ABSTRACT
Boilers Boilers are pressure pressure vessels designed to heat water or produce produce steam, which can then be used to provide space heating and/or service water heating to a building. In most commercial commercial building heating applications, applications, the heating source in the boiler boiler is a natural natural gas fired burner. Oil fired burners and electric resistance heaters can be used as well. Steam is preferred preferred over hot water in some applications, applications, including absorption absorption cooling, kitche kitchens, ns, laundr laundries, ies, steriliz sterilizers, ers, and steam steam driven driven equipm equipment ent.. Boiler Boilerss have have severa severall strengths that have made them a common feature of buildings. he! have a long life, can achieve efficiencies up to "#$ or greater, provide an effective method of heating a building, and in the case of steam s!stems, require little or no pumping energ!. energ!. %oweve %owever, r, fuel fuel costs costs can be consid considerab erable, le, regula regularr mainte maintenan nance ce is require required, d, and if maintenance is dela!ed, repair can be costl!. &uidance for the construction, operation, and maintenance maintenance of boilers is provided provided primaril! b! the 'S() 'S() *'merican Societ! of (echanical )ngineers+. Boilers are often one of the largest energ! users in a building. or ever! !ear a boiler s!stem goes unattended, boiler costs can increase appro-imatel! $. Boiler operation and maintenance is therefore a good place to start when looking for wa!s to reduce re duce energ! use and save mone!.
CONTENTS:
CHAPTER-1 INTRODUCTION
INTRODUCTION COMPANY PROFILE
ENMAX ENGINEERING (INDIA) PRIVATE LIMITED
HYDERABAD – 500 055, INDIA
R!"#$%& '" * +'%# S%./ 15, S%%2, 3$46% (M7&), R7!%&&/ (D$8), H/&%4& – 500 055, I7&"
P%'&$ %7! 180
+#$ 9$ %'.%/ #/#$2# '%
0
1rocess plants like Sulphuric acid plants, Sulphur recover! units, 2itric acid
plants, %!drogen plants, 'mmonia plants etc., 0
3oal based plants like 3oke oven plants
0
(etallurgical plants like Blast furnaces, 4inc plants, 5ead plants, 3opper plants
and Sponge iron plants etc.., 0
3arbon black industries
0
3ombined c!cle power plants like %6S& behind &as turbines and &as engines
0
3ement plants
0
7& &ensets
0
Incinerators
18
E7!"7%"7! ;"627$
0
7e8aerators cum feed water storage tanks,
0
Blow down s!stems
0
S3'1% *Steam coil air pre heaters+
0
51 heaters, (1 heaters and %1 heaters
0
Surface condensers and 7ump condensers
0
1ressure vessels
0
%eat e-changers
18<
B'"% #6%#
0
Bed coils *both plain 9 stud t!pe+
0
Super heater coils
0
)conomizer coils 9 bends
0
:ater wall panels
D#"!7# * S$7&%&#
:e design and manufacture the equipment as per codes like 0
'S()
0
IB6
0
BS
0
7I2
0
IS
0
67
M7$%"7! ""$"# )nma- is situated at Balanagar82arasapur state highwa! near ;eedimetla industrial area in %!derabad *India+. Situated in the heav! fabrication and engineering zone where all kind of facilities like transportation, heav! cranes for material handling, sub vendors for dish end manufacturing, plate rolling *higher thickness+ etc., are available. :orks is spread over < Sq !ards *both covered and un8covered+ area with ample natural and supporting lighting s!stem, ventilation, water, )lectric power and ambience. Shop 9 manufacturing facilities are approved b! Indian Boiler 6egulating authorities *IB6+, 5lo!ds and B=>I. )nma- is holding an ISO accreditation *"?@A+ through B=>I since @".
