LAYOUT of Thermal Power Station

CW System CT system Equipment cooling water system Water system Coal Handling plant & MGR Compressed Air system Switchyard Boiler & Auxiliaries Turbine & auxiliaries Generator
2/10/2014 1

CW System
Individual unitwise system Common header system Combination system

2/10/2014

Cooling Tower
TYPE OF AIR & WATER FLOW Cross flow type Counter flow type DRAFT: Induced draft Forced draft

2/10/2014

ECW System
DM water system Clarified water system Raw water system

2/10/2014

Boiler - Auxiliaries
Coal Bunker Coal Feeder Mill & HFO system PA Fan Seal Air fan Air PreHeater Burner FD Fan Scanner Air Fan
5

2/10/2014

Boiler - Auxiliaries
Wind Box ESP ID Fan Chimney

2/10/2014

Air & Draft System

Natural, Induced, Forced & Balanced draft Air- Primary Air- Hot PA & Cold PA Secondary Air Seal Air Scanner Air & Ignitor Air

2/10/2014

 Theoretical Air PA Fan- functions, Requirements FD Fan

2/10/2014

Windbox Assembly

2/10/2014

Windbox Arrangement (Typical)

2/10/2014

10

Fuel System
HFO Ignitors Coal Mill Burners

2/10/2014

11

2/10/2014

12

BOILER
BOILER FUNDAMENTAL Combustion Thermal efficiency of a boiler Water system- Circulation system ( Natural, controlled & once through) Economiser, D/C, Water wall, Drum SuperHeater Types- Horzontal, Vertical & combined Radiant Convective Desuperheater Reheater FSSS

2/10/2014

13

Loss due to moisture in air.

Heat gained by boiling water 40%

Loss due to moisture in fuel.

Loss due to combustion generated moisture. Dry Exhaust Gas Losses

Fuel Energy 100%

Hot gas

~ 4.5%

Flue gas

Heat loss from furnace surface. Heat gained by Unburned carbon losses.

superheater & reheater 40% Incomplete combustion losses.

Loss due to hot ash.
2/10/2014

Heat gained by economizer & air preheater 12%

14

Steam Theory
Within the boiler, fuel and air are forced into the furnace by the burner. There, it burns to produce heat. From there, the heat (flue gases) travel throughout the boiler. The water absorbs the heat, and eventually absorb enough to change into a gaseous state steam. To the left is the basic theoretical design of a modern boiler. Boiler makers have developed various designs to squeeze the most energy out of fuel and to maximized its transfer to the water.
2/10/2014

15

Basic Boiler Configurations

2/10/2014

16

Thermal Structure of A SG
drum
DPNL SH R H T R

screen tubes

Platen SHTR

LTSH

Economiser BCW pump Furnace

stack

APH
2/10/2014

ESP

ID Fan
17

Bottom ash

2/10/2014

18

2/10/2014

19

Boiler Furnace
Structurally boiler furnace consists of the combustion space surrounded by water walls. The furnace is designed to perform two functions simultaneously, namely: Release of the chemical energy of fuel by combustion The first task of combustion technology is to burn the fuel efficiently and steadily, to consume controlled excess air (as little as possible), To generate a flame with controlled shape which will generate lowest amount of pollutants. Transfer of heat from the furnace to the working fluid inside the water walls. The important task of furnace heat removal is to produce a controlled Furnace Exit Gas Temperature (FEGT). FEGT is an important aspect of boiler safety.
2/10/2014 20

Five Requisites for Good Combustion

Fuel MATtr Theory:

M : Proper mixing of the reactants. A: Sufficient air. T: Conducive temperature T: Sufficient time r: Satisfactory density of reactant.

Fourth DF systems contains various auxiliaries to staisfy MATtr theory as completely as possible.

