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BOILER AND ITS AUXILIARIES

NTPC KORBA

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 CONTENTS
 Introduction
 Types of Boiler
 Fire and Water Tube boiler
 Natural and Forced circulation Boiler
 Boiler Mountings
 Boiler accessories
 Boiler auxiliaries and its system

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INTRODUCTION
a) Steam for power generation

 As per Indian Boiler Regulations(IBR) act

1923, “Boiler” means any closed vessel
exceeding 22.75 litres (five gallons) in
capacity which is used expressly for
generating steam under pressure and includes
any mounting or other fitting attached to such
vessel, which is wholly or partly under
pressure when steam is shut off.

 Broadly speaking, a boiler is a device used for

generating :-
 Steam for power generation
 Hot water for heating purpose
a) g purpose

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WORKING OF A BOILER
 Boiler works on the same principle as
water is boiled in a closed vessel.
 Due to heat, water is converted to steam at
a certain pressure and temp.
 This steam can be used for various
industries for ex:-
 Thermal power plant
 Sugar mills
 Textiles

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USE OF BOILER IN THERMAL POWER PLANT

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 STEAM BOILER EFFICIENCY

Steam boiler efficiency depends upon the size of boiler used.

 A typical efficiency of steam boiler is 80% to 88%.

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RIMARY REQUIREMENTS OF BOILER

 The primary requirements of steam generators or boilers are:

 
The primaryTherequirements
primary requirements
of steam generators
of steam or
generators
boilers or boilers
are:
1. The waterare:
must be contained safely
2. The steam must be delivered safely in desired conditions as regards its
a) Thepressure,
water temperature,
a) must
The water quality
be contained
must and required
besafely
contained safelyrate
b) The steam
b) must
The steam
be delivered
must besafely
delivered
in desired
safelyconditions
in desired conditions
as regards its
aspressure,
regards its
temperature,
pressure, temperature,
quality and quality and
required rate
required rate

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Copyright © 2016 Your Company All Rights Reserved. 8
CLASSIFICATION OF STEAM BOILERS

Though there are many classifications of steam boilers, yet the following are important.
1. ACCORDING TO THE CONTENTS IN THE TUBE:
a) fire tube or smoke tube boiler
b) water tube boiler.

2. ACCORGING TO POSITION OF FURNACE:

a) Internally fired boilers

b) Externally fired boilers

3. ACCORDING TO AXIS OF FURNACE:

a) Vertical boilers

b) Horizontal boilers

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 4. ACCORDING TO NUMBER OF TUBES:
a) Single tube boilers
b) Multi tube boilers

5. ACCORDING TO METHOD OF CIRCULATION OF WATER:

c) Natural circulation boilers
d) Forced circulation boilers

6. ACCORDING TO THE USE

e) Stationary boilers
f) Mobile boilers

7. ACCORDING TO HEAT SOURCE

 Coal
 Gas
 Nuclear etc

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FACTORS AFFECTING THE CHOICE OF
BOILER
The selection of type and size of a steam boiler depends upon the following factors:
The selection of type and size of a steam boiler depends upon the following factors:
 The power required and the working pressure
 The power required and the working pressure
 Geographical
 Geographical position
positionofofthe
theplant
plant
 Availability
 Availabilityofoffuel
fuel
 Supply and
Supply and quality
quality of
offeed
feedwater
water
 The probable load
load factor
factor

 Space
Space available
available
 Labour available
 Labour available
 Adaptability to the type of furnace and stoker
 Adaptability
 Steam pressureto thesuperheat
and type of desired
furnace and stoker

 Steam and
Nature pressure andofsuperheat
intensity draught desired
 Nature and intensity of draught

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FIRE AND WATER TUBE BOILERS

FIRE-TUBE BOILER WATER-TUBE BOILER

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 FIRE-TUBE BOILER
 Combustion gasses passes through inside of tube and water surrounding
it.
 Fuel is burnt in firebox to produce combustion gasses
 Hot gasses flowing in firetube heat the water and produce saturated
steam
 Steam rises to highest point of boiler steam dome where it is collected
 Some examples include:-Cornish boiler, Lanchasire boiler, Locomotive
boiler etc.

