Brief Introduction: Satyakam Mohapatra Engineer (Mechanical)

Brief Introduction
Satyakam Mohapatra
Engineer(Mechanical)
Monnet Power Company Ltd 1

BOILER
In General, A boiler is a closed pressure vessel strongly
constructed of steel or iron where water is converted to steam
by application of heat.
According Indian Boilers Act, 1923, -
“Boiler" means a pressure vessel in which steam is generated for
use external to itself by application of heat which is wholly or
partly under pressure when steam is shut off but does not
include a pressure vessel,-
(i) with capacity less than 25 litres (such capacity being measured
from the feed check valve to the main steam stop valve);
(ii) with less than one kilogram per centimetre square design
gauge pressure and working gauge pressure; or
(iii) in which water is heated below one hundred degrees centi-
grade;
Usage of Boiler
 In Power Sectors
 In Independent Power Plant(IPP) &
Captive Power Plant(CPP).
 In Process Plants
 In Oil Refineries, Paper Industry, Sugar
Industry, Chemical Industry, Rice mill,
Steel Industry etc.

Criteria Types
Content of Tube Fire Tube Boiler, Water Tube Boiler
Type of firing Solid, Liquid & Gas Fired
Type of Circulation Natural Circulation, Natural Assisted or

Controlled Circulation, Forced
Circulation
Steam Pressure Sub Critical Boiler, Super Critical Boiler
Draught Natural Draught, Mechanized

Draught(Forced, Induced, Balanced)

Content of Tubes
Fire Tube Water Tube
In fire tube boiler hot flue In water tube boiler
gas will be moved inside the
water will be moved
tubes & water outside the
tube. inside the tube & hot flue
In fire tube boiler mode of gases outside the tubes.
firing is generally internally Mode of firing is
fired. externally fired.
In fire tube boiler operating Operating pressure can
pressure limited to 25 kg/cm² exceed 125 kg/cm² or
more

FIRE TUBE
BOILER
WATER TUBE
BOILER

Type of Firing
Solid Liquid Gas
AFBC CFBC PC Fired WHRB
Atmospheric Circulating Pulverized Waste Heat

Fluidized Bed Fluidized Bed Coal Fired Recovery Boiler
Combustion Combustion
Bed Material Used Boiler. Waste Heat
Bed Material Used -
– Crushed Coal : F from Flue Gas
Crushed Refractory (
Refractory( + 0.8
+ 0.8 mm to -2.8 mm) Grade(3000- of Other
mm to -2.8 mm) 3500 Kcal/Kg) process used in
Velocity – 3-5  Velocity – 7-8 m/s.
m/sec Coal – F-Grade, Size is 65µto boiler for Steam
Coal – F-Grade, Washery Reject 80µ. generation
Washery Reject  Combustion Eff.- No Bed is
Combustion Eff- 95 % Required
80-85%
Combustion
Eff : 99 %
AFBC CFBC
WHRB PC Fired

Type of Circulation
Natural Assisted/Controlled Forced

Circulation Circulation Circulation
Density Beyond 175 kg/cm2(g) Mechanical

pressure in a re circulation
Difference is the system, circulation through pumps are used to
driving force. the evaporator is to be over come the
Limited to boiler assisted with mechanical
frictional losses
pumps to overcome
with drum frictional losses in the Operating
operating tubes. A pump called boiler pressure is above
circulation pump will be
pressure around placed in the down comer
224.6 kg/cm2(g)
175 kg/cm2(g). between the Drum & water
wall ring header to do this
function is called
controlled circulation.

SH
SH
SH
Separator
ECO Drum ECO Drum

Water
from
Feed
Station
Furnace Furnace BCP

Wall Wall WW
CC
Pump
Distribution Distribution Economiser

Header Header
Natural Assisted
Forced Circulation
Circulation Circulation
Steam Pressure
Sub Critical Boiler Super Critical Boiler
Boilers Operating below the Boilers Operating above Critical

Critical Pressure(224.6 Pressure (224.6 kg/cm2(g)) &
kg/cm2(g)). Critical Temp (374 0C)
These are recirculation type or These are only Once Through
once through . Type.
Steam Drum is required to Drum is not required as cycle
separate water & steam. medium is a single phase fluid
having homogenous property.