C96$%- B'"% I7$%'&$"'7
18INTRODUCTION OF BOILER ' boiler is a closed vessel in which water under pressure is transformed into steam b! the application of heat. In the boiler furnace, the chemical energ! in the fuel is converted into heat, and it is the function of the boiler to transfer this heat to the contained water in the most efficient manner. he boiler should also be designed to generate high qualit! steam for plant use. ' boiler must be designed to absorb the ma-imum amount of heat released in the process of combustion. his heat is transferred to the boiler water through radiation, conduction and convection. he relative percentage of each is dependent upon the t!pe of boiler, the designed heat transfer surface and the fuels. he boiler house or steam generation facilit! within an! given plant is frequentl! referred to as the heart. Boilers have several strengths that have made them a common feature of buildings. he! have a long life, can achieve efficiencies up to "#$ or greater, provide an effective method of heating a building, and in the case of steam s!stems, require little or no pumping energ!. %owever, fuel costs can be considerable, regular maintenance is required, and if maintenance is dela!ed, repair can be costl!.
Boilers are often one of the largest
energ! users in a building. or ever! !ear a boiler s!stem goes unattended, boiler costs can increase appro-imatel! $. Boiler operation and maintenance is therefore a good place to start when looking for wa!s to reduce energ! use and save mone!. &uidance for the construction, operation, and maintenance of boilers is provided primaril! b! the 'S() *'merican Societ! of (echanical )ngineers+.
F"!%(1):R%$'%/
81 DEFINITION OF BOILER . It is a closed vessel or arrangement of vessels and tubes, together with a furnace or other heat source, in which steam or other vapour is generated from water to drive turbines or engines, suppl! heat, process certain materials, etc. @. ' boiler is defined as a closed vessel in which water or other liquid is heated, steam or vapor is generated, steam is superheated, or an! combination thereof, under pressure or vacuum, for use e-ternal to itself, b! the direct application of energ! from the combustion of fuels, from electricit! or nuclear energ!. he boiler is not the heating s!stemC it is onl! one of the parts in the global heating s!stem.
8 CLASSIFICATION OF BOILER H'%"='7$, V%$" '% I7"7& ? 7epending upon the orientation of the a-is of a
boiler it can be classified as horizontal, vertical, or inclined. If the a-is of the boiler is horizontal, it is called horizontal boiler. If the a-is is vertical, it is called vertical boiler and if the a-is is inclined at an angle then it is called inclined boiler. F"% T4 7& +$% T4? In fire tube boilers, hot flue gases flows through the tubes and water
surrounds the tubes. )-amples? 3ochran, 5ancashire and 5ocomotive boilers. In water tube boilers, water flows inside the tube and hot flue gases surrounds the tubes. )-amples? Babcock and :ilco-, Stirling, Darrow boiler. E>$%7/ F"%& 7& I7$%7/ F"%& ? If the fire or burning of the fuel is done
outside the shell then it is called e-ternall! fired boiler. )-amples? Babcock and :ilco-, Stirling boiler. If the burning of fuel or the furnace is located inside the shell then it is called internall! fired boiler. )-ample? 3ochran, 5ancashire boiler. F'%& C"%$"'7 7& N$% C"%$"'7 ? In forced circulation boilers, a forced
pump is used for the circulation of water through the tubes. )-amples? =elo-, 5amont, Benson boilers. In natural circulation boilers, circulation of water takes place due to natural convection currents produced b! the application of heat. )-amples? Babcock and :ilco-, 5ancashire boiler. H"!9 P%##% 7& L'? P%##% B'"%# ? he boilers which produce steam at
pressures above A bar are called high pressure boilers. )-ample? =ole-, 5amont,
Benson, Babcock and :ilco- boilers. Boilers which produce steam at pressure below A bar are called low pressure boilers. )-ample? 3ochran, 5ancashire and 5ocomotive boilers. S$$"'7%/ 7& P'%$4? Boiler which are fi-ed at one place are called portable boilers like the boiler
used in power plants. 1ortable boilers are small in size and are used in locomotive t!pe, and temporar! on site purposes. here are two general t!pes of boilers? EEfire8tubeEE and EEwater8tubeEE. Boilers are classified as high8pressure or low8pressure and steam boiler or hot water boiler. Boilers that operate higher than # psig are called high8pressure boilers. ' hot water boiler, strictl! speaking, is not a boiler. It is a fuel8fired hot water heater. Because of its similarities in man! wa!s to a steam boiler, the term FFhot water boilerGG are used. %ot water boilers that have temperatures above @#H ahrenheit
•
or pressures higher than < psig are called EEhigh temperature hot water boilersEE. %otwater boilers that have temperatures not e-ceeding @#H ahrenheit or
•
pressures not e-ceeding < psig are called EElow temperature hot water boilerEs. %eating boilers are also classified as to the method of manufacture, i.e., b! casting *#$ "%'7 4'"%#+ or fabrication *steel boilers+. hose that are cast usuall! use iron, bronze, or brass in their construction. hose that are fabricated use steel, copper, or brass, with steel being the most common material.
