210 MW BOILER

FUNCTION
SYSTEM CYCLES
MAIN AUXILIARIES
OPERATIONS
Kimbahune Vikrant V.
J.E. UNIT 3(Operation)
 BOILER FUNCTION, TYPE& PARAMETERS

• GENERATE STEAM AT SPECIFIC TEMPERATURE

AND PRESSURE
• TANGENTIALLY FIRED, BALANCED DRAUGHT,
NATURAL CIRCULATION, RADINT REHEAT TYPE,
DRY BOTTOM WITH DIRECT FIRED PULVERISED
COAL WITH BOWL MILLS
• MAIN STEAM FLOW @ SH OUTLET--700 T/HR
• MAIN STEAM TEMP. @ SH OUTLET--540 ºC
• MAIN STEAM PRESSURE @ SH OUTLET-- 137 KG/CM²
 BOILER FUNCTION
• GENERATE STEAM AT SPECIFIC TEMPERATURE
AND PRESSURE
• COMBUSTION = FIRE - FUEL ( OIL / COAL) +
OXYGEN – AIR
• COAL CYCLE – AIR CYCLE – WATER CYCLE –
STEAM GENERATION - FLUE GAS PATH – ASH
EVACUATION
 BOILER MAIN PROCESS
• SENDING DM WATER (700 T/HR) TO THE BOILER
THROUGH BOILER DRUM TO BOILER TUBES
• SENDING FUEL ( FURNACE OIL AND COAL) TO THE
BOILER THROUGH DAMPERS (3000 MT/DAY)
• SENDING REQUIRED AMOUNT OF PRIMARY(300T/HR)
& SECONDARY AIR (600 T/HR)TO THE BOILER
• SUPPLY SUPERHEATED STEAM (5400C) OF ADEQUATE
TEMPERATURE AND PRESSURE TO TURBINES
• EXTRACTING FLUE GASES FROM THE BOILER AND
DISCHARGING THEM TO ATMOSPHERE
• REMOVING BOOTOM ASH FORMED AS A RESULT OF
COMBUSTION PROCESS
• REMOVING FLY ASH FROM ELECTROSTATIC
PRECIPITATOR HOPPERS
 BOILER MAIN AUXILARIES
• AIR HEATERS - 02 NOS.
• FUEL OIL PUMPS - 03 NOS.
• OIL GUNS / IGNITORS - 12 NOS. (4 NOS.AT 1 ELEVATION)
• COAL MILLS - 06 NOS.
• PRIMARY AIR FANS - 02 NOS.
• FORCE DRAFT FANS - 02 NOS.
• INDUCED DRAFT FANS - 02 NOS.
• BOILER FEED PUMPS - 03 NOS.
• EMERGENCY LIFT PUMPS - 02 NOS.
• SEAL AIR FANS - 02 NOS.
• SCANNER FANS - 02 NOS.
• BOTTOM ASH GRINDERS - 04 NOS.( 2NOS. FOR ONE PASS)
• ELECTROSTATIC PRECIPETATOR - 24 ESP FIELDS (48 HOPPERS)
-
 COAL AND FLUE GAS CYCLE
Coal from
CHP
Drum
S/H R/H
S/H

Coal
Chimney
Bunker
Boiler

LTSH
FD Fan
HFO
WindBox
Eco
Feeder

APH ID fan
ESP
Coal Mill
PA Fan
 Primary Air System
Cold Air

Sealing

Hot Air
To Coal Mill P.A. Fan ‘B’

Primary A.P.H.’B’

Primary A.P.H.’A’
To Coal Mill

Hot Air
P.A. Fan ‘A’

Sealing
Cold Air
Secondary Air System
Secondary A.P.H.’B’
S.C.A.P.H.

F.D. fan B

FURNACE

F.D. fan A

S.C.A.P.H.
Secondary A.P.H.’A’
 210 MW BOILER FLUE GAS PATH
PLATEN REHEATER
PLATEN FINAL SUPER
SUPERHEATER
WATER HEATER
WALL

765ºC
823ºC

622ºC
1010ºC
LOW TEMP.
572ºC
1123ºC 1123ºC SUPER HEATER

479ºC

ECONOMIZER

369ºC

AIR HEATER

140ºC

ESP A ESP B

140ºC

ID FAN ID FAN

140ºC

CHIMNEY
Boiler Drum
• Boiler drum is a pressure vessel which acts as a reservoir of boiler water
• Function of Drum:
1) Separate steam and water,
2) Mix feed water and distribute to furnace tube circuit
3) Add chemicals to improve water quality
4) Blow downs to maintain water quality
Material SA299 Carbon steel 135mm,
Construction: Feed Nozzle, tube & Header, Turbo separators, Chemical dozing
line, Blow down line, Separating chamber, Screen dryers, Safety valve,
Guage glass, Air vents, Temp & Pressure tapping
Setting of boiler drum
+175 (very High) BFP & Turbine Trip…. +125 (High)
----0 ---- Normal
-175 (Very low) Boiler Trip to avoid starvation … - 125(low) --
 STEAM AND CONDENSATE CYCLE

Drum
S/H R/H 5400
S/H
dearator
1700
FST HPT IPT LPT G
HP Heaters
Boiler
3 2 1

LTSH Ejector
1600 750 Lp1
3250 900
WindBox BFP 4 3 2 GC1 Condenser
2650
Eco
Water wall 450
LP Heaters
CEP
APH

