BOILERS INSTRUMATION AND CONTROL

Submitted by
MARU CHINTAN (130070109033)
LADUMOR PRAKASH (130070109031)
BACHELOR OF ENGINEERING
In
ELECTRICAL ENGINEERING

BIRLA VISHWAKARMA MAHAVIDHYALAYA,

V.V.NAGAR, GUJARAT

BIRLA VISHWAKARMA MAHAVIDYALAYA

ELECTRICAL
2013
CERTIFICATE
Date:
This is to certify that the dissertation entitled BOILERS INSTRUMATION
AND CONTROL has been carried out by MARU CHINTAN and
LADUMOR PRAKASH 1st semester under my guidance during the
academic year 2013-14.

Guides:
PROF M.N. SHINHA
Head of the department

ABSTRACT
That is a brief introduction to some basic
information about the boiler like classification of boiler, types
of boiler, control the boiler and safety and joining the boilers.
That is also known which boiler is used in thermal power
station .collect the some information about the electrical
boiler used in thermal power station.

LIST OF CONTENT

CHAPTER
CHAPTER
CHAPTER
CHAPTER

:( 1) INFORMATION ABOOUT THE BOILER

:( 2) BOILER TECHNOLOGIES
:( 3) PLANT BATTEEMENT /RENOVATION
:(4) LIST OF VARIOUS THARMAL POWER STATION

CHAPTER(1):INFORMATION ABOUT BOILER

1.1 Introduction
The requirements of stem as a working substance is either for
power generation or for process and space heating in industrial
applications
Steam generator or a boiler as per Indian boiler act 1923 is a
closed pressure vessel used for generation of steam under
A boiler is usually made of steel in which the chemical energy of fuel is
converted by combustion into heat and this heat energy of products of
combustion is transferred to water so as to produce steam.
In case steam is used for power generation, it is generated at
high pressures and in large requirements. The design of such boiler is
quite. It depends upon capacity of field.
In case. The steam is to be used for industrial process heating or
for space heating of building; the reunited boiler pressures are low. The
design of such boiler is comparatively simpler and these are easy to
operate.

1.2Classification of boiler:
The boiler may be classified mainly as follows:
I.
Depending upon the relative position of water and flue
games:
a. Smoke tube boilers: in these type of boilers the hot
gases or the flue
Gases form the furnace are passed through the tube
surrounded by the water outside to be evaporated
b. Water tube Boilers : In the boilers are water to be
evaporated passes
Through the tubes and the Examples: Babcock-Wilcox,
Striling boilers etc.
II.
Depending upon the position furnace:
a. Infernally fired boilers: In there the furnace is inside
the body of the boilers shell. Example: Locomotive and
Lancashire boilers etc.

b. Externally fired boilers: In there the furnace is

outside the boilers shell. Examples: Sterling, BabcockWilcox and Loffler boilers etc.

III.

IV.

Depending upon the position of axis of the boiler:

a. Vertical boilers: In which the axis of the billers shell is
in vertical plan.
b. Horizontal boilers: In which the axis of the boilers
shell is in the horizontal plane.
Depending upon the service to the boilers is put, like
stationary, portable, marine of locomotive boilers etc.

V.

Depending upon the source of heat :

The source of heat may be due to:
Heat generated due to combustion of solid, liquid
field.
Hot waste gases or electrical or atomic energy etc.

VI.

According to the method of circulation of water and steam:

a. Natural circulation: In case natural circulation steam
boilers, the water is circulated by natural convection
which is set up due to heating of water. The
temperature gradient causes the density gradient along
the length of the tube due to which flows from high
density water and steam. Example: Babcock-Wilcox
boiler.
b. Forced circulation: In forced circulation boiler, the
water is circulating with the help of centrifugal pump
driven by external source of owe, such a method of
water circulation is usually employed in high pressure
boilers.
Example: LaMont and Loeffer boilers.

VII.

According to the pressure of steam generated:

The boilers which produce steam at less than 20 bar
pressure are

Called low pressure boiler.

Examples: Cochran, Lancashire and locomotive boilers.
The boilers which produce stamp above 20 bar pressure
are called high pressure boilers.
Example: Babcock-Wilcox, Sterling and Loffler boilers etc.
VIII.