"8
F"%-$4 B'"%# ire tube boilers consist of a series of straight tubes that are housed inside a water8filled outer shell. he tubes are arranged so that hot combustion gases flow through the tubes. 's hot gases flow through the tubes, the! heat the water that surrounds the tubes. he water is confined b! the outer shell of the boiler. o avoid the need for a thick outer shell, fire tube boilers are used for lower8 pressure applications. &enerall!, the heat input capacities for fire tube boilers are limited to # (Btu/h or less, # but in recent !ears the size of fire tube boilers has increased. ire tube boilers are subdivided into three groups. %orizontal return tubular *%6+ boilers t!picall! have horizontal, self8 contained fire tubes with a separate combustion chamber. Scotch, Scotch marine, or shell boilers have the fire tubes and combustion chamber housed within the same shell. irebo- boilers have a water8acketed firebo- and
emplo!, at most, three passes of combustion gases. (ost modern fire tube boilers have c!lindrical outer shells with a small round combustion chamber located inside the bottom of the shell. 7epending on construction details, these boilers have tubes configured in either one, two, three, or four pass arrangements. Because the design of fire tube boilers is simple, the! are eas! to construct in a shop and can be shipped full! assembled as a package unit. able@.. identifies various t!pes of fire tube boilers and the associated fuels that the! t!picall! burn.
F F"% $4
C'
F '"
N$% !#
B"'2##
4'"% $/6 HRT 4'"%#
Y#
Y#
Y#
Y#
S'$9 4'"%#
Y#
Y#
Y#
N'
F"%4'> 4'"%#
Y#
Y#
Y#
Y#
T4(1):F# #&
F"!%():F"% $4 4'"%8
A&.7$!# ' "%-$4 4'"%#:
•
6elativel! ine-pensive.
•
)as! to clean.
•
3ompact in size.
•
'vailable in sizes from <, btu/hr to #,, btu/hr.
•
)as! to replace tubes.
•
:ell suited for space heating and industrial process applications.
D"#&.7$!# ' "%-$4 4'"%#: 2ot suitable for high pressure applications @# psig and above.
•
5imitation for high capacit! steam generation
•
""8
+$%-$4 B'"%#
In
a water8tube boiler, the water is inside the tubes and combustion gases pass around the outside of the tubes. he advantages of a water8tube boiler are a lower unit weight8per8pound of steam generated, less time required to raise steam pressure, a greater fle-ibilit! for responding to load changes, and a greater abilit! to operate at high rates of steam generation. ' water8tube design is the e-act opposite of a fire8tube. %ere, the water flows through the tubes and is encased in a furnace in which the burner fires. hese tubes are connected to a steam drum and a mud drum. he water is heated and steam is produced in the upper drum. 5arge steam users are better suited for the water8tube design. he industrial water8tube boiler t!picall! produces steam or hot water primaril! for industrial process applications, and is used less frequentl! for heating applications. he best gauge of which design to consider can be found in the dut! in which the boiler is to perform. Jhe abilit! of water tube boilers to generate superheated steam makes these boilers particularl! attractive in applications that require dr!, high8pressure, high8 energ! steam, including steam turbine power generation.K Owing to their superb working properties, the use of water tube boilers is highl! preferred in following maor areas? =ariet! of process applications in industries 3hemical processing divisions 1ulp and 1aper manufacturing plants 6efining units Besides, the! are frequentl! emplo!ed in power generation plants where large quantities of steam *ranging up to # kg/s+ having high pressures i.e.
appro-imatel! < bar and high temperatures reaching up to ##H3 are generall! require
F"!%(<): +$%-$4 B'"%
A&.7$!# ' +$%-$4 4'"%#: •
're available in sizes far greater than a fire8tube design , up to several million pounds8per8hour of steam.
•
're able to handle higher pressures up to #, psig.
•
6ecover faster than their fire8tube cousin.
•
%ave the abilit! to reach ver! high temperatures.
