POINTS OF DISCUSSION

 SUB CRITICAL & SUPER CRITICAL BOILER

 SIPAT BOILER DESIGN

 BOILER DESIGN PARAMETERS

 CHEMICAL TREATMENT SYSTEM

 OPERATION
 FEED WATER SYSTEM

 BOILER CONTROL

 BOILER LIGHT UP

 START UP CURVES
 WHY SUPER CRITICAL TECHNOLOGY

 To Reduce emission for each Kwh of electricity generated : Superior Environmental

1% rise in efficiency reduce the CO2 emission by 2-3%

 The Most Economical way to enhance efficiency

 To Achieve Fuel cost saving : Economical

 Operating Flexibility

 Reduces the Boiler size / MW

 To Reduce Start-Up Time

 UNDERSTANDING SUB CRITICAL TECHNOLOGY

 Water when heated to sub critical pressure, Temperature increases until it

starts boiling

 This temperature remain constant till all the water converted to steam

 When all liquid converted to steam than again temperature starts rising.

 Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And
Water

 The mass of this boiler drum, which limits the rate at which the sub critical
boiler responds to the load changes

 Too great a firing rate will result in high thermal stresses in the boiler drum
Role of SG in Rankine Cycle

Perform Using Natural resources of energy …….

 UNDERSTANDING SUPER CRITICAL TECHNOLOGY

 When Water is heated at constant pressure above the critical pressure, its
temperature will never be constant

 No distinction between the Liquid and Gas, the mass density of the two
phases remain same

 No Stage where the water exist as two phases and require separation : No
Drum

 The actual location of the transition from liquid to steam in a once through
super critical boiler is free to move with different condition : Sliding Pressure
Operation

 For changing boiler loads and pressure, the process is able to optimize the
amount of liquid and gas regions for effective heat transfer.
Circulation Vs Once Through
No Religious Attitude
 540°C, 255 Ksc

568°C, 47
Ksc 492°C, 260 Ksc

FUR ROOF
457°C, 49 Ksc
I/L HDR ECO HGR
O/L HDR
HRH LINE

MS LINE

411°C, 411°C,
277Ksc 275 Ksc

SEPARATOR

S
T FINAL SH
FINAL
O RH LTRH
R
DIV PANELS SH PLATEN
A SH
G
E
T
A VERTICAL WW
N
ECO

305°C, 49 Ksc
G K JUNCTION
HDR
LPT LPT IPT
C
O HPT
N ECONOMISER
D
E
N
S
E
R
ECO I/L

FEED WATER
BWRP
290°C, 302 KSC

FUR LOWER HDR

FRS
 Steam

Partial Steam Generation

Complete or Once-through
Steam Generation

Heat Input
Water

Heat Input

Water
Water
Boiling process in Tubular Geometries
SEPARATOR TANK
 PENTHOUSE Eco. O/L hdr (E7)

LTRH O/L hdr (R8)

2nd pass top hdrs (S11)

Back pass Roof o/l hdr (S5)

SH final I/L hdr (S34) SH final O/L hdr (S36)

F19
1st pass top hdrs RH O/L hdr (R12)
RH I/L hdr (R10)

F28 Platen O/L hdr (S30)

Platen I/L hdr (S28) F28

Div. Pan. I/L hdrs Div. Pan. O/L hdrs (S24)

(S20)
F8 1st pass top hdrs
Back pass Roof i/l hdr
S2
Separator (F31) Storage Tank (F33)
 SIPAT SUPER CRITICAL BOILER

 BOILER DESIGN PARAMETER

 DRUM LESS BOILER : START-UP SYSTEM

 TYPE OF TUBE
 Vertical
 Spiral

 SPIRAL WATER WALL TUBING

 Advantage
 Disadvantage over Vertical water wall
Vertical Tube Furnace

 To provide sufficient flow per tube, constant pressure furnaces

employ vertically oriented tubes.

 Tubes are appropriately sized and arranged in multiple passes in the

lower furnace where the burners are located and the heat input is
high.

