BOILER-TRB-ABDUL MOIZ

Boiler
The boiler at HPS is single drum natural circulation boiler which is fired using heavy fuel oil.

Boiler Specifications
The specifications of boiler are
Manufacturer IHI
Type Single Drum Forced Draught, Water tube
with natural circulation
Main Steam Flow (at BMCR) 1030100 kg/hr
Reheat Steam Flow (at BMCR) 892900 kg/hr
Design Boiler & Super Heater Pressure 197 kg/cm2 g
Design Re Heater Pressure 51 kg/cm2 g
Steam Condition at Super Heater Outlet (at 175 kg/cm2 g x 541oC
BMCR)
Fuel RFO
Draught System Forced Draught
Boiler Components
The boiler components include:
Economizer
Steam Drum
Down Comers
Risers (Water Walls)
Primary Super Heater
Secondary Super Heater
Final Super Heater
Furnace

Economizer
The economizer is located below the Primary Super Heater tubes.
The economizer tubes receive flue gas at the lowest temperature.
The economizer tubes are counter flow.
There are 218 tubes.

Steam Drum
Steam drum is located at the top front of the boiler.
Water is separated from steam in the steam drum. The three phases of separation are:
Circumferential baffles: moisture gets deposited on the baffles while the steam
passes.
Horizontal separator: present at mid-level of steam drum and steam gets
separated through centrifugal forces.
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Chevron dryer: Change of direction of flow causes water to drain to drum

bottom while saturated steam moves to the inlet of Primary Super Heater.
The vortex eliminators are installed at the inlet of down-comers to reduce entry of
steam into the down-comers. Otherwise steam can decrease the natural circulation of
the boiler.

Super Heaters
The super heaters are divided into three stages
o Primary Super Heater
It is located above Economizer tubes in the second gas pass. The tubes are
counter flow.
o Secondary Super Heater
It is located nearest the burners and faces the highest temperature of all the
heat exchangers in the boiler. The tubes are parallel flow.
o Final Super Heater
It is located above the secondary super heater. The tubes are parallel flow

Re-Heater
The reheater is located above the final super heater.
The tubes are counter flow.

Furnace
The furnace contains the downcomers and waterwalls (risers).
Feed water travels from the steam drum to the waterwalls through downcomers. It
flows naturally due to density difference.
There are a total of six downcomers
o 2 front down comers
o 2 rear down comers
o 2 side down comers
Steam is generated in waterwalls (risers) due to the heat present in furnace.
There are a total of 436 water wall tubes
o 163 front wall tubes
o 163 rear wall tubes
o 105x2 side wall tubes
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Main Steam Flow

Feedwater exits HP7 and enters Economizer inlet

After pre-heating in economizer, it enters the steam drum.

From steam drum, feedwater gains heat as it falls through the downcomers and then rises as
steam through the water walls (risers) back to steam drum

In steam drum, water and steam get separated and steam goes to PSH (Primary Super Heater) for
super heating

From PSH, steam goes to SSH for further heat gain. *Steam attemperation done at SSH inlet to
control steam temperature

From SSH, steam goes to FSH for further heat gain. *Steam attemperation done at inlet of FSH to
control steam temperature

From FSH, steam goes to HP turbine where it expands

From HP turbine, expanded steam comes to reheater through cold reheat pipe and gains heat

From reheater, steam goes into IP turbine through hot reheat pipe
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Gas Air Heater

Gas Air Heater is a regenerative type heat exchanger.
It consists of a stationary casing and a rotor with bearings and auxiliary systems.
Purpose of GAH is to pre-heat combustion air before it enters the furnace.
GAH exchanges heat between the outgoing flue gases and the incoming air from
SAH.
Rotor Assembly
The rotor assembly contain heat storing plates.
The plates absorb heat from flue gases in gas pass and transfer it to air in air pass.
The heat absorbing elements are mounted on sector compartments.
There are a total of 16 sector compartments on each side of the air and gas passes.
On the Cold side, each sector compartment consists of one single element.
On the hot side, each sector compartment consists of six elements. This is done as
cold side has lower flue gas temperature and therefore, the elements are more prone to
corrosion. Having elements divided makes replacement of a corroded element easier.
The cold end layer material is CRLS (Corrosion Resistant Low Alloy Steel) with
thickness of 1mm.