DRAUGHT
Natural Draught Mechanized Draught
Forced Induced Balanced
The draught
Here Fans are Fans installed at Both Forced
required for the flow used to draw air the outlet of
& Induced
of air & gas inside from atmosphere boiler, evacuate
the gases from draught fans
the boiler is created & push into the
furnace. furnace. So a are used to
by chimney alone The entire boiler negative Pr. Is derive the
will be kept developed in benefits of
above furnace & air from
atmosphere enters both systems.
atmospheric
the furnace
pressure

Boiler Mountings
 Safety Valves
 Feed Check Valves
 Pressure Gauge
 Drum Water Level gauge
 Blow Down Valve
 Main Stop Valve…etc
Boiler Mounting are basically used for safe operation of

Boiler.

Description of Boiler Mountings
 Safety Valve : The Function of a safety valve is to blow off steam when the pressure in
the boiler exceeds the working pressure.
 Feed Check Valve : A feed check valve is used to control the supply of feed water to
boiler & also to act as a non-return valve.
 Pressure Gauge : Pressure gauge indicates the pressure of steam in a boiler.
 Drum Water Level Gauge : The Function of water gauge glass is to indicate the water
level in the Drum.
 Blow Down Valve : Blow down Valves are designed for continuous use to control the
concentration of dissolved solids in boiler water.
 Main Stop Valve : Function of a steam stop valve is to stop or allow the flow of steam
from the boiler to Main Steam line.

 Maker : Bharat Heavy Electricals Ltd
 Boiler Maker No : 0675,0676
 Type : Controlled Circulation, Sub Critical, Two Pass, Single Reheat,
Balance draught, Tangential PC Fired.
 Boiler Rating : 51793 m2
 Boiler Drum Design Pressure : 210 kg/cm2(g)
 Boiler Hydrotest Pressure : 315 kg/cm2(g) ,(For RH-78 kg/cm2(g) )
 Boiler Drum Design Temp : 369 OC
 Steam flow at SHO: 1700TPH
 Steam pressure at SHO: 192.2 kg/cm2(g)
 Steam temperature at SHO: 540OC
 Reheat Steam flow: 1468.1TPH
 Steam pressure at RHI: 52.4 kg/cm2(g)
 Steam temperature at RHI: 337OC
 Steam pressure at RHO: 52.4 kg/cm2(g)
 Steam temperature at RHO: 540OC
 Boiler Efficiency: 86 %
Boiler Pressure parts
The Following parts generally comes under this category –
• Drum
 Economiser
 Water Walls
 Radiant Roof Tubes
 Steam Cooled Walls
 LTSH Coil
 Div Panelette SH
 Platen SH
 Rehaeter Coil Assy.
RH O/L Hdr

Water Circuit
Feed
Water
Station
ECO Feed ECO I/L ECO O/L ECO

ECO Coil
Pipe Header Header Link
Water Wall Water Bottom

Down
Outlet Wall Ring DRUM
Comer
Headers Tubes Header

BOILER DRUM
 In a Sub-Critical re-circulation boiler, the
drum plays an important role. In the erection
of a Power Boiler, the lifting of the Boiler
Monnet Power Company Ltd

Drum is the first mile stone activity.
 The Functions of Drum are
 Separation of saturated steam from the steam-
water mixture produced by evaporating tubes.
 Mixing feed water from economiser and water
separated from steam-water mixture, and re-
circulate through the evaporating tubes
 Carrying out blow down for reduction of boiler
20
water dissolved solid concentration.
 Treatment of Boiler Water by chemicals
TECHNICAL DATA OF DRUM
Design Pressure 210 kg/cm2(g)
Operating Pressure 197 kg/cm2(g)
Water Holding Capacity 60 m3