According to nature of draught employed:

When the fuel is burnt on the surface due to natural
circulation of air, the draught is called natural ire
chimney draught. If the air is circulated with the help of
fan driven by external source of power, the draught
used is called artificial draught.

1.3Babcok-Wilcox boiler:

This is one of the most important types of boiler of a water

tube boiler generally employed in the power houses for
power generation as shown in fig.
It is consists of number of inclined water tubes(wt.)
connected between the uptake header(uh) and the down
take header (dh).headers arte provided with hand holes in
the front tubes And are covered with caps.
Whole combustion chamber is divided into number of parts
with the help of baffles(b) so that the hot gases first move
from the furnace (f)upwards between the water tubes and
then move dower word and upward the baffles over the
tubes and finally these are executed to the chimney
through the dumper(dip)

The dampers regulate the amount of flue gases and thus

the supply of air to the gate. Doors (D) are provided for
amen to enter in the boiler for cleaning and purposes.

The feed water enter the front of the drum(dry) and travel
to the back part of the drum and then descends through
the vertical tube to the uptake header and then gain to the
drum.

The water tubes near the uptake header are in contact with
the hotteerflue gases compared to the portion near the
downtake header due to which the water in the uptake
header rises due to decreased density and enters the drum
which is replaced by the colder water from the downtake
header.
Water continues to circulate like this till it is
evaporated.this type of circulation of water occurring due
to density difference is called free circulation.
The superheating of steam in done in superconductor(sh).it
consists of large number of steel tubes.
We steam from the boiler drum enters in the outer tube
(OT), then passes into the superheated tubes and during
its passage it gets further heated up. Superheated steam

now enters into the inner tubes(IT) and from here it is

withdrawn through a stop valve(sv).
The boiler also has its usual mountings like pressure gauge
(pg), safety value (sfv), water, water level indicators (wli),
feed valve (fv) etc.

1.4High pressure boilers

However, to improve the efficiency of the power plant, it is

coomen practice to use high pressure and high
temperature of steam. It reduces the cost of the power
generation.it is generating steam above 160 per pressure
and temperatures up to 600 are usually categorized as
mordent boilers.
In recent past the boilers have been built which generate
steam above critical pressure of221.2 bar and critical
temperature of 374.15.
At this pressure and temperature conditions, the steam
and water would have the same a case there density
And the water is converted directly into steam

.
The requirement of boilers for power is of capacitors
30,000 to 6, 50,000 kg/hr. and at a pressure above 160 bar
and steam temperature in the range of 500-600. The
design and operation of such modern boilers differ from
subcritical pressure boilers.

1.5Loeffer boiler

This is another type of modern boiler, water tube boiler showed

in fig.

It is consist of two super heaters. One is horizontal

convective superheated (c) and other is radiant
superheated(r) which is located directly above the furnace
and receives instance heat by rendition.
Feed water with the help of feed pump (fop) is passed
through the economizer (e) on its way to evaporating
drum.
The rate of flow of feed water and superheated steam is so
maintained that after mixing it evaporates feed water into
steam of high dryness fraction.

The steam from the evaporating drum is drum by steam

circulation pump (SCP) and it is passed to the radiant
superheated at pressure higher than the drum pressure.

About 35 to 40% of this superheated steam is supplied to

the steam turbine for the expansion work.

A drain D is provided for cleaning the evaporating drum.

A blower draws the cold air from surrounding where it is

heated in the air preheater by the flue gases to the
combustion chamber.

The advantages of this boiler compare to LaMont boilers is

that the evaporating tubes in the boiler only carries
superheated steam due to which no self-deposits can occur
on the tubes.

These boilers are compact in design and generate steam

up to 1 lake kg/hr. up to a pressure of 150 bars.

1.6Boiler Mounting For Safety

I.
II.
III.

Two water level indicators-2

Two safety valves.
Combine high steam and low water safety valves.

1.7Boiler Mounting For Control

I.
II.
III.
IV.
V.

Pressure gauge
Junction or stop valve
Feed Check Valve
Blow-off cock
Man Hole And mud Hole

CHAPTER(2):Boiler Technologies
2.1Existing and emerging trends
Boiler technology the world over has evolved vastly over the years.
From the conventional pulverized coal boilers to fluidised bed
combustion technology and multi-fuel firing boilers, the industry has
indeed come a long way.
This write-up describes the available and emerging technology options,
their benefits and limitations.

