Generating Steam in the Power Plant

Lesson 1: Transforming Energy into Work

Topics

Energy and Matter; Fuels; Combustion; Temperature Measurement; Pressure Measurement; Quantity of Heat; Heat Transfer; Conduction; Radiation; Convection; Sensible and Latent Heat; Vaporization; Boiling Point; Enthalpy; Heat and Work; Basic Steam Generation

Objectives

• Define energy and describe the main forms of energy encountered in a power plant.
• Explain the process of combustion and list the three elements necessary for combustion to occur.
• Explain the principles of temperature and pressure measurement and describe the four scales on which temperature is measured.
• Describe the methods of heat transfer and the types of effects heat transfer can have on a material.
• Summarize the interrelationship of temperature, volume, and pressure in a gas.

Lesson 2: Boiler Operation

Topics

Types of Boilers; Boiler Characteristics; Water Treatment for Boiler Use; Boiler and Cooling Tower Blowdown; Wastewater Disposal; Efficiency in the Power Plant; Thermodynamic Efficiency; Conserving Energy in the Power Plant

Objectives

• Compare the two basic types of boilers.
• Describe the characteristics by which boilers are classified.
• Explain the different processes by which water is treated for use in a boiler.
• Define blowdown and explain its importance in boiler operation.
• List the problems associated with wastewater disposal and describe how these problems are overcome.
• Describe the factors that affect boiler efficiency, as well as auxiliary equipment efficiency.
• Calculate thermodynamic efficiency.
• List practices that aid in energy conservation in all areas of the power plant.

Lesson 3: Boiler Maintenance

Topics

Soot Removal; Scale Removal; Corrosion; Casing Corrosion; Refractory; Control Systems; Calibration and Cleaning; Compressed Air Systems; Maintaining Boiler Auxiliaries; Maintaining Stacks and Cyclones; Maintenance Schedules and Reports

Objectives

• Explain how the two types of sootblowers remove soot and slag from heat exchange surfaces.
• Describe how scale forms on boiler surfaces and list the three common removal methods.
• Explain why both hot-end and cold-end corrosion occur in a boiler, and tell what practices help prevent corrosion.
• Describe how refractory should be maintained and list the problems that can occur if it is not properly maintained.
• List the primary functions of boiler control systems and describe the three common types.
• Explain how to calibrate and clean boiler control systems and maintain compressed air systems.
• Summarize maintenance procedures for boiler auxiliaries such as pumps, valves, motors and electric circuits.

Lesson 4: Combustion and How It Works

Topics

Coal Ranks; Coal Analyses; Coal Sizes; Coal Storage; Oil Properties; Natural Gas; Chemistry of Combustion; Oil Burners; Gas Burners; Flame Color; Flame Adjustment for Oil and Gas; Coal Firing Systems; Pulverized Coal Burners; Overfeed Stokers; Underfeed Stokers; Ash Analysis for Carbon; Combustion Efficiency; Handling Unburned Solids

Objectives

• Identify the different ranks of coal and describe how the makeup of coal affects its heating value.
• List the properties that are tested in a coal analysis.
• Summarize the properties of oil and natural gas fuels.
• Explain the combustion process in detail.
• Describe how to interpret and adjust a flame's characteristics in coal, oil, and gas burners.
• Describe the three types of coal firing systems.
• List the ways in which combustion efficiency is measured.

Lesson 5: Steam Generation

Topics

The Steam Generation Process; Temperature and Pressure Relationship; Superheating Steam and Steam Quality; Volume and Pressure Relationship; Steam Tables for Saturated Steam; How to Use Steam Tables; Circulation of Boiler Water; Steam Circulation and Tube Temperature; Steam Drum Design; Operating a High-Pressure Boiler at Low Pressure; The Complete Steam Generation System; Conserving Energy; Blowdown; Makeup Water

Objectives

• Trace the flow of water and steam through the boiler system.
• Explain the relationship between temperature and pressure and explain why superheated steam has a higher quality than saturated steam.
• Read a steam table properly and apply its information to a boiler system.
• Compare natural circulation boilers with forced circulation boilers, and explain how pressure and temperature affect the type of boiler used.
• Describe the process of operating a high-pressure boiler at low pressure.
• Describe how proper maintenance of steam traps, valves, packing, flanges, and insulation improve the energy conservation rate in a boiler system.