A Brief Introduction to Industrial boiler. And details about Boiler of Monnet Power Company Ltd(2X525 MW) Thermal Power Plant. Details about parts of Boiler, Water & Steam path, Oil Circuit, flue Gas Circuit.
The document discusses boiler circulation systems and boiling phenomena. It covers:
1) Sub-critical and super-critical boiler systems and different circulation methods like natural, forced, and assisted circulation.
2) Features of boiling like nucleate boiling, critical heat flux, film boiling, and departure from nucleate boiling (DNB).
3) Special features of once-through supercritical boilers including their start-up system using a boiler circulation pump (BCP) to maintain minimum flow during low load conditions.
Hello,
I am trying to explain about Steam Generator (Boiler) in this session, due to length of said presentation, I am deciding to divide it in three parts.
Part 1 cover the “Introduction & Types of Steam Generator”
Part 2 cover about the “Parts of Steam Generator and Its Accessories & Auxiliaries” and
Part 3 cover the “Efficiency & Performance”
The document discusses the HP/LP bypass system used in thermal power stations. The bypass system allows live steam from the boiler to bypass the turbine and be dumped into the condenser. This allows the boiler to continue operating during turbine trips or startup before the turbine is up to temperature. It comprises HP and LP bypass valves, spray valves, and other components. The bypass system cuts startup time, allows boiler operation during trips, and helps match boiler and turbine temperatures for efficient operation.
This document provides information about the boiler drum and its functions:
1. The boiler drum separates steam and water mixtures, stores water, and reduces dissolved solids in steam through blowdown. It contains internals like turbo separators and screen dryers for separation.
2. The drum connects to downcomers, risers, feed lines, and superheater lines. Auxiliary lines include blowdown, chemical dosing, and instrumentation.
3. Proper fitting and alignment of internals is important for efficient steam separation and prevention of impurity carryover into steam.
A boiler is a device that generates steam by transferring heat from burning fuel to water. There are two main types: fire-tube boilers where hot gases pass through tubes surrounded by water, and water-tube boilers where water passes through tubes surrounded by hot gases. Boilers have many applications including power generation, heating, and industrial processes. Key factors in boiler selection include required steam properties, size, cost, and fuel/water availability. Boilers are also classified based on design features such as tube layout, firing method, pressure, and circulation.
The document discusses different types of steam boilers. It describes steam generators/boilers as closed vessels that transfer heat from fuel combustion to water to generate steam. It then summarizes the key components and classifications of boilers, including fire tube vs water tube designs. Specific boiler types are then outlined in more detail, such as the Cochran, Lancashire and Cornish boilers, describing their designs, specifications and working principles.
This document provides an overview of boilers, including their classification, components, and applications. It discusses:
- The basic function of boilers is to produce steam using the thermal energy released from fuel combustion.
- Boilers can be classified based on their tube layout (fire tube vs water tube), axis, furnace location, application, pressure, and water circulation. Common types discussed include fire tube (Cochran, Lancashire), water tube (B&W, Stirling), and locomotive boilers.
- Key requirements for boilers include safety, accessibility, sufficient capacity, efficiency, low cost/maintenance, and ease of starting. Applications include power generation, heating, and industrial processes.
The document discusses boiler circulation systems and boiling phenomena. It covers:
1) Sub-critical and super-critical boiler systems and different circulation methods like natural, forced, and assisted circulation.
2) Features of boiling like nucleate boiling, critical heat flux, film boiling, and departure from nucleate boiling (DNB).
3) Special features of once-through supercritical boilers including their start-up system using a boiler circulation pump (BCP) to maintain minimum flow during low load conditions.
Hello,
I am trying to explain about Steam Generator (Boiler) in this session, due to length of said presentation, I am deciding to divide it in three parts.
Part 1 cover the “Introduction & Types of Steam Generator”
Part 2 cover about the “Parts of Steam Generator and Its Accessories & Auxiliaries” and
Part 3 cover the “Efficiency & Performance”
The document discusses the HP/LP bypass system used in thermal power stations. The bypass system allows live steam from the boiler to bypass the turbine and be dumped into the condenser. This allows the boiler to continue operating during turbine trips or startup before the turbine is up to temperature. It comprises HP and LP bypass valves, spray valves, and other components. The bypass system cuts startup time, allows boiler operation during trips, and helps match boiler and turbine temperatures for efficient operation.
This document provides information about the boiler drum and its functions:
1. The boiler drum separates steam and water mixtures, stores water, and reduces dissolved solids in steam through blowdown. It contains internals like turbo separators and screen dryers for separation.
2. The drum connects to downcomers, risers, feed lines, and superheater lines. Auxiliary lines include blowdown, chemical dosing, and instrumentation.
3. Proper fitting and alignment of internals is important for efficient steam separation and prevention of impurity carryover into steam.
A boiler is a device that generates steam by transferring heat from burning fuel to water. There are two main types: fire-tube boilers where hot gases pass through tubes surrounded by water, and water-tube boilers where water passes through tubes surrounded by hot gases. Boilers have many applications including power generation, heating, and industrial processes. Key factors in boiler selection include required steam properties, size, cost, and fuel/water availability. Boilers are also classified based on design features such as tube layout, firing method, pressure, and circulation.
The document discusses different types of steam boilers. It describes steam generators/boilers as closed vessels that transfer heat from fuel combustion to water to generate steam. It then summarizes the key components and classifications of boilers, including fire tube vs water tube designs. Specific boiler types are then outlined in more detail, such as the Cochran, Lancashire and Cornish boilers, describing their designs, specifications and working principles.
This document provides an overview of boilers, including their classification, components, and applications. It discusses:
- The basic function of boilers is to produce steam using the thermal energy released from fuel combustion.
- Boilers can be classified based on their tube layout (fire tube vs water tube), axis, furnace location, application, pressure, and water circulation. Common types discussed include fire tube (Cochran, Lancashire), water tube (B&W, Stirling), and locomotive boilers.
- Key requirements for boilers include safety, accessibility, sufficient capacity, efficiency, low cost/maintenance, and ease of starting. Applications include power generation, heating, and industrial processes.
