july 9,2008

CONTENTS Boiler Fundamental 1-Combustion 2. Boiler & Classification 3.Arrangament of main components Water Circulation System 1-Types of circulation system 2-Nucleate ,film boiling ,ww rifiled tubes 3-Flow Chart 4-Economiser Operation 5-Drum &Drum internals

November 9,2006

Principal of combustion

Fuels :
Gaseous fuel Liquid fuel solid fuel

Heat :

HEA LDO HFO

Air :
Less amount of air will cause incomplete combustion Excess amount of air will cause boiler losses

Three Ts for efficient combustion

1. Time 2. Temperature 3. Turbulence( proper mixing)

Combustion efficiency:
1. design of boiler 2. fuel used 3. skill in obtaining combustion with minimum amount of air

Boiler :
Boiler is device for generating steam for power, processing, or heating purpose

Classification:
1. Tube contents a .water tube b. fire tube 2.Firing a. tangential b.center

Contd..

3.Circulation a. natural b. controlled c. combined 4. Use a. utility b.industrial

ARRANGEMENT OF MAIN BOILER (STEAM GENERATOR)

A STEAM GENERATOR IS A COMPLEX INTEGRATION OF THE FOLLOWING ACCESSORIES: * ECONOMISER * BOILER DRUM * DOWN COMERS * CCW PUMPS * BOTTOM RING HEADER * WATER WALLS * LTSH * DIV PANEL * PLATEN SH * REHEATER * BURNERS * APHs

SUPPORTING STRUCTURES
MAIN COLUMNS: SUPPORTS DRUM, SHs, RH, ECO, APH BURNERS & GALLERIES AT VARIOUS LEVELS AUX COLUMNS: SUPPORTS THE BOILER PLATFORM AND OTHER DUCTS

GALLERIES & STAIRWAYS

COMBUSTION & HEAT RECOVERY AREAS FOR PROPER APPROACH STAIRWAYS ARE PROVIDED ON BOTH THE SIDES OF BOILER ALL THE FLOORS ARE COVERED WITH FLOOR GRATINGS FOR WALKWAYS

FURNACE

PROVIDES PROPER INSTTALATION, OPERATION MAINTENANCE OF FUEL BURNING EQUIPMENTS SUFFICIENT VOLUME FOR COMBUSTION

ADEQUATE REFRACTORIES & INSULATION

BOILER DRUM
FUNCTIONS:SEPRATES WATER AND STEAM REDUCED DISSOLVED SOLID CONTENTS OF STEAM STORAGE OF WATER

ECONOMISER
LOCATED IN 2ND PASS BELOW LTSH. PREHEATS BFW BEFORE GOING TO DRUM

SUPER HEATERS
LTSH(LOW TEMP. SUPER HEATER) DIVISIONAL PANEL(PANEL SUPERHEATER) PLATEN SUPERHEATER(FINAL)

REHEATERS
HEAT TRANSFER BY RADIATION & CONVECTION COMPOSED OF FRONT & REAR PENDANT SECTION

AIR PREHEATERS
LOCATED IN FLUE GAS PASS AFTER ECONOMISER

BURNERS
COAL BURNERS OIL BURNERS AUX. AIR SUPPLY DAMPERS O/F AIR DAMPERS BURNER TILT MECHANISM

HEA IGNITORS
PROVIDED WITH ALL OIL BURNERS 4 SPARKS /SEC, 12 J /SPARK,120 V

November 9,2006

Water circulation system (WCS): H.

M.S
C.R.H

R. H

FROM F.R.S BOTTOM RNG HDR& Z-PANEL 1 PASS W.W O/L HDRS
ST

1 PASS W.W
ST

ROOF I/L HEADER 2nd PASS LOWER C-HDRS LTSH O/L HEADER D.P.O/L HEADER R.H.HEADER ECONOMISER

2ND PASS UPPER C-HDR LTSH I/L HEADER D.P.I/L HEADER S.H. HEADER 2
ND

PASS ROOF O/L HDR(REAR

Circulation ratio
The ratio of the weight of water to the weight of steam In mixture leaving the absorption surfaces is called Circulation ratio

Various types of WCS of boiler:

1. Natural circulation system 2. Controlled circulation system 3. Combined circulation system

Natural circulation system

thermo-siphon principal used for pressure up to 140 kg/cm2 circulation ratio = 14 to 16

2. Controlled circulation system:

use of controlled circulation pump used for pressure up to 194kg/cm2 (sub critical pr.) circulation ratio=6-9

3.Combined circulation system:

Circulation ratio=2 No use of drum Use of controlled circulation pump Use for pressure above 200kg/cm2.

Important phenomenon

Nucleate boiling Film boiling

Water wall refile tubes

Flow chart of WCS

condensor T=40,P=-.9mm LP HEATERS DEARETORS

BFP p=<drum p B.DRUM

HPH

ECO

DOWN COMER

BRH

URH

WATER WALL

ECONOMISER OPERATION
Improved efficiency Counter flow arrangement of flue gasses & water Role of soot blowers

PRECAUTION:INCORPORATION OF STOP &NON RETURN VALVE AVOID STEAMING

WATER WALLS

Tangential arrangement of tubes Nucleate boiling Absorb around 50%heat released by combustion of fuel

Drum & drum internals