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Steam, its generation and use
اطلاعات کتابشناختی
Steam, its generation and use
Author :
Publisher :
Babcock & Wilcox,
Pub. Year :
2005
Subjects :
Steam-boilers, Water-tube. Steam, Superheated.
Call Number :
TJ 315 .B2 .A3 2005
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ترتيب
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فهرست مطالب
Steam 41 Main Contents
(1)
Title Page
(2)
Copyright © 2005
(3)
Disclaimer
(3)
Steam, Edition: 41
(4)
Preface
(6)
Table of Contents
(7)
Table of Contents (Page 2 of 2)
(8)
Acknowledgments
(9)
Acknowledgments (Page 2 of 2)
(10)
System of Units
(11)
Editors’ Foreword
(12)
Section I – Steam Fundamentals
(13)
Section II – Steam Generation from Chemical Energy
(14)
Section III – Applications of Steam
(15)
Section IV – Environmental Protection
(16)
Section V – Specification, Manufacturing and Construction
(17)
Section VI – Operations
(18)
Section VII – Service and Maintenance
(19)
Section VIII – Steam Generation from Nuclear Energy
(20)
Introduction to Steam
(22)
Steam as a resource
(22)
The early use of steam
(23)
Fire tube boilers
(25)
Early water tube design
(25)
The Babcock & Wilcox Company
(26)
George Herman Babcock
(27)
Stephen Wilcox, Jr.
(28)
Water tube marine boilers
(27)
Bent tube design
(28)
Electric power
(28)
Pulverized coal and water-cooled furnaces
(30)
Integral Furnace boiler
(30)
Requirements of a Perfect Steam Boiler – 1875
(30)
Shop-assembled water tube boilers
(31)
Further developments
(31)
Universal Pressure boilers
(31)
Other fuels and systems
(32)
Modified steam cycles
(32)
Nuclear power
(33)
Materials and fabrication
(34)
Research and development
(34)
Environmental protection
(35)
Fuels and combustion technology
(35)
Heat transfer and fluid dynamics
(36)
Materials and manufacturing technologies
(37)
Structural analysis and design
(37)
Fuel and water chemistry
(38)
Measurements and monitoring technology
(38)
Steam/its generation and use
(38)
Introduction Frontispiece
(39)
Chapter 1 – Steam Generation – An Overview
(40)
Steam generation fundamentals
(41)
Boiling
(41)
Circulation
(42)
System arrangement and key components
(43)
Fossil steam generator classifications
(45)
Impact of energy source
(45)
Impact of steam conditions
(45)
Fossil fuel systems
(45)
Fossil fuel steam generator components
(45)
Steam-water flow system
(47)
Combustion system and auxiliaries
(48)
Air-gas flow system
(49)
Emissions control
(49)
Nuclear steam generating systems
(49)
Overview
(49)
Nuclear steam system components
(50)
Nuclear steam system classifications
(51)
Engineered safety systems
(52)
Steam system design
(53)
Steam generator interfaces
(53)
Systematic approach
(53)
System design example
(53)
Other steam producing systems
(56)
Common technical elements
(56)
Bibliography
(57)
Chapter 1 Frontispiece
(59)
Chapter 2 – Thermodynamics of Steam
(60)
Properties of steam
(60)
Properties of gases
(66)
Conservation of mass and energy
(66)
Applications of the energy equation
(68)
Steam turbine
(68)
Steam boiler
(68)
Water flow through a nozzle
(68)
Flow of a compressible fluid through a nozzle
(68)
Compressor
(68)
Pump
(68)
Entropy and its application to processes
(69)
The first and second laws of thermodynamics
(69)
Concept and definition of entropy
(69)
Application of entropy to a reversible process
(69)
Irreversible processes
(70)
Principle of entropy increase
(71)
Cycles
(71)
Carnot cycle
(71)
Rankine cycle
(72)
Regenerative Rankine cycle
(73)
Available energy
(76)
Rankine cycle efficiency
(76)
Rankine cycle heat rate
(78)
Steam cycle in a nuclear plant
(78)
Supercritical steam cycles
(79)
Process steam applications
(80)
Gas turbine cycle
(81)
Combined cycles and cogeneration
(82)
Waste heat boilers
(83)
Cogeneration
(83)
Combustion processes
(84)
Gibbs free energy
(85)
References
(86)
Chapter 2 Frontispiece
(87)
Chapter 3 – Fluid Dynamics
(88)
Fundamental relationships
(88)
Conservation of mass
(89)
Conservation of momentum
(89)
Energy equation (first law of thermodynamics)
(90)
Energy equation applied to fluid flow (pressure loss without friction)
(91)
Ideal gas relationships
(91)
Pressure loss from fluid friction
(92)
Friction factor
(94)
Laminar flow
(95)
Turbulent flow
(95)
Velocity ranges
(96)
Resistance to flow in valves and fittings
(96)
Contraction and enlargement irreversible pressure loss
(98)
Flow through bends
(100)
Flow through rectangular ducts
(100)
Turning vanes
(100)
Pressure loss
(102)
Flow over tube banks
(102)
Flow through stacks or chimneys
(102)
Pressure loss in two-phase flow
(103)
Entrainment by fluid flow
(103)
Boiler circulation
(104)
References
(104)
Chapter 3 Frontispiece
(105)
Chapter 4 – Heat Transfer
(106)
Nomenclature
(107)
Fundamentals
(106)
Basic modes of heat transfer
(106)
Governing equations
(110)
Radiation balances for enclosures
(112)
Heat transfer properties and correlations
(114)
Thermal conductivity, specific heat and density
(114)
Radiation properties
(115)
Working formulas for convection heat transfer
(119)
Natural or free convection
(119)
Forced convection
(120)
General heat transfer topics
(124)
Heat exchangers
(124)
Extended surface heat transfer
(125)
NTU method
(126)
Heat transfer in porous materials
(127)
Film condensation
(127)
Mass diffusion and transfer
(127)
Evaporation or boiling
(127)
Fluidized-bed heat transfer
(128)
Numerical modeling
(128)
Conduction
(128)
Radiation
(128)
Design considerations
(129)
Furnaces
(129)
Convection banks
(132)
Cavities
(133)
Insulation
(134)
Applications
(134)
Example 1 – Conduction through a plane wall
(134)
Example 2 – Heat flow in a composite wall with convection
(134)
Example 3 – Heat flow in an insulated pipe
(135)
Example 4 – Heat flow between a small object and a large cavity
(136)
Example 5 – Heat flow between two surfaces
(136)
Example 6 – Radiation from a hot gas to furnace walls
(136)
Example 7 – Radiation in a cavity
(137)
References
(137)
Chapter 4 Frontispiece
(139)
Chapter 5 – Boiling Heat Transfer, Two-Phase Flow and Circulation
(140)
Boiling process and fundamentals
(140)
Boiling point and thermophysical properties
(140)
Boiling curve
(141)
Flow boiling
(141)
Boiling heat transfer evaluation
(142)
Heat transfer coefficients
(143)
Critical heat flux phenomena
(143)
Supercritical heat transfer
(146)
Two-phase flow
(147)
Flow patterns
(147)
Pressure loss
(148)
Instabilities
(150)
Steam-water separation
(152)
Factors affecting steam separation
(152)
Natural gravity-driven separation
(153)
Baffle-assisted primary separation
(153)
Mechanical primary separators
(154)
Mechanical separator performance
(155)
Steam drum capacity
(156)
Circulation
(156)
Natural circulation
(157)
Forced circulation
(158)
Circulation design and evaluation
(158)
Critical flow
(159)
References
(159)
Bibliography
(160)
Chapter 5 Frontispiece
(161)
Chapter 6 – Numerical Modeling for Fluid Flow, Heat Transfer, and Combustion
(162)
Numerical modeling – an overview
(162)
Benefits
(163)
Increased understanding
(163)
Exploration of unfamiliar conditions
(163)
Design validation/examination of interactions
(163)
Troubleshooting
(163)
Flexibility
(163)
Historical perspectives
(163)