Design Temperature 369 0C
No of Cyclone Separator 92(46X2)
No of Secondary Drier 124
OD of Drum 1778 mm
Thickness 155 mm
(Straight Portion/Dished Portion)
Weight of Drum without Internals 214.7 MT 21
3 SH
Conn
Pipe 4
Stubs
5
Riser
6
1

Stub
Safety
Valve DC
Stub
2 Nozzle
Feed
Nozzle
Taping No Details Qty(In Nos)

1 DWLG & EWLI 15 (Both Side)
2 Test Tapings 4
3 Air Vent 2
4 Chemical Feed Nozzle 1
22
5 DWLG & EWLI 15 (Both Side)
6 CBD 1
The main components of Boiler Drum:
 Turbo separator
 Screen Dryer
 Baffle Plate
 Anti Vertex Spider

STAGES OF STEAM & WATER SEPARATION :
 Separation takes place in the concentric cylinder of Turbo separator.
 The second stage of separation takes place in the corrugated sheets
connected to the top of the Turbo separator.
 The third and final stage of separation takes place in Screen Driers.
 The Anti Vertex spider is provided at the inlet of Down comer to avoid
whirl formation in DC.
23
Drier Assembly(62X2)
Drum Internals of MPCL Boiler
Turbo
Separator
(2X46)
Separating
Chamber
Feed Header
Feed Nozzle
DC Nozzle
TURBO SEPERATOR

Economiser System
O Application of economisers is to capture the heat from flue
gas and transfer it to the feed water. This raises the
temperature of the boiler feed water, lowering the needed
energy input, in turn increases efficiency.
O Total System Consists of ECO feed line, Eco I/L Header, ECO
Coil Assy, ECO O/L Hdr, ECO Link to Drum.
TECHNICAL DATA
No of Banks 3 Banks( 92 Sets)
Total Heating Surface of ECO 20,000 Sq. Mtr

System
Total Water Holding Capacity 150 m3

Description Size Design Temp( 0C) Design Pressure
(DiaXThick) (kg/cm2(g))
(In mm)
ECO Feed Pipe 457.2X50 283 219.7
ECO Inlet Header 508X65 283 215
ECO Coil 38.1X4.5 336 215
ECO Outlet 406.4X60 353 210.8

Header
ECO Link to 368X40 357 210.8

Drum 323.9X36

ECONOMISER COIL

Water Wall System
O The water walls are tube panels through which the
water for steam generation will be circulated. In Water
Wall only heat is added to evaporate the feed water to
steam.
O It also forms the major part of furnace enclosure.
TECHNICAL DATA
Design Temp & Pr. at WW Inlet 3680C & 212 kg/cm2(g)
Hdr
Design Temp & Pr. at WW Outlet 3680C & 209 kg/cm2(g)
Hdr
Total Heating Surface of WW Tubes 7000 Sq.Mtr
Water Holding Capacity of 170 m3
Circulating System
(DiaXThck) (kg/cm2(g))
(In mm)
Down Comer 368X36 368 212
Bottom Ring 914X85 368 212

Header
WW Tubes 51X5.6/6.0/7.1 396 214
63.5X7.1
Front, Hanger Tube & 273X40 368 209
Screen Tube O/L
Header
Side WW O/L 273X50 368 209
Header
Riser Pipes 159X18 368 209

Platen
SH
WW
Panels
Div
SH
Panel

CC PUMP
Boiler water circulating pump is used in
high capacity boiler (Super critical or Sub
critical), It assists the circulation of water, to
overcome the friction losses in Boiler.
Make : Torishima
Type : Single Suction-Double discharge
No of Pumps : Three
Design pressure : 210 kg/cm2(g)
Hydr0 test pressure : 315 kg/cm2(g)
Design Temperature : 366 oC
Motor Rating : 350 KW
Full Load Speed : 1450 rpm
Suction Pressure : 197kg/cm2(g)
Quantity Pumped : 48453 l/min(2850 tph)
Wt. of Motor : 7300 kg
Wt. of Pump casing : 5200 kg
Saturated Steam Circuit
Risers
Sat Steam
Rad Roof Fur Roof SH Roof BP L/R Side

