Training on

Professional
Operation Development
and Maintenance Course on
of Boiler
June 2013
Operation and Maintenance of Boiler

BOILER FUNDAMENTALS
Typical of coal fired power plant

Operation and Maintenance of Boiler

 Deaerator

Stack

Forced Draft Steam

Fan (FD Fan) Drum
Flue Gas
Desulphurization
(FGD)
Electrostatic Boiler
Precipitator (ESP)

Air Heater
(Rotary Heat
Exchanger)
Burner

Induced Draft
Fan (ID Fan)

Feed Water
Heater

Coal Conveyor

Coal Plant
Pulverizer
Boiler Feed Pump

Steam Turbine Generator

Condensor

Operation and Maintenance of Boiler

 THERMAL POWER PLANT EQUIPMENT
FUEL (COAL) TO FLUE GAS LINE EQUIPMENT :
Flue Gas Equipment
Fuel (Coal) Equipment
Coal Yard or Coal Plant Oil (HSD) for Boiler Furnace
Start-Up

Conveyor System Air Heater (Rotary HX)

Burner
Coal Silo System Electrostatic
Precipitator (ESP)
Pulverizer Coal or

Hot Air from Bag House Filter

Air Heater

Flue Gas
Hot Air from Air Desulphurization (FGD)
Heater

Induced Draft Fan

(ID Fan)

STACK
Operation and Maintenance of Boiler
 FLUE GAS FLOW SCHEMATIC
To Atmosphere

Air Pollution Equipment

Steam
Generator Stack

Air Heater Dry Baghouse

Scrubber Filter
Pulverizer Gas Forced Draft Induced Draft
Recirculating Fan (FD Fan) Fan (ID Fan)
Fan
Operation and Maintenance of Boiler
WATER TO STEAM LINE EQUIPMENT :

Operation and Maintenance of Boiler

 COAL FIRED POWER PLANT
BALANCE MASS AND ENERGY
PLANT PERFORMANCE TERMINOLOGY

1. Gross Plant Output (at Maximum

Continous Rate (MCR)) in kWe
(kilowatt electricity)
2. Gross Plant Heat Rate (at Maximum
Continous Rate (MCR)) in
kcal/kWeh
3. Net Power Output in kWe (kilowatt
electricty)
4. Net Plant Heat Rate in kcal/kWeh
 BASIC FACTORS TO SELECT BOILER
1. Power required to be generated
2. Operating Pressure
3. Fuel-quality and type
4. Water availibility and its quality
5. Probable load factoe
6. Location of the power house or process
plants
7. Cost of operations and maintenance
8. Cost of installations and erection
9. Availibility of floor space

Operation and Maintenance of Boiler 10

RANGE OF STEAM GENERATOR

Operation and Maintenance of Boiler

ESSENTIAL QUALITY CRITERIA OF GOOD BOILER
1. It should be capable of quick start-up
2. Should meet large load fluctuations
3. Occupy less floor space
4. Should afford easy maintenance and inspection
5. Should essentially posses the capacity of producing maximum
steam with minimum fuel consumption
6. Light and simple in construction
7. Various joints should be accessible for inspection and should
be away from direct flame impact
8. Tubes should be sufficiently strong to resist wear and
corrosion
9. Mud and other deposits should not collect on heated plates
10. The velocity of water and that of flue gas should be a
minimum.
Operation and Maintenance of Boiler
 What is Steam ?
• Steam results from adding sufficient heat to water to cause
it to vaporize. This vaporization occurs in 2 steps:
o by adding heat to the water to raise it to the boiling
temperature (sensible heat)
o by continuing the addition of heat to change the state from
water to steam (latent heat)
o Saturated steam:
o steam at which boiling occurs at a constant pressure
o same temperature with the boiling water (mixed steam +
water)
• Superheated steam:
o steam with temperature higher then saturated steam at the
same pressure
o close to the properties of a perfect gas

Operation and Maintenance of Boiler

 Why Steam ?
o Contain thermal energy (enthalpy) related to its
pressure and temperature
o Relatively easy to converse its thermal energy to
mechanical energy or other human/industrial purposes
o Easy to handle and transport it
o Easy to produce it, a lot of water resources
o Recycle process: water - steam - water - steam ….