2.2CURRENT TECHNOLOGIES
2.2.1Pulverised fuel boiler
Pulverised fuel boiler is the most commonly used method in thermal
power plants, and is based on many decades of experience. Units
operate at close to atmospheric pressure, simplifying the passage of
materials through the plant.

Most coal-fired power station boilers use pulverised coal, and many of
the larger industrial watertube boilers also use this fuel. This
technology is well developed, and there are thousands of units around
the world, accounting for well over 90 per cent of coal-fired capacity.
The coal is ground (pulverized) to a fine powder so that less than 2 per
cent is +300 micro metre (m) and 70-75 per cent is below 75
microns, for bituminous coal. The pulverized coal is blown with part of
the combustion air into the boiler plant through a series of burner
nozzles. Secondary and tertiary air may also be added. Combustion
takes place at temperatures from 1,300 to 1,700 oC, depending largely
on coal grade. Particle residence time in the boiler is typically two to

five seconds, and the particles must be small enough for complete
combustion to have taken place during this time.
This system has many advantages such as the ability to fire varying
qualities of coal, quick responses to changes in load, use of high
preheat air temperatures, etc. Pulverised coal boilers have been built
to match steam turbines, which have outputs of between 50 and 1,300
Mwe. In order to take advantage of the economies of scale, most new
units are rated at over 300 mew, but there are relatively few really
large ones with outputs from a single boiler-turbine combination of
over 700 Mew. This is because of the substantial effects such units
have on the distribution system if they should trip out for any reason,
or be unexpectedly shut down.

2.2.2Fluidised bed combustion

Fluidized bed combustion has emerged as a viable alternative and has
significant advantages over the conventional firing system and offers
multiple benefits. Some of the benefits are compact boiler design, fuel
flexibility, higher combustion efficiency and reduced emission of
noxious pollutants such as SOx and NOx. The fuels burnt in these
boilers include coal, washery rejects, rice husk, bagasse and other
agricultural waste. Fluidised bed boilers have a wide capacity range
from 0.5 T per hour to over 100 T per hour.
2.2.3There are three basic types of fluidized be combustion
boilers:
Atmospheric classic fluidized bed combustion system (AFBC).
Atmospheric circulating (fast) fluidized bed combustion system
(CFBC)
Pressurised fluidized bed combustion system (PFBC).

2.3AFBC/ Bubbling bed

In AFBC, coal is crushed to a size of 1-10 mm depending on the rank of
coal, and type of fuel fed into the combustion chamber. The
atmospheric air, which acts as both the fluidisation air and combustion

air, is delivered at a pressure and flows through the bed after being
preheated by the exhaust flue gases. The velocity of fluidizing air is in
the range of 1.2 to 3.7 m per second. The rate at which air is blown
through the bed determines the amount of fuel that can be reacted.
Almost all AFBC/ bubbling bed boilers use in-bed evaporator tubes in
the bed of limestone, sand and fuel for extracting the heat from the
bed to maintain the bed temperature. The bed depth is usually 0.9 m
to 1.5 m and the pressure drop averages about 1 inch of water per inch
of bed depth. Very little material leaves the bubbling bed-only about 2
to 4 kg of solids are recycled per kg of fuel burnt.
The combustion gases pass over the superheater sections of the boiler,
flow past the economiser, the dust collectors and the air preheaters
before being exhausted to the atmosphere.
The main feature of atmospheric fluidized bed combustion is the
constraint imposed by the relatively narrow temperature range within
which the bed must be operated. With coal, there is a risk of clinker
formation in the bed if the temperature exceeds 950 oC and loss of
combustion efficiency if the temperature falls below 800 oC. For
efficient sulphur retention, the temperature should be in the range of
800 850 oC.

2.4Features of bubbling bed boilers

Fluidised bed boilers can operate at near-atmospheric or
elevated pressure and have these essential features:
Distribution plate through which air is blown for fluidising,
Immersed steam-raising or water heating tubes which extract heat
directly from the bed,
Tubes above the bed, which extract heat from hot combustion gas
before it enters the flue duct.

