The Boiler Design

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)

Evaporator Air Preheater Air input

Exhaust of combustion Gases to smoke stack

F
Furnace part

Fuel Input Secondary Air

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

To the saturated surfaces to add latent heat

2. Superheater (SH) and reheater (RH) tube banks to cool the flue gases and accelerate
heat to superheat and reheat the steam
3. Back-end equipment consisting of
a. Economizer (ECON) tube banks to further cool the gases to transfer heat to the
subcooled water
b. Airheater (AH) to cool the gases in the last stage and transfer heat to the
combustion air
 Furnace
The furnace is the enclosure around the firing
equipment, which provides adequate:
1.Volume to permit completion of combustion,
that is, to meet the residence time requirement
to burn the fuel
2. Surfaces to cool the gases to an acceptable
level to enter the downstream surface, usually
the SH, without the fear of ash deposits or tube
overheating
Table 6.1 provides a guide for residence times. Residence time is required for a fuel
particle to reach the midpoint of the furnace exit aperture from the firing equipment
(center of heat input, to be precise), assuming the whole furnace to be at the
isothermal temperature of FEGT. In package boilers with horizontal gas flow, the
burners decide the cross section and the residence time whereas the flame length
governs the length of the furnace.
 Furnace Exit-Gas Temperature or
Furnace Outlet Temperature

An accurate estimation of FEGT is not possible by theoretical calculations alone

because several variables keep changing in a furnace with not-so-simple geometry.
The size and the number of flames, emissivities, flame temperatures, and
cleanliness of furnace are all subject to constant change. The practical adjusted
surface (AS) or EPRS method, is proprietary to each boilermaker, evolved over time
and fuel- and geometry-specific. The calculations involve the following steps:
Calculate PRS of the lower furnace up to the open pass (below platens) and total
furnace up to the furnace exit.
Derive EPRS from projected surface by multiplying with effectiveness factors for
each wall. Effectiveness factor varies from 0.9 to 0.98 for membrane walls
depending on the fuel and the slope of the wall.
Calculate the heat released and available (HR and A) from the fuel and air. The
total available heat, based on fuel net calorific c value (NCV), including the heat
addition in AH, is adjusted for the possible unburnt carbon loss and furnace
radiation losses (assumed to be half of the total). Ambient temperature is taken as
the datum to calculate this heat.
 Furnace with Grate type for combustion of solid fuels

Grate Fuel qG=mf.CVH/AG , kJ/m2h

Manually operated Minerals coals, 2.926 to 3.762x106
Plane grate bricks, wood
Same with 3.344 to 5.016x106
Under-grate blast
Travelling grate Minerals coal,
With primary air brown coal bricks
Supply in zones 2.926 to 5.852x106
Furnace with Grate type for combustion of solid, liquid and gas fuels

Sort of furnace Fuel qch=mf.CVH/Vch , kJ/m3h

Grate furnace Minerals coal 1.045 to 1.463x106
Coal-dust furnace Minerals coal 0.627 to 0.7524x106
(With solid slag)
Coal-dust furnace (many sorts) 1.672 to 20.9x106
(with liquid slag)
Oil furnaces Oil 3.135 to 12.54x106
Gas furnace Gas 3.135 to 12.54x106
 Evaporator Surface Area for different types of Boilers

Boiler type qhs=ms/Ahs , kgs/m2h

Flame tube boiler 20 to 25
Locomotive boiler 20 to 25
Locomotive boiler 50 to 60
Scotch ship boiler 20 to 25
Smoke tube boiler 30 to 40
Water tube boiler up to 200
 Furnace losses for combustion of solid fuels
Furnace losses percentage
hfurnace= 0.85 to 0.96

i) Loss due to incomplete combustion

a. With coal grate and fire control 2%
b. With coal using fine grain coal 5%
i) Loss due to blowing coal particles out and soot 1 to 8%
deposition
ii) Loss due to unburned gases such as CO, H2, CH2, 1%
CnHn
iii) Loss due to heat in tap cinder -
 Steam Boiler Efficiency for Types
Steam Boiler Efficiency hfboiler

i) Small boiler such as flame tube type 0.74 to 0.78

ii) Bigger boiler with mechanical furnace, 0.77 to 0.83
coal-dust, oil or gas furnace
iii) Very large plant 0.84 to 0.88
iv) Most recent boilers 0.92
 Steam Boiler System t/h Pressure Steam Area
bar output m2