STEAM GENERATOR IS REQUIRED !!

Operation and Maintenance of Boiler

 O-A: ICE WARMING A-O : ICE COOLING
E A-B: ICE MELTING B-A : ICE FREEZING
T
B-C: WATER HEATING C-B : WATER COOLING
K C-D: WATER BOILING D’-C’: STEAM CONDENSING
D-E: STEAM SUPERHEATING E-D’ : STEAM EXPANDING
P3
THE HIGHER PRESSURE PROVIDED TO THE PROCESS
P1 WILL RESULT IN HIGHER BOILING TEMPERATURE
C
P2
D B-E : PROCESS IN THE BOILER
E-D’ : PROCESS IN THE STEAM TURBINE
D’-C’: PROCESS IN THE CONDENSOR
C’ D’ C’-B : WATER FROM CONDENSOR BACK TO THE BOILER
K : CRITICAL POINT = 3208 Psia, STEAM & WATER
PROPERTIES ARE IDENTICAL
A B
0
0C O
S
 HEATING STEAM FOR INDUSTRIAL NORMALLY TAKEN FROM MIXED AREA TO THE UPPER
LIMIT LINE (LUL) --> SATURATED STEAM
 THE SUPERHEATED STEAM AREA WILL BE USED FOR STEAM TURBINE
 THE ADVANTAGES OF SUPERHEATED STEAM :
o INCREASE TURBINE EFFICIENCY
o PREVENT DAMAGING AT THE LOW STEAM TURBINE BLADES DUE TO CONDENSATION
o LESS CONDESATION WHEN TRAVEL THROUGH A LONG PIPE LINE
 GENERATIVE (PREHEATED) PROCESS TO THE FEEDWATER WILL INCREASE BOILER
EFFICIENCY
Boiler Energy Flow
Water - Steam Circulation
o Circulation is the movement of water, steam, or a mixture of the
two, through heated tubes
o Circulation Ratio (Mw/Ms): the mass rate of water fed to the
steam-generating tubes divided by the mass rate of steam
generated
o Adequate circulation will result:
– The cooling fluid absorbing heat from the tube metal at a rate
which maintains the tube temperature at or below design
condition
– Keep the tube within the other physical and chemical
limitations required by the inside and outside environment
o Two types of Circulation:
– Natural Circulation or Thermo Symphonic
– Forced Circulation or Controlled Circulation

Operation and Maintenance of Boiler

 Steam-Water
Circulation System
 NATURAL CIRCULATION
⚫ The water/steam circulates naturally by the density different
between the higher temperature fluid and the lower temperature
fluid
Characteristic of Natural
Circulation
⚫ Circulation Ratio = Mw/Ms is low
⚫ The water wall tubes normally
have larger diameter to reduce
Steam the pressure drop of steam/water
(Ms)
inside the tubes
⚫ Friction factors that oppose
circulation:
– friction between water and
metal tube (+ any scale
Water
(Mw)
deposit inside the tube)
– friction in tube bent
– friction in lower drum and
header
– friction around upper drum
Operation and Maintenance of Boiler
internal
FORCED CIRCULATION
⚫ The water/steam circulates forced by circulating pump
⚫ The circulating pump provide addition head to the existing
thermal head
Characteristic of Forced Circulation
⚫ Circulation Ratio = Mw/Ms is high
Steam ⚫ The steam produced is higher
(Ms)
then Natural Circulation Boiler for
the same running time
⚫ Furnished with Orifice located at
the inlet of Furnace Wall tubes to
assist in obtaining an adequate
Water water flow of varying length and
(Mw)
heat absorbsion. The other
functions:
– create pressure drop
– measure the water flow
– regulate the flow balance
 What main factors will impact to the
Water/Steam Circulation ?
o Water/Steam Velocity
– The velocity relates to the force. The force is depend on
the density different and the height of boiler circuit
o Pressure
– The higher pressure of boiler will cause the water/steam
density smaller
o Heat Supply
– The higher heat supply to the combustion will increase
produced steam. It will reduce the water/steam density
hence the Circulation ratio will increase
o Area
– Natural circulation must have tubes with larger diameter
to reduce the water/steam resistance within the tube
Operation and Maintenance of Boiler
 HEAT TRANSFER
Heat transfer
calculation in the Boiler
design:
o To determine the rate of
heat to be transferred by
involving calculation of
surface area and working
temperature
o To determine how much
heat or energy required by
the boiler
o To estimate the cost,
practicability, and size of the
boiler equipment