D"#&.7$!# ' $9 +$%-$4 4'"%#? •
%igh initial capital cost.
•
3leaning is more difficult due to the design.
•
2o commonalit! between tubes.
1h!sical size ma! be an issue.
•
A66"$"'7# ' +$%-$4 B'"% . Boilers are used mainl! in power plant for generating high pressure steam to produce electricit!. In power plant high pressure steam is e-panded through nozzles to run steam turbine which generates electricit!. @. In cold countries hot water producing boilers are used for heating the buildings. L. Boilers also find its application in te-tile industries for sizing and bleaching, and man! other industries like sugar mills and chemical industries.
8< A&.7$!# ' B'"% .
heir silent work
@.
1rogramming modes of operation for different times of the da!, that reduce the amount of mone! for heating
L.
heir simple installation
M.
he! are safer and there is no risk of fire or e-plosions
#.
here is no need for fuel
<.
It is possible to install a new heating s!stem, or to replace a pre8e-isting one
N.
' chance for a parallel connection with other heat boilers
A.
he s!stem cannot freeze *ion boiler heat carriers do not freeze until a temperature of 8MH3+,
".
)nvironmental meritC 'n energ!8saving product from a new generation
8@ E##7$" ;"$"# '% !''& B'"%: . Should meet large load fluctuations. @. Occup! less floor space. L. Should afford eas! maintenance and inspection. M. 5ight and simple in construction. #. ubes should be sufficientl! strong to resist wear and corrosion.
<. (ud and other deposits should not collect on heated places. N. he velocit! of gases and other flue gases should be minimum. A. he oints must be accessible and awa! from direct flame impact. ". 3apable of producing ma-imum steam with minimum fuel consumption.
85 P! B'"% D#"!7 ' 6! 4'"% or 6!& 4'"% is a modern form of steam boiler. he! are factor!8made to a range of standard designs, according to the size and evaporative capacit! required. he advantages of a package boiler are that the! are available Eoff the shelfE without a length! design step and also that the! are simpler to install. 1ackage boilers are also cheaper to operate as the! automaticall! manage their burner and water level, so not requiring the continual attention of a boiler man. 1ackage boilers are not used for large8scale power purposes such as electrical power generation. hese use more comple- and more efficient custom8designed boilers, usuall! toda! water8tube boilers working at high pressure.
F"!%(@):P! B'"%
ig # <
8581 P! 4'"% 2'&# 7& $/6#:
858C%"$%" '% $9 #$"'7 ' B'"%: he factors taken into account while selecting a boiler are as follows? . 1ower required to be generated. @. Operating pressure. L. uel qualit! and t!pe. M. :ater availabilit! and its qualit!. #. 1robable load factor. <. 5ocation of the power house or process plants. N. 3ost of operation and maintenance. A. 3ost of installation and erection. ". 'vailabilit! of floor space.
858
58 6ear tube sheet fit up in main shell and welding. 8 &usset plates fit up and welding for rear main tube sheet. 8 6.3 shell to tube sheets*front and rear+ fit up and welding. 8 (ain shell nozzle orientation marking, cutting and grinding*including man hole+.
8 2ozzle pipes marking and cutting. 108 2ozzle langes (arking, 3utting, (achining and 7rilling. 118 2ozzle pipe to flange fit up and welding. 18 2ozzles and (/% fit up on main shell ad welding. 1<8 urnace end plate, stiffener rings fit up and welding. 1@8 'ccess shell fit up on rear tube sheet of 6.3 and welding. 158 urnace shell8@ fit up and welding on furnace end plate. 18 urnace shells mockup and welding to 6.3 chamber. 18 urnace and 6.3 assembl! bo- up on inside of the main shell. 18 ront main tube sheet fit up and welding. ". 'ccess shell to rear main tube sheet welding. @. Saddle, 'sh nozzle fit up and welding. @. Sta! rods fit up and welding @@. Sta! tubes fit up and welding. @L. usible plug adopters fit up and welding. @M. 5evel gauge nozzles fit up and welding. @#. Steam dr!er fit up and welding.
@<. Insulation rings fit up and welding. @N. 5ifting hooks, 1latform pads fit up and welding. @A. Smoke and reversing chambers fit up and welding. @". 2ozzle stiffeners fit up and welding. L. urnace shell fit up and welding. L. 7ress up. L@. %!dro test.
