CHAPTER - 3

BOILER
3.1. BASIC BOILER SYSTEM
Boiler or the steam generator is the main part in the power generation process.
Boiler acts as a medium in which the water is converted into the steam by using the
heat released in the process of combustion of coal in the presence of oxygen. A steam
boiler is composed of two basic system. One basic boiler system is the water-steam
which is known as boiler waterside. In waterside of boiler, water is heated and
released by movement via water tubes, then water is transferred to steam and also it
retains as steam in the system.

System boiler need to manage chemical stability. The method where this is
performed could interact to control system of feed water. The quality of blow down
should be regarded in the control design of feed water, particularly when the blow
down is continually performed. Frequently, the flow of blow down is separated by
content level ratio of the flow feed water. The popular method pertaining to
managing the chemical content level is continuous blow down.

On big scale boiler this could possibly be performed automatically by way of

measuring conductivity of boiler water to regulate blow down rate. Mixing ratio
control of blow down with conductivity and comparing feed water flow to blow
down is carried out to get blow down rate. Blow down is usually obtained and
conductivity is measured in utility plants. This is needed on a regular schedule or
maybe any time the conductivity becomes very high.

The other basic boiler system is the fuel-flue gas-air system. This system is a
well-known as the boiler fireside. This specific system supplies

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heat which is transferred into boiler fireside system. The combustion air and fuel is
as well-known as wind-box. Ash and gas will be the output of this system.

Here in 500 MW POWER PLANT the type of boiler used in the water tube
boiler. The steam generator is a forced circulation, single drum type, corner fired,
and balanced draft type. In water tube boiler, boiler feed water flows through the
tubes and enters the boiler drum. The circulated water is heated by the combusted
gases and converted into steam. There are many mountings to the boiler, which are
compulsory for the safe run of the boiler. Also, there are accessories, which increase
the efficiency of the boiler.

3.2. ARRANGEMENT OF MAIN BOILER IN 500 MW

POWER PLANT
The illustration given in figure below shoes a symbolic arrangement of
various accessories of a boiler. These accessories include:

 Economizer
 Boiler drum
 Down comers
 Controlled circulation water pump
 Water walls
 Low temperature super heater
 Platen super heater
 Final super heater
 Re- heater
 Burner
 Igniters

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 Fig 3.1. Boiler Terminology

3.3. SUPPORTING STRUCTURES

Boiler supporting structure consists of arrangement of columns stiffened with
horizontal beams and vertical diagonal bracings and comprise of Low carbon steel
material. It is composed of 18 main columns and 12 auxiliary columns. The main
columns support the main boiler components viz. drum, water wall, membrane,
panels, super heaters, Re-heaters, Economizers, air preheater, burners and galleries
at various levels. The auxiliary columns, supports the boiler platforms and other
ducts coming in that region. The total weight of supporting structures is about 6000
Tons.

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3.3.1. FURNACE

A boiler furnace is that space under or adjacent to a boiler in which fuel is

burnt and from which the combustion products pass into the boiler proper. It
provides a chamber in which the combustion reaction can be isolated and confined
so that the reaction remains in a controlled manner. In addition it provides support
or enclosure for the firing equipment.

Fig 3.2.Furnace Internal Structure

3.3.2. BOILER DRUM

The function of steam drum is to separate the water from the steam generated
in the furnace walls and to produce the dissolved solid contents of the steam to below
the prescribed limit of 1 ppm. The drum is located on the upper front of boiler

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 Fig 3.3. Boiler Drum

3.3.3. ECONOMIZER
The purpose of economizer I to preheat the boiler feed water before it is
admitted into the steam drum by recovering heat from the flue gases leaving the
boiler. The economizer is located in the boiler rear gas pass below the rear horizontal
super heater (LTSH).The economizer is continuous unpinned loop type and water
flows in upward direction and gas in the downward direction.

Fig 3.4. Economizer Coils

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3.3.4. SUPER HEATER

There are three stages of super heater besides the side walls and extended
sidewalls .The first stage consists of horizontal super heater of convection mixed
flow type with upper and lower banks located above economizer assembly in the
rear pass. The upper bank terminate into hanger tubes, which are connected to outlet
header of the first stages super heater. The second stage super heater consists of
pendant platen which I of radiant parallel flow type .The third stage super heater
pendant spaced is of convection parallel flow type. The outlet temperature and
pressure of the steam coming out from the upper heater are 540°C and 157Kg/cm^2
respectively for H.P units.