i) Small boiler such From 16 to 18 15 to 300

as flame tube type 0.07 18 t/h
ii) vertical boilers 500 70 80
iii) Biggest boilers 500 to
2000
Superheater:
Qsh =Ush Ash DTmsh
Ush = 29 to 58.2 W/m2oC for tube diameter = 2.54 to 5.082 cm
Tgi= 450 oC to 800 oC smoke boiler
Tgi = 700 oC to 1200 oC Water tube boiler
Vsteam = 12 to 15 m/s
Water Economizer:
QEC =UEC AEC DTmEC
UEC = 11.6 to 20.9 W/m2oC for ribbed CI tubes
UEC = 20.9 to 29 W/m2oC steel tubes
Tgi = 300 oC to 400 oC Water tube boiler
Vgas= 6 to 12 m/s
Air Preheater:
There two types:
1. Tubular air type 2. Plate air type
Qah =Uah Aah DTmah
Uah = 8 to 23.2 W/m2oC
Tgi = 300 oC to 400 oC Water tube boiler
Vgas= 8 to 9 m/s
 The furnace
(1-Lradiation)Qf= CVL mf = mg cpg Tfg mair cpair Tair
(1-Lradiation)CVL = (mg/mf) cpg Tfg (mair/mf)cpair Tair
(1-Lradiation)CVL=((mf+mair)/mf)cpgTfgmair/mf)cpairTair
(1-Lradiation)CVL = (1+a/f) cpg Tfg (a/f)cpair Tair
Tfg=[(1-Lradiation)CVL/(1+a/f)cpg]+[Tair(a/f)/(1+a/f)](cpair/cpg)
Where
Lradiation = radiation and unburnt loss fraction in the furnace about 13 to 20%

mg cpg Tfg

mair cpair Tair

(1-Lradiation)QF
The Furnace
 The Evaporator
mshfg= mg cpg (Tfg Tg1)
Tg1=Tfg-mshfg/[mair(1+1/(a/f))cpg]

TFg

Tg1
mg cpg Tg1
Tsaturation

ms hsat, vapour The Evaporator mshsat,liquid

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]

QEc = AEC UEC DTm,EC

Tg2

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

SIPAT BOILER DESIGN

BOILER DESIGN PARAMETERS

CHEMICAL TREATMENT SYSTEM

OPERATION
FEED WATER SYSTEM

BOILER CONTROL

BOILER LIGHT UP

START UP CURVES
 WHY SUPER CRITICAL TECHNOLOGY

To Reduce emission for each Kwh of electricity generated : Superior Environmental

1% rise in efficiency reduce the CO2 emission by 2-3%

The Most Economical way to enhance efficiency

To Achieve Fuel cost saving : Economical

Operating Flexibility

Reduces the Boiler size / MW

To Reduce Start-Up Time

 UNDERSTANDING SUB CRITICAL TECHNOLOGY

Water when heated to sub critical pressure, Temperature increases until it

starts boiling

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

Perform Using Natural resources of energy .

 UNDERSTANDING SUPER CRITICAL TECHNOLOGY

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

FUR LOWER HDR

FRS
 Steam

Partial Steam Generation

Complete or Once-through
Steam Generation

Heat Input
Water

Heat Input

Water
Water
Boiling process in Tubular Geometries
SEPARATOR TANK
 PENTHOUSE Eco. O/L hdr (E7)

LTRH O/L hdr (R8)

2nd pass top hdrs (S11)

Back pass Roof o/l hdr (S5)

SH final I/L hdr (S34) SH final O/L hdr (S36)

F19
1st pass top hdrs RH O/L hdr (R12)
RH I/L hdr (R10)

F28 Platen O/L hdr (S30)

Platen I/L hdr (S28) F28

Div. Pan. I/L hdrs Div. Pan. O/L hdrs (S24)

(S20)
F8 1st pass top hdrs
Back pass Roof i/l hdr
S2
Separator (F31) Storage Tank (F33)
 SUPER CRITICAL BOILER

BOILER DESIGN PARAMETER

DRUM LESS BOILER : START-UP SYSTEM

TYPE OF TUBE
Vertical
Spiral

SPIRAL WATER WALL TUBING

Advantage
Disadvantage over Vertical water wall
 Vertical Tube Furnace

To provide sufficient flow per tube, constant pressure furnaces employ

vertically oriented tubes.