2/10/2014

21

Essentials of Optimum Coal Combustion

Fuel Preparation: Distribute the fuel in a larger combustion volume. Fuel feed quality and size shall be consistent. Fuel feed shall be measured and controlled as accurately as possible. Fuel line fineness >75% passing a 200-mesh screen. Distribution to Burners : Distribute the total air required into many streams, namely Primary air, Secondary air and tertiary air. Primary airflow shall be accurately measured and controlled to 3% accuracy. Primary air to fuel ratio shall be accurately controlled when above minimum. Fuel line minimum velocities shall be 12 m/sec. Fuel lines shall be balanced in fuel flow to within 10% of average.
2/10/2014 22

Pulverized fuel
Coal is ground to face powder size to ensure rapid combustion. For pulverized fuel, the processes of drying, devolatilization and char combustion are sequential.

2/10/2014

23

Drying
Heat is convected and radiated to the particle surface and Conducted into the particle Drying time = time required for the particle to the vaporization point

2/10/2014

24

Volatile matter
Volatile matter should be at least 20% to maintain flame stability. For low-volatile and/or high ash coal the flame speed is low and the air from the secondary nozzle should be mixed in more slowly to avoid instability.

2/10/2014

25

Ignition
Low-rank coals represent ignition difficulties because of their high moisture content as-fired Low-volatile coals (anthracites and semianthracites) are much more difficult to ignite.

2/10/2014

26

Flame stability
Fuel-air mixture must have a composition within the flammability limits Stability of the flame is determined by the concentration of gas phase volatiles and air The flame speed depends on the volatile matter and ash levels of the coal The maximum flame speed occurs at 2/10/2014 27 mixtures which are sub-stoichiometric

Role of burners

Burner Governs: Fuel Ignition Aerodynamics of Fuel air mixture Generation of combustion conditions.

The performance of the burner determines whether combustion equipment will operate reliably & economically. Types of burners: Swirl types Direct or Parallel-flow types

2/10/2014

28

Simple Burner

Burning Velocity Flow velocity

Air

Fuel
2/10/2014 29

Stability & Flammability Limits

Burning Velocity > Flow Velocity : Flash Back Limit Burning Velocity < flow Velocity : Blow Off Limit Burning Velocity = Flow Velocity : Stable Flame.

Fuel Flow rate

Rich Mixture

Flash Back

Stable Flame
Lean Mixture Air Flow rate

Blow off

2/10/2014

30

Burning Velocity & Residence Time

Quality of Fuel & Fuel Chemistry. Air-fuel ratio Turbulence level Time to be spent by fuel particle in the furnace before it burns completely. Residence time is inversely proportional to burning velocity. Fuel particle is continuously moving. The distance traveled by the fuel particle should be much larger than furnace height. Swirl motion will ensure the required residence time. Internally generated swirl : Swirl Burners. Externally generated swirl: Direct Burners.

2/10/2014

31

Coal particle size distribution

Maximum amount of fine particles - 79-75 mass % through 200-mesh Minimum amount of coarse particles -less than 0.1-0.5% on 50-mesh
2/10/2014 32

Coal particle size distribution contd

If 1-2% remain on 50 mesh screen, most of this very coarse coal will not burn and will end up in the bottom ash. It also frequently causes slagging around the burners. If 200 mesh fineness is poor, we may get high combustibles in the fly ash.

2/10/2014

33

Role of burners

Burner Governs: Fuel Ignition Aerodynamics of Fuel air mixture Generation of combustion conditions.

The performance of the burner determines whether combustion equipment will operate reliably & economically. Types of burners: Swirl types Direct or Parallel-flow types

2/10/2014

34

2/10/2014

Optimization of Furnace Parameters.

35

2/10/2014

36

Ash content
Ash properties of coal are broadly rankdependant A higher proportion of mineral matter of low-rank coals may have higher levels of some or all of the basic elements associated with fouling or slagging (iron, calcium, magnesium, sodium, potassium)

2/10/2014

37

Slagging and Fouling

Slagging the formation of fused or melted deposits Fouling the formation of bonded or lightly-sintered deposits at lower temperatures

2/10/2014

38

Slagging and Fouling contd

Influencing factors: (a) Temperature: --- The temperature history of the flame partly determines the condition of the ash as it approaches the boiler surfaces

2/10/2014

39

Slagging and Fouling contd

Thus, fine grinding may be a good idea Also, particles less than 30 mm will tend to follow the flow around the tubes rather than impinging on their surfaces. But, fine particles are more liable to stick together

2/10/2014

40

Slagging and Fouling contd

(b) heat flux
The heat flux to the boiler surface, its temperature, and the thermal conductivity Of the deposit upon it, together determine the thickness that can be reached before the outer surface melts or fuses.

