Why pressure reducing of steam is being done before de-super heating?

 Following advantages we can have, if pressure reducing is done before de-super heating

1.  Reducing the pressure before de-super heating helps in controlling the steam temperature with great accuracy.High-pressure steam entering the de-superheating station can be challenging to control accurately due to its high energy content. By reducing the pressure, the energy content decreases, allowing for better control of the de-superheating process and ensuring that the desired steam temperature is achieved.
2.  Heat transfer between water & steam is more better at lower pressure
3.  Helps is protecting the down stream equipment if desuper heating is done at lower pressure since there will not be no any much chances of low or high temperature steam entry into the Turbine or process.
4.  Erosion of down stream pipe lines can be minimized due to high pressure & high velocity steam
5.  Cost of high pressure lines can be reduced.
6.  Total head required for de-superheating water will be reduced, thereby reducing feed pump pumping power.
7.  Related cost of control valves & pipe lines will be reduced
8.  Damage to the de-super heating equipment can be reduced by avoiding thermal shock by avoiding direct mixing of high pressure steam and high pressure water
9.  Pressure reduction before the de-superheating station helps maintain safe operating condition.High-pressure steam carries a greater risk of causing damage or injury in the event of a malfunction or sudden pressure surge. By reducing the pressure beforehand, the risk of high-pressure steam reaching the de-superheating station is mitigated, enhancing overall system safety.
10.  Pressure reduction can also contribute to overall system efficiency. Lowering the pressure before the de-superheating station helps control the temperature more effectively, resulting in more efficient heat transfer and reduced energy consumption.
11. Reducing the pressure before de super heating will also helps in reducing the temperature of steam, which helps in reduction of water quantity required for desuper heating

 

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Questions and answers on Thermic fluid heaters

 

What is Thermic fluid heater?

A thermic fluid heater, also known as a thermal oil heater or hot oil heater, is  used to heat a process fluid to a specific temperature using thermal energy. It operates by circulating a heat transfer fluid, commonly referred to as a thermic fluid or thermal oil, through a closed-loop system.

 What is meant by heat transfer fluid in Thermic fluid heaters?

 A specialized heat transfer fluid, often a mineral-based or synthetic oil, is used as the medium to transfer heat. It has high thermal stability and a high boiling point to ensure efficient heat transfer and safe operation at elevated temperatures.

 What type of combustion chamber is used in Thermic fluid heaters? & how heat generation starts?

 A thermic fluid heater is equipped with a combustion system, which can use various fuels such as natural gas, diesel, heavy oil, coal, or biomass. The fuel is burned in a burner assembly to generate heat.

 How does heat exchanger takes role in Thermic fluid heaters?

 The heat exchanger is the core component of a thermic fluid heater. It consists of a coil or tube bundle immersed in the thermic fluid. The hot combustion gases pass through the coil, transferring their heat to the fluid. This process raises the temperature of the thermic fluid.

The heat generated from the combustion process is transferred to the thermic fluid. The hot flue gases and combustion products flow over the surface of a coil or heat exchanger immersed in the furnace. The coil or heat exchanger is filled with the thermic fluid, which absorbs the heat from the hot gases.

 How does circulation of thermic fluid happens in Thermic fluid heaters?

 The thermic fluid, now heated, circulates through the coil or heat exchanger via a circulation pump. The pump provides the necessary pressure to move the fluid through the system.

 How does heat is being utilized from Thermic fluid?

 The heated thermic fluid carries the absorbed heat to the point of application or process equipment where heat is required. This could be reactors, dryers, presses, or any other heat-consuming equipment.

At the point of application, the thermic fluid transfers its heat to the process equipment or medium, raising its temperature as needed. The thermic fluid's temperature decreases as it gives up its heat energy to the process.

The cooled thermic fluid returns to the heater through a separate return line. In the heater, the thermic fluid is reheated by passing through the heat exchanger or coil, where it once again absorbs heat from the combustion process.

 What is the function of expansion tank in Thermic fluid heaters?

 A thermic fluid heater system typically includes an expansion tank to accommodate the expansion and contraction of the thermic fluid as it is heated and cooled during operation. It helps maintain the desired fluid volume and prevents excessive pressure build-up in the system.

 What is the significance of Control system in Thermic fluid heaters?

 A control system is employed to regulate the heating process, including temperature control, fuel supply, and safety features. It ensures precise temperature control and monitors various parameters to maintain safe and efficient operation.

The temperature of the thermic fluid is controlled and maintained within a desired range using temperature control systems. The system may include temperature sensors, control valves, burner modulation, and circulation pump speed control to regulate the fluid temperature.

