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Section 1&2: -excess air- somewhat more than enough air supplied

-flue gases- products of combustion


Wind PP- consists of windmill and electric generator -CO2, N2- flue gases when theoretical amt of air supply is used; with
Windmill- converts energy of wind to mechanical energy turning uncombined O2 when excess air is used
shaft of generator -incomplete combustion indicated by presence of CO
Electric Generator- device that converts mechanical energy to -analysis of flue gases- basis for judging completeness of
electrical combustion
“Tea Kettle” System- converts chem energy in fuel into electrical -process of combustion is stimulated by heat; process will not start
energy; consists of fire, tea kettle, “windmill”, electric generator until fuel is brought to kindling temp w/c makes it desirable to heat
Basic Energy Processes- conversion from one type of energy to air for combustion to increase efficiency
another; type of energy produced in steam PP is electrical energy -putting a heating coil (air preheater) in stack will provide necessary
Four Basic BEP: heat to air w/c makes it n integral part of every steam PP
1 Combustion: Conversion of Potential Chemical Energy into Heat- -bellows are replaces with fan (Forced Draft Fan); use of bellows
chem energy in coal is converted to heat (real energy) depended upon natural draft w/c is provided by stack utilized by the
2 Absorption of Heat Energy by Water- thermal energy is absorbed difference in the weight of heated air and cold air (same principle as
by water converting it to steam home fireplace)
3 Thermal Energy of Steam Converted to Mech Energy -Mechanical Draft: (1) FDF- forced air into the furnace (2) IDF-
4 Mech Energy from a Turbine is used to turn the shaft of a before the stack to draw the gases out of furnace
Generator -ash- parts of coal that did not burn; may be wet, dry, hot,dusty,
“tea kettle” system- improved by enclosing the steam generating soft/ large hard clinkers
equipment -slag- removed from the furnace by drpping into ash tank; fly ash-
Furnace- containing fire and fuel exhaust out the stack with fue gases and removed by dust collector
Boiler- tea kettle w/c receives water and converts to steam by -smoke-represents unburned coal and results from inefficient
absorbing heat from fuel operation w.c can be remedied by propercombustion
Stack- chimney in PP -85% of refuse is fly ash
Turbine- acts as windmill in PP -for ash removal- use of ash tank(w/ conveyor) removes slag and
-steam PP is same as “tea kettle” system but in a complicated way ESP removes fly ash
-objective: produce the most kWh of electricity w/ least amt of fuel -circulation currents bring the bubbles bring the bubbles to the
-50 years ago, 3 pounds coal/1 kWh; Present: <1 pound/1 kWh surface to the open space
Gas, oil, coal- most used fossil fuels Fxn of steam drum: (1) flow of water to heated areas (2) flow of
Furnace- equipment for convertin chem en to heat en; most steam and heated water to upper areas (3) release of steam to the
important equipment in PP; where actual burning takes place; gives collection area above water level
a better control over the size of the fire and control heat flow -generating tubes- increase steaming rate by increasing the heating
Types of Furnace area (attaching tubes/pipes to the drum)
1 Hand-Fired – for early furnaces like coal burning steam boilers for -boiler-consists of one steel drum connected by a number steel
home heating; problem: moving tons of coal per coal (had to be pipes connected to it; placed inside furnace so hot gases will pass
done mechanically); burning takes place in grates through the bank of tubes; steam drum- upper drum where steam
2 Stoker Fired- stoker- type f conveyor that moved the coal into the rises; receive water and start circulation by admitting water to
furnace; problem: getting a complete and rapid combustion; tubes; supply a water surface for steam separaton as mixture of
smaller lumps has more surface area and would burn more quicly water and steam arise from the tubes and collecting space for
and completely; burning takes place in grates steam; provide an outlet for the steam n its way to turb; minor fxn:
3 Puleverized Burning- ground up coal is blown into the furnace and provide water column connections to determine water level and
burning takes place in mid-air of steel box place to install a boiler pressure safety valve
-Mill –machine for grinding the coal to proper size -if water run dry in boiler, it could be hot, soften and rupture; if
-Exhauster- fan that blows the coal to furnace water is filled with too much water it can force water out of the