A$% H/&%' T#$: 18 6.3 7oors fit up with anchors and welding. 8 Smoke chamber door fit up with anchors and welding. <8 'ir nozzle fit up and welding. @8 &rade bar fit up . 58 urnace front door fit up and welding. 8 uel feeding line fit up and welding. 8 'ir inection line fit up and welding. 8 'ir entr! duct fit up and welding. 8 &ates fit up and welding on chambers. 108 6efractor! arrangements. 118 'ccess shell flange, door fit up and welding. 18 6efector! 858@ B'"% D#"!7
:hether the boiler is a drum or whether it is an individual unit or a small part of large comple-, it is necessar! in design to give proper consideration to performance required from the total comple- of the steam generating unit. :ithin this frame work, there are some important items, which must be accomplished in boiler design. he items which are of importance are as stated below? . 7etermine the heat to be absorbed in the boiler and other heat transfer equipment, the optimum efficienc! to use and the t!pe of fuel or fuels dor which the unit is to be designed. :hen a particular fuel is selected, determine the amount of fuel required the necessar! or preferred preheated air temperature and the quantities of air required and flue gases to be generated. @. 7etermine the size and shape required for the furnace, giving considerations to location, the space requirements of burners or fuel bed, and incorporating sufficient furnace volume to accomplish complete combustion. 1rovision must also be made for proper furnace walls to reduce the gas temperature leaving the furnace to the desired value. L. he general disposition of the convection heating surfaces must be so planned that the super heater and the re8heater when provided, are located at the optimum temperature zone where the gas temperature is high enough to afford good heat transfer from the gas to the steam, !et not no high as to result in e-cessive tube temperatures or e-cessive fouling from ash in the fuel. M. 1ressure parts must be designed in accordance with applicable codes using approves materials with stresses not e-ceeding those allowable at the temperatures e-perienced during operation. #. ' tight boiler setting or enclosure must be constructed around the furnace and boiler, and gas tight flues or ducts must be provides to conve! the gases of combustion to the stack. <. Supports for pressure and setting must be designed with adequate consideration for e-pansion and local requirements, including wind and earthquake loading.
8585 B#" R;"%27$# ' B'"%:
. 1roper workmanship and simple construction, using materials which e-perience has shown to be the best, thus avoiding the necessit! of earl! repairs. @.
' mud drum to receive all impurities deposited from the water, and so placed as to be removed from the action of the fire.
L. ' steam and water capacit! sufficient to prevent an! fluctuation in steam pressure or water level. M.
' water surface for the disengagement of the steam from the water, of sufficient e-tent to prevent foaming.
#. ' constant and thorough circulation of water throughout the boiler, so as to maintain all parts at the same temperature. <.
he water space divided into sections so arranged that, should an! section fail, no general e-plosion can occur and the destructive effects will be confined to the escape of the contents. 5arge and free passages between the different sections to equalize the water line and pressure in all.
N.
' great e-cess of strength over an! legitimate strain, the boiler being so constructed as to be free from strains due to unequal e-pansion, and, if possible, to avoid oints e-posed to the direct action of the fire.
A.
' combustion chamber so arranged that the combustion of the gases started in the furnace ma! be completed before the gases escape to the chimne!.
".
he heating surface as nearl! as possible at right angles to the currents of heated gases, so as to break up the currents and e-tract the entire available heat from the gases.
. 'll parts readil! accessible for cleaning and repairs. his is a point of the greatest importance as regards safet! and econom!. . 1roportioned for the work to be done, and capable of working to its full rated capacit! with the highest econom!.
@. )quipped with the ver! best gauges, safet! valves and other fi-tures.
C96$%-< RA+ MATERIALS
<81 R? M$%" #& '% B'"%: L..1late material L..@ube material L..L1ipe material
<8181 P$ M$%": SA51 G%80 S' stands for 'merican Societ!.his specication covers carbon steel plates intended primaril! for service in welded pressure vessels where improved notch toughness is important. 1lates under this specification are available in four grades having different strength levels as follows? ensile Strength, &rade P.S. QSIR
ksi Q(1aR
## QLAR
##N# QLA8##R
< QM#R
<A QM#8##R
<# QM#R
<#A# QM#8#A#R
N QMA#R
N" QMA#8
<@R
T4():T7#" #$%7!$9#
he ma-imum thickness of plates is limited onl! b! the capacit! of the composition to meet the specified mechanical propert! requirementsC however, current practice normall! limits the ma-imum thickness of plates furnished under this specification as follows?
