Continuous blow separator cyclone type designed to separate the boiler blowdown water into steam and water formed from the blowdown water of steam boilers when its pressure is reduced from intra-boiler pressure to the pressure in the separator and for the purpose of subsequent use of the heat of water and steam. Separation occurs due to the action of centrifugal forces caused by the tangential input of water into the separator. After this, steam is supplied to the consumer high degree dryness.

Continuous blowing separator SNP-0.15-1.4

Separators can be used in condensate collection systems to reduce the consumption of steam consumed and heat losses from the removed steam-condensate mixture.

In addition to the tangential supply of condensate (blowdown water), the separators are equipped with vertical louvered drop eliminators for drying the secondary boiling steam. The separator is used in circuits with an atmospheric deaerator.

Main parameters and technical characteristics

Design and principle of operation

The separator is a vertical cylindrical vessel (see Fig. 1) with elliptical bottoms, oppositely placed inlet pipes, steam and water outlet pipes, a level indicator for visual control, a spring safety valve, and a float steam trap that automatically maintains the water level. The swirling of the flow is carried out due to the organized supply of the steam-water mixture to the inner wall of the separator with the installation of internal guide devices. Typically, the blowdown water consumption for the separator ranges from 1% to 5% of the boiler output.

Separation into steam and water occurs in the middle part of the separator. The steam, while maintaining rotational motion, is directed into the steam space and discharged through a pipe located on the upper bottom. Water flows down the inner surface of the separator into the water volume and is discharged through a pipe located in the lower part of the housing. A fitting is provided on the lower bottom for draining water from the separator when it is turned off and for periodically cleaning the lower part of the water volume from sludge and contaminants.

Rice. 1. Continuous blow separator

Rice. 2. Continuous blowing separator piping diagram

On the cylindrical part of the body, two supports are welded for installing the separator and nozzles for the tangential supply of the steam-water mixture of boiler purge water to the separator. In the upper bottom of the separator there is a pipe with a flange for the outlet of separated steam, and in the lower bottom there is a fitting with a valve for draining water from the separator when it is turned off and for the possibility of periodically removing sludge and contaminants from the lower part of the water volume.

The lower cylindrical part of the housing has a float-type condensate drain and a level indicator. Using a level indicator, the water level is visually monitored. The float steam trap is designed for automatic maintenance constant water level in the separator.

Rice. 3. Connection diagram of the separator to the continuous blowdown of boilers.

1 – input of continuous boiler blowdown; 2 – pipelines high pressure; 3 – boiler blowing control unit; 4 – limit washers; 5 – shut-off valve; 6 – supply pipeline low pressure; 7 – supply pipes (nozzles); 8 – steam output; 9 – drainage; 10 – output of separated water.

The steam is directed into the steam space, and the separated water flows down the inner wall of the separator into the water volume.

Installation procedure

The separator is installed in accordance with the technical documentation developed by specialized design organizations and the requirements of the installation instructions.

To prevent a possible increase in pressure, a spring safety valve is provided on the separator body.

The separator is installed in a vertical position on pre-assembled support beams. Next, control and measuring instruments are installed, safety devices, float-type condensate trap and piping is carried out.

The installation of the separator must provide the possibility of inspection, repair and cleaning from both the inside and outside, and must eliminate the danger of it tipping over. Hanging of the separator on the connecting pipelines is not allowed.

During installation, for ease of maintenance of the separator, platforms and stairs can be installed, which should not interfere with the strength, stability and possibility of free inspection and cleaning of the outer surface.

After installing and fastening the separator, piping it and equipping it with fittings, it is necessary to perform a hydraulic (pneumatic) test. After the hydraulic test, the separator and pipelines are washed, the functionality of the fittings, the float steam trap is checked, safety valve, after which the separator is put into operation.

Maintenance and Operation

The condition for normal and reliable operation of the separator is to ensure continuous removal of steam and water from the separator and maintain pressure in the separator within established limits. This is achieved if the float steam trap and safety valve are in good condition.