The document discusses points related to sub critical and super critical boiler design, including boiler design parameters, chemical treatment systems, operation, feedwater systems, boiler control, and startup curves. It provides explanations of sub critical and super critical boiler technologies, comparing drum type sub critical boilers to drumless super critical boilers. Key differences in operation and response to load changes are highlighted.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
Thermal Power Plant Simulator, Cold, warm and Hot rolling of Steam TurbineManohar Tatwawadi
The presentation describes the cold rolling, warm rolling and hot rolling and synchronising of steam turbine. The Temperature Matching Chart for Turbine metal and Steam is also discussed in the presentation
Unit lightup synchronisation & shutdownNitin Mahalle
This document provides information about the start-up process for a 660 MW power generating unit at Adani Power Limited in Tiroda, India. It discusses the key steps in preparing boiler and turbine systems, warming up and rolling the turbine, synchronizing with the grid, and gradually loading the unit to full power. The start-up involves flushing the boiler, lighting the furnace, warming casings, rolling the turbine to operating speed, switching over steam flows, and cutting in coal mills in stages to ramp up load. Critical parameters are monitored at each stage to ensure safe and efficient start-up of the unit.
The document provides information on protection and interlocks in modern power plants. It discusses various boiler safety protections that detect abnormal conditions like high or low drum level, high steam pressure or temperature. It also describes interlocks that isolate faulty equipment to prevent damage and switch on backup equipment. Specific causes, effects and actions are outlined for issues like drum level high/low, flame failure, boiler feed pump failure, and loss of fans. The protections and interlocks are designed to trip the boiler or isolate equipment in emergencies to maintain continuous and reliable plant operation.
Cooling water is used to remove heat from machines and can be recycled or used once. Recirculating systems use cooling towers or ponds to remove heat. Industrial cooling towers use water sources like rivers as makeup water to replace evaporated water. They continuously circulate water through heat exchangers where heat is absorbed and rejected to the atmosphere through partial water evaporation. Different types of cooling towers exist like natural draft, induced draft, and forced draft towers which vary based on design and how air is moved through the tower. Key components, performance parameters, and maintenance factors of cooling towers are discussed.
The document provides information on different types of boiler systems and their components. It discusses 7 types of boilers - fire tube boiler, water tube boiler, packaged boiler, stoker fired boiler, pulverized fuel boiler, waste heat boiler, and fluidized bed boiler. It provides details on the mechanisms, advantages and disadvantages of each type. It specifically focuses on describing the mechanisms of fluidized bed combustion and the 3 types of fluidized bed combustion systems - atmospheric fluidized bed combustion, pressurized fluidized bed combustion, and circulating fluidized bed combustion.
An air preheater is a heat exchanger that heats incoming combustion air by transferring heat from the flue gases before they are exhausted to the atmosphere. This improves boiler efficiency. There are two main types: recuperative, which uses stationary heat transfer surfaces, and regenerative, which uses rotating heat transfer surfaces. Proper operation and maintenance is important to minimize issues like air leakage, erosion, corrosion, plugging, and fouling that can reduce the air preheater's effectiveness over time. Regular inspection and cleaning helps maintain high performance.
This document discusses various operational aspects and emergencies that can occur in an atmospheric fluidized bed combustion (AFBC) boiler. It outlines important parameters to monitor such as bed height, air pressures, temperatures, and fuel sizes. It then describes several emergency conditions that can happen including low or high drum levels, high furnace pressure, high or low bed/furnace temperatures, tube failures, and flame failures. For each condition, it discusses potential causes, effects on the boiler, and recommended actions to address the problem.
Boiler Water Circulation Pumps
1 SCOPE
2 CHOICE OF TYPE AND NUMBER OF PUMPS
2.1 Need for Continuous Flow
2.2 Pump Reliability
3 CHOICE OF DRIVER
4 DUTY CALCULATIONS
5 CHOICE OF SEAL
5.1 Mechanical Seals
5.2 Soft-packed Glands
5.3 Construction Features
5.4 Guarding
6 CONSTRUCTION FEATURES
6.1 Vertical Glandless Wet-stator Motor Pumps
7 LAYOUT
7.1 Non-return Valves
7.2 Reducers at Pump Connections
7.3 Glandless Pumps for System Pressures
Exceeding 60 bar abs
7.4 Access round Glandless Pumps
7.5 Cooling Water Supply
8 RECOMMENDED LINE DIAGRAMS
8.1 Horizontal Pumps in Category 1
8.2 Vertical Wet-stator Motor Pumps in Category
APPENDICES
A PROPERTIES OF WATER AT THE SATURATION LINE
B ANNEX TO API 610, 6TH EDITION 1981:
VERTICAL GLANDLESS WET-STATOR MOTOR PUMPS
C ANNEX TO API 610, 6TH EDITION 1981:
HORIZONTAL BACK PULL-OUT PUMPS FOR BOILER
WATER CIRCULATION DUTY
FIGURES
3.1 NPSH CORRECTION FOR WATER
3.2 VELOCITY OF SOUND IN WATER AT 50 BAR
(NO BUBBLES)
3.3 VELOCITY OF SOUND IN WATER AT 50 BAR
(WITH 3% VAPOR CONTENT)
8.1 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - CATEGORY 1
8.2 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - SOFT PACKED GLAND INSTALLATION
8.3 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - MECHANICAL SEAL INSTALLATION
8.4 RECOMMENDED LINE DIAGRAM VERTICAL WET STATOR PUMPS - CATEGORY 2
BIBLIOGRAPHY
The document outlines the startup sequence for a CFBC burner. It involves 14 steps: 1) satisfying pre-interlocks, 2) satisfying main interlocks, 3) satisfying purge interlocks, 4) starting purge for 5 minutes, 5) purge completing, 6) resetting MFTs, 7) satisfying gas firing permissives, 8) burners becoming ready for start, 9) starting burner A through 10 automatic commands, and 10) burner A gas firing starting. It provides details on the conditions that must be met at each step.
