Documente Academic
Documente Profesional
Documente Cultură
Boiler is basically a closed vessel into which water is heated until the water is
converted into steam at required pressure. The basic working principle of boiler is simple and
easy to understand. The boiler is essentially a closed vessel inside which water is stored. Fuel
(generally coal) is bunt in a furnace and hot gasses are produced. These hot gasses come in
contact with water vessel where the heat of these hot gases transfer to the water and
consequently steam is produced in the boiler. Then this steam is piped to the turbine of
thermal power plant. The percentage of total heat exported by outlet steam in the total heat
supplied by the fuel is called steam boiler efficiency.
Steam boiler efficiency (%) =
X100
5425/-3
1
2
134 kg/ cm
Page 1
cm 3 /L or less as
well as essentially eliminating carbon dioxide. There are two basic types of deaerators, the
tray-type and the spray-type. In cogen we use spray cum tray type deaerator. The tray-type
(also called as cascade-type) includes a vertical domed deaeration section mounted on the top
of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank.
The typical horizontal tray-type deaerator has a vertical domed deaerator section
mounted above a horizontal boiler feedwater storage vessel. Boiler feedwater enters the
vertical deaerator section above the perforated trays and flows downward through the
perforations. Low-pressure deaeration steam enters below the perforated trays and flows
upward through the perforations. Some designs use various types of packing material rather
than perforated trays, to provide good contact and mixing between the steam and the boiler
feedwater. The steam strips the dissolved gas from the boiler feedwater and exits via the vent
at the top of the domed section. Some designs may include a vent condenser to trap and
recover any water entrained in the vented gases. The vent line usually includes a valve and
just enough steam is allowed to escape with the vented gases to provide a small and visible
telltale plume of steam.
Boiler
Page 2
The deaerated water flows down into the horizontal storage vessel from where it is
pumped to the steam generating boiler system. Low-pressure heating steam, which enters the
horizontal vessel through a sparger pipe in the bottom of the vessel, is provided to keep the
stored water feedwater warm. External insulation of the vessel is typically provided to
minimize heat loss.
Specifications:
Type
Capacity
228 TPH
130C
Operating pressure
3
2.75 kg cm
0.007 PPM
Design pressure/temp
3
4.0 kg/ cm &full vacuum/150C
68.85 Cu.M
Model/size
HGB 3/15
No. of stages
15
Boiler
3
84.50 m /hr
Page 3
20.00 m
2
40.00 kg/ cm
MCR flow
76.80 m
130C
Fluid density
934.60 kg/ m
Pump speed
1450 rpm
/hr
/hr
5-8 sec
Suction pressure
3.77 kg/ cm
10.85m
Furnace:
Furnace is closed structure which has sufficient open space for bagasse combustion. And
there should be adequate arrangements to accommodate the boiler auxiliaries. The boiler
furnace auxiliary equipment includes bagasse feeders discharge chute, travelling grate which
is a platform for bagasse combustion, S.A air nozzles water wall tubes and super heater coils
at the top.
Specifications:
Boiler
Width
10824 mm
Depth
6248 mm
Height
22600 mm
Tube size
OD 63.5x4.5 thk
120
72
Page 4
72
120
134 kg/ cm
360 C
Economiser:
An economiser is a mechanical device which is used as a heat exchanger by
preheating a fluid to reduce energy consumption. In a steam boiler, it is a heat ex-changer
device that heats up fluids or recovers residual heat from the combustion product i.e. flue
gases in thermal power plant before being released through the chimney. Flue gases are the
combustion exhaust gases produced at power plants consist of mostly nitrogen, carbon
dioxide, water vapour, soot carbon monoxide etc. Hence, the economiser in thermal power
plants is used to economise the process of electrical power generation, as the name of the
device is suggestive of. The recovered heat is in turn used to preheat the boiler feed water,
which will eventually be converted to super-heated steam. Thus, saving on fuel consumption
and economising the process to a large extent, as we are essentially gathering the waste heat
and applying it to, where it is required. Nowadays however, in addition to that, the heat
available in the exhaust flue gases can be economically recovered using air pre-heater which
are essential in all pulverized coal fired boiler.
Principle of Operation:
The flue gases coming out of the steam boiler furnace carry a lot of heat. Function of
economiser in thermal power plant is to recover some of the heat from the heat carried away
in the flue gases up the chimney and utilize for heating the feed water to the boiler. It is
simply a heat ex-changer with hot flue gas on shell side and water on tube side with extended
heating surface like Fins or Gills. Economisers in thermal power plant must be sized for
the volume and temperature of flue gas, the maximum pressure drop passed the stack, what
kind of fuel is used in the boiler and how much energy needs to be recovered. Out, of these 3
major heat ex-changer components, only the economizer operates with, zero fuel
consumption, and thus it is one of the most vital and economical equipment in a thermal
power plant.
Steam Drum:
A steam drum is a standard feature of a water-tube boiler. The drum stores the steam
generated in the water tubes and acts as a phase-separator for the steam/water mixture. The
difference in densities between hot and cold water helps in the accumulation of the "hotter"Boiler
Page 5
water/and saturated-steam into the steam-drum. The separated steam is drawn out from the
top section of the drum and distributed for process. Further heating of the saturated steam will
make superheated steam and used to drive steam turbine. Saturated steam is drawn off the top
of the drum and re-enters the furnace in through a superheater. The steam and water mixture
enters the steam drum through riser tubes, drum internals consisting of demister separate the
water droplets from the steam producing dry steam. The saturated water at the bottom of the
steam drum flows down through the downcomer pipe, normally unheated, to headers and
water drum. Its accessories include a safety valve, water-level indicator and level controller.
