Power generation and superheater upgrade project at the burnaby msw plant leo lakowski, p. When calculating heat loss for a boiler, it does not matter if the unit is gas or oilfired. Thermodyne manufactures both coil type and shell type superheaters depending upon the type of boiler and boiler capacity coil type superheaters design generally consists of 180 o coils welded through the headers on both the sides. In this paper, a creepfatigue design life study of a typical hrsg superheater header has been conducted under various cyclic conditions. Superheater installations backed by more than 300 years of combined expertise. Superheaters can be of convective or radiant design or a. Boiler superheaters steam superheater services nbs. The asme sa2 grade t11 tube had been in service for 6 to 8 years until failure. Superheater absorbs heat by direct radiation from furnace, by nonluminous radiation and by convection. This web page focuses on software and computer programs related to hydronic systems. Boiler software and computer programs load design sizing.
The introduction of digital ecosystems connecting electronic control hardware and software to the cloud is catalyzing a new era of mobile machine and equipment design innovation. Each cad and any associated text, image or data is in no way sponsored by or affiliated with any company, organization or realworld item, product, or good it may purport to portray. Coil type superheaters design generally consists of 180 o coils welded through the headers on both the sides. Stress analysis of the lha1 class superheater header by. Design concepts to minimize superheater corrosion in municipal waste combustors an overview anthony j. In anticipation of performance trials, eight examples were fitted with schmidt and robinson superheaters, and two others remained saturated. Results indicated that the improper structure, the original welding defects, higher. Recent experience in condition assessment of boiler header. Firecad superheater design module is a windows based user friendly design software. Based on the results of a comprehensive engineering evaluation of the cracked header, the unit was returned. In this context, the header and coil design is a promising configuration to minimize the stresses.
Superheater working principle superheater is a subcritical boilers component that heat the saturated vapor, at constant pressure, so it becomes superheated steam. Russ anderson, power and process specialist ron richter, plant manager montenay inc. This reference page has an index that will guide you directly to boilerrelated computer programs online. The high pressure steam headers of the thtr steam generators have been subject to special attention during the design phase due to the following reasons. The computeraided design cad files and all associated content posted to this website are created, uploaded, managed and owned by third party users. In this paper, the stress analysis of the superheater outlet header of a 600 mw supercritical boiler in peak load operation was investigated by carrying out a threedimensional finite elementfe analysis. The headers are constructed from sa335 p22 214 % chromium 1 % molybdenum low alloy steel, 20 0. Regardless of the software program used, designers need to have a fundamental understanding of various factors affecting vhe design lengths. In all cases, metallurgical analysis of failed tubes has shown overheating of material, high temperature oxidation, bulging, cracks and.
Whether it is water tube type or fire tube, whether coal fired, biomass fired or gasoil fired, firecad has got all solutions for. Not only that, dry steam also is less likely to condense within the cylinders of a reciprocating engine or the casing of a steam. Power generation and superheater upgrade project at the. Firecad is the worlds leading solution for thermal design of industrial boilers. Superheater tubes and reheater tubes in a comprehensive range of stainless steels and nickel alloys covering outside diameters 12 to 260 mm 0. A pressure relief valve was often fitted to the end of the inlet header.
Superheaters headers operate in a steamy environment under the pressure of 15. Our superheaters are all custom made and built to meet the specific design requirements of each application. Large database of waste heat gases and boiler exhaust gases is provided. The flue gases flow outside the tubes usually in counter flow. Pdf lifetime estimation of superheater header researchgate. Im not sure of the superheater header material as i dont have the datasheet with me now. Mechanical stress analysis of a 600mw supercritical boiler. Superheaters are often the most expensive heat transfer surface. Boiler manufacturers, engineers, consultants and academicians use firecad for designing various types of industrial boilers. The information about the header template, from which the. Analysis on welding crack of subcritical power station. Our superheaters are manufactured according to the ibr regulations. The superheater composed of 3 single return loops of 14 od ss tube to fit into the 3 flues of 78 od type l. This research considers the header as a thick walled.
In a coil type designs steam is inside the coil and flue gases are outside the coil. In a coil type designs steam is inside the coil and flue. The boilers utilize a splitheader design for the outlet of the radiant superheater comprised of two 45 foot headers positioned endtoend across the full width of the boiler. The baffles for all but the last pass are formed by having separate headers, but that for the last pass is welded into the outlet header. Therefore, creepfatigue interaction should be considered. Failure analysis study of a cracked superheater outlet header. The information about the header template, from which the specimens were machined. The interactions between steam piping and boiler outlet. Asme certified, monitor controller, safety valve, skidded packaged, superheater.
Fired heater design this case study demonstrates the implementation of an api 560 fired heater compound component in flownex. Superheater technology has been used since the use of steam engines early 20th century. Pdf thermal analysis of superheater platen tubes in boilers. Robert uries design of superheater for the lswr was the product of experience with his h15 class 460 locomotives. This paper presents a method to design the header and coil heat exchangers of the steam generator, taking into account lowcycle fatigue requirements, by defining minimum allowable heating rates for the evaporator and superheater. In a subcritical boiler, the sh is between the mainsteam header and the steam drum and consists of saturated tubes that transport steam from the drum to the sh inlet header when the sh tubes are not directly connected to the drum. Superheater dimensioning plays a major role in boiler cost as superheaters are typically manufactured from much more expensive alloyed steel tubes than other boiler parts nishikawa, 1999. However, for a header subjected to two shift cyclic operating conditions, fatigue damage could be increased significantly. A superheater can vary in size from a few tens of feet to several hundred feet a few metres or some hundred metres. The mode of failure was shortterm stress rupture due to significant overheating. Shell type superheaters design generally used to superheat the steam electrically using special heating elements stacked in a shell and the steam flows over the heating elements. Right design of the superheater is very critical in the boiler.
