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SALIENT FEATURES OF 210 MW BOILER

( RTPS)
INTRODUCTION:

BOILER IS MAINLY A STEAM GENERATOR IT CONVERTS CHEMICAL ENERGY


(AVAILABLE IN FUEL) INTO HEAT ENERGY. SO IT IS ALSO AN ENERGY
CONVERTER.

IN THE INITIAL STAGES (LIKE IN LOCOMOTIVES) FUEL WAS FIRED


MANUALLY USING SHOVEL IN THE BOILERS. SUBSEQUENTLY STOKER
FIRED BOILERS WERE INTRODUCED. IN STOKER FIRED BOILERS ONLY
UPTO 15 T/HR COAL COULD BE BURNT. DEMAND FOR HIGHER CAPACITY
OF STEAM GENERATION HAS LEAD TO THE TYPE OF BOILERS WHAT WE
SEE IN POWER PLANTS.

CAPACITY OF 210 MW BOILER - STEAM GENERATING CAPACITY UNDER NCR


CONDITION - 630 T/HR AT MCR - 680 T/HR. MAIN STEAM AND HRH TEMP -
540OC, OPERATING PRESSURE OF MAIN STEAM -151 KSC.
BOILERS SPECIFICATION

NATURAL CIRCULATION, BALANCED DRAFT, REHEAT TYPE, TANGENTIALLY


FIRED SEMI -OUTDOOR TYPE WATER TUBE BOILER.
BOILER IS SUSPENDED AT THE TOP THROUGH SUPPORT STRUCTURES AND IT
IS FREE TO EXPAND AT THE BOTTOM IN SEAL TROUGH. MAX EXPANSION IS
6" IN 210-MW UNIT AT FULL LOAD. SEAL TROUGH ALSO PREVENTS ENTRY OF
ATMOSPHERIC AIR INTO THE FURNACE WHICH IS UNDESIRABLE.

THERE ARE 16 PLATFORMS STARTING FROM 7.9 M TO 54.55 M EL. MOST OF


THE IMPORTANT COMPONENTS ARE LOCATED IN FIRING FLOOR (17.9 M EL)
AND DRUM LEVEL (52 M EL)

TOTAL WEIGHT OF THE BOILER AND AUX. IS 10,848 MT OUT OF


WHICH THE
PRESSURE PART WEIGHS 2190 MT.

COMPONETS OF THE BOILER & AUX.

1) PRESSURE PARTS
2) BOILER MOUNTINGS AND FITTINGS
3) FIRING EQUIPMENTS (COAL AND OIL FIRING).
4) BOILER ACCESSORIES (APH,ESP,PA FAN,FD FAN, ID FAN & SCANNER AIR
FAN)
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BOILER PRESSURE PARTS :

IT CAN BE DIVIDED INTO 3 ZONES


1) FIRST PASS LEFT WALL
2) HORIZONTAL PASS 130 TUBES
3) SECOND PASS
CORNER 1 CORNER 2
FURAN
I. I PASS CONSISTS OF CE

1) WATER WALLS FRONT WALL REAR WALL


2) BOTTOM RING HEADER 181 TUBES 181TUBES

3) W.W. OUTLET HEADER


4) DRUM CORNER 4 RIGHT WALL CORNER 3
5) PLATEN SUPER HEATER (29 ASSY) 130 TUBES
6) FURNACE ROOF

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WATER WALL TUBE SIZE -Ø 63.5 X 5.5 SA 210 GRADE C.


FURNACE ROOF TUBES (SH RADIANT ROOF TUBE) Ø51 X 4.5 SA 209 T1.
PLATEN SUPERHEATER TUBE SIZES
Ø47.63 X 6.6 SA 213 T11 Ø 47.63 X 6.3 SA 213 TP 347 H
Ø 47.63 X 5 SA 213 T11 Ø 47.63 X 6.6 SA 213 T 22
Ø 47.63 X 10 SA 213 T22 Ø 47.63 X 7.6 SA 213 T 22

ALL THE WALLS AND ROOF ARE MADE UP OF TUBES. WATER WALL IS OF
FUSION WELDED IN CONSTRUCTION, ROOF IS OF PEG FIN WELDED
CONSTRUCTION, STEAM COOLED WALL OF SECOND PASS IS OF FIN WELDED
CONSTRUCTION.