-Burners- openings in steel box where coal enters the furnace drum
-Cyclone Burner- burns coal at ¼’’; Conventional Burner- burns -generating tubes- in early designs; placed directly in the path of hot
coal that is ground to the fineness of face powder flue gases; receive water and discharges a mix of water and steam;
-it takes 11 lb of air/lb of fuel (SMC: 7.5 lb) replaced with water walls
-when fire is enclosed in a steel box, it is necessary to force air into -water walls- eliminated brick-lined furnace; characeristics of
the furnace modern of furnace w/c requires a layer of insulation
-Imaginary bellows- supply air for combustion -if pockets of steam is trapped ingenerating tubes would overheat
1⁰ air- air that goes to mill to pick up powdered coal and rupture; causes hot spots; can be eliminated by proper
2⁰ air- eneters the furnace through dampers near the burner arrangement of drums and tubes
-heat is supplied by a gas/ oil torch w/c brings the temp in the -mud drum- lowest point of water in boiler; where impurities
furnace up to the ignition temp concentrates
-ignition temp- temp at w/c coal will burn -saturated steam- steam at temp same as boiling point; water in
-combustion continues because heat from burning coal is available steam is like sand in blast jet
-air is mainly composed of 21% O2, 78% N2, 1% Ar -superheater-adds heat to the stem after it leaves drum;
-O2 will combine w/ carbon in fuel forming CO2/CO arrangemet of steel alloy placed in gas path
-CO is to be avoided since coal is partially burned and releases ½ of -superheated steam has two advantages (1) increases efficiency (2)
heat available; goal: increase CO2 in order obtain more heat less likely to condense in turb
-perfect mixing of air and coal is not possible
-turbine- changes steam enrgy to mechanical energy; blades are
arranged n group called stages; one third of energy has been given
up in three stages w/c leaves as exhaust steam; commercial turb has
multiple nozzles and blades ith curved entrances and exits
-reheaters- ssuperheaters that reheat steam ; after HP turbine, t
goes to reheater located at gas path; reheated steam has temp close
t the primary steam with lower pressure
-use of vacuum in the exhaust of turb: better turb efficiency- atm
exerts abot 15 psi around turb, removing this pressure, steam will
encounter less resstance
Cooling water- lrgest water system; it takes 1200 tons (300,000
gallons to cool exhaust produced by 1 ton of coal
-condenser- create vacuum ad convert steam to water to be reused
-excess air in condenser can cause the condenser to be air bound
w.c cause loss of vac and decreasing cooling of exhaust steam
-evactor- remove air in condenser
-hotwell- a chamber that collects still warm
-condensate pump- pumps the water/condensate to FW heaters
-make-up water- added to mainitain water level in hotwell; must be
very pure; utreated water can scale the boiler; water treatment
apparatus (demineralizing system) is essential for processing make-
up water
-cold water cannot be added diretly to boiler: (1) lower the temp n
the boiler w.c decreases steaming rate (2) produ ce strain because
of temp diff between water and boiler
-for FW heaters: steam can be extracted from the intermediate
stages of turb; better to extract at the exhaust end (lower pressure);
two FW heaters: low P, low T heater and high P, High T heater
-regenerative FW heating- heating the boiler FW; can be s many as
8 heaters
-deaerating heater-adds heat and remove dissolved gases
-economizer- located in the path between reheaters and air
reheater; can increase the economy by adding bank of tubes
-boiler feed pump- get water to steam drum; must operate at a
pressure high enough to overcome pressure in boiler; if pumps fail,
boiler can dry at about 90 secs
-controls regulate: quantity of coal and air, turb speed, turb load,
steam and water P, levels, temp
-subsytems: systems for lubrication, fuel oil and natural gas supply,
air and compressed air supply
Section 3: -balanced draft- combustion takes place less than atm P
-draft- force that causes air (gases to be set in motion
-most work in science and math is based upon exact -chimney draft is natural draft
measurement of physical quantities -heated air in chimney exerts less downward pressure
-three fundamental units: mass , length, time -fans and blowers are used to move the gases in and out of
-length-measure of distance from one point to another the furnace
-mass- measure of quantitiy of matter -flow/flow rate –refers to the ovement of specific quantity of
-time- measure of period during w/c an event occurs gas/liquid within specific time