(a-imum &rade P.S. QSIR
hickness, in. QmmR
## QLAR
@ QL#R
< QM#R
A Q@#R
<# QM#R
A Q@#R
N QMA#R
A Q@#R
T4(<):M>"22 $9"7##
F"!%():P$
F"!%(): P$ ' SA51 G%80
<818T4 2$%": SA 10 G% A-1 his specification covers minimum8wall8thickness, seamless medium8carbon steel, boiler tubes and boiler flues, including safe ends , arch and sta! tubes, and super heater tubes.
E27$
G%& A-1
G%& C
3arbon, ma-
.@N
.L#
(anganese
."L ma-
.@".<
1hosphorus, ma-
.L#
.L#
Sulphur, ma-
.L#
.L#
Silicon, min
.
.
T4(): C92" 6%'6%$"#
S"= ' T4
S"= ' L'$
@ in. *#.A mm+ and over in diameter
not more than # tubes
and .@ in. *#. mm+ and over in wall thickness @ in. *#.A mm+ and over in outside
not more than N# tubes
diameter and under .@ in. *#. mm+ in wall thickness 5ess than @ in. *#.A mm+ but over in. *@#.M mm+ in outside diameter or
not more than N# tubes
over in. in outside diameter and under .@ in. *#.A mm+ in wall thickness in. *@#.M mm+ or less in outside
not more than @# tubes
7iameter T4(): N24% ' $4# "7 '$ 9$ $%$& 4/ $9 '7$"7'# 6%'##8
&rade'8 i.
&rade3
ensile strength, min, ksi Q(1aR
< QM#R
N QMA#R
Dield strength, min, ksi Q(1aR
LN Q@##R
M Q@N#R
iii.
)longation in @ in. or # mm, min, $
L
L
iv.
or longitudinal strip tests, a deduction shall
.#
.#
ii.
be made for each TL@ in. Q.AmmR decrease in wall thickness under #T< in. QA mmR from the basic minimumelongation of the following percentage points. v.
:hen standard round @ in. or # mm gage length or smaller proportionall! sized specimen with the gauge length equal to M7 *four times the diameter+ is used.
@@
@
T4() : T7#" %;"%27$#
F"!%():T4#
<818< P"6 2$%" : SA10 G%8B his specification covers seamless carbon steel pipe for high8temperature service. 1ipe ordered under this specification shall be suitable for bending, flanging, and similar forming operations, and for welding. :hen the steel is to be welded, it is presupposed that a welding procedure suitable to the grade of steel and intended use or service will be utilized. Supplementar! requirements of an optional nature are provided for seamless pipe intended for use in applications where a superior grade of pipe is required. hese supplementar! requirements call for additional tests to be made and when desired shall be so stated in the order.
C'26'#"$"'7
3arbon, ma-
G%& A .@#
G%& B .L
G%& C .L#
(anganese
.@N."L
.@".<
.@".<
1hosphorus, ma-
.L#
.L#
.L#
Sulphur, ma-
.L#
.L#
.L#
Silicon, min
.
.
.
3hrome, ma-
.M
.M
.M
3opper, ma-
.M
.M
.M
(ol!bdenum, ma-
.#
.#
.#
2ickel, ma-
.M
.M
.M
=anadium, ma-
.A
.A
.A
T4() : C92" R;"%27$#
ensile strength, min, psi *(1a+
Dield strength, min, psi *(1a+
&rade '
&rade B
&rade 3
MA QLLR
< QM#R
N QMA#R
L Q@#R
L# Q@MR
M Q@N#R
T4(10): T7#" %;"%27$#
F"!%(10):P"6#
C96$%-@ D#"!7 C$"'7#
@81D"%7$ '&# 3odes used in 7esign of boiler are IB68"#,'S() sec viii 7iv ,'S() sec8. @8 P%'## &#"!7 $"'7# '% B'"%
&as flow ? M2mUL/hr @881G# '26'#"$"'7:
%@O ? @.$ , O @ ? @$ , 2 @ ? NM$ , 3O @ ? @$. &as Inlet emperature
? g@ V "# c
&as Outlet emperature
? g@ V @M c
'llowable 1ressure 7rop
? mm :&
Operating 1ressure Of &as ? #mm :& @88G# P%'6%$"# A$ A.%! T26%$%:
*avg+g V *gWg@+/@ V *"#W@M+/@ V #"#c &as 7ensit!