 What are the various applications of Thermic fluid heaters?

 Thermic fluid heaters found applications in chemical, pharmaceutical, textile, food processing, and oil and gas.

 What are the main advantages of Thermic fluid heaters?

• High temperature accuracy,
• Efficient heat transfer,
• Versatility in fuel options, and the
• Ability to provide uniform heating over large areas.

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How do you calculate the work done & specific steam consumption of a back pressure steam turbine?

 

In back pressure turbines, steam just inters through HP valves & exists through exhaust, no any bleed or condensation is done.

The efficiency of the back pressure turbines is more as compared to condensate & condensate cum extraction steam turbines. However specific steam consumption of back pressure turbines is very less as compared to above both type of Turbines

 How do you calculate the work done per kg of steam?

 Let us assume 1 kg/sec of steam is entering into Turbine whose enthalpy is H1 kcal/kg & existing from turbine at enthalpy H2 kcal/kg

Then, work done per kg of steam is given as =(H1-H2) kcal/s

Or 4.18 X (H1-H2) KW, since 1 KJ/sec = 1 KW

 How do you calculate specific steam consumption of a back pressure Turbine?

 Specific steam consumption is defined as the amount of steam consumed to generate 1 KW of power

 SSC = 860 / (Difference in inlet & exhaust enthalpy)

 i.e 860 / (H1-H2)

 A back pressure turbine is operating at pressure & temperature 64 kg/cm2 and 490 deg C respectively, the exhaust steam at pressure 2 kg/cm2& temperature 140 deg C is being used for process.Calculate the work done and specific steam consumption?

 Enthalpy of inlet steam at pressure & temperature 64 kg/cm2 and 490 deg C  = 809 kcal/kg

 Enthalpy of inlet steam at pressure & temperature 2 kg/cm2 and 140 deg C  = 660 kcal/kg

 Work done = (809-660) = 149 kcal/sec

Or 4.18 X 149 = 622.82 kJ/kg or 622.82 KW

Specific steam consumption SSC = 860 / (Difference in inlet & exhaust enthalpy)

SSC = 860 / 149 = 5.78 kg/kw or MT/MW

 A back pressure turbine having inlet steam enthalpy and exhaust enthalpy 780 kcal/kg & 580 kcal/kg, then calculate the specific steam consumption of that Turbine?

 SSC = 860 / (Difference in inlet & exhaust enthalpy)

SSC = 860 / (780-580)

SSC =4.3 MT/MW

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What are the various interlocks used in Boilers??

 

1.What do you mean by Interlocks?

 Interlocks are the programmed or hardwired control system made to protect the machine or system from damages or disturbances

Interlocks and protections involve sensors, cables, wires, local push buttons, logics, timers, probes etc.

 2.What is the significance of interlocks?

 Significance of interlocks;

• To protect the system against damages/disturbance
• To protect the equipment
• To avoid damages to the man and machine
• To avoid operation disturbances

 3.What are the various protections used in Boilers?

• High drum level trip
• Low drum level trip
• High main steam pressure trip
• High positive draught trip
• High negative draught trip
• High main steam temperature trip

 4.What are the various interlocks provided for Boiler feed pumps?

 Boiler feed pumps trip on acting following interlocks

• Low de-aerator level
• High bearing vibration
• High bearing temperature
• High feed water temperature at suction
• High drum level

 5.Write a brief note on Boiler interlocks

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Sl No.	Interlock	Significance
1	High drum level-FD fans trip followed by fuel feeding system & ID fans	To avoid carryover of water particles in steam To avoid thermal shock to super heater coils
2	Low drum level-FD fans trip followed by fuel feeding system & ID fans	To avoid over heating of pressure parts due to lack of water
3	FD fans trip-Fuel feeding system trip	To avoid jamming of fuel feeding system & grate
4	High furnace draught-FD & SA fans trip	To avoid furnace explosion
5	Low furnace draught-ID fans trip	To avoid explosion of ESP & related ducts to vacuum pressure
6	High main steam pressure-Boiler trips (FD & fuel feeding system)	To avoid failure of pressure parts due to high steam pressure
7	High main steam temperature-Boiler trips (FD & fuel feeding system)	To avoid failure of pressure parts due to high steam temperature
8	PA fan trips- Fuel feeding system trips	To avoid jamming of fuel feeding system
9	High main steam pressure-Start up vent CV auto open	To avoid failure of pressure parts due to high steam pressure

 

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11-differences between star connection and delta connections

 

