11/14/2019

What is Boiler?
Boiler Function, Boiler Accessories
Kshirod Mohan Bose
Executive Engineer (Mechanical)
Ghorashal 3rd Unit CCPP.
Mobile: 01711-076856
E-mail: kshirod124@yahoo.com

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Phenomenon Water (Steam Generation) Pressure Temperature Relationship for Water

Sensible Latent Heat Sensible Latent Heat Sensible Temperature °C
CRITICAL POINT
Heat of fusion Heat of vaporization or condensation Heat
150oC
400 374.15°C What is Supercritical
350°
Pressure ?
Water boiling 22123 kPa
15000 kPa Critical point in water
100oC
Temperature oC

300° 10000 kPa vapour cycle is a

Steam Condensing thermodynamic state
250° 5000 kPa where there is no clear
3000 kPa distinction between
200° liquid and gaseous state
Change of State of water
Ice Melting 150° 600 kPa
Steam Water reaches to this
0oC Water
Ice Freezing 100° 100 kPa state at a critical
ICE Change of State pressure above 22.1 MPa
-17.77oC 50° and 374 oC
37 kJ 334 kJ 418 kJ 2250 kJ 97.4 kJ
Heat (kJ) per kg of Water 0° Pressure kPa

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Classification of Boiler
On the basis of Use: For power
Plant On the basis of
On the basis of
furnace Position
Tube of Boiler
Stationary For Utility of Boiler
Boiler Power Plant
Water Externally
For Plant
Process
Tube Fired
Boiler

Locomotive Internally
Fire Tube
Mobile Fired
boiler
Marine

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On the basis of Steam On the basis of

Circulation Draught
Boiler
Natural Natural Draught
Hot Waste Gases as By- Circulation Boiler Boiler
Solid/Liquid/Gaseous Fuel product of other
Electrical Nuclear
(Conventional Boiler) Chemical Process Energy Energy
(HRSG) Forced Forced Draught
Circulation Boiler Boiler

Induced Draught
HRSG
Gas &
HRSG with
Boiler
Coal Fired Oil Fired Gas Fired Oil/Duel
without Burner/d
Boiler Boiler Boiler Fuel
Burner uct Firing
Boiler Balanced
System
Draught Boiler

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• Application: hotel, heater, small industrial • Application: Auxiliary boiler, industrial process
Low Pressure
process • Fuel: Oil and Gas only
boiler
• Fuel: Oil, Gas • Steam Capacity up to 220 Ton/hr
(P<1.275 MPa)
• Steam capacity up to 5 Ton/h • Design Pressure up to 110 Bar
• Saturated temperature • Design Temperature up to 500o C
Medium Pressure
boiler (P<3.82 • Design pressure up to 2.5 Bar • Mainly shop assembly, very minimum site works
Sub Critical MPa) • Fully shop assembly
Pressure boiler
(P<16.67 MPa) High Pressure
Boiler boiler
Super Critical (P<9.8 MPa)
Pressure boiler
(P<22.13 MPa) Super High
Pressure boiler
(P<13.73 MPa)

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Heat Recovery Steam Generator (HRSG)

• Application: Steam turbine drive

(turbine propulsion) in the shipboard
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 70 Ton/hr
• Design Pressure up to 58 Bar
• Design Temperature up to 500o C
• Limited spaces, compact arrangement
• Dynamic behavior

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HRSG of Ghorashal 3rd Unit

• Application: Industrial process, Steam

Bypass Stack

turbine drive (< 50 MW)

Stack
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 200 Ton/hr
• Design Pressure up to 120 Bar
• Design Temperature up to 500o C
• Site assembly
LP Super-heated
IP Super-heated
Steam
HP FWP IP FWP
Consideration of Industrial Boiler:
IP HP – Multi-fuel Burning capability
Steam
OTC OTC
– Waste Fuel Utilization (biomass, waste acid,
Deaerator
sludge, etc.)
HP Super-heated Steam
Triple Pressure Drum, Natural Circulation Type – Cogeneration Potential to maximize heat
from their fuel