Operation and Maintenance of Boiler

 HEAT TRANSFER MODE
• Convection q = h As T
– tranportation and exchange of heat due to the mixing motion of
different parts of a fluid
– natural convection and forced convection
• Conduction q = k Ac
dT
dx
– heat transfer across through fixed (solid) material
• Radiation q =  As T 4
– transfer radiant energy from a source to a receiver
(without medium = electromagnetic wave)
– luminous radiation and non-luminous radiation

MOST OF PRACTICAL APPLICATION IS COMBINATIONS OF THOSE TWO OR

THREE HEAT TRANSFER MODES

Operation and Maintenance of Boiler

Heat Transfer in Boiler Pressure Parts
⚫ Furnace
Spaced SH o radiation mode
Radiant SH

Radiant (Platen) Superheater

Evap.
⚫
o luminous radiation mode
o non-luminous radiation mode
Econ.
o convection mode
⚫ Convective (Spaced)
Superheater
o non-luminous radiation mode
o convection mode
⚫ Evaporator (Boiler Bank)
Furnace

o convection mode
⚫ Economizer
o convection mode

Operation and Maintenance of Boiler

 Heat Transfer Relates to Boiler Pressure

The total heat absorbed in a boiler bank is reduced significantly at higher

pressure unit:
➢ Superheater absorbes greater heat to increase steam temperature
➢ Water temperature in the Boiler Bank is higher for higher pressure
➢ Boiler Bank will not be effective for the higher pressure boiler
Operation and Maintenance of Boiler
 Metal Temperature Consideration

The water/steam within the

tube exposed to furnace hot gas
will pass through a series of
resistance:
➢ gas film adjacent to the tube
➢ slag on tube surface
➢ tube wall
➢ internal scale deposite
➢ water & steam film

⚫ As thermal conductivity of the water film is higher --> Tube metal

temperature of Boiler Bank and Economiser is close to the
temperature of water inside the tubes
⚫ Tube metal temperature of Superheater, Reheater should be
considered carefully --> thermal conductivity of the steam film is
low
Operation and Maintenance of Boiler
COAL FIRED POWER PLANT PT. PETROKIMIA GRESIK 2 X 35 MW
Boiler
Stack
Coal Electrostatic
Steam Silo Precipitator
Turbine

Pulverized
FD Fan Coal ID Fan

Operation and Maintenance of Boiler

 COAL FIRED POWER PLANT PT.
PETROKIMIA GRESIK 2 X 35 MW

Boiler 150 ton/hr

o Superheater Metal
Temperatures 675 - 780°C
o Pressures 300 - 400 bar
o Inlet High Pressure and
Intermediate Pressure
Turbine Rotor 650 - 720°C
Operation and Maintenance of Boiler
Operation and Maintenance of Boiler
What factors will impact to heat transfer ?
❑ Temperature different
❑ Heat source
❑ Heating surface area
❑ Physical properties
➢ thermal conductivity
➢ heat transfer coefficient
➢ emissivity
➢ wall thickness
➢ slag or ash layer
➢ internal scales or sludge layer

REGULAR BOILER MAINTENANCE & INSPECTION IS REQUIRED

Operation and Maintenance of Boiler

 Typical Boiler Design Parameters
o Furnace heat release rate
– maximized local absorbsion rate and avoid “hot spot”
– prevent excessive slag accumulation
– influences completeness of combustion process
o Flue gas velocities through tube banks
– limit the draft loss to control flue-gas velocity
o Tube spacing
– prevent slaging especially for residual oil, coal with low
ash-fushion temperature

