Basics of Boiler: Power Sector - Technical Services

POWER SECTOR – TECHNICAL SERVICES
BASICS OF BOILER
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Session Objectives
This session is intended to discuss the following :
1. Boiler and its classification.

2. Fundamentals of Combustion and heat transfer.
3. Boiler system details and their importance.
4. Boiler operation and control.
5. Boiler Safety.
6. Operation Standards and Codes.
7. Control & Safety for automatically fired boilers.
8. Inspection and Maintenance of Boilers.
9. Boiler and burner efficiency.
10. Troubleshooting.
POWER SECTOR - TECHNICAL SERVICES 1

Session Objectives

5. Boiler Safety.

BOILER / STEAM GENERATOR
BOILER : an energy convertor.

Converts the chemical energy of fuels or heat energy of waste gas streams into
heat energy of steam.
Main areas of Application: Thermodynamically, a Boiler is a blend of :
1. Power Generation 1. Combustion

2. Process Steam 2. Heat Transfer

BOILER CLASSIFICATION
1) Based on what flows through the boiler tubes.

2) Based on the end use of the boiler.
3) Based on Type of firing.
4) Based on the operating pressure.
5) Based on the circulation of feed water.
6) Based on the draught considerations.
7) Based on type of support.
8) Based on furnace construction.

Based on what flows through the boiler tubes:
 Fire tube or flue tube or shell type when flue gases are inside and
water is outside.
 Water tube when water is inside the tubes and flue gases are
outside.
 Combination type (combo boiler) when flue gas and water flow
both outside and inside the tubes in a boiler that contains an
external furnace and shell-type boiler in a sequence.

Based on the end use of the boiler.
• Industrial boilers.
• Utility boilers.
• Marine boilers.
• Nuclear boilers.
Based on the type of firing.
• Stoker fired boilers.

• CFBC: Circulating fluidized bed combustion boilers.
• Pulverised fuel-fired boilers—wall fired and corner fired
• Liquor-fired boilers
• WH boilers—Process waste heat (WH) recovery boilers.
• Heat recovery steam generators behind GTs

Based on the operating pressure.
Low pressure boiler; Pr < 20 bar

Medium pressure boiler; 20<Pr<75 bar
High pressure boiler; Pr>75 bar
Based on the circulation of feed water.
Natural circulation or drum-type boilers

Forced circulation boilers
Once-through (OT) supercritical boiler or no drum boilers

Based on the draught considerations.
• Natural or balanced draught boilers

• Forced Draught or pressurized fired boilers
Based on type of support.
• Top-supported boilers
• Bottom-supported boilers
• Middle-/girdle-supported boilers
Based on furnace construction.
Two-pass boilers
• 1½ pass boilers
• Single or tower-type boilers
• Down shot or Arch fired boilers

Session Objectives

5. Boiler Safety.

COMBUSTION REQUIREMENTS
Sufficient
Combustion Air
Temperature Combustion
Fuel Mixing within Time
above
is Flammable Temperature
Ignition
Gasified Range Turbulence
Point
3 T’s of Combustion
1
POWER SECTOR - TECHNICAL SERVICES
FUNDAMENTALS OF COMBUSTION
Heat
Complete
(Air) Oxygen Fuel
Products Flue Gas
O2 H2 H2O
+
C CO2
Heat
Incomplete
Oxygen Fuel Flue Gas
Products
H2 H2O
O2 +
C CO2
CO
H2
• Other Combustibles - Sulphur to Sulphur Oxides C
• Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides
• Ash
1
Session Objectives

5. Boiler Safety.
1
BOILER / STEAM 40%

TURBO- STEAM CONDENSER
GENERATOR
UTILITY PLANT
20%
Stack
COOLING TOWER
Steam
6% Aux. Power + Losses THERMAL EFFICIENCY - 34%
100% 34% Electricity