? Xg ? .MM#< kg/2m L
7!namic =iscosit! ? Y g ? MN.M" Z 8< kg/ms Specific %eat of gas ? 3 pg? .@N 1randtl number
? 1r ? .
hermal conductivit! ? k
? .N kcal/mhr c
@88
> V mgZ3 pgZXgZ."A*g8g@+ V MZ.@NZ.MM# V .A
'mount of Steam ? m s ? kg/hr ? @# eed water inlet temperature ? w ? c ? 't A#c Saturated )nthalp! h ? kcal/kg ? .
>
V ms*h@8h+
V[.MLA V @#*h@8.+ V[h@ V
i. ii.
7ensit!
? Xw ? kg/mL ? @.LL"M
\inematic viscosit! ? ]w ? m@/sec ? .
iii.
hermal conductivit! ? \ w ? kcal/m hr c ? .MM"
iv.
1randtl number
? 1r ? .LAN#
Specific heat
? 3 p ? kcal/kgc ? ."A@
v.
otal number of tubes provided V @@ 2umber of sta! tubes
V @A
hickness of plain tubes V M.
mfg *mL/hr+ V* mfg *2mL/hr+Z*@NLW*avg+g+ / *@NLZgas pressure+ V MZ*@NLW#"#+/*@NLZ.#+ V AMNA.< Xg *kg/mL+ V* X*kg/2mL+Z@NLZgas pressure+ / *@NLW*avg+g+ V *.MM#
_ V *.A@log*6e+8.
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Our manual valve selection includes ball, check. diaphragm, elliptic, metring, needle, pinch, plug, pressure relief, and stopcock valves.Our actuated valve selection includes electricall! actuated ball, elliptic, pinch, proportionating, and genaral8purpose solenoid valves. C'7#"& C'7#"&% % /'% "& $/6(! $/6(!## '%
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eflo eflon n withst withstand andss man! man! harsh harsh or corros corrosive ive chemical chemicals. s. or safet! safet! reasons reasons,, alwa!s use metal valves for pressurized gases. D$%2"7 $9 $26%$%, 6%##%, 7& '? %$ 7&% ?9"9 /'% .. ?" 4 '6%$"7!8
In general, metal valves with stand higher temperatures and pressures than plastic valves. C'7#"&% /'% 2"7$77 %;"%27$#:
Ball valves resist plugging an are easiest to sevice.
@85 +&"7! &$" ' B'"%#(A# 6% ASME *IBR)
@8581 +&"7! P%'##: SMA+ SUBMERGED ARC +ELDING PIPES: he pipes shall be manufactured
from plate, sheet or strip with either a single or double longitudinal seam or spiral seam and welded across the abutting edges b! an automatic submerged arc welding process using at least two runs, one of which shall be on the inside of the pipes. 6eference
Steel &rades 'pplicable
(ethod of (anufacturing
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Seamless )lectric resistance including induction welded Submerged 'rc :elding *including spirall! welded+
F"!%(11):A% +&"7!