3.3.5. RE-HEATER

The function of Re-heater I to reheat the steam coming out from high pressure
turbines to a temperature of 565°C.The Re-heater is composed of two sections, the
front pendant section and the rear pendant section.

3.3.6. IGNITER
There are 16 eddy plate oil/H.E.A igniters per boiler. The atomizing air for
igniters is taken from plant air compressors at 7Kg/cm^2(gauge).

The burners are located at four elevations. Each elevation has four oil burner
and igniters .These elevations are normally known as AB elevation, CD elevation,
EF elevation and GH elevation.

Igniters are used for lighting the main oil gun .Mainly two types of igniters
are used.

1. Eddy Plate Igniter.

2. High Energy Arc Type Ignite.

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3.3.7. P.A. FAN

The primary air fans are designed for handling atmospheric air up to a
temperature of 50°C. These fans are located at boiler ʻ0ʼ M level. The air supplied
by this PA fan is used for drying the coal and to carry the pulverized coal from the
mill to the furnace.

3.3.8. AIR PRE˗HEATER

Tri-sector air pre-heater transfers heat from flue gases to cold primary and /
or secondary air by means of rotating heating surface elements .Beneath these
regenerative type air pre-heaters, there exists a steam coil air pre-heater. These are
located in the secondary pass of the furnace at a height of around ʻ16ʼM level. Each
500 MW unit is provided with two such air pre-heater.

Fig 3.5. Air Preheater

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3.3.9. F.D.FAN

The forced draft fans (2 per unit -60% capacity each) are designed for
handling secondary air for the boiler. These fans are located at ʻ0ʼM level near the
P.A. Fan.

3.3.10. ELECTROSTATIC PRECIPITATOR

These are generally two plate type located between boiler and the chimney.
The precipitator is arranged for horizontal gas flow and I constructed with welded
steel casings.

3.3.11. I.D.FANS
There are two induced draft fans per boiler located between the electrostatic
precipitator and the chimney .These fans are used for sucking flue gas from furnace.

3.3.12. FUELS

These are two types of fuels which play a vital role in fuel firing system. They
are:

a) Coal
b) Oil

3.3.12.1. COAL
Fuel (coal) is fed from mines to the boiler through the fuel feeding plant
commonly known as “Coal handling plant ʺ.election of proper methods of coal
supply from the mines to the power station depends upon the system capacity in the
tons/hour, location of available outsides storage and overhead coal bunkers. The
unloading will take place by “Merry Go Round” system in which loading and
unloading will take place within 12-20 minutes. Coal is crushed to the sizes of 50

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mm in the crusher house before it is fed to the bunkers of individual units. The coal
from CHP is transferred to the bunkers through the conveyor belts via turning points.
The storage capacity of bunkers in terms of time is 14 hours. The coal from the
bunkers enters the mill through the coal feeders by gravity action. The quantity of
coal reaching the coal mill is controlled by feeders by altering the speed of motors
as per the requirements of the unit.

3.3.12.1.1. COAL BUNKER

These are in process storage silos used for storing crushed coal from the coal
handling system .Generally, these are made up of welded steel plants. There are eight
such bunkers supplying coal of the corresponding mills .These are located on top of
the mills so as to aid in gravity feeding of coal.

Fig 3.6. Coal Bunker

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3.3.12.1.2. COAL FEEDERS

In most of the power stations the types of feeders used for transporting coal from
raw coals to the mills are:

1. Volumetric feeders
2. Gravimetric type feeders

Fig 3.7. Coal Feeder

3.3.12.1.3. MILLS
Pulverized fuel firing is a method whereby the crushed coal, generally reduced
to fitness such that 70-80% passes through a 200 mesh sieve, is carried forward by
air through pipes directly to burners or storage bins from where it is passed to
burners. When discharged into combustion chamber, the mixture of air and coal get
ignited and burns in suspension. The economic motives for the introduction and
development of pulverized fuel firing are: Efficient utilization of cheaper low grade
coals.

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 Flexibility in firing with ability to meet fluctuating loads.
 Elimination of bunking losses.
 Better reaction to automatic control.
 Ability to use high combustion air temperature; increasing the overall
efficiency of boiler.
 High availability.
 The only disadvantage is that the initial cost of equipment for
preparation of pulverized coal mill will be high.

Fig 3.8. Mill

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