam
boilers is very often a
highly neglected or
abused aspect of routine
boiler room maintenance. The purpose of boiler blowdown is to control solids in the boiler water.
Blowdown protects boiler surfaces from severe scaling or corrosion problems that can result otherwise.
Cross - section of typical

blowdown valve
There are two types of boiler
blowdowns - continuous and
manual.
A continuous blowdown
utilizes a calibrated valve and a
blowdown tap near the boiler
water surface. As the name
implies, it continuously takes
water from the top of the boiler
at a predetermined rate. A
continuous blowdown is an optional feature and may not be included on your steam boiler. However, all
steam boilers should include a means for manual blowdown as standard equipment.
Manual blowdowns are accomplished through taping at the bottom of the boiler. These openings allow
for the removal of solids that settle at the bottom of the boiler. Manual blowdown is also used to keep
water level control devices and cutoffs clean of any solids that would interfere with their operation. All
steam boilers require manual blowdown whether or not they are supplied with continuous blowdowns.
Boiler feed pumps
Boiler feed pumps are essential to boiler operation. The boiler feed pump controls the water volume
being fed to the boiler since the boiler also has a water level and it is necessary for the level of water in

the boiler to be controlled. The Boiler feed pump is sized to handle the evaporation rate of the boiler and
also the recirculation.
Boiler feed pump
Boiler stop valves

A steam boiler must
be fitted with a stop
valve (also known as
a crown valve)
which isolates the
steam boiler and its
pressure from the
process or plant. It is
generally an angle
pattern globe valve
of the screw-down
variety. Figure
below shows a
typical stop valve of
this type.
The stop valve is not

designed as a
throttling valve, and should be fully open or closed. It should always be opened slowly to prevent any
sudden rise in downstream pressure and associated water hammer, and to help restrict the fall in boiler
pressure and any possible associated priming.
On multi-boiler applications an additional isolating valve should be fitted, in series with the crown
valve. At least one of these valves should be lockable in the closed position. The additional valve is
generally a globe valve of the screw-down, non-return type which prevents one boiler pressurising
another. Alternatively, it is possible to use a screw-down valve, with a disc check valve sandwiched
between the flanges of the crown valve and itself.
The type of this valve can be installed in superheater outlet.

Boiler stop valve
Feedwater check
valves
The feedwater
check valve (as
shown in two figure
below) is installed
in the boiler
feedwater line
between the feed
pump and boiler. A
boiler feedwater
check valve (feed
stop valve) is fitted
at the boiler shell.
The check valve

includes a spring equivalent to the head of water in the elevated feed tank when there is no pressure in
the boiler. This prevents the boiler being flooded by the static head from the boiler feed tank.
Boiler check valve

Under normal
steaming conditions
the check valve
operates in a
conventional manner
to stop return flow
from the boiler
entering the feedline
when the feedpump is
not running. When the
feedpump is running,
its pressure overcomes
the spring to feed the
boiler as normal.
Because a good seal is required, and the temperatures involved are relatively low (usually less than
100°C) a check valve with a EPDM (Ethylene Propylene) soft seat is generally the best option.

Location of feed check

valve
Inspector’s Test
Attachment
The attachment for an

inspector’s test pressure
gauge shall consist of a
suitable valve or cock
carrying in a vertical
position a receiving
socket fitted with a
removable plug or cap.
Some said, it called man hole.
Except where such valve or cock is located in the pressure gauge connection it shall be mounted on the
top of the steam boiler shell near the pressure gauge.
Fusible Plug
A fusible plug is a threaded metal cylinder usually of bronze, brass or gunmetal, with a tapered hole
drilled completely through its length. This hole is sealed with a metal of low melting point (such as tin)
that flows away if a pre-determined, high temperature is reached. The initial use of the fusible plug was
as a safety precaution against low water levels in steam engine boilers
Fusible plug was installed in between the top of combustion chamber and the lowest boiler’s water level.
Therefore, half part of fusible plug was exposed to the water, and another half part exposed to the heat
from combustion chamber.
At normal condition, fusible plug doesn’t melt because it cooled by the water surround it. But, when the
heat from combustion chamber reaching dangerous level (229 to 232 ˚C), so the tin that filled the center
hole will melt. Then, the steam will go through the fusible plug hole dan make a wisel sound.
Furthermore, the steam will entered to combustion chamber and extinguish the fire.
Normally, fusible plug must be replaced within one to two years because there was a fear that it will not
function as new one.
Fusible Plug
Low Water Alarm

The action of the low water
level alarms is as follows:

 1st low level alarm -Shuts down the burner at the alarm level, but allows it to re-fire if the level
recovers.
 2nd low level alarm (often called lockout) -Also shuts down the burner at the alarm level, but
the burner controls remain 'locked out' even if the water level recovers and any faults have been
rectified. The lockout has to be manually reset to allow the burner to re-fire.
Typical Water Alarm
High Water Alarm

