Guideline for Technical Regulation Volume 2

SOCIALIST REPUBLIC OF VIETNAM Ministry of Industry and Trade (MOIT)

Guideline for Technical Regulation

Volume 2

Design of Thermal Power Facilities Book 1/12

? Boiler ?

Final Draft

June 2013

Japan International Cooperation Agency Electric Power Development Co., Ltd. Shikoku Electric Power Co., Inc.

West Japan Engineering Consultants, Inc.

IL CR(2) 13-092

Table of Contents

Chapter-1. Comparison between Technical Regulation and Technical Guideline of boiler............................1 Chapter-2. Each Items of Guideline................................................................................................................2 Chapter-3. Reference International Technical Standards ............................................................................118 Chapter-4. Reference Japanese Technical Standards ..................................................................................123 Chapter-5. Reference TCVN.......................................................................................................................128 Chapter-6. Referenced Literature and Materials.........................................................................................132

List of Tables

Table- 1: Comparison between Technical Regulation and Technical Guideline of boiler............... 1 Table- 2: Classification of types for boiler ...................................................................................... 4 Table- 3: Type of power boiler ........................................................................................................ 6 Table- 4: Steam condition for boiler ................................................................................................ 7 Table- 5: Classification of steam power plant by use conditions (C1) ............................................ 7 Table- 6: Classification of steam power plant by use conditions (C2, C3, C4) ............................... 8 Table- 7: Comparative example for general properties of C-heavy oil, VR, Orimulsion.............. 10 Table- 8: Analysis value of petroleum coke and bituminous coal ................................................. 11 Table- 9: Type of fuel for thermal power boiler ............................................................................ 17 Table- 10: Type of HRSG .............................................................................................................. 29 Table- 11: Sample of effluent composition.................................................................................... 34 Table- 12: Outlet steam pressure of HRSG ................................................................................... 35 Table- 13: Furnace heat liberation ratio......................................................................................... 43 Table- 14: Seismic design methodology........................................................................................ 58 Table- 15: Shape of fin-tube .......................................................................................................... 64 Table- 16: Recommended materials for main part of boiler .......................................................... 75 Table- 17: Standards for tough fracture ......................................................................................... 79 Table- 18: Limitation of thickness for cylindrical or conical body ............................................... 81 Table- 19: "" value (according to ASME) ................................................................................... 82 Table- 20: Factor "" for minimum thickness of water type, super-heater tube, re-heater tube,

economizer tube .......................................................................................................... 91 Table- 21: Longitudinal joint efficiency ........................................................................................ 92 Table- 22: "" value....................................................................................................................... 92 Table- 23: Corrosion allowance..................................................................................................... 92 Table- 24: Limit of minimum thickness ........................................................................................ 93 Table- 25: Boiler trip item and application.................................................................................. 115 Table- 26: Reference international technical standards ............................................................... 118 Table- 27: Reference Japanese technical standards ..................................................................... 123

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Table- 28: Reference TCVN ........................................................................................................ 128

List of Figures

Fig- 1: Independent super-heater cycle............................................................................................ 3 Fig- 2: Independent super-heater ..................................................................................................... 3 Fig- 3: Dry accumulator .................................................................................................................. 3 Fig- 4: Wet accumulator .................................................................................................................. 3 Fig- 5: Gas-fired once-through boiler (700MW)............................................................................. 9 Fig- 6: Typical fuel System of gas-fired boiler................................................................................ 9 Fig- 7: Oil-fired once-through boiler (700MW) ............................................................................ 12 Fig- 8: Typical fuel system of heavy oil-fired boiler ..................................................................... 12 Fig- 9: Coal-fired Once-through boiler (1000MW)....................................................................... 15 Fig- 10: Coal-fired Once-through boiler (1050MW)..................................................................... 15 Fig- 11: Coal-fired Once-through boiler (1050MW)..................................................................... 15 Fig- 12: Typical fuel system of coal for pulverized coal-fired boiler ............................................ 16 Fig- 13: Boost arrangement of primary fan ................................................................................... 16 Fig- 14: Parallel arrangement of primary fan ................................................................................ 16 Fig- 15: EL Paso type boiler (B&W)............................................................................................. 18 Fig- 16: Natural circulation type boiler (156MW) ........................................................................ 19 Fig- 17: Carolina type boiler (B&W) ............................................................................................ 19 Fig- 18: Relation specific gravity of water with steam.................................................................. 20 Fig- 19: Lamont boiler................................................................................................................... 20 Fig- 20: Forced circulation type boiler (220MW) ......................................................................... 20 Fig- 21: Universal pressure (UP) boiler (B&W) ........................................................................... 22 Fig- 22: Mono tube Sulzer boiler .................................................................................................. 23 Fig- 23: Mono tube Sulzer boiler .................................................................................................. 23 Fig- 24: Benson boiler (Rise and fall type) ................................................................................... 23 Fig- 25: Benson boiler (Meander type) ......................................................................................... 23 Fig- 26: Benson boiler (BKH) ....................................................................................................... 24 Fig- 27: Benson boiler (BKH) ....................................................................................................... 24 Fig- 28: Ramsin boiler................................................................................................................... 25 Fig- 29: Relation furnace gas velocity with solid combustion method ......................................... 26 Fig- 30: Bubbling FBB .................................................................................................................. 26 Fig- 31: Internally CFB boiler (Ebara) .......................................................................................... 26 Fig- 32: Typical system of coal-fired circulation fluidized bed boiler .......................................... 27 Fig- 33: CFB reheat boiler (B&W)................................................................................................ 28 Fig- 34: CFB non-reheat boiler (B&W) ........................................................................................ 28