The separator must be under constant supervision service personnel. The proper condition of the float steam trap should be properly monitored:
- check the sight glass, which must be installed behind the condensate drain, once per shift;
- monitor steam pressure at least 3 times per shift;
- at least 3 times per shift, monitor the presence of a normal level of condensate in the housing using the water indicator glass.
- purge the level indicator at least once per shift, depending on the quality of the purge water.

The safety valve must be forcibly undermined at least once per shift, followed by monitoring of the return of the valve to its original position and the absence of steam leaks. Periodic inspection of the separator should be carried out both for preventive purposes and to identify the causes of problems that have arisen.

Inspection and cleaning of the separator body must be carried out at least once every 2-3 years when the separator is shut down for routine and major repairs.

Continuous blowing separators must undergo technical inspection after installation, before putting into operation, periodically during operation and during necessary cases extraordinary examination.

In case of long-term repairs, as well as insufficient density of the shut-off valves, the equipment being repaired should be switched off. The thickness of the plugs must correspond to the parameters of the working environment.

When loosening the bolts flange connections Care must be taken to ensure that steam and water inside the separator and pipelines do not cause burns to people.

A continuous blowdown separator of the cyclone type is designed to separate boiler blowdown water into steam and water formed from the blowdown water of steam boilers when its pressure is reduced from intra-boiler pressure to the pressure in the separator and for the purpose of subsequent use of the heat of water and steam. Separation occurs due to the action of centrifugal forces caused by the tangential input of water into the separator. After this, steam with a high degree of dryness is supplied to the consumer.

Separators can be used in condensate systems to reduce the consumption of steam consumed and heat losses from the removed steam-condensate mixture.

In addition to the tangential supply of condensate (blowdown water), the separators are equipped with vertical louvered drop eliminators for drying the secondary boiling steam.

The separator is used in circuits with an atmospheric deaerator ( overpressure in the deaerator 0.02 MPa)

Name and symbol separator:
SNP -0.15-0.06 is a continuous blowing separator with a capacity of -0.15 m3 and a working pressure of 0.06 MPa.

Main parameters and technical characteristics

Design and principle of operation

The separator is a vertical cylindrical vessel (see Fig. 1) with flat or elliptical bottoms, a flattened inlet pipe or a circular pipe, steam and water outlet pipes and a float regulator that automatically maintains the water level. The flow is swirled through the organized supply of a steam-water mixture to the inner wall of the separator or through the installation of internal guide devices. Typically, the blowdown water consumption for the separator ranges from 1% to 5% of the boiler output.

Separation into steam and water occurs in the middle part of the separator. The steam, while maintaining rotational motion, is directed into the steam space and discharged through a pipe located on the upper bottom. Water flows down the inner surface of the separator into the water volume and is discharged through a pipe located in the lower part of the housing. A fitting is provided on the lower bottom for draining water from the separator when it is turned off and for periodically cleaning the lower part of the water volume from sludge and contaminants.

Rice. 1. Continuous blowing separator
A – supply of purge water; B – removal of separated steam; B – drainage; G – removal of separated water.
1 – gate valve for separated water outlet; 2 – water level regulator; 3 – nozzle for the inlet of the purge steam-water mixture; 4 – supports; 5 – pipe for steam outlet; 6 – upper and lower bottom; 7 – separator body; 8 – water level indicator; 9 – valve for drainage.

On the cylindrical part of the body, two supports 4 are welded for installing the separator and a nozzle 3 for the tangential supply of the steam-water mixture of boiler purge water to the separator. In the upper bottom of the separator there is a pipe with a flange 5 for the outlet of separated steam, and in the lower bottom there is a fitting with a valve 9 for draining water from the separator when it is turned off and for the possibility of periodically removing sludge and contaminants from the lower part of the water volume.

In the lower cylindrical part of the housing there is a float regulator for the water level in the separator 2 and a level indicator 8. Using the level indicator, the water level is visually monitored. The float level controller is designed to automatically maintain a constant water level in the separator.

The operating diagram of the float level regulator is shown in Fig. 2. The upper position of the float can be fixed by turning the lock handle at an angle of 30 degrees.