Seals
There are three kinds of seals in GAH
Rotor Seals
Prevents air at high pressure to pass into gas pass.
Radial Seals
Prevents air flow against flue gas flow
Circumferential Seals
Seals off rotor against casing.

Bearing
Self-aligning roller bearings support the shaft.
The bearing housing contains bearings along with shaft seals
Lubrication of bearing is through grease
Bearing is cooled through water.

Drive Unit:
Rotor is driven by electric motor.
The speed of the rotor is reduced through rack to pinion gear arrangement.
The reduction ratio is 1/93.63.
Air motor with over-running clutch serves as auxiliary drive unit and it takes over in
case of electric motor failure.

Soot Blower
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Soot blowing is a daily operation performed through soot blower system to remove deposits
that form on the boiler tubes due to combustion oil. Without soot blowing, the heat transfer is
reduced since the soot acts as insulation.

Components
The components in Soot blower are:
o Lance Tube
o Feed Tube
o Poppet Valve
o Nozzle head with 2 venturi type nozzles
o Gear Box
o Limit Switches (on front & rear end)
Design
The soot blower is of a long retractable type and consists of a feed tube flanged on to
a lance tube.
The feed tube is connected with the poppet valve which admits steam when operated
and from the feed tube goes into the lance tube.
On the front end of the lance tube two venture nozzles are present 180 degrees apart.
A gear box is attached to the feed tube. The gear box consists of a worm gear which
drives a worm wheel. The wheel moves on a rack taking the carriage forward &
backward.
The tube rotates through a simple chain and gear arrangement. A chain is attached
with the drive gear. The chain is connected with a gear on the feed tube.
A wall box is also present which is the area taking the lance tube inside the boiler.
There are two disk packages with the wall box to prevent the flue gases coming into
atmosphere. Seal air is used to provide sealing between the two disks.

Working
Steam admittance is through a mechanically controlled spring-loaded valve which is
flanged to inlet steam pipe. When valve is pushed down, the stem is moved down and
allows the steam to flow through the feed tube.
The feed tube is flanged to the poppet valve assembly.
The nozzles of the lance tube are present in wall box when the soot blower is
stationary.
When the motor is switched on, the carriage starts its forward motion and the lance
tube starts rotating. The actuation of motor is accompanied by opening of poppet
valve through the trip pin. The assembly moves forward till the forward limit switch is
hit.
As soon as forward position is reached, the reverse travel is actuated. The soot blower
stops blowing before the nozzle reach the wall box.

Soot Blower Specifications:

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No. of Soot Blowers for Boiler 14

No. of Soot Blowers for GAH 4

Pressure of Steam 20 bar

Operational Time (Forward and reverse) 662s

Total Travel 8000mm

Speed 1.45/min

Inspection of poppet valve:

One of the field activities observed during our rotation was the routine inspection of Poppet
Valve for Unit-1 4L Soot Blower. The Poppet Valve consists of:
Valve Body (including seat)
Valve Stem
Valve Plug
Spring
Notch
Air Inlet opening
On-load notch setting
Gasket
Operation of Poppet Valve
The operation of poppet valve involves the following steps:
When a signal is generated to open the poppet valve, a trip pin puts downward force
on the spring.
The stem moves downwards
The plug goes below the seat
Steam enters from the bottom of the valve and goes into the lance tube.
The pressure at which the steam would enter the lance tube can be regulated not only through
the PCV at the Steam Inlet header but also locally at the Poppet valve through the Notch.
Movement of one notch line can increase or decrease the pressure by 0.5 bar. The notch itself
can be regulated on load through a provision at the back of the valve.
Air is used whenever no steam passes through the poppet valve. The air entry is sealed during
operation of the soot blower due to the pressure of steam in the poppet valve. Once steam
supply gets cut, the passage for air inlet opens.
Inspection
The valve, stem, plug, notch and gasket was inspected and all was found in satisfactory
condition.
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Wash down Sump Pump

