BOILER FUNDAMENTAL

BY MANOJ KUMAR SR. ENGINEER O&M(OPERATION)

BOILER
UTILITY BOILER ARE DESIGN IN ORDER TO MEET THE STEAM QUANTITY AND QUALITY FOR BMCR RATING

500 MW CE DESIGN BOILER

BALANCED DRAFT CONTROLLED CIRCULATION DRY BOTTOM FURNACE RADIANT REHEAT SINGLE DRUM TOP SUPPORTED

BOILER AND AUX

FIRING SYSTEM CIRCULATION SYSTEM DRUM SUPERHEATER REHEATER ECONOMISER AIRPREHEATER AIR AND FLUE GAS SYSTEM ESP BOTTOM HOPPER AND CLINKER

BOILEROVERVIEW
D P

P L

R H

LT S H

E C O

AP H

FIRING SYSTEM
BOILER IS EQUIPED WITH 5 ELEVATION OF OIL GUNS AND 9 COAL MILLS OIL GUNS ARE CAPABLE FOR 30% BMCR RATING BOTTOM MOSTELEVATION ARE PROVIDED WITH BOTH LDO AND HFO OIL GUNS

TANGENTIAL FIRING
TANGENTIAL FIRING CREATE IMAGINARY FIREBALL INSIDE THE CENTRE OF FURNACE
COR2 1 COR3 1

COR1 1

COR4 1

MILLING SYSTEM PULVERISED COAL BENEFITS

INCREASE THE EFFECTIVE SURFACE AREA FOR COMBUSTION INCREASE COMBUSTION EFFICIENCY QUICK RESPONSE TO LOAD CHANGES LOW RESIDENCE TIME AND HIGH COMBUSTION EFFICIENCY

MILLING SYSTEM
XRP 1003 MILL ARE DESIGN FOR 66 T PULVERISD COAL WITH FINENESS70% THROUGH 200 MESH MILL FEED RATE IS CONTROLLED BY GRAVAMETRIC TYPE FEEDER

BOILERCIRCULATION
WITH INCREASE IN PRESSURE DENSITY DIFFERENCE BETWEEN STEAM AND WATER DECREASES CAUSING REDUCTION IN DRIVING FORCE FOR STEAM WATER CIRCULATION THIS IS OVERCOME BY INTRODUCTION OF BCW PUMP WHICH ASSIST IN CIRCULATION

BOILER DRUM
MAIN PURPOSE OF DRUM IS TO SEPARATE STEAM WATER MIXTURE DRUM IS EQUIPPED WITH DRUM INTERNALS IN ORDER TO ENSURE WATER FREE STEAM IN S/H CIRCUIT AND STEAM FREE WATER IN DOWNCOMER IT ALSO HELP IN MAINTAINING THE CHEMISTRY OF WATER

SUPERHEATER
BOILER IS DESIGNED WITH THREE STAGE OF SUPERHEATER CIRCUIT LOW TEMP SUPERHEATER DIVISIONAL PANEL PLATEN

DESUPERHEATER
FOR TEMP CONTROL DSH IS PROVIDED WHERE LOW TEMP WATER IS SPRAY DSH IS DONE BETWEEN LTSH O/L AND DP INLET THIS FACILITATE GOOD RESPONSE TO TEMP CONTROL AND NO WATER CARRYOVER

REHEATER
RH AGAIN INCREASE THE TEMP OF STEAM WHICH IS COMING AFTER EXPANSION IN HP TURBINE REHEATER SPRAY IS USED IN CRH FOR REHEATER TEMP CONTROL BURNER TILT IS MAINLY USED FOR RH TEMP CONTROL

DRAINS AND VENTS

DRUM AND SUPERHEATER HEADER IS PROVIDED WITH DRAIN AND VENT SYSTEMS THIS FACILITATE DURING INITIAL FILLING ,LIGHT UP ,DRAINING.

SAFETY VALVE
BOILER DRUM,SH,RH IS PROVIDED WITH SAFETY VALVE SO THAT IN CASE OF ANY ABNORMAL PRESSURE RISE IN THE SYSTEM IT CAN BE SAFELY DEPRESSURISED TO NORMAL WORKING PRESSURE. DRUM IS EQUIPPED WITH 6 SPRING LOADED SAFETY VALVE. SUPER HEATER LEFT AND RIGHT HEADER EACH HAVING ONE SPRING LOADED SAFETY VALVE ANDTWO ERV.CRH IS PROVIDED WITH TWO NOS SPRING LOADED SAFETY VALVE EACH SIDE AND HRH ONR SPRING LOADED AND TWO ERV.

SOOT BLOWING SYSTEM

BOILER WATERWALL,SH,RH TUBE IS SUBJECTED UNDER COBUSTION SOOTS. THIS REDUCES OVERALL HEAT TRANSFER CO-OFFICIENT OF HEATING SURFACE. SOOT BLOWING IS DONE IN ORDER TO CLEAN THE HEATING SURFACE. SUPER HEATED STEAM FROM DIV PANEL O/L IS TAKEN FOR SOOTBLOWING

ECONOMISER
ECONOMISER IS USED TO PREHEAT THE FEED WATER BEFORE ENTERING INSIDE THE DRUM. THIS INCREASE THE BOILER EFFICIENCY BY RECLAIMING HEAT FROM FLUE GAS .

AIRPREHEATER
APH IS USED TO HEAT THE PRIMARY AIR AND SECONDARY AIR . BOILER IS EQUIPPED WITH 2 PAPH AND 2 SAPH INCREASE BOILER EFFICIENCY BY CAPTURING HEAT FROM FLUE GAS

FORCED DRAFT FAN

TWO NOS FORCED DRAFT FAN IS PROVIDED EACH 60% CAPACITY THIS IS DESIGN TO GIVE SUFFICIENT AIR FOR COMPLETE COMBUSTION

INDUCED DRAFT FAN

TWO NOS INDUCED DRAFT FAN IS PROVIDED EACH 60% CAPACITY THIS IS DESIGN TO MAINTAIN ADEQUATE FURNACE DRAFT.

BOTTOM DEASHING
15 TO 20% OF TOTAL ASH IS COLLECTED IN THE FORM OF BOTTOM ASH . THIS IS COLLECTED IN THE BOTTOM HOPPER WHICH IS PERIODICALLY EVACUATED WITH CLINKER GRINDER AND HP JET WATER IN THE FORM OF SLURRY.

FLY DEASHING
85% TO 80%% OF TOTAL ASH IS COLLECTED IN THE FORM OF FLY ASH . THIS IS COLLECTED IN THE ESP HOPPERWHICH IS DIVIDED IN FOUR PASS EACH HAVING 32 HOPPERS. FLY ASH EVACUATION CAN BE DONE EITHER WET OR DRY FORM.