BOILER SPECIFICATIONS
Controlled circulation Single drum Top supported Tangential corner fired Riffle tubes Balanced draught Radiant reheat Dry bottom Furnace area 14770m3 Manufacturer BHEL
BOILER DRUM, DOWNCOMERS, CC PUMP, FURNACE,(WATER WALL AND STEAM COOLED WALL) FUEL FIRING SYSTEM,(oil gun,ignitor,burner,burner tilt mechanism,scanner) SADC,(secondary air damper control) WATER WALL TUBE OR RISER ECONOMISER ,(THREE STAGE) SUPER HEATER,(LTSH,DIVISIONAL
BOILER COMPONENTS
REHEATER, SOOT BLOWER SYSTEM(WATER WALL,LRSB AND APH) ,BOTTOM ASH HOPPER(CRUSHER,REFACTORY,THR OUGH SEAL) BOILER AUXILLARIES FANS(PA FANS,FD FANS, ID FANS) MILLING SYSTEM(MILL,RAW COAL FEERDER,SEAL AIR FAN) AIR PREHEATER(SAPH,PAPH) ESP ASH DISPOSAL SYSTEM.(DRY ASH SYSTEM,WET ASH SYSTEM
BOILER DRUM
FUNCTIONS:-
SEPRATES WATER AND STEAM
REDUCED DISSOLVED SOLID CONTENTS OF STEAM
STORAGE OF WATER
FURNACE
PROVIDES PROPER INSTTALATION, OPERATION MAINTENANCE OF FUEL BURNING EQUIPMENTS SUFFICIENT VOLUME FOR COMBUSTION
ADEQUATE REFRACTORIES & INSULATION
ECONOMISER
LOCATED IN 2ND PASS BELOW LTSH.
PREHEATS BFW BEFORE GOING TO DRUM
SUPER HEATERS
LTSH(LOW TEMP. SUPER HEATER)
DIVISIONAL PANEL(PANEL SUPERHEATER)
PLATEN SUPERHEATER(FINAL)
Principal of combustion
Fuels :
Gaseous fuel Liquid fuel solid fuel
Heat :
LDO HFO
Air :
Less amount of air will cause incomplete combustion Excess amount of air will cause boiler losses
Three Ts for efficient combustion
1. Time 2. Temperature 3. Turbulence( proper mixing)
Combustion efficiency:
1. design of boiler 2. fuel used 3. skill in obtaining combustion with minimum amount of air
REHEATERS
HEAT TRANSFER BY RADIATION & CONVECTION
COMPOSED OF FRONT & REAR PENDANT SECTION
AIR PREHEATERS
LOCATED IN FLUE GAS PASS AFTER ECONOMISER TO HEAT PRIMARY AND SECONDARY AIR
BCW PUMP
BCW PUMP IS SINGLE STAGE, GLANDLESS ,SINGLE SUCTION DOUBLE DISCHARGE, CENTRIFUGAL PUMP.
BURNERS
COAL BURNERS OIL BURNERS AUX. AIR SUPPLY DAMPERS O/F AIR DAMPERS BURNER TILT MECHANISM
HEA IGNITORS
PROVIDED WITH ALL OIL BURNERS 4 SPARKS /SEC,
HFO SCHEME AT BOILER FRONT
HOTV FT HOFCV
AB ELEVATION
CD ELEVATION EF ELEVATION GH ELEVATION
SHORT RECIRCULATION
FT
HORV
HFO SUPPLY LINE HFO RETURN LINE
ATOMISING STEAM SCHEME AT BOILER FRONT
AB ELEVATION
CD ELEVATION
EF ELEVATION
GH ELEVATION
OIL GUN CONNECTION
HFO NOZZLE VALVE
SCAVENGE VALVE
OIL GUN
ATOMISING STEAM VALVE
Important phenomenon
Nucleate boiling
Film boiling
Water wall refile tubes
Flow chart of WCS
condensor
T=40,P=-.9mm
LP HEATERS
DEARETORS
BFP p=<drum p
HPH
ECO
B.DRUM
DOWN COMER
BRH
URH
WATER WALL
Drum & drum internals
ECO.SPECIFICATIONS
MATERIAL CARBON STEEL SA210 GRA1,SA210 GRC 76 51 5.6
NO.OF COILS OD OF TUBES(MM) ACTUAL THICKNESS
DES.PR OF TUBES
DES.PR OF HEADERS
207.4
219.7
M.S
FROM F.R.S
Economiser
WATER WALLS SPECIFICATIONS
FW NUMBER OD(MM) D.THCKNESS A.THICKNESS JOINING DES.PR OF TUBE DES.MET.TEMP 283 51 5.19 5.6 BUTT 208.8 448 SW 444 51 5.19 5.1 BUTT 207.3 197.3 417 RW 283 51 5.19 5.1 BUTT 207.3 197.3 417 ROOF 142 57 5.54 5.1 BUTT 204.9 192.3 416
MAX.PR OF TUBE 197.0
WATER WALL HEADERS
INLET OUTLET
NO.OF HEADERS
OUTSIDE DIA(MM)
4
914.4
5
273
DES THICKNESS(MM)
ACTUAL THICKNESS DES PR.OF HEADERS MAX.WORKING PR MATERIAL
86
89 208.8 197.0 SA-299
50
45 204 192.2 SA-106
Bottom Ring Header
SH.SPECIFICATIONS
NO.OF TUBES OD(MM) JOINING MAX.STEM TEMP MAX GAS TEMP LTSH STAGE-I 708 PLATEN STAGE-II 444 PLATEN STAGE-III 456
51.0
BUTT 366(H) 467(P) 482(H) 512(P)
51.0
BUTT 488 548
54.0
BUTT 558 628
M.S
FROM F.R.S
Sh 1
M.S
FROM F.R.S
SH 2
M.S
FRM F.R.S
LTSH
M.S
FROM F.R.S
Final SH
RH SPECIFIFATIONS
STAGE-I
MAX.OPERATING PR 46.7
STAGE-II
45.8
DESIGN PR
MAX.GAS SIDE MT OD(MM) JOINING
56.2
460 60.3 BUTT
56.2
566 612 54.0 644+92 BUTT
MAX.STEAMSIDE MT 397
TOTAL NO.OF TUBES 248+254
M.S
FROM F.R.S
RH
SH&RH HEADERS
SH
MAX.OPERATI 188.2 NG PR DESIGN PR 204