2.5Circulating fluidized bed combustion

CFBC technology has evolved from conventional bubbling bed
combustion as a means to overcome some of the drawbacks
associated with conventional bubbling bed combustion.
CFBC technology utilizes the fluidised bed principle in which crushed
(6-12 mm size) fuel and limestone are injected into the furnace or
combustor. The particles are suspended in a stream of upwardly
flowing air (60-70 per cent of the total air), which enters the bottom of
the furnace through air distribution nozzles. The fluidizing velocity in
circulating beds ranges from 3.7 to 9 m per second. The balance of the

combustion air is admitted above the bottom of the furnace as

secondary air. The combustion takes place at 840-900 oC, and the fine
particles (<450 microns) are elutriated out of the furnace with flue gas
velocity
of 4-6 m per second. The particles are then collected by the solid
separators and circulated back into the furnace. Solid recycle is about
50 to 100 kg per kg of fuel burnt.
There are no steam generation tubes immersed in the bed. The
circulating bed is designed to move a lot more solids out of the furnace
area and to achieve most of the heat transfer outside the combustion
zone convection section, water walls, and at the exit of the riser.
Some circulating bed units even have external heat exchanges.
The particle circulation provides efficient heat transfer to the furnace
walls and longer residence time for carbon and limestone utilisation.
Similar to pulverized coal (PC) firing, the controlling parameters in the
CFBC process are temperature, residence time and turbulence.
For large units, the taller furnace characteristics of CFBC boilers offer
better space sorbent residence time for efficient combustion and SO2
capture, and easier application of staged combustion techniques for
NOx control than AFBC generators. CFBC boilers are said to achieve
better calcium to sulphur utilisation 1.5 to 1 versus 3.2 to 1 for the
AFBC boilers, although the furnace temperatures are almost the same.
CFBC boilers are generally claimed to be more economical than AFBC
boilers for industrial applications requiring more than 75-100 T per
hour of steam. CFBC requires huge mechanical cyclones to capture and
recycle the large amount of bed material, which required a tall boiler.
At right fluidizing gas velocities, a fast recycling bed of fine material is
superim posed on a bubbling bed of larger particles. The combustion
temperature is controlled by the rate of recycling of fine material. Hot
fine material is separated from the flue gas by a cyclone and is
partially cooled in a separate low velocity fludised bed heat exchanger,
where the heat is given up to the steam. The cooler fine material is
then recycled to the dense bed.
At elevated pressure, the potential reduction in boiler size is
considerable due to the increased amount of combustion in pressurised
mode and high heat flux through in-bed tubes.
2.5.1A CFBC boiler could be a good choice if the following
conditions are met:
Capacity of boiler is large to medium,

 Sulphur emission and NOx control is important,

The boiler is required to fire low-grade fuel or fuel with highly
fluctuating fuel quality.

2.6Pressurised fluid bed combustion

PFBC is a variation of fluid bed technology that is meant for large-scale
coal burning applications. In PFBC, the bed vessel is operated at
pressure up to 16 ata (16 kg per cm2).
The off-gas from the fluidized bed combustor drives the gas turbine.
The steam turbine is driven by steam raised in tubes immersed in the
fluidized bed. The condensate from the steam turbine is preheated
using waste heat from gas turbine exhaust and is then taken as
feedwater for stem generation.
The PFBC system can be used for cogeneration or combined cycle
power generation. By combining the gas and steam turbines in this
way, electricity is generated more efficiently than in the conventional
system. The overall conversion efficiency is higher by 5 to 8 per cent.

2.7EMERGING BOILER TECHNOLOGY

Up till the 1970s, certain high-grade fuels like oil and better quality
coals were utilised in boilers for power generation purposes. But with
growing awareness of sustainable use of energy, extensive utilisation
of better quality fuels has become a cause for concern.

To conserve fossil sources for purposes other than burning and steam
generation, boilers with better fuel utilisation technology are required
in addition to adopting boilers with multi-fuel burning capability. In this
regard, there has been increased interest in areas like supercritical
boiler technology, intergrated coal gasification combined cycle and
advance PFBC technology, to name a few. Boilers now also burn a
variety of waste fuels such as biomass and bagasse for cogeneration
purposes.