Fig.2. Scheme of operation of the float level regulator

The nozzle supplying purge water to the separator has a flattened cross-section at the outlet, which enhances the centrifugal effect by obtaining a pre-stratified flow of the steam-water mixture. The primary separation of the steam-water mixture begins outside the separator, in the low-pressure supply pipeline (see Fig. 3), made of the same diameter as the nozzle. The separation of the steam-water mixture into steam and water, which began in the supply pipeline, ends in the separator.

Rice. 3. Connection diagram of the separator to the continuous blowdown of boilers.
1 – input of continuous boiler blowdown; 2 – high pressure pipelines; 3 – boiler blowing control unit; 4 – limit washers; 5 – shut-off valve; 6 – low pressure supply pipeline; 7 – supply pipe (nozzle); 8 – steam output; 9 – drainage; 10 – output of separated water.

The steam is directed into the steam space, and the separated water flows down the inner wall of the separator into the water volume.

Installation procedure

The separator is installed in accordance with the technical documentation developed by specialized design organizations and the requirements of the installation instructions.

The connection of the continuous blowing separator to the steam boiler room circuit should be performed in accordance with the diagram shown in Fig. 4.

Rice. 4. Connection diagram of the separator to the steam boiler house circuit.
1 – steam boiler; 2 – continuous blowing separator; 3 – water-water heat exchanger; 4 – chemical water treatment filter; 5 – raw water supply; 6 – tank; 7 – deaerator.

To prevent a possible increase in pressure in the separator, it is necessary to install a water seal on the outlet pipeline near the separator to the shut-off valve. Do not install shut-off valves on the steam outlet line from the separator to the deaerator.

The separator is installed in a vertical position on pre-assembled support beams. Next, instrumentation, safety devices, a float level regulator are installed and piping is carried out.

The installation of the separator must provide the possibility of inspection, repair and cleaning from both the inside and outside, and must eliminate the danger of it tipping over. Hanging of the separator on the connecting pipelines is not allowed.

During installation, for ease of maintenance of the separator, platforms and stairs can be installed, which should not interfere with the strength, stability and possibility of free inspection and cleaning of the outer surface.

After installing and fastening the separator, piping it and equipping it with fittings, it is necessary to perform a hydraulic (pneumatic) test. After the hydraulic test, the separator and pipelines are washed, the functionality of the fittings, float level regulator, and safety valve is checked, after which the separator is put into operation.

Maintenance and Operation

The condition for normal and reliable operation of the separator is to ensure continuous removal of steam and water from the separator and maintain the pressure in the separator within the established limits. This is achieved if the float level regulator and water seal are in good condition.

The separator must be under constant supervision of maintenance personnel. The proper condition of the level regulator should be properly monitored:

• once a shift, check the mobility of the float and associated parts by turning the drain valve lock handle;
• Monitor steam pressure at least 3 times per shift;
• At least 3 times per shift, monitor the presence of a normal level of condensate in the housing using the water indicator glass.
• Purge the level indicator at least once per shift, depending on the quality of the purge water.

Reliable operation of the water seal must be ensured by the design and compliance with the requirements of the instructions for its maintenance.

When the separator is completely disconnected from the purge lines, in order to prevent a possible connection of the deaerator with the atmosphere through the separator in this case, the level control valve and the gate valve at the water outlet from the separator should be completely closed.

Periodic inspection of the separator should be carried out both for preventive purposes and to identify the causes of problems that have arisen.

Inspection and cleaning of the separator body must be carried out at least once every 2-3 years when the separator is shut down for routine and major repairs.

Continuous blowing separators must undergo technical inspection after installation, before putting into operation, periodically during operation and, if necessary, extraordinary inspection.

In case of long-term repairs, as well as insufficient density of the shut-off valves, the equipment being repaired should be switched off. The thickness of the plugs must correspond to the parameters of the working environment.

When loosening bolts on flange connections, care must be taken to ensure that steam and water inside the separator and piping do not cause burns to people.

The article provides information about continuous and periodic boiler purging, provides a real purge diagram and design drawings related to RNP and RPP

Problems due to salts in boiler water

The boiler water must maintain a constant salt composition, i.e. the introduction of salts and contaminants with the feed water must correspond to their removal from the boiler. This is achieved by carrying out continuous and periodic blowdowns.