Modeling process
(163)
Limitations
(164)
Uses
(164)
Theory
(164)
Fundamental equations
(166)
Representation of turbulence
(166)
Fluid flow and heat transfer
(166)
Turbulence model
(166)
Discrete phase transport
(168)
Combustion
(168)
Radiative heat transfer
(169)
Discretization of equations
(169)
Finite volume approach
(169)
Discrete ordinates method
(170)
Mesh generation
(170)
Cell types
(171)
Structured mesh
(171)
Unstructured mesh
(171)
Embedding and adaption
(171)
Example applications
(171)
Wet scrubbers
(171)
Popcorn ash
(173)
Kraft recovery boilers
(175)
Wall-fired pulverized-coal boiler furnaces
(175)
Windbox
(177)
SCR systems with economizer bypass
(179)
Waste-to-energy systems
(182)
Advanced burner development
(182)
References
(186)
Chapter 6 Frontispiece
(187)
Chapter 7 – Metallurgy, Materials and Mechanical Properties
(188)
Metallurgy
(188)
Crystal structure
(188)
Defects in crystals
(188)
Physical metallurgy of steel
(189)
Specific effect of alloying elements
(192)
Heat treating practices
(195)
Fabrication processes
(196)
Welding
(197)
Weld quality issues
(198)
Materials
(199)
Mechanical properties
(203)
Low temperature properties
(203)
Tensile test
(203)
Hardness test
(204)
Toughness tests
(204)
Formability tests
(205)
High temperature properties
(205)
Tensile strength
(205)
Creep and creep-rupture test
(206)
Material applications in boilers
(207)
ASME specifications and allowable stresses
(207)
Pressure part applications
(208)
Boiler, furnace waterwall, convection pass enclosures and economizers
(208)
Superheaters and reheaters
(208)
Selection factors
(209)
Cost
(210)
Headers and piping
(210)
Drums
(210)
Heat resistant alloys for nonpressure parts
(211)
References
(211)
Chapter 7 Frontispiece
(213)
Chapter 8 – Structural Analysis and Design
(214)
Pressure vessel design and analysis
(214)
Stress significance
(214)
Strength theories
(215)
Design criteria
(215)
Stress analysis methods
(216)
Fracture mechanics methods
(223)
Construction features
(226)
ASME Code calculations
(218)
Structural support components
(227)
Design criteria
(227)
Typical support design considerations
(228)
References
(230)
Bibliography
(230)
Chapter 8 Frontispiece
(231)
Chapter 9 – Sources of Chemical Energy
(232)
World availability of coal
(232)
U.S. availability of coal
(233)
How coal is formed
(234)
Classifying coal
(236)
ASTM classification by rank
(236)
Other classification systems
(237)
Coal characterization
(238)
Standard ASTM analyses
(238)
Special B&W tests
(239)
Properties of selected coals
(240)
Fuels derived from coal
(240)
Coke
(240)
Gaseous fuels from coal
(240)
Byproduct gas from gasification
(242)
Fuel oil
(243)
Fuel oil characterization
(243)
Fuel analyses
(245)
Properties of fuel oils
(246)
Natural gas
(247)
Past consumption and availability
(247)
Natural gas characteristics
(247)
Properties of natural gas
(248)
Other fuels
(248)
Coke from petroleum
(248)
Oil emulsions
(249)
Wood
(249)
Bagasse
(250)
Other vegetation wastes
(250)
Municipal solid waste
(250)
References
(250)
Chapter 9 Frontispiece
(251)
Chapter 10 – Principles of Combustion
(252)
Concept of the mole
(252)
Fundamental laws
(252)
Conservation of matter
(252)
Conservation of energy
(252)
Ideal gas law
(254)
Law of combining weights
(254)
Avogadro’s law
(254)
Dalton’s law
(254)
Amagat’s law
(254)
Application of fundamental laws
(254)
Molar evaluation of combustion
(254)
Gaseous fuel
(254)
Solid/liquid fuel
(255)
Composition of air
(255)
Theoretical air requirement
(256)
Products of combustion – mass/mass fuel basis
(257)
Alternate units – Btu method
(257)
Heat of combustion
(258)
Measurement of heat of combustion
(258)
Higher and lower heating values
(261)
Ignition temperatures
(261)
Adiabatic flame temperature
(262)
Practical combustion application issues
(262)
Sorbents and other chemical additives
(262)
Residue versus refuse
(265)
Unburned carbon
(265)
Excess air
(266)
Combustion and efficiency calculations
(267)
Combustion air – theoretical air
(267)
Flue gas
(267)
Efficiency
(268)
Surface radiation and convection loss
(270)
Unburned carbon loss
(270)
Other losses and manufacturers’ margins
(270)
Enthalpy
(270)
Enthalpy of air and gas
(270)
Enthalpy of solids and fuels
(271)
Measurement of excess air
(272)
Flue gas analysis
(272)
Flue gas sampling
(272)
Testing heterogeneous fuels
(272)
BAC calculation method
(274)
Combustion calculations – examples
(274)
Mole method
(274)
Btu method
(274)
References
(275)
Bibliography
(276)
Chapter 10 Frontispiece
(283)
Chapter 11 – Oil and Gas Utilization
(284)
Fuel oil
(284)
Preparation
(284)
Transportation, storage and handling
(284)
Fuel properties
(285)
Natural gas
(285)
Preparation
(285)
Transportation, storage and handling
(285)
Fuel properties
(286)
Other liquid and gaseous fuels
(286)
Oil and gas combustion – system design
(286)
Performance requirements
(287)
Excess air
(287)
Stability and turndown
(287)
Burner pulsation
(288)
Combustion efficiency
(288)
Emission control techniques
(288)
Oxides of nitrogen
(288)
Oxides of sulfur
(291)
Particulate matter
(291)
Opacity
(292)
Burner selection and design
(292)
Circular burner
(292)
XCL-S type burner
(292)
Corner-firing system
(293)
Fuel oil equipment
(294)
Natural gas equipment
(296)
Byproduct gases
(297)
Cold start and low load operation
(297)
Igniters
(298)
Safety precautions
(299)
Chapter 11 Frontispiece
(301)
Chapter 12 – Solid Fuel Processing and Handling
(302)
Coal mining
(302)
Surface mining
(303)
Underground mining
(303)
Raw coal size reduction and classification
(304)
Sizing requirements
(304)
Size reduction equipment selection
(304)
Screen selection
(305)
Coal cleaning and preparation
(305)
Coal characterization
(306)
Coal cleaning and preparation operations
(307)
Impact on steam generator system operations
(309)
Coal transportation
(309)
Rail
(310)
Barge
(310)
Truck
(311)
Continuous transport
(311)
Coal handling and storage at the power plant
(311)
Raw coal handling
(313)
Rail car unloading
(313)
Barge unloading
(314)
Truck unloading
(314)
Stockpile storage
(314)
Silo storage
(315)
Bunker storage
(315)
Bunker design
(315)
Feeder design
(316)
Coal blending
(317)
Resolution of common coal handling problems
(318)
Dust suppression
(318)
Oxidation
(318)
Frozen coal
(318)
Coal pile fires
(318)
Bunker flow problems
(318)
Bunker fires
(319)
Environmental concerns
(319)
Alternate solid fuel handling
(319)
Economics
(320)
References
(320)
Bibliography
(320)
Chapter 12 Frontispiece
(321)
Chapter 13 – Coal Pulverization
(322)
Vertical air-swept pulverizers
(322)
Principles of operation
(322)
Pulverizer control
(323)
Pulverizer design requirements
(323)
Pulverizer designs
(324)
Horizontal air-swept pulverizers
(325)
High speed pulverizers
(325)
Low speed pulverizers
(326)
Application engineering
(326)
Pulverizer systems
(327)
Outlet temperature
(329)
Effects of coal properties
(329)
Pulverizer size selection
(331)
Performance testing
(331)
Fineness testing
(331)
Evaluating test results
(331)
Operations
(332)
Power consumption
(332)
Maintenance
(332)
Fires and explosions
(333)
Controls and interlocks
(333)
Special safety systems
(334)
Advanced designs
(334)
Rotating classifiers
(334)