DRUM I/L Hdr Panel O/L Hdr Upp Hdr
SH Conn
Pipes
SH Rear BP Front SH BP BP L/R

BP Front
Roof Lower Lower Side Side Wall
Wall Front Hdr
Tubes Hdr Panel
SH Rear ECO
Junction SH Rear
Support
Hanger
Hdr Int. Hdr
Tube Tube
BP Lower
BP Upper LTSH I/L BP Lower BP Lower
Rear Wall Rear Hdr
Side Rear
Rear Wall Hdr Hdr

Saturated Steam Circulation System
Description Size Design Temp Design Pressure
(DiaXThick) ( 0C) (kg/cm2(g))
(In mm)
Rad Roof Inlet Header 273X50 369 208.8
Fur Roof Panel 57X6.0 414 208.8
Rad Roof O/L Hdr 406.4X55 369 208.2
BP L/R Side I/L. Hdr 368X48 368 208.0
BP L/R Side Panel 63.5X6.3/7.1. 393 208.0

51.0X5.0/5.6
SH BP Lower Side 406.4X60 393 207.4
Front Hdr
SH BP Front Lower Hdr 406.4X60 393 207.4
BP Front Wall 51X5.0/5.6 393 207.4

63.5/6.3
BP Front Hanger Tubes 51X6.3 394 207.4
Monnet Power Company Ltd Contd.. 34

Description Size Design Temp Design Pressure
(DiaXThck) ( 0C) (kg/cm2(g))
(In mm)
SH Rear Roof Panel 51X5 394 206.8
SH Rear Junction Hdr 273X50 395 206.7
BP Rear Upper Wall 51X5 395 206.7
BP Lower Side Rear Hdr 323.9X50 393 206.3
BP Lower Rear Hdr 323.9X45 393 206.3
BP Rear Lower Panel 44.5X5 394 206.3
ECO Support Tubes 44.5X7.1 393 207.4
SH Inter. Hdr 219.1X28 393 207.3
SH Hanger Tubes 51X11 394 207.2
• Total Heating Surface of SH Roof – 830 Sq Mtr

• Total Heating Surface of Steam Cooled Wall – 2010 Sq. Mtr

Superheated Steam Circuit
LTSH
I/L Hdr
LTSH LTSH SH DESH Div SH

Coil O/L Hdr Link I/L Hdr
SH Vertical SH Div SH Div

Div SH
Platen I/L Panel O/L Panelette
Hdr Links O/L Hdr Assy
MS Line
SH Vertical SH Platen HP
Platen Assy O/L Hdr Turbine
MS Line
Super Heater System
O Superheater is a component of a boiler that superheats steam i.e. heats
steam above its saturation temperature. Superheated steam contains
more thermal energy and increases the overall efficiency of the cycle.
O There are 3 stages of Super Heaters – LTSH, Divisional Panelette SH &
Platen Super Heater.
TECHNICAL DATA
No of Sets LTSH-62 Sets, Divisional SH- 24 Sets,

Platen SH – 25 Sets
Total Heating Surface LTSH -10,100 m2, Div SH -2025 m2,

Platen SH – 2200 m2
Total Water Holding Capacity of SH 130 m3

system
Superheater System
(In mm)
LTSH I/L Hdr 323.9X50 395 205.8
LTSH Horizontal 47.63X5.6 445 205.8