If there is insufficient removal of salts from the boiler, they accumulate in the boiler water and intensive scale formation occurs on the heat-stressed sections of the screen pipes, which reduces the thermal conductivity of the pipes, leads to holes, ruptures, emergency shutdowns, and, accordingly, to a decrease in the reliability and efficiency of the boiler. Therefore, optimal and timely removal of salts and sludge from the boiler is of decisive importance.

Drum steam separators

The higher the steam parameters, the worse the dissolution of salts in the feed water. The fewer dissolved salts in the boiler water and the drier the resulting steam, the cleaner it is considered. The removal of moisture with steam is considered unacceptable, since it contains salts, and during evaporation they will settle on the internal surfaces of the pipes in the form of sediment.

Inside the boiler drum there are special devices (separators) that separate moisture from steam. Very often, cyclone separators are installed inside the boiler drums, which separate water particles from steam. Louvre separators are also used; such a separator is shown in the diagram of a medium pressure drum.

To prevent scale formation on the heat exchange surfaces of the boiler, phosphates are introduced into the drum, which results in the formation of sparingly soluble compounds in the form of sludge in the boiler water. The removal of salts from the boiler drum is achieved through blowing.

Usually the drum is divided into a clean compartment and a dirty one. Water is blown from the clean compartment into the dirty one.

This is done in order to lose as little water as possible with purging. Blowing will be carried out from the dirty (salt compartment), where the concentration of salts is much higher than in the clean compartment, therefore, the carryover of water with blowing from the dirty compartment will be lower.

Dirty compartments are smaller than clean ones, so the main part of the steam is generated in the clean compartment and therefore general content salts in the steam drops. This is called stage evaporation. Staged evaporation in the boiler drum (or outside it in the case of using remote cyclones) reduces the cost of water treatment and fuel costs, since we lose heat with blowing.

Read also: generator-T-16-2UZ

How is continuous boiler purging carried out?

Boiler water must be of such quality as to exclude:

1. Scale and sludge on heating surfaces.
2. Sediments various substances in the boiler superheater and steam turbine.
3. Corrosion of steam and water pipelines.

Calculation of the boiler blowdown amount:

Blowdown is determined as a percentage of the boiler's nominal steam output:

Р=Gpr/Gpar * 100%

According to clause 4.8.27 of the rules technical operation of electrical stations and networks of the Russian Federation, the value of continuous boiler output is taken:

• No more than 1% for IES
• No more than 2% for CPPs and heating CHP plants, where losses are replenished with chemically purified water
• No more than 5% at heating CHP plants, with 0% steam return from consumers

That is, if you, for example, have a condensing station with a K-330-240 turbine with a fresh steam flow rate of 1050 t/h, then the blowdown amount will be 10.5 t/h.

Accordingly, the steam flow from the boiler is determined as the difference between the drinking water flow and the blowdown flow.

The size of the continuous blowdown under various operating modes must be remotely maintained using a continuous blowdown flow meter or adjusted by the boiler operator at the request of the chemical shop personnel.

Periodic purge

Periodic purge produced to remove sludge from the lowest points of all collectors and sent to the expander periodic purging and then through the bubbler into the industrial storm drain.

Periodic purging, as the name implies, is not permanent and is carried out from time to time. Periodic purge is limited in time and lasts no more than 30 seconds. It is believed that almost all the sludge is removed immediately in the first seconds of purging.

Example from operation: Periodic purging of boiler No. 3 is carried out on Wednesday and Saturday by KTC personnel under the supervision operational personnel chemical workshop. Each screen panel is purged by fully opening the periodic purge valve for 30 seconds. If the regimes are violated, at the request of the chemical shop personnel, extraordinary periodic blowdowns are carried out. When firing up the boiler, periodic blowdowns are carried out at 20, 60 atm in the boiler drum and when the nominal parameters are reached.

The size of continuous blowing and the time of periodic blowing are recorded in the daily reports of the express laboratory by the laboratory assistant on duty or the shift supervisor of the chemical workshop.