Rotating throats
(335)
Variable spring loading
(335)
Fine grinding
(335)
References
(336)
Bibliography
(336)
Chapter 13 Frontispiece
(337)
Chapter 14 – Burners and Combustion Systems for Pulverized Coal
(338)
Combustion
(339)
Volatile matter content
(340)
Char particles
(340)
Effect of moisture content
(340)
Effect of mineral matter content
(341)
Pulverized coal combustion system
(341)
Effect of coal type
(341)
Combustion system and boiler integration
(342)
Burner integration
(343)
Burner functions
(344)
Performance requirements
(345)
Conventional PC burners
(346)
Conventional circular burner
(346)
Cell burner
(346)
S-type burner
(346)
Low NOx combustion systems
(346)
NOx formation
(346)
NOx control by combustion
(347)
Dual register burner
(348)
DRB-XCL burner
(349)
DRB-4Z burner
(350)
Low NOx cell burner
(351)
Air staged systems
(351)
Burners for difficult coals
(355)
Enhanced ignition burner
(355)
Primary air exchange burner
(355)
Unburned combustibles
(356)
Fineness
(356)
Oxygen availability
(356)
Air/fuel imbalances
(356)
Residence time
(356)
Gaseous losses
(356)
Advanced techniques
(357)
Auxiliary equipment
(357)
Oil/gas firing equipment
(357)
Igniters
(357)
Flame safety system
(357)
Safety and operation
(357)
Other PC applications
(358)
Pulverized coal in metal and cement industries
(358)
References
(358)
Chapter 14 Frontispiece
(359)
Chapter 15 – Cyclone Furnaces
(360)
Cyclone furnace arrangement and basic operation
(360)
Principles of operation
(360)
Cyclone combustion
(361)
Air distribution
(361)
Heat rates
(361)
Slag layer
(362)
Suitable fuels
(362)
Fuel criteria
(362)
Cyclone coal burner types
(363)
Design features
(364)
Boiler furnace
(364)
Coal preparation
(365)
Coal feeders
(366)
Slag handling equipment
(367)
Oil and gas burners
(367)
Waste burning
(368)
Combustion controls
(368)
Operation
(369)
Igniters
(369)
Sectional secondary air control dampers
(369)
Low load operations
(369)
Power requirements
(369)
Maintenance
(369)
Tubing – pin studs and refractory
(369)
Tubing – flat studs
(370)
Metallization
(370)
Refractory
(370)
Coal crusher
(370)
Additional advancements
(371)
Air pollution control
(371)
Flyash
(371)
Sulfur dioxide (SO2) reduction
(371)
Nitrogen oxides (NOx) reduction
(372)
Applications
(372)
Chapter 15 Frontispiece
(373)
Chapter 16 – Stokers
(374)
Underfeed stokers
(375)
Mass feed stokers
(376)
Spreader stokers
(376)
Spreader coal firing
(377)
Feeders for spreader stokers
(377)
Grates for spreader stokers
(378)
Carbon reinjection systems
(379)
Combustion air system
(379)
Spreader stoker coal characteristics
(379)
Selection of a spreader stoker
(380)
Ash removal
(380)
Spreader stoker firing of bark, wood and other biomass fuels
(380)
Bark distributor feeders
(380)
Grates for firing bark and other biomass fuels
(381)
Combustion air system
(382)
Combustion carryover and flyash reinjection
(382)
Grate sizing
(383)
Combustion air temperature
(383)
Ash removal
(383)
Emissions
(383)
Chapter 16 Frontispiece
(385)
Chapter 17 – Fluidized-Bed Combustion
(386)
The fluidized-bed process
(386)
Bubbling fluidized-bed (BFB) boilers
(387)
Bed temperature control and fuel feed
(389)
Bed inventory control
(392)
Bed density and heat transfer (in-bed)
(392)
BFB emissions
(393)
Circulating fluidized-bed (CFB) boilers
(394)
Furnace temperature and heat transfer control
(395)
Solids separation
(396)
Solids inventory control
(397)
CFB emissions
(397)
Pressurized fluidized-bed combustion
(398)
References
(400)
Chapter 17 Frontispiece
(401)
Chapter 18 – Coal Gasification
(402)
What is gasification
(402)
Basic gasification reactions
(402)
Gasifier types and applications
(404)
Up-flow (countercurrent)
(404)
Down-flow (co-current)
(405)
Cross-flow
(405)
Fixed (Moving) bed
(405)
Fluidized bed
(406)
Entrained flow
(407)
Transport
(408)
Major gasifier process developers
(408)
GE/Texaco
(408)
Royal Dutch Shell
(409)
ConocoPhillips/E-Gas [Destec (Dow)]
(409)
British Gas/Lurgi
(409)
Winkler
(409)
Babcock & Wilcox gasifier development
(410)
Development issues
(412)
Gas cooling
(412)
Particulate removal
(413)
Sulfur removal
(414)
IGCC for power generation
(415)
Future IGCC development
(416)
References
(417)
Bibliography
(418)
Chapter 18 Frontispiece
(419)
Chapter 19 – Boilers, Superheaters and Reheaters
(420)
Boilers
(420)
Boiler configurations
(420)
Boiler design
(422)
Enclosure surface design
(423)
Convection boiler surface
(425)
Numerical analysis
(426)
Design of pressure parts
(427)
Boiler enclosure
(427)
Boiler supports
(427)
Superheaters and reheaters
(428)
Advantages of superheat and reheat
(428)
Superheater types
(428)
Tube geometry
(429)
Relationships in superheater design
(429)
Relationships in reheater design
(430)
Tube materials
(430)
Supports for superheaters and reheaters
(430)
Internal cleaning
(431)
External cleaning and surface spacing
(431)
Steam temperature adjustment and control
(431)
Definitions of terms
(432)
Effect of operating variables
(432)
Adjustment
(433)
Control
(433)
Bypass and startup systems
(435)
UP boiler startup systems
(435)
Drum boiler bypass system
(439)
Operation
(439)
Chapter 19 Frontispiece
(441)
Chapter 20 – Economizers and Air Heaters
(442)
ECONOMIZERS
(442)
Economizer surface types
(442)
Bare tube
(442)
Extended surfaces
(443)
Velocity limits
(444)
Other types of economizers
(445)
Steaming economizers
(445)
Performance
(445)
Heat transfer
(445)
Gas-side resistance
(446)
Water-side pressure drop
(446)
Economizer support systems
(446)
Bank size
(447)
Access requirements
(447)
Headers
(447)
Vibration ties
(447)
Tube geometry, materials and code requirements
(447)
SCR considerations
(448)
AIR HEATERS
(448)
Classification of air heaters
(448)
Recuperative
(448)
Regenerative
(450)
Advantages and disadvantages
(453)
Performance and testing
(453)
Thermal performance
(453)
Leakage
(453)
Pressure drop
(454)
Operational concerns
(454)
Corrosion
(454)
Plugging and cleaning
(455)
Erosion
(455)
Fires
(455)
Utility applications
(456)
Industrial applications
(456)
Environmental air heater application
(456)
NOx removal
(456)
SO2 reduction
(457)
Bibliography
(458)
Chapter 20 Frontispiece
(459)
Chapter 21 – Fuel Ash Effects on Boiler Design and Operation
(460)
Ash content of coal
(460)
Furnace design for ash removal
(461)
Ash deposition
(462)
Characteristics of coal ash
(462)
Sources of coal ash
(462)
Mineralogical composition
(463)
Chemical composition
(463)
Ash fusibility
(464)
Influence of ash elements
(466)
Ash classification
(466)
Effect of iron
(466)
Base to acid ratio
(467)
Influence of alkalies on fouling
(469)
Viscosity-temperature relationship of coal ash
(470)
Ash reflectivity
(472)
Ash characterization methods
(472)
Ash classification
(472)
Coal ash effects on boiler design
(473)
Furnace design
(473)
Effect of slagging potential on furnace sizing
(475)
Convection pass design
(475)
Flyash erosion
(476)
Effect of operating variables
(476)
Application of advanced diagnostic and control systems
(476)
Non-routine ash evaluation methods
(477)
Laboratory ashing furnace
(477)
Measurement of ash viscosity
(478)
Ash sintering strength
(478)
Measurement of ion exchangeable cations in coal
(478)
Coal ash corrosion
(479)