II. HORIZONTAL PASS

HORIZONTAL PASS CONSISTS OF RH COILS (59 ASSY), FINAL SUPER HEATER


(119 ASSY) & ROOF TUBES (120 TUBES)
RE HEATER TUBES-Ø 60.3 X 4.0 SA 213 T11.
FINAL SUPER HEATER TUBES-

Ø 44.5 X 4.0 SA 209 T1. Ø 54.0 X 3.6 SA 213 T22.


Ø 44.5 X 5.0 SA 213 T22. Ø 54.0 X 4.5 SA 213 T22.
Ø44.5 X 7.6 SA 213 T22 Ø 54.0 X 5.0 SA 213 T22.
Ø44.5 X 8.0 SA 213 T22 Ø 60.3 X 4.0 SA 213 T22.
Ø44.5 X 9.0 SA 213 T22

III. SECOND PASS


SECOND PASS CONSISTS OF STEAM COOLED WALL, ROOF, LTSH COILS (120
ASSY) AND ECONOMISER UPPER AND LOWER BANK (162 COILS ASSY IN UNITS#
3 TO 7 AND 145 COIL ASSY IN UNITS# (1, 2 & 3).

STEAM COOLED WALL TUBES Ø44.5 X 5 SA 210 GRADE A1

LTSH COIL TUBES - Ø44.5 X 4.5 SA 210 GRADE A1


Ø 44.5 X 4.5 SA 209 T1
Ø 44.5 X 5.0 SA 213 T11
ECONOMISER TUBES- Ø44.5 X 4.5 SA 210 GRADE A1

FLOW THROUGH BOILER IS DIVIDED INTO WATER & STEAM CIRCUIT.


WATER FROM FEED REGULATING STATION ENTERS INTO ECO INLET HEADER,
FLOWS THROUGH ECONOMIZER COILS, INTERMEDIATE HEADERS AND
THROUGH SERIES OF ECO HANGER TUBES, REACHES ECO OUTLET HEADER
AND THEN ENTERS DRUM THROUGH 2 ECO LINKS. DURING THIS COURSE THE
FEED WATER ABSORBS HEAT FROM FLUE GAS AND FEED WATER
TEMPERATURE INCREASES.

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FEED REGULATING STATION DETAILS: (SKETCH)

DRUM

DRUM IS OF BI-THICKNESS (170MM AND 135 MM PLATES) AND WEIGHS ABOUT


125 MT.IT IS THE SINGLE HEAVIEST COMPONENT IN BOILER. WATER FROM
ECO ENTERS DRUM AND FLOWS THROUGH SIX DOWNCOMERS & ENTERS
BOTTOM RING HEADERS. FROM THE RING HEADER WATER RISES IN WATER
WALL TUBES AND DUE TO HEAT RELEASED OUT OF COMBUSTION IN
FURNACE, WATER STARTS BOILING. DUE TO DENSITY DIFFERENCE BETWEEN
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FEED WATER AND BOILING WATER IN WATER WALL, A THERMOSYPHON


ACTION IS CREATED AND FLOW IS ESTABLISHED. THIS IS CALLED NATURAL
CIRCULATION. IN HIGHER PRESSURE (>180 KSC) BOILERS, SEPARATE PUMPS
ARE PROVIDED FOR CIRCULATION (FORCED CIRCULATION). IN BOTH THE
CASES OF NATURAL/ FORCED CIRCULATION, AROUND 25% TO 33% OF FEED
WATER (BY WEIGHT) ENTERING THE CIRCUIT GETS EVAPORATED. THIS IS
EQUAL TO A CIRCULATION RATIO OF 3 TO 4. CIRCULATION RATIO IS THE
RATIO OF WT. OF WATER ENTERING THE CIRCUIT TO WT. OF STEAM LEAVING.

THE WATER AND STEAM MIXTURE REACHES WATERWALL OUTLET HEADERS


AND THROUGH 118 RISER TUBES (Ø 127 X 12.5 SA 106 GR B) FROM OUTLET
HEADERS, STEAM AND WATER MIXTURE ENTERS SEPARATING CHAMBER OF
THE DRUM WHICH HAS GOT BAFFLES. FROM THE SEPARATING CHAMBER
WATER AND STEAM MIXTURE FLOWS THROUGH PRIMARY AND SECONDARY
STAGES OF TURBO SEPARATORS (58 NOS). THE PRIMARY SEPARATOR
CONSISTS OF TWO CONCENTRIC CANS. THE INNER CAN HAS GOT SPINNER
BLADES. AS THE MIXTURE PASSES THROUGH SPINNER BLADES THEY IMPART
CENTRIFUGAL MOTION TO THE MIXTURE, THEREBY THROWING WATER
OUTSIDE. THE WATER FLOWS THROUGH THE ANNULUS AND FALLS INTO
WATER SPACE IN DRUM.