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

Benefits from averaging of heat absorption variation : Less tube leakages

Simplified inlet header arrangement
Use of smooth bore tubing
No individual tube orifice
Reduced Number of evaporator wall tubes & Ensures minimum water flow
Minimizes Peak Tube Metal Temperature
Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE

Complex wind-box opening

Complex water wall support system
tube leakage identification : a tough task
More the water wall pressure drop : increases Boiler Feed Pump Power
Adherence of Ash on the shelf of tube fin
 BOILER OPERATING PARAMETER
FD FAN 2 NoS ( AXIAL ) 11 kv / 1950 KW 228 mmwc

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

COAL REQUIREMENT 471 T / Hr

SH / RH SPRAY 89 / 0.0 T / Hr
BOILER EFFICIENCY 87 %
 Coal Analysis

Design Worst Best Young Hung Tangjin 1. High erosion

Parameter Unit
Coal Coal Coal #1,2(800MW) #5,6(500MW) potential for
High Heating Value kcal/kg 3,300 3,000 3,750 6,020 6,080 pulverizer and
backpass tube is
Total Moisture % 12.0 15.0 11.0 10.0 10.0 expected due to
Proximate Volatile Matter % 21.0 20.0 24.0 23.20 26.53 high ash content.
Analysis Fixed Carbon % 24.0 20.0 29.0 52.89 49.26
Ash % 43.0 45.0 36.0 13.92 14.21
2. Combustibility
Fuel Ratio (FC/VM) - 1.14 1.00 1.21 2.28 1.86 Index is relatively
Combustibility Index - 2,067 2,353 2,476 2,781 3,492
low but
combustion
Carbon % 39.53 31.35 40.24 63.03 62.15 characteristic is
Hydrogen % 2.43 2.30 2.68 3.60 3.87 good owing to
high volatile
Nitrogen % 0.69 0.60 0.83 1.53 1.29
Ultimate
content.
Oxygen % 6.64 5.35 8.65 7.20 7.80
Analysis
Sulfur % 0.45 0.40 0.60 0.72 0.68
Ash % 43.00 45.00 36.00 13.92 14.21
Moisture % 12.00 15.00 11.00 10.00 10.00
Grindability HGI 50 47 52 45 48
HiVol. C HiVol. C HiVol. C Midium Vol. HiVol. C
ASTM Coal Classification -
Bituminous Bituminous Bituminous Bituminous Bituminous
 Ash Analysis

Design Worst Best Young Hung Tangjin

Parameter Unit
Coal Coal Coal #1,2(800MW) #5,6(500MW)
SiO2 % 61.85 62.40 61.20 57.40 57.40 1. Lower
Al2O3 % 27.36 27.31 27.32 29.20 29.20 slagging
potential is
Fe2O3 % 5.18 4.96 5.40 4.40 4.40 expected due
CaO % 1.47 1.42 1.52 2.70 2.70 to low ash
Ash MgO % 1.00 1.03 0.97 0.90 0.90 fusion temp.
Analysis Na2O % 0.08 0.08 0.08 0.30 0.30 and low basic
K2O % 0.63 0.32 1.22 0.70 0.70 / acid ratio.
TiO2 % 1.84 1.88 1.80 1.30 1.30 2. Lower fouling
P2O5 % 0.54 0.55 0.44 - - potential is
SO3 % 0.05 0.05 0.05 - - expected due
Others % - - - 3.10 3.10
to low Na2O
o and CaO
Ash Fusion Initial Deformation C 1150 1100 1250 1200 1200
content.
Temp. (oC) Softening o
C - - -
o
(Reducing Hemispheric C 1400 1280 1400
Atmos.) o
Flow C 1400 1280 1400
Ash Content kg/Gcal 130.3 150.0 96.0 23.12 23.37
Basic / Acid B/A 0.09 0.09 0.10 1.63 1.63
 AIR AND FLUE GAS SYSTEM

AIR PATH : Similar as 500 MW Unit

FLUE GAS PATH :

No Of ESP Passes : 6 Pass

No Of Fields / Pass : 18 1-7 fields 70 KV.

8&9 field 90 KV

No Of Hopper / Pass : 36

Flue Gas Flow / Pass : 1058 T/ Hr

 M M M
M TO PULVERISER SYSTEM

HOT PRIMARY AIR DUCT

PAPH # A
M M
PA FAN # A
M AIR MOTOR

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

LHS WIND BOX

FURNACE
FINAL SUPERHEATER
DIVISIONAL PANEL

BACK PASS
FINAL REHEATER

ECONOMISER
PLATEN COILS

LTRH

RHS WIND BOX

AIR PATH
 FUEL OIL SYSTEM

Type Of Oil : LDO / HFO

Boiler Load Attainable With All Oil Burner In Service : 30 %

Oil Consumption / Burner : 2123 Kg / Hr

Capacity Of HFO / Coal : 42.1 %

Capacity Of LDO / Coal : 52.5 %

HFO Temperature : 192 C

All Data Are At 30 % BMCR

 DESIGN BASIS FOR SAFETY VALVES :
1. Minimum Discharge Capacities.