General characteristics of corrosion
(480)
Corrosive ash deposits
(480)
Corrosion mechanisms
(481)
Corrective measures
(481)
Fuel oil ash
(481)
Origin of ash
(482)
Release of ash during combustion
(482)
Oil slag formation and deposits
(482)
Characteristics of fuel oil ash
(483)
Boiler design
(483)
Boiler operation
(483)
Oil ash corrosion
(484)
High temperature corrosion
(484)
Low temperature corrosion
(484)
Methods of control
(484)
Fuel oil supply
(485)
Fuel oil additives
(485)
Excess air control
(486)
Chapter 21 Frontispiece
(487)
Chapter 22 – Performance Calculations
(488)
Operating conditions
(489)
Heat and material balances
(490)
Component performance calculations
(490)
Furnace
(490)
Screen
(491)
Heat transfer
(491)
Draft loss
(495)
Pressure drop
(495)
Superheater
(495)
Heat transfer
(495)
Draft loss
(498)
Steam pressure drop
(498)
Boiler bank
(498)
Heat transfer
(498)
Draft loss
(499)
Pressure drop
(500)
Cavity between boiler bank and economizer
(500)
Heat transfer
(500)
Economizer
(500)
Heat transfer
(501)
Draft loss
(502)
Water side pressure drop
(502)
Air heater
(503)
Heat transfer
(503)
Draft loss (gas inside tubes)
(504)
Air resistance (air crossflow over tubes)
(505)
Boiler thermal performance summary
(505)
Flues, ducts and stack
(505)
Air side loss – forced draft fan outlet to furnace
(505)
Gas side loss – furnace to stack
(506)
Summary
(508)
Chapter 22 Frontispiece
(509)
Chapter 23 – Boiler Enclosures, Casing and Insulation
(510)
Boiler setting
(510)
Design requirements
(510)
Tube wall enclosures
(510)
Membrane tubes
(510)
Membrane tubes with refractory lining
(510)
Flat stud tube walls
(511)
Tangent tube walls
(511)
Flat stud and tangent tube wall upgrades
(511)
Casing enclosures
(512)
Hopper
(512)
Windbox
(512)
Tempering gas plenum
(512)
Penthouse
(512)
Design considerations
(513)
Resistance to ash, slag and erosion
(513)
Expansion
(513)
Support
(513)
Explosions
(513)
Implosions
(514)
Vibration
(514)
Heat loss
(514)
Mineral wool
(514)
Calcium silicate block
(515)
High temperature plastic
(515)
Ceramic fiber
(515)
Heat loss calculations
(515)
Ventilation, surface temperature, conditions
(515)
Leakage
(516)
Corrosion
(516)
Resistance to weather
(517)
Fabrication and assembly
(518)
Serviceability
(518)
Appearance
(518)
Chapter 23 Frontispiece
(519)
Chapter 24 – Boiler Cleaning and Ash Handling Systems
(520)
BOILER CLEANING SYSTEMS
(520)
Sootblower terminology
(520)
Cleaning medium
(520)
Peak impact pressure
(521)
Jet progression velocity
(521)
Cleaning radius and tube bank penetration
(521)
Wall box
(521)
Lance tube
(521)
Feed tube
(521)
Element
(521)
Furnace cleaning
(521)
Principles
(521)
Cleaning devices
(521)
Control considerations
(523)
Unique applications
(524)
Convection pass cleaning
(524)
Principles
(524)
Cleaning devices
(524)
Diagnostic and sootblower control techniques
(527)
Back pass/economizer cleaning
(527)
Principles
(527)
Cleaning devices
(527)
SCR catalyst cleaning
(528)
Principles
(528)
Cleaning devices
(529)
Popcorn ash
(529)
Air heater cleaning
(529)
Regenerative air heaters
(529)
Cleaning devices
(530)
Tubular air heaters
(530)
Cleaning devices
(531)
Other cleaning applications
(531)
ASH HANDLING SYSTEMS
(531)
Bottom ash systems
(532)
Hydraulic bottom ash systems
(532)
Mechanical drag systems for bottom ash
(533)
Plunger ash extractor
(534)
Mill rejects
(534)
Economizer ash systems
(534)
Flyash systems
(535)
Vacuum systems
(535)
Pressure systems
(536)
Combination vacuum/pressure systems
(537)
Dense phase systems
(538)
Separation and storage
(538)
Silo unloading equipment
(539)
Chapter 24 Frontispiece
(541)
Chapter 25 — Boiler Auxiliaries
(542)
Safety and relief valves
(542)
Code requirements for once-through boilers
(543)
Air and flue gas dampers
(544)
Louver dampers
(544)
Round or wafer dampers
(545)
Guillotine or slidegate dampers
(545)
Expansion joints
(546)
Stacks and draft
(547)
Stack effect
(547)
Sample stack effect calculation
(548)
Chimney or stack
(549)
Stack flow loss
(549)
Sample stack size selection
(550)
External factors affecting stack height
(551)
Stack design
(551)
Stack operation and maintenance
(551)
Fans
(551)
Power
(551)
Fan performance
(552)
Fan capacity margins
(554)
System effects and fan margin
(554)
Typical fan applications
(554)
Forced draft fan
(554)
Induced draft fan
(555)
Gas recirculation fans
(555)
Primary air fans
(555)
Fan maintenance
(555)
Fan testing
(555)
Fan types
(556)
Centrifugal fans
(556)
Control of centrifugal fan output
(556)
Axial flow fans
(558)
Performance and control characteristics
(559)
Parallel operation
(559)
Stall characteristics
(560)
Stall prevention
(560)
Fan arrangement
(560)
Induced draft fan blade wear
(561)
Aerodynamic characteristics
(561)
Types of fan shaft bearings
(561)
Acoustic noise
(561)
Condensing attemperator system
(562)
References
(564)
Chapter 25 Frontispiece
(565)
Chapter 26 – Fossil Fuel Boilers for Electric Power
(566)
Selection of steam generating equipment
(566)
Boiler designer’s requirements
(567)
Design practice
(567)
Fuels
(567)
Steam requirements
(568)
Steam flow requirement
(569)
Boiler feedwater
(570)
Environmental considerations
(570)
Space and geographical considerations
(570)
Power for driving auxiliaries
(571)
Guarantees
(571)
Pulverized coal firing
(571)
Babcock & Wilcox pulverized coal-fired boiler types for electric power
(571)
Supercritical (once-through) boilers
(571)
Spiral wound UP boiler – variable pressure operation with pulverized coal
(572)
Universal Pressure boiler for load cycling operation with pulverized coals
(574)
Advanced supercritical boiler designs
(575)
Subcritical (drum) boilers
(576)
Radiant boiler for pulverized coal – Carolina
(577)
Radiant boiler for pulverized coal – Tower
(579)
Radiant boiler for anthracite – Downshot
(580)
Oil- and gas-fired utility boilers
(581)
Fuels
(581)
B&W Radiant boiler for natural gas and oil
(581)
Chapter 26 Frontispiece
(583)
Chapter 27 – Boilers for Industry and Small Power
(584)
Industrial boiler design
(584)
Steam requirements
(585)
Combined cycles
(587)
Simple combined cycle system
(588)
Commercial combined cycle systems
(588)
Water treatment
(589)
Other design requirements
(589)
Environmental control
(590)
B&W boilers for solid and multifuel applications
(591)
Stirling power boilers
(591)
Towerpak boiler
(591)
Circulating fluidized-bed boiler
(591)
Bubbling fluidized-bed boiler
(594)
B&W boilers for oil and gas applications
(595)
FM boiler
(595)
High Capacity FM boiler
(595)
PFM boiler
(595)
PFI boiler
(596)
PFT boiler
(596)
Enhanced Oil Recovery steam generator
(597)
B&W boilers for specialty and waste heat applications
(598)
Heat recovery steam generator
(598)
CO boiler
(600)
General waste heat boiler
(601)
Heat transfer from waste gases
(601)
Application factors
(602)
Basic oxygen furnace/oxygen converter hood
(603)
Chapter 27 Frontispiece
(605)
Chapter 28 – Chemical and Heat Recovery in the Paper Industry
(606)
Major pulping processes
(606)
Kraft pulping and recovery process
(606)
Kraft process
(606)
Rated capacity of a recovery unit
(608)
Process flows through the recovery boiler
(609)
Boiler thermal performance
(609)
Black liquor as a fuel
(612)
Black liquor
