DUCTS AND DAMPERS
DUCTS & DAMPERS
Duct is a closed path for the flow of cold air , hot air
and gases from one point to another point in a
system . This can be of any shape like Circular ,Elbow
, Straight , Square, Rectangular or some other shape.
There are eleven duct systems in Boiler :
1 . Cold air duct - FD fan to air heater.
- PA fan to air heater.
2 . Tempering Air system .
HOT AIR DUCTS :
* Hot air To Wind box
* Hot air To Bus duct
* Hot air to Mills
GAS DUCTS :
* Gas To Economizer
* Gas To Boiler Outlet
* Gas To Electro statics precipitator
* Gas To ID Fan
* Gas To Chimney
COLD SECONDARY AIR DUCTING
Hot Secondary Air Duct
COLD PRIMARY AIR DUCTING
Hot Primary Air Bus to Mill &
Tempering Air Duct
Economiser to Airheater Duct
Air Heaters to BOF
BOF TO AIR HEATERS
BOF to EP Duct
EP to ID Fan
ID Fan to Chimney Duct
Raichur 7, 210 MW Boiler Plant
Raichur 7, 210 MW Boiler Drum area
Raichur 7, 210 MW – Top View
Raichur 7, 210 MW – Left side view
Raichur 7, 210 MW – Right side view
Raichur 7, 210 MW – Front view
Raichur 7, 210 MW – Rear view
Circular to Y duct
Straight duct Rectangular duct Transition duct
Elbow duct Bend duct
T duct
Anatomy of a simple straight duct
STIFFENER
DUCT WITH
INTERNAL
TRUSS
DUCT
PLATE
CORNER
ANGLE
FLANGE
FLUE
3D VIEW OF TUBULAR GAS
OUT
AIRPREHEATERS WITH
DUCTS
COLD
AH-I
AIR IN
FLUE
GAS IN
AH-II ELBOW DUCT
AH-III
HOT AIR TRANSITION
OUT DUCT
SUPPORT
FLOW METER
EXPANSION JT
HOT SECONDARY AIR DUCT
ECONOMISER DUCT AT SHOP
INTERNAL TRUSS WORK IN
ECONOMISER DUCT
GUSSET PLATE :
This is a plate for welding cross bracing (ex. Strut tube)
inside the duct.
Strut tube
Gusset plate
Welding
STRUT TUBE :
This is used for load transfer and retain the shape of
duct.
JOINTS IN DUCTS
* FFJ - FLANGE FIELD JOINT
* FJ - FIELD JOINT
* IFJ - INTERNAL FIELD JOINT
DUCT CORNER CONSTRUCTION
CORNER
WELDING
CORNERA
NGLE
FIELD FLANGE JOINT-FFJ
5
50 (150)
Duct Plate
FIELD JOINT (FJ)
FJ - Plate 5
5
50(150)
Duct Plate
INSIDE FIELD JOINT (IFJ)
Duct Plate
5 50(150)
IFJ - Plate
5
TYPE OF SUPPORTS IN DUCT
1 * TOP SUPPORT
a . Hanger support .
2 * BOTTOM SUPPORT
a . Fixed Type .
b . Sliding Type .
Normally hot air ducts will be provided with sliding bottom
supporting .
HANGER SUPPORTS:
a . Fixed hanger supports :
Where the downward movement of the duct need not be
allowed .
b . Spring hanger supports:
Duct is allowed to move in the down ward direction .
* Variable load hangers ( VLH ) .
Used where the difference between the cold loads and hot loads
is very small .
* Constant load hangers ( CLH ) .
Used where the difference between the cold loads and hot loads
is very large .
3 * RESTRAINTS : (STOPS & TIES )
Used to take the horizontal loads on the ducts like
1 . Wind loads
2 . Seismic loads
3 . Expansion joint loads &
4 . Unbalanced pressure loads .
SHEAR TIES & PIN TIES :
These are used to support the toggle section inside the duct itself .
TOP SUPPORT WITH HANGER
AND BRACKET
TOP SUPPORT WITH HANGER AND BRACKET
TOP SUPPORT WITH
HANGER AND LUG PLATE
RESTRAINT SUPPORT
RESTRAINT SUPPORT
SINGLE RESTRAINT SUPPORT
HANGER TYPE
SUPPORT WITH
RESTRAINT
STIFFENER
DIFFERENT TOP SUPPORTS
DUCT WITH BOTTOM SUPPORT
FLANGE WITH
FITUP HOLES
DETAIL - B
SUPPORT
DETAIL - A
SUPPORT
CORNER GUSSET
ANGLE PLATE
STRUTTUBE WELD
RESTRAINT BASE PLATE
WITH (BEARING)
I-BEAM
SUPPORT
TOP PLATE
BEARING PLATE
BASE PLATE
BOTTOM SUPPORT WITH BASE
PLATE AND BEARING PLATE
BOTTOM SUPPORT
WITH STOPPERS
TOP PLATE
BEARING PLATE
BASE PLATE
WITH STOPPER
SHEAR TIES
TYPES
TYPES OF
OF EXPANSITION
EXPANSITION JOINTS
JOINTS ::
1 * Non - metallic expansion joints .