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Fig- 35: CFB FA nozzle in furnace................................................................................................ 28 Fig- 36: Circulation FBB............................................................................................................... 28 Fig- 37: Pressurized fluidized bed combustion boiler ................................................................... 29 Fig- 38: Temperature gradient diagram for HRSG ........................................................................ 33 Fig- 39: Temp. VS Enthalpy diagram of exhaust gas components ................................................ 34 Fig- 40: Stationary stoker boiler .................................................................................................... 36 Fig- 41: Travelling stoker boiler .................................................................................................... 36 Fig- 42: Kiln stoker boiler ............................................................................................................. 37 Fig- 43: Typical construction of dual system to prevent thermal stress ........................................ 39 Fig- 44: Drum internal (B&W)...................................................................................................... 40 Fig- 45: Centrifugal steam separator (for large boiler).................................................................. 40 Fig- 46: Inversion steam separator (for middle boiler).................................................................. 41 Fig- 47: Centrifugal steam separator (for large boiler).................................................................. 41 Fig- 48: Horizontal centrifugal steam separator (for large) ........................................................... 41 Fig- 49: Water separator and drain tank......................................................................................... 42 Fig- 50: Typical construction of furnace wall................................................................................ 44 Fig- 51: Spiral tube wall ................................................................................................................ 45 Fig- 52: Vertical tube wall ............................................................................................................. 45 Fig- 53: Typical construction of furnace wall corner .................................................................... 45 Fig- 54: Typical construction of welded water wall ...................................................................... 45 Fig- 55: Typical construction of super-heater, re-heater, economizer ........................................... 48 Fig- 56: Flow type of super-heater ................................................................................................ 49 Fig- 57: Construction of de-super-heater....................................................................................... 51 Fig- 58: Cooling method by surface-heat exchange ...................................................................... 51 Fig- 59: Supporting bracket for separating wall ............................................................................ 52 Fig- 60: Supporting bracket for hanging SH ................................................................................. 52 Fig- 61: Steam cooling type support.............................................................................................. 52 Fig- 62: Supporting bracket for RH hot part ................................................................................. 52 Fig- 63: Serial economizer ............................................................................................................ 54 Fig- 64: Seismic Design procedure for boiler steel structure ........................................................ 57 Fig- 65: Schematic diagram of stabilizer....................................................................................... 60 Fig- 66: Furnace corner backstay .................................................................................................. 61 Fig- 67: Furnace side-wall backstay .............................................................................................. 61 Fig- 68: CFB vs. PC heat flux distribution .................................................................................... 62 Fig- 69: Typical construction of Re-heat triple pressure HRSG (horizontal type) ........................ 64 Fig- 70: Typical construction of Re-heat triple pressure HRSG (vertical type) ............................ 64 Fig- 71: Typical construction of drum internal .............................................................................. 66 Fig- 72: Vertical type HRSG.......................................................................................................... 67

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Fig- 73: Vertical type HRSG.......................................................................................................... 67 Fig- 74: Bottom support type panel ............................................................................................... 68 Fig- 75: Top support type panel..................................................................................................... 68 Fig- 76: System of incineration plant based on stoker boiler technology ..................................... 69 Fig- 77: System of incineration plant based on kiln boiler technology ......................................... 72 Fig- 78: Steam condition and unit output of power boiler............................................................. 74 Fig- 79: USC thermal power plant ................................................................................................ 74 Fig- 80: Critical point .................................................................................................................... 74 Fig- 81: Type1 ............................................................................................................................... 80 Fig- 82: Type2 ............................................................................................................................... 80 Fig- 83: Type3 ............................................................................................................................... 80 Fig- 84: Type4 ............................................................................................................................... 80 Fig- 85: Type5 ............................................................................................................................... 80 Fig- 86: Details of dished heads .................................................................................................... 84 Fig- 87: Various dished heads........................................................................................................ 85 Fig- 88: Reinforcement of hole by infolded flange ....................................................................... 87 Fig- 89: Type1 ............................................................................................................................... 95 Fig- 90: Type2 ............................................................................................................................... 95 Fig- 91: Type3 ............................................................................................................................... 95 Fig- 92: Typical construction of supercritical safety valve.......................................................... 100 Fig- 93: Diagram for calculating the amount of blow (based on amount of feed water%) ......... 111 Fig- 94: Change of the concentration of boiler water by blow-down.......................................... 111 Fig- 95: Example of flush type continuous blow......................................................................... 112 Fig- 96: Example of non-flush type continuous blow ................................................................. 113