RH
46.7 56.2 117800
WEIGHT(KGS) 223000
M.S
FROM F.R.S
RE HEATER CIRCUIT NON DRAINABLE PORTION DRAINABLE PORTION UNIT 7 BOILER HYDRO TEST
M.S
FROM F.R.S
RE HEATER CIRCUIT NON DRAINABLE PORTION DRAINABLE PORTION UNIT 7 BOILER HYDRO TEST
SOOT BLOWING SYSTEM
88 Nos. of wall Blowers, 34 Nos of LRSBs and 4 Nos of APH Soot Blowers are provided in first and second pass of boilers to remove Soot from furmace / SH coils and APH Elements. Each wall blower is provided with a rotary & traverse motor with associated gear box arrangements for rotary & traverse motion of the lance 34 Nos of LRSBs are mounted on the water wall covering SH and reheater sections to remove ash dust from SH and RH coils
Coal from Mines to Mills
MGR System Coal Handling Plant RC Bunker Size = 200 mm to 25 mm
Feeder
Pulverizer/Mill Powdered Form
Coal Feeders
Coal feeders is used to regulate the flow of coal from bunker the pulverizer Types of Coal Feeders: 1. Volumetric Feeders 2. Gravimetric Feeders Coal Entry to feeder from
Coal Feeders
Gravimetric Coal Feeder : Feeding the Coal from Bunker to Pulverizer as per requirement Leveling Bar Specialized Belt Conveyer Amount of Coal entry controlled by the speed of the Drive pulley Drive pulley connected through motor with variable speed drive Either DC Motor or Motor with Magnetic clutch is used
Pulverization of Coal
Pulverization : It is a method by which the coal is crushed to a fineness such that 70-80% passes through a 200 mesh sieve Importance of Pulverization Coal firing: 1. High Boiler Efficiency 2. Ability to use high combustion air temp. 3. Low Excess Air Requirement 4. Ability to burn a wide variety of coals 5. Better reaction to automatic control
Low Speed Mill
Tube and Ball Mill Operate at 17 to 20 Rpm Coal Feed from both end of the Tube Small Ball of 30,40, 50 mm Sizes are used Hot air blown to move coal to classifiers at two elevations in boiler furnace No Maintenance for long periods Better availability so no spare mill required Always a reserve of coal so there is no spark produced between Steel balls Consumption of power is more High Foundation and Initial cost of Equipment
Tube and Ball Mill
RC Feeder Classifiers 4 No. Drum Feeder Classifiers Distributors 2 No. Hot Air Entry Ball and Tube Mill Coal entry to Drum
Tube and Ball Mill
Steel Balls
High Speed Mill
Impact Mills and Beater Mill Directly Coupled to the Motor 500 to 1000 Rpm Compact in Size Less Power Consumption Rate of Wear of the grinding elements is High High Maintenance Cost
Bowl Mill
Coal Entry
Hot Air Flow from PA Fan
Classifiers To burners Rollers
Burners
Design consideration: Atomise the oil Properly shaped jet Combustion must be complete Excess air should be minimum Ready accessibility for repairs
Burner Arrangement
Flue Gas System
Air Heaters
It is a heat transfer surface in which air temperature is raised by transferring heat from other medium such as flue gas. These are used for heating the primary and secondary air before entering the furnace.
Advantages
1. Increase in boiler efficiency. 2. Stability of combustion increases by use of hot air.
3. Intensify and improved combustion.
4. Permitting to burn poor quality of coal. 5. High heat transfer rate in the furnace and hence lesser heat transfer area requirement. 6. Less un burnt fuel particle in flue gas thus combustion and both efficiency is improved.
7. intensified combustion permits faster load variation and fluctuations.
Types of Air Heaters
1. Recuperative type a. Tubular Reheater b. Plate type Airheater c. Steam Air Preheater 2. Regenerative type a. Ljungstrom type b. Rothemuhle type
Ljungstorm Airheater
OVERVIEW OF AIR FLOW IN TPP
FURNACE
CHIMNEY SECONDRY AIR HEATER
MILLS
FD FAN A FD FAN B
ID FAN A
PRIMERY AIR HEATER
Atmosphe ESP air ric
PA FAN A
PA FAN B
ID FAN B
Atmospheric air Atmosphe ric air
