Boiler

•Enclosed Pressure Vessel

•Steam Generator:Heat generated by Combustion of Fuel is
transferred to water to become steam
•Process: Evaporation
•Steam volume increases to 1,600 times from water at atm pr and
produces tremendous force
•IBR Boiler =>22.75 Liters in capacity
 Boiler..
• Steam is supplied from boiler house to
– PMD Tobacco Processing Target 46 , Actual 48 Ltr/ton
– HVAC System For maintaining Target 7, Actual 4 Ltr/Mnc
conditions on shop floor
– Canteen For food preparation
– Boiler Accessories FO heating , Water pre heating .
• Details of boilers
Registration Working CAP. Chimmney
S.No. MAKE Boiler Type Burner Type
No. pressure (tons/hr) Height
1 UP 5535 10.54 NESTLER 4 Fire tube, 3 Step modulation type
Pass, wet (two step)
2 UP 3503 9.975 NESTLER 4 back design, 54.86 Mtr.,
Step modulation type 2.12 m
horizontal
(two step) Diameter
3 KTK 2435 11.7 J.N. Marshall 6 Air jet modulating burner
(modulation 0-100%)
4 UP 5785* 10.5 THERMAX 2.25 Water tube, Connected with flue 33.0 Mtr, 0.6
vertical, gases of D.G. Sets m Diameter
waste heat
Furnace Oil system
 Furnace Oil system..
 
Sr.No Characteristics Grade MV2
1 Inorganic acidity Nil
2 Ash, % wt. Max 0.1
3 Gross calorific value, Cal/ gm (typical 10000)
4 Flash point (PMCC) OC. Min 66
5 Kinematic viscosity, cSt at 50OC 125-180
6 Sediment, % wt. Max 0.25
7 Sulphur, total % wt. Max 4
8 Water content, % v/v, Max 1
9 *Pour Point, OC, Max. 27
*Pour Point varies between Summer and Winter.
 Furnace Oil system..
• Improvement suggestion in current FO system :
– FO Supply line Insulation is week and damage need repairing.
– Double Filter system should be provided on FO tank loading side & supply side. One Pot
filter additional to prevent loss from choking & cleaning purpose.
– Moisture drain system require in tank. Spillage observed from all tank in draining
moisture.
– FO tank Valve’s Gland change procedure should be condition based . Leakage
– Heating system of jacketed FO supply line , Hot water or condensate should use instead
of steam & control valve provided according to FO temperature .
– FO over flow system of service tank is electrical control ,supplementary system for
collecting FO in additional Tank or Boiler’s under ground oil collection tank can use for
this purpose ,incase electrical system fails.
 Oil Firing Burner
• The primary function of burner is to atomise fuel to millions of small droplets so that
the surface area of the fuel is increased enabling intimate contact with oxygen in air.
• Normally, atomisation is carried out by primary air and completion of combustion is
ensured by secondary air. Burners for fuel oil can be classified on the basis of the
technique to prepare for burning i.e. atomisation.  
• Improvement suggestion:
– Burner in 4 TPH boilers of Nestler is having designed for High / Low and On/Off
operations , should convert in fully automatic functionality:
• a – Boiler start high fire @ pressure reaches to 120 psi (Both nozzle in
operation)
• b - 132 psi to 135 psi boiler operates @ low fire (one nozzle in operation)
• c - 135 psi and above boiler burner off & again start @ 120psi.
– Oil pressure is 20 – 22 kg / cm 2 -adequate
– Oil Temperature maintain @ 100 – 110 Deg C -sufficient.
– Burner s – blowing air requirement for 4TPH boilers are control by drive by two
speed only Blower motor runs 1900 rpm @ low fire & 2300 rpm @ high fire .For
further balancing excess air operators use to adjust damper setting , which is a
wrong practice.
 Feed Water Circuit
DM Water 60 - 70% Condensate return
30%

Feed Water Tank Metering & Temp

Steam line measurement Common Header
(cap 15 KL)
to raise FWT
FWT 70 -80 0C
Check Valve Feed Water Pump
7.5 hp
Head : 107 Mtr
Flow : 12 m3/hr
Boiler
Blow down
Casing Kitchen
To Canteen DCCC
To PMD Header HT
KLD 2
To HVAC Ad moist
From WHRB STS
TC Dryer
 DM Plant
Multi
Cation Anion
grade