(612)
Emissions
(613)
Ash
(613)
Recovery boiler design evolution
(615)
Wall and floor construction
(616)
Two-drum generating bank
(617)
Evolution of the modern, single-drum design
(617)
Black liquor solids concentration
(617)
Floor design
(617)
Superheater design
(618)
Economizer design
(619)
Combustion air system
(620)
Design considerations for B&W recovery boiler
(620)
Furnace design
(620)
Upper furnace and arch arrangement
(621)
Furnace screen
(621)
Convection surface
(622)
Superheater
(622)
Boiler bank
(622)
Economizer
(623)
Emergency shutdown system
(623)
Recovery boiler auxiliary systems
(623)
Black liquor evaporation
(623)
Black liquor oxidation
(624)
Black liquor system
(625)
Ash system
(626)
Combustion air system
(626)
Flue gas system
(628)
Cleaning system
(628)
Auxiliary fuel system
(628)
Non-condensable gases/waste streams
(628)
Smelt spout system
(629)
Green liquor system
(630)
Alternate processes and liquors
(630)
Soda process
(630)
Nonwood fiber liquor
(631)
Sulfite process
(631)
Black liquor gasification
(632)
Advanced technologies – gasifier development
(632)
Potential BLG advantages
(632)
BLG processes
(633)
Status and development needs
(633)
References
(634)
Chapter 28 Frontispiece
(635)
Chapter 29 – Waste-to-Energy Installations
(636)
Refuse combustion alternatives
(637)
Corrosion
(637)
Lower furnace corrosion
(638)
Mass-fired units
(638)
RDF-fired units
(640)
Mass burning
(640)
Overall boiler design and gas flow path
(641)
Boiler plant sizing
(643)
Stoker capacity
(644)
Stoker design
(645)
Fuel handling
(646)
Fuel feed system
(646)
Combustion air system
(646)
Ash handling systems
(647)
Ash extractor
(647)
Scrubber, precipitator, and baghouse flyash
(647)
RDF firing
(648)
Dedicated RDF-fired boilers
(648)
RDF processing
(649)
RDF yield
(650)
RDF quality
(651)
RDF processing systems
(651)
Fuel feed system: metering feeders
(652)
Air-swept distributor spouts
(652)
Traveling grate stoker
(652)
Fluidized-bed combustion
(653)
Lower furnace design configuration
(653)
Furnace exit gas temperature
(653)
Ash handling systems
(653)
Retrofits to RDF
(654)
Boiler components
(655)
Superheater
(655)
Boiler design
(655)
Air heater
(656)
Ash cleaning equipment
(656)
Auxiliary input burners
(656)
Upper furnace maintenance platforms
(657)
Air pollution control equipment
(657)
Dry systems
(657)
NOx and CO control
(658)
Wet systems
(658)
Chapter 29 Frontispiece
(659)
Chapter 30 – Wood and Biomass Installations
(660)
Steam supply for power production
(660)
Cogeneration in industry
(660)
Biomass-fired utilities
(660)
Steam supply to process
(661)
Pulp and paper
(661)
Food processing
(661)
Fuels
(662)
Constituents
(662)
Burning wood and biomass
(662)
Burning in combination with traditional fuels
(663)
Sludge burning
(663)
Combustion systems
(663)
Dutch oven
(663)
Pinhole grate
(663)
Traveling grate
(664)
Vibrating grate
(664)
Furnace configurations
(665)
Dryers and pulverizers
(666)
Fluidized-bed combustion
(666)
Boiler component design for wood and biomass burning
(666)
Grate
(666)
Fuel distributor
(667)
Burners
(667)
Furnace
(667)
Superheater
(667)
Boiler bank
(667)
Economizer
(667)
Air heater
(668)
Auxiliary equipment
(668)
Air systems
(669)
Emissions control equipment
(669)
Environmental impact
(670)
Particulate emissions
(670)
Nitrogen oxides
(670)
Sulfur dioxide
(670)
Carbon monoxide
(670)
Volatile organic compounds
(670)
Chapter 30 Frontispiece
(671)
Chapter 31 – Marine Applications
(672)
General design considerations
(672)
Integral Furnace naval boiler
(672)
Indicated field of application
(673)
General comments
(673)
Integral Furnace merchant boiler
(673)
Indicated field of application
(674)
General comments
(674)
Reheat boilers
(674)
Coal-fired marine boilers
(674)
Auxiliary package marine boilers
(675)
Waste heat marine boilers
(676)
Marine boiler design
(677)
Oil burners
(677)
Furnace heat absorption
(678)
Furnace tube temperatures
(678)
Boiler tube banks
(679)
Superheaters
(679)
Superheater fouling and high temperature corrosion
(680)
Steam temperature control
(680)
Auxiliary desuperheaters
(681)
Reheaters
(681)
Economizer and air heater cycles
(681)
Boiler casing
(683)
Circulation and steam separation
(683)
Chapter 31 Frontispiece
(685)
Chapter 32 – Environmental Considerations
(686)
Sources of plant emissions and discharges
(686)
Air pollution control
(686)
U.S. legislation – Clean Air Act
(686)
The 1990 Clean Air Act Amendments
(689)
International regulations – air pollution control
(691)
Kinds of pollutants, sources and impacts
(691)
Air pollution control technologies
(693)
Mercury emissions and control technologies
(695)
Regulatory considerations
(695)
Mercury in U.S. coals
(695)
Mercury in coal combustion flue gas
(695)
Mercury control technologies
(696)
Mercury capture in conventional coal-fired systems
(697)
Enhanced mercury capture
(697)
Water pollution control
(698)
U.S. legislation – Clean Water Act
(698)
Power plant discharge sources
(698)
Water pollution control technologies
(700)
Solid waste disposal
(700)
The Resource Conservation and Recovery Act
(700)
Solid combustion wastes
(701)
Solid waste treatment methods
(701)
Disposal and utilization methods and requirements
(702)
References
(702)
Chapter 32 Frontispiece
(703)
Chapter 33 – Particulate Control
(704)
Regulation of particulate emissions
(704)
Particulate control technologies
(705)
Dry electrostatic precipitators
(705)
Dry ESP applications
(706)
Dry precipitator components
(707)
Dry precipitator sizing factors
(709)
Performance enhancements
(710)
Wet electrostatic precipitators
(711)
Fabric filters
(711)
Operating fundamentals
(711)
Types of fabric filters
(712)
Design parameters
(713)
Applications
(713)
Fabric filter components
(714)
Casing, hoppers and dampers
(714)
Bag materials and supports
(714)
Filter media cleaning
(714)
Mechanical collectors
(715)
Wet particulate scrubbers
(715)
Equipment selection
(715)
References
(716)
Chapter 33 Frontispiece
(717)
Chapter 34 – Nitrogen Oxides Control
(718)
NOx formation mechanisms
(718)
Thermal NOx
(718)
Fuel NOx
(718)
Global effects of NOx in atmosphere
(719)
Acid rain
(719)
Particulate matter
(719)
NOx control technologies in steam generation
(719)
Pre-combustion fuel switching
(719)
Combustion control
(720)
Post-combustion reduction
(720)
Selective catalytic reduction
(720)
NOx reduction process
(720)
SCR system description
(720)
Catalyst
(722)
Ammonia reagents and control
(723)
Ammonia flow controls
(725)
Distribution requirements
(725)
Injection design and mixing
(726)
Operating issues
(727)
Retrofit and general equipment issues
(727)
Operating system service needs
(728)
Technology enhancements
(730)
Selective noncatalytic reduction technology
(730)
NOx reduction reaction
(730)
Reagent equipment and injection
(731)
Emerging technologies
(731)
References
(732)
Bibliography
(732)
Chapter 34 Frontispiece
(733)
Chapter 35 – Sulfur Dioxide Control
(734)
SO2 emissions regulations
(734)
SO2 control
(734)
Wet scrubbers
(735)
Reagents
(735)
Absorber design
(735)
Absorption of SO2
(738)
Limestone forced oxidized (LSFO) process description
(739)
Reagent preparation
(739)
Slurry dewatering and disposal
(741)
Purge system
