BOILER

SABARI GIRISH N
SR. ENGINEER (O)

SESSION PLAN
Boiler fundamentals

Principle of Combustion
Classification of Boilers Arrangement of main boiler

WHAT IS A BOILER?
BOILER

means any closed vessel exceeding 22.75 litres in capacity which is used expressly for generating steam under pressure and includes any mounting or other fitting attached to such vessel, which is wholly or partly under pressure when steam is shut off.
As per INDIAN BOILER REGULATIONS

BOILER FUNDAMENTALS
STEAM WATER COAL BOILER AIR ASH FLUE GAS

CO, CO2, H2, H2O, 02

COMBUSTION EQUATIONS..
C +O2
2C+O2

CO2
2CO H2O SO2

33820 KJ/Kg
10200 KJ/Kg

2H+O2 S +02

COMBUSTION EQUATIONS..
AIR REQUIRED

=4.31[(8/3)C 8(H-0/8)-S]
O2 - 23% by weight O2- 21% by volume

ATMOSPHERIC AIR = N2 - 77% N2 -79% EXCESS AIR

FOR COMPLETE COMBUSTION- 15 TO 20%

REQUIREMENTS FOR GOOD COMBUSTION

3Ts
temperature time Turbulance

COMBUSTION EFFICIENCY
Design of the boiler Fuel used Skill of obtaining combustion with minimum excess air ( CO monitoring)

EFFICIENCY CALCULATION METHODS

DIRECT METHOD

IN-DIRECT METHOD

CLASSIFICATION OF BOILERS
BASED ON ARRANGEMENT
FIRE TUBE

WATER TUBE

CLASSIFICATION OF BOILERS
FIRING ARRANGEMENT
FRONT FIRED CORNER /TANGENTIAL FIRED GRATE FIRED PULVERIZED FUEL FIRED

CIRCULATION
NATURAL CIRCULATION FORCED CIRCULATION

CLASSIFICATION OF BOILERS
APPLICATION
UTILITY BOILERS INDUSTRIAL BOILERS

CONSTRUCTION
TOWER TYPE TWO PASS BOILERS

MANUFACTURERS
CE-BHEL ANSOLDO LMZ

COMPONENTS OF A BOILER
ECONOMISER BOILER DRUM DOWN COMERS WATER WALL PRIMERY SUPER HEATER PLATEN SUPER HEATER FINAL SUPER HEATER RE-HEATER BURNER OIL GUNS IGNITORS BUCK STAYS

STAGE-I

ECONOMISER
FORMS PART OF FEED WATER CIRCUIT PRE HEAT BOILER FEED WATER RECOVERY OF HEAT FROM FLUE GAS LOCATED IN BOTTOM OF REAR PASS NO STEAM FORMATION

BOILER DRUM
TO SEPARATE WATER FROM STEAM TO REMOVE DISSOLVED SOLIDS TO PROTECT WATER WALLS FROM STARVATION ACTS AS TEMPORARY PRESSURE RESERVOIR

DURING TRANSIENT LOADS

WATER WALL
FORMS FURNACE ENCLOSURE
GENERATION OF STEAM

PROVIDES SEALING TO FURNACE

SUPER HEATER
RAISE STEAM TO HIGHER TEMPERATURE ARRANGED IN 3 STAGES LTSH LOCATED ABOVE ECONOMISER

RADIANT PENDENT TYPE (DIV PANEL)

ABOVE FURNACE CONVECTIVE FINAL SUPER HEATER

ABOVE FURNACE IN CONVECTIVE PATH

RE HEATER
RE HEAT THE STEAM FROM HP TURBINE TO 540 DEG

COMPOSED OF THREE SECTIONS

RADIANT WALL REHEATER ARRANGED IN FRONT & SIDE WATER WALLS REAR PENDANT SECTION ARRANGED ABOVE GOOSE NECK

FRONT SECTION ARRANGED BETWEEN UPPER

HEATER PLATEN & REAR WATER WALL HANGER TUBES

BURNERS
32 COAL BURNERS & 16 OIL BURNERS IN ALL IN CE TYPE BOILERS OF STAGE-II 500 MW 24 COAL BURNERS & 24 OIL GUNS IN STAGE-I

ANSALDO BOILER ARRANGED ON THE FRONT

IN 500 MW BOILERS BURNERS CAN TILTED +30 TO -30. DENPENDING ON THE REQUIREMENT NO SUCH PROVISION IN STAGE- 1 BURNERS

IGNITORS
EACH GUN IS PROVIDED WITH AN IGNITOR HIGH ENERGY ARC, EDDY CURRENT IGNITORS OUT PUT VOLTAGE 2500V DC

SPARKS
DUTY CYCLE

4 SPARKS PER SECOND

15 MIN ON , 30 MIN OFF

CONTROL CIRCULATION PUMPS

THREE PUMPS PER BOILER(2X50%)
ASSIST IN CIRCULATING WATER THROGH WATER WALL TUBES

EACH PUMP CAPACTY

DIFFERENTIAL PRESSURE SPECIFIC GRAVITY

2879.4 T/HR
1.948 KSC .5993@362 DEG

BUCKSTAYS
MECHANICAL SUPPORT BEAMS
SUPPORTS BOILER ENCLOSURE TO SAFE GUARD FURNACE GEOMETRY , EXPECIALLY FURNACE EXPLOSION /IMPLOSIONS