Assy.
LTSH Terminal Tube 47.63X5.6 464 205.8

Assy
LTSH O/L Hdr 457.2x65 435 204.2
SH DESH Link 508x60 440 204.0

558x60 426
SH Div I/L Hdr 406.4X60 419 202.8
Monnet Power Company Ltd Contd.. 38

(In mm)
SH Div. Panelette 44.5X5 483/ 202.8
Assy 44.5X7.1 522
Div. SH O/L Hdr 406.4X70 487 198.9
SH Div Panel O/L 508X60 487 198.6

Link
SH Vertical Platen 406.4X60 487 197.4

I/L Hdr
SH Vertical Platen 63.5X6.3/12 476/533 197.4

Assy 51X6.3/11 476/551
SH Platen O/L Hdr 508X110 540 192.2

LTSH COIL

Div SH Panel

Platen SH

Reheater Circuit
CRH
Line From
HP
Turbine
Exhaust
RH O/L Hdr (F)

RH I/L RH Coil
Hdr Assy
RH O/L Hdr (R)
HRH
Line
IP
Turbine

Reheater System
O Reheater is a boiler component in which heat is added to
intermediate-pressure steam, which has lost some of its
energy in expansion through the high-pressure turbine.
O Reheater System comprises of : RH Inlet Header, RH Front
Platen Coil Assy, RH Rear Spaced Assy, RH Outlet Header
TECHNICAL DATA
No of RH Coil Assy 74 Sets (Both Front & Rear)
Total Heating Surface of RH Coils 7628 Sq. Mtr
Total Water Holding Capacity of RH 105 m3
Design Temp. & Pr. at RH Inlet Hdr 361 0C ,52.4 kg/cm2(g)
Design Temp. & Pr. at RH Outlet Hdr 540 0C,52.4 kg/cm2(g)
Size of RH front Coil Assy 63.5 mm Dia X 4 mm Thck
54 mm Dia X 4.5 mm Thck
Size of RH Rear Coil Assy 54 mm Dia X 4.5 mm Thck
RH Coil Assy

H.
R.
M.S C.R.H H
Boiler
Drum
RH
Platen Coil
Assy
SH
DC
LTSH
CC Div SH
Pump
ECO Coil
Furnace Wall
FROM F.C.S
WATER
SATURATED STEAM
SUPER HEATED STEAM
REHEATED STEAM
Bottom Ring Header
Air Flow path
PA Fan FD Fan FD Fan PA Fan
Cold
Cold PA
PA to
SCAPH SCAPH
to Mill
Mill
Pri. Flue Sec Sec. Flue Pri.

Side Gas Side Scanner Side Gas Side
Air fan
APH APH
Hot PA Wind Box Hot PA

to Mill to Mill
Forced Draught Fan
• These fans supply air necessary for fuel combustion for proper
burning of the specific fuel. These are generally axial type.
• The FD fans supply secondary & over fire air, which is preheated in
secondary sector APH.
• Over fire air can be admitted to the furnace through the upper
levels of furnace wind box nozzle to assist in reducing the amount
of NOx formed in furnace.
• Control of airflow to WB is effected by FD fan blade pitch control
& distribution of secondary air to WB compartments is controlled
by secondary air damper.
• Steam Coil Air Pre Heater(SCAPH) are provided in the by pass
ducts before each APH to prevent corrosion of cold end of APH
normally at start up & low load operation.

Suction
Chamber
Blades
Diffuser
Forced Draught Fan
Primary air fan
 These fans supply the air needed to dry & transport coal from
coal mills to the furnace. These fans are generally axial type of
fan.
• To achieve the required temperature at mill inlets(For Proper
Drying of Coal) , part of air(Tempering air) by passes the APH &
is mixed with hot air coming out of APH.
 The PA Fan blade pitch is modulated to maintain a pre

determined pressure in pulveriser hot air bus duct.
 Mill Air flow is maintained by adjusting the hot air regulating

damper while the mill outlet temp is maintained by adjusting the
cold air regulator damper. Venturi is provided in the mill inlet
duct to measure the individual mill air flow.