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Drum
Final Super Heater
Down comer
• Application: Electric Utility (more
Secondary Super Heater
than 50 MWe) Primary Super Heater
• Main Fuel: Coal Water Wall Re- Heater
• Steam Capacity up to 1,850
Ton/hr (600 MW) Burner Position
• Design Pressure up to 173 Bar Economizer
• Design Temperature up to 550o C Lower Header
• Site assembly

Cross Sectional View of an

Utility Boiler

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To IPC From HPC

To HPC

Stack
Platen SH

Con. SH 1

Con. SH 2

RH 2
RH 1

• Application: Electric Utility

• Fuels: Pulverized Coal
• Steam Capacity up to 2,500
Econ. Ton/hr (800 MW)
Regenerative Air • Design Pressure up to 253 Bar
Radiant SH FW Heater • Design Temperature up to
565o C
• Higher efficiency (no steam
drum, no blow-down system)
FD Fan

Air
ID Fan

FUEL • Feed water quality is major

concern
Furnace Boiler of 210 MW Ghorashal Power Station • Site assembly
Sub- critical, Super High Pressure, Water Tube,
Balanced Draft with Condensing Turbine
© kshirod124@yahoo.com

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Kshirod Mohan Bose, XEN, G3 CCPP,

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 11/14/2019

Features of Super Critical Boiler Efficiency and CO2 Emission

• Latent heat for evaporation is not required
• Internally Ribbed Tube construction
• Increases heat transfer rate Steam Steam CO2
Plant type Efficiency
Pressure Temperature Emissions
• Spiral tube water wall construction with power rating (%)
(kg/cm2) (C) (g/kW-hr)
• Absence of nuclear boiling
• Maintenance free boiler
Sub Critical
• Circulation is forced type 170 540 35 900
(Maximum Capacity 500 MW)
• Absence of Dozing, Condensate Polishing Unit (CPU) is applied for maintaining the
water quality
# Super Critical 247 565 40 830
• Less emission Up to Crip limit

• Higher efficiency Ultra Super Critical 250 600 42 784

• Less fuel consumption
• No Blow down (Less water consumption) Advanced Ultra Super
300 700 45 740
Critical

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Circulation of Water and Steam in Boiler

Natural Circulation • Forced Circulation
 Furnace
– radiation mode
STEAM (Ms)
Spaced SH
Radiant SH

Evap.

Ms  Radiant (Platen) Super-heater

– luminous radiation mode
Econ.
WATER – non-luminous radiation mode
Mw
(Mw) – convection mode
COLD SIDE

Steam +
Convective (Spaced) Super-heater
DOWNTAKE or
DOWNCOMER


Water
– non-luminous radiation mode
HOT SIDE
HOT SIDE
COLD SIDE

– convection mode
 Evaporator (Boiler Bank)
Furnace

– convection mode
 Economizer
ORIFICE – convection mode
CIRCULATING PUMP

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Water Wall Construction

Tube & Tile
Furnace and convection pass

Tangential Tube
Water Circuits, including drums and steam separators and re-heater.

Connection Piping and Headers Studded Tube

Burners
Membrane Wall Studded Tube

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Boiler Drum Internals Burner

Cyclone Separators

Water Level
• Fuel
• Natural Gas
• Oil
• Coal Dust
• Quantity
• Boiler Size

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Boiler Auxiliaries Air Heaters

Non- pressure Boiler
Components Balance of Plant
Equipment
(Fuel & Air System)
• Fuel preparation • Fans
Equipments • Feed Pumps
• Burners • Pollution Control
• Air Heaters Equipment
• Duct works and supports. • Controls
Tubular Air Heater Re- Generative Air Heater 28

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Economizer

• Used for Feed Water

Heating.
• For adding heat at higher
temperature
• Use waste Heat
• Increases Efficiency.