BOILER DESIGN IS TAILORED TO THE FUELS & FIRING SYSTEM

Operation and Maintenance of Boiler

 BOILER TYPE
Based on Purposes & Construction:
1. Package Boiler 5. Supercritical Boiler
2. Industrial Boiler 6. Marine Boiler
3. Utility Boiler 7. Biomass Boiler
4. Circulating Fluidized Bed (CFB)

Based on Heating Area:

1. Fire Tube Boiler 2. Water Tube Boiler

Based on Heat Source:

1. Conventional Boiler 2. Heat Recovery Steam Generator

Based on Circulation:
1. Natural Circulation 2. Forced Cirulation

Based on Support:
1. Bottom Supported 2. Top Supported

Operation and Maintenance of Boiler

STEAM

FIRETUB
Fire Tubes Boiler
ES

BURNE
o Application: hotel,
R
heater, small industrial
process
o Fuel: Oil, Gas
o Steam capacity up to 5
Ton/h
o Saturated temperature
o Design pressure up to
2.5 Bar
o Fully shop assembly

Operation and Maintenance of Boiler

 Package Boiler

• Application: Auxiliary
boiler, industrial
process
• Fuel: Oil and Gas
only
• Steam Capacity up to
220 Ton/hr
• Design Pressure up
to 110 Bar
• Design Temperature
up to 500o C
• Mainly shop
assembly, very
minimum site works
Operation and Maintenance of Boiler
 Industrial Boiler
• Application: Industrial process,
Steam turbine drive (< 50 MW)
• 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

Consideration of Industrial Boiler:

▪ Multifuel Burning capability
▪ Waste Fuel Utilisation (biomass, waste
acid, sludge, etc.)
▪ Cogeneration Potential to maximize
heat from their fuel

Operation and Maintenance of Boiler

 Utility Boiler

• Application: Electric Utility

(more than 50 MWe)
• Main Fuel: Coal
• Steam Capacity up to 1,850
Ton/hr (600 MW)
• Design Pressure up to 173
Bar
• Design Temperature up to
538o C
• Site assembly
Operation and Maintenance of Boiler
Circulated Fluidized Bed (CFB) Boiler

• Application: Industrial
process, Steam Turbine drive
• Fuel: Flexible Solid fuels
• Emission: Low, environmental
friendly
• Steam Capacity up to 800
Ton/hr
• Design Pressure up to 120
Bar
• Design Temperature up to
500oC
• Site assembly

Operation and Maintenance of Boiler

Circulated Fluidized Bed (CFB) Boiler

o Application: Industrial
process, Steam Turbine
drive
o Fuel: Flexible Solid fuels
o Emission: Low,
environmental friendly
o Steam Capacity up to 265
Ton/hr
o Design Pressure up to
100 Bar
o Design Temperature up to
500o C
o Modularized concept

Operation and Maintenance of Boiler

 Super Critical Boiler
o Application: Electric
Utility
o Fuels: Pulverized Coal
o Steam Capacity up to
2,500 Ton/hr (800 MW)
o Design Pressure up to
253 Bar
o Design Temperature up
to 538oC
o Higher efficiency (no
steam drum, no blow-
down system)
o Feedwater quality is
major concern
o Site assembly
Operation and Maintenance of Boiler
Heat Recovery Steam Generator (HRSG)
• Application: Cogeneration,
Combined Cycle
• Type: Horizontal (Natural
Ciculation), Vertical (Forced
Circ.)
• Steam Capacity up to 400
Ton/hr (GT 9 FE size)
depend on GT type
• Single, Dual or Triple
Pressures up to 120 Bar
• Design Temperature up to
450o C
• Site assembly

Operation and Maintenance of Boiler

 Marine Boiler

• 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 500oC
• Limited spaces, compact
arranggement
• Dynamic behavior

Operation and Maintenance of Boiler

BIOMASS BOILER