Single drum boiler are used mainly for the power plants. The pressure limit for single drum
boilers is higher than that of the bi drum boilers as the stress concentration is reduced to a
greater extent. There exists only one drum and the downcomers are welded to it.
Specifications:
Inside diameter
1372 mm
Shell thickness
95 mm
Drum length
9960 mm
Material
SA 516 Gr. 70
Design pressure
2
134 kg/ cm g
Design temperature
332 C
3
15.70 m
Superheaters:
A superheater is a component of a boiler unit that superheats steam, that is, heats steam above
its saturation temperature. The steam passes inside the steam drum on to the superheater
coils, a set of tubes in the furnace. Here the steam picks up more energy from hot flue gases
outside the tubing and its temperature is now superheated above the saturation temperature.
The superheated steam is then piped through the main stream line to the valves before the
high pressure turbine.
Boiler
Page 6
Specifications:
Primary super heater 1 & 2:
Unit
Method of support
PSH-1
PSH-2
Top
Top
mm
96
96
mm
110
110
84+12 (plugged)
96
16
10
134
134
Design pressure
Kg/ cm
Design temperature
i.
Part A
401
476
ii.
Part B
418
489
Boiler
Method of support
Top
96 mm
132 mm
80
Design pressure
134
2
kg/ cm g
Page 7
Design temperature
i.
Part A
533C
ii.
Part B
586C
33C
207C
No. of blocks
Size of tube
90 mm
80 mm
33C
207C
Specifications:
Boiler
Page 8
No. of blocks
Size of tube
90 mm
80 mm
ID Fans:
Capacity
403020 m
Motor
520 KW
/hr
Induced draft (ID) fans are placed at the outlet of the boiler system and exhaust all gaseous
combustion products, or flue gas, from the boiler by creating a negative pressure or suction
within the furnace. These fans handle hot flue gas, they are generally more susceptible o
erosion and corrosion even with particulate removal equipment (ESP). If greater wear
resistance is necessary, a modified radial, forward-curved, or backward-inclined blading can
be used at the expense of efficiency loss.
Specifications:
Fan type/ Model
horizontal, radial
Site elevation
Ambient temperature
30 C (for design)
Relative humidity
Type of control
VFD
Fan speed
Volume flow
72.90 m
-238 mmwc
20 mmwc
79.30 %
/sec
268 mmwc
Page 9
FD Fans:
Capacity
97668
Motor
110 KW
Forced draft (FD) fans supply the air necessary for fuel combustion by pushing the air
through from the bottom of the furnace. The air supplied by the FD fans is generally
preheated in APH. These fans are typically the most efficient fans in the power plant because
they have the cleanest operating environment. Typically, these fans are centrifugal fans
utilizing radial airfoil blading or variable pitch axial fans.
Specifications:
Fan type/ Model
horizontal, radial
Site elevation
Ambient temperature
30 C (for design)
Relative humidity
Type of control
VFD
Fan speed
Volume flow
22.84 m
-20 mmwc
200 mmwc
82.20 %
/sec
235 mmwc
SA Fans:
Capacity
3
62280 m /hr
Motor
180 KW
Secondary air (SA) fans are more important for the efficient combustion. It takes air from
ambient and gives it to the furnace where the fuel undergoes turbulence and rapidly moves all
over the furnace to gain the complete combustion effectively. The air supplied by the SA fans
Boiler
Page 10
is generally preheated by the APH and it will enter the combustion air from the sides of the
furnace.
Specifications:
Fan type/ Model
horizontal, radial
Site elevation
Ambient temperature
30 C (for design)
Relative humidity
Type of control
VFD
Fan speed
Volume flow
3
15.22 m /sec
-20 mmwc
615 mmwc
81.90 %
645 mmwc
ESP:
Electrostatic precipitators have been used for over half a century to particulate emission in all
power plants. They have very high collection efficiency, sometimes exceeding 99% and
handle large exhaust gas volumes at high temperatures.
Usually the ESP contains six essential components, they are as follows:
Boiler
Discharge electrodes
Collection electrodes
Electrical systems
Rappers
Hoppers
Shell
Page 11
The basic process underlying ESP operation is that pollutant particles in a gas stream
are electrically charged (usually with a negative charge), which causes them to migrate
towards and attach themselves to collection plates or tubes that are oppositely charged. The
collection and discharge electrodes are then rapped which causes the particles attached to the
electrodes to fall into a collection hopper.
A high-voltage direct current is applied to a discharge wire (electrode), negatively
charging it. Voltage to the wire is increased until a corona (a visible electric discharge) is
produced around the wire. As the particle-laden flue gas passes through the corona, the
particles contained in the flue gas passes through the corona, the particles contained in the
flue gas become negatively charged. Because the discharge electrodes are negatively charged
and the collecting electrodes are positively charged, a strong electric field is created between
them. This electrical field propels the negatively charged particles toward the positively
charged collection electrodes, where the particles attach themselves.
Specifications:
Gas flow rate at ESP exit
138 m
/sec (operating)
3
155 m /sec (design)
150 C (operating)
Page 12
160 C (design)
Flue gas density at ESP inlet
3
0.7505 kg/ m (operating)
0.7336 kg/ m
Design temperature (mechanical)
250 C
400 mmwg
No. of rappers
54 sets
(design)
288 nos
Boiler
36 nos
Page 13