SECONDARY SEPARATOR CONSISTS OF TWO ROWS OF CLOSELY


PACKED OPPOSED BANKS OF THIN CORRUGATED SHEETS. AS THE
STEAM RISES TO THE TOP FROM PRIMARY SEPARATOR AT LOW SPEED,
WATER PARTICLES ARE SEPARATED FURTHER AND PURE STEAM GOES TO
THE TOP OF THE DRUM.
AT THE TOP THERE ARE TWO ROWS OF SCREEN DRYERS. HERE FURTHER
SEPARATION OF WATER PARTICLES TAKES PLACE AND PURE STEAM GOES TO
THE SH CIRCUIT.

FURNACE ROOF TUBES STEAM COOLED SIDE WALLS STEAM


COOLED FRONT WALL AND EXTENDED STEAM COOLED WALL
WALL ROOF TUBES AND REAR STEAM COOLED WALL TUBES LTSH
COILS SH ATTEMPERATOR PLATEN SH FINAL SH HP
TURBINE.

REHEATER: THE CRH STEAM FROM HP TURBINE ENTERS RH INLET


HEADER IN BOILER AND FLOWS THROUGH 59 REHEATER COIL ASSEMBLIES
AND ABSORBS HEAT FROM FLUE GAS AND GETS HEATED TO 540ºC AND FLOWS
TO RH OUTLET HEADER. FURTHER IT GOES TO IPT THROUGH HRH LINES.
IN BOILER D.M WATER IS USED FOR FILLING AND MAKEUP.

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BOILER MOUNTINGS / FITTINGS

SAFETY VALVES - TOTALLY 8 NOS. THEY ARE OF SPRING LOADED


TYPE.
MAIN STEAM -1
DRUM - 3 (LEFT -2, RIGHT - 1)
HRH - 3
CRH- 1
EMRV- 1 (UNIT # 4 - 2 NOS.)

SAFETY VALVE IS CHARETERISED BY SUDDEN OPENING OF THE VALVE


AT THE SET PRESSURE.

AS PER IBR, SAFETY VALVE SIZE AND NOS. SHOULD BE SUCH THAT
ENTIRE STEAM GENERATING CAPACITY OF THE BOILER SHOULD BE
EXHAUSTED WHEN ALL THE SAFETY VALVES OPEN.
THE PRESSURE AT WHICH THE SAFETY VALVE CLOSES IS KNOWN AS
RESET PRESSURE. THE DIFFERENCE BETWEEN OPENING PRESSURE AND
CLOSING PRESSURE EXPRESSED AS A PERCENTAGE OF OPENING
PRESSURE IS KNOWN AS BLOW DOWN OF A SAFETY VALVE. NORMALLY
IT IS AROUND 3 TO 5%.

SETTINGS OF BOILER SAFETY VALVES:

OPENING CLOSING
PRESSURE (KSC) PRESSURE(KSC).

 DRUM SAFETY VALVE- 177.0 169.9


180.5 171.6
182.3 173.2
 M. S SAFETY VALVE 164.4 158.6
 R.H SAFETY VALVE - (CRH) 45.0 42.7
 R.H SAFETY VALVE - (HRH) 42.4 40.3
42.8 40.7
44.6 42.4
 EMRV 162.8 157.9

EMRV IS POWER OPERATED AND IS ACTUATED AUTOMATICALLY WHEN


THE PRESSURE INCREASES THE SET PRESSURE. ALSO IT CAN BE OPENED
BY PUSHING A BUTTON FROM UCB WHENEVER NECESSARY.

BOILER FITTINGS - DRUM GAUGE GLASS (STATUTORY REQUIREMENT),


REMOTE WATER LEVEL INDICATOR, SAMPLING VALVES, BOILER STOP
VALVES(TO SUPPLY STEAM TO TURBINE), FEED STATION VALVES, SPRAY
VALVES, DRAIN VALVES, VENT VALVES ETC. FORM BOILER FITTINGS.