Read also: deaerator operating principle

Schemes and drawings of boiler purge

Boiler blowdown diagram

This is part of a real detailed diagram of a 450 MW combined cycle plant. The diagram shows how continuous and periodic purging is carried out.

The continuous purge from the high pressure drum enters the continuous purge separator/expander. The following is installed on the line along the flow of the medium: shut-off manual fittings, flow meter, electrified regulator, set of throttle washers, electrified fittings and set of throttle washers.

At the end of the article, an example of calculating a continuous blowdown expander is given.

The RNP is equipped with a safety valve.

In this scheme, saturated steam from the continuous blowdown separator is sent to the low pressure drum. Manual shut-off valves and a check valve are installed on the steam line. Drainage from the RNP will be sent to the clean waste tank.

The blowdown from the RNP is sent to the periodic blowdown expander; an electric control valve and manual shut-off valves are installed on the line. Next, the drainage from the RPP is discharged into the boiler drain tank.

Drawing of a steam pipeline from a continuous blowing separator to a deaerator

The design assembly drawing shows the layout of the low pressure steam line from the continuous blowdown expander to the atmospheric deaerator. There are two fittings installed on the steam line, one is a shut-off valve (position 2) and the other is a check valve (position 1) so that steam cannot flow back into the expander.

Exhaust drawing from RNP safety valve

Another drawing shows the exhaust pipe from the RNP safety valve. The pipeline from the safety valve is directed to the edge of the main building and, at the point of the columns, is led to the roof, to a height of more than 2 meters, to ensure the safety of the station personnel. A water seal is provided on the exhaust pipeline to remove drainage into the drainage collector. Based on operating experience, it is recommended to make the diameter of the water seal pipe larger than that of a conventional drain to prevent it from clogging, since leaves and other dirt can enter the exhaust pipe from the atmosphere.

Drawing of vapor from a periodic blowdown expander

thermal calculation of RNP

Let's look at expander balances using an example. We will consider the blowdown of the EP-670-13.8-545 GM boiler operating with a T-180/210-130 turbine.

Initial data: feed water consumption: Gpw = 187.91 kg/s

We accept the flow rate of purge water: Gpr = 0.3% * Gpv = 0.03*187.91 = 5.64 kg/s

We assume the pressure in the continuous blowing expander: Prnp = 0.7 MPa

We will have two equations and two unknowns, namely:

• Gpr1 - water flow at the outlet of the RNP
• Gpr2 – steam flow at the outlet of the RNP (this steam is discharged into a high-pressure deaerator 0.6 MPa)

Equations:

1. Gpr = Gpr1 + Gpr2
2. Gpr*hpr = Gpr1* hpr’ + Gpr2* hpr’’

Known quantities: 1.20 GB (1,300,147,052 bytes)

• Blowdown flow rate coming from the boiler drum: Gpr = 5.64 kg/s
• Enthalpy of blowing water from the drum: hpr is defined as the enthalpy of water at saturation pressure in the drum, hpr = f(Pb)=f(13.8 MPa) = 1563 kJ/kg
• Enthalpy of water at the exit from the RNP: hpr’, is defined as the enthalpy of water at saturation in the RNP: hpr’=f(Prnp) = f(0.7 MPa) =697.1 kJ/kg
• Enthalpy of steam at the exit from the RNP: hpr’’, is defined as the enthalpy of saturated steam in the RNP: hpr’=f(Prnp) = f(0.7 MPa) =2763.0 kJ/kg

All enthalpies were determined in the water steam pro program, we talked about it in the article Material balance equation and selection of a deaerator, and there are also links where you can download it.

Final equations:

1. 5.64 = Gpr1 + Gpr2
2. Gpr*1563 = Gpr1* 697.1 + Gpr2* 2763.0

Finding unknowns:

• Gpr1 = 3.27 kg/s
• Gpr2 = 2.36 kg/s

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graduate work

2.7 Design and principle of operation of a continuous blowing separator

To use the heat of the blowdown water for deaeration, separators for continuous blowdown from the boilers are installed in the boiler area control room.