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
This document discusses fans used in thermal power plants. It describes the main types of fans used - forced draft fans, induced draft fans, primary air fans, and gas recirculation fans. It explains their purposes and characteristics. The key points are: forced draft fans supply air for combustion, induced draft fans exhaust flue gas, primary air fans supply air to coal pulverizers, and gas recirculation fans control steam temperature. Common damage mechanisms for power plant fans are erosion, corrosion, and vibration. Condition monitoring is important to predict failures.
This document provides an overview of boiler fundamentals and best practices. It discusses steam production and uses, steam purity and quality, types of boilers including fire tube, water tube and waste heat boilers. It also covers basic boiler principles, calculations, and internal water treatment programs. Effective internal water treatment is needed to control deposition, corrosion and carryover in boilers. Common treatment programs use polymers and phosphates to precipitate hardness and control sludge through crystal modification and dispersion.
This document provides guidance on diagnosing poor condenser vacuum in thermal power plants. It explains that a slight increase in condenser pressure can result in significant energy losses. It describes the key components and function of a surface condenser, and explains how lower condenser pressure allows more steam turbine exhaust energy to be converted. Diagnosing the root cause of higher pressure involves comparing to expected design pressures and evaluating potential issues like low cooling water flow, tube fouling, incondensable gases in the condenser shell, or excessive heat duty. Definitions of relevant temperature terms are also provided.
Feedwater heaters are used in thermal power plants to pre-heat feedwater and improve cycle efficiency. They extract steam from various turbine stages and use it to heat incoming feedwater in stages. This reduces the amount of heat needed in the boiler and lowers the condenser pressure, improving efficiency. Feedwater heaters come in low-pressure and high-pressure varieties and utilize extracted steam in shell-and-tube or open heat exchangers. Their performance impacts the overall plant heat rate and emissions. Maintaining optimal temperatures and addressing issues like fouling or leaks is important for efficiency.
Boilers produce steam using heat from fuel combustion. Water tube boilers have tubes that carry water and shells that carry hot gases, allowing for higher steam pressures and capacities than fire tube boilers which have tubes that carry hot gases and shells that carry water. Key components of boilers include shells, burners, drums, furnaces, safety valves, and feed pumps. Boilers are classified by their tube configuration and common types include water tube, fire tube, and vertical or horizontal orientations. Water tube boilers have advantages over fire tube in steam generation speed, capacity, efficiency and maintenance access.
A boiler is a closed vessel that heats water or another fluid. Boilers are constructed from low-carbon steel and have corrugated furnaces for strength. On ships, steam is used for heating, powering turbines, pumps, and other machinery. There are different types of boilers classified by their orientation, circulation method, pressure rating, and whether water or hot gases pass through tubes. Fire tube boilers have hot gases passing through tubes surrounded by water while water tube boilers have water passing through tubes surrounded by hot gases. Packaged boilers are self-contained and efficient units that produce steam quickly.
The document discusses points related to sub critical and super critical boiler design, including boiler design parameters, chemical treatment systems, operation, feedwater systems, boiler control, and startup curves. It provides explanations of sub critical and super critical boiler technologies, comparing drum type sub critical boilers to drumless super critical boilers. Key differences in operation and response to load changes are highlighted.
1. Supercritical boilers operate above the critical pressure of water (221 bar), where there is no distinction between water and steam.
2. Operating above the critical pressure provides benefits like higher cycle efficiency, lower fuel consumption and emissions, and improved load change flexibility compared to subcritical boilers.
3. The key difference between subcritical and supercritical boilers is that supercritical boilers are drumless, with evaporation occurring in a single pass and flow induced by the feed pump rather than natural circulation.
Thermal Power Plant Simulator, Cold, warm and Hot rolling of Steam TurbineManohar Tatwawadi
The presentation describes the cold rolling, warm rolling and hot rolling and synchronising of steam turbine. The Temperature Matching Chart for Turbine metal and Steam is also discussed in the presentation
Unit lightup synchronisation & shutdownNitin Mahalle
This document provides information about the start-up process for a 660 MW power generating unit at Adani Power Limited in Tiroda, India. It discusses the key steps in preparing boiler and turbine systems, warming up and rolling the turbine, synchronizing with the grid, and gradually loading the unit to full power. The start-up involves flushing the boiler, lighting the furnace, warming casings, rolling the turbine to operating speed, switching over steam flows, and cutting in coal mills in stages to ramp up load. Critical parameters are monitored at each stage to ensure safe and efficient start-up of the unit.
The document provides information on protection and interlocks in modern power plants. It discusses various boiler safety protections that detect abnormal conditions like high or low drum level, high steam pressure or temperature. It also describes interlocks that isolate faulty equipment to prevent damage and switch on backup equipment. Specific causes, effects and actions are outlined for issues like drum level high/low, flame failure, boiler feed pump failure, and loss of fans. The protections and interlocks are designed to trip the boiler or isolate equipment in emergencies to maintain continuous and reliable plant operation.
Cooling water is used to remove heat from machines and can be recycled or used once. Recirculating systems use cooling towers or ponds to remove heat. Industrial cooling towers use water sources like rivers as makeup water to replace evaporated water. They continuously circulate water through heat exchangers where heat is absorbed and rejected to the atmosphere through partial water evaporation. Different types of cooling towers exist like natural draft, induced draft, and forced draft towers which vary based on design and how air is moved through the tower. Key components, performance parameters, and maintenance factors of cooling towers are discussed.
The document provides information on different types of boiler systems and their components. It discusses 7 types of boilers - fire tube boiler, water tube boiler, packaged boiler, stoker fired boiler, pulverized fuel boiler, waste heat boiler, and fluidized bed boiler. It provides details on the mechanisms, advantages and disadvantages of each type. It specifically focuses on describing the mechanisms of fluidized bed combustion and the 3 types of fluidized bed combustion systems - atmospheric fluidized bed combustion, pressurized fluidized bed combustion, and circulating fluidized bed combustion.