With the exception of one or
two operating standards, the
risks from a water level too
high are treated very lightly, if
not ignored altogether.
The dangers of an excessively

high water level in a steam
boiler include:
 Increased carryover of
water into the steam will
result in poor operation and
/ or malfunction of the steam system components, due to dirt.
 Wet and dirty steam can contaminate or spoil the product where it is used directly. Wet steam can
increase the water film thickness of the heat transfer surface, lower processing temperatures, perhaps
interfering with proper sterilization of food products or processing of pharmaceuticals, and causing
wastage. At best, lower process and production efficiency will increase process time and unit costs.
 Overfilling the boiler can lead to water hammer in the steam system, risking damage to plant and
even injury to personnel.
All of these, taken together, can result in:

 Spoilt product
 Lower production rates
 Poor product quality
 Increased plant and component maintenance
 Damage to the steam system
 Risk to personnel
As can be seen, the dangers of an excessively high water level are too serious to ignore, and deserve
equal consideration to that given to low water level conditions.
A high water condition could:

 Simply sound an alarm if the boiler house is manned.
 Shut-down the feedpump.
 Lockout the burner
 Close the feedwater valve

The action to be taken largely depends on the individual plant requirements.
Water level
indicator
Low-Water
Fuel Cutoff
A low-water
fuel cutoff is
used on both
steam and hot
water boilers
to shut off the
fuel or source
of heat when
the water
drops below a
predetermined,
safe operating
level. The
most common
type of low
water fuel
cutoff is a float
inside a
chamber. The
float
mechanism actuates an electrical switch when the float reaches a preset level.
Another popular form of low-water fuel cutoff is called a probe type. This variation uses rod-like
electrical probes inserted into the boiler or in an external chamber. When the probes are in contact with
the water, an electrical circuit is completed using the water as a conductor. If the probes lose contact
with the water, the electrical circuit is opened. Some low-water fuel cutoffs have a manual reset device
built in. The purpose of this is to alert the operator that the low-water fuel cutoff has activated. The
operator should then look for the problem that caused the low-water condition before resetting the
device and restarting the boiler.
Low Water Cut Off

Mechanism
Manufacturer's Name Plate

The manufacturer’s name plate use as identification of boiler. The serial number and model number
uniquely identify the boiler and are used when ordering spares from the manufacturer and in the main
boiler log book.
Manufacturer's Name Plate

Registration Plate
The purpose of registration

plate is to identified boiler
registration with related
authorities (JKKP, DOSH,
etc..)
Registration Plate

Natural Boiler Water Circulation
Many water-tube boilers operate on the principle of natural water circulation (also known as
thermosiphoning'). This is a subject that is worth covering before looking at the different types of water-
tube boilers that are available. Figure below helps to explain this principle:
Natural Boiler Water

Circulation
Cooler feedwater is introduced

into the steam drum behind a
baffle where, because the
density of the cold water is
greater, it descends in the
'downcomer' towards the lower
or 'mud' drum, displacing the
warmer water up into the front
tubes.
Continued heating creates
steam bubbles in the front
tubes, which are naturally
separated from the hot water in
the steam drum, and are taken off.
However, when the pressure in the water-tube boiler is increased, the difference between the densities of
the water and saturated steam falls, consequently less circulation occurs. To keep the same level of
steam output at higher design pressures, the distance between the lower drum and the steam drum must
be increased, or some means of forced circulation must be introduced.
Effect of Heating Surface Size on the Boiler Capacity and Efficiency
Heating surface is the aggregate surface exposed to fire or to the heated products of combustion, esp. of
all the plates or sheets that are exposed to water on their opposite surfaces; - called also fire surface
Boiler capacity is the rate of heat output in kJ/hr at the design pressure and/or temperature, measured at
boiler outlet. Rates fuel input at the sites elevation.
Boiler efficiency technically applies to a measure of the fuel-to-steam efficiency. However, it is also
often used to refer to the boiler’s combustion or thermal efficiency.
The increasing of heating surface easily can increase the boiler efficiency and boiler capacity. The more
heating surface can give more room for water change phase to steam. Therefore, the boiler capacity can
be increase. In other hand, the more steam produce, will increase fuel to steam ratio and this make the
boiler more efficient.
Boiler horse power

One boiler horsepower unit, or BHP, is equal to a boiler thermal output of 33,475 Btu/h (9.811 kW),
which is the energy rate needed to evaporate 34.5 lb (15.65 kg) of water at 212 °F (100 °C) in one hour.
The term was originally developed at the Philadelphia Centennial Exhibition in 1876, where the best
steam engines of that period were tested.
Boiler horsepower ratings are rapidly phased out and rarely found in new boiler installations, except for
American boilers.
Identify methods of connecting boiler

Justify methods of strengthening boiler drum construction
Factors Consider in Selecting Boiler
There are a lot of factor that should be consider before purchase and install a boiler. Some of them, list
below.
Codes and regulation. It is very important for boiler operate follow the codes and regulation by NIOSH.
The NIOSH will approve and give operating license to a boiler. It seem annoying. But, this is important
for safety purpose.
Steam or hot water. Choose both of them. The system cant be change easily. In other hand, if steam is
decide, make clearly sure it is a high pressure or low pressure. Low pressure boilers are typically used
for process heating applications. High pressure boilers are typically used for process loads.
Boiler load and capacity. Loads vary and a Boiler plant must be capable of handling the minimum load,
the maximum load, and any load variations. Boiler selection is often dictated by the variation in load
demand, rather than by the total quantity of steam or hot water required.
The seasonal and daily variations define the size of the load that the boiler(s) must handle. Seasonal and
daily variations also help define the number of boilers and turn-down requirements. If the instantaneous
demand is not included in the system load calculations, the boiler(s) may be undersized.
Fire Tube Boiler
For this type of boiler, heat from furnace/burner will supply to series of tube. Those tubes were placed
inside the boiler and it’s surrounded by water. Hot gases will through the tube and it will heat a water
surround it. This heating process will produce steam that used to spin a turbine. Meanwhile, the exhaust
from hot gases will release through chimney.