FIRING EQUIPMENT.
PULVERISED FUEL FIRING IS USED IN BOILER, THEREBY COMBUSTION
EFFICIENCY IS IMPROVED.
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TWO TYPES OF FIRING EQUIPMENTS

A) OIL FIRING EQUIPMENT : IS USED FOR LIGHT UP AND STABILISATION


OF COAL FLAME. LDO AND HFO CAN BE USED.

B) COAL FIRING EQUIPMENT: IS USED FOR PULVERIZED FUEL FIRING.

THERE ARE 12 OIL BURNERS AND 24 COAL BURNERS. THEY ARE HOUSED
IN THE CORNERS OF BOILER IN A ZONE CALLED AS WIND BOX. EACH
WIND BOX HAS 13 COMPARTMENTS, 3 FOR OIL NOZZLES, 6 FOR COAL
NOZZLES AND 4 FOR AUXILIARY AIR NOZZLES. FROM ALL THE
COMPARTMENTS, SECONDARY AIR PASSES THROUGH SECONDARY AIR
DAMPERS. ALL THE 52 DAMPERS ARE LINKED TO A CONTROL SYSTEM
CALLED SADC (SECONDARY AIR DAMPER CONTROL).

FOR OIL FIRING, THERE ARE OIL GUNS IN 3 ELEVATIONS(AB, CD,


EF).EACH ELEVATION HAS 3 OIL GUNS LOCATED IN 4 CORNERS. STEAM IS
USED TO ATOMISE HFO. HFO IS HEATED TO 120ºC IN HEATERS AND
CIRCULATED TO FIRING ZONE.
NORMAL HFO PRESSURE AT FIRING ZONE 6 KSC.
NORMAL ATOMISING STEAM PRESSURE 5.2 KSC.
FOR LDO SERVICE AIR IS USED FOR ATOMISATION. NORMAL LDO
PRESSURE AT GUN IS 4KSC.
NORMAL ATOMISING AIR PRESSURE IS 5.2 KSC.
LDO CAN BE FIRED ONLY IN AB ELEVATION.

LDO SYSTEM HFO SYSTEM:

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THE FIRING PROCESS IS CONTROLLED BY A SYSTEM CALLED FSSS. (FURNACE


SAFEGUARD AND SUPERVISORY SYSTEM). THE SYSTEM HAS GOT MANY
PROTECTIONS TO SAFEGUARD THE BOILER AND ALSO PREVENT
MALOPERATION.
MOLTEN ASH RESULTING OUT OF COMBUSTION HAS A TENDENCY TO GET
LODGED ON TO WATER WALLS. THIS (SLAG) IS REMOVED BY IMPINGING
STEAM AT A PRESSURE OF 10 KSC THROUGH NOZZLES. THIS SYSTEM IS
CALLED SOOT BLOWING / WALL BLOWING SYSTEM. THERE ARE 56 BLOWERS
IN THE FIRING ZONE. THEY ARE ARRANGED IN 4 ELEVATIONS (14 IN EACH
ELEVATION).EACH BLOWER OPERATES FOR 1.5 MINUTES.

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BOILER AUXILIARIES.
BOILER AUXILIARIES (FD FANS, PA FANS, ID FANS, SCANNER AIR FANS, ESP
AND APH) FORM THE FOLLOWING SYSTEMS.
FLUE GAS SYSTEM.
PRIMARY AIR SYSTEM.
SECONDARY AIR SYSTEM.

AIR PRE HEATER: IT IS A HEAT EXCHANGER. PRIMARY AIR AND


SECONDARY AIR ARE HEATED IN APH BEFORE GOING TO FURNACE.
HEATING ELEMENTS ARE IN THE FORM OF THIN SHEETS OF DU (DOUBLE
UNDULATED)AND NF(NOTCHED FLATF) PROFILES CLOSELY PACKED TO
FORM BASKETS. THE BASKETS ARE HOUSED IN COMPARTMENTS CALLED
MODULES OF ROTOR. BASKETS ARE ARRANGED IN 3 ROWS I,E HOT END ,
HOT INTERMEDIATE END AND COLD END. APH ROTOR IS DEVIDED INTO 3
ZONES CALLED SECTORS. WHEN THE BASKETS ARE IN FLUE GAS ZONE
THEY PICKUP HEAT FROM FLUE GAS AND THESE BASKETS WHEN COME
TO PRIMARY AND SECONDARY AIR ZONE THEY RELEASE HEAT TO
PRIMARY AIR AND SECONDARY AIR. THUS THE HEAT FROM FLUE GAS IS
ABSORBED. APH ROTOR ROTATES AT AROUND 1.5RPM. THERE ARE TWO
AIR PREHEATERS.
TYPE OF AIRHEATER- LJUNGSTROM REGENERATIVE TYPE.