-three unit systems: English sys, mks sys, cgs sys -fan and air compressor rating is usually expressed in CFM
-In US, mks with some cgs is used for physics calculations (cubic feet/min)
while English is used for engineering calculations -unbalanced pressure- make fluid move or flow from high P to
-mks system- denotes powers of 10 low P
-properties of subs- observable and measurable -friction/resistance to flow has to be overcome; resistances:
characteristics of substace fluid rubbing against interior surfaces of piping, changes in
1 Mass- measure of amont of substance present direction of flow or obstructions
-weight- force exerted by the subs when it is pulled by -pressure is needed to maintain flow of fluids and overcome
gravity friction and resistance
-in PP, mass = weight -pumps - move liquids
2 Volume – measure of amt of space it occupies -pressure drop only occurs when there is a fluid flow
3 Density- mass/volume -three ways to measure flow: (1) measuring pressure drop
-Specific Gravity- measure of relative density compared to (head loss) across a certain length of pipe (2) measuring P
water; unit less quantity drop on either side of an orifice plate/nozzle (3) measuring P
4 Pressure- force per unit area drop across a venture tube
-three ways to create pressure: (1) weight of substance (2) -orifice plate-cause larger pressure drop which is easier to
mechanical force (3) heating a fluid in enclosed container measure
-solid object cause pressure due to its weight; pressure= -venturi tube- constricts or narrows the area; operation is
weight/area based on high velocity, low pressure vice versa
-air contains nitrogen, oxygen, argon, carbon dioxide, -air pressure differential- difference in air pressure between
hydrogen, neon, krypton, helium, xenon inlet and outlet of air flow path
- air is held around the Earth by force of gravity -reading air pressure indicates air flow; change in readings
-container may rupture/explode due to high steam P indicate that the equipment is not operating properly
-in PP, almost all pressure measurements are in psi -draft gages-indicate the pressure at various places in the
-barometer- measures atmospheric pressure boiler; determine whether boiler is foled/plugged w/ ash w/c
-vacuum- pressures less than atm P causes greater pressure diff
-perfect vacuum – 0 psi, 30”Hg
-any gases mixed with steam decreases vacuum and Section 4
prevent efficient heat transfer -energy- capacity to do work
-back pressure- special term in PP used to refer to -work- action of a force moving an object through a distance
vacuum; absolute pressure at the point where steam leaves -defining energy by observing the amount of work it does
the turb to enter condenser -types of energy: mech en, chem en, elec en, thermal en,
-differential pressure- pressure measured at two diff nuclear en
points; usually used by flow measuring devices -total energy of subs- sum of magnitudes of various types of
-manometer- measures pressure energy
-the greater the pressure, the greater the height -energies (prop of subs) important in PP: potential energy,
-Bourdon Tube gage- mst commonly used instruments in kinetic energy, PV energy, internal energy
PP; indicate pressure in psi; usually measurespressure of -forms of energy w/c are not prop of subs: work, heat (this
water, oil and steam; calibrated in psig; indicate both pressure energy are transit, can be transferred from or to subs)
and vac -potential energy- energy of position
-vac is usually measure by mercury filled manometer and -kinetic energy- energy of motio; the heavier the body, the
occurs at the opposite leg of manometer greater the velocity, the greater kinetic energy
-head- pressure produced by large pum; water will rise to -potential and kinetic energy are energies associated with
height directly proportional to the head produced by pump with substance as a whole; in terms of velocity and position of
-discharge head- height of water level in tank above center subs
line of pump -a substance possesses several forms of energy due to
-head in feet- pressure produced by BFP vibration, rotation and movement of molecule; temperature
-draft/negative P- pressure below atm P used in connection is one outward form of this energy
with furnaces
-internal energy- total sum of energy; in BTU;often referred as 2 Water hammer in pipes Filled with Water and Steam
thermal energy Bubbles at Same Temp-steam/air enters water in the form of
-heating a substance, increases the internal movement of bubbles w/c divide into sections, called slugs w/c causes noise
molecules in water w/c increases temp an internal energy and vibration; occur if pressure in hot water is lost;