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Feed Pump

• Multi- stage
centrifugal pump
• Driven by Motor or
Turbine
• May be configured as
1 100%, 2  100%, 3
 66%

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COMBUSTION AIR and FLUE GAS CIRCUITS

Fan types

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What turbine?
Details Discussion on Different • Turbine is an engine that converts energy of fluid into mechanical
energy
types of Turbine

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On the basis of Action On the Basis of Working Fluid

Turbine
Turbine
Hydro Steam Gas Turbine
Turbine Turbine (Reaction)

Impulse Reaction Pelton

Turbine
Kaplan Turbine
(Axial Flow -
Francis Turbine
(Radial Flow- Impulse
Impulse &
Reaction
Turbine Turbine (Impulse) Reaction) Reaction) Reaction

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On the basis of Steam flow

Steam Turbine

Condensing Back pressure Extraction

Turbine Turbine Turbine

Condensing Back Pressure

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Impulse Turbine Impulse Turbine

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Reaction type

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Blade Arrangement
Impulse Turbine Reaction Turbine

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IMPULSE-REACTION TURBINE

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Gas Turbine Components of Gas Turbine

Combustion Chamber
• Compressor to compress air[Iso-entropic Compression]
• Combustion Chamber to add Heat by burning the fuel [Constant
Air Exhaust Pressure Heat Addition]
Flue Gas • Turbine to convert energy for flue gas to Mechanical Energy [Iso-
~
entropic Expansion]

Generator
Compressor Turbine

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Air intake system: Compressor

• Compressor sucks air • Compressor is rotary type air
through an air intake compressor which is coupled
manifold. with the turbine hence is
• The air used for GT is driven by the turbine.
filtrated.
• To control air flow Inlet guide
• The air from vanes is used, named Variable
Atmosphere through
air cleaners in which Inlet Guide Vane (VIGV) &
big & small dust Variable Guide Vanes (VGVs).
particles are removed. • The compressor has multi-
stages of blades.

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Combustion System: Turbine and exhaust system:

• Heavy Duty Gas turbine of common type has three to five
stages.
• Each stage blade is provided
• with air-cooling system to sustain in high temperature. The
flue gas temperature just after firing is about 900o C to
1300oC the final temperature at exhaust zone is about only
550oC to 650oC
• The flue gas after combustion passed through stages of
nozzle and Blades (Conventionally called Bucket)
• Passing through blades the flue gas goes to exhaust
diffuser at reduced pressure and temperature.

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GT26 Operating Principle

From Air Intake
Combustion Chamber Turbine Blades Exhaust Diffuser
System

Compressor

Fig.-Simple Cycle Single Shaft Heavy Duty Gas Turbine

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Electrical System (Simplified SLD)

230 kV Substation Hydro Energy
HCB
Gen Step-up
Transformer
YNd1, 392 MVA
ODAF
20/230 kV
Service Transformer
20/6.75/3.5 kV
GCB 30/20/15 MVA
To 6.6 KV
Excitation Transformer
Static Starting Device (SSD)

Generator,
375 MVA at
40oC
~ Static Excitation System
From 0.4 kV

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Kshirod Mohan Bose, XEN, G3 CCPP,

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 11/14/2019

Types of Hydroelectric Installation Meeting Peak Demands

Head (50 m above)
• Hydroelectric plants:
Head 15 m to 50 m • Start easily and quickly and change power output rapidly
Head less than 15 m
• Complement large thermal plants (coal and nuclear), which are most efficient
in serving base power loads.
• Save millions of barrels of oil

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Conventional Impoundment Dam Large Hydropower

Hoover Dam (US)

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Example
Diversion (Run-of-River) Hydropower Diversion Hydropower (Tazimina, Alaska)

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UMM, Indonesia Experiences in Micro-hydro

Small Hydropower

Small hydropower facilities

can produce
100 – 30,000 kilowatts
(kW) of electricity.
Small hydropower facilities
may involve a small dam,
or be a diversion of the
main stream, or be a
run-of-the-river system.

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Types of Hydropower Turbines Classification of Hydro Turbines

• Reaction Turbines
• Derive power from pressure drop across turbine
• Totally immersed in water
• Angular & linear motion converted to shaft power
• Propeller, Francis, and Kaplan turbines
• Impulse Turbines
• Convert kinetic energy of water jet hitting buckets
• No pressure drop across turbines
• Pelton, Turgo, and cross flow turbines

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Francis Turbine Fixed-Pitch Propeller Turbine

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Kaplan Turbine Kaplan Turbine

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Vertical Kaplan Turbine Setup Horizontal Kaplan Turbine

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© Kshirod Mohan Bose, XEN, GPS +8801711076856,

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kshirod124@yahoo.com

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