List of Photos

Photo- 1: HRSG for GTCC (Horizontal type) ............................................................................... 30 Photo- 2: HRSG for GTCC (Horizontal type) ............................................................................... 30 Photo- 3: HRSG for GTCC (Vertical type).................................................................................... 30 Photo- 4: HRSG for GTCC (Vertical type).................................................................................... 30 Photo- 5: Kiln boiler ...................................................................................................................... 37 Photo- 6: Drum internal without parts ........................................................................................... 41 Photo- 7: Typical furnace wall tube ............................................................................................... 46 Photo- 8: Burner throat on furnace wall ........................................................................................ 47 Photo- 9: Ready for burner casting work....................................................................................... 47 Photo- 10: Serial economizer ........................................................................................................ 54 Photo- 11: Economizer tube with straight-fin................................................................................ 54

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Photo- 12: Economizer tube with straight-fin ............................................................................... 54 Photo- 13: Economizer tube with spiral-fin................................................................................... 54

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AFNOR API ASME BFB BS B&W CFB COM CWM DCC EN FDF FW GRF GTCC HRSG ISO JIS LNG LPG MWe NGL NOx MLR OMLR OTU RDF RPF PAF PFBC SAH SOx TDR UP VR

List of Acronyms/Abbreviations

Agence Fracaise de Normalisation American Petroleum Institute American Society of Mechanical Engineers Bubbling Fluidized Bed British Standard Babcock and Wilcox Circulation Fluidized Bed Coal Oil Mixture Coal Water Mixture Drag Chain Conveyor European Standard Forced Draft Fan Foster Wheeler Gas Recirculation Fan Gas Turbine Combined Cycle Heat Recovery Steam Generator International Organization for Standardization Japanese Industrial Standard Liquefied Natural Gas Liquefied Petroleum Gas Megawatt electric Natural Gas Liquid Nitrogen Oxide Multi Lead Robbed Tube Optimized Multi Lead Ribbed Tube Once Through Utility Refuse Derived Fuel Refuse Paper and Plastic Fuel Primary Air Fan Pressurized Fluidized Bed Combustion Steam Air Heater Sulfur Oxide Technische Regeln f?r Dampfkessel Universal Pressure Vacuum Residual Oil

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Chapter-1. Comparison between Technical Regulation and Technical Guideline of boiler

The article number of this guideline is shown in the Table-1 contrasted technical regulation with technical guideline for easy understanding.

Table- 1: Comparison between Technical Regulation and Technical Guideline of boiler

Article 21. -1. -2. -3. -4.

Article 22. -1. -2. Article 23. -1. -2.

Article 24. -1. -2. Article 25. -1. -2.

Article 26. -1. -2. Article 27. -1. Article 28. -1.

Technical Regulation

General provision Definition of boiler Function of boiler Function of independent super-heater Function of steam accumulator

Material for boiler, etc. Pressure parts Stable chemical composition and mechanical strength Structure for boiler, etc. Safety structure Allowable stress

Safety valve for boiler, etc. Over-pressure Appropriate safety valve Feed-water equipment for boiler, etc. Requirement for feed-water equipment Harmful heat

Isolation of steam and feed-water of boiler, etc. Isolation of steam Isolation of feed-water Blow-down equipment for boiler, etc. Blow-down equipment for circulation boiler Instrument equipment for boiler, etc. Instrument to monitor operation status

Article 21. -1. -2. -3. -4. -5. -6. -7. -8. Article 22. -1. -2.

Article 23. -1. -2. -3. -4. -5. -6. -7. -8. -9. -10. -11. -12. Article 24. -1. -2. Article 25. -1. -2. -3. -4. Article 26. -1. -2. Article 27. -1. Article 28. -1. -2.

Technical Guideline

General provision Definition of boiler Function of boiler Function of independent super-heater Function of steam accumulator Classification of types for boiler Typical construction of boiler Steam condition for boiler Materials for main part of boiler Material for boiler, etc. Pressure parts Stable chemical composition and mechanical strength

Structure for boiler, etc. Structure for boiler, etc. Allowable stress of material Hydrostatic test Body of vessel Rectangle header Head for vessel Flat head plate of vessel Dished cover plate with flange for vessel Tube sheet for vessel Pipe and stub Flange Cylindrical boiler Safety valve for boiler, etc. Over-pressure Appropriate safety valve Feed-water equipment for boiler, etc. Quantity of feed-water equipment Type of feed-water equipment Two or more feed-water equipment of boiler Harmful heat Isolation of steam and feed-water of boiler, etc. Main steam stop valve Feed-water valve and non-return valve Blow-down equipment for boiler, etc. Blow-down equipment for circulation boiler Instrument equipment for boiler, etc. Instrument to monitor operation status Boiler trip item and application

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