Beruflich Dokumente
Kultur Dokumente
Dr Atef A Aly
The boiler
A boiler is a plant in which essentially two
processes are at work, namely, combustion
and heat transfer.
1. Combustion to release heat from fuel in the
firing equipment.
2. Transfer of the released heat to water and
steam in the various heat traps of the boiler.
Super-heated Steam output
Superheater
Water Heater
water inlet
Boiler Part
(Economizer)
Primary Air
The evaporator
1. Evaporator surfaces consisting of, sequentially, a. Furnace, which is a chamber
made of water-cooled surfaces to
i. Give the burning fuel adequate time for completion of combustion.
ii. Cool the flue gases and transfer the heat to furnace tubes. Furnace tubes in
natural circulation boilers transfer heat to boiling water and to sub-cooled water in
supercritical (SC) boilers.
b. Boiler bank (BB) or evaporator bundles to cool the flue gases and transfer heat
mg cpg Tfg
TFg
Tg1
mg cpg Tg1
Tsaturation
mg cpg TFg
The Superheater
ms(h1-hsat)= mg cpg (Tg2 Tg1)
Tg2=Tg1-Ms(h1-hsat)/[mair(1+a/f)cpg]
Tg1
Tg2
mg cpg Tg2
T1
ms h 1 ms hsat,vapour
Tsat The Superheater
mg cpg Tg1
The Economizer
ms cpw(Tsat-TFB)= mg cpg (Tg3 Tg2) =QEc
Tg3=Tg2-mscpw(Tsat-TFB)/[mair(1+a/f)cpg]
Tg3
mg cpg Tg3
Tsat
TFB ms hsat,vapour ms cpTFB
The Economizer
mg cpg Tg2
The Air Preheater
ma cpa(Tair2-Tair1)= mg cpg (Tg3 Tg4)
Tg4=Tg3-cpa(Tair2-Tair2)/[(1+1/(a/f))cpg]
Tg3
Tg4
mg cpg Tg4
Tair2
Tair1 ma Cpa Tair2 ma cpaTair1
The Air Preheater
mg cpg Tg3
The Chimney
Chimney
P1 P2 P
a g(Z H ch ) a gZ g gH ch P
( a g )gH ch P
P
Hch
( a g )g
P Pcc Ppasses
l v2
Note : Ppipe f (Pa)
2d
21
Ejector
22
The calculation
In a BB, the amount of HS is known because of the predetermined configuration. BB
exit-gas temperature (BEGT) can be found using Equation 6.3.
For single-pass BBs, the T2 t is in the range of 120150C, whereas for two-pass BBs,
it is 100C for coal-fi red boilers
Tube Expansion in Boiler Bank
The superheater
Superheater configuration
Superheater
Superheater
Vertical superheater
POINTS OF DISCUSSION
SUB CRITICAL & SUPER CRITICAL BOILER
OPERATION
FEED WATER SYSTEM
BOILER CONTROL
BOILER LIGHT UP
START UP CURVES
WHY SUPER CRITICAL TECHNOLOGY
Operating Flexibility
This temperature remain constant till all the water converted to steam
When all liquid converted to steam than again temperature starts rising.
Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And
Water
The mass of this boiler drum, which limits the rate at which the sub critical
boiler responds to the load changes
Too great a firing rate will result in high thermal stresses in the boiler drum
Role of SG in Rankine Cycle
50bars, 550oC
264oC
230oC
3350 kJ/kg
When Water is heated at constant pressure above the critical pressure, its
temperature will never be constant
No distinction between the Liquid and Gas, the mass density of the two
phases remain same
No Stage where the water exist as two phases and require separation : No
Drum
The actual location of the transition from liquid to steam in a once through
super critical boiler is free to move with different condition : Sliding Pressure
Operation
For changing boiler loads and pressure, the process is able to optimize the
amount of liquid and gas regions for effective heat transfer.