An air preheater is a heat exchanger that heats incoming combustion air by transferring heat from the flue gases before they are exhausted to the atmosphere. This improves boiler efficiency. There are two main types: recuperative, which uses stationary heat transfer surfaces, and regenerative, which uses rotating heat transfer surfaces. Proper operation and maintenance is important to minimize issues like air leakage, erosion, corrosion, plugging, and fouling that can reduce the air preheater's effectiveness over time. Regular inspection and cleaning helps maintain high performance.
This document discusses various operational aspects and emergencies that can occur in an atmospheric fluidized bed combustion (AFBC) boiler. It outlines important parameters to monitor such as bed height, air pressures, temperatures, and fuel sizes. It then describes several emergency conditions that can happen including low or high drum levels, high furnace pressure, high or low bed/furnace temperatures, tube failures, and flame failures. For each condition, it discusses potential causes, effects on the boiler, and recommended actions to address the problem.
Boiler Water Circulation Pumps
1 SCOPE
2 CHOICE OF TYPE AND NUMBER OF PUMPS
2.1 Need for Continuous Flow
2.2 Pump Reliability
3 CHOICE OF DRIVER
4 DUTY CALCULATIONS
5 CHOICE OF SEAL
5.1 Mechanical Seals
5.2 Soft-packed Glands
5.3 Construction Features
5.4 Guarding
6 CONSTRUCTION FEATURES
6.1 Vertical Glandless Wet-stator Motor Pumps
7 LAYOUT
7.1 Non-return Valves
7.2 Reducers at Pump Connections
7.3 Glandless Pumps for System Pressures
Exceeding 60 bar abs
7.4 Access round Glandless Pumps
7.5 Cooling Water Supply
8 RECOMMENDED LINE DIAGRAMS
8.1 Horizontal Pumps in Category 1
8.2 Vertical Wet-stator Motor Pumps in Category
APPENDICES
A PROPERTIES OF WATER AT THE SATURATION LINE
B ANNEX TO API 610, 6TH EDITION 1981:
VERTICAL GLANDLESS WET-STATOR MOTOR PUMPS
C ANNEX TO API 610, 6TH EDITION 1981:
HORIZONTAL BACK PULL-OUT PUMPS FOR BOILER
WATER CIRCULATION DUTY
FIGURES
3.1 NPSH CORRECTION FOR WATER
3.2 VELOCITY OF SOUND IN WATER AT 50 BAR
(NO BUBBLES)
3.3 VELOCITY OF SOUND IN WATER AT 50 BAR
(WITH 3% VAPOR CONTENT)
8.1 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - CATEGORY 1
8.2 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - SOFT PACKED GLAND INSTALLATION
8.3 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - MECHANICAL SEAL INSTALLATION
8.4 RECOMMENDED LINE DIAGRAM VERTICAL WET STATOR PUMPS - CATEGORY 2
BIBLIOGRAPHY
The document outlines the startup sequence for a CFBC burner. It involves 14 steps: 1) satisfying pre-interlocks, 2) satisfying main interlocks, 3) satisfying purge interlocks, 4) starting purge for 5 minutes, 5) purge completing, 6) resetting MFTs, 7) satisfying gas firing permissives, 8) burners becoming ready for start, 9) starting burner A through 10 automatic commands, and 10) burner A gas firing starting. It provides details on the conditions that must be met at each step.
Water steam Circuit in Supercritical Boiler for 660MW Power PlantHareesh VS
An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM
This document discusses fans used in thermal power plants. It describes the main types of fans used - forced draft fans, induced draft fans, primary air fans, and gas recirculation fans. It explains their purposes and characteristics. The key points are: forced draft fans supply air for combustion, induced draft fans exhaust flue gas, primary air fans supply air to coal pulverizers, and gas recirculation fans control steam temperature. Common damage mechanisms for power plant fans are erosion, corrosion, and vibration. Condition monitoring is important to predict failures.
This document provides an overview of boiler fundamentals and best practices. It discusses steam production and uses, steam purity and quality, types of boilers including fire tube, water tube and waste heat boilers. It also covers basic boiler principles, calculations, and internal water treatment programs. Effective internal water treatment is needed to control deposition, corrosion and carryover in boilers. Common treatment programs use polymers and phosphates to precipitate hardness and control sludge through crystal modification and dispersion.
This document provides guidance on diagnosing poor condenser vacuum in thermal power plants. It explains that a slight increase in condenser pressure can result in significant energy losses. It describes the key components and function of a surface condenser, and explains how lower condenser pressure allows more steam turbine exhaust energy to be converted. Diagnosing the root cause of higher pressure involves comparing to expected design pressures and evaluating potential issues like low cooling water flow, tube fouling, incondensable gases in the condenser shell, or excessive heat duty. Definitions of relevant temperature terms are also provided.
Feedwater heaters are used in thermal power plants to pre-heat feedwater and improve cycle efficiency. They extract steam from various turbine stages and use it to heat incoming feedwater in stages. This reduces the amount of heat needed in the boiler and lowers the condenser pressure, improving efficiency. Feedwater heaters come in low-pressure and high-pressure varieties and utilize extracted steam in shell-and-tube or open heat exchangers. Their performance impacts the overall plant heat rate and emissions. Maintaining optimal temperatures and addressing issues like fouling or leaks is important for efficiency.
Boilers produce steam using heat from fuel combustion. Water tube boilers have tubes that carry water and shells that carry hot gases, allowing for higher steam pressures and capacities than fire tube boilers which have tubes that carry hot gases and shells that carry water. Key components of boilers include shells, burners, drums, furnaces, safety valves, and feed pumps. Boilers are classified by their tube configuration and common types include water tube, fire tube, and vertical or horizontal orientations. Water tube boilers have advantages over fire tube in steam generation speed, capacity, efficiency and maintenance access.
A boiler is a closed vessel that heats water or another fluid. Boilers are constructed from low-carbon steel and have corrugated furnaces for strength. On ships, steam is used for heating, powering turbines, pumps, and other machinery. There are different types of boilers classified by their orientation, circulation method, pressure rating, and whether water or hot gases pass through tubes. Fire tube boilers have hot gases passing through tubes surrounded by water while water tube boilers have water passing through tubes surrounded by hot gases. Packaged boilers are self-contained and efficient units that produce steam quickly.
