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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

FLUE GAS
BOILER

AIR
ASH

CO, CO2, H2, H2O, 02

COMBUSTION EQUATIONS..
C +O2

CO2

33820 KJ/Kg

2C+O2

2CO

10200 KJ/Kg

2H+O2

H2O

S +02

SO2

COMBUSTION EQUATIONS..
=4.31[(8/3)C 8(H-0/8)-S]

AIR REQUIRED

ATMOSPHERIC AIR = N2 - 77%


N2 -79%

EXCESS AIR

O2 - 23% by weight
O2- 21% by volume

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

2879.4 T/HR

DIFFERENTIAL PRESSURE

1.948 KSC

SPECIFIC GRAVITY

.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

BHEL-(CE DESIGN)

TYPE

BALANCED DRAFT, DRY BOTTOM, SINGLE DRUM, CONTROLLED


CIRCULATION PLUS, TILTING TANGENTIAL

NO OF MILL WITH OUT


OIL SUPPORT

2 ADJACENT MILLS @ 50% OF CAPACITY

EXPLOSION/IMPLOSIO
N CAPACITY

+660 OR -660 mmwc

VOLUME

14820 M3

SIZE

62.456MTR

TUBES

OD -51MM THICKNESS-5.6MM,
WT 583.2 TONS

DRUM

22070X2130X1778 END THICKNESS 152.4mm CYCLONES 96 SA 299


WT 246 T, ( 224 T WITHOUT INTRNL)

CAPACITY

10 SEC FROM NORMAL TO LO-LO TRIP

SAFTEY VALVES

DRUM -6 SUP HEATER 6 (2+4), CRH -4, HRH -8 (4+4)

TUBE LENGTH

350 KM approx( FOR 500 MW BOILER) , 58000 BUTT WELLDS approx

(FROM BA HOPPER TO FURNACE ROOF) X 15.289 X 18.034


PITCH 63.5 DSGN PR 208.8 SA 210C

PARAMETERS
Flow

MCR

NCR

S H steam

1725

1384

RH steam

1537

1527

Feed water

1725

1527.3

Spray

22.7

Secondary

1464

1337

Primary air

558

477

Total Air

2021

1814

COAL( 4300
kcal/kg)

296

266

COMPARISON
SL.
NO

PARAMETER

ST.-1

ST.-2

FIRING

FRONT FIRED

CORNER FIRED

CIRCULATION

NATURAL

CONTROLLED

PF
TRANSPORTATION

PA FAN TO EACH MILL

COMMON PA
FANS-2NOs.

OIL

LFO/HFO

LSHS or HFO

REHEATERS

IN CONVECTIVE ZONE

IN CONV. &
RADIATION ZONE

APHs

COMMON TO SEC. AND


PRIMARY AIR

SEPARATE APHs

FLY ASHING

CONTINUOUS(u#2 & 3)

INTERMITTENT

BOILER CONTROL

BMS

FSSS

COAL MILL

BALL AND RACE

BOWL

Contd.
SL.
NO

PARAMETER

ST.-1

ST.-2

10

SH/RH TEMP.
CONTROL

GAS BY PASS &


ATTEMPERATION

ATTEMPERATION &
BURNER TILT

11

DOWN COMERS

12

SECONDARY AIR
CONTROL

NOT POSSIBLE

POSSIBLE

13

MILL CHANGE
OVER

REQUIRE GUNS
SUPPORT

ADJACENT MILL
SUPPORT IS
SUFFICIENT

14

IGNITORS

REQUIRES LFO
SUPPORT

HIGH ENERGY ARC.


NO OIL.

15

OIL GUN TIP

16

AIR

PRIMARY AIR,
SECONDARY AIR

PA, SA, AUX. AIR, END


AIR, OVER FIRE

Contd.

SL.
NO

PARAMETER

ST.-1

ST.-2

17

FD FAN CONTROL

VANE
CONTROL

BLADE PITCH
CONTROL

18

PA FAN CONTROL

VANE
CONTROL

BLADE PITCH
CONTROL

SAFETY VALVES ( STAGE-II)

BOILER DRUM
6 SPRING LOADED
SUPER HEATER
2 SPRING LOADED, 4 ERVs
CRH 4 SPRING LOADED
HRH
4 SPRING LOADED, 4 ERVs
NO
SET PR RESET PR
B1 200
191
4
B2-B6
202- 206
SH 184
178
3
SH ERVs 180-182 176-178 4.8
CRH
55-56 53-55 3
HRH
48.5-49 47-47.5 3
HRH ERVs 47.5-48 46.6-47 1.97

%BLOWDOWN
192-1965

SOOT BLOWING SYSTEM

NO BLOWERS

104+34+4
WALL BLOWER
TRAVEL
305
NOZZLE DIA
26
BLOWING PRESSURE
12
TIME
1.44 MIN
RATE
CONSUMPTION
3349 (PER GROUP)

LRSB
9200 mm
32 mm
12.5 ksc
(PER PAIR)

833 KG/HR (PER PAIR)


116.62 KG (PER PAIR)

293

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

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