 By passing the flow twice through the lower furnace periphery (two
passes), the mass flow per tube can be kept high enough to ensure
sufficient cooling.

 In addition, the fluid is mixed between passes to reduce the upset

fluid temperature.
Spiral Tube Furnace

 The spiral design, on the other hand, utilizes fewer tubes to obtain
the desired flow per tube by wrapping them around the furnace
to create the enclosure.

 This also has the benefit of passing all tubes through all heat
zones to maintain a nearly even fluid temperature at the outlet of
the lower portion of the furnace.

 Because the tubes are “wrapped” around the furnace to form the
enclosure, fabrication and erection are considerably more
complicated and costly.
 SPIRAL WATER WALL

ADVANTAGE

 Benefits from averaging of heat absorption variation : Less tube leakages

 Simplified inlet header arrangement
 Use of smooth bore tubing
 No individual tube orifice
 Reduced Number of evaporator wall tubes & Ensures minimum water flow
 Minimizes Peak Tube Metal Temperature
 Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE

 Complex wind-box opening

 Complex water wall support system
 tube leakage identification : a tough task
 More the water wall pressure drop : increases Boiler Feed Pump Power
 Adherence of Ash on the shelf of tube fin
 BOILER OPERATING PARAMETER
FD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc

1732 T / Hr
PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc

947 T / Hr
ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW 3020 T / Hr
TOTAL AIR 2535 T / Hr
SH OUT LET PRESSURE / TEMPERATURE / 256 Ksc / 540 C
FLOW 2225 T / Hr
RH OUTLET PRESSURE/ TEMPERATURE / 46 Ksc / 568 C
FLOW 1742 T / Hr
SEPARATOR OUT LET PRESSURE/ 277 Ksc / 412 C
TEMPERATURE
ECONOMISER INLET 304 Ksc / 270 C
MILL OPERATION 7 / 10

COAL REQUIREMENT 471 T / Hr

SH / RH SPRAY 89 / 0.0 T / Hr
BOILER EFFICIENCY 87 %
 Coal Analysis

Design Worst Best Young Hung Tangjin 1. High erosion

Parameter Unit
Coal Coal Coal #1,2(800MW) #5,6(500MW) potential for
High Heating Value kcal/kg 3,300 3,000 3,750 6,020 6,080 pulverizer and
backpass tube is
Total Moisture % 12.0 15.0 11.0 10.0 10.0 expected due to
Proximate Volatile Matter % 21.0 20.0 24.0 23.20 26.53 high ash content.
Analysis Fixed Carbon % 24.0 20.0 29.0 52.89 49.26
Ash % 43.0 45.0 36.0 13.92 14.21
2. Combustibility
Fuel Ratio (FC/VM) - 1.14 1.00 1.21 2.28 1.86 Index is relatively
Combustibility Index - 2,067 2,353 2,476 2,781 3,492
low but
combustion
Carbon % 39.53 31.35 40.24 63.03 62.15 characteristic is
Hydrogen % 2.43 2.30 2.68 3.60 3.87 good owing to
high volatile
Nitrogen % 0.69 0.60 0.83 1.53 1.29
Ultimate
content.
Oxygen % 6.64 5.35 8.65 7.20 7.80
Analysis
Sulfur % 0.45 0.40 0.60 0.72 0.68
Ash % 43.00 45.00 36.00 13.92 14.21
Moisture % 12.00 15.00 11.00 10.00 10.00
Grindability HGI 50 47 52 45 48
Hi–Vol. ‘C’ Hi–Vol. ‘C’ Hi–Vol. ‘C’ Midium Vol. Hi–Vol. ‘C’
ASTM Coal Classification -
Bituminous Bituminous Bituminous Bituminous Bituminous
 Ash Analysis