-PV energy- arises from pressure and volume of substance 3 Water Hammer in Drain Headers- handles water and carries
-temperature- measure of molecular activity of subs; higher steam in the form of bubbles w/c collapses the bubbles,
temp, greter movement of molecules; not a measure of heat; leaving empty pockets in water
it is the measure of ability to transfer heat; prop of subs -heat of fusion- heat required to change the phase from liquid
-heat-energy that flow between two bodies because of to solid
temperature difference; form of energy that can be -heat of vaporization- heat required from liquid to gaseous
transferred state
-degree- each space in sale of thermometer -superheated steam- steam at a temperature above the biling
-two temp scales in PP: Celsius and Fahrenheit point
-sea level-used as a standard -most outdoor storage tanks that holds oil, water and gas can
-below -39C, mercury freezes and becomes solid braced only internal pressure that is why it should be vented
-electric thermometer/resistance thermometer- operates at to prevent possibility of vac
a principle that wire’s resistance changes as temp is changed; -it is a common practice to open vents at boiler drum as it
higher temp, greater resistance;contains battery w/c provides approached atmospheric during shutdown; a vac in boiler
voltage to generate electric current and ammeter that could pull in handhold plates/man access doors and case leaks
measures electric current; calibrated using melting ice(32F) -heat capacity- amt of heat required to raise the temp by a
and boiling water (212F) certain amt
-thermocouple- two diff metals is connected in a junction and -specific heat- property that inly depends on the subs; amt of
the other ends is connected to an ammeter; a change in temp heat added to a unit weight of substance to raise temp by one
changes voltage and current degree
-water and steam- working fluid in steam PP -boiling point increases with temp while heat vap decreases
-PV work/flow work- force that results from P of working fluid w/ high temp; freezing pt decreases slightly and heat of fusion
through distance associated with a change in volume; in terms increases
of expansion and contraction of fluid -there are small changes in density of water due to pressure;
-work in PP is measured by determining the electrical eergy density changes with temp
produced/used -density is a primary steam property; density is changed with
-BTU- amount of heat required to raise the 1 pound of changing temp and pressure
material by 1 F -Steam Tables- tables of steam properties
-two types of units used to measure energy: (1) mechanical
units (ft-lb) (2) thermal uits (BTU)

Section 5
-water- liquid phase; composed of 2 hydrogen and one atom
of oxygen
-ice to water (melting); water to steam (vaporization/boiling);
steam to water (condensation); water to ice
(freezing/solidification)
-water cooled to about 39F will expand upon further cooling
-water filling a closed section can develop a pressure up to
45,000 psi I it freezes
-since water is practically incompressible, a little change n
olume is observed w/c causes noise, vibration, and damage in
piping system called water hammer
-hydraulic testing- used to test a heater for pipe/boiler leaks
-fill and pressurize with cold water
Forms of water hammer:
1 Water Hammer in Steam Pipes- at 212F, water has 1600
times weight of same volume of steam; if water is present in
steam pipes, it can be picked by steam and speeded up the
velocity of the steam; equalizing valve is cracked open to start
a small flow of steam to cold piping and if it is opened
instantly, water is picked up by steam and hurled against the
bend
Section 6:

-fire triangle-(1) combustible material (2) oxygen (3) heat


-flammable- <100C
-combustible- >100C
-combustible material- coal, oil, gas
-basic elements of combustible material are H and C
-the nitrogen nd other gases in air do not enter combustion
but carry away the gases out of combustion
-kindling/ignition temp- temp at w/c fuel will start a fue to
unite w/ oxygen causing combustion
-combustion- special case of oxidation
-nothing burns unless it is converted to gaseous state
-hydrocarbon- fuel gas used for ignition; usually methane
-fuel-air ratio- relationship between gas/coal and air; amt of
air and fuel needed for complete combustion
-ignition temp- the lowest temp at w/c the combustion no
longer depends on added heat and instantaneous occurs; it
becomes self-sustaining
-electric spark- used initiate heat to ignite the gas/air mixture
-flashpoint temp- vapors flash into flamr at that temp
-higher temp produces more radiant energy w/c produces