Fuel
Air
STEAM TURBINE GENERATOR TRANSMISSION

BOILER
1
Steam
Water Steam / Water System
Blowdown
Fuel
Mixing of Furnace Heat Transfer Flue Gas
Fuel & Air Surface
Ash
Air
1
Hot Reheat
Steam
Spray
Water Main Steam
Drum
Attemperator
Attemperator
Cold
Reheat
Platen Final Primary Final Primary
Steam
Super Re Re Super Super Spray
Heater Heater Heater Heater Heater Water
Down
Comers Flue Gas
Economiser
Feed Water
Furnace
Flue Gas
Water Wall Out to
Risers Air Heater
BOILER WATER & STEAM SYSTEM

Bottom Ring Header
1
BOILER WATER & STEAM SYSTEM
Process Performance Highlights
• Heat Transfer by Radiation and Convection
• Boiler Water Circulation - Natural or Controlled
• Heat Transfer depends on Heat Transfer Area & Time
• Heat Transfer is affected by Fouling, Boiler Pressure, Boiler Water Quality

and % MCR Load
1
ID Fan ID Fan
AIR & FLUE GAS PATH
PA Fan FD Fan FD Fan PA Fan
S S
C C
Cold PA A A Cold PA
ESP P P
H
ESP
H
Scanner
Air Fan
Pri Sec Sec Pri
Flue Air Flue Air
Air Air
Gas Side Gas Side
Side Side Seal Air
Fan
Hot PA Hot PA
Wind Box
Mill Mill
Furnace

AIR & FLUE GAS SYSTEM
Process Performance Highlights

• Generation of Draft - Natural / Induced / Forced / Balanced
• Supply of Air for Transport of Pulverised Coal
• Pre-heating of Air
• Distribution of Air in Combustion Chamber
• Fan capacity depends on Flow, Density & System Resistance
• Fan performance is affected by temperature, density, barometric pressure and speed
• Gas flow is restricted by ash deposits on boiler surfaces

FUEL PREPARATION SYSTEM - COAL
Raw Coal Bunker To Mill Discharge

Valves
To Hot PA
Other
Coal Feeder Mills
Coal+Air
to Burners
Mill A Cold PA
To
Other
Mills
To Other Mills Seal Air Fans

FUEL PREPARATION SYSTEM - OIL
Atomising
Steam/Air
PCV
Fuel Oil
Return
Short Long
Recirc Recirc
PCV
Fuel Oil
Oil Heater To Burners
Supply
FCV FOTV
Steam
Fuel Oil Pumps
FUEL OIL

BOILER MISCELLANEOUS SYSTEMS
Boiler Auxiliary Cooling Water System
• Ensures continuous supply of cooling water to Boiler & it’s auxiliaries
• Consists of Overhead Tank, Pumps & Heat Exchangers
Chemical Dosing System
• Prepares & supplies chemicals for treatment of Boiler Water
• Consists of Preparation Tanks, Mixers & Metering Pumps

Condensate from LP Heater
DEAERATION & FEED HP Heater Drains To HP

Heaters
PUMPING SYSTEM Aux. Steam
CRH Steam
Deaerator
IPT Extraction
Aux. Steam Steam
for Feed Storage Tank
Pegging To HP Bypass
Spray
Hydrazine
T o APRDS
Dosing Spray
Ammonia Recirculation
Dosing Valve
M
Discharge Valve
Boiler Feed Pumps

Boiler Operation & Control
2
Session Objectives

5. Boiler Safety.
2
Session Objectives


2
BOILER SAFETY

Session Objectives

5. Boiler Safety.

2
BOILER STANDARDS & CODES
Rules of Safety concerned with the safety aspects of the boilers to prevent
the occurrence of disastrous explosions that marked the early period of boiler history.
Extensions of pressure vessel (PV) codes customized for fired equipment.
ASME boiler and pressure vessel (BPV) codes are the most widely accepted and used worldwide.
These codes deal with the safety aspects in all areas of boiler making and operation and thus cover
• Mechanical design
• Manufacturing and workmanship
• Materials and stresses
• Inspection and testing
• Documentation and marking
• Care and operation
• Welder qualifications

Session Objectives
5. Boiler Safety.

