Boiler Funda

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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What is a boiler?

What is a boiler?

What are the main components of a boiler?

What are the main components of a boiler?

BOILER

means any closed vessel

CO, CO2, H2, H2O, 02

ATMOSPHERIC AIR = N2 - 77%

FOR COMPLETE COMBUSTION- 15 TO 20%

REQUIREMENTS FOR GOOD

FORMS PART OF FEED WATER CIRCUIT

PRE HEAT BOILER FEED WATER

RECOVERY OF HEAT FROM FLUE GAS

LOCATED IN BOTTOM OF REAR PASS

TO SEPARATE WATER FROM STEAM

TO REMOVE DISSOLVED SOLIDS

TO PROTECT WATER WALLS FROM

ACTS AS TEMPORARY PRESSURE RESERVOIR

FORMS FURNACE ENCLOSURE

LTSH LOCATED ABOVE ECONOMISER

RADIANT PENDENT TYPE (DIV PANEL)

CONVECTIVE FINAL SUPER HEATER

RE HEAT THE STEAM FROM HP TURBINE TO 540 DEG

COMPOSED OF THREE SECTIONS

RADIANT WALL REHEATER ARRANGED IN FRONT &

REAR PENDANT SECTION ARRANGED ABOVE GOOSE

FRONT SECTION ARRANGED BETWEEN UPPER

32 COAL BURNERS & 16 OIL BURNERS IN ALL IN

24 COAL BURNERS & 24 OIL GUNS IN STAGE-I

IN 500 MW BOILERS BURNERS CAN TILTED +30

NO SUCH PROVISION IN STAGE- 1 BURNERS

EACH GUN IS PROVIDED WITH AN IGNITOR

HIGH ENERGY ARC, EDDY CURRENT IGNITORS

OUT PUT VOLTAGE 2500V DC

4 SPARKS PER SECOND

CONTROL CIRCULATION PUMPS

THREE PUMPS PER BOILER(2X50%)

ASSIST IN CIRCULATING WATER THROGH

EACH PUMP CAPACTY

MECHANICAL SUPPORT BEAMS

TO SAFE GUARD FURNACE

Constituents of coal (%)

500 MW RSTPS BOILER

BALANCED DRAFT, DRY BOTTOM, SINGLE DRUM, CONTROLLED

NO OF MILL WITH OUT

2 ADJACENT MILLS @ 50% OF CAPACITY

+660 OR -660 mmwc

22070X2130X1778 END THICKNESS 152.4mm CYCLONES 96 SA 299

10 SEC FROM NORMAL TO LO-LO TRIP

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

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

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

PA FAN TO EACH MILL

COMMON TO SEC. AND

BALL AND RACE

GAS BY PASS &

HIGH ENERGY ARC.

OIL GUN TIP

PA, SA, AUX. AIR, END