Typical Fire Tube

Boiler
Advantages of fire
tube boiler
1. Fast and
consistent
steam
production
2. Low initial
cost (there
was no
brickworks)
3. Low
maintainan
cost
4. Minimum
floor area
5. Factory assembly – better quality control
6. Easy to build
7. Stabil fluid movement
Disadvantages of fire tube boiler

1. Low steam capacity
2. Can’t use for the application that need high pressure (over 50 bar)
Various Fire Tube Boiler
Cochran Boiler
Characteristics
 Vertical Boiler
 Multi tube Boiler
 Straight tube Boiler
 Low pressure Boiler
 Coal fired Boiler
 Single tube Boiler
 Natural draft Boiler
 Natural circulation Boiler
 Stationary Boiler
 Internally fired Boiler
Construction: Cochran boiler consists of a cylindrical shell with a dome shaped top where the space is
provided for steam. The furnace is one piece construction and is seamless. Its crown has a hemispherical
shape and thus provides maximum volume of space.

Working: The fuel is burnt on the grate and ash is collected and disposed of from ash pit. The gases of
combustion produced by burning of fuel enter the combustion chamber through the flue tube and strike
against fire brick lining which directs them to pass through number of horizontal tubes, being
surrounded by water. After which the gases escape to the atmosphere through smoke box and chimney.
Advantages:
 The minimum floor area is required.
 Cost of construction is low.
 It can be moved and stet up take it to different location.
 Boiler has self contained furnace . No brick work setting is necessary.
 Any type of flue can be used.
Disadvantages:
 Steam raising capacity is less due to vertical design.
 Difficult in cleaning and inspection due to vertical design.
 The capacity and pressure are limited.
 The boiler requires high head room.

Figure: Cochran Boiler

Lancashire Boiler
Characteristic
 Double fire tube boiler
 Internally fired
 Horizontal
 Natural draught
 Natural circulation
 Widely used in sugar mills and chemical industries.
Construction
Its main features to make the brickwork setting is shown in the figure. Several rings of steel plates are
either welded or riveted to make the cylindrical shell of suitable dimension. This boiler has two parallel
flue pipes through out the length of boiler.
Both the flue tubes, which carry hot gasses, lay below the water level. To accommodate a grate of
sufficient area and minimum length, these flue tubes are larger in diameter at the front of the shell. To
control the gas flow and to control the amount of air entering the grate, dampers are used which are
placed in path of flue gases.
Working
Coal is fed to the grates through fire doors. Each of the flue tubes has its own furnace with grates where
its combustion takes place and the flue gases rising from the furnace pass over the fire bridge and
traverse along the horizontal part.
The hot gases leaving the grate pass up to the back end of the tubes and hen travel back from the bottom
flue passage to the front of boiler, where the gases bifurcate and pass into the two side flues. Thereafter,
the gases in the two side flues enter the common flue and finally discharged to the atmosphere through
chimney.
Advantages
 Simplicity of design
 Ease of operation
 Good steaming quality
 Can use coal of inferior quality
 Low maintenance and operating cost
Disadvantages
Need large reservoir of water
Figure: Lancashire Boiler
Locomotive Boiler
Working
In this section, we will take a look at the working principles of the steam engine used in locomotives.
Basically, solid fuel such as coal is burned to heat up water. When it gets hot enough, water will
condense into steam. The pressure of the steam pushes the pistons which consequently move the gears
and the wheels, thus moving the locomotive.
The Flow of the Steam and Gases

Solid fuel is burned on the grate inside the firebox. The primary air is admitted below the grate and is
drawn to the firebed while the secondary air is admitted through the firehole door. The firebrick arch
lengthens the path of the hot gases from the burning of the fuel to ensure complete combustion. The hot
gases are then drawn through long tubes in the boiler to the smokebox and out of the locomotive from
the chimney.
The heat from the firebox heats up the water in the boiler. Water is also heated by the heat from the hot
gases going through the long tubes. As water becomes hotter, it turns into saturated steam which collects
above the water. The regulator valve, which controls the passage of the steam to the cylinders, is situated
in the dome. There are also safety valves on top of the boiler to release steam if the pressure tends to rise
to a dangerous level.
The saturated steam flows through the main steam pipe to the superheater header. It then travels through
superheater element pipes in the boiler where it is heated up. After coming out of these pipes through the
superheater header, it will have become superheated steam. The extremely hot steam then flows through
steam pipes to the cylinders where its pressure moves the pistons which move the wheels of the
locomotive.
In the smokebox, exhaust steam passes through the blastpipe to the chimney at high speed due to the
confined vent of the blastpipe. This creates a partial vacuum in the smokebox which provides the draw
of the air to the firebox and ensures that the hot gases are drawn out of the firebox via the tubes in the
boiler.