SPECIFICATION OF APH - 27 VI MT 2000.(72 PA)


27-APH SIZE
V- VERTICAL SHAFT.
I-INVERTED GAS FLOW.
M-MODULAR ROTOR.
T-TRI SECTOR.
2000-ELEMENT DEPTH IN MM.
TOTAL BASKETS IN HOT END - 120, HEIGHT 300 MM.
TOTAL BASKETS IN HOT INTERMEDIATE END- 120, HEIGHT 850 MM.
TOTAL BASKETS IN COLD END- 168, HEIGHT 850 MM.
APH SOOT BLOWING IS PROVIDED IN THE COLD END OF APH TO
REMOVE SOOT FORMED IN BASKETS. ONCE IN A SHIFT, APH SOOT
BLOWING IS CARRIED OUT.
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APH IS DRIVEN BY MEANS OF A MOTOR THROUGH REDUCTION DRIVE


GEAR BOX. THERE IS A STANDBY MOTOR, WHICH COMES INTO SERVICE,
IN CASE MAIN MOTOR TRIPS. IN THE EVENT OF STANDBY MOTOR
FAILURE, AN AIR MOTOR COMES INTO SERVICE. IF THERE IS ROTOR
STOPPAGE UNDER HOT CONDITION, SEALS WILL GET DAMAGED.

FORCED DRAUGHT FAN (FD FAN)


THERE ARE TWO FD FANS TO SUPPLY NECESSARY AIR (SECONDARY AIR)
FOR COMBUSTION. FD FAN IS AXIAL REACTION TYPE.

SPECIFICATION- AP 1 18/11
AP-AXIAL FAN PROFILE BLADED.
1- SINGLE STAGE
18- IMPELLER OUTER DIAMETER IN DECIMETERS.
11 -IMPELLER HUB DIAMETER IN DECIMETERS.

OUT PUT OF THE FAN IS CONTROLLED BY MEANS OF BLADE PITCH CONTROL


MECHANISM WHICH VARIES THE BLADE ANGLE OF THE INDIVIDUAL BLADES.
THERE ARE TWENTYTHREE BLADES IN IMPELLER. EACH FAN HAS GOT A LUB
OIL SYSTEM THAT SUPPLIES LUBRICATING OIL FOR BEARINGS AS WELL AS
OIL (CONTROL OIL) FOR SERVOMECHANISM (FOR VARYING BLADE ANGLE)
NORMAL LUBE OIL PRESSURE - 1.2 KSC. NORMAL CONTROL OIL
PRESSURE - 9 KSC.
NORMAL DISCHARGE PRESSURE OF FD FAN 200 - 275 MM OF WC.
FD FAN MOTOR RATING - 600 KW.

PRIMARY AIR FAN (PA FAN)- PA FAN SUPPLIES THE NECESSARY AIR TO DRIVE
OUT THE PULVERIZED COAL FROM MILL TO THE BURNERS. THERE ARE TWO
PA FANS FOR EACH BOILER. PA FAN IS OF RADIAL TYPE.

SPECIFICATION OF PA FAN- NDV 22 TIEFSTACK.


ND- RADIAL FAN
V - SINGLE SUCTION SIMPLY SUPPORTED FAN.
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22 - NOMINAL DIAMETER OF THE IMPELLER DECIMETERS.


TIEFSTACK - TYPE OF IMPELLER.
OUTPUT OF THE FAN IS REGULATED BY INLET DAMPER CONTROL METHOD
TO MEET THE VARYING LOAD CONDITIONS.
THE FAN IS SIMPLY SUPPORTED WITH TWO SLEEVE BEARINGS SUPPLIED
WITH LUBRICATING OIL FROM A SEPARATE LUBE OIL SYSTEM.

PA FAN MOTOR RATING - 1350 KW.