faster ignition and speeds up the rate of flame travel
-Sulfur ignites at 470F Carbon (bituminous) ignites at 766F;
flue gases ignites at 900F to 1200F
-temp produced normal combustion is 2500F to 3000F
Factors Affecting Combustion of Coal
1 Mixture- accomplished by creating turbulence in furnace
2 Surface Character- rough surface provides a staring place
for combustion; heat generated causes the surface to break
open due to explosive effect of formation of steam and
gaseous products
3 Ratio of Surface to Volume- finely ground powder takes
advantage of larger surface-to volume ratio
4 Time- if the cooling of gases takes place too soon,
combustion wil be incomplete and results poor efficiency;w/c
influences the size of furnace and cost
Factors Affecting Burning of Natural Gas:
1 Temperature- ignition temp is at least 1200F; ignition temp
is the temp above the flash point w/c combustion will start;
the flu gas temp is same as 2500F to 3000F
2 Mixture-less than 3.8% or greater than 9% of gas in weight
will not explode or burn
3 Time- flame length can be varied by control of air and
should be relatively short
-efficiency of boiler dependent upon the amt of heat that is
wasted
-sensible heat- heat that you can feel; greatest loss;
oversupply of air can increase heat loss and cools the boiler
-the amount of gases produced per pound can be determined
by gas analysis and carbon content of coal
-moisture in coal- second largest heat loss
-potential heat loss- heat that wasn’t produced but could
have been if combustion is complete
-Incomplete Combustion
-Unburned Carbon- has little content in slag (in pulverized
and cyclone firing); in fly ash; low C content in pulverized fring
Section 17: -S &T: CW treated with hypochlorite and strained
-PTV- P: 100-200 psi; T: not important, V: depends on
Circulating Water- used to condense steam that passed demand of ash and dust handling
through turbine and condenser -Importance: usually an on and off system; it is shut down
Condenser tubes- made of titanium w/c is more resistant to when not needed
erosion and fouling Low Pressure Service Water System
Intake tunnel- large pipes/concrete channes where water -all-purpose system w/c is primarily used in cooling
from lake or river flows through -for use: check pg (207)
Circulating Pump- take the water from these tunnels and -S&T-from strained and filtered CW
pump it through condenser; pumps wih piping sizes of 60” -PTV- P: 40-60 psi; T: 110F hydrogen temp; V: governed by
diameter; handle large quantities of water at low pressure; temp demands
vertical pumps Sanitary Water System
-PP not located adjacent to natural waters uses cooling -S: city water, deep and shallow wells; must strict health
lake/cooling tower codes
Trash Rack- catch and retain the large refuse located at the -U: for drinking, showers, toilets, make-up water
mouth of tunnel; sufficiently close to screen out anything that -T: treatment deending on chemical and mineral contingent
could damge the operation of revolving screens; cleaned by -PT: P: demand according to demand; designed to have 2 to
rake; large logs is removed by hoist/derrick 3 pumps; T: not critical; water coolers is used cool SW
Revolving Screens- 3/8” mesh baskets catch and retake the - a connection between service water and sanitary water is
bulk of refuse that passes through the trash rack; refuse is prohibited
removed from screens by water spray w/c washs it to debris Compressed Air System
trough -spraying, sandblasting, pneumatic controls, sootblowing, air
-treatment of CW consists of feeding it with hypochlorite hoists
solution to retard/kill algae w/c foul up condenser tubes 1 Service Air Supply (House Supply)- for general use; supplied
System Problems: by single/multiple compressor
-water flow is reduced when intake screens become 2 Combustion Control Air- kept from moisture and impurities;
blocked with refuse /ice use for pneumatic devices that provide automatic control of
-holes develop in screens and permits derbis to pass combustion and steaming rate; use in level control valves,
through wc damages condenser tubes, suction pipe/ impeller norma and emergency make-up valves, heater drain valves,
of pump that reduces pump capacity check valves
-efficiency of condenser is lowered when warm water -compressed air at 90 psi
recicrculates in the inlet -can be taken directly from service supply; clean dry air
Gland Water System 3 Sootblowing Air- advantage over steam: lower cost,
-Gland power- water used to many glands in power station uninsulated piping is used, avoids pur condensate losses due
Use: to steam blowing, thorough cleaning due to air density;
-cooling of stuffing boxes on pumps, quenching the high T reduces boiler tube corrosion, saves fuel