(741)
WFGD system water balance
(741)
Process flow diagram and mass balance
(741)
Wet scrubber chemistry
(742)
Performance enhancing additives
(745)
Dry scrubbers
(745)
System design
(746)
Process description
(747)
Process flow diagram and mass balance
(749)
Dry scrubber chemistry
(749)
Sulfur trioxide (SO3)
(751)
SO3 and acid mist formation
(751)
Control methods
(751)
References
(752)
Bibliography
(752)
Chapter 35 Frontispiece
(753)
Chapter 36 – Environmental Measurement
(754)
Instrumentation
(754)
pH measurement
(754)
Liquid level
(755)
Solids level
(756)
Solids concentration (density)
(757)
Pressure, flow and temperature
(757)
Continuous emission monitoring systems
(757)
Monitoring process performance
(759)
Performance testing
(760)
Sample location selection
(760)
Gas-side measurements
(761)
Particulate and SO2 removal efficiencies
(766)
Stack opacity
(766)
NOx concentration
(766)
NH3 concentration
(766)
Condensible particulate matter
(766)
Makeup water requirements
(766)
Reagent consumption
(766)
Gypsum purity
(766)
Other test methods
(766)
Mercury emissions measurement
(766)
The future of environmental measurement
(767)
Bibliography
(767)
Chapter 36 Frontispiece
(769)
Chapter 37 – Equipment Specification, Economics and Evaluation
(770)
Project feasibility studies and technology selection
(770)
Specifications
(771)
Performance – steam generating equipment
(771)
Performance – environmental control systems
(773)
Project requirements
(774)
Scope of work
(774)
Commercial terms and conditions
(776)
Evaluation criteria
(776)
General bid evaluation
(776)
Scope
(777)
Operating ease
(777)
Maintenance costs
(777)
Operating costs
(777)
Service organization
(777)
Design features
(777)
Construction features
(777)
Schedule
(777)
Project management and project team
(777)
Experience
(778)
Terms and price
(778)
Commercial structure
(778)
Traditional commercial structures
(778)
Collaborative partnerships/alliances
(778)
Power system economics
(779)
Constant versus current cost basis
(780)
Definitions
(780)
System cost evaluation
(780)
Evaluation parameters
(781)
Methods for evaluating operating costs
(782)
Other considerations
(782)
Examples
(783)
Example 1
(784)
Example 2
(785)
Example 3
(785)
Example 4
(786)
References
(783)
Chapter 37 Frontispiece
(787)
Chapter 38 – Manufacturing
(788)
Welding
(788)
Welding automation
(788)
Metal removal
(789)
Forming
(790)
Castings
(791)
Fabrication of fossil fuel equipment
(792)
Drum fabrication
(792)
Headers as terminal pressure vessels
(793)
Tubes as heat transfer surfaces
(793)
Longflow economizers
(795)
Structural steel and casings
(795)
Fuel preparation and burning equipment
(795)
Tube manufacturing
(797)
Engineering-manufacturing interface
(797)
Quality assurance and quality control
(797)
Nondestructive examination
(798)
Quality control of fossil fuel equipment
(799)
Technologies
(799)
Reference
(800)
Chapter 38 Frontispiece
(801)
Chapter 39 – Construction
(802)
Estimating and cost development
(803)
Scope
(803)
Direct costs
(803)
Installation factors
(803)
Indirect labor and support requirements
(803)
Other factors
(803)
Schedule and project plan development
(803)
Construction project management
(804)
Design for constructability
(805)
Implementation
(805)
Evaluation
(805)
Integrated design process for retrofits
(805)
Construction technology
(806)
Approaches to construction – erection methodology
(807)
Construction engineering and rigging design
(809)
Background
(809)
Engineering principles
(809)
Engineered systems
(809)
Material handling and setting considerations
(809)
Serviceability
(810)
Imposed loads and forces
(810)
Load stability
(811)
Load control
(811)
Load distribution
(811)
Design loading
(812)
Other site considerations – storage
(812)
Construction of a fossil fuel unit
(812)
Structural supports
(812)
Assembly of pressure components
(813)
Field welding
(814)
Processes and equipment
(815)
Applications
(815)
Qualification of welding procedures and personnel
(815)
Thermal treatment
(815)
Codes, inspections and examinations
(815)
Construction of environmental equipment
(816)
Sequencing and modularization
(816)
Construction safety
(817)
Internal cleanliness of pressure parts
(817)
Manufacturing and shipping
(817)
Field assembly
(817)
Post-construction testing
(818)
Hydrostatic testing
(818)
Air testing
(819)
Assembly of nonpressure parts and auxiliaries
(819)
Refractory materials
(819)
Casing
(819)
Insulation
(819)
Sheet metal lagging
(820)
Pre-operational inspection
(820)
References
(820)
Chapter 39 Frontispiece
(821)
Chapter 40 – Pressure, Temperature, Quality and Flow Measurement
(822)
Pressure measurement
(822)
Instrument corrections
(824)
Location of pressure measurement connections
(824)
Temperature measurement
(824)
Methods of measuring temperature
(825)
Changes of state
(825)
Expansion properties
(825)
Radiation properties
(826)
Optical properties
(827)
Electrical properties
(827)
Acoustic properties
(827)
Other properties
(828)
Thermocouples
(828)
Multiple circuits
(828)
Practical application and multiple circuits
(828)
Millivolt potentiometer
(831)
Direct reading potentiometer
(831)
Temperature recorders
(831)
Temperature of fluids inside pipes
(831)
Tube temperature measurement
(832)
Furnace wall tubes
(832)
Gradient thermocouple
(833)
Superheater and reheater applications
(835)
Gas temperature measurement
(835)
High velocity thermocouple
(835)
Measurement evaluations
(837)
Insulation and casing temperature
(837)
Outer surfaces
(837)
Steel casings
(837)
Measurement of steam quality and purity
(838)
Obtaining the steam sample
(838)
Sodium tracer method
(838)
Conductivity method
(839)
Throttling calorimeter
(840)
Gravimetric analysis
(840)
Flow measurement
(841)
Computer application to measurement
(845)
Performance computation
(845)
Process control
(845)
Data acquisition system
(845)
Signal multiplexer
(845)
Data acquisition computer program
(845)
References
(846)
Bibliography
(846)
Chapter 40 Frontispiece
(847)
Chapter 41 – Controls for Fossil Fuel-Fired Steam Generating Plants
(848)
Basic control theory
(848)
Open loop control
(849)
Closed loop control
(849)
Proportional control
(849)
Proportional plus integral control
(851)
Proportional plus integral plus derivative control
(851)
Feedforward/feedback control
(851)
Control system design philosophy for a utility boiler
(852)
Characteristics of different control modes
(852)
Variable pressure operation
(854)
Cycling operation
(854)
Feedwater control systems
(855)
Furnace draft control
(857)
Superheat and reheat temperature control
(857)
Combustion control systems (air and fuel flow control)
(857)
Control system design philosophy for Universal Pressure once-through boilers
(859)
Combustion guides
(860)
Excess Air
(860)
Steam flow-air flow
(860)
Air flow measurement
(860)
Fuel flow-air flow
(860)
Fuel flow measurement
(860)
Gas analysis
(861)
Comparison of combustion guides
(861)
Burner management systems
(861)
Supervised manual control
(861)
Remote manual sequence control
(861)
Automatic sequence control
(861)
Fuel management
(862)
Flame detection
(862)
Classification of lighters/igniters
(863)
Failure mode analysis
(864)
Post-combustion NOx emissions control