Design Worst Best Young Hung Tangjin

Parameter Unit
Coal Coal Coal #1,2(800MW) #5,6(500MW)
SiO2 % 61.85 62.40 61.20 57.40 57.40 1. Lower
Al2O3 % 27.36 27.31 27.32 29.20 29.20 slagging
potential is
Fe2O3 % 5.18 4.96 5.40 4.40 4.40 expected due
CaO % 1.47 1.42 1.52 2.70 2.70 to low ash
Ash MgO % 1.00 1.03 0.97 0.90 0.90 fusion temp.
Analysis Na2O % 0.08 0.08 0.08 0.30 0.30 and low basic
K2O % 0.63 0.32 1.22 0.70 0.70 / acid ratio.
TiO2 % 1.84 1.88 1.80 1.30 1.30 2. Lower fouling
P2O5 % 0.54 0.55 0.44 - - potential is
SO3 % 0.05 0.05 0.05 - - expected due
Others % - - - 3.10 3.10
to low Na2O
o and CaO
Ash Fusion Initial Deformation C 1150 1100 1250 1200 1200
content.
Temp. (oC) Softening o
C - - -
o
(Reducing Hemispheric C 1400 1280 1400
Atmos.) o
Flow C 1400 1280 1400
Ash Content kg/Gcal 130.3 150.0 96.0 23.12 23.37
Basic / Acid B/A 0.09 0.09 0.10 1.63 1.63
 AIR AND FLUE GAS SYSTEM

AIR PATH : Similar as 500 MW Unit

FLUE GAS PATH:

No Of ESP Passes : 6 Pass

No Of Fields / Pass : 18 1-7 fields  70 KV.

8&9 field  90 KV

No Of Hopper / Pass : 36

Flue Gas Flow / Pass : 1058 T/ Hr

 M M M
M TO PULVERISER SYSTEM

HOT PRIMARY AIR DUCT

PAPH # A
M M
PA FAN # A
M AIR MOTOR

M
M M M
M M AIR MOTOR

M
SAPH # A
M M
FD FAN # A
M

M M
M SAPH # B

M AIR MOTOR
M M M
FD FAN # B

M
M AIR MOTOR

M M
M PAPH # B
HOT PRIMARY AIR DUCT

TO PULVERISER SYSTEM
M M
M
PA FAN # B

LHS WIND BOX

FURNACE
FINAL SUPERHEATER
DIVISIONAL PANEL

FINAL REHEATER

BACK PASS
ECONOMISER
PLATEN COILS

LTRH

RHS WIND BOX

AIR PATH
 FUEL OIL SYSTEM

Type Of Oil : LDO / HFO

Boiler Load Attainable With All Oil Burner In Service : 30 %

Oil Consumption / Burner : 2123 Kg / Hr

Capacity Of HFO / Coal : 42.1 %

Capacity Of LDO / Coal : 52.5 %

HFO Temperature : 192 C

All Data Are At 30 % BMCR

 DESIGN BASIS FOR SAFETY VALVES :
1. Minimum Discharge Capacities.

Safety valves on Separator and SH Combined capacity 105%BMCR

(excluding power operated impulse safety valve)

Safety valves on RH system Combined capacity 105% of Reheat

flow at BMCR
(excluding power operated impulse safety valve)

Power operated impulse safety valve 40%BMCR at super-heater outlet

60% of Reheat flow at BMCR at RH

outlet

2. Blow down 4% (max.)b

 BOILER FILL WATER REQUIREMENT

Main Feed Water Pipe ( FW Shut Off Valve to ECO I/L HDR) 28.8 m3

Economizer 253.2 m3

Furnace ( Eco Check Valve to Separator Link) 41.5 m3

Separators & Link 13.8 m3

OXYGENATED TREATMENT OF FEED WATER

“WATER CHEMISTRY CONTROL MAINTAINS PLANT HEALTH.”

Dosing of oxygen(O2) or Hydrogen peroxide

(H2O2) in to feed water system.

Concentration in the range of 50 to 300 µg/L.

Formation of a thin, tightly adherent ferric oxide

(FeOOH) hydrate layer.

This layer is much more dense and tight than

that of Magnetite layer.