leak-off from high T pumps, sealing pump glands, lubricating -Operate at higher pressure around 200 psig
pump packing, keeping glands clean in pump
Supply and Treatment
-city waterand well water (ideal for gland water service), CW
(must strained/filtered)
Bearing Cooling Water
Use
-control bearing temp by cooling oil lubricating bearings;
used in hydraulic couplings and mill journal
Supply and Treatment
-CW (strained and filtered)
-closed system that uses a make-up; corrosion is remedied
using sodium chromate
Pressure, Temp, Volume
-cooling water pressure depend on plant design; must be
established maintain temp of outler w/in temp limits
-temp: 85F to 95F
-must be constant flow; Bearing Cooling Water Pump- used
to furnish a constant supply of water
High Pressure Service Water System
-Use: ash and dust handling system and fire protection
Section 18 -oil is fed into the top of bearing in the direction of shaft
travel; builds a wedge to raise journal and cools the journal
Lubrication- separate moving loaded surfaces by interposing -bearings are fitted to journal with minimum clearance and
oil/grease film between surface to reduce friction, heat and lubricated by low viscosity/thin oil
water Ring Lubricated Sleeve Bearing- by means of ring around the
-full lubrication is acheieved when shaft reaches operating shaft w/ larger diameter; bottom part is immersed in oil
speed; a wedge of lubrication is built by pressure of rotation -too much in oil in ring can turn the shaft slowly while little
Oils amt of oil may not able to carry a suff amt to lubricate and
1 Mineral Oil- produced from crude petroleum refining cool bearing
process; it should be further refined to get rid of waxy Ball and Roller Bearing- anti-friction bearings; only contact is
compounds that becomes solid at low temperatures and filter in balls or rollers; oil is used to avoid rust and corrosion w.in
foreign matter bearing that would pi moving parts
2 Fixed Oils- vegetable/animal origin; usually organic oil and -grease is used in ati-friction bearings; housing should be
greases; vegetable oil- produced from seeds and fruits spec. filled from 1/3 to ½ full when usng grease
castor, olive, cottonseed, coconut, peanut oil; animal oil- -overfilling with grease may rupture the seals and overheat
produced by heating/rendering fatty tissues wc includes Coupling Lubrication
tallow, lard, neats-foot, whale, fish oils; one or more of these -coupling- forms link between pump and driver
can compounded with mineral oil that forms a steam cylinder Types:
oil lubricant that can mix with steam; Lard oil ommonly used -Mechanical Coupling- oil/grase lubricated; filled with oil
as thread oil, machine lathe and grease and the revolving motion spreads the lubricant to
-very little value as lubricants when used alone reduce friction and wear
3 Synthetic Oils- compounded from elements other than -Hydraulic Coupling- uses turbine oil/fluid; uses the fluid
mneral and organic oil; far superior than petroleum base to transmit energy from driver to pump; must maintain
oils;wide tem range -40F to 300F; use to light to moderate correct level
loads
Additives- added to mineral oil w/v gives oil an ability to do a
lubricating job that oil alone was not capable of doinf.
1 Detergents- maintain a clean internal surface in engines
2 Oxidation Inhibitors- helps the oil give a better service for a
longer priod; oxidation destroys lubricating prop
3 Rust Inhibitors-coats metal with protective film which
prevent moisture from reaching metal surfaces
4 “Oiliness” and Extreme P Additives- gives extremely thin oil
lubricating qualities and help prevent break down/squeeze
out under heavy bearing load
Greases- semi solid w/c combines luid lubricant with
thickening agent; density is designated by number; No. 1
relatively thin; No. 5 thick/heavy
Types of Greases:

Viscosity- internal resistance to motion w/in itself; expressed


in SAE (Soc of Automotive Eng) for automobile; SAE 10W-
low viscosity suitable for cold weather; SAE30- Climates with
90F(32C)
-higher viscosity, heavier, higher resistance w/in itself
-viscosity decrease, with increase of temp
-increase in oil pressure, increases viscosity
--lower viscosity oil I used in high speed machinery
-in choosing a lubricant, the speed of journal and load is
established; next is viscosity and oil temp
Bearing Lubrication
Sleeve Bearing- referred s friction bearings around shaft; can
be lubricated by grease/oil
-slow speed, heavily loaded-grease lubricated
-high speed, high temp-oil lubricated (turbine and generator
bearings)

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