Suction
Chamber
Diffuser Assy.
Primary Air Fan

1st Stage
Blade
2nd Stage
Blade
Primary Air Fan

Technical specification of Fans
Description Unit PA Fan FD Fan
Make N.A. BHEL BHEL
Type N.A. PAF 19/10.6-2 FAF 23/12.5-1
Motor Rating KW 3600 1200
Capacity M3/Hr 105 215
Speed rpm 1490 990
Pressure mmwc 1290 410
Temp of Medium 0C 50 50
Handled
Bearing N.A. Oil Lubrication(ISO Oil Lubrication(ISO
Lubrication VG68) VG68)

Air Pre Heater
 The purpose of APH is to recover heat from the boiler
flue gas & heat air before another process and so as to
increase the thermal efficiency.
Ljungstrom (Regenerative) Air Pre Heater:
 The basic component of Ljungstrom APH is a continuously
rotating cylinder, called rotor, that is packed with
thousands of square feet of specially formed sheets of heat
transfer surface.
 As the Rotor revolves, waste heat is absorbed from the hot
flue gas passing through one half of the structure. The heat
transfer cycle is continuous as the surface are alternatively
exposed to the outgoing gas & incoming air stream.
Technical Data
Description Value
Type Regenerative, Trisector
No per Boiler Two
Rotor Diameter 6789 mm
Arrangement Vertical
Heating Surface Area 84200 M2
Main Drive 18.5 KW,1500 rpm
Aux. Drive Air Motor with gear box & muffler, Air consumption
8 Nm3/min at pressure 6.33 kg/cm2(g)

Soot blowers
 As the flue gas moves over the heat transfer areas of
boiler, the ash deposits on the heating surfaces. This is
known as soot deposit. Soot Blowers are installed to
blow away these soot deposits to facilitate smooth heat
transfer.
 There are two types of Soot Blowers-Wall Blowers &
Long Retractable Soot Blowers.
 Wall Blowers are used to blow off soots deposited in
water walls in furnace
 LRSB are used in Super Heaters, Economiser &
Reheater Zone.

WALL
BLOWER
LRSB

WALL BLOWER
Technical Data
Description Unit Wall Blower LRSB
No per Boiler No. 88+16(Future) 40+18(Future)
Travel mm 305 9700
Blowing Pressure kg/cm2(g) 11 12.5/10.5
Blowing Steam Temp 0C 383 383
Speed of Travel mpm 6.1 1.55
Speed of Rotary rpm 0.7 5.87
Blowing Rate per group Kg/min 89 152/93/79
Blowing time per group Min 1.4 12.04
Operating time per cycle Min 66 75.12/325.52/100.16
Steam Consumption per cycle Kg 5500 47708
Steam Consumption Kg 62.5 1192
/Cycle/Blower
Total Steam Consumption per Day Kg 159624
Blowing Steam Temp & Pr. 383 0C & 30 kg/cm2
Cycles per Day No 3 3
Blowing Angle Deg.
Monnet Power Company Ltd 3600 3600 61
14 kg/cm2(g)
250 0C
LDO & HFO Circuit
LDO cap.-50m3/hr HFO cap.-50m3/hr Unloading
& Pr.- 2 Kg/cm2
LDO HFO & Pr.- 5 Kg/cm2 Pump
PRS Pumps Pumps
House
4.5 kg/cm2(g)
232 0C
Tanker 1
12KL
Tanker 2
12KL HFO HFO Contd..
Tank #1 Tank #2
3000 m3 3000 m3
Tanker 3
12KL
Tanker 4
12KL
LDO LDO
Tanker 5 Tank#1 Tank#2
1000 m3 1000 m3
12KL
LDO Unloading Header
HFO Unloading Header
Tanker 6 LDO Discharge Line
12KL
HFO Discharge Line
Steam Line to Tanks
Condensate Line to Flash Tank
LDO & HFO Circuit
1x100 % Forwarding Pump House
LDO Pump
LDO Set(Both
Tank Units)
2X1000 m3
HFO Pump
Set(Unit I)
Boiler I Boiler II
HFO 2x100 %
Tank
HFO Pump
Set(Unit
2X3000 m3 II)
HFO
Heater-1
Steam Steam
HFO Tracing Tracing
Line Line
Heater-2
14 kg/cm2(g)
210 0C Aux. Steam
HFO Drain
System
Condensate Line to
Monnet Power Company Ltd Nearest Trench 63
Technical specification of hfo & Ldo
Description Unit LDO HFO
Standard N.A. IS 1460-1974 IS-1593/1971/Gr HV/Oil
Flash Point 0C 66 66
Pumping Temp. 0C 35 55
Firing Temp. 0C 35 120
Viscosity cst 2 to 20 @Firing Temp. 180 at 55 0C
Total Sulphur N.A. 1.8 % by weight 4.5 % by weight
GCV Kcal/kg 10720 10270
Sp. Gravity at 15 0C N.A. 0.85-0.87 0.85-0.95