(864)
Ammonia flow control
(864)
Flue gas inlet temperature
(864)
SO2 emissions control
(864)
Wet scrubbers
(864)
Dry scrubbers
(866)
Developments in instrumentation and controls
(866)
Power plant automation
(866)
Human factor engineering
(867)
Smart transmitters
(867)
Installation and service requirements
(868)
Performance monitoring
(868)
Chapter 41 Frontispiece
(869)
Chapter 42 – Water and Steam Chemistry, Deposits and Corrosion
(870)
Chemistry-boiler interactions
(870)
Control of deposition, corrosion, and steam purity
(871)
Boiler feedwater
(873)
Makeup water
(874)
Returned condensate – condensate polishing
(875)
Feedwater pH control
(875)
Deaeration and chemical oxygen scavengers
(875)
Attemperation water
(876)
Drum boilers and internal boiler water
(876)
Blowdown
(876)
Traditional all volatile treatment
(877)
Oxygen treatment
(877)
Coordinated phosphate treatment
(877)
High-alkalinity phosphate treatment (low-pressure boilers only)
(880)
Dispersants, polymers, and chelants (low pressure boilers only)
(880)
Once-through universal pressure boilers
(881)
Steam purity
(881)
Water sampling and analysis
(882)
Common fluid-side corrosion problems
(883)
Pre-operational cleaning
(887)
Alkaline boilout
(887)
Chemical cleaning
(887)
Steam line blowing
(888)
Periodic chemical cleaning
(888)
Cleaning frequency
(888)
Chordal thermocouples
(888)
Chemical cleaning procedures and methods
(889)
Circulation cleaning method
(889)
Soaking method
(890)
Solvents
(890)
Deposits
(890)
Inhibitors
(891)
Determination of solvent conditions
(891)
Preparation for cleaning
(892)
Cleaning procedures
(892)
Precautions
(893)
Chemical cleaning of superheater, reheater and steam piping
(893)
Solvent disposal
(893)
Layup
(894)
Boiler shutdown for layup
(894)
Draining for boiler maintenance and inspection
(895)
Hot standby and hot layup
(895)
Cold standby for up to thirty days
(896)
Boiler storage for more than seven days
(896)
Reheaters – all periods
(896)
Nitrogen blanketing
(896)
Wet (water-filled) layup
(896)
Dry (dehumidified) layup
(896)
Vaporous corrosion inhibitors (VCI)
(897)
References
(897)
Chapter 42 Frontispiece
(899)
Chapter 43 – Boiler Operations
(900)
General boiler operations
(900)
Fundamental principles
(900)
Initial commissioning operations
(901)
Operator requirements
(901)
Preparations for startup
(901)
Operating techniques for maximum efficiency
(905)
Key operation functions
(906)
Shutdown operations
(908)
Operation of Cyclone furnaces
(909)
Fuels
(909)
Combustion air
(909)
Operation of once-through boilers
(910)
Principles
(910)
Operating practice
(910)
Operating skills
(911)
Operation of fluidized-bed boilers
(912)
CFB systems overview
(912)
BFB systems
(914)
Operation of Kraft recovery boilers
(914)
Overview
(914)
Black liquor combustion process and air flow
(915)
Auxiliary burners
(915)
Operating problems
(915)
Smelt-water reactions
(916)
Chapter 43 Frontispiece
(917)
Chapter 44 – Maintaining Availability
(918)
Strategic plan for high availability
(918)
Emphasis on high availability
(918)
Increased capacity and operability
(919)
Strategic plans yield high returns on investment
(919)
Impact of environmental regulations
(919)
Maintaining availability
(919)
Pulverizer availability improvement strategies – E and EL mills
(920)
Pulverizer degradation mechanisms
(920)
E and EL upgrades
(920)
Roll wheel pulverizer upgrades
(921)
Low temperature pressure components
(922)
Degradation mechanisms
(923)
Availability improvement strategy examples
(924)
High temperature pressure components
(928)
High temperature component degradation mechanisms
(928)
Availability improvement strategy examples
(930)
Circulation upgrades
(932)
Cycling boiler upgrades
(932)
Drum boiler bypass system upgrade
(933)
Circulation improvements
(933)
Strategies for fuel switching while maintaining high commercial availability
(935)
Fuel switching example
(935)
Capacity upgrades and environmental regulations
(937)
Example strategy for capacity upgrade while maintaining high commercial availability
(937)
Chapter 44 Frontispiece
(939)
Chapter 45 – Condition Assessment
(940)
Condition assessment examination methods
(940)
Nondestructive examinations
(940)
Destructive examinations
(945)
Condition assessment of boiler components and auxiliaries
(945)
Boiler drums
(945)
Boiler tubing
(946)
Headers
(946)
Attemperators
(948)
High temperature piping
(948)
Low temperature piping
(949)
Tubular air heaters
(950)
Boiler settings
(950)
Analysis techniques
(950)
Steam-cooled tubes
(950)
Water-cooled tubes
(952)
Headers and piping
(953)
Destructive samples
(955)
Leak detection
(955)
Cycling effects and solutions
(956)
Cycle definition
(956)
Economizer thermal shock
(956)
Furnace subcooling
(957)
Tube leg flexibility
(958)
Drums
(959)
Developments
(959)
Advances in nondestructive examinations
(959)
References
(960)
Chapter 45 Frontispiece
(961)
Chapter 46 – Steam Generation from Nuclear Energy
(962)
First generation power plants
(962)
Second generation power plants
(963)
PWR installations
(964)
Containment building
(964)
Nuclear steam supply system (NSSS)
(965)
PWR reactor and fuel
(966)
Reactor vessel and internals
(966)
Fuel assemblies
(969)
Refueling
(971)
Energy transport
(972)
Instrumentation
(973)
Reactor vessel closure heads
(970)
Background
(970)
Closure head replacement requirements
(970)
Replacement head features
(970)
Steam generators
(973)
Pressurizer
(973)
Description
(973)
Function
(973)
Heaters
(974)
Spray
(974)
Pressure control devices
(974)
Pumps and piping
(974)
Description and function
(974)
Pump characteristics
(975)
Integrated control system
(975)
Function
(975)
Limits and controls
(976)
Reactor protection system
(976)
Function
(976)
Safety features actuation system
(976)
High pressure injection system
(976)
Low pressure injection system
(977)
Core flood system
(977)
Reactor building cooling and spray systems
(978)
Decay heat removal system
(978)
Makeup and purification system
(978)
Abnormal transient operating guidelines
(979)
NSSS design: today and in the future
(979)
Nuclear ship propulsion
(980)
Commercial nuclear ships
(981)
Nuclear merchant ship Savannah
(981)
Nuclear merchant ship Otto Hahn
(982)
Naval nuclear ships
(982)
U.S. naval nuclear propulsion program
(982)
U.S.S. Nautilus
(983)
U.S.S. Seawolf
(984)
U.S.S. Skipjack
(985)
Technological advancements
(985)
International naval nuclear programs
(985)
Future U.S. Navy
(985)
Submarines
(985)
Aircraft carriers
(986)
References
(986)
Chapter 46 Frontispiece
(987)
Chapter 47 – Fundamentals of Nuclear Energy
(988)
Fundamental particles and structure of the atom
(988)
Nuclides and isotopes
(988)
Mass
(989)
Mass defect
(989)
Binding energy
(989)
Radioactivity and decay
(989)
Nuclear radiations
(989)
Biological effects of radiation
(990)
Radiation protection
(990)
Decay rate
(991)
Half life
(991)
Induced nuclear reactions
(991)
Probability of nuclear reactions – cross-sections
(992)
The fission process
(993)
Energy from fission
(994)
Neutrons from fission
(994)
Fission neutron energy distribution
(994)
Burnup
(995)
Fission products
(995)
Fission product behavior with time
(996)
Nuclear reactor composition
(996)