BOILER AUXILIARIES
COAL FEEDERS MILLS PRIMARY AIR FANS SEAL AIR FAN FORCED DRAFT FANS WIND BOX SCANNER FAN AIR PRE HEATERS ESP INDUCED DRAFT FANS CHIMNEY SOOT BLOWERS

COMBUSTION
Constituents of coal (%)
Carbon Volatile matter Moisture Ash Sulphure 36.54 21.6 10 32 .38

500 MW RSTPS BOILER

MANUFACTURER TYPE NO OF MILL WITH OUT OIL SUPPORT EXPLOSION/IMPLOSIO N CAPACITY VOLUME SIZE TUBES DRUM CAPACITY SAFTEY VALVES TUBE LENGTH BHEL-(CE DESIGN) BALANCED DRAFT, DRY BOTTOM, SINGLE DRUM, CONTROLLED CIRCULATION PLUS, TILTING TANGENTIAL 2 ADJACENT MILLS @ 50% OF CAPACITY +660 OR -660 mmwc 14820 M3 62.456MTR (FROM BA HOPPER TO FURNACE ROOF) X 15.289 X 18.034 PITCH 63.5 DSGN PR 208.8 SA 210C OD -51MM THICKNESS-5.6MM, WT 583.2 TONS

22070X2130X1778 END THICKNESS 152.4mm CYCLONES 96 SA 299 WT 246 T, ( 224 T WITHOUT INTRNL) 10 SEC FROM NORMAL TO LO-LO TRIP DRUM -6 SUP HEATER 6 (2+4), CRH -4, HRH -8 (4+4) 350 KM approx( FOR 500 MW BOILER) , 58000 BUTT WELLDS approx

PARAMETERS
Flow MCR NCR

S H steam
RH steam Feed water Spray Secondary Primary air Total Air

1725
1537 1725 1464 558 2021

1384
1527 1527.3 22.7 1337 477 1814

COAL( 4300 kcal/kg)

296

266

COMPARISON
SL. NO
1 2 3 PARAMETER FIRING CIRCULATION PF TRANSPORTATION ST.-1 FRONT FIRED NATURAL PA FAN TO EACH MILL ST.-2 CORNER FIRED CONTROLLED COMMON PA FANS-2NOs.

4 5 6
7

OIL REHEATERS APHs

FLY ASHING

LFO/HFO IN CONVECTIVE ZONE

COMMON TO SEC. AND PRIMARY AIR CONTINUOUS(u#2 & 3)

LSHS or HFO IN CONV. & RADIATION ZONE SEPARATE APHs

INTERMITTENT

8
9

BOILER CONTROL
COAL MILL

BMS
BALL AND RACE

FSSS
BOWL

Contd.
SL. NO 10 11 12 13 14 PARAMETER SH/RH TEMP. CONTROL DOWN COMERS SECONDARY AIR CONTROL ST.-1 GAS BY PASS & ATTEMPERATION 7 NOT POSSIBLE ST.-2 ATTEMPERATION & BURNER TILT 6 POSSIBLE ADJACENT MILL SUPPORT IS SUFFICIENT HIGH ENERGY ARC. NO OIL.

MILL CHANGE OVER

IGNITORS

REQUIRE GUNS SUPPORT

REQUIRES LFO SUPPORT

15
16

OIL GUN TIP

AIR

Y
PRIMARY AIR, SECONDARY AIR

J
PA, SA, AUX. AIR, END AIR, OVER FIRE

Contd.

SL. NO 17 18

PARAMETER FD FAN CONTROL PA FAN CONTROL

ST.-1 VANE CONTROL VANE CONTROL

ST.-2 BLADE PITCH CONTROL BLADE PITCH CONTROL

SAFETY VALVES ( STAGE-II)

BOILER DRUM SUPER HEATER CRH HRH 6 SPRING LOADED 2 SPRING LOADED, 4 ERVs 4 SPRING LOADED 4 SPRING LOADED, 4 ERVs

NO SET PR B1 200 B2-B6 202- 206 SH 184 SH ERVs 180-182 CRH 55-56 HRH 48.5-49 HRH ERVs 47.5-48

RESET PR 191 192-196 178 176-178 53-55 47-47.5 46.6-47

%BLOWDOWN 4 5 3 4.8 3 3 1.97

SOOT BLOWING SYSTEM

NO BLOWERS 104+34+4 WALL BLOWER LRSB TRAVEL 305 9200 mm NOZZLE DIA 26 32 mm BLOWING PRESSURE 12 12.5 ksc TIME 1.44 MIN (PER PAIR) 833 KG/HR (PER PAIR) 116.62 KG (PER PAIR) 293

RATE CONSUMPTION 3349 (PER GROUP)

ELECTRO STATIC PRECIPITATOR

COLLECTION EFFICIENCY TREATMENT TIME DUST CONCENTRATION COLLECTING RAPPER FREQUECY EMITTING RAPPER FREQUECY HOPPERS HOPPER CAPACITY HOPPER HEATERS FIELD CURRENTS ( mA) VOLTAGE 99.9% 33.33 SEC 115mg / M3 (LIMIT) 15- 2 RAPS/ HR 10 RAPS /HR 96 8HRS +10% 96X6 150 250 325 450 600 750 70 KV PEAK