BOILER FUNDAMENTALS

PRINCIPLE OF COMBUSTION

• CONVERSION OF CHEMICAL ENERGY TO HEAT ENERGY.

• COMBINE CARBON AND HYDROGEN (HYDRO CARBONS) WITH OXYGEN.

IGNITION

• RAISING THE TEMPERATURE OF THE FUEL TO IGNITION TEMP.

THEORITICAL AIR & EXCESS AIR

FACTORS FOR EFFICIENT COMBUSTION (3Ts)

•TIME

•TEMPERATURE

•TORBULENCE
COMBUSTION EFFICIENCY

THERMAL EFFICIENCY= HEAT TRANSFERRED/1 KG OF FUEL USED.

• DESIGN OF BOILER.

• FUEL USED.

• OBTAINING MINIMUM EXCESS AIR.

BASIS OF BOILER CLASSIFICATION

•USE (STATIONARY/MOBILE)

•PRESSURE

•MATERIALS

•SIZE

•TUBE CONTENT(FIRE TUBE/WATER TUBE)

•TUBE SHAPE AND POSITION

•FIRING (FIRED/NONFIRED)

•HEAT SOURCE

•FUEL (COAL/GAS/NUCLEAR)

•FLUID (WATER/MERCURY WATER)

•CIRCULATIONS (NATURAL/FORCED)

•FURNACE POSITION (INTERNAL FIRED/EXTERNAL FIRED)

•FURNACE TYPE

•GENERAL SHAPE

•TRADE NAME

•SPECIAL FEATURES (DIFFERENTIAL/HORIZONTAL/TANGENTIAL FIRING)

TYPES OF BOILER

• STEEL BOILER • SHELL TYPE

• FIRE TUBE TYPE • CAST IRON BOILERS
• WATER TUBE TYPE • SPECIAL DESIGN BOILERS
• HORIZONTAL STRAIGHT TUBE • NUCLEAR REACTORS
• BENT TUBE END USE
POSITIVE CIRCULATION • UTILITY
• NATURAL CIRCULATION • INDUSTRIAL
MAJOR ACCESSORIES

• ECONOMISER • PLATEN SUPERHEATERS

• BOILER DRUMS • FINAL SUPERHEATERS
• DOWN COMERS • REHEATERS
• WATERWALLS • BURNERS
• PRIMARY SUPERHEATERS/LOW • IGNITERS (EDDY PLATE/HIGH
TEMP SUPERHEATERS (LTSH) ENERGY ARC)
ECONOMIZERS:
THE ECONOMIZER IS THE HEAT EXCHANGER THAT RAISES THE TEMP. OF
THE WATER LEAVING THE HIGHEST-PRESSURE FEEDWATER HEATER TO
THE SATURATION TEMP. CORRESPONDING TO THE BOILER PRESSURE.
THIS IS DONE BY GASES LEAVING THE LAST SUPERHEATER/REHEATER.
GAS TEMP. AT ECONOMIZERS- 350 TO 375 C

BOILER DRUM:
THE STEAM DRUM PROVIDED EXCEPT ONCE-THROUGH BOILER IS WHERE
FEEDWATER FROM ECONOMIZER IS FED, SATURATED STEAM IS
SEPARATED FROM THE BOILING WATER IS RECIRCULATED. THE DRUM IS
ALSO USED FOR CHEMICAL TREATMENT AND BLOWDOWN TO REDUCE
SOLIDS IN WATER.
DOWNCOMERS:
DOWNCOMERS ARE PROVIDED UNDER THE DRUM WHERE THE
SEPARATED WATER FROM STEAM AT BOILER DRUM COMES TO
THE BOTTOM RING HEADERS & FROM WHICH IT ENTERS INTO
THE WATER WALLS FOR THE FORMATION OF STEAM.

WATER WALLS:
IN WATER WALLS THE SEPARETD WATER FROM THE DRUM
THROUGH BOTTOM RING HEADER CONVERTED INTO STEAM BY
HEAT TRANSFER PROCESSES.
SUPERHEATERS AND REHEATERS:
THE STEAM SEPARATED AT THE DRUM PASSES THROUGH THE
SUPERHEATERS/REHEATERS THEREBY PICK UP ADDITIONAL HEATS
FROM THE GASES BY CONVECTION & RADIATION.
LTSH, LOW TEMP SUPERHEATERS
DIVISIONAL PANEL
PENDANT/FINAL SUPERHEATERS

REHEATERS:
IN REHEATERS THE HEAT IS TRANSFERRED FROM THE FLUE GASES
TO THE USED STEAM FROM THE HP TURBINE THEREBY INCREASING
THE EFFICIENCY.
OTHER IMPORTANT COMPONENTS:
SUPERHEATER DESUPERHEATERS
REHEATER DESUPERHEATERS
WATER COOLED FURNACE
WATERWALL INLET HDRS/BOTTOM RING HDR
CHEMICAL DOSING SYSTEM (TSP)

FUEL FIRING SYSTEM:

FUEL OIL SYSTEM
COAL SYSTEM
BURNERS/NOZZLES
TILTING TANGENTIAL FIRING SYSTEM:
AIR & FUEL NOZZLES TILTS
WIND BOX ASSEMBLY.

FUEL OIL FIRING SYSTEM:

FUELS
BURNER ARRANGEMENT
COMBUSTION & DISTRIBUTION
FURNACE PURGE
BOILER LOW LOAD OPERATION
BOILER LOAD ABOVE 30%
FUEL AIR DAMPERS
FUEL OIL ATOMISATION
HFO RECIRCULATION
OIL FLOW CONTROL
STEAM REQUIREMENT
HFO BURNERS
FUEL OIL PUMP
IGNITORS
FUEL OIL GUN ADVANCE/RETRACT MECHANISM
STEAM SCAVENGING OF FUEL OIL GUNS
HEAT TRACING OF HFO LINES
HFO PUMPS & ACCESSORIES

COAL FIRING SYSTEM:

PULVERIZED COAL SYSTEM
PULVERIZERS
FEEDERS
PULVERIZED COAL DRYING
COAL PIPING
GRAVIMETRIC FEEDERS
AIR SYSTEM: AIR & GAS PATH
SCANNER AIR FANS
SEAL AIR FANS
PRIMARY AIR/MILL SEAL AIR SYSTEM
SECONDARY AIR SYSTEM/FORCED DRAUGHT FANS
PRIMARY AIR FANS
INDUCED DRAUGHT FANS
AIR PREHEATERS (PRIMARY & SECONDARY)
SOOT BLOWING SYSTEM (WATER WALL/LRSB/APH)