39
All Volatile
Treatment

Oxygenated
Water
Treatment

40
DOSING POINTS

41
“AVT” Dosing Auto Control

42
“OWT” Dosing Auto Control

43
 FUR ROOF I/L HDR U#1
VENT HDR VENT HDR
WATER LINE
N2 FILL LINE N2 FILL LINE N2 FILLING LINE
SAMPLE COOLER
VENT LINE
SAMPLE COOLER
DRAIN LINE
SEPRATOR #1 SEPRATOR #2
SAMPLE COOLER LINE

1 2 1 2 1 2 1 2
VENT HDR

VENT HDR

FUR WW HDR

FUR INTERMITTENT HDR

STORAGE TANK
DRAIN HDR

FUR BOTTOM RING HDR

FLASH TANK
DRAIN HDR

MIXING PIECE
VENT HDR WR ZR

BACK PASS ECO O/L HDR

N2 FILL LINE

ECO JUNCTION HDR BRP ECO MIXING LINK

BACK PASS ECO I/L HDR

BLR FILL PUMP

FROM FEED WATER

TO DRAIN HDR

WATER CIRCULATION SYSTEM

 FEED WATER SYSTEM

MODES OF OPERATION

1. BOILER FILLING

2. CLEAN UP CYCLE

3. WET MODE OPERATION (LOAD < 30 % )

4. DRY MODE OPERATION (LOAD > 30 %)

5. DRY TO WET MODE OPERATION ( WHEN START UP SYSTEM NOT AVAILABLE)

 BOILER FILLING LOGIC

 If the water system of the boiler is empty (economizer, furnace walls, separators),
then the system is filled with approximately 10% TMCR ( 223 T/Hr) feed water flow.

 When the level in the separator reaches set-point, the WR valve will begin to open.

 When the WR valve reaches >30% open for approximately one minute, then
increase feed water flow set-point to 30% TMCR ( approx 660 T/Hr).

 As the flow increases, WR valve will reach full open and ZR valve will begin to
open.

 The water system is considered full when:

 The separator water level remains stable for two(2) minutes

and
 The WR valve is fully opened and ZR valve is >15% open for two(2)
minutes

After completion of Filling, the feed water flow is again adjusted to 10 % TMCR for
Clean up cycle operation
 BOILER INITIAL WATER LEVEL CONTROL (UG VALVE)

 The boiler circulating pump is started following the start of a feed water
pump and the final clean-up cycle.

 This pump circulates feed water from the evaporator outlet back to the
economizer inlet.

 Located at the outlet of this pump is the UG valve which controls

economizer inlet flow during the start-up phase of operation.

 Demand for this recirculation, control valve is established based on

measured economizer inlet flow compared to a minimum boiler flow set
point.
 Boiler Clean-up
When the feedwater quality at the outlet of deaerator and separator is not
within the specified limits, a feedwater clean-up recirculation via the boiler is
necessary.

During this time, constant feedwater flow of 10% TMCR ( 223 T/Hr) or more
is maintained.

Water flows through the economizer and evaporator, and discharges the
boiler through the WR valve to the flash tank and via connecting pipe to the
condenser.

From the condenser, the water flows through the condensate polishing
plant, which is in service to remove impurities ( Like Iron & its Oxide, Silica,
Sodium and its salts ), then returns to the feed water tank.

The recirculation is continued until the water quality is within the specified
limits.
FEED WATER QUALITY PARAMETER FOR START UP
 MODE OF OPERATION

WET MODE :

 Initial Operation Of Boiler Light Up. When Economizer Flow is maintained by

BCP.

 Boiler Will Operate till 30 % TMCR on Wet Mode.