2 * Metallic expansion joints.
Round corner expansion joint - Full .
Round corner expansion joint - Half .
Square corner expansion joint .
Omega type expansion joint .
Full size round corner expansion joints have 8.5 inches height and are
made from 2.5 mm thick sheet .Half size round corner expansion joints
have 4.25 inches height and are made from 1.6mm thick sheet .
EXPANSION JOINT
ASSEMBLED IN DUCT
With
With metallic
metallicexp..
exp..joint
joint
With
With non
non--metallic
metallicexpansion
expansionjoint
joint
TOGGLE SECTION :
A small piece of duct having expansion pieces on
either
ends . It may be floating or pinned at one end
or pinned at both
ends. The duct piece may be straight or tapered .
A toggle section
which is floating can take expansion in all the
directions at both the
expansion joints .
With
With metallic
metallic toggle
toggle
Lateral
With non-metallic EJ
Axial
FIGURE
FIGURE--11
CL of support C L of support
Movement
Lateral movement to Toggle of duct
Axial movement
Movement
of A. H.
AIR - HEATER
Axial movement
ROUND
ROUNDCORNER
CORNEREXPANSION
EXPANSIONJOINT
JOINT--FULL
FULL
SECTION A - A
A
DEPTH
WIDTH
STYLE 1
STYLE
STYLE22
FULL
FULLROUND
ROUNDCORNER
CORNEREXPN.
EXPN.JOINT
JOINT
216 mm
271.8 mm
STYLE
STYLE66
DAD Circle / BHEL , TRICHY
DAD Circle / BHEL , TRICHY
DAD Circle / BHEL , TRICHY
Clamp
Re-usable duct
mating flange
Lifting lug
Bolt & Strut pipe
Nut
Match plate
DAD Circle / BHEL , TRICHY
PTFE SEALING ELASTOMER COATED GLASS FABRIC
LAYER OUTER LAYER (silitex) SUPPORT LAYER
CAVITY
PILLOW
GLASS FABRIC
BOLSTER
DUCT S.S WIREMESH
FABRIC DETAILS FOR N.M.E.J
• Supplied SILITEX coated outer layer is inadequate for the intended
application
• FLUORO polymer based outer layer is recommended
What is guillotine gate ?
GATE Guillotine gates are
used in boilers to
isolate the flow in duct
for online maintenance
of auxiliary equipment
of boilers and for part
load operations.
Gate with CONVENTIONAL LEAF SEAL
LEAF SEAL WHEN
BLADE CLOSED
LEAK TIGHTNESS ACHIEVED FOR TALCHER COLD
AIR GATE IS 96.85% WITH OUT SEAL AIR
GUILLOTINE
GATES AND
BIPLANE
DAMPERS ARE
USED WHERE
100% LEAKE
TIGHTNESS IS
REQUIRED.
100% LEAK TIGHTNESS
The seal air is admitted inside the
seal air chamber with a pressure of
125 mm WC more than the system
pressure.
P2>P1&P2
PLENUM DUCT
BLOWER TESTING TUBE
FLOW
P3
P1 P2
UNCHAHAR FLAP DAMPER
ACTUATOR
GEAR BOX
SEAL AIR FAN
CASING
BLADE
PRODUCTION OF FLAP DAMPER AT SHOP
FLAP DAMPER WITH TOGGLE
LEVER ARRANGEMENT AND
SINGLE ACTUATOR
ACTUATOR
TOGGLE
LEVER FLAP
SIMHADRI 2x500MW
EXPANSION JOINT
ACTUATOR
ECONOMISER
HOPPER
FLAP DAMPER
WITH TOGGLE-
To AIR-HEATER
LEVER
EXPANSION JOINT
ECONOMISER
HOPPER
FLAP DAMPER
WITH TOGGLE-
LEVER To AIR-HEATER
FLOW-IN
DUCT
FLAP WITH
TOGGLE-
LEVER
ACTUATOR
FLOW-IN
DUCT
FLAP WITH
TOGGLE-
LEVER
IN
OUT