INDUCED DRAUGHT FAN ( ID FAN) - DRIVES OUT THE FLUE GAS COMING
OUT OF THE FURNACE. ID FAN IS RADIAL TYPE WITH DOUBLE SUCTION.

SPECIFICATION OF ID FAN - ND ZV 31 SIDOR.


ND- RADIAL FAN .
ZV - DOUBLE SUCTION SIMPLY SUPPORTED.
31 - NOMINAL DIAMETER OF THE IMPELLER IN DECIMETERS.
SIDOR - TYPE OF IMPELLER.
ID FAN HAS GOT TWO SLEEVE BEARINGS AT TWO ENDS WHICH ARE
SUMP LUBRICATED. THE OUTPUT OF THE FAN IS VARIED BY VARYING
THE SCOOP POSITION OF HYDRAULIC COUPLING IN U# 1, 2 , 3, 4 & 7 AND
BY VARYING THE SPEED OF THE MOTOR THROUGH VFD(VARIABLE
FREQUENCY DRIVE) IN UNITS# 5 & 6.

ID FAN MOTOR RATING 1500 KW.

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SCANNER AIR FAN - PROVIDES THE COOLING AIR FOR THE FLAME SCANNERS.
IN THE NORMAL COURSE, A.C SCANNER AIR FAN WILL BE IN SERVICE. IN CASE
OF FAILURE OF THIS FAN, D.C SCANNER AIR FAN WILL COME INTO SERVICE.

ELECTRO STATIC PRECIPITATORS (ESP) -SEPARATES THE FLY ASH FROM THE
FLUE GAS SO THAT POLLUTION IS CONTROLLED. AS PER THE PRESENT
NORMS STACK EMISSION SHOULD NOT BE MORE THAN 150 MG/NM³.
AT THE ESP INLET, NORMAL DUST CONCENTRATION AT FULL LOAD IS 88.4
GM/NM³. D.C VOLTAGE FROM A 70 KVA SOURCE IS APPLIED ACROSS THE
EMITTING AND COLLECTING ELECTRODES.
EMITTING ELECTRODE IS IN THE FORM OF A SPRING AND COLLECTING
ELECTRODE IS IN THE FORM OF A PLATE. ASH PARTICLES DUE TO CORONA
GENERATION EFFECT GET ELECTRICALLY CHARGED AND GET ATTRACTED
TOWARDS COLLECTING ELECTRODE. ASH COLLECTED ON THE COLLECTING
ELECTRODE IS REMOVED BY RAPPING PERIODICALLY. ASH GETS COLLECTED
IN A HOPPER, WHICH IS REMOVED BY SEPARATE ASH HANDLING SYSTEM.
NOMINAL LENGTH OF THE COLLECTING PLATE - 750MM.
NOMINAL HEIGHT OF THE COLLECTING PLATE - 12.5 METRES.
TOTAL NO. OF COLLECTING ELECTRODES - 4392.

EMITTING ELECTRODE DIAMETER - 2.7MM.


TOTAL NO. OF EMITTING ELECTRODES - 38880.
TOTAL NO. OF HOPPERS - 48.
NORMAL OPERATING VOLTAGE - 40KV.
COLLECTING EFFICIENCY OF ESP - 99.83%.POWER CONSUMPTION - 600
KW.
FOR BETTER COLLECTION TREATMENT TIME SHOULD BE >8 SECS. IT IS
THE TIME TAKEN BY ASH PARTICLES TO TRAVEL FROM ESP INLET TO
ESP OUTLET.
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COLLECTION EFFICIENCY ALSO DEPENDS ON


 MIGRATION VELOCITY OF DUST PARTICLES. IT SHOULD BE LESS
THAN 2M/SEC.
 ASPECT RATIO. IT SHOULD BE >1.
ASPECT RATIO = TOTAL LENGTH OF ESP / HEIGHT OF COLLECTING
ELECTRODE.

CAUSES OF BOILER TRIP

 ALL ID OFF.
 ALL FD OFF.
 SPARE TRIP.
 EMERGENCY TRIP.
 RH PROTECTION TRIP.
 FURNACE PRESSURE VERY HIGH.
 FURNACE PRESSURE VERY LOW.
 DRUM LEVEL VERY HIGH/LOW.
 LOSS OF 220 V DC/ 24 V DC
 LOW AIR FLOW.
 FLAME FAIL TRIP.
 LOSS OF FUEL TRIP.
 FEED BACK AND LOSS OF AC.