Figure: Locomotive
Boiler
Review the method

to assemble boiler
Water Tube Boilers
Figure: Water Tube

Boiler
A water tube boiler

is a special type of
boiler where water
circulates in small
pipes. These pipes
are heated by a
furnace inside of the
heater. The water
will circulate inside
of these pipes. The
hated water will change to steam phase and it will hit and rotate a turbine. Meanwhile, the smoke and
exhaust that produce by furnace will release through chimney.
Advantages
1. Generation of steam is much quicker due to small ratio of water content to steam content. This also
helps in reaching the steaming temperature in short time.
2. The evaporative capacity is considerably larger and the steam pressure range is also high-200 bar.
3. Heating surfaces are more effective as the hot gases travel at right angles to the direction of water
flow.
4. The combustion efficiency is higher because complete combustion of fuel is possible as the
combustion space is much larger.
5. The thermal stresses in the boiler parts are less as different parts of the boiler remain at uniform
temperature due to quick circulation of water.
6. Damage due to the bursting of water tube is less serious. Therefore, water tube boilers are
sometimes called safety boilers.
7. All parts of the water tube boilers are easily accessible for cleaning, inspecting and repairing.
8. The water tube boiler's furnace area can be easily altered to meet the fuel requirements.
Disadvantages
1. It is less suitable for impure and sedimentary water, as a small deposit of scale may cause the
overheating and bursting of tube. Therefore, use of pure feed water is essential.
2. They require careful attention. The maintenance costs are higher.
3. Failure in feed water supply even for short period is liable to make the boiler over-heated
Various Water Tube Boiler
Babcock Wilcox Boiler
Figure: Babcock
Wilcox Boiler.
Characteristic:
 Horizontal
Boiler
 Muli tube Boiler
 Water tube
Boiler
 Straight tube
Boiler
 Externally
Boiler
 Multi tube
Boiler
 Natural draft
Boiler
 Natural circulation Boiler
 Coal fired Boiler

 Stationary Boiler
 Low & Medium pressure Boiler
Construction:
Babcock and Wilcox boiler with longitudinal drum. It consists of a drum connected to a series of front
end and rear end header by short riser tubes. To these headers are connected a series of inclined water
tubes of solid drawn mild steel. The angle of inclination of the water tubes to the horizontal is about 15°
or more.
Working:
The fire door the fuel is supplied to grate where it is burnt. The hot gases are forced to move upwards
between the tubes by baffle plates provided. The water from the drum flows through the inclined tubes
via down take header and goes back into the shell in the form of water and steam via uptake header. The
steam gets collected in the steam space of the drum. The steam then enters through the antipriming pipe
and flows in the superheater tubes where it is further heated and is finally taken out through the main
stop valve and supplied to the Steam turbine or Steam engine when needed.
The pressure of steam in case of cross drum boiler may be as high as 100 bar and steaming capacity upto
27000 kg/h.At the lowest point of the boiler is provided a mud collector to remove the mud particles
through a blow-dawn-cock.
Advantages:
It uses both solid as well as liquid fuel for burning.
The drought losses as compared to other boiler in minimum.
As compared to other boiler the evaporation capacity is high.
The circulation of water is natural.
The defective tubes can be replaced easily.
It is used in power stations for generation large quantity of steam.
La Mont Boiler
A forced circulation boiler was first introduced in 1925 by La Mont. The arrangement of water
circulation and different components are shown in figure below.
Working
The feed water from hot well is supplied to a storage and separating drum (boiler) through the
economizer. Most of the sensible heat is supplied to the feed water passing through the economizer. A
pump circulates the water at a rate 8 to 10 times the mass of steam evaporated. This water is circulated
through the evaporator tubes and the part of the vapour is separated in the separator drum. The large
quantity of water circulated (10 times that of evaporation) prevents the tubes from being overheated

Figure: La Mont
Boiler
The centrifugal pump

delivers the water to
the headers at a
pressure of 2.5 bar
above the drum
pressure. The
distribution headers
distribute the water
through the nozzle into
the evaporator.
The steam separated in
the boiler is further
passed through the
super-heater.
Secure a uniform flow