2/10/2014

41

Slagging and Fouling contd

(c) Reducing conditions -- gaseous atmospheres containing high levels of CO lower the melting temperature of the ash to some 200oC below its melting temperature under oxidizing conditions

2/10/2014

42

Supercritical Boilers

Water circulation--Drum Type Boiler

Natural Circulation Boiler

Circulation thru water walls by

thermo-siphon effect

Controlled Circulation Boiler

Thermo-siphon effect supplemented by pumps
2/10/2014 43

Boiler Water Circulating Systems

Choice of Circulating system depends on Operating Pressure The density difference between water and steam

provides the driving force for the Circulating fluid

Higher pressures units warrant pumps to ensure

circulation (Natural circulation not adequate)

2/10/2014

44

Types of Circulation

2/10/2014

45

Natural Circulation

Controlled Circulation

2/10/2014

46

Controlled Circulation (Vs) Once Thru

CC
2/10/2014

OT
47

Fan Selection
Volume Head to be developed

Temperature
Density

2/10/2014

48

Energy Saving Measures

Adoption of variable frequency drives for ID fan

Use of double-stage Axial reaction PA fans

Micro-processor based integrated operating system (IOS) controls for esp to reduce corona power consumption. Direct ignition of pulverised coal to reduce oil

consumption in coal-fired boilers.

2/10/2014

49

Super heaters

Super heater heats the high-pressure steam from its saturation temperature to a higher specified temperature. Super heaters are often divided into more than one stage. The enthalpy rise of steam in a given section should not exceed 250 420 kJ/kg for High pressure. > 17 MPa < 280 kJ/kg for medium pressure. 7 Mpa 17 MPa < 170 kJ/kg for low pressure. < 7 MPa

2/10/2014

50

Furnace Wall

2/10/2014

51

Superheater System

2/10/2014

52

2/10/2014

53

Platen Superheater
Platen Superheater : Flat panels of tubes located in the upper part of the furnace, where the gas temperature is high. The tubes of the platen SH receive very high radiation as well as a heavy dust burden. Mechanism of HT : High Radiation & Low convection Thermal Structure: No. of platens No. of tubes in a platen Dia of a tube Length of a tube

2/10/2014

54

Reheater

The pressure drop inside reheater tubes has an important adverse effect on the efficiency of turbine. Pressure drop through the reheater should be kept as low as possible. The tube diameter : 42 60mm. The design is similar to convective superheaters. Overall 2/10/2014 Heat Transfer Coefficient : 90 110 W/m2 K.
55

Thermal Structure of Economizer

Out side diameter : 25 38 mm. Tube thinckness: 3 5 mm Transverse spacing : 2.5 3.0 Longitudinal spacing : 1.5 2.0 The water flow velocity : 600 800 kg/m2 s The waterside resistance should not exceed 5 8 %. Of drum pressure. Flue gas velocity : 7 13 m/s.

2/10/2014

56

Attemperators

2/10/2014

57

Various Energy Losses in A SG

Heat loss from furnace surface. Unburned carbon losses. Incomplete combustion losses. Loss due to hot ash. Loss due to moisture in air. Loss due to moisture in fuel. Loss due to combustion generated moisture. Dry Exhaust Gas Losses.