A boiler is a closed vessel that heats water or another fluid using combustion of fuels like wood, coal, oil, or gas. The heated fluid exits the boiler for use in processes or heating applications. There are different types of boilers including fire-tube boilers where hot gases pass through tubes in the boiler, water-tube boilers where water circulates in externally heated tubes, and flash boilers which rapidly vaporize water into steam. Boilers can be made of materials like steel, iron, or copper and come in configurations such as pot, fire-tube, water-tube, and sectional designs.
This document discusses boilers and boiler draught. It defines a boiler as a closed vessel that converts water into steam under pressure. It explains that boilers come in two types - fire tube boilers and water tube boilers, depending on whether the flame and hot gases pass through tubes surrounded by water (fire tube) or whether water circulates through tubes surrounded by hot gases (water tube). It also defines draught as the pressure difference needed to move air through the fuel bed and hot gases out of the boiler/chimney. Draught can be natural, using chimney height, or artificial using forced or induced fans. Artificial draught allows for higher pressure, better combustion control and efficiency than natural draught.
The document describes the key systems of a boiler, including the water and steam system, air/furnace/flue gas system, fuel system, ash system, and utility systems. It provides details on components like the deaerator, boiler feedwater pump, steam drum, superheater, furnace, sootblower, electrostatic precipitator, induced draft fan, and related conveyors, valves, transmitters and more.
An economiser is a device that increases the temperature of feed water using waste heat from flue gases leaving the boiler. It consists of vertical cast iron or steel pipes through which feed water flows and is heated by hot flue gases passing over the pipes. This preheats the feed water, reducing fuel consumption and increasing boiler efficiency. However, economisers also cause a pressure drop in flue gases. An air preheater similarly uses waste heat to preheat combustion air entering the furnace, improving combustion and efficiency but requiring forced draught.
Try to explain about the steam generator (boiler), it has three parts. Part 1 cover the types, part 2 about its parts & auxiliaries & accessories and part 3 about performance.
The document describes the key components of a boiler system. It discusses 7 essential boiler mountings: 1) water level indicator, 2) main steam stop valve, 3) pressure gauge, 4) feed check valve, 5) fusible plug, 6) blow down valve, and 7) safety valve. It then provides more detailed descriptions and diagrams of the blow down valve, fusible plug, feed check valve, water level indicator, main steam stop valve, pressure gauge, and safety valve, explaining their purposes and functions within the boiler system.
This document provides information about boilers, including:
1. It defines what constitutes a boiler according to Indian law and defines related terms like boiler components and steam pipes.
2. It describes the basic systems that make up a boiler system, including the water treatment, fuel supply, air supply, and flue gas systems.
3. It lists different types of fuels that can be used in boilers and describes the main types of boilers, including fire tube, water tube, packaged, stoker fired, pulverized fuel, waste heat, and fluidized bed boilers.
ABSTRACT
Heat/light/electrical energy is out today’s necessity and has scarcity also. Energy conservation is key requirement of any industry at all times.
In general, industries use heat energy for conservation of raw material to finished product. The source of heat energy is generally saturated or super heated steam. The steam generation is common use one boiler with carity of fuels. Whatever may be the fuel the generation should be as economy as possible which adds to the product cost. Further the usage of steam and recycling steam condensate back to boiler is an art depending on plant layouts.
In this project the steam generator is water tube boiler fired with rice husk. The steam is transferred to the tyre/tube moulds where tyres/tubes are cured while the heat is rejected to the tyres the condensate forms and this condensate is put back to the boiler. While doing so the steam is also stopped back to boiler without rejecting complete heat to the product. This gets flashed into atmosphere at feed water tank. The science of separation of condensate from steam saves energy. Better the separation more the fuel conservation.
In the steam generator the fuel is burnt to heat the water and form steam. This fuel burnt flue gas carries lot of energy, out through chimney. Prior to exhausting through the heat left in flue need to be recovered, through heat recovery mechanisms’. In this project an air-preheater condensate heat recovery unit is the major energy consuming station.
This document discusses natural draught systems used in power plant boilers. It defines draught as the pressure difference needed to maintain air and gas flow through a boiler. Natural draught uses the density difference between hot flue gases in a chimney and cold outside air to create this pressure. The document estimates the height and diameter of a chimney needed using formulas involving gas temperature, air temperature, and flow rates. It also discusses conditions for maximum discharge through a chimney and the low efficiency of natural draught systems. Advantages include low cost and maintenance while limitations include dependence on atmospheric conditions and inability to increase draught during peak loads.
1. Steam boilers can be classified based on their orientation, tube configuration, firing method, circulation type, pressure, portability, and number of tubes. Common types include fire tube boilers like Cochran and water tube boilers like Babcock & Wilcox.
2. Boilers have various components like shells, tubes, furnaces, and mountings. Accessories like economizers and air preheaters are used to increase efficiency.
3. Modern high pressure boilers like once-through designs operate at supercritical pressures and temperatures but require high purity feedwater and advanced materials.
The document discusses high pressure boilers used in thermal power plants. It describes the Rankine cycle used to generate electricity from heat energy. In the Rankine cycle, water is pumped to high pressure, heated to become steam, expanded through a turbine to produce work, and condensed back into a liquid. The key components of a thermal power plant that use this cycle are boilers, steam turbines, condensers, and feed pumps. Several types of high pressure boilers are then outlined, including fire-tube, water-tube, Benson, Velox, and Loeffler boilers, explaining their unique designs and advantages over conventional boilers.
This presentation provides an overview of boilers. It defines a boiler as a vessel that heats water to produce hot water or steam. The presentation describes the basic principle of operation where hot gases produced from burning fuel transfer heat to water inside the boiler vessel. It then discusses the main types of boilers, including fire tube and water tube boilers, and describes their key characteristics and differences. Examples are given of commonly used boiler designs like Babcock and Wilcox, pulverized fuel, and fluidized bed boilers. Factors for selecting an appropriate boiler based on requirements are also summarized.