Safety valves on Separator and SH Combined capacity 105%BMCR

(excluding power operated impulse safety valve)

Safety valves on RH system Combined capacity 105% of Reheat

flow at BMCR
(excluding power operated impulse safety valve)

Power operated impulse safety valve 40%BMCR at super-heater outlet

60% of Reheat flow at BMCR at RH

outlet

2. Blow down 4% (max.)b

 BOILER FILL WATER REQUIREMENT

Main Feed Water Pipe ( FW Shut Off Valve to ECO I/L HDR) 28.8 m3

Economizer 253.2 m3

Furnace ( Eco Check Valve to Separator Link) 41.5 m3

Separators & Link 13.8 m3

OXYGENATED TREATMENT OF FEED WATER

WATER CHEMISTRY CONTROL MAINTAINS PLANT HEALTH.

Dosing of oxygen(O2) or Hydrogen peroxide

(H2O2) in to feed water system.

Concentration in the range of 50 to 300 g/L.

Formation of a thin, tightly adherent ferric oxide

(FeOOH) hydrate layer.

This layer is much more dense and tight than

that of Magnetite layer.

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

FUR INTERMITTENT HDR

STORAGE TANK
DRAIN HDR

FUR BOTTOM RING HDR

FLASH TANK
DRAIN HDR

MIXING PIECE
VENT HDR WR ZR

BACK PASS ECO O/L HDR

N2 FILL LINE

ECO JUNCTION HDR BRP ECO MIXING LINK

BACK PASS ECO I/L HDR

BLR FILL PUMP

FROM FEED WATER

TO DRAIN HDR

WATER CIRCULATION SYSTEM

 FEED WATER SYSTEM

MODES OF OPERATION

1. BOILER FILLING

2. CLEAN UP CYCLE

3. WET MODE OPERATION (LOAD < 30 % )

4. DRY MODE OPERATION (LOAD > 30 %)

5. DRY TO WET MODE OPERATION ( WHEN START UP SYSTEM NOT AVAILABLE)

 BOILER FILLING LOGIC

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.

The water system is considered full when:

The separator water level remains stable for two(2) minutes

and
The WR valve is fully opened and ZR valve is >15% open for two(2) minutes

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.

Demand for this recirculation, control valve is established based on measured

economizer inlet flow compared to a minimum boiler flow set point.
 Boiler Clean-up
When the feedwater quality at the outlet of deaerator and separator is not within the
specified limits, a feedwater clean-up recirculation via the boiler is necessary.

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 :

Initial Operation Of Boiler Light Up. When Economizer Flow is maintained by

BCP.

Boiler Will Operate till 30 % TMCR on Wet Mode.

DRY MODE :

At 30 % TMCR Separator water level will become disappear and Boiler

Operation mode will change to Dry

BCP Will shut at this load

Warm Up system for Boiler Start Up System will get armed

Boiler will turn to once through Boiler

ECO Water flow will be controlled by Feed Water Pump in service

 SYSTEM DESCRIPTION ( WET MODE OPERATION)
1. Flow Control Valve ( 30 % Control Valve )

Ensures minimum pressure fluctuation in Feed Water Header

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

2. 100 % Flow Valve To Boiler

Remains Closed

3. BFP Recirculation Valve

It Measures Flow at BFP Booster Pump Discharge

Ensures minimum Flow through BFP Booster Pump

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

It measures value from Storage tank level Transmitter

Maintain Separator Storage Tank Level

5. UG Valve

Maintain Minimum Economizer Inlet Flow ( 30 % TMCR = Approx 660 T/Hr)

Maintain DP across the BRP ( Approx 4.0 Ksc)

It Measures Flow Value from Economizer Inlet Flow Transmitter

6. WR / ZR Valve

Maintains Separator Storage Tank Level

It Measures value from the Storage tank Level

7. Storage Tank Level

3 Nos Level Transmitter has been provided for Storage tank level measurement

1 No HH Level Transmitter has been provided

At 17.9 Mtr level it will trip all FW Pumps also MFT will act

1 No LL Level Transmitter has been provided

At 1.1 Mtr level MFT will Act

 SYSTEM DESCRIPTION ( DRY MODE OPERATION)