Circulation Vs Once Through
No Religious Attitude
540C, 255 Ksc
568C, 47
Ksc 492C, 260 Ksc
FUR ROOF
457C, 49 Ksc
I/L HDR ECO HGR
O/L HDR
HRH LINE
MS LINE
411C, 411C,
277Ksc 275 Ksc
SEPARATOR
S
T FINAL SH
FINAL
O RH LTRH
R
DIV PANELS SH PLATEN
A SH
G
E
T VERTICAL WW
A
ECO
305C, 49 Ksc
G N
K
JUNCTION
HDR
LPT LPT IPT
C
O HPT
N ECONOMISER
D
E
N
S
E
R
ECO I/L
FEED WATER
BWRP
290C, 302 KSC
Heat Input
Water
Heat Input
Water
Water
Boiling process in Tubular Geometries
SEPARATOR TANK
PENTHOUSE Eco. O/L hdr (E7)
F19
1st pass top hdrs RH O/L hdr (R12)
RH I/L hdr (R10)
TYPE OF TUBE
Vertical
Spiral
Advantage
Disadvantage over Vertical water wall
Vertical Tube Furnace
Tubes are appropriately sized and arranged in multiple passes in the lower
furnace where the burners are located and the heat input is high.
By passing the flow twice through the lower furnace periphery (two passes),
the mass flow per tube can be kept high enough to ensure sufficient cooling.
In addition, the fluid is mixed between passes to reduce the upset fluid
temperature.
Spiral Tube Furnace
The spiral design, on the other hand, utilizes fewer tubes to obtain the
desired flow per tube by wrapping them around the furnace to create the
enclosure.
This also has the benefit of passing all tubes through all heat zones to
maintain a nearly even fluid temperature at the outlet of the lower portion
of the furnace.
Because the tubes are wrapped around the furnace to form the enclosure,
fabrication and erection are considerably more complicated and costly.
SPIRAL WATER WALL
ADVANTAGE
DISADVANTAGE
1732 T / Hr
PA FAN 2 Nos ( AXIAL) 11 KV / 3920 KW 884 mmwc
947 T / Hr
ID FAN 2 Nos ( AXIAL) 11 KV / 5820 KW 3020 T / Hr
TOTAL AIR 2535 T / Hr
SH OUT LET PRESSURE / TEMPERATURE / 256 Ksc / 540 C
FLOW 2225 T / Hr
RH OUTLET PRESSURE/ TEMPERATURE / 46 Ksc / 568 C
FLOW 1742 T / Hr
SEPARATOR OUT LET PRESSURE/ 277 Ksc / 412 C
TEMPERATURE
ECONOMISER INLET 304 Ksc / 270 C
MILL OPERATION 7 / 10
8&9 field 90 KV
No Of Hopper / Pass : 36
M
M M M
M M AIR MOTOR
M
SAPH # A
M M
FD FAN # A
M
M M
M SAPH # B
M AIR MOTOR
M M M
FD FAN # B
M
M AIR MOTOR
M M
M PAPH # B
HOT PRIMARY AIR DUCT
TO PULVERISER SYSTEM
M M
M
PA FAN # B
FURNACE
FINAL SUPERHEATER
DIVISIONAL PANEL
BACK PASS
FINAL REHEATER
ECONOMISER
PLATEN COILS
LTRH
AIR PATH
FUEL OIL SYSTEM
Main Feed Water Pipe ( FW Shut Off Valve to ECO I/L HDR) 28.8 m3
Economizer 253.2 m3
105
All Volatile
Treatment
Oxygenated
Water
Treatment
106
DOSING POINTS
107
AVT Dosing Auto Control
108
OWT Dosing Auto Control
109
FUR ROOF I/L HDR U#1
VENT HDR VENT HDR
WATER LINE
N2 FILL LINE N2 FILL LINE N2 FILLING LINE
SAMPLE COOLER
VENT LINE
SAMPLE COOLER
DRAIN LINE
SEPRATOR #1 SEPRATOR #2
SAMPLE COOLER LINE
1 2 1 2 1 2 1 2
VENT HDR
VENT HDR
FUR WW HDR
MIXING PIECE
VENT HDR WR ZR
TO DRAIN HDR
MODES OF OPERATION
1. BOILER FILLING
2. CLEAN UP CYCLE
If the water system of the boiler is empty (economizer, furnace walls, separators), then the
system is filled with approximately 10% TMCR ( 223 T/Hr) feed water flow.
When the level in the separator reaches set-point, the WR valve will begin to open.
When the WR valve reaches >30% open for approximately one minute, then increase feed
water flow set-point to 30% TMCR ( approx 660 T/Hr).
As the flow increases, WR valve will reach full open and ZR valve will begin to open.