Washdown sump pump is a vertical type immersible pump i.e. its impeller is submerged in
the fluid while the motor is outside. A PR was raised for Wash down Sump 1 Pump 2 as the
pump was not giving any discharge. It was decided to remove the pump from site and bring it
into the workshop to look at the problem.
Specifications of Washdown Sump Pump
Pump Specifications
Capacity 240 cubic meter/hr
Head 20.65m
Model Series 5500
Make FYBROC
Size 4x6x13 (Discharge dia: 4 inches;
Suction dia: 6 inches; Impeller dia: 13
inches
Motor Specifications
Voltage 380V
Frequency 50Hz
Power 22kW
IP IP54
Speed 1485rpm
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Steps of Removal of Pump from Site:

Motor connections removed by EMD.
Check Valve at pump discharge removed.
Flange with pump discharge removed
Motor coupling with pump removed (flexible bellow coupling)
Motor lifted through Merlo and handed over to EMD in workshop
Pedestal bolts unscrewed and pump in sump lifted along with pedestal through Merlo
Pump transported to workshop and handed over to EMB team.
Steps of Disassembly of Pump at Workshop
Strainer at the intake of impeller removed.
Discharge pipe disconnected from pump.
Double volute pump casing removed
Impeller removed
Impeller nut removed
2 Sleeve bearings mounted on shaft removed
Coupling (pump end) removed
Shaft removed
Ball bearing removed
Problems Found and Actions taken
The back of the impeller body was found broken (new impeller needed)
The strainer was choked (strainer cleaned)
The sleeves on shaft were in poor condition (new sleeves to be fabricated in machine
shop)
The shaft was eccentric as indicated by run-out

Flexible Coupling Run-out Check

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Sleeve Bearing
Pump Transportation

Double Volute Casing Motor

Impeller
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Welding
Classification

Welding

According to Arc According to Filler

Arc Non-Arc Filler Non-Filler

TIG Resistance TIG Ultrasonic

MIG Gas MIG

SMAW Ultrasonic Resistance

Gas

Where,
TIG=Tungsten Inert Gas
MIG=Metal Inert Gas
SMAW=Shielded Metal Arc Welding
The two types of welding carried out at Hub Power Station are:
GTAW (TIG)=Gas Tungsten Arc Welding
SMAW=Shielded Metal Arc Welding

GTAW
As the classification shows, GTAW
Establishes an arc to reach high temperatures required for melting of base metal
Uses a filler material (similar to base metal) for the purpose of joining two metals.
Uses Tungsten as an electrode which is non-consumable
Uses inert gas for protection of welding surface from contamination (Argon used at
Hub Power Station)
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Polarity for GTAW and its Effects

A DC field is normally given for the purpose of arc generation. The generated arc creates
heat which results in melting of the base metal. The polarity of the DC field plays a major
role on the welding results.
There are two ways in which the DC field can be used to create an arc between the electrode
and the work piece:

DCEN (Direct Current Electrode Negative)

The electrode is connected with the negative terminal of the DC battery while the
work piece is connected to the positive terminal. This is the conventional electrical
connection arrangement for GTAW and is considered reverse polarity connection.

As the figure shows, electrons move from the electrode to the work piece while the
ionized inert gas moves from the work piece to the electrode. This results in:
o Heat concentrated on work piece (electrode at lower temperature and does not
get consumed as a result)
o Deep and narrow welding
o Formation of oxide layer at work piece as ionized inert gas moves away from
the work piece
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DCEP (Direct Current Electrode Positive)

The electrode is connected with the positive terminal of the DC battery while the
work piece is connected to the negative terminal. This is the non-conventional
electrical connection arrangement for GTAW and is considered true polarity
connection.

As the figure shows, electrons move from the work piece to the electrode while the
ionized inert gas moves from the electrode to the work piece. This results in:
o Heat concentrated on electrode (electrode at higher temperature and gets
consumed as a result)
o Shallow welding
o Clean action of oxide layer at work piece as ionized inert gas moves towards
the work piece
SMAW
As the classification shows, SMAW is:
Establishes an arc to reach high temperatures required for melting of base metal
Uses a filler material (electrode which is similar to base metal) for the purpose of
joining two metals.
Uses a layer of flux (mixture of carbon and silicate) over the consumable electrode for
protection of welding surface from contamination.
The only electrical connection through which arc is established in SMAW is positive polarity
i.e. DCEP. Since the electrode itself is consumed in SMAW, it is imperative that the heat is
concentrated on the electrode. Therefore, DCEP is used in SMAW.