BOILER SPECIFICATIONS

Controlled circulation Single drum Top supported Tangential corner fired Riffle tubes Balanced draught Radiant reheat Dry bottom Furnace area 14770m3 Manufacturer BHEL

BOILER DRUM, DOWNCOMERS, CC PUMP, FURNACE,(WATER WALL AND STEAM COOLED WALL) FUEL FIRING SYSTEM,(oil gun,ignitor,burner,burner tilt mechanism,scanner) SADC,(secondary air damper control) WATER WALL TUBE OR RISER ECONOMISER ,(THREE STAGE) SUPER HEATER,(LTSH,DIVISIONAL

BOILER COMPONENTS

REHEATER, SOOT BLOWER SYSTEM(WATER WALL,LRSB AND APH) ,BOTTOM ASH HOPPER(CRUSHER,REFACTORY,THR OUGH SEAL) BOILER AUXILLARIES FANS(PA FANS,FD FANS, ID FANS) MILLING SYSTEM(MILL,RAW COAL FEERDER,SEAL AIR FAN) AIR PREHEATER(SAPH,PAPH) ESP ASH DISPOSAL SYSTEM.(DRY ASH SYSTEM,WET ASH SYSTEM

BOILER DRUM
FUNCTIONS:-

SEPRATES WATER AND STEAM

REDUCED DISSOLVED SOLID CONTENTS OF STEAM

STORAGE OF WATER

FURNACE

PROVIDES PROPER INSTTALATION, OPERATION MAINTENANCE OF FUEL BURNING EQUIPMENTS SUFFICIENT VOLUME FOR COMBUSTION

ADEQUATE REFRACTORIES & INSULATION

ECONOMISER
LOCATED IN 2ND PASS BELOW LTSH.

PREHEATS BFW BEFORE GOING TO DRUM

SUPER HEATERS
LTSH(LOW TEMP. SUPER HEATER)
DIVISIONAL PANEL(PANEL SUPERHEATER)

PLATEN SUPERHEATER(FINAL)

Principal of combustion

Fuels :
Gaseous fuel Liquid fuel solid fuel

Heat :

LDO HFO

Air :
Less amount of air will cause incomplete combustion Excess amount of air will cause boiler losses

Three Ts for efficient combustion

1. Time 2. Temperature 3. Turbulence( proper mixing)

Combustion efficiency:
1. design of boiler 2. fuel used 3. skill in obtaining combustion with minimum amount of air

REHEATERS
HEAT TRANSFER BY RADIATION & CONVECTION

COMPOSED OF FRONT & REAR PENDANT SECTION

AIR PREHEATERS
LOCATED IN FLUE GAS PASS AFTER ECONOMISER TO HEAT PRIMARY AND SECONDARY AIR

BCW PUMP
BCW PUMP IS SINGLE STAGE, GLANDLESS ,SINGLE SUCTION DOUBLE DISCHARGE, CENTRIFUGAL PUMP.

BURNERS
COAL BURNERS OIL BURNERS AUX. AIR SUPPLY DAMPERS O/F AIR DAMPERS BURNER TILT MECHANISM

HEA IGNITORS
PROVIDED WITH ALL OIL BURNERS 4 SPARKS /SEC,

HFO SCHEME AT BOILER FRONT

HOTV FT HOFCV

AB ELEVATION
CD ELEVATION EF ELEVATION GH ELEVATION
SHORT RECIRCULATION

FT

HORV
HFO SUPPLY LINE HFO RETURN LINE

ATOMISING STEAM SCHEME AT BOILER FRONT

AB ELEVATION

CD ELEVATION

EF ELEVATION

GH ELEVATION

OIL GUN CONNECTION

HFO NOZZLE VALVE

SCAVENGE VALVE

OIL GUN

ATOMISING STEAM VALVE

Important phenomenon

Nucleate boiling
Film boiling

Water wall refile tubes

Flow chart of WCS

condensor
T=40,P=-.9mm

LP HEATERS

DEARETORS

BFP p=<drum p

HPH

ECO

B.DRUM

DOWN COMER

BRH

URH

WATER WALL

Drum & drum internals

ECO.SPECIFICATIONS
MATERIAL CARBON STEEL SA210 GRA1,SA210 GRC 76 51 5.6

NO.OF COILS OD OF TUBES(MM) ACTUAL THICKNESS

DES.PR OF TUBES
DES.PR OF HEADERS

207.4
219.7

M.S

FROM F.R.S

Economiser

WATER WALLS SPECIFICATIONS

FW NUMBER OD(MM) D.THCKNESS A.THICKNESS JOINING DES.PR OF TUBE DES.MET.TEMP 283 51 5.19 5.6 BUTT 208.8 448 SW 444 51 5.19 5.1 BUTT 207.3 197.3 417 RW 283 51 5.19 5.1 BUTT 207.3 197.3 417 ROOF 142 57 5.54 5.1 BUTT 204.9 192.3 416

MAX.PR OF TUBE 197.0

WATER WALL HEADERS

INLET OUTLET

NO.OF HEADERS
OUTSIDE DIA(MM)

4
914.4

5
273

DES THICKNESS(MM)
ACTUAL THICKNESS DES PR.OF HEADERS MAX.WORKING PR MATERIAL

86
89 208.8 197.0 SA-299

50
45 204 192.2 SA-106

Bottom Ring Header

SH.SPECIFICATIONS
NO.OF TUBES OD(MM) JOINING MAX.STEM TEMP MAX GAS TEMP LTSH STAGE-I 708 PLATEN STAGE-II 444 PLATEN STAGE-III 456