gaser
bed bed

De-
filter

DM plant :
•Capacity : 300 KL , Make : Ion exchange
•Multi grade filter : for removal of impurities from ground water.
•Cation Bed : for absorption of Ca , Mg , Positive ion
•Degaser : Removal of gases in water
•Anion Bed : for absorption of Negative Ion
•Conductivity Maintains after Anion Bed is less then 30 µS
•pH 8- 9 , TDS -20-30 , Hardness -0
• Because of high consumption rate of steam ,capacity of the plant is not sufficient after
every four days (on avg 50 – 70 KL water feed into the boiler)
•Capacity require minimum 500 KL.
 Demineralization
• Demineralization is the complete removal of all salts.
• This is achieved by using a “cation” resin, which exchanges the cations in the
raw water with hydrogen ions, producing hydrochloric, sulphuric and carbonic
acid.
• Carbonic acid is removed in degassing tower in which air is blown through the
acid water.
• Following this, the water passes through an “anion” resin which exchanges
anions with the mineral acid (e.g. sulphuric acid) and forms water.
• Regeneration of cations and anions is necessary at intervals using, typically,
mineral acid and caustic soda respectively. The complete removal of silica can
be achieved by correct choice of anion resin.
 De-aeration
• When heated in boiler systems, carbon dioxide (CO2) and oxygen (O2) are
released as gases and combine with water (H2O) to form carbonic acid,
(H2CO3).

•In de-aeration, dissolved gases,

such as oxygen and carbon dioxide,
are expelled by preheating the feed
water before it enters the boiler.

Figure 2.9 Deaerator

 Boiler system..
Blowdown Rate

•Blow down Quantity varies in our plant from 0.3 ton to 1.2 ton per day.
•Feed water TDS will low as much as , blowdown % will decreases.
•TDS needs to be maintain below 10 , so conductivity of water needs to maintain Under
15. [(TDS)ppm = Conductivity µS/cm x 0.67].
 Boiler Feed water
• Feed water service tank capacity : 15 KL.
• Temp. maintain between 80- 90°C by steam line given inside the tank & also Condensate
return from PMD.
• Economizer require for preheating of boiler feed water
• Amount of steam generated at 10kg/cm2(g)
Enthalpy of steam(sat) at 10 kg/cm2(g) pressure:665 K.Cal/kg
Feed water temperature : 850

• For Example :
• 4 TPH x 540 kCal/kg = 3.72 TPH
(665-85) kCal/kg

• In example : 85 °C is boiler feed water temp ,

• Boiler Efficiency in direct Method:
η = M (Hs – Hw)x100/(m x CV)
η = Thermal efficiency of boiler
M: Mass of feed water/steam generated
Hs: Enthalpy of steam
Hw: Enthalpy of hot water
m : Mass of Oil
CV : Calorific Value of Oil (9600 Kcal/Kg of F.O.)
 Energy Saving Opportunity
• As much as feed water temperature will high Boiler efficiency will increases.
• Boiler Stack temp in low fire goes to 220 -240 °C & in high fire 240- 260 °C
• An economizer must be used to reduce it to 200 ° C from 260 °C
• Increase in overall thermal efficiency 3%.
• 6 ° C raise in feed water temperature, by economizer/condensate recovery,
corresponds to a 1% saving in fuel consumption
 Waste heat recovery
• DG exhaust gas Temp is 500 - 450 °C , we are running 2 DG in day time & one DG
continuously in night time .
• Convective Recuparator needs to be installed , Heat exchange through metallic / ceramic
walls . Duct / tubes carry combustion air for preheating .

Waste heat Engine generator

source: exhaust

Capacity of
Engines: 800KW X 2 No

Fuel fired in
Engines: HSD

Total flue gas

quantity: 4000 Kg./hr each

Flue gas inlet

temp.: 450- 550°C
 Waste heat recovery
• Q = V x ρ x Cp x ∆T
• Q is the heat content in kCal ,
• V is the flowrate of the substance in m3/hr: 3361 m3 /hr (Approx value)
• M= V x ρ kg / hr
• ρ is density of the flue gas in kg/m3 1.19kg/m3
• Cp is the specific heat of the substance in kCal/kg oC
• ∆T is the temperature difference in oC
• Cp (Specific heat of flue gas) = 0.24 kCal/kg/oC
• Excess air requirement approx 15 – 20 % by wt
• Heat available (Q) = 4000 X 0.24 x (450-180) = 259200 kCal/hr from one
DG .
•
Steam
For a boiler is operating at a pressure of 8 kg/cm 2, steam saturation temperature is 170 oC, and steam enthalpy or total heat of dry
saturated steam is given by:
• hf +hfg = 171.35 +489.46 = 660.81 kCal/kg.
•  If the same steam contains 4% moisture, the total heat of steam is given by:
• 171.35+ 0.96 x 489.46 = 641.23 kCal/kg
• For a boiler is operating at a pressure of 8 kg/cm2, steam saturation temperature is 170 oC, and steam enthalpy or total heat of dry
saturated steam is given by