The document provides information about the Farakka Super Thermal Power Station (FSTPS) located in West Bengal, India. It discusses the key details of the power station including its 1600MW capacity from 5 generation units commissioned between 1986-1994. The power station uses coal from the nearby Rajmahal coalfields and water from the Farakka feeder canal. It supplies power to West Bengal and neighboring states. The document also provides an overview of the coal handling process and steam generation process used at the power station.
boiler accessories, basics of economizer, types of economizer, air preheater, types of air preheater, reheater, basics of superheater, types of superheater.
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Husk based power plant 6 t 32 kg fbc with single stage turbine for finance,...Radha Krishna Sahoo
This document provides an offer from Industrial Boilers Ltd for a high pressure husk fired fluidized bed combustion boiler and back pressure steam turbine system for a rice mill. It includes design parameters for the 6000 kg/hr boiler such as a steam pressure of 32 kg/cm2. It also lists the scope of supply for the boiler and its components as well as exclusions such as civil works and insulation. Annexures provide further details on the boiler, turbine, commercial offer, and terms and conditions.
The document provides information about the Sanjay Gandhi Thermal Power Station located in Birsinghpur, India. It has a total installed capacity of 1340 MW distributed across 5 units ranging from 210-500 MW each. The power plant uses coal as its primary fuel sourced from local mines via rail. Water for the plant is sourced from the nearby Johila River and Dam. The plant has conventional systems for coal handling, steam generation in the boiler, power generation in the turbine, and effluent management. It provides key specifications and details of the various units and systems to run the thermal power generation process.
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This presentation report describes about steam boiler,classification of boiler ,boiler mounting,
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How to improve the efficiency of water tube boilerMd Rabiul Hasan
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A Brief Introduction to Boilers
1. Brief Introduction
1
SatyakamMohapatra
Engineer(Mechanical)
Monnet Power Company Ltd
2. 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;
Monnet Power Company Ltd 2
3. 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.
Monnet Power Company Ltd 3
4. 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)
Monnet Power Company Ltd 4
5. Content of Tubes
Fire Tube Water Tube
In fire tube boiler hot flue
gas will be moved inside the
tubes & water outside the
tube.
In fire tube boiler mode of
firing is generally internally
fired.
In fire tube boiler operating
pressure limited to 25 kg/cm²
In water tube boiler
water will be moved
inside the tube & hot flue
gases outside the tubes.
Mode of firing is
externally fired.
Operating pressure can
exceed 125 kg/cm² or
more
Monnet Power Company Ltd 5
7. Type of Firing
Solid Liquid Gas
AFBC CFBC PC Fired WHRB
Atmospheric
Fluidized Bed
Combustion
Bed Material Used
– Crushed
Refractory( + 0.8
mm to -2.8 mm)
Velocity – 3-5
m/sec
Coal – F-Grade,
Washery Reject
Combustion Eff-
80-85%
Circulating
Fluidized Bed
Combustion
Bed Material Used -
Crushed Refractory (
+ 0.8 mm to -2.8 mm)
Velocity – 7-8 m/s.
Coal – F-Grade,
Washery Reject
Combustion Eff.-
95 %
Waste Heat
Recovery Boiler
Waste Heat
from Flue Gas
of Other
process used in
boiler for Steam
generation
Pulverized
Coal Fired
Boiler.
Coal : F
Grade(3000-
3500 Kcal/Kg)
Size is 65μto
80μ.
No Bed is
Required
Combustion
Eff : 99 %
Monnet Power Company Ltd 7
9. Type of Circulation
Natural
Circulation
Forced
Circulation
Assisted/Controlled
Circulation
Density
Difference is the
driving force.
Limited to boiler
with drum
operating
pressure around
175 kg/cm2(g).
Mechanical
pumps are used to
over come the
frictional losses
Operating
pressure is above
224.6 kg/cm2(g)
Beyond 175 kg/cm2(g)
pressure in a re circulation
system, circulation through
the evaporator is to be
assisted with mechanical
pumps to overcome
frictional losses in the
tubes. A pump called boiler
circulation pump will be
placed in the down comer
between the Drum & water
wall ring header to do this
function is called
controlled circulation.
Monnet Power Company Ltd 9
10. SH
ECO Drum ECO
Drum
SH
Furnace
Wall
Furnace
Wall
Distribution
Header
Distribution
Header
CC
Pump
Natural
Circulation
SH
Forced Circulation
Assisted
Circulation
BCP
Economiser
WW
Separator
Water
from
Feed
Station
Monnet Power Company Ltd 10
11. Steam Pressure
Sub Critical Boiler Super Critical Boiler
Boilers Operating below the
Critical Pressure(224.6
kg/cm2(g)).
These are recirculation type or
once through .
Steam Drum is required to
separate water & steam.
Boilers Operating above Critical
Pressure (224.6 kg/cm2(g)) &
Critical Temp (374 0C)
These are only Once Through
Type.
Drum is not required as cycle
medium is a single phase fluid
having homogenous property.
Monnet Power Company Ltd 11
12. DRAUGHT
Natural Draught Mechanized Draught
The draught
required for the flow
of air & gas inside
the boiler is created
by chimney alone
Forced Induced Balanced
Here Fans are
used to draw air
from atmosphere
& push into the
furnace.
The entire boiler
will be kept
above
atmospheric
pressure
Fans installed at
the outlet of
boiler, evacuate
the gases from
furnace. So a
negative Pr. Is
developed in
furnace & air from
atmosphere enters
the furnace
Both Forced
& Induced
draught fans
are used to
derive the
benefits of
both systems.
Monnet Power Company Ltd 12
13. 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.
Monnet Power Company Ltd 13
14. 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.
Monnet Power Company Ltd 14
15. Maker : Bharat Heavy Electricals Ltd
BoilerMaker No : 0675,0676
Type : Controlled Circulation, Sub Critical, Two Pass, Single Reheat,
Balance draught,Tangential PC Fired.
Boiler Rating : 51793m2
Boiler Drum Design Pressure : 210 kg/cm2(g)
Boiler Hydrotest Pressure : 315 kg/cm2(g) ,(For RH-78 kg/cm2(g) )
Boiler DrumDesignTemp : 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
Steampressure 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: Monnet P8o6we%r Company Ltd 15
16. 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.