2
A boiler is meant to convert fw into steam at certain parameters of p & t by burning

the specified fuels for use in process or ST over a range of loads. The operating parameters
of the boiler should be continuously monitored and regulated such that it is fuel efficient and
safe for personnel and equipment. Control systems are needed for performing this task
supported by various measuring and control instruments.
If combustion and other associated systems are considered apart,
the essential boiler control involves balancing of main inputs namely FW, fuel and air in step with the steam demand.
For this, the only parameters required to be kept constant at their set points are, the:
1. Steam header pressure
2. Furnace draught
To achieve this, the controls required are
1. Steam pressure
2. Combustion
3. Furnace draught
4. Drum level/fw
In addition, the following controls are also needed, namely:
5. Steam temperature
6. O2 trim














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POWER SECTOR – TECHNICAL SERVICES

1. Boiler and its classification.

POWER SECTOR - TECHNICAL SERVICES 1

2. Fundamentals of Combustion and heat transfer.

POWER SECTOR - TECHNICAL SERVICES 2

BOILER / STEAM GENERATOR

BOILER : an energy convertor.

Main areas of Application: Thermodynamically, a Boiler is a blend of :

1. Power Generation 1. Combustion

POWER SECTOR - TECHNICAL SERVICES 3

1) Based on what flows through the boiler tubes.

POWER SECTOR - TECHNICAL SERVICES 4

Based on what flows through the boiler tubes:

POWER SECTOR - TECHNICAL SERVICES 5

Based on the end use of the boiler.

Based on the type of firing.

• Stoker fired boilers.

POWER SECTOR - TECHNICAL SERVICES 6

Based on the operating pressure.

Low pressure boiler; Pr < 20 bar

Based on the circulation of feed water.

Natural circulation or drum-type boilers

POWER SECTOR - TECHNICAL SERVICES 7

Based on the draught considerations.

• Natural or balanced draught boilers

Based on type of support.

Based on furnace construction.

POWER SECTOR - TECHNICAL SERVICES 8

1. Boiler and its classification.

3. Boiler system details and their importance.

POWER SECTOR - TECHNICAL SERVICES 9

4. Boiler operation and control.

BOILER / STEAM 40%

6% Aux. Power + Losses THERMAL EFFICIENCY - 34%

100% 34% Electricity

STEAM TURBINE GENERATOR TRANSMISSION

BOILER WATER & STEAM SYSTEM

BOILER WATER & STEAM SYSTEM

Process Performance Highlights

• Heat Transfer by Radiation and Convection

• Boiler Water Circulation - Natural or Controlled

• Heat Transfer depends on Heat Transfer Area & Time

• Heat Transfer is affected by Fouling, Boiler Pressure, Boiler Water Quality

POWER SECTOR - TECHNICAL SERVICES 17

AIR & FLUE GAS SYSTEM

Process Performance Highlights

POWER SECTOR - TECHNICAL SERVICES 18

FUEL PREPARATION SYSTEM - COAL

Raw Coal Bunker To Mill Discharge

To Other Mills Seal Air Fans

POWER SECTOR - TECHNICAL SERVICES 19

FUEL PREPARATION SYSTEM - OIL

POWER SECTOR - TECHNICAL SERVICES 20

BOILER MISCELLANEOUS SYSTEMS

Boiler Auxiliary Cooling Water System

• Ensures continuous supply of cooling water to Boiler & it’s auxiliaries

• Consists of Overhead Tank, Pumps & Heat Exchangers

Chemical Dosing System

• Prepares & supplies chemicals for treatment of Boiler Water

• Consists of Preparation Tanks, Mixers & Metering Pumps

POWER SECTOR - TECHNICAL SERVICES 21

Condensate from LP Heater