DRY MODE :

 At 30 % TMCR Separator water level will become disappear and Boiler

Operation mode will change to Dry

 BCP Will shut at this load

 Warm Up system for Boiler Start Up System will get armed

 Boiler will turn to once through Boiler

 ECO Water flow will be controlled by Feed Water Pump in service

 SYSTEM DESCRIPTION ( WET MODE OPERATION)
1. Flow Control Valve ( 30 % Control Valve )

 Ensures minimum pressure fluctuation in Feed Water Header

 It measures Flow at BFP Booster Pump Discharge and compare it with a calculated flow
from its downstream pressure via a function and maintains the difference “ 0 “

2. 100 % Flow Valve To Boiler

 Remains Closed

3. BFP Recirculation Valve

 It Measures Flow at BFP Booster Pump Discharge

 Ensures minimum Flow through BFP Booster Pump

 Closes when Flow through BFP Booster Pump discharge > 2.1 Cum
 Open When Flow through BFP Booster Pump Discharge < 1.05 Cum
( Minimum Flow will be determined by BFP Speed via BFP Set limitation Curve)

4. BFP Scoop

 It measures value from Storage tank level Transmitter

 Maintain Separator Storage Tank Level

5. UG Valve

 Maintain Minimum Economizer Inlet Flow ( 30 % TMCR = Approx 660 T/Hr)

 Maintain DP across the BRP ( Approx 4.0 Ksc)

 It Measures Flow Value from Economizer Inlet Flow Transmitter

6. WR / ZR Valve

 Maintains Separator Storage Tank Level

 It Measures value from the Storage tank Level

7. Storage Tank Level

 3 No’s Level Transmitter has been provided for Storage tank level measurement

 1 No HH Level Transmitter has been provided

 At 17.9 Mtr level it will trip all FW Pumps also MFT will act

 1 No LL Level Transmitter has been provided

 At 1.1 Mtr level MFT will Act

 SYSTEM DESCRIPTION ( DRY MODE OPERATION)

1. Following System will be isolated during Dry Mode Operation

 FCV ( 30 % )

 Start Up System Of Boiler

 WR / ZR Valve
 Storage Tank
 BRP
 BRP Recirculation System

 BFP Recirculation Valve

2. Following System will be in service

 UG Valve ( Full Open)

 100 % FW Valve ( Full Open)

 Platen / Final Super-heater spray control

 Start Up System Warming Lines

 Separator Storage Tank Wet Leg Level Control

 SYSTEM OPERATION ( DRY MODE OPERATION)

1. START UP SYSTEM

 In Dry Mode Start Up System Of Boiler will become isolated

 Warming System for Boiler Start Up system will be charged

 Separator Storage Tank level will be monitored by Separator storage tank wet leg level
control valve ( 3 Mtr)

2. TRANSITION PHASE :- Changeover of FW Control valve (30 % to 100 % Control )

 100 % FW Flow valve will wide open

 During the transition phase system pressure fluctuates

 The system pressure fluctuation will be controlled by 30 % FW Valve. After stabilization of

system 30 % CV Will become Full Close

3. FEED WATER CONTROL

 It will be controlled in three steps

 Feed Water demand to maintain Unit Load

 Maintain Separator O/L Temperature
 Maintain acceptable Platen Spray Control Range
 FEED WATER DEMAND ( DRY MODE OPERATION)

1. FINAL SUPER HEATER SPRAY CONTROL

 Maintain the Final Steam Outlet Temperature ( 540 C)

2. PLATEN SUPER HEATER SPRAY CONTROL

 Primary purpose is to keep the final super heaer spray control valve in the desired
operating range

 Measures the final spray control station differential temperature

 It Compares this difference with Load dependent differential temperature setpoint
 Output of this is the required temperature entering the Platen Super Heater Section
(Approx 450 C)

3. FEED WATER DEMAND

1. FEED FORWARD DEMAND

 It is established by Boiler Master Demand.

 This Demand goes through Boiler Transfer Function where it is matched with the actual
Evaporator Heat Transfer to minimize the temperature fluctuations

2. FEED BACK DEMAND

 Work With two controller in cascade mode

 FEED WATER DEMAND ( DRY MODE OPERATION)

2. FEED BACK DEMAND

 Work With two controller in cascade mode

 FIRST CONTROLLER

 One Controller acts on Load dependent average platen spray differential

temperature

 Its Output represents the desired heat transfer / steam generation to maintain
the desired steam parameters and Flue gas parameters entering the Platen
section