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EXAMPLE: LOCOMOTIVE BOILER

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 WATER-TUBE BOILER
 Exact opposite of fire-tube boiler.
 Water flowing inside tube is externally heated by fire
 Fuel is burnt inside furnace creating hot gasses.
 Hot gases surrounds tubes and heats the water inside the tubes.
 The heated water then rises into steam drum
 To make boiler economical exhaust gases are used to pre-heat the
air blown into furnace and heat the water feed.
 Some examples include:-Babcock & Wilcox boiler, Stirling boiler
etc.

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EXAMPLE:BABCOCK AND WILCOX BOILER

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Difference between Fire and Water Tube Boiler
FIRE TUBE BOILER WATER TUBE BOILER
Hot flue gases flow inside the tube and the water Water flows inside the tubes and hot flue gases outside
outsides the tubes. the tube.
These boilers are generally internally fired. These boilers are generally externally fired.

The maintenance of this boiler is costly. It requires

They are easy to maintain as they are externally fired.
regular inspection.

The fire-tube boiler has a lower rate of steam

A higher rate of steam production.
production.
Not suitable for larger power plants. Suitable for larger power plants.

The risk of the explosion is higher due to high boiler

Involves lesser risk of explosion due to low pressure.
pressure.
For a given power, it occupies large floor space. For a given power, it occupies small floor space.

This boiler is difficult to construct. Simple in construction.

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 Circulation in Boiler
The steam generator has to produce steam at highest purity, and at
high pressure and temperature required for the turbine. Water must flow
through the heat absorption surface of the boiler in order that it be
evaporated into steam Natural circulation is the ability of water to
circulate continuously, with gravity and changes in temperature being
the only driving force known as "thermal head“.

The ratio of the weight of water to the weight of steam in the mixture
leaving the heat absorption surfaces is called Circulation Ratio.

Cold feedwater is introduced into the steam drum where, because the density of the cold water
is greater, it descends in the 'downcomer' towards the lower bottom ring header, displacing the
warmer water up into the front tubes.
Continued heating creates steam bubbles in the front tubes, which are naturally separated from
the hot water in the steam drum, and are taken off.

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Why controlled circulation is required?
 AS THE PRESSURE
INCREASES,THE DIFFERENCE
IN DENSITY BETWEEN WATER
AND STEAM REDUCES .
 THUS THE HYDROSTATIC HEAD
AVAILABLE WILL NOT BE ABLE
TO OVERCOME THE
FRICTIONAL RESISITANCE FOR
A FLOW CORRESPONDING TO
THE MINIMUM REQUIREMENT
OF COOLING OF WATER WALL
TUBES.
 NATURAL CIRCULATION IS
LIMITED TO 175KSC
Diff in Density
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 Natural Circulation & Forced Circulation Boiler

Natural Circulation
 The downcomer contain relatively cold
water, whereas the riser tube contain
steam water mixture ,whose density is
comparitively less .this density difference
is the driving force ,for the mixture.
(thermo-siphon principle)
 Circulation takes place at such a high rate
that the driving force and frictional
resisitance in water wall are balanced.
Natural Circulation Forced Circulation

Forced Circulation
 Beyond 180 Kg/cm2 of pressure, circulation is to be assisted with mechanical pumps, to
overcome frictional losses. To regulate the flow through various tubes, orifice plates are
used. This system is applicable in the high sub-critical regions (say 200 Kg/cm2).

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STEAM POWER PLANT

mechanical power
mechanical
is produced
power is produced
by a heat engine
by that
a heattransforms
engine that transforms
thermal energy
thermal (from
energy (from
combustion of combustion
a fuel) ofintoa fuel) into
rotational energy
rotational energy

Heat (generated Heat

in (generated
the in the
furnace) is transmitted
furnace) is totransmitted
the to the
boiler where boiler
water forced
where water
into forced into
the boiler by the
the boiler
feed pump
by theis feed pump is
converted into converted
steam into steam

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Typical Boiler
Layout
Reheater Chimney
Boiler
Drum Final Super
Heater
Platen Super LTSH
Heater
Economizer
Coal
Secondary Air
Bunker
Wind Duct PA duct
Box

Furnace
Flue Gas
APH Duct
Coal Feeder

Coal Mill

December 31, 2024 F D Fan P A Fan

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TWO PASS BOILER ARRANGEMENT

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BOILER MOUNTINGS
 Used for safe and proper functioning of Boiler
 Some important mountings are:
 Water Level Indicator
 Pressure gauge
 Safety valves
 Stop valve
 Blow off cock
 Feed check valve
 Fusible Plug