1. Following System will be isolated during Dry Mode Operation

FCV ( 30 % )

Start Up System Of Boiler

WR / ZR Valve
Storage Tank
BRP
BRP Recirculation System

BFP Recirculation Valve

2. Following System will be in service

UG Valve ( Full Open)

100 % FW Valve ( Full Open)

Platen / Final Super-heater spray control

Start Up System Warming Lines

Separator Storage Tank Wet Leg Level Control

 SYSTEM OPERATION ( DRY MODE OPERATION)

1. START UP SYSTEM

In Dry Mode Start Up System Of Boiler will become isolated

Warming System for Boiler Start Up system will be charged

Separator Storage Tank level will be monitored by Separator storage tank wet leg level
control valve ( 3 Mtr)

2. TRANSITION PHASE :- Changeover of FW Control valve (30 % to 100 % Control )

100 % FW Flow valve will wide open

During the transition phase system pressure fluctuates

The system pressure fluctuation will be controlled by 30 % FW Valve. After stabilization of

system 30 % CV Will become Full Close

3. FEED WATER CONTROL

It will be controlled in three steps

Feed Water demand to maintain Unit Load

Maintain Separator O/L Temperature
Maintain acceptable Platen Spray Control Range
 FEED WATER DEMAND ( DRY MODE OPERATION)

1. FINAL SUPER HEATER SPRAY CONTROL

Maintain the Final Steam Outlet Temperature ( 540 C)

2. PLATEN SUPER HEATER SPRAY CONTROL

Primary purpose is to keep the final super heaer spray control valve in the desired
operating range

Measures the final spray control station differential temperature

It Compares this difference with Load dependent differential temperature setpoint
Output of this is the required temperature entering the Platen Super Heater Section
(Approx 450 C)

3. FEED WATER DEMAND

1. FEED FORWARD DEMAND

It is established by Boiler Master Demand.

This Demand goes through Boiler Transfer Function where it is matched with the actual
Evaporator Heat Transfer to minimize the temperature fluctuations

2. FEED BACK DEMAND

Work With two controller in cascade mode

 FEED WATER DEMAND ( DRY MODE OPERATION)

2. FEED BACK DEMAND

Work With two controller in cascade mode

FIRST CONTROLLER

One Controller acts on Load dependent average platen spray differential

temperature

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

Second Controller acts on the load dependent Separator Outlet Temperature

adjusted by Platen spray differential temperature

This controller adjust the feed water in response to firing disturbances to

achieve the separator O/L Temperature

THE RESULTING DEMAND FROM THE COMBINED FEEDFORWARD AND FEEDBACK

DEMANDSIGNAL DETERMINED THE SETPOINT TO THE FEED WATER MASTER CONTROL
SETPOINT
DRY TO WET MODE OPERATION ( START UP SYSTEM NOT AVAILABLE)

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

BLR PATH ( WHEN WET MODE)

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

BLR Path (When Dry Mode)

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

406 451 440 486 480 540

DSH1 DSH2

15% 3%
 BOILER LOAD CONDITION

Constant Pressure Control

Above 90% TMCR The MS Pressure remains constant at rated pressure

The Load is controlled by throttling the steam flow

Below 30% TMCR the MS Pressure remains constant at minimum

Pressure

Sliding Pressure Control

Boiler Operate at Sliding pressure between 30% and 90% TMCR

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.

This is called .sliding pressure operation..

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.

The ability to use sliding pressure operation is determined by the boiler

Boilers can be designed to accommodate sliding pressure.

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 fixed pressure operation , temperature change in the turbine when load

changes, while in sliding-pressure operation ,they change in the boiler
 The enthalpy increase in the boiler for preheating, evaporation and superheating changes
with pressure.

However, pressure is proportional to output in sliding pressure operation

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)

Able to maintain constant first stage turbine temperature

Reducing the thermal stresses on the component : Low Maintenance & Higher
Availability

No additional pressure loss between boiler and turbine.

low Boiler Pr. at low loads.

WHY NOT S.P.O. IN NATURAL/CONTROL CIRCULATION BOILERS

Circulation Problem : instabilities in circulation system due to steam formation in

down comers.

Drum Level Control : water surface in drum disturbed.