Technical specification of HFO & LDO Forwarding
Pumps
Description Unit LDO Pump HFO Pump
Make N.A. Alekton Alekton
No of Pump per Blr No 01(Common for 01
Both Unit)
Model No. N.A. DH 330-770-3 DH 600-1400-3 SJ
Capacity at max cst lpm 281(14.3 tph) 879(50.1 tph)
Speed rpm 2920 1450
Suction Pressure kg/cm2(g) -0.5 -0.5
Delivery Pressure kg/cm2(g) 25 30
Motor rating KW 18.5 75
Motor Make N.A. Crompton Greaves Crompton Greaves
Bearing Lubrication N.A. Grease IS 719 Gr.3 Grease IS 719 Gr.3
Pump Efficiency(at min cst) % 78 83.7

TT burners assy.
OVER FIRE AIR
UPPER HFO OIL BURNERS
OVER FIRE AIR Service Ignition of Pulverised Fuel, Stabilization of
LOWER
Coal Flame at lower loads etc.
HH END
AIR Capacity Maximum 30 % MCR
H COAL No of Oil Guns 16(4 per elevation)
GH OIL+AIR Locations Aux air nozzles AB,CD,EF & GH
G COAL HFO flow per Gun 2420 kg/hr(Max), 950 kg/hr(Min)
FG AIR HFO Pressure 10.5 kg/cm2(g)(Max), 4.0 kg/cm2(g)(Min)
F COAL Atm. Steam Flow/Gun 250 kg/Hr
EF OIL+AIR At. Steam Pr. 5.25 kg/cm2(g)
E COAL
DE AIR
D COAL
LDO OIL BURNERS
Service Initial startup & warm-up.
CD OIL+AIR
Capacity Maximum 7.5 % MCR
C COAL
No of Oil Guns 4(In One Elevation)
BC AIR
Locations Aux air nozzle AB
B COAL
LDO flow per Gun 2420 kg/hr(Max), 950 kg/hr(Min)
AB OIL+AIR
LDO Pressure 10.0 kg/cm2(g)(Max), 3.5 kg/cm2(g)(Min)
A COAL
Atm. air Flow/Gun 241 kg/ Hr
END
AIR
AA At. air Pr. 5.25 kg/cm2(g)

Coal Circuit
Coal
To four
From
corners
CHP
Coal of
Bunker Boiler
Feeder Pulveriser

Flue gas path
1404 0C 1150 0C 1040 0C 904 0C 7100C
Combustion Platen RH LTSH

Chamber Div SH
SH Coil Coil
ESP
Pass A
3340C 1270C ID
APH Fan
C
541 0C ESP H
Pass B I
M
Economiser N
ESP
E
Pass C Y
ID
Fan
127 0C
APH ESP
3340C Pass D
Flue Gas Path
-19 mmwc
C
-33 mmwc H
I
M
N
E
-5 mmwc -79 ESP Y
-270 +32
mmwc
-213 mmwc mmwc
mmwc
APH

