Superheater

Description:

The Steam Superheater is a coil type heat exchanger which is

A superheater is a vital part of the a boiler system that is used to

Are there more than one type of Super Heater? There certainly is. In all, there are three types of Super
Heaters: radiant superheaters, convection superheaters and separately fired superheaters. Depending
on the size of the plant, they can vary from a few meters long to a few hundred meters.

Use of Superheaters in Industrial Boilers

 Superheaters are used where only dry steam is required in a process/machines such as Turbines.
Any moisture content in a steam in such cases happens to degrade or corrode the machine
thereby affecting its average operating life. So, superheater converts low-quality steam to high
quality for end users.
 Sometimes, superheater is also needed when we need to transport steam to far off places as
there are some temperature losses during its transportation.
 Superheaters can be used in a steam engine where absolute dry steam is needed to prevent
wear and tear of engine parts.

Types of Superheater in Boiler

Depending upon the steam temperature requirement, Superheaters are divided into two parts:

 Radiant Superheaters
o Radiant superheaters are the type of superheaters that are installed in a radiation zone
just after the furnace. In high-pressure boilers when the temperature difference in
saturated and superheated steam is around 100oC. Superheaters must be installed in a
radiant zone.
 Convective Superheaters
o Convective superheaters are installed after the convective bank of tubes. When the
temperature difference between saturated and superheated steam is not more than
50oC. Superheaters must be installed in a convective zone.
Issues

 Material Buildup: Ash and particulate buildup can cause serious problems within superheaters.
Without adequate and regular cleaning, the material buildup could create long term damage.
 Overheating: Almost all types of devices or tubes which carry water or steam and are exposed to
high operating temperatures are susceptible to overheating. Long term overheating usually
occurs in superheaters and reheaters as a result of deposits or restricted steam/water flow.
 Leakage: Malfunctions such as leaks immediately start decreasing a boiler’s efficiency and
reliability. Properly sealing an air heater can reduce a plant’s heat rate by up to 75 kWh,
increasing production and income as a result.
 Tube erosion: Boiler tube erosion caused by older cleaning methods can lead to unscheduled
shutdowns and a lack of Power Generation.
 Fouling: Fouling of Economiser heat exchange surfaces is a constant problem (especially for
power station engineers). It reduces boiler efficiency leading to lengthy downtime for cleaning
which can be hard to plan and difficult to carry out safely.

Air Preheater

Air Heaters are an important part of the heat exchange process. Similar to economisers, they are devices
that transfer heat from one surface to another - but this time from fluid to air. The main objective is to
increase the thermal efficiency of a boiler system by recovering the heat from the flue gas and using it to
heat the air.

Air heaters can be classified as tubular, recuperative or regenerative based on their operating principle.
The first two are usually found in steam generators in thermal power stations.

In the recuperative type, fluid (such as flue gas) is warmed through energy that is passed through a heat
absorbing surface such as a metallic tube or plate. The captured heat is released into the cooler air and
directed back into the boiler.

Regenerative air preheaters are usually used for iron or glass manufacture. They capture and recycle
about 60% of the heat energy exiting the boiler, which would otherwise be lost.

Electric Power Generator

Description: The Generator converts mechanical energy from the steam turbine into three-phase
alternation current. The conversion is accomplished by rotating a magnetic field (rotor), through a
stationary conductor (stator).

Turbine

Description: The Turbine Steam System converts the thermal energy (heat) in the steam into rotational
mechanical energy (torque) by using the combined high, intermediate, and low-pressure turbine
modules.

Turbine Auxiliaries

Electric Power Transformer

Description: Transforms the 22 kV system from the electric power generator to 230 kV grid of NGCP
Gas Insulated Transformer

Description: Transforms the 22 kV system from the electric power generator to 230 kV grid of NGCP

Steam Drum

Description: The Boiler Steam Drum separates the water vapor from the steam and reduces the dissolve
solids.

Reverse Osmosis Facility

Description: A water processing plant whereby sea water is passed through series of filtration, has an
end product of a good quality water. The product water is called filtered water and it is the source for
the water firefighting system, and domestic water requirements. The filtered water is further processed
through the demineralization plant to produce very high quality water to supply the Condensate system.

Demineralization facility

The Water treatment system takes filtered water and removes the mineral composition of the water to
be used for the plant cycle water. This water is used for the production of steam for driving the turbine

Condensate Extraction Pump

Description: The Condensate Extraction Pumps extracts condensate from the condenser hotwell, add
pressure and deliver the condensate to the Deaerator

Deaerator

Description: The Deaerator removes non-condensable gases from the condensate and provides a
storage volume and positive suction pressure for the boiler feed pumps

Boiler Feed Pump

Description: The Boiler Feed Pumps supply the boiler with the required quantity of water for all
conditions of operation. The boiler feed pumps also supplies desuperheater spray water to the
superheaters and HP Bypass System

Economizer

Description:

The final pre heating system of the feed water before it is being injected to the Boiler. The heat is
recovered from the flue gas

Aptly named, an economiser is a mechanical device that reduces energy consumption. It does this by
acting as a heat exchanger, preheating the fluids that enter a boiler or recovering residual heat from the
combustion products. It is designed to save energy by using the exhaust gases from the boiler to preheat
the cold fluid, mainly water, that is used to fill it. An increase in fuel prices means that power plants are
having to increase the boiler efficiency and this is made possible with the assistance of Economisers.
As well as a boiler system, economisers cal also be found in heating, refrigeration, ventilation and air
conditioning systems.