2.8Advanced-PFBC (A-PFBC) system

The A-PFBC (series type) technology, developed in Japan, makes use of
the advantageous conditions of the raised GT temperatures and

improved steam conditions while mitigating developmental loads

(there is no need to develop a topping combustor).
In the A-PFBC system, the gas produced in the partial gasifier (syngas)
is fed to a high temperature dry desulphuriser where syngas is
desupphurised by using limestone, and then is cooled by a syngas
cooler (SGC). The desulphurisation of the gas prior to cooling makes
SGC atmosphere slow corrosive and enables more sensible heat of the
gas to be recovered as high temperature steam. The cooled gas
(450oC) is subjected to strict dust removal with a cyclone, ceramic
filter and is then fed to the combustor of the gas turbine to generate
power.
The oxidiser plays a role not only in the combustion of unburnt carbon
(char) transferred from the partial gasifier but also in oxidizing CaS
formed in the desulphuriser into gypsum (CaSO4). The high
temperature flue gas from the oxidizer is introduced into the partial
gasifier; thus the heat energy (sensible heat) of the flue gas is
effectively used as a heat source for the partial gasifier.

2.9Integrated coal gasification combined cycle

Integrated coal gasification combined cycle (IGCC) is a new coalutilised power generation technology that achieves higher thermal
efficiency and better environmental performance for the next
generation.
In Japan, the development of original air-blown IGCC technology has
been pushed forward as a national project.
Like PFBC, the technology is relatively new in connection with power
generation. It was only in the late 1990s that coal-based IGCC plants
for power generation started gaining acceptance.
IGCC uses a combined cycle format with a gas turbine driven by the
combusted syngas, while the exhaust gases are heat exchanged with
water/ steam to generate superheated steam to drive a steam turbine.
Using IGCC, more of the power comes from the gas turbine. Typically
60 70 per cent of the power comes from the gas turbine with IGCC,
compared with about 20 per cent using PFBC.
Coal gasification takes place in the presence of a controlled shortage
of air/oxygen, thus maintaining reducing conditions. The process is
carried out in an enclosed pressurised reactor, and the product is a

mixture of CO and H2 (called synthesis gas, syngas or fuel gas). The

product gas is cleaned and then burnt with either oxygen or air,
generating combustion products at high temperature and pressure.
The sulphur present mainly forms H2S but there is also a little COS.
The H2S can be more readily removed than SO2. Although no NOx is
formed during gasification, some is formed when the fuel gas or
syngas is subsequently burnt.
The IGCC demonstration plants use different flow sheets, and therefore
test the practicalities and economics of different degrees of
integration. As with PFBC, the driving force behind the development is
to achieve high thermal efficiencies together with low levels of
emissions.

2.10Supercritical boiler
The earliest supercritical boilers were built in the US in the late 1950s
and early 1960s. Designed to operate above steams critical pressure
of 3208 psi, these early units developed a reputation for high
thermodynamic efficiency (around 35 per cent, based on lower heating
value-LHV) but low reliability.
The materials of that era, plant owners came to realise, were simply
not up to the temperature and pressure challenges, and the North
American industry put supercritical technology on the backburner.
The ascent of gas-fired combined cycles continued to suppress interest
in the technology in this region.
In Europe and Asia, however, supercritical technology continued to be
pursued, and by the 1990s it had come to dominate new capacity
projects. The capital cost of supercritical technology is slightly higher
than subcritical, but fuel savings and environmental advantages can
tip the scale.
Compared to the 1950s designs, steam pressures in most of these
units have increased well into the supercritical range up to 4,500
psig- although steam temperatures were maintained around the same
1,000 oF limit. The result was a thermal efficiency of approximately 40
per cent (LHV).
More advanced designs introduced in the late 1990s have raised steam
temperature as high as 1,150 of, achieving efficiencies of 44 per cent.
And main steam conditions above 1,200 of are foreseen, which should
yield an efficiency approaching 50 per cent. The increase in efficiency

not only reduced fuels cost, but also specific (per MW) emissions of
NOx and SO2, as well overall emission of CO2, compared to sub critical
coal-fired boilers.
All supercritical boilers are of a once through arrangement, meaning
that water and steam flow through the boiler circuitry only once.
Contrast this with drum boilers, in which water and steam recirculate
through the furnace enclosure. The major difference between the
various once-through boiler technologies in the market is the
configuration of the furnace enclosure circuits and in the system used
to circulate the water through those circuits during start-up and at
lower loads.

FIG ON BOILER USE IN THERMAL POWER STATION