After completion of Filling, the feed water flow is again adjusted to 10 % TMCR for Clean up cycle
operation
BOILER INITIAL WATER LEVEL CONTROL (UG VALVE)
The boiler circulating pump is started following the start of a feed water pump and
the final clean-up cycle.
This pump circulates feed water from the evaporator outlet back to the economizer
inlet.
Located at the outlet of this pump is the UG valve which controls economizer inlet
flow during the start-up phase of operation.
During this time, constant feedwater flow of 10% TMCR ( 223 T/Hr) or more is
maintained.
Water flows through the economizer and evaporator, and discharges the boiler
through the WR valve to the flash tank and via connecting pipe to the condenser.
From the condenser, the water flows through the condensate polishing plant, which is
in service to remove impurities ( Like Iron & its Oxide, Silica, Sodium and its salts ), then
returns to the feed water tank.
The recirculation is continued until the water quality is within the specified limits.
FEED WATER QUALITY PARAMETER FOR START UP
MODE OF OPERATION
WET MODE :
DRY MODE :
It measures Flow at BFP Booster Pump Discharge and compare it with a calculated flow
from its downstream pressure via a function and maintains the difference 0
Remains Closed
Closes when Flow through BFP Booster Pump discharge > 2.1 Cum
Open When Flow through BFP Booster Pump Discharge < 1.05 Cum
( Minimum Flow will be determined by BFP Speed via BFP Set limitation Curve)
4. BFP Scoop
6. WR / ZR Valve
3 Nos Level Transmitter has been provided for Storage tank level measurement
At 17.9 Mtr level it will trip all FW Pumps also MFT will act
FCV ( 30 % )
WR / ZR Valve
Storage Tank
BRP
BRP Recirculation System
1. START UP SYSTEM
Separator Storage Tank level will be monitored by Separator storage tank wet leg level
control valve ( 3 Mtr)
Primary purpose is to keep the final super heaer spray control valve in the desired
operating range
This Demand goes through Boiler Transfer Function where it is matched with the actual
Evaporator Heat Transfer to minimize the temperature fluctuations
FIRST CONTROLLER
Its Output represents the desired heat transfer / steam generation to maintain
the desired steam parameters and Flue gas parameters entering the Platen
section
SECOND CONTROLLER
1. The combined Feed Forward and Feed back demand ( as calculated in dry mode operation)
will be compared with minimum Economizer Flow
This ensures the minimum flow through Economizer during the period when start up system
is unavailable
2. Output of the first controller is subjected to the second controller which monitors the
Separator Storage tank level ( Since the system is in Wet Mode now)
3. The output of the second controller is the set point of Feed water master controller.
4. The Feed back to this controller is the minimum value measured before the start up system
and Economizer inlet.
WATER & STEAM PATH
Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP By-pass -
Cold R/H Line - Primary R/H (Lower Temp R/H) - Final R/H - LP By-pass - Condenser
Primary Eco - Secondary Eco - Ring HDR - Spiral W/W - W/W Intermediate HDR - Vertical W/W
- Separator - Backpass Wall & Extended Wall - SH Division - Platen SH - Final SH - HP TBN - Cold
R/H Line - Primary R/H (Lower Temp R/H)- Final R/H - IP and LP TBN - Condenser
Wet Mode and Dry Mode of Operation
DIV SH PLATEN SH FINAL SH
15% 3%
BOILER LOAD CONDITION
The Steam Pressure And Flow rate is controlled by the load directly
CONSTANT PRESSURE VS SLIDING PRESSURE
Valve throttling losses occur because the boiler operates at constant pressure while the turbine doesn't.
The most obvious way to avoid throttling losses therefore is to stop operating the boiler at constant
pressure!
Instead, try to match the stop valve pressure to that existing inside the turbine at any given load.
Since the turbine internal pressure varies linearly with load, this means that the boiler pressure must
vary with load similarly.
If the boiler pressure is matched to the pressure inside the turbine, then there are no valve throttling
losses to worry about!
While sliding pressure is beneficial for the turbine, it can cause difficulties for the boiler.
ADVERSE AFFECT
As the pressure falls, the boiling temperature (boiling point) changes. The boiler is divided into zones in
which the fluid is expected to be entirely water, mixed steam / water or dry steam. A change in the
boiling point can change the conditions in each zone.