51.0
BUTT 366(H) 467(P) 482(H) 512(P)

51.0
BUTT 488 548

54.0
BUTT 558 628

M.S

FROM F.R.S

Sh 1

M.S

FROM F.R.S

SH 2

M.S

FRM F.R.S

LTSH

M.S

FROM F.R.S

Final SH

RH SPECIFIFATIONS
STAGE-I
MAX.OPERATING PR 46.7

STAGE-II
45.8

DESIGN PR
MAX.GAS SIDE MT OD(MM) JOINING

56.2
460 60.3 BUTT

56.2
566 612 54.0 644+92 BUTT

MAX.STEAMSIDE MT 397

TOTAL NO.OF TUBES 248+254

M.S

FROM F.R.S

RH

SH&RH HEADERS
SH
MAX.OPERATI 188.2 NG PR DESIGN PR 204

RH
46.7 56.2 117800

WEIGHT(KGS) 223000

M.S

FROM F.R.S

RE HEATER CIRCUIT NON DRAINABLE PORTION DRAINABLE PORTION UNIT 7 BOILER HYDRO TEST

M.S

FROM F.R.S

RE HEATER CIRCUIT NON DRAINABLE PORTION DRAINABLE PORTION UNIT 7 BOILER HYDRO TEST

SOOT BLOWING SYSTEM

88 Nos. of wall Blowers, 34 Nos of LRSBs and 4 Nos of APH Soot Blowers are provided in first and second pass of boilers to remove Soot from furmace / SH coils and APH Elements. Each wall blower is provided with a rotary & traverse motor with associated gear box arrangements for rotary & traverse motion of the lance 34 Nos of LRSBs are mounted on the water wall covering SH and reheater sections to remove ash dust from SH and RH coils

Coal from Mines to Mills

MGR System Coal Handling Plant RC Bunker Size = 200 mm to 25 mm

Feeder
Pulverizer/Mill Powdered Form

Coal Feeders

Coal feeders is used to regulate the flow of coal from bunker the pulverizer Types of Coal Feeders: 1. Volumetric Feeders 2. Gravimetric Feeders Coal Entry to feeder from

Coal Feeders
Gravimetric Coal Feeder : Feeding the Coal from Bunker to Pulverizer as per requirement Leveling Bar Specialized Belt Conveyer Amount of Coal entry controlled by the speed of the Drive pulley Drive pulley connected through motor with variable speed drive Either DC Motor or Motor with Magnetic clutch is used

Pulverization of Coal
Pulverization : It is a method by which the coal is crushed to a fineness such that 70-80% passes through a 200 mesh sieve Importance of Pulverization Coal firing: 1. High Boiler Efficiency 2. Ability to use high combustion air temp. 3. Low Excess Air Requirement 4. Ability to burn a wide variety of coals 5. Better reaction to automatic control

Low Speed Mill

Tube and Ball Mill Operate at 17 to 20 Rpm Coal Feed from both end of the Tube Small Ball of 30,40, 50 mm Sizes are used Hot air blown to move coal to classifiers at two elevations in boiler furnace No Maintenance for long periods Better availability so no spare mill required Always a reserve of coal so there is no spark produced between Steel balls Consumption of power is more High Foundation and Initial cost of Equipment

Tube and Ball Mill

RC Feeder Classifiers 4 No. Drum Feeder Classifiers Distributors 2 No. Hot Air Entry Ball and Tube Mill Coal entry to Drum

Tube and Ball Mill

Steel Balls

High Speed Mill

Impact Mills and Beater Mill Directly Coupled to the Motor 500 to 1000 Rpm Compact in Size Less Power Consumption Rate of Wear of the grinding elements is High High Maintenance Cost

Bowl Mill
Coal Entry

Hot Air Flow from PA Fan

Classifiers To burners Rollers

Burners
Design consideration: Atomise the oil Properly shaped jet Combustion must be complete Excess air should be minimum Ready accessibility for repairs

Burner Arrangement

Flue Gas System

Air Heaters
It is a heat transfer surface in which air temperature is raised by transferring heat from other medium such as flue gas. These are used for heating the primary and secondary air before entering the furnace.

Advantages
1. Increase in boiler efficiency. 2. Stability of combustion increases by use of hot air.

3. Intensify and improved combustion.

4. Permitting to burn poor quality of coal. 5. High heat transfer rate in the furnace and hence lesser heat transfer area requirement. 6. Less un burnt fuel particle in flue gas thus combustion and both efficiency is improved.

7. intensified combustion permits faster load variation and fluctuations.

Types of Air Heaters

1. Recuperative type a. Tubular Reheater b. Plate type Airheater c. Steam Air Preheater 2. Regenerative type a. Ljungstrom type b. Rothemuhle type

Ljungstorm Airheater

OVERVIEW OF AIR FLOW IN TPP

FURNACE

CHIMNEY SECONDRY AIR HEATER

MILLS

FD FAN A FD FAN B
ID FAN A

PRIMERY AIR HEATER

Atmosphe ESP air ric

PA FAN A

PA FAN B

ID FAN B

Atmospheric air Atmosphe ric air