Drip Drip
 COAL CYCLE
• COAL MINE - UNSHAPE, UNSIZED RAW
BITUMINOUS COAL –CRUSHER – BUNKER
(STACK)
• COAL BUNKERS (20MM SIZE COAL) – COAL
FEEDERS ( CONTROLLING INPUT TO COAL
MILL) – COAL MILLS
• POWDER, PULVERISED COAL LIFTED BY
PRIMARY AIR AND SENDING THROUGH COAL
PIPES - COAL DAMPERS - TO FURNACE FOR
COMBUSTION
 FEED WATER CYCLE
• DM WATER – FEED STORAGE TANK – BOILER
FEED PUMP – H P HEATERS – FEED STATION –
ECONOMISER – BOILER DRUM – BOILER
TUBES
 FUEL ( FO / LDO) OIL CYCLE
• FURNACE OIL (FO) / LIGHT DIESEL OIL (LDO)
TANKS – FUEL OIL PUMPS – HEATERS (STEAM)
– OIL DAMPERS - OIL GUNS – TO FURNACE
• FURNACE OIL IS NON EXPLOSIVE, DIFFICULT
TO IGNITE IN BULK, NO SPONTANEOUS
COMBUSTION
• EXPENSIVE RS. 45-60 THOUSAND/KL
 AIR CYCLE
• PRIMARY AIR FANS – MIXTURE COLD & HOT
AIR SUPPLIES TO LIFTING COAL TO FURNACE
• FORCED DRAFT FANS – SUPPLIES HOT AIR
REQUIRED FOR COMBUSTION
• INDUCED DRAFT FANS – MAINTAIN
CONTINUITY OF COMBUSTION AND MAINTAIN
NEGATIVE PRESSURE (-10 MMWC). EXTRACT
FLUE GASES FROM FURNACE AND DISCHARGE
THEM TO ATMOSPHERE
 I.D. FAN
Interlocks :
1. Any AH must be running
2. LOP running with adequate pressure(3)
3. Discharge damper closed
4. Suction vanes must be minimum
 FD Fans
• FD fans are Axial Impulse (Unit 3) / Axial
reaction (Unit 4 & 5)
• FD discharge goes to AH gets heated up then
goes to wind box (left & right) enters into
boiler through dampers
• Interlocks : One ID running, LOP (if) running,
D/Damper closed, IGV minimum
• Tripping interlock -- ID fan trip, Bearing Temp
high, Motor protections
 P.A. Fans
• Supplies Cold and Hot air for firing coal from
coal mill to boiler
• Interlock :No boiler trip, LOP running,
D/damper closed, Suction vane minimum,
• Triping : Motor/Fan brg temp, Boiler trip,
Motor protection, LOP trip,
• When boiler trip, PA fan must trip to avoid
ingress of coal into furnace in tripping
condition
 FLUE GAS PATH
• Whenever combustion takes place chemical
energy converted into heat energy (depends on
CV)
• Various gases CO2, SO2, N2, water vapour
• Heat carried away through flue gas is used in
Air Heater & Economiser to improve Boiler
Efficiency
• Furnace(11230C)- Plattern SH(10100C)-Rehater Front(8230C)-
Rehater Rear (7650C)-Final Super Heater (6620C)-Horozontal
SH(4790C)-Economiser(3690C)-Air Heater(1400C)-ESP(1250C)-
ID Fan(1220C)-Chimeny(1200C)
DRAFT FLUE GAS PATH OUT.TEMP
-5 FURNACE 1123
-6 PLATTERN SUPER HEATER 1010
-8 REHEATER FRONT 823
-14 REHEATER REAR 765
-16 FINAL SUPER HEATER 662
-19 HORIZONTAL SUPER HEATER 479
-45 ECONOMISER 369
-84 AIR HEATER 140
-230 E.S.P. 125
-270 I.D.FAN 120
CHIMNEY 120
 IMPROVING BOILER EFFICIENCY
• ECONOMISER - Absorbs heat from flue gas and
add this sensible heat to Feed Water before water
enters to Boiler
• AIR PRE-HEATER – Flue gases passes through
Heater tubes and Cold air passes through air heater
heated up and Hot air used for combustion. Flue gas
temp at outlet of Economiser is @3200C if discharge
to atmosphere-lot of wastage of heat
 Rotary Vertical Regenerative Type
AIR HEATER (Ljungstorm)
• Re-cuperative type (old plants 120-140 MW) –
Tubular / Plate type
• Re-generative type – Heating Element made from
CRCA(Cold rolled Cold Annealed) Steel Buckets
arranged in 3 layers circular manner –Hot flue gas
passes though bucket & gets heated. The heated
buckets comes in pair of air which gets heated up
and bucket cooled. The cycle continues….
• Construction – Rotor, Housing, Seals, Bearing, Soot
blowers
• AH Inlet / Outlet Temp – 330/140 0C
• AH Inlet Air Temp - 30 0C
• AH Outlet PA / SA Temp -- 300/290 0C
• When Boiler Initially fired AH soot blowing required to avoid
fired in AH
• AH should not be standstill in hot—bucket damaged, uneven
expansion rotor can get buckled…Air motor provided to cool it
upto 500C
• When both AH trip then both ID/FD must trip to avoid flow in
standstill AH
 BOILER AUXILARIES
• SEAL AIR FANS GIVES SEALING TO COAL MILLS
AND ITS GEAR BOXES
• SCANNER USED TO MONITOR FLAME IN
BOILER
• SCANNER FANS SUPPLIES COOLING AIR TO
SCANNER HEADS
• SOOT BLOWER SYSTEM IS USED TO REMOVE
SOOT FORMATION ON BOILER TUBES
SAVE ENERGY - SAVE NATION

SWITCH OFF LIGHTS

WHEN NOT IN USE

THANK YOU
- Vikrant V. Kimbahune