The heat transfer coefficient in each zone depends upon the pressure. As the pressure falls, the heat
transfer coefficient reduces. This means that the steam may not reach the correct temperature. Also, if
heat is not carried away by the steam, the boiler tubes will run hotter and may suffer damage.
CHALLANGES
The heat transfer coefficient also depends upon the velocity of the steam in the boiler
tubes.
Any change in pressure causes a change in steam density and so alters the steam
velocities and heat transfer rate in each zone.
Pressure and temperature cause the boiler tubes to expand. If conditions change, the
tubes will move. The tube supports must be capable of accommodating this movement.
The expansion movements must not lead to adverse stresses.
When it is used, coal fired boilers in the 500 to 1000 MW class normally restrict sliding pressure to a
limited load range, typically 70% to 100% load, to minimize the design challenge. Below this range, the
boiler is operated at a fixed pressure.
This achieves an acceptable result because large units are normally operated at high load for economic
reasons.
In contrast, when sliding pressure is used in combined cycle plant, the steam pressure is varied over a
wider load range, typically 50% to 100% load or more
As stated, in coal-fired plant, sliding pressure is normally restricted to a limited load range to
reduce design difficulties.
In this range, the boiler pressure is held at a value 5% to 10% above the turbine internal pressure.
Consequently, the governor valves throttle slightly.
The offset is provided so that the unit can respond quickly to a sudden increase in load demand
simply by pulling the valves wide open.
This produces a faster load response than raising the boiler firing rate alone.The step in load
which can be achieved equals the specified margin ie 5% to 10%.
The throttling margin is agreed during the tendering phase and then fixed.
A margin of 5% to 10% is usually satisfactory because most customers rely upon gas turbines,
hydroelectric or pumped storage units to meet large peak loads.
The throttling margin means that the full potential gain of sliding pressure is not achieved.
Nevertheless, most of the throttling losses which would otherwise occur are recovered.
ADVANTAGES
Temperature changes occur in the boiler and in the turbine during load changes. These can
cause thermal stresses in thick walled components.
These are especially high in the turbine during constant-pressure operation. They therefore
limit the maximum load transient for the unit.
By contrast, in sliding pressure operation, the temperature changes are in the evaporator
section. However, the resulting thermal stresses are not limiting in the Once through boiler
due to its thermo elastic design.
In a uniformly heated tube, the transitions from preheat to evaporation and from
evaporation to superheat shift automatically with load such that the main steam temperature
always remains constant.
Sliding Pressure
At loads over 25% of rated load, the water fed by a feed-water pump flows through the high
pressure feed-water heater, economizer ,furnace water wall, steam-water separator, rear-wall
tubes at the ceiling, and super heaters, The super heaters steam produced is supplied to the
turbine.
At rated and relatively high loads the boiler is operated as a purely once through type. At partial
loads, however, the boiler is operated by sliding the pressure as a function of load.
25
Turbine inlet pressure Mpa
24.1 Mpa
20
15
10
5 9.0 Mpa
0
0 25 50 75 100
Turbine load (%)
CONSTANT PRESSURE Vs VARIABLE PRESSURE BOILER CHARACTERSTIC
Boiler Load %
20 40 60 80 100
+1
Variable Pressure
Efficiency Change %
-1
-2
-3
-4
Benefits Of Sliding Pressure Operation ( S.P.O)
Reducing the thermal stresses on the component : Low Maintenance & Higher
Availability
Drum : (most critical thick walled component) under highest thermal stresses
The Basis of Boiler Start-up Mode
SH Outlet Temp 465 above 300 above 100 above 100 below
STARTING TIME
Hot - -
Restart 30 90
PURGE CONDITIONS
No Boiler Trip Condition Exists
Start one ID fan, then the corresponding FD fan and adjust air flow to a min. of 30% TMCR
Adjust fan and SADC to permit a purge air flow of atleast 30% of TMCR and furnace draft of
approx. -12.7 mmWC.
When fans are started, SADC should modulate the aux. air dampers to maintain WB to furnace
DP at 102 mmWC(g).
FURNACE READINESS
PRESSURE PARTS
SCANNER AIR FAN
BOTTOM ASH HOPPER READINESS
FUEL FIRING SYSTEM
START UP SYSTEM
CONDENSATE SYSTEM
CONDENSER
CEP
CPU
Spiral wall Horizontal and vertical buck stay with tension strip