of feed water through
each of the parallel boiler circuits a choke is fitted
entrance to each circuit. These boilers have been built to generate 45 to 50 tonnes of superheated steam
at a pressure of 120 bar and temperature of 500°C.
Benson Boiler
The main difficulty experienced in the La Mont boiler is the formation and attachment of bubbles
on the inner surfaces of the heating tubes. The attached bubbles reduce the heat flow and steam
generation as it offers higher thermal resistance compared to water film.
1. Benson in 1922 argued that if the boiler pressure was raised to critical pressure (225 atm.), the
steam and water would have the same density and therefore the danger of bubble formation can be
completely.
2. Natural circulation boilers require expansion joints but these are not required for Benson as the
pipes are welded. The erection of Benson boiler is easier and quicker as all the parts are welded at
site and workshop job of tube expansion is altogether avoided.
3. The transport of Benson boiler parts is easy as no drums are required and majority of the parts are
carried to the site without pre-assembly.
4. The Benson boiler can be erected in a comparatively smaller floor area. The space problem does not
control the size of Benson boiler used.
5. The furnace walls of the boiler can be more efficiently protected by using small diameter and close
pitched tubes.
6. The superheater in the Benson boiler is an integral part of forced circulation system, therefore no
special starting arrangement for superheater is required.
7. The Benson boiler can be started very quickly because of welded joints.
8. The Benson boiler can be operated most economically by varying the temperature and pressure at
partial loads and overloads. The desired temperature can also be maintained constant at any
pressure.
9. Sudden fall of demand creates circulation problems due to bubble formation in the natural
circulation boiler which never occurs in Benson boiler. This feature of insensitiveness to load
fluctuations makes it more suitable for grid power station as it has better adaptive capacity to meet
sudden load fluctuations.
10. The blow-down losses of Benson boiler are hardly 4% of natural circulation boilers of same
capacity.
11. Explosion hazards are not at all severe as it consists of only tubes of small diameter and has very
little storage capacity compared to drum type boiler.
12. During starting, the water is passed through the economiser, evaporator, superheater and back to the
feed line via starting valve A. During starting the valve B is closed. As the steam generation starts
and it becomes superheated, the valve A is closed and the valve B is opened.
13. During starting, first circulating pumps are started and then the burners are started to avoid the
overheating of evaporator and superheater tubes.
Loeffler Boiler
The major difficulty experienced in Benson boiler is the deposition of salt and sediment on the inner
surfaces of the water tubes. The deposition reduced the heat transfer and ultimately the generating
capacity. This further increased the danger of overheating the tubes due to salt deposition as it has high
thermal resistance.
The difficulty was solved in Loeffler boiler by preventing the flow of water into the boiler tubes. Most
of the steam is generated outside from the feedwater using part of the superheated steam coming
out from the boiler.
The pressure feed pump draws the water through the economiser and delivers it into the evaporator
drum as shown in the figure. About 65% of the steam coming out of superheater is passed through the
evaporator drum in order to evaporate the feed water coming from economiser.
The steam circulating pump draws the saturated steam from the evaporator drum and is passed through
the radiant superheater and then connective superheater. About 35% of the steam coming out from the
superheater is supplied to the H.P. steam turbine. The steam coming out from H.P. turbine is passed
through reheater before supplying to L.P. turbine as shown in the figure.
The amount of steam generated in the evaporator drum is equal to the steam tapped (65%) from
the superheater. The nozzles which distribute the superheated steam through the water into the
evaporator drum are of special design to avoid priming and noise.
This boiler can carry higher salt concentration than any other type and is more compact than indirectly
heated boilers having natural circulation. These qualities fit it for land or sea transport power generation.
Loeffler boilers with generating capacity of 94.5 tonnes/hr and operating at 140 bar have already been
commissioned.

Figure:
Loeffler
Boiler
5.10.5.
VELOX-
BOILER
Now, it is
known fact that
when the gas
velocity
exceeds the
sound-velocity,
the heat is
transferred
from the gas at
a much higher
rate than rates
achieved with
sub-sonic flow.
The advantages
of this
theory are taken to effect the large heat transfer from a smaller surface area in this boiler.

Figure: Velox Boiler
Air is compressed to 2.5 bar with an help of a compressor run by gas turbine before supplying to
the combustion chamber to get the supersonic velocity of the gases passing through the combustion
chamber and gas tubes and high heat release rates (40 MW/m3). The burned gases in the combustion
chamber are passed through the annulus (is a ring-shaped object, especially a region bounded by two
concentric circles) of the tubes as shown in figure. The heat is transferred from gases to water while
passing through the annulus to generate the steam. The mixture of water and steam thus formed then
passes into a separator which is so designed that the mixture enters with a spiral flow.
Figure: Annulus Tube
The centrifugal force thus

produced causes the
heavier water particles to
be thrown outward on the
walls. This effect separates
the steam from water. The
separated steam is further
passed to superheater
and then supplied to the prime-mover. The water removed from steam in the separator is again passed
into the water tubes with the help of a pump.
The gases coming out from the annulus at the top are further passed over the superheater where
its heat is used-for superheating the steam. The gases coming out of superheater are used to run a gas
turbine as they carry sufficient kinetic energy. The power output of the gas turbine is used to run the air
compressor.
The exhaust gases coming out from the gas turbine are passed through the economiser to utilise the
remaining heat of the gases. The extra power required to run the compressor is supplied with
the help of electric motor. Feed water of 10 to 20 times the weight of steam generated is circulated
through the tubes with the help of water circulating pump. This prevents the overheating of metal walls.
The size of the velox boiler is limited to 100 tons per hour because 400 KW is required to run the
air compressor at this output. The power developed by the gas turbine is not sufficient to run the
compressor and therefore some power from external source must be supplied as mentioned above.
Advantages
1. Very high combustion rates are possible as 40 MJ/m3 of combustion chamber volume.
2. Low excess air is required as the pressurised air is used and the problem of draught is simplified.
3. It is very compact generating unit and has greater flexibility.
4. It can be quickly started even though the separator has a storage capacity of about 10% of the
maximum hourly output.
Compare the use of different types of drum
There are several classifications for water tube boiler. But, usually it classified by the tube design.
a) Straight tube
b) Bent tube
The figure above shows straight water tube boiler. The tube can arrange vertically as the figure above or
can arrange horizontal or inclined.
But, nowadays, straight water tube boiler is less popular than bent water tube boiler. The bent tube can
make the boiler more efficient because the the extra tube can be placed on hot gases flow. That can
increase surface area of heated water. So, it will increase heat transfer rate from hot gases to the water
inside the tube. This situation will increase thermal efficiency of the boiler.
Figure below show example of bent water tube boiler.
Babcock Wilcock Boiler
Unlike solid construction and