The separator consists of a housing, a volute, a plate-type droplet eliminator, a blow-off water outlet regulator, a separated steam outlet, an outlet to a safety valve, a water meter glass, and drainage outlet pipelines.

The principle of operation of the separator is based on the release of steam and condensate from the blowing emulsion removed from boilers with continuous blowing, due to a sharp change (increase) in the volume in the expander (separator body) and, accordingly, a drop in the pressure of the supplied blowing medium to the pressure in the expander.

Blowdown water with a pressure equal to the steam pressure in the drum of the recovery boiler is supplied to the blowdown water inlet of the separator through a common blowdown water collector. Due to the tangential location of the purge water inlet, the flow acquires a rotational motion, due to which the steam-water emulsion is intensively divided into steam and water, having different densities, at the opposite walls of the separator volute. Passing through the gap in the cochlea, the flow enters inner space separator housing (expander). Due to a sharp change in volume, the pressure of the supplied water drops and boiling of superheated water occurs.

The steam separated in the volute and the steam released when the liquid boils enters the upper steam part of the separator, passes through a droplet eliminator, where it is freed from water particles captured by the steam flow and then goes through a pipeline to the deaeration column. Water enters bottom part separator, where a normal water level is maintained using a float regulator (a level that fluctuates in the middle part is considered normal water indicator glass). Excess water is removed to the sewer.

If necessary (if the level regulator malfunctions, the water level in the separator increases above the permissible level, etc.), water can be removed through the drainage in the lower part of the separator.

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Continuous blowdown separators are designed to separate the steam-water mixture formed from the blowdown water of steam boilers into steam and water by reducing its pressure to the pressure in the separator (which leads to boiling of the water), followed by using the heat of water and steam.

To speed up the separation process, a tangential supply of purge water is used. The separators also have vertical louvered drop eliminators for drying secondary boiling steam.

The separator is a vertical cylindrical vessel welded structure and consists of a body with a lower elliptical bottom welded to it; The upper elliptical bottom is connected to the body using a flange connector. In the middle part of the body, 2 or 4 supports are welded for installing the separator in a suspended state on support beams.

In the lower part of the housing there is a receiving device, consisting of two concentrically installed shells and two tangentially welded pipes into the housing, designed to receive tangentially supplied purge water.

In the upper part of the housing, a separating device is bolted to the ring, consisting of a set of specially bent blades and designed to separate small drops of water from steam.

A constant level of separated water is automatically maintained by a float level regulator built into the fitting at the bottom of the housing.

To visually monitor the level of separated water, the separator is equipped with a water-indicating device, consisting of a water-indicating glass and valve-type taps.

To monitor the working pressure in the steam space of the separator, there is a pressure gauge indicating a measurement limit of up to 1.6 MPa with a 3-way purge valve and a drain valve.

Cutting off steam pressure in the housing above the permissible level (0.75 MPa) is ensured by a full-lift flange safety valve, equipped with a replaceable spring operating at a pressure in the range of 0.7-1.3 MPa. Valve operation is adjusted to a pressure of 0.75 MPa. Top part The valve is closed by a cap, which contains an adjusting screw for setting the spring to a given pressure.

The operation of the separator is to receive a steam-water mixture from the boiler, dividing it into steam and water due to the expansion and rotational movement of the flow in the separator receiving device. The steam is finally dried in a separating device.

The continuous purge separator is selected based on the purge water flow rate

where is the consumption of residual water at the outlet of the SNP, t/h;

Steam consumption at the outlet of the SNP, t/h

Based on the given conditions, we select separators of the SP-0.28-0.45 brand produced by the Saratov Power Engineering Plant. The main characteristics of SP-0.28-0.45 are given in the table. dimensions are indicated in Figure 3.3.3.

Table 3.3.3 - Specifications SP-0.28-0.45

Figure 3.3.2 - Overall dimensions of the separator SP-0.28-0.45: A-fitting of the level regulator; B-supply of steam-water mixture; B-output of separated steam; G-output of separated water; D - for safety valve; E-drainage; F-coupling of the pressure gauge; I-couplings for level indicator; K-fitting inspection