 SECOND CONTROLLER

 Second Controller acts on the load dependent Separator Outlet Temperature

adjusted by Platen spray differential temperature

 This controller adjust the feed water in response to firing disturbances to

achieve the separator O/L Temperature

THE RESULTING DEMAND FROM THE COMBINED FEEDFORWARD AND FEEDBACK

DEMANDSIGNAL DETERMINED THE SETPOINT TO THE FEED WATER MASTER CONTROL
SETPOINT
DRY TO WET MODE OPERATION ( START UP SYSTEM NOT AVAILABLE)

1. The combined Feed Forward and Feed back demand ( as calculated in dry mode operation)
will be compared with minimum Economizer Flow

This ensures the minimum flow through Economizer during the period when start up system
is unavailable

2. Output of the first controller is subjected to the second controller which monitors the
Separator Storage tank level ( Since the system is in Wet Mode now)

3. The output of the second controller is the set point of Feed water master controller.

4. The Feed back to this controller is the minimum value measured before the start up system
and Economizer inlet.
 WATER & STEAM PATH

BLR PATH ( WHEN WET MODE)

Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH -

HP By-pass - Cold R/H Line - Primary R/H (Lower Temp R/H) - Final R/H - LP By-
pass - Condenser

BLR Path (When Dry Mode)

Primary Eco - Secondary Eco - Ring HDR - Spiral W/W - W/W Intermediate HDR -
Vertical W/W - Separator - Backpass Wall & Extended Wall - SH Division - Platen
SH - Final SH - HP TBN - Cold R/H Line - Primary R/H (Lower Temp R/H)- Final R/H
- IP and LP TBN - Condenser
Wet Mode and Dry Mode of Operation
 DIV SH PLATEN SH FINAL SH

406 451 440 486 480 540

DSH1 DSH2

15% 3%
 BOILER LOAD CONDITION

Constant Pressure Control

 Above 90% TMCR The MS Pressure remains constant at rated pressure

 The Load is controlled by throttling the steam flow

 Below 30% TMCR the MS Pressure remains constant at minimum

Pressure

Sliding Pressure Control

 Boiler Operate at Sliding pressure between 30% and 90% TMCR

 The Steam Pressure And Flow rate is controlled by the load directly
 CONSTANT PRESSURE VS SLIDING PRESSURE
 Valve throttling losses occur because the boiler operates at constant pressure while the turbine
doesn't.

 The most obvious way to avoid throttling losses therefore is to stop operating the boiler at
constant pressure!

 Instead, try to match the stop valve pressure to that existing inside the turbine at any given load.

 Since the turbine internal pressure varies linearly with load, this means that the boiler pressure
must vary with load similarly.

 This is called .sliding pressure operation..

 If the boiler pressure is matched to the pressure inside the turbine, then there are no valve
throttling losses to worry about!
 While sliding pressure is beneficial for the turbine, it can cause difficulties for the boiler.

ADVERSE AFFECT

 As the pressure falls, the boiling temperature (boiling point) changes. The boiler is divided into
zones in which the fluid is expected to be entirely water, mixed steam / water or dry steam. A
change in the boiling point can change the conditions in each zone.

 The heat transfer coefficient in each zone depends upon the pressure. As the pressure falls, the
heat transfer coefficient reduces. This means that the steam may not reach the correct
temperature. Also, if heat is not carried away by the steam, the boiler tubes will run hotter and
may suffer damage.
CHALLANGES

 The heat transfer coefficient also depends upon the velocity of the steam in the boiler tubes.
 Any change in pressure causes a change in steam density and so alters the steam velocities and
heat transfer rate in each zone.

 Pressure and temperature cause the boiler tubes to expand. If conditions change, the tubes will
move. The tube supports must be capable of accommodating this movement.
 The expansion movements must not lead to adverse stresses.

 The ability to use sliding pressure operation is determined by the boiler

Boilers can be designed to accommodate sliding pressure.

 When it is used, coal fired boilers in the 500 to 1000 MW class normally restrict sliding pressure to
a limited load range, typically 70% to 100% load, to minimize the design challenge. Below this
range, the boiler is operated at a fixed pressure.