compact design of fire tube
boiler, water tube boiler design
usually at a large scale.
Therefore, the hot gases has a
tendency to waste to
surroundings. So, baffle was use
around the boiler system to prevent the hot gasses waste to surroundings. Besides, the baffle was used to
control hot gases flow so it will go to certain water tubes. Usually baffle was made from a brick or/and
steel plate.
The tubes in water tube boilers usually will arrange closely. It will give more space for additional tube.
This situation will give more heating surface. This arrangement seems to be forming a layer of the wall.
The inside tube surface that facing a water call water wall. Meanwhile the outside tube surface that
facing hot gasses call fire wall. The layer of tube usually has a percise design and CNC machine was use
to fabricate it.
Types of Steam Drums

ﾧ
Boiler steam drum
1 Three drum ﾧ/ Four drum boilers - Are the veterans of the normal day boilers,
although they are still used in some industries.
2 Bi drum boiler - are used for power generation and steam generation both. For
power generation they are used now seldom and are replaced by single drum boilers
as the bi drum boilers are non-reheat units. So, due to the high heat rate of the
plant a single drum boiler or a once through boiler is more feasible. In process
steam generation the bi drum boilers are used commonly as they can adapt to the
high load fluctuation and respond to load changes.
3 Single drum boiler- used mainly for the power plants for power generation. The
pressure limit for single drum boilers is higher than that of the bi drum boilers
as the stress concentration is reduced to a greater extent. There exists only one
drum and the downcomers are welded to it. Single drum boilers are suitable and
can adapt to both reheat and non-reheat type of boilers. They can be designed as
Corner tube boiler ﾧ where the frame is not required as the downcomers itself serves
the purpose of it and also they are designed as top supported where the whole
boiler assembly needs an external frame and supported by top drum.
Water tube arragment Benson

Boiler

STEAM TURBINE
Steam turbine is prime movers which continuously convert the energy of high pressure, high
temperature steam supplied by a steam generator into shaft work with the low temperature steam
exhausted to a condenser.
As simpler definition, a steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into rotary motion
This energy conversion essentially occurs in two steps:

 The high pressure, high temperature steam first expands in nozzle and comes out at a high
velocity
 The high velocity jets of steam coming out of the nozzle, impinge on the blades mounted on a
wheel, get deflected by an angle and suffer a loss of momentum which is absorbed by the
rotating wheel in producing torque.
A steam turbine is basically an assemblage of nozzle and blades.
Figure: A
rotor of a
modern steam
turbine, used
in a power
plant
An impulse
turbine has
fixed nozzles
that orient the
steam flow into
high speed jets.
These jets
contain
significant
kinetic energy,
which the rotor
blades, shaped
like buckets,
convert into
shaft rotation as the steam jet changes direction. A pressure drop occurs across only the stationary
blades, with a net increase in steam velocity across the stage.
As the steam flows through the nozzle its pressure falls from inlet pressure to the exit pressure
(atmospheric pressure, or more usually, the condenser vacuum). Due to this higher ratio of expansion of
steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving the moving
blades has a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of
energy due to this higher exit velocity is commonly called the "carry over velocity" or "leaving loss".
Figure: Impulse
steam turbine
Figure: Impluse turbine cross-sectional
3.0 Reaction Steam Turbine

In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles. This type
of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed
by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet
that fills the entire circumference of the rotor. The steam then changes direction and increases its speed
relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net change in steam velocity
across the stage but with a decrease in both pressure and temperature, reflecting the work performed in
the driving of the rotor.
Figure:
Reaction turbine concept
If high velocity of steam is allowed to flow through one row of moving blades, it produces a rotor speed
of about 30000 rpm which is too high for practical use. It is therefore essential to incorporate some
improvements for practical use and also to achieve high performance. This is possible by making use of
more than one set of nozzles, and rotors, in a series, keyed to the shaft so that either the steam pressure
or the jet velocity is absorbed by the turbine in stages. This is called compounding. Three types of
compounding can be accomplished:
(a) Velocity compounding
(b) Pressure compounding
(c) Pressure-Velocity compounding
Either of the above methods is used to reduce the high rotational speed of the single stage turbine.
4.1 The Velocity Compounding of the Impulse Turbine
Rings of moving blades separated by rings of fixed blades, are keyed in series' on the turbine shaft,
figure below. The steam is expanded through nozzles from the boiler-to the back-pressure, to a high
velocity, and is then passd over the first ring of moving blades. Only a portion of the high velocity is
absorbed, the remainder being exhausted on to the next ring of fixed blades, which change the steam
direction without appreciably altering the velocity. The jet then passes on to the next ring of moving
blades, the process repeating itself until practically all the velocity of the jet has been absorbed. It will be
noticed that, due to the pressure remaining constant as the steam passes over the blades, the turbine is an
impulse turbine.
Figure: Velocity Compounding
4.2 The Pressure Compounded Impulse Turbine
In this type, the total pressure drop of the steam does not take ' place in the first nozzle ring, but is
divided up between all the nozzle rings. The steam from the boiler is passed through the first nozzle ring
in which it is only partially expanded. It then passes over the first moving blade ring where nearly all of
its velocity is absorbed. From this ring it exhausts into the next nozzle ring and is again partially
expanded; this absorbs a further portion of its total pressure drop. It then passes over the second ring of
moving blades, the process thereby repeating itself. As the pressure remains constant during the flow