Using this module, engineers can design superheater for fired boilers, for waste heat boilers, for hrsgs and for other hot gas sources of chemical plants. Superheater dimensioning is based on determining appropriate radiative and convective heat transfer as well as ash deposit properties on the superheater surface. Boiler outlet headers in fossil power plants by james p. It is also the only product on the market to take your custom tube header design and break it down to fabrication instructions using prebent mandrel tubing. Analysis of superheater tubes failure e3s web of conferences. A superheater is a device found in steam boilers that is used to convert wet, saturated steam into dry steam. Superheaters are a very beneficial part of the steam cycle, because dry steam contains more thermal energy and increases the overall efficiency of the cycle. In super heaters there should not be any fins as it increases the thermal stresses and carful should be taken when choosing the superheater material that is stand for high temp and corrosion resistance. The calculations were performed with a computer program on the basis of transfer. Feed water enters the tube through one header and leaves through the other. Superheater tube from boiler metallurgical technologies.
References throughout this standard the following dated and undated standardscodes are referred to. Boiler performance benchmarking case studies of successful projects. Full text of stress analysis of the lha1 class superheater header by finite element method. Process design of steam boilers project standards and specifications page 3 of 45 rev. Our proven experience in managing complete and partial superheater replacements allows us to install or modularize a superheater to regulate your boiler system and ensure optimal temperature ranges are maintained at all times at nbs, we work exclusively with some of the largest and most reliable superheater and. Locomotive boiler construction working and application. A superheater is a device used to convert saturated steam or wet steam into dry steam used in steam engines or in processes, such as steam reforming. Superheaters and reheaters superheaters are one of the most important accessories of boiler that improves the thermal efficiency. But sometimes, we are done with the superheated steam but need mo. The favored design approach for matching steam temperatures with those required by the steam turbine is to insert a desuperheater between primary and secondary superheater and reheater sections in. Counter and parallel flow type with or without protective screen.
Video shows headers of superheater and reheater of thermal power plant boiler. And the laws of the thermal stress, the mechanical stress and the total stress. This header is called the first pass or intermediate header. All structured data from the file and property namespaces is available under the creative commons cc0 license. Creep fatigue damage assessment of an inservice superheater. Locomotive boiler construction working and application with diagram march 2. When we superheat steam, its not that precise so we essentially overheat the steam and then cool it down to a precise temperature by injecting water. Finite element stress analysis of a 600 mw supercritical. We will also take the help of cfd design software to design a superheater that gives the maximum plant efficiency. Sap 80 structural analysis program was utilized to conduct the analysis. A typical condition assessment program for these boiler pressure components would con. Thermal analysis of superheater platen tubes in boilers. See other formats dudley kuoy w aval post g5 monterey, li j library i ar r j atu school j. Fired heater design engineering systems simulation.
A 909456002 naval postgraduate school monterey, california thesis stress analysis of the lha1 class superheater header by finite element method by jon w. It uses simple terms and technology that are easy to understand. Main propulsion plant dd445 and 692 classes and converted. Using the steam property calculator, properties are determined using header pressure and the header specific enthalpy. Design of superheater for 210 mw thermal powerplant final. The preheated water then enters the boiler at the economizer inlet header. The ansys software was adopted to analyze the distribution of the stress. If this is a new boiler design then it does seem implausible that the organisation s design standards contain insufficient information on how to design a superheater arrangement superheating has. Files are available under licenses specified on their description page. In steam generator boiler of thermal power plant, superheaters heat saturated steam to superheated steam by using. Its design temperature t is 604 c, and the design pressure p acting on. Besides, the pressure data during the process of load pickup is passed as boundary conditions. Welding crack analysis was carried out on tee joint crack of boiler platen superheater header 12cr1mov of subcritical power station applying finite element analysis,microanalysis, mechanical properties test, chemical composition analysis, metallography examination and sem observation etc.
Obviously, the buildings design loads, the grounds soilrock thermal conductivity and mean ground temperature play significant roles in determining design lengths see. Firecad superheater trial free download windows version. This page was last edited on 27 january 2019, at 12. And the second one is that which connects the superheater exit end to the steam engine. Design concepts to minimize superheater corrosion in. All types of bare tube, fin tube and gill tube superheater can be designed. Construction working and application with diagram deepesh tandon. Superheater header painting boiler and pressure vessel. Background during a forced outage of the unit 1 boiler in september of 1992, extensive internal borehole and ligament cracking was discovered in the radiant superheater outlet header. Design upgrade of an intermediate secondary superheater july 22, 2005 rev. Superheaters headers operate in a steamy environment under the pressure of.
The main purpose is to increase the heat energy contained by the steam, so that increasing the thermal efficiency of the engine. In this instance, we incorporated a 30 degree inlet and outlet taper. Boilers, superheater, power control panels can all be assembled on a modular skid package. Acme electric steam superheaters are available for use with steam boilers as an auxiliary piece of equipment. Superheater outlet header is one of the high temperature and high pressure critical component of a power boiler. Optimizing boiler system design according to best practices. Design superheater for fired boilers, waste heat boilers, hrsgs and for other hot gas sources of chemical plants. Superheaters and reheaters philadelphia university. Design study of a superheater header subjected to cyclic. The combined inlet pressures are adjusted to match the header pressure without energy loss or gain. Superheater tubes for boilers sandvik materials technology.
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