11-differences between start connection and delta connections

Sl No.	Star connection	Delta connection
1	Two types of star connections are possible A-4-wire, 3-phase system B-3 wire. 3-phase system	Only 3 wire. 3-phase system is possible
2	Out of 4 wires, 3 wires are the phases and one is neutral	All 3 wires are phases in Delta connection
3	In Star  connection, one end of all the three wires are connected to a common point in the shape of Y to form neutral	In Delta connection every wire is connected to two adjacent wires in the form of triangle.And all the three common points of the connection form the three phases
4	Line current and phase currents are same	Line current and phase current are different.Line current =√Phase current
5	Line voltage and phase voltages are different, Line voltage =√Phase voltage	Line voltage and phase voltages are same
6	Since line voltage is more than phase voltage, insulation required for each phase is less	In Delta connection line and phase voltages are same hence more insulation is required
7	Star connections are used for both transmission and distribution applications/networks	This connection is generally used for distribution networks
8	Since insulation required is less, these connections are used for longer distances	Since insulation required is more, these connections are used for shorter distances
9	Star  connections are used where less starting current and starting torque is required	Delta connections are used where starting current and Torque is more
10	Power calculation in Start connections.   P = 3 X Vp X Ip X Cosθ   Or   P = (√3 X VL) X IL X Cosθ	Power calculation in Delta connections.   P = 3 X Vp X Ip X Cosθ   Or   P = (√3 X IL) X VL X Cosθ
11	In star connections different voltage levels are used as line voltage & phase voltages are different	In Delta connections, only single voltage is used

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IBR STANDARD INSPECTION PROCEDURES

 

A-Standard Inspection procedure for Dry & thorough inspection

• Checking the registration number of the Boilers
• Carryout thorough inspection of Boiler from both inside and out side
• Check for defects like corrosion, erosion, bend, bulging, pitting, deformation, thermal expansion etc of pressure parts
• Check thickness of pressure parts
• Check the conditions of mountings & fittings
• Witness non destructive tests if required

B-Standard procedure for ground inspection of pressure parts under erection

• Verification of documents of pressure parts with relevant certificates
• Verification of approved drawings
• Checking pressure parts makers stamp & other identification marks with form no-II
• Checking of leading dimension of the parts & comparing with approved drawings
• Checking general condition of the pressure parts like dent marks, pitting, bend etc
• Checking of fittings & mountings with relevant drawings

C-Standard procedure for material inspection

• Verification of the approved drawings corresponding to the materials & documents
• Checking of the pressure parts materials with relevant IBR certificate and  approved drawing.Check name of the material, its specification, heat no, cast no.class, size, identification number & stamping etc
• Checking of leading dimension of the parts & comparing with approved drawings
• Checking general condition of the pressure parts like dent marks, pitting, bend etc
• Selection of samples for physical and chemical analysis/testing

D-Standard Procedure for weld set up inspection

• Verification of approved drawing
• Verification of Welder’s certificate
• Verification of the certificates of welding consumables
• Verification of the approval of contractor for particular job
• Verification for the procedure of welding procedure
• Verification for the site satisfactory  simulation test results
• Verification of test results of pipe, tube or plates
• Checking of root gap,weld groove profile and alignment of the pressure parts to be welded as per approved drawing
• Ensure weld joint area to be welded is free from dust, dirt, oil & grease.And also ensure it is crack free
• Check weld joint identification number.

E-Standard Procedure for welding joint inspection

• Visual inspection of general condition of the weld joint like, slag, under cut, finish, surface crack, leg length etc
• Check alignment of the pressure parts
• Witnessing Dye penetrant test, magnetic particle inspection test & hardness tests if required
• Selection of weld joints for NDT test like ultrasonic & radio graphic tests

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F-Standard Procedure for Boiler Hydraulic tests

• Verification of the satisfactory non destructive tests of the welding joints
• Verification of PMI (Positive Material Identification) report of the weld joints
• Verification of pressure parts calculation approval
• Verification of all previous inspection reports and Post weld heat treatment (PWHT) charts
• Check the calibration reports of pressure gauges using for hydraulic test
• Witnessing Hydraulic test carried out as per IBR-1950
• Checking of deflection, distortion and extension of pressure parts during hydraulic test
• Thorough inspection of pressure parts for any leakages and sweating

G-Standard Procedure for Boiler steam tests

• Verification of the provisional order of the Boiler
• Witnessing the steam test carried out as per IBR-1950
• Check, popping pressure, reset pressure, blow down, accumulation, chattering, lift
• Checking of the performance of the mountings and fittings

 

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