over the moving blades, the turbine is an impulse turbine. This method of pressure compounding is used
in Rateau and Zoely turbines.
Figure: Pressure Compounding
4.4 The Pressure - Velocity Compounded Impulse Turbine
In this type of turbine, both of the previous two methods are utilised. This has the advantage of allowing
a bigger pressure drop in each stage and, consequently, less stages are necessary, resulting in a shorter
turbine for a given pressure drop. It may be seen that the pressure is constant during each stage; the
turbine is, therefore, an impulse turbine. The method of pressure-velocity compounding is used in the
Curtis turbine.

Pressure – Volocity
Compounding
1.6.4 Describe various

application of steam
turbine
1.7 Explain heat saving

instrument in steam power
plant 1.7.1 Explain Steam
Purifier 1.7.2 Explain
Super heater 1.7.3 Justify
methods of controlling the
super heater temperature
1.7.4 Explain Feed Water
Heater 1.7.5 Explain
Economizer 1.7.6 Explain
Air Pre-heater 1.7.7
Explain the use of soot
blower 1.7.8 Explain the use
of steam trap
Injap tiup turun digunakan

untuk membuang air
dandang secara keseluruhan atau membuang mendapan dan bendasing yang mendak di bahagian bawah
dandang. Injap ini diletakkan di bahagian dandang yang paling bawah.
1.1 PERALATAN PENJIMATAN HABA LOJI KUASA STIM
Haba merupakan sumber tenaga loji kuasa stim. Memandangkan bahan api fosil semakin berkurangan
dari hari ke hari, maka amatlah penting untuk menguruskan bahan api dan tenaga haba dengan betul.
Pengurusan haba dandang boleh dibantu dengan penggunaan beberapa peralatan yang khusus.
Antaranya:-
1.6.1 Perangkap stim
A steam trap is a mechanical device that uses to separate a pure steam with a air and condensation steam.
Perangkap stim adalah suatu peralatan mekanikal yang digunakan untuk memisahkan stim tulen dengan
udara dan stim yang terkondensasi.
Ini berlaku dengan menghentikan aliran stim secara automatik. Oleh itu tenaga haba dapat dipindahkan
dan udara dan stim yang terkondensasi boleh dikeluarkan dari system.
Perangkap stim biasanya diletakkan pada salur paip stim seperti pada penukar haba, dan sebelum turbin.

1.6.2 Superheater
Superheater was use in steam power plant to change wet steam to dry steam. The dry steam was
important to increase steam velocity and make it powerfull enough to hit turbine blade. The was two
type of superheater, there was convection and radiant.
1.6.3 Feed water heater
Pemanas air suapan berfungsi untuk memanaskan dahulu air sebelum dimasukkan ke dalam dandang. Ini
penting untuk penjimatan bahan bakar. Dengan air panas yang memasuki dandang, dandang tidak perlu
bekerja keras dan menunggu lama untuk menukarkan air kepada stim.
Terdapat dua jenis pemanas air suapan, iaitu:-

i) Jenis terbuka
ii) Jenis tertutup
1.6.4 Penjimat
Konsep penjimat atau penukar haba hamper sama dengan pemanas air suapan. Bezanya, air dari tangki
air akan melalui cerobong yang mengalirkan haba ekzos yang panas dari relau. Pergerakan ini akan
menyebabkan haba panas ekzos relau akan dipindahkan ke air dari tangki. Seterusnya, air tersebut akan
dimasukkan kembali ke dalam dandang.
1.6.5 Pra-pemanas udara
Pra- pemanas udara digunakan untuk memanaskan udara yang membantu pembakaran dalam relau.
Dengan udara panas ini, bahan bakar lebih mudah terbakar, dan pembakaran akan menjadi lebih
lengkap. Pembakaran yang lengkap ini akan meningkatkan kecekapan dandang untuk menukarkan air
kepada stim.
1.7 UJIAN DAN RAWATAN AIR DANDANG
1.7.3 Kesan air dandang yang tidak di rawat.
Air yang tidak dirawat akan menghasilkan kesan negatif terhadap dandang. Antaranya
1.7.3.1 Bawa sebelah (carry over)
Diistilahkan sebagai satu keadaan dimana air dan partikel kandungan air (terutamanya jika tidak
dirawat) dari dandang akan naik bersama stim ke saluran stim dan seterusnya air ini bersama partikel
akan dibawa sehinggalah ke turbin. Hal ini akan memendekkan jangka hayat turbin kerana ketumpatan
stim telah berubah kerana telah bercampur dengan air dan partikel. Situasi pembawaan air ke bahagian
sebelah stim itulah yang dinamakan bawa sebelah.