Drum : (most critical thick walled component) under highest thermal stresses
The Basis of Boiler Start-up Mode

Mode Basis Restart

Starting Time
Hot Warm Cold

Stopped time 2Hr Within 6~12Hr 56Hr Within 96Hr Above

SH Outlet Temp 465 above 300 above 100 above 100 below

Separator Tank pr 120200/ 30120/ 30/ below 0/

STARTING TIME

Light off TBN Light off

Startup Mode Rolling(minutes) Full Load(minutes)
Cold 120 420 Except Rotor and Chest Warming Time

Warm 90 180 "

Hot - -

Restart 30 90
 PURGE CONDITIONS
No Boiler Trip Condition Exists

All System Power Supply Available

Unit Air Flow > 30 % BMCR

Nozzle Tilt Horizontal and Air Flow < 40 %

Both PA Fans Off

The Following Condition Exist At Oil Firing System

The HOTV / LOTV Should Be Closed
All Oil Nozzle Valve Closed

The Following Condition Exists at Coal Firing System

All Pulverisers are Off
All Feeders are Off
All Hot Air Gates Of Pulverisers are closed

All Flame Scanner on all elevation shows no Flame

Aux Air Damper At All Elevation should be modulating

After Purging Boiler Light Up activites are same as in 500 MW plant

 MFT CONDITIONS
Both ID Fans Off
Both FD Fans Off
Unit Air Flow < 30 % TMCR
All Feed Water Pumps Are Off For More Than 40 Sec
2 / 3 Pressure Transmitter indicate the furnace pressure High / Low for more than 8 sec ( 150
mmwc / -180 mmwc))
2 / 3 Pressure Transmitter indicate the furnace pressure High High / Low - Low ( 250 mmwc
/ - 250 mmwc)
Loss Of Re-heater Protection
EPB Pressed
All SAPH Off
Economizer Inlet Flow Low For More Than 10 Sec (223 T/Hr)
Furnace Vertical Wall Temperature High For more than 3 Sec (479 C)
SH Pressure High On Both Side (314 KSc)
SH Temperature High For More Than 20 Sec ( 590 C)
RH O/L Temperature High For More Than 20 Sec ( 590 C)
Separator Level Low-Low During Wet Mode ( 1.1 M)
Separator Level High-High During Wet Mode ( 17.7 M)
 MFT Relay Tripped
Loss Of Fuel Trip : It Arms when any oil burner proven.
it occurs when all of the following satisfied
All Feeders Are Off
HOTV Not Open or all HONV Closed
LOTV Not Open or all LONV Closed
Unit Flame Failure Trip : It Arms when any Feeder Proves
it occurs when all 11 scanner elevation indicates flame failure as listed below ( Example is
for only elevation A)
Feeder A & Feeder B is Off with in 2 Sec Time Delay
following condition satisfied
Any oil valve not closed on AB Elevation
3 /4 valves not proven on AB Elevation
Less Than 2 / 4 Scanner Shows Flame
Both Of The Following Condition Satisfied
Less Than 2 / 4 Scanner Flame Shows Flame
2 / 4 Oil Valves not open at AB Elevation
 Boiler Light Up Steps

Start the Secondary Air Preheater

Start one ID fan, then the corresponding FD fan and adjust air flow to a min. of 30% TMCR

Start the scanner air fan.

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).

Check that all other purge permissives are satisfied.

Place FTPs in service.

Check The MFT Conditions

For First Time Boiler Light Up do the Oil Leak Test

Initiate a furnace purge.

 SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

FURNACE READINESS
PRESSURE PARTS
SCANNER AIR FAN
BOTTOM ASH HOPPER READINESS
FUEL FIRING SYSTEM
START UP SYSTEM

SEC AIR PATH READINESS

FD FAN
SAPH
WIND BOX / SADC

FLUE GAS SYSTEM

ESP PASS A , B
ID FAN
 SYSTEM / EQUIPMENT REQUIRED FOR BOILER LIGHT UP

CONDENSATE SYSTEM
CONDENSER
CEP
CPU

FEED WATER SYSTEM

D/A
MDBFP # A
VACCUME SYSTEM
SEAL STEAM SYSTEM
TURBINE ON BARRING
Evaporator heat absorption
Reduced number of evaporator wall tubes.

Ensures minimum water wall flow.

SPIRAL WALL ARRAMGEMENT AT BURNER BLOCK AREA :
Support System for Evaporator Wall

Spiral wall Horizontal and vertical buck stay with tension strip

Vertical wall Horizontal buck stay