Monnet Power Company Ltd 16
19. Water Circuit
ECO Feed
Pipe
ECO I/L
Header
ECO Coil
ECO O/L
Header
ECO
Link
DRUM
Down
Comer
Bottom
Ring
Header
Water
Wall
Tubes
Water Wall
Outlet
Headers
Feed
Water
Station
Monnet Power Company Ltd 19
20. 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 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 water dissolved solid
concentration.
Treatment of Boiler Water by chemicals
Monnet Power Company Ltd
20
21. 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
(Straight Portion/Dished Portion)
155 mm
Monnet Power Company Ltd
Weight of Drum without Internals 214.7 MT 21
22. Feed
Nozzle
DC
Nozzle
Safety
Valve
Stub
SH
Conn
Pipe
Stubs
Riser
Stub
1
2
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
5 DWLG & EWLI 15 (Both Side)
6 CBD 1
3
4
5
6
Monnet Power Company Ltd
22
23. 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.
Monnet Power Company Ltd
23
24. Turbo
Separator
(2X46)
Drum Internals of MPCL Boiler
Separating
Chamber
Drier Assembly(62X2)
Feed Header
Feed Nozzle
DC Nozzle Monnet Power Company Ltd
24
26. 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 System
20,000 Sq. Mtr
Total Water Holding
Capacity
150 m3
Monnet Power Company Ltd 26
27. Description Size
(DiaXThick)
(In mm)
Design Temp( 0C) Design Pressure
(kg/cm2(g))
ECO Feed Pipe 457.2X50 283 219.7
ECO Inlet Header 508X65 283 215
ECO Coil 38.1X4.5 336 215
ECO Outlet
Header
406.4X60 353 210.8
ECO Link to
Drum
368X40
323.9X36
357 210.8
Monnet Power Company Ltd 27
29. 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 Hdr
3680C & 212 kg/cm2(g)
Design Temp & Pr. at WW
Outlet Hdr
3680C & 209 kg/cm2(g)
Total Heating Surface of WW
Tubes
7000 Sq.Mtr
Water Holding Capacity of
Circulating System
170 m3
Monnet Power Company Ltd 29
30. Description Size
(DiaXThck)
(In mm)
Design Temp( 0C) Design Pressure
(kg/cm2(g))
Down Comer 368X36 368 212
Bottom Ring
Header
914X85 368 212
WW Tubes 51X5.6/6.0/7.1
63.5X7.1
396 214
Front, Hanger Tube &
Screen Tube O/L
Header
273X40 368 209
Side WW O/L
Header
273X50 368 209
Riser Pipes 159X18 368 209
Monnet Power Company Ltd 30
31. WW
Panels
Div
SH
Panel
Platen
SH
Monnet Power Company Ltd 31
32. 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
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33. Saturated Steam Circuit
Sat Steam
DRUM
Rad Roof
SH Conn I/L Hdr
Pipes
Fur Roof
Panel
SH Roof
O/L Hdr
BP L/R Side
Upp Hdr
BP L/R
Side Wall
Panel
SH BP
Lower Side
Front Hdr
BP Front
Lower
Hdr
BP Front
Wall
SH Rear
Roof
Tubes
Junction
Hdr
BP Upper
Rear Wall
ECO
Support
Tube
SH Rear
Int. Hdr
SH Rear
Hanger
Tube
LTSH I/L
Hdr
BP Lower
Side Rear
Hdr
BP Lower
Rear Hdr
BP Lower
Rear Wall
Risers
Monnet Power Company Ltd 33
34. Saturated Steam Circulation System
Description Size
(DiaXThick)
(In mm)
Design Temp
( 0C)
Design Pressure
(kg/cm2(g))
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.
51.0X5.0/5.6
393 208.0
SH BP Lower Side
Front Hdr
406.4X60 393 207.4
SH BP Front Lower Hdr 406.4X60 393 207.4
BP Front Wall 51X5.0/5.6
63.5/6.3
393 207.4
BP Front Hanger Tubes 51X6.3 394 207.4
Monnet Power Company Ltd Contd.. 34
35. Description Size
(DiaXThck)
(In mm)
Design Temp
( 0C)
Design Pressure
(kg/cm2(g))
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
Monnet Power Company Ltd 35
36. Superheated Steam Circuit
LTSH
I/L Hdr
LTSH
Coil
SH DESH
Link
Div SH
I/L Hdr
LTSH
O/L Hdr
SH Div
Panelette
Assy
Div SH
O/L Hdr
SH Div
Panel O/L
Links
SH Vertical
Platen I/L
Hdr
SH Vertical
Platen Assy
SH Platen
O/L Hdr
MS Line
HP
Turbine
MS Line
Monnet Power Company Ltd 36
37. 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
system
130 m3
Monnet Power Company Ltd 37
38. Superheater System
Description Size
(DiaXThick)
(In mm)
Design Temp( 0C) Design Pressure
(kg/cm2(g))
LTSH I/L Hdr 323.9X50 395 205.8
LTSH Horizontal
Assy.
47.63X5.6 445 205.8
LTSH Terminal Tube
Assy
47.63X5.6 464 205.8
LTSH O/L Hdr 457.2x65 435 204.2
SH DESH Link 508x60
558x60
440
426
204.0
SH Div I/L Hdr 406.4X60 419 202.8
Monnet Power Company Ltd Contd.. 38
39. Description Size
(DiaXThick)
(In mm)
Design Temp( 0C) Design Pressure
(kg/cm2(g))
SH Div. Panelette
Assy
44.5X5
44.5X7.1
483/
522
202.8
Div. SH O/L Hdr 406.4X70 487 198.9
SH Div Panel O/L
Link
508X60 487 198.6
SH Vertical Platen
I/L Hdr
406.4X60 487 197.4
SH Vertical Platen
Assy
63.5X6.3/12
51X6.3/11
476/533
476/551
197.4
SH Platen O/L Hdr 508X110 540 192.2
Monnet Power Company Ltd 39
43. Reheater Circuit
RH I/L
Hdr
RH Coil
Assy
RH O/L Hdr (R)
From
HP
Turbine
Exhaust
CRH
Line
HRH
Line
IP
Turbine
RH O/L Hdr (F)
Monnet Power Company Ltd 43
44. 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
Monnet Power Company Ltd 44
46. WATER
SATURATED STEAM
SUPER HEATED STEAM
REHEATED STEAM
M.S
H.