• Electrostatic Precipitator : An electrostatic
precipitator (ESP) is a highly efficient filtration device
that removes fine particles, like dust and smoke, from a
flowing gas using the force of an induced electrostatic
charge minimally impeding the flow of gases through
the unit.
 No of pass per boiler : 4
 Gas flow at inlet : 566.7 Nm3/s
 Temp. at inlet : 127 0C
 Dust concentration at inlet : 86.8 gm/Nm3 (Worst Coal),
70.69 gm/Nm3 (Design Coal)
 Dust concentration at outlet : 50 mg/Nm3(Worst Coal)
 Efficiency : 99.942 %

 Induced Draught Fan : ID Fans evacuate combustion
products from the boiler furnace by creating sufficient
negative pressure to establish a slight suction in
furnace.
 Make : BHEL
 No per Boiler : Two
 Model No. - NDZV 47 SIDOR
 Fan Regulation : Inlet damper & VFD
 Temp. of Medium : 150 0C
 Motor Rating : 3800 KW
 Flow : 565 m3/Hr
 Draught at Inlet : -270 mmwc
 Draught at Outlet : 32 mmwc
 Bearing Lubrication : Oil Lubrication(ISO VG68)
INDUCED DRAUGHT FAN
Suction
Chamber
Motor
Front
Side
Bearing
Rear
Side Discharge Impeller
Bearing Monnet Power Company Ltd
Chamber 72
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Brief Introduction: Satyakam Mohapatra Engineer (Mechanical)

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Brief Introduction

Monnet Power Company Ltd 1

Monnet Power Company Ltd 3

Type of firing Solid, Liquid & Gas Fired

Type of Circulation Natural Circulation, Natural Assisted or

Draught Natural Draught, Mechanized

Monnet Power Company Ltd 4

Fire Tube Water Tube

Monnet Power Company Ltd 5

Monnet Power Company Ltd 6

AFBC CFBC PC Fired WHRB

Atmospheric Circulating Pulverized Waste Heat

Monnet Power Company Ltd 8

Natural Assisted/Controlled Forced

Density Beyond 175 kg/cm2(g) Mechanical

Monnet Power Company Ltd 9

ECO Drum ECO Drum

Furnace Furnace BCP

Distribution Distribution Economiser

Sub Critical Boiler Super Critical Boiler

Boilers Operating below the Boilers Operating above Critical

Monnet Power Company Ltd 11

Forced Induced Balanced

Monnet Power Company Ltd 12

Boiler Mounting are basically used for safe operation of

Monnet Power Company Ltd 13

the boiler exceeds the working pressure.

boiler & also to act as a non-return valve.

 Pressure Gauge : Pressure gauge indicates the pressure of steam in a boiler.

level in the Drum.

concentration of dissolved solids in boiler water.

from the boiler to Main Steam line.

Monnet Power Company Ltd 17

ECO Feed ECO I/L ECO O/L ECO

Water Wall Water Bottom

Monnet Power Company Ltd 19

Monnet Power Company Ltd

Operating Pressure 197 kg/cm2(g)

Water Holding Capacity 60 m3

Monnet Power Company Ltd

No of Cyclone Separator 92(46X2)

No of Secondary Drier 124

Monnet Power Company Ltd

Taping No Details Qty(In Nos)

Monnet Power Company Ltd

Monnet Power Company Ltd 25

Total Heating Surface of ECO 20,000 Sq. Mtr

Monnet Power Company Ltd 26

ECO Feed Pipe 457.2X50 283 219.7

ECO Inlet Header 508X65 283 215

ECO Coil 38.1X4.5 336 215

ECO Outlet 406.4X60 353 210.8

ECO Link to 368X40 357 210.8

Monnet Power Company Ltd 27

Monnet Power Company Ltd 28

Bottom Ring 914X85 368 212

Monnet Power Company Ltd 30

Monnet Power Company Ltd 31