Physical description of nuclear chain reactions
(997)
Control of the chain reaction
(998)
Reactivity
(998)
Calculation of reactor physics parameters
(999)
Cross-sections
(999)
Critical boron concentration
(1000)
Power distribution
(1000)
Control rod worths
(1000)
Reactivity coefficients
(1001)
Neutron detectors
(1001)
Neutron source
(1001)
Fast reactors
(1002)
Conversion and breeding
(1002)
References
(1002)
Chapter 47 Frontispiece
(1003)
Chapter 48 – Nuclear Steam Generators
(1004)
B&W once-through nuclear steam generator (OTSG)
(1005)
Design configuration and flow
(1005)
Modes of secondary-side heat transfer
(1006)
Instrumentation
(1007)
Recirculating steam generator (RSG)
(1007)
Design configuration and flow
(1007)
Steam-water separation
(1010)
Circulation and hydraulic performance
(1011)
Replacement steam generators
(1012)
Replacement recirculating steam generators (RRSG)
(1013)
Replacement once-through steam generators (ROTSG)
(1016)
Further development
(1017)
References
(1017)
Bibliography
(1018)
Chapter 48 Frontispiece
(1019)
Chapter 49 – Nuclear Services and Operations
(1020)
Maintenance – key issues
(1020)
Personnel protection
(1020)
Limited accessibility
(1020)
Application of remote technology
(1020)
Component maintenance
(1021)
Plant life management
(1021)
Steam generator primary side maintenance
(1022)
Steam generator secondary side maintenance
(1026)
Reactor vessel and internals
(1026)
Control rod drive mechanisms (CRDM)
(1027)
In-core instrumentation
(1028)
Reactor coolant pumps
(1028)
Pressurizer
(1028)
Instrumentation and controls (IC)
(1029)
Valves and actuators
(1029)
Piping
(1029)
Equipment diagnostics
(1029)
Refueling
(1030)
Major activities
(1030)
Fuel handling equipment
(1031)
Reactor vessel disassembly and reassembly
(1031)
Radiation detection and monitoring
(1032)
Nuclear operations
(1033)
Major licensing requirements
(1033)
Plant licensing
(1033)
Technical specifications
(1033)
Pre-operational testing
(1034)
Fuel loading and zero power testing
(1037)
Power ascension tests
(1038)
Acceptance testing
(1039)
Commercial operation
(1039)
Electrical power production
(1039)
References
(1040)
Chapter 49 Frontispiece
(1041)
Chapter 50 – Nuclear Equipment Manufacture
(1042)
Typical component description
(1042)
Manufacture of reactor vessel components
(1042)
Fabrication of replacement reactor vessel closure heads
(1042)
Manufacture of steam generators
(1043)
Cylindrical shells
(1044)
Tubesheet manufacture
(1045)
Steam generator heads
(1045)
Pressure boundary assembly
(1046)
Tube bundle components
(1047)
Tube bundle assembly
(1049)
Steam drum internals
(1051)
Final assembly
(1051)
Final inspection and testing
(1052)
Surface conditioning
(1052)
Shipping
(1053)
Manufacture of pressurizers
(1053)
Pressure boundary assembly
(1053)
Post weld heat treatment
(1053)
Manufacture of dry shielded canisters
(1054)
Reference
(1054)
Chapter 50 Frontispiece
(1055)
Symbols, Acronyms and Abbreviations
(1056)
Symbols
(1056)
Greek symbols
(1059)
Subscripts
(1059)
Acronyms and Abbreviations
(1060)
Index
(1067)
A
(1067)
B
(1068)
C
(1070)
D
(1073)
E
(1074)
F
(1075)
G
(1077)
H
(1077)
I
(1078)
J
(1078)
K
(1078)
L
(1078)
M
(1078)
N
(1079)
O
(1080)
P
(1081)
Q
(1082)
R
(1082)
S
(1083)
T
(1086)
U
(1087)
V
(1087)
W
(1087)
X
(1088)
Y
(1088)
Appendix 1 – Conversion Factors, SI Steam Properties and Useful Tables
(1089)
Part 1: Conversion Factors
(1089)
Table 1.1 Length
(1090)
Table 1.2 Length, Small Units
(1090)
Table 1.3 Area
(1090)
Table 1.4 Volume
(1090)
Table 1.5 Mass
(1090)
Table 1.6 Force
(1090)
Table 1.7 Pressure or Force per Unit Area
(1091)
Table 1.8 Energy, Work and Heat
(1091)
Table 1.9 Power or Rate of Doing Work
(1091)
Table 1.10 Density (Mass/Volume)
(1091)
Table 1.11 Thermal, Heat Transfer and Flow Parameters
(1091)
Table 1.12 Multiplying Prefixes
(1091)
Table 1.13 Selected Additional Conversion Factors
(1092)
Part 2: Systemè International d’Unitès (SI), Steam Tables Plus Selected Charts and Figures
(1089)
Table 2.1 SI Properties of Saturated Steam and Saturated Water (Temperature)
(1093)
Table 2.2 SI Properties of Saturated Steam and Saturated Water (Pressure)
(1094)
Table 2.3 SI Properties of Superheated Steam and Compressed Water (Temperature and Pressure)
(1095)
Table 2.3 (Part 2 of 2)
(1096)
Fig. 2.1 Mollier diagram (H-s) for steam – SI units
(1097)
Fig. 2.2 Pressure-enthalpy diagram for steam – SI units
(1098)
Fig. 2.3 Psychrometric chart – SI units
(1099)
Part 3: Useful Charts and Tables
(1089)
Fig. 3.1 Temperature-enthalpy diagram (MPa = 0.006895 × psi)
(1100)
Fig. 3.2 Estimates of the weight of air required for selected fuels and excess air levels
(1100)
Fig. 3.3 Estimates of the weight of the products of combustion for selected fuels and excess air levels
(1100)
Fig. 3.4 Estimates of the percent total air for flue gas percent oxygen for selected fuels
(1101)
Fig. 3.5 Estimates of efficiency loss due to unburned combustibles for selected fuels and ash contents
(1101)
Fig. 3.6 Estimates of theoretical air required for the combustion of coal based upon volatile mater content
(1101)
Table 3.1 SO2, SO3 Estimated Emissions from Boilers Firing Coal or Fuel Oil
(1101)
Table 3.2 Conversion Formulae for Emission Rates
(1102)
Table 3.3 Periodic Table of the Elements
(1103)
Part 4: Typical 500 MW Pulverized Coal-Fired Power Plant Parameters
(1089)
Table 4.1 Coal and Ash Analysis, an Example of a High Sulfur Bituminous Coal
(1104)
Table 4.2 Mechanical Equipment Nominal 500 MW PC-Fired Drum Boiler Plant
(1104)
Table 4.3 Environmental Equipment Nominal 500 MW PC-Fired Drum Boiler Plant
(1104)
Table 4.4 Plant Performance Summary Nominal 500 MW PC-Fired Drum Boiler Plant
(1104)
Appendix 2 – Codes and Standards
(1105)
The ASME Boiler and Pressure Vessel Code
(1105)
ASME BPVC history
(1105)
ASME BPVC additions
(1106)
Organization of the ASME Boiler and Pressure Vessel Committee
(1106)
Code Editions, Code Addenda and Code Cases
(1107)
Technical Inquiries
(1107)
General design philosophy and safety factors
(1107)
Allowable stress values
(1108)
Method for development of allowable stress values
(1108)
Strength theories
(1109)
Design criteria
(1109)
The ASME Code for Pressure Piping, B31
(1110)
Editions, Addenda, Cases and Interpretations
(1110)
Design philosophy, safety factors and strength theory
(1110)
Bibliography
(1110)
Selected Color Plates
(1111)
Plate 1 – B&W supercritical boiler with spiral wound Universal Pressure (SWUP) furnace
(1112)
Plate 2 – Carolina-type 550 MW Radiant boiler for pulverized coal
(1113)
Plate 3 – Large coal- and oil-fired two-drum Stirling power boiler for industry, 885,000 lb/h (112 kg/s) steam flow
(1114)
Plate 4 – Single-drum chemical recovery boiler for the pulp and paper industry
(1115)
Plate 5 – Coal-fired circulating fluidized-bed combustion steam generator
(1116)
Plate 6 – Wet flue gas desulfurization scrubber module for sulfur dioxide control
(1117)
Plate 7 – Dry flue gas desulfurization spray dryer absorber for sulfur dioxide control (upper left) and fabric filter baghouse for particulate control (lower right)
(1118)
Plate 8 – Modern 660 MW coal-fired utility boiler system with environmental control equipment
(1119)
