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Definition
As per Indian Boiler Act 1923, Boiler is defined as any closed vessel exceeding 22.75 liters in capacity
which is used exclusively for generating steam under pressure and includes any mounting or accessories
attached to such vessel, which is wholly or partially under pressure, when steam is shut off.
A good Boiler should have some essential qualities.
1. Capable to meet large load fluctuations.
2. Fuel efficient i.e. to generate maximum steam with minimum fuel consumption.
3. Ability to start‐up quickly.
4. Easy in maintenance and inspection.
5. Occupy less floor space.
6. Lower friction loss in water and flue gas circuit
7. Little attention for operation and maintenance.
Systems in a Boiler
A Boiler mainly contains following systems :
1. Feed water system.
2. Steam system.
3. Air system.
4. Flue gas system.
5. Fuel handling system.
6. Ash handling system.
Boiler Mountings
Fittings on a Boiler which are required for its safe and efficient operation are called mountings. These
are as follows :
1. Safety valve
2. Water level sight glass (gauge glass)
3. Pressure gauge
4. Blow down valve
5. Main steam stop valve
6. Feed water check valve (NRV)
7. Air Vent
8. Start‐up vent
9. Manhole
Boiler Accessories
The devices which are used in a Boiler as an integral part and help to run the Boiler efficiently are called
Boiler Accessories. These are :
1. Super heater
2. De‐super heater
3. Economizer
4. Air Pre‐heater
5. Soot Blower
6. Feed Pump
7. ID and FD fans
8. Ash Removal system
9. Fuel supply system
10. Dosing system
11. Deaerator
Steam Generation In A Boiler..contd
In a Boiler fuel is burnt to get heat energy which is converted from chemical energy stored in a fuel. This
heat energy is utilized to produce steam from feed water.
Fuel is fired in the furnace of the Boiler. Different fuel is used in different Boilers. Accordingly furnace is
designed. Water tubes are arranged around the furnace and flue gas path. Water tube arrangement
made around the furnace is called as water wall. Feed water is circulated in these tubes. Water comes to
water wall from Boiler drum, and circulated back to drum after absorbing heat. Due to difference in
density which is created due to difference in temperature, water circulates in these tubes naturally.
Therefore, it is called Natural Circulation.
During circulation of water in tubes, steam is generated and collected at the upper part of the Drum.
This is called Saturated Steam corresponding to Boiler drum pressure. This steam is further heated in
Superheaters and becomes superheated steam.
Boiler Drum is filled with fresh feed water. The feed water, before entering into drum is heated at
Economizer. Economizer is placed at the flue gas path. Most of the heat of the flue gas is utilized inside
the Boiler. Still considerable amount of heat energy is available in it. This heat is utilized in Economizer
to heat up the feed water.
For burning of fuel, required Oxygen is obtained from atmospheric air. Air is required in Boiler furnace
for combustion. This is supplied by Forced Draught (FD) fan. This air is heated at air pre‐heater (APH)
before being sent into furnace. If cold air is used then there will be loss in energy. Air pre‐heater is
placed at the flue gas path after Economizer. Air pre‐heater is a heat exchanger which exchanges the
heat of flue gas to the cold air, which is to be used in furnace. By heating the air, burning of fuel is easier
and loss of energy is minimized. If hot flue gas would not be used to heat up feed water at Economizer
and air at Air Pre‐heater then it would escape into atmosphere.
Finally the flue gas passes through Electrostatic Precipitator (ESP) and exhausted to atmosphere through
chimney. At ESP the dust particle in the flue gas is trapped and clean gas escapes to atmosphere.
Ash which is produced in the Boiler due to combustion of solid fuel is collected at Boiler bottom and also
in Economizer, Air Pre‐heater and ESP. This ash is disposed off with the help of suitable ash handling
system.
Preparations for Cold Start‐up
1. All the manhole doors should be in close condition. Tightness of the Nuts and Bolts of the man hole
doors to be checked properly.
2. All the water wall drain lines should be in close condition.
3. All the steam drain lines should be in open condition.
4. Start‐up vent Root Manual isolation valve should be in open condition.
5. Drum level should be at Normal Water Level (NWL).
6. Continuous Blow Down (CBD) and Intermittent Blow Down (IBD) drains should be in close condition.
7. All the super heater vents including Drum vent and Puppy Header vent should be in open condition.
8. Before and After Isolation valves at Feed Control Station (FCS) should be in open condition.
9. Attemperation Control valve before and after isolation valve should be in open condition .
10. Hydra step should be in healthy condition.
11. Safety valves should be in healthy condition.
12. Main Steam stop valve and by‐ pass valve should be in close condition.
13. Soot blower manual isolation valve and control valve should be in close condition.
14.Boiler Drum Gauge glass steam side and water side isolation cocks should be in open condition.
15. HP Dosing Pumps should be in Healthy condition and open suction and discharge valves of the
pump.
16. Solution in HP Dosing agitator tank should be at normal level.
17. Boiler Feed Pumps should be in healthy condition.
18.Deaerator water level should be maintained at 60% by taking DM Transfer pump in service.
19. Air compressors should be in healthy condition.
20. Ash handling systems should be in healthy condition.
21. ESP should be in healthy condition.
22. ID fan damper should be in Zero position.
23. All the interlocks and protection should be checked properly viz. Drum level low, Deaerator level
low, Boiler Feed Pump (BFP) discharge pressure low, Flue gas temperature at Post Combustion Chamber
(PCC) outlet high, silo level.
Cold Start‐up process
1. After Kiln light‐up, when flue gas temperature at PCC outlet increases to more than 450 deg.C, open
ID fan damper 5%. Due to natural draught created by chimney, flue gas passes through Boiler and slow
heating and expansion takes place.
2. After opening of ID fan damper, Boiler furnace temperature rises slowly. When the furnace
temperature rises to 250 deg C, Open ID fan damper 10%.
3. When Flue gas temperature at PCC outlet rises more than 600 deg C., close the ID fan damper
and start ID fan.
4. When Drum pressure reaches 5 Kg/cm2, close the Drum vent and Puppy header vent.
5. When Boiler Drum pressure reaches 20 Kg/cm2, give blow down of the water wall to remove the
deposition or sludge.
6. By adjusting damper opening raise the Boiler pressure upto 45 kg/cm2 and 485 deg C.
7. Start‐up vent should be in open condition since the admittance of hot flue gas in boiler.
8. Open the Main steam line drains in between Boiler Main Steam Stop Valve (MSSV) and TG MSSV.
9. Open the MSSV by pass valve to remove all the condensate in main steam line and ensure that TG
MSSV is in close condition.
10. After removal of all the condensates in Main steam line and proper line heating, open Main Steam
stop valve of Boiler.
11. Close Super heater drains.
12. Put Drum level controller in Auto mode.
13. Put Attemperator controller in Auto mode.
14. Close Start up vent as per the steam demand of TG set.
15. Charge ESP when Flue gas temperature after Economizer reaches 160deg. C
Finally the flue gas passes through Electrostatic Precipitator (ESP) and exhausted to atmosphere through
chimney. At ESP the dust particle in the flue gas is trapped and clean gas escapes to atmosphere.
Ash which is produced in the Boiler due to combustion of solid fuel is collected at Boiler bottom and also
in Economizer, Air Pre‐heater and ESP. This ash is disposed off with the help of suitable ash handling
system.