R.
C.R.H H
FROM F.C.S
CC
Pump
Div SH
Platen
SH
RH
Coil
Assy
ECO Coil
Boiler
Drum
DC
Furnace Wall
Bottom Ring Header
LTSH
Monnet Power Company Ltd 46
47. Air Flow path
PA Fan FD Fan FD Fan PA Fan
Pri.
Side
Sec
Side
APH
SCAPH SCAPH
Hot PA Wind Box
to Mill
Hot PA
to Mill
Cold
PA
to
Mill
Cold
PA
to
Mill
Scanner
Air fan
Flue
Gas
Sec.
Side
Pri.
Side
Flue
Gas
APH
Monnet Power Company Ltd 47
48. 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.
Monnet Power Company Ltd 48
51. 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.
Monnet Power Company Ltd 51
53. 1st Stage
Blade
2nd Stage
Blade
Primary Air Fan
Monnet Power Company Ltd 53
54. 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
Lubrication
N.A. Oil Lubrication(ISO
VG68)
Oil Lubrication(ISO
VG68)
Monnet Power Company Ltd 54
55. 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.
Monnet Power Company Ltd 55
57. 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)
Monnet Power Company Ltd 57
58. 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.
Monnet Power Company Ltd 58
61. 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. 3600 3600
Monnet Power Company Ltd 61
62. LDO & HFO Circuit
14 kg/cm2(g)
Tanker 1
12KL
Tanker 2
12KL
Tanker 3
12KL
Tanker 4
12KL
Tanker 5
12KL
Tanker 6
12KL
HFO
Tank #1
3000 m3
HFO
Tank #2
3000 m3
LDO
Tank#1
1000 m3
LDO
Tank#2
1000 m3
LDO
Pumps
HFO
Pumps
Unloading
Pump
House
Contd..
LDO Unloading Header
HFO Unloading Header
LDO Discharge Line
HFO Discharge Line
Steam Line to Tanks
PRS
250 0C
4.5 kg/cm2(g)
232 0C
Condensate Line to Flash Tank
62
LDO cap.-50m3/hr
& Pr.- 2 Kg/cm2
HFO cap.-50m3/hr
& Pr.- 5 Kg/cm2
Monnet Power Company Ltd
63. LDO & HFO Circuit
LDO
Tank
HFO
Tank
1x100 %
LDO Pump
Set(Both
Units)
HFO Pump
Set(Unit I)
HFO Pump
Set(Unit
II)
HFO
Heater-1
HFO
Heater-2
HFO Drain
System
Boiler I Boiler II
Condensate Line to
Nearest Trench
Aux. Steam
2X1000 m3
2X3000 m3
14 kg/cm2(g)
210 0C
2x100 %
63
Forwarding Pump House
Steam
Tracing
Line
Steam
Tracing
Line
Monnet Power Company Ltd
64. 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
Monnet Power Company Ltd 64
65. 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
Both Unit)
01
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
Monnet Power Company Ltd 65
66. TT burners assy.
UPPER HFO OIL BURNERS
END
AIR
COAL
OIL+AIR
COAL
AIR
COAL
OIL+AIR
COAL
AIR
COAL
OIL+AIR
COAL
AIR
COAL
OIL+AIR
COAL
END
AIR
OVER FIRE AIR
OVER FIRE AIR
LOWER
HH
H
GH
G
FG
F
EF
E
DE
D
CD
C
BC
B
AB
A
AA
Service Ignition of Pulverised Fuel, Stabilization of
Coal Flame at lower loads etc.
Capacity Maximum 30 % MCR
No of Oil Guns 16(4 per elevation)
Locations Aux air nozzles AB,CD,EF & GH
HFO flow per Gun 2420 kg/hr(Max), 950 kg/hr(Min)
HFO Pressure 10.5 kg/cm2(g)(Max), 4.0 kg/cm2(g)(Min)
Atm. Steam Flow/Gun 250 kg/Hr
At. Steam Pr. 5.25 kg/cm2(g)
LDO OIL BURNERS
Service Initial startup & warm-up.
Capacity Maximum 7.5 % MCR
No of Oil Guns 4(In One Elevation)
Locations Aux air nozzle AB
LDO flow per Gun 2420 kg/hr(Max), 950 kg/hr(Min)
LDO Pressure 10.0 kg/cm2(g)(Max), 3.5 kg/cm2(g)(Min)
Atm. air Flow/Gun 241 kg/ Hr
At. air Pr. 5.25 kg/cm2(g)
Monnet Power Company Ltd 66
67. Coal Circuit
Coal
Bunker
Pulveriser
To four
corners
of
Boiler
Coal
From
CHP
Feeder
Monnet Power Company Ltd 67
68. Combustion
Chamber Div SH
Platen
SH
RH
Coil
LTSH
Coil
Economiser
APH
APH
ESP
Pass A
ESP
Pass B
ESP
Pass C
ESP
Pass D
ID
Fan
ID
Fan
C
H
I
M
N
E
Y
Flue gas path
1404 0C 1150 0C 1040 0C 904 0C 7100C
541 0C
1270C
3340C
3340C
127 0C
Monnet Power Company Ltd 68
69. -79
mmwc
APH
C
H
I
M
N
E
Y
Flue Gas Path
-19 mmwc
-33 mmwc
-5 mmwc ESP
-213
mmwc
-270
mmwc
+32
mmwc
Monnet Power Company Ltd 69
70. • 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 %
Monnet Power Company Ltd 70
71. 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)
Monnet Power Company Ltd 71
72. Suction
Chamber
Discharge
Chamber
Motor
Impeller
Rear
Side
Bearing
Front
Side
Bearing
INDUCED DRAUGHT FAN
Monnet Power Company Ltd 72