 This achieves an acceptable result because large units are normally operated at high load for
economic reasons.

 In contrast, when sliding pressure is used in combined cycle plant, the steam pressure is varied
over a wider load range, typically 50% to 100% load or more
 As stated, in coal-fired plant, sliding pressure is normally restricted to a limited load
range to reduce design difficulties.

 In this range, the boiler pressure is held at a value 5% to 10% above the turbine internal
pressure. Consequently, the governor valves throttle slightly.

 The offset is provided so that the unit can respond quickly to a sudden increase in load
demand simply by pulling the valves wide open.

 This produces a faster load response than raising the boiler firing rate alone.The step in
load which can be achieved equals the specified margin ie 5% to 10%.

 The throttling margin is agreed during the tendering phase and then fixed.

 A margin of 5% to 10% is usually satisfactory because most customers rely upon gas
turbines, hydroelectric or pumped storage units to meet large peak loads.

 The throttling margin means that the full potential gain of sliding pressure is not achieved.

 Nevertheless, most of the throttling losses which would otherwise occur are recovered.
ADVANTAGES

 Temperature changes occur in the boiler and in the turbine during load
changes. These can cause thermal stresses in thick walled components.

 These are especially high in the turbine during constant-pressure operation.

They therefore limit the maximum load transient for the unit.

 By contrast, in sliding pressure operation, the temperature changes are in the

evaporator section. However, the resulting thermal stresses are not limiting in the
Once through boiler due to its thermo elastic design.

In fixed pressure operation , temperature change in the turbine when load

changes, while in sliding-pressure operation ,they change in the boiler
 The enthalpy increase in the boiler for preheating, evaporation and superheating
changes with pressure.

 However, pressure is proportional to output in sliding pressure operation

 In a uniformly heated tube, the transitions from preheat to evaporation and from
evaporation to superheat shift automatically with load such that the main steam
temperature always remains constant.
 Sliding Pressure

 At loads over 25% of rated load, the water fed by a feed-water pump flows through
the high pressure feed-water heater, economizer ,furnace water wall, steam-water
separator, rear-wall tubes at the ceiling, and super heaters, The super heaters
steam produced is supplied to the turbine.
 At rated and relatively high loads the boiler is operated as a purely once through
type. At partial loads, however, the boiler is operated by sliding the pressure as a
function of load.

25
Turbine inlet pressure Mpa

24.1 Mpa
20

15

10

5 9.0 Mpa

0
0 25 50 75 100
Turbine load (%)
CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC

Boiler Load %
20 40 60 80 100
+1
Variable Pressure
Efficiency Change %

-1

-2

-3

-4
Benefits Of Sliding Pressure Operation ( S.P.O)

 Able to maintain constant first stage turbine temperature

 Reducing the thermal stresses on the component : Low Maintenance & Higher
Availability

 No additional pressure loss between boiler and turbine.

 low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

 Circulation Problem : instabilities in circulation system due to steam formation in

down comers.

 Drum Level Control : water surface in drum disturbed.

 Drum : (most critical thick walled component) under highest thermal stresses
The Basis of Boiler Start-up Mode

Mode Basis Restart

Starting Time
Hot Warm Cold

Stopped time 2Hr Within 6~12Hr 56Hr Within 96Hr Above

SH Outlet Temp 465℃ above 300℃ above 100℃ above 100℃ below

Separator Tank pr 120～200㎏/㎠ 30～120㎏/㎠ 30㎏/㎠ below 0㎏/㎠

STARTING TIME

Light off →TBN Light off →

Startup Mode Rolling(minutes) Full Load(minutes)
Cold 120 420 Except Rotor and Chest Warming Time

Warm 90 180 "