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BOILER MOUNTINGS

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BOILER ACCESSORIES
 Boiler accessories are those devices which are used to improve efficiency of
boiler
 Some importanct boiler accessories are
 Feed pump
 Economiser
 Air pre-heater
 Superheater
 Steam separator

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AIR DRAFT SYSTEM OVERVIEW

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FEED PUMP

 Its is a pump which is used to

deliver feed water to the boiler.
 The appliances in common use
for delivering the feed-water into
the steam boilers are:
a) Turbine driven Boiler Feed pump
b) Motor Driven boiler feed pump

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ECONOMISER

 An economiser is a device in
which the waste heat of the flue
gases is utilised for heating the
feed water.
 Economiser are of two types :
a) Independent type, and
b) Integral type

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AIR PREHEATER

 The function of the air pre-heater

is to increase the temperature of
air before it enters the furnance.
It is generally placed after the
economiser.
 These are generally of 2 types
 Tubular type airprehater
 Regenerative airpreheater

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 SUPERHEATER

• Used in boilers to increase the

temperature of the steam above the
saturation temperature.

• 3 stages of superheater-
1. Low temperature superheater
2. Divisional panel superheater
3. Final superheater

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STEAM SEPERATOR
• Steam separator is fitted before
steam turbine to separate water
particles from steam.
1. PRIMARY SEPERATORS
 CONSISTS OF BAFFLE
ARRANGEMENT DEVICES
WHICH CHANGE THE
DIRECTION OF FLOW OF
STEAM AND WATER
MIXTURE

2. SECONDARY SEPERATORS

SEPERATORS EMPLOYING
SPINNING ACTION

3. SCREENING DRYERS

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BOILER AUXILIARIES AND ITS SYSTEM
 Fuel system-Coal mills and Feeders
 Steam & Water circulation system
 Air Draft system
 Electrostatic Precipitator

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1. Fuel system
 The Major components are :
 Coal Preparation Equipments
 Feeders
 Mills
 Coal Firing Equipments
 Burners

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Role of Mills and Feeders

• Produces Pulverized coal 70-75 % of which passes through 200 mesh

• Air mixed with Pulverized coal (PF) is carried to the coal nozzle in the
wind box assembly
• PF from coal nozzle is directed towards the centre of boiler burning
zone
• Pre-heated secondary air enters boiler and surrounds the PF and help in
combustion
• Feeder is used to feed coal into the mill at a specified rate

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STEAM AND WATER CIRUCLATION SYSTEM
• Steam and water circulation system
consists mainly of
 Economizer
 Boiler drum
 Down Comers
 Water walls
 Primary super heater
 Platen super heater
 Final super heater
 Reheater

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 H.
R.
M.S C.R.H H

FROM F.R.S
BOTTOM RNG HDR & Z-PANEL 1ST
PASS W.W
1ST PASS W.W O/L HDRS ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
S.H. HEADER R.H.HEADER

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PASS ROOF O/L HDR(REAR ECONOMISER
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3. AIR DRAFT SYSTEM

Combustion Boiler
Air
Flue Gases

• Air needed for combustion

• Flue are needed to be evacuated
• Losses due to flow need to be overcome
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MAJOR FANS IN BOILER DRAFT SYSTEM
 PA Fans-For carrying coal to furnace
 FD Fans-For combustion in furnace
 ID Fans-For extracting flue gas to atmosphere

Centrifugal
Axial fan
fan

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4. ELECTROSTATIC PRECIPITATOR

 Particulate Collection Device used in

industries to minimize air pollution
 Principle of operation-Electrostatic
attraction
 Efficiency of 99% in many industries
 Can handle large gas volumes with a wide
range of inlet temperatures, pressures,
dust volumes, and acid gas conditions ESP
 Can collect particles of varying sizes in
dry and wet states

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WORKING PRINCIPLE OF ELECTROSTATIC PRECIPITATOR

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Specification of Reference Plant
Description Value Unit
Capacity 500 MW
Steam flow 1498.5 TPH
Boiler efficiency 84.91 %
Furnace width 19.177 m
Furnace depth 15.797 m
Furnace height(Ring header to furnace 63.550 m
roof)
Furnace volume 16900 m3
Maximum feed water pressure 197.8 Kg/cm2
Super heater pressure 177.7 Kg/cm2
Super heater temperature 540 C
0

Reheater pressure 42 Kg/cm2

Reheater temperature 540 C
0

Number of ID fans 2 No.

Number of FD fans 2 No.
Number of APH (Regenerative) 4 No.
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