2/10/2014

58

Furnace Exit Gas Temperature

The temperature of products of combustion at the exit of the furnace is called FEGT. Defines the ratio of furnace heat absorption to outside heat absorption. High FEGT Compact furnace & Large secondary section FEGT < Ash Deformation Temperature. Generally FEGT = Ash Softening Temperature 100. FEGT is a Right Measure of Steam Generator Health ! A Healthy SG will Always Perform Better !!! A SG Always Healthy will Perform Better !
2/10/2014 59

Regenerative Trisector Airheater

REGENERATIVE TRISECTOR AI RHEATER

4 3

1 .PRI M ARY AIR IN 2 .SECONDARY AIR IN 3 .PRI M ARY AIR OUT 4 .SECONDARY AIR OUT 5 .GAS IN 6 .GAS OUT

1 6
2/10/2014

404

60

Regenerative Bisector Airheater

AI R P REH EATER ASSEM B L Y- B I SECTOR

GAS OUT

GAS IN

2/10/2014

AIR IN

AIR OUT

61

REGENERATIVE AIR HEATER

The heating surfaces are alternately heated up by the flue gas passing through and cooled by the air passing over it The heat is absorbed by the heat transfer matrix from the flue gases and then released to the air

2/10/2014

62

SALIENT COMPONENTS OF AIRHEATER

1. 2. 3. 4. 5. 6. 7. Modular Rotor Rotor housing and connecting plates Heating elements Sealing system Support bearing and guide bearing Lubricating oil pumps and circuits. Drive mechanism including auxiliary drive 8. Access doors 9. Observation port and light 10. Cleaning and washing devices 11. Rotor stoppage alarm 12. Deluge system 13. Elements handling arrangement

2/10/2014

63

HEATING ELEMENTS
Air heater is provided with multi-layers of heating elements. The material for the cold end element is selected based on the Sulphur content expected in the starting and stabilizing fuel oils. The cold end elements are basketed for easy removal and replacement from the sides. Hot end elements are removable from the top of the gas ducts. Provision is made to accommodated the future addition of elements at hot end. (If planned)
2/10/2014 64

SEALING SYSTEM
The rotor is divided into equal sectors each forming a separate air or gas passage through the rotor. Fixed leaf type metal seals are attached radially and axially to the rotor structure between each sector. Sector shaped unrestrained radial sealing plates provide the sealing surfaces that divide the rotor into air and 2/10/2014 65 gas passages.

Airheater Selection
Gas temperature entering airheater Gas quantity entering airheater Air quantity leaving airheater Desired pressure drop on air/gas side Gas temperature leaving airheater

2/10/2014

66

Airheater Performance
Gas temperature entry Actual Vs Design Air entry temp Actual Vs Design Coal Moisture Actual Vs Design Gas side minimum pressure drop to ensure at min gas flow condition for stable load. Condition of element thickness Condition of seals 2/10/2014

67

Performance Indicators
Air-in-Leakage
Gas Side Efficiency X - ratio

Flue gas temperature drop

Air side temperature rise Gas & Air side pressure drops The indices are affected by changes in entering air or gas temperatures, their flow quantities and coal moisture.
2/10/2014 68

Boiler Air Ingress

Air ingress can be quantified by the increase in oxygen % in flue gas; The temperature drop of the flue gas from air heater outlet to ID fan discharge also provides an indication of the same.
Oxygen % at various locations in boiler
10 8 6 4 2 0

O2 %

Furn Outlet
210 MW

AH Inlet
210 MW

AH Outlet
500 MW

ID outlet
210 MW

2/10/2014

69

Boiler Exit Gas Temperature

Ideal flue gas temperature at stack outlet should be just above the dew point to avoid corrosion; Higher gas temperatures reduce efficiency; Possible causes of temperature deviations are

Dirty heat transfer surfaces High Excess air Excessive casing air ingress Fouled/corroded/eroded Air heater baskets Change in ambient temp or AH leakage levels Non - representative measurement
70

2/10/2014

Effect of Boiler side Parameters (Approx.)

OFF Design/Optimum Conditions Parameter Excess Air (O2) Exit Gas Temp Unburnt Carbon Coal moisture Boiler Efficiency Deviation per % per oC per % per % per % Effect on Heat Rate 7.4 Kcal/kWh 1.2 Kcal/kWh 5-15 Kcal/kWh 2-3 Kcal/kWh 25 Kcal/kWh

2/10/2014

71