Hot - - ․

Restart 30 90 ․
 PURGE CONDITIONS
 No Boiler Trip Condition Exists

 All System Power Supply Available

 Unit Air Flow > 30 % BMCR

 Nozzle Tilt Horizontal and Air Flow < 40 %

 Both PA Fans Off

 The Following Condition Exist At Oil Firing System

 The HOTV / LOTV Should Be Closed
 All Oil Nozzle Valve Closed

 The Following Condition Exists at Coal Firing System

 All Pulverisers are Off
 All Feeders are Off
 All Hot Air Gates Of Pulverisers are closed

 All Flame Scanner on all elevation shows no Flame

 Aux Air Damper At All Elevation should be modulating

After Purging Boiler Light Up activites are same as in 500 MW plant

 MFT CONDITIONS
 Both ID Fans Off
 Both FD Fans Off
 Unit Air Flow < 30 % TMCR
 All Feed Water Pumps Are Off For More Than 40 Sec
 2 / 3 Pressure Transmitter indicate the furnace pressure High / Low for more than 8 sec ( 150
mmwc / -180 mmwc))
 2 / 3 Pressure Transmitter indicate the furnace pressure High – High / Low - Low ( 250 mmwc
/ - 250 mmwc)
 Loss Of Re-heater Protection
 EPB Pressed
 All SAPH Off
 Economizer Inlet Flow Low For More Than 10 Sec (223 T/Hr)
 Furnace Vertical Wall Temperature High For more than 3 Sec (479 C)
 SH Pressure High On Both Side (314 KSc)
 SH Temperature High For More Than 20 Sec ( 590 C)
 RH O/L Temperature High For More Than 20 Sec ( 590 C)
 Separator Level Low-Low During Wet Mode ( 1.1 M)
 Separator Level High-High During Wet Mode ( 17.7 M)
 MFT Relay Tripped
 Loss Of Fuel Trip : It Arms when any oil burner proven.
it occurs when all of the following satisfied
 All Feeders Are Off
 HOTV Not Open or all HONV Closed
 LOTV Not Open or all LONV Closed
 Unit Flame Failure Trip : It Arms when any Feeder Proves
it occurs when all 11 scanner elevation indicates flame failure as listed below ( Example is
for only elevation A)
 Feeder A & Feeder B is Off with in 2 Sec Time Delay
 following condition satisfied
 Any oil valve not closed on AB Elevation
 3 /4 valves not proven on AB Elevation
 Less Than 2 / 4 Scanner Shows Flame
 Both Of The Following Condition Satisfied
 Less Than 2 / 4 Scanner Flame Shows Flame
 2 / 4 Oil Valves not open at AB Elevation
 Boiler Light Up Steps

 Start the Secondary Air Preheater

 Start one ID fan, then the corresponding FD fan and adjust air flow to a min. of
30% TMCR

 Start the scanner air fan.

 Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and
furnace draft of approx. -12.7 mmWC.

 When fans are started, SADC should modulate the aux. air dampers to maintain
WB to furnace DP at 102 mmWC(g).

 Check that all other purge permissives are satisfied.

 Place FTPs in service.

 Check The MFT Conditions

 For First Time Boiler Light Up do the Oil Leak Test

 Initiate a furnace purge.

 SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

FURNACE READINESS
 PRESSURE PARTS
 SCANNER AIR FAN
 BOTTOM ASH HOPPER READINESS
 FUEL FIRING SYSTEM
 START UP SYSTEM

SEC AIR PATH READINESS

 FD FAN
 SAPH
 WIND BOX / SADC

FLUE GAS SYSTEM

 ESP PASS A , B
 ID FAN
 SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

CONDENSATE SYSTEM
 CONDENSER
 CEP
 CPU

FEED WATER SYSTEM

 D/A
 MDBFP # A
VACCUME SYSTEM
SEAL STEAM SYSTEM
TURBINE ON BARRING
Evaporator – heat absorption
Reduced number of evaporator wall tubes.

 Ensures minimum water wall flow.

SPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA :
Support System for Evaporator Wall

• Spiral wall  Horizontal and vertical buck stay with tension strip

• Vertical wall  Horizontal buck stay

Key source

 NTPC SIPAT
 DOSSAN BOILER
 BGR ENERGY

THANK
YOU