BRIEF SPECIFICATION OF 210MW BOILER


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TYPE: RADIANT, REHEAT, NATURAL, CIRCULATION, SINGLE


DRUM, SEMI OUTDOOR TYPE, FIRING COAL
AS THE PRINCIPAL FUEL.

CONSTRUCTION DETAILS (U# 1 & 2)

SL.N CONSTRUCTION DETAILS SPECIFICATION


O
1. DIAMETER OF BOILER DRUM 1778 MM
(INSIDE DIA)
2. FURNACE WIDTH 13.868 MTRS.
3. FURNACE DEPTH 10.592 MTRS.
2. LENGTH OF BOILER DRUM 12.81 MTRS.
3. FURNACE VOLUME 5200 M3
4. NO. OF. CYCLONE SEPARATORS IN 60 NOS. (30 IN EACH
THE DRUM ROW).
5. NO. OF . DOWN COMERS SIX
6 NO.OF FEED CONNECTIONS TO THE TWO
DRUM
7. HEATING SURFACE OF WATER 2120 SQ. MTRS.
WALLS
8. HEATING SURFACE OF 8210 SQ. MTRS.
SUPERHEATERS
9. HEATING SURFACE OF RE-HEATERS 2800 SQ. MTRS.
10. HEATING SURFACE OF 6200 SQ. MTRS.
ECONOMISER
11. HEATING SURFACE OF AIR 18300 SQ. MTRS.
PREHEATER
12. HEAT ABSORPTION BY DIFFERENT
SECTIONS
ECONOMISER 6%
WATER WALLS 50%
SUPERHEATERS 30%
RE-HEATERS 14%
13. HEAT ABSORPTION
SENSIBLE HEAT 20%
LATENT HEAT 36%
SUPERHEAT 30%
RE-HEAT 14%
14 BOILER VOLUME
1. WATER WALL 126.5 M³
2. DRUM 37.0 M³
3. ECONOMIZER 30.0 M³
4. SUPER HEATER 95.0M³
5. REHEATER 48.0 M³
TOT 336.5M³
AL
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OPERATING CONDITIONS OF U# 1 & 2 AS PER DESIGN.

1) CAPACITY OF THE BOILERS : 670 T/HR.


2) DRUM PRESSURE : 166.1 KSC.
3) SH PRESSURE AT DRUM OUT LET : 154.5 KSC.
4) COLD RE-HEAT PRESSURE : 38.69 KSC.
5) HOT RE-HEAT PRESSURE : 37.19 KSC.
6) SUPER HEAT STEAM TEMP. : 540 0C.
7) RE-HEAT STEAM TEMP. : 540 0C.
8) FEED WATER TEMP. TO ECO. : 245 0C.
9) WATER WALL OUT SIDE TEMP. : 400 0C.
10) WATER WALL INSIDE TEMP. : 355 0C.
11) FEED WATER TEMP. IN THE TUBE : 345 0C.
12) QTY. OF AIR FOR COMBUSTION : 861.35 T/HR.
13) QTY. OF SECONDARY AIR : 602.48 T/HR.
14) QTY. OF PRIMARY AIR FOR
PULVERISERS : 237.32 T/HR.
15) EXCESS AIR FACTOR : 25%
16) TEMP IN FURNACE : 1600 0C.
17) GAS TEMPERATURE ENTERING
PLATEN SH : 1150 0C.
18) GAS TEMPERATURE RH OUTLET : 795 0C.
19) GAS TEMPERATURE AT FINAL SH : 730 0C.
20) GAS TEMPERATURE LEAVING LTSH : 468 0C.
21) GAS TEMPERATURE LEAVING ECO : 337ºC.
22) GAS TEMPERATURE LEAVING APH : 142º C.
23) AIR TEMPERATURE ENTERING APH : 38 0C.
24) SECONDARY AIR LEAVING APH : 312 0C.
25) PRIMARY AIR LEAVING APH : 317 0C.
26) BOILER EFFICIENCY : 86.97%
27) HEAT LOSS DUE TO DRY GAS : 4.5%
28) HEAT LOSS DUE TO HYDROGEN
MOISTURE IN FUEL : 4.56%
27) HEAT LOSS DUE TO RADIATION : 0.2%
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