Fenomena bawa sebelah ini juga boleh berlaku apabila tiub-tiub air menjadi sempit. Hal tersebut
disebabkan oleh saluran tiub yang menjadi kecil akibat sisik dan enap cemar yang terhasil akibat dari air
yang tidak dirawat. Situasi tersebut akan mendorong paras air tinggi dan menggalakkan air untuk
tertolak masuk ke saluran stim.
1.7.3.2 Penyebuan (priming)
Istilah dan fenomena penyebuan mirip bawa sebelah. Cuma, ia berlaku akibat keadaan air yang berkocak
di dalam dandang, selain dari paras air yang tinggi akibat dari sisik dan enap cemar. Selain dari masalah
air tidak dirawat, penyebuan boleh terjadi akibat kadar pembakaran dandang yang berubah-ubah.
Masalah priming boleh diselesaikan dengan merawat air dengan betul, dan meletakkan perangkap stim
pada saluran stim.
1.7.3.3 Pembusaan (foaming)
Pembusaan berlaku apabila wujudnya buih dalam ruangan stim dalam dandang. Hal tersebut akan
menyebabkan pengoksidaan berlaku dan boleh menghakis tiub dandang. Buih tersebut terjadi akibat dari
bendasing, mendakan dan partikel yang tak boleh larut ada dalam kandungan air yang tidak dirawat.
Juga, ia berlaku akibat keadaan air dandang yang terlalu alkali.
1.7.4 Pemeriksaan ke atas tiub dan kebuk dandang
1.7.4.1 Kesan minyak

1.7.4.2 Kakisan
1.7.5 Mengatasi masalah akibat kesan minyak dan kakisan
1.7.6 Pengedaran semulajadi air dandang.
1.8 CUCI ALIR DAN PEMERIKSAAN DANDANG
1.8.1 Tujuan cuci alir dalam kendalian dandang

1.8.2 Ujian BOD
1.8.3 Ujian COD
1.8.4 Langkah menyediakan dandang untuk sesuatu pemeriksaan
a) Buang air dandang dan basuh dandang sekali lalu.
b) Tanggalkan plat manhole dan handhole, cuci palam dan sambungan tiang air. Bersihkan
relau dan kebuk pembakaran.
c) Tanggalkan semua besi penghalang
d) Buang sebahagian batu-batu sekeliling dandang bagi membolehkan pemeriksa memasuki
dandang dan memeriksa keadaan relau dan tiang-tiang sokongan dandang.
e) Cut off any leakage of hot water into the boiler by disconnecting pipes or valve.
1.8.5 Langkah-langkah ujian hidrostatik dan pemeriksaan dandang berdasarkan

Akta Kilang dan Jentera.

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POWER PLANT TECHNOLOGY STEAM POWER PLANT

STEAM POWER PLANT

Steam power plant basic layout and equipment

Steam power plant

Water filled into boiler and

Boiler actually is such as closed

ROSHAIZUL NIZAM BIN MOHD SANI

The steam that rotate the

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Fuel and handling system

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Once broken down,

The coal pile can

High Pressure vs Low Pressure Boiler

Low-Pressure Boiler Definition

Low-Pressure Boiler Uses

High-Pressure Boiler Definition

High-Pressure Boiler Uses

Boiler Mounting and Fittings

ROSHAIZUL NIZAM BIN MOHD SANI

Steam pressure from boiler

Relief valve has a

ROSHAIZUL NIZAM BIN MOHD SANI

ROSHAIZUL NIZAM BIN MOHD SANI

ROSHAIZUL NIZAM BIN MOHD SANI

Steam Pressure gauge

The dial should be at least

Pressure gauges are

ROSHAIZUL NIZAM BIN MOHD SANI

Blow down valve

Blow down valve was

Cross - section of typical

Boiler feed pumps

ROSHAIZUL NIZAM BIN MOHD SANI

Boiler feed pump

Boiler stop valves

The stop valve is not

The type of this valve can be installed in superheater outlet.

ROSHAIZUL NIZAM BIN MOHD SANI

Boiler stop valve

The check valve

Boiler check valve

ROSHAIZUL NIZAM BIN MOHD SANI

Location of feed check

The attachment for an

Low Water Alarm

ROSHAIZUL NIZAM BIN MOHD SANI

Typical Water Alarm

High Water Alarm

The dangers of an excessively

All of these, taken together, can result in:

A high water condition could:

ROSHAIZUL NIZAM BIN MOHD SANI

The action to be taken largely depends on the individual plant requirements.

Low Water Cut Off

Manufacturer's Name Plate

ROSHAIZUL NIZAM BIN MOHD SANI

Manufacturer's Name Plate

The purpose of registration

ROSHAIZUL NIZAM BIN MOHD SANI

Natural Boiler Water Circulation

Natural Boiler Water

Cooler feedwater is introduced