TIG +ELDING
G# $7!#$7 % ?&"7! *GTA++, also known as $7!#$7 "7%$ !# *TIG+ ?&"7!, is
an arc welding process that uses a non8consumable tungsten electrode to produce the weld. he weld area is protected from atmospheric contamination b! an inert shielding gas *argon or helium+, and a filler metal is normall! used, though some welds, known as autogenousl! welds, do not require it. ' constant8current welding power suppl! produces energ! which is conducted across the arc through a column of highl! ionized gas and metal vapors known as a plasma. &': is most commonl! used to weld thin sections of stainless steel and non8ferrous metals such as aluminum ,magnesium, and copper allo!s. he process grants the operator greater control over the weld than competing processes such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher qualit! welds. %owever, &': is comparativel! more comple- and difficult to master, and furthermore, it is significantl! slower than most other welding techniques. ' related process, plasma arc welding, uses a slightl! different welding torch to create a more focused welding arc and as a result is often automated. Q
F"!%(1):GTA+
F"!%(1<):T7!#$7 % ?&"7! GAS CUTTING:
O>/-$/7 !#
he o-!acet!lene process produces a high temperature flame, over L degrees 3, b! the combustion of pure o-!gen and acet!lene. It is the onl! gas mi-ture hot enough to melt steelC other gases *propane, 51& or h!drogen+ can be used for lower melting point non8ferrous metals, for brazing and silver soldering and as a preheating/piercing gas for cutting. H7&"7! '26%##& !##
3!linders are fitted with regulators to reduce the gas pressure in the c!linder to the working pressure of the torch. he regulator has two gauges, a high pressure gauge for the gas in the c!linder and a low pressure gauge for the gas being fed to the torch. he gas flow rate is controlled b! a pressure adusting screw which sets the outlet gas pressure. he B3&' 3ode of 1ractice 31N recommends the gauges are checked annuall! and replaced ever! # !ears. actors to be considered are that the gas s!stem is suitable for the pressure rating and the hoses are connected without an! leaks. =alve threads should be cleaned
before screwing in the regulator. he valve of an acet!lene c!linder can be opened slightl! to blow out the threads but the threads in o-!gen c!linders are best cleaned using clean compressed air *the threads on h!drogen c!linders must alwa!s be blown out using compressed air+. 's o-!gen can react violentl! with oils and grease, lubricating oils or sealant for the threads must not be used. U#"7! '26%##& !##
&ases are mi-ed in the hand8held torch or blowpipe in the correct proportions. %oses between regulator and torch should be color codedC red for acet!lene and blue for o-!gen. %oses should be kept as short as possible and users should check periodicall! that the! are not near hot or sharp obects which could damage the hose wall. 'cet!lene c!linders must alwa!s be used upright. :hen connecting the s!stem, and at least at the start of each shift, hoses and torch must be purged to remove an! inflammable gas mi-tures. It is essential the o-!gen stream does not come into contact with oil which can ignite spontaneousl!. 1urging should also not be carried out in confined spaces. he torch should be lit with a friction lighter or stationar! pilot flame to avoid burning the handsC matches should not be used and the flame should not be reignited from hot metal, especiall! when working in a confined space. 'lthough ver! little P= is emitted, the welder must wear tinted goggles.
F"!%(1@):!# $$"7!
C976%-5 M7$%"7!, O6%$"'7 7& M"7$"77 P%'##
581 M7$%"7! P%'##: 18 6aw material matching as per our requirement 8 3utting plan <8 Shell rolling as per the design calculations @8 :elding process 58 ube sheet cutting 8 ube sheet 7rilling 8 Shell bo- up 8 ube sheet fit up
58 P%6%$"'7 ' M"7 S9: •
6aw material? 1lates S'## &r.N or S'#< &r.N.
•
'pproved plates shall be selected as per Bill of material.
•
Size of (ain Shell as per drawing? O7 @@@M - L@# lg - @mm thick.
•
*7eveloped length of shell? O7 thickV mean dia. of shell is required to calculate development of shell
•
O78V @@@M8@V@@@ is mean diameter of shell, 7eveloped lengthV @@@ - ^ *@@/N+ V <"#@mm. +
•
%ence required 1late for main shell is <"#@ - L@# - @ mm
•
1lates are available in @# - -@. (arking of plates as mentioned below.
•
Inspection of marking on plates and clearance for &as cutting.
•
'fter cutting of shell sections8I 9 II, edge preparation of plates is required for 5ong seam and circumferential oints as mentioned below.
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6olling of (ain Shell section I and (ain Shell section8II.
•
it up of 5ong seam I and 5ong seam II, it up inspection and clearance for welding.
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'fter welding, visual inspection of welding and clearance for 27 *6adiograph! est+
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Interpretation of 6 films and after acceptance8 3learance for 3ircumferential oints.
•
it up inspection of 38seam and clearance for welding.
•
'fter welding =isual inspection of :eld oint and clearance for 27*6+
•
Interpretation of 6 films and after acceptance main shell is cleared for further processing.
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