• For a boiler is operating at a pressure of 10 kg/cm2, steam saturation temperature is 180 oC, and steam enthalpy or total heat of dry
saturated steam is given by:
• hf +hfg = 182 + 663= 845 kCal/kg.
•  If the same steam contains 4% moisture, the total heat of steam is given by:
• 182+ 0.96x 663 = 819 kCal/kg

• The working pressure .The distribution pressure of steam is influenced by a number of factors, but is limited by:
• The maximum safe working pressure of the boiler
• The minimum pressure required at the plant
• As steam passes through the distribution pipework, it will inevitably lose pressure due to
• Frictional resistance within the pipework
• Condensation within the pipework as heat is transferred to the environment
 Steam Pipe Sizing

F = Pressure factor
P1 = Factor at inlet pressure
P2 = Factor at a distance of L metres
L = Equivalent length of pipe (m)
 Steam Pipe Sizing…
The allowance for pipe fittings
The length of travel from the boiler to the unit heater is known, but an allowance must be included for the additional frictional resistance
of the fittings. This is generally expressed in terms of 'equivalent pipe length'. If the size of the pipe is known, the resistance of the fittings
can be calculated. As the pipe size is not yet known in this example, an addition to the equivalent length can be used based on
experience.
If the pipe is less than 50 metres long, add an allowance for fittings of 5%.
If the pipe is over 100 metres long and is a fairly straight run with few fittings, an allowance for fittings of 10% would be made.
A similar pipe length, but with more fittings, would increase the allowance towards 20%.
In this instance, revised length = 150 m + 10% = 165 m
 Steam Pipe Sizing
Method
Select the point on the saturated steam
line at 7 bar g, and mark Point A.
From point A, draw a horizontal line to
the steam flowrate of 286 kg/h, and
mark Point B.
From point B, draw a vertical line
towards the top of the nomogram (Point
C).
Draw a horizontal line from 0.24 bar/100
m on the pressure loss scale (Line DE).
The point at which lines DE and BC cross
will indicate the pipe size required. In
this case, a 40 mm pipe is too small, and
a 50 mm pipe would be used.
 Relation Between CO2 , O2and Excess Air for Fuel Oil
100

90
80
250
Excess air (% )

70
200
150 60
Excess air %

100 50
50
40
0
301 2 3 4 5 6 7 8 9 10 11 12 13 14 15
20 R e s idua l Oxyge n (%)

10 Figure 1.3: Re lation be twe e n Re sidual O xyge n and Exce ss Air

0
8.4 9 10 11 12 13 14 15
Carbon dioxide %
 Boiler Performance Monitoring
• Boiler EVR is calculated on daily basis and it is > 13.5 Kg/Ltr. It is calculated by taking direct reading
of steam/water and FO consumption.
• Boiler Thermal efficiency can be calculated on the basis of following formula
η = M (Hs – Hw)x100/(m x CV)
η = Thermal efficiency of boiler
M: Mass of feed water/steam generated
Hs: Enthalpy of steam
Hw: Enthalpy of hot water
m : Mass of Oil
CV : Calorific Value of Oil (9600 Kcal/Kg of F.O.)
 Indirect Method of Efficiency measurement

η = 100 – Losses
Losses = Flue gas loss + Blow down losses + radiation loss
 Effimax is installed on 6 TPH boiler to monitor the boiler performance. We can get all the losses,
steam flow, oil flow & indirect efficiency of the boiler.
 Boiler - Statuary Requirements
• Hydraulic Test : Every Boiler must be hydraulically tested every year in
presence of Boiler inspector. It is carried out by applying 1.5 times the
working pressure of boiler for 30 min. (testing water temp should be
between 20 °C to 50 ° C)
• Steam Test : Yearly, in presence of inspector, For checking whether safety
valves are working at desired pressure to relieve boilers excess steam.
• Stack Emission: This must be less than 250 mg/NM3. (This is checked by
M/s Envirochem)
 Maintenance Schedule - Boiler
• Preventive Maintenance is carried out time to time as per
detail given below:
– Burner & Pumps maintenance: This is carried out on weekly basis
along with PMD maintenance day.
– De-carbonizing : Normally this is carried out on weekly basis.
– De-scaling : This is carried out as per requirement on the basis of
tube conditions.
– Yearly maintenance Jobs : Major maintenance of boiler is carried out
like lapping of all the valves, de-scaling, de-carbonizing, gauge glass
maintenance, tube inspection etc.
– The boiler maintenance job is outsourced.