In the flow diagram given above, the symbols indicates the following.

a:

Steam Generator

b:

Turbine

c:

Surface Condenser

d:

Condensate extraction pump

e:

Gland steam condenser

f:

Deaerator

g:

Boiler Feed pump

h:

High pressure feed water Heater -1

k:

High pressure feed water Heater -2

r:

Transfer pump

m:

Distillery

n:

Sugar process plant

q:

Feed water storage tank

STEAM GENERATOR
A steam generator generates steam at the desired rate at the desired temperature and pressure by
burning fuel in its furnace. A steam generator is a complex integration of furnace, superheater,
reheater, boiler or evaporator, economizer, and air preheater along with various auxiliaries such
as pulverizers, burners, fans, stokers, dust collectors and precipitators, ash handling equipment,
and chimney or stack. The boiler (or evaporator) is that of the steam generator where phase
change (or boiling) occurs from liquid (water) to vapor (steam), essentially at constant
temperature and pressure.
The steam generator installed in the plant is Thermax Babcock and Wilcox manufactured by
Thermax Limited, Pune, India. It incorporates travelling grate furnace and three types of fuel
namely bagasse, coal and biogas produced from the effluent of the process plant. The technical
specification is given in the following table.

S.No.

Particulars

Details

Pressure

110 kg/cm2 a

Superheater steam outlet Temperature

540 0C

Evaporation capacity

135 TPH

Main fuel

Bagasse, coal and Biogas

Feed water inlet temperature to Economizer

2100C

Heat Transfer Surface area

Boiler( Furnace panels and convective banks)

3090 m2

Economizer
Heating surface area for superheating steam
Primary Superheater 1
Primary Superheater 2
Secondary superheater 1
Efficiency of the steam generator
On Bagasse firing
On coal firing

3142 m2
1515 m2
1515 m2
609 m2
71 %
85 %

The following flow diagram indicates the various heat transfer surfaces and the path of the flue
gas of the steam generator.

BOILER PRESSURE PART DESCRIPTION

This boiler is a single drum, natural circulation, top supported, and membrane wall construction.
Various pressure parts are grouped as follows:
1.
2.
3.
4.
5.
6.
7.
8.

Steam Drum
Downcomer tubes
Furnace membrane water walls
Riser tubes
Saturated steam supply tubes
Super heater
Convection Bank
Economizer

The short description of each of the part is given below.

STEAM DRUM
Steam Drum is welded cylindrical vessel made of SA 517 Gr. 70 material. It is provided with
manholes for maintenance purpose. It is fitted with several components to perform important
functions like water level gauge, level transmitters, drum safety valves, continuous blow down
outlet, HP dosing connection to dose phosphate in to the steam drum to maintain the boiler water
quality, two air vent with isolation valves, local pressure gauge.
Steam drum internals are provided to supply moisture free steam to S.H. coils. Steam drum
receives water/steam mixture from the water wall panels through the riser tubes in the baffles of
the boiler drum. From the drum internal pocket, water steam mixture flows tangentially through
the Cyclone steam separators. In this tangential flow, water which is heavier is separated from
steam and trickle down to mix with the water in the drum. Steam rises upward to flow through
the two rows of scrubbers, Primary scrubbers (21) and secondary scrubbers (16) and finally
through perforated sheets to steam outlet of the drum.
FURNACE
Furnace is the part of the boiler where the chemical energy in the fuel is converted into thermal
energy by absorbing the heat produced through combustion of fuel. The furnace is designed for
efficient and complete combustion, with due consideration to the factors that effect, combustion
efficiency like fuel residence time inside the furnace, temperature and the turbulence required for
complete mixing of the air and fuel.

Furnace is constructed with membrane (water wall) construction. It comprises of front panel,
rear panel, L.H panel and R.H panel.
RISER TUBES
The purpose of these tubes is to carry the saturated steam from side wall panels, front wall and
rear wall to steam drum. The total numbers of riser tubes from all four sides that are connected to
steam drum are 50, each of 101.6 mm OD and 5.6 mm thick.
SUPER HEATER
From the drum, steam flows to primary super heater -1 inlet header ( 250 NB *160 SCH) through
7 nos. 101.6 OD* 5.6 thick supply tubes. From the primary superheater inlet header steam flows
to primary superheater -1 outlet header through 50.8 OD * 5.6 thick coils.
Primary SH-1 outlet header is connected to attemperator -1 header. Attemperator-1 is provided to
control the temperature after P SH-2 by water spray from feed water system. One spray nozzle is
provided in attemperator-1. From attemperator, steam is passed through primary SH-2 inlet
header and from the PSH-2 steam flows to PSH-2 outlet header through 50.6 OD* 4.5 thick
coils.
Form P SH-2 outlet header, steam passes through attemperator-2. Attemperator-2 is provided to
control the final superheater temperature. Spray nozzle is provided in the attermperator-2. From
attemperator-2, steam is passed through secondary SH -2 inlet header. Steam then, flows to S
SH-2 outlet header through 50.8 OD* 4.5 thick coils.
The main function of attemperator is to limit the temperature within the set point of each
superheater.
CONVECTION BANK
The name itself indicates that heat transfer in this area is by convection mode. This is a single
drum boiler and the convection bank is in the form of modules between two headers. Water is
supplied to the convection bank by 101.6 OD *5.6 thick Downcomer. Convection bank are
connected to steam drum through 12 nos. 101.6 O.D*5.6 thick riser tubes. Convection bank
modules are constructed with 50.8 OD *4.06 thick tubes. Both ends of the tubes are welded to
the convection bank top and bottom header.
ECONOMIZER
The function of the economizer in a steam generating unit is to absorb heat from the flue gases
and add this as a sensible heat to the feed water, before the water enters to the steam drum

Provision of this additional heating surface, increases the efficiency of the steam generating unit
and saving in fuel consumption is achieved. Economizer is located in between boiler bank outlet
and air pre-heater.
Economizer assembly is constructed with 62 rows of 38.1 OD * 4.06 thick tubes ,in four banks
and two headers. Both the ends of the coil were terminated to the top and bottom header by
welding.
Feed water flows from the bottom header to the top header through these coils. Heated water
flows out from the top header to steam drum through the convecting pipe.
Economizer is provided with 6 nos. motorized soot blowers to clean the external deposits.

SOOT BLOWERS
Soot blowers are the devices in steam generator that functions to remove soot deposited on the
heat transfer surfaces on various zones like furnace wall, super heater, and economizer. There are
18 soot blowers in the steam generator.
There are two types of soot blowers installed in the steam generator
1. Rotary Soot Blower
2. Long Retractable soot blower
Rotary Soot blowers
It is also called wall blower. The lance extends a short distance around 200 mm from the furnace
wall. The nozzle direction is such that the steam impinges on the walls cleaning the surface.
During operation, the lance rotates cleaning the radial area covered by the steam form the nozzle.
There are 14 rotary soot blowers .Among them, 4 are in water walls, 4 in convection bank tubes
and remaining 6 are in economizer tubes.
Long Retractable soot blowers
The function of the long retractable soot blowers is to remove the soot deposited on coil/tubes in
high temperature zone.( eg. Superheater coils). To avoid sagging of lance element from high
temperature of flue gas, LRSB is parked outside the boiler. Venturi nozzles fitted on lancing
element achieve high cleaning efficiency.
Operation
The soot blower consists of lance tube with a nozzle at the end. When it is operated, the lance
tube is extended into the boiler and steam is admitted through the lance. The steam comes out at

a high velocity jet through the nozzle which cleans the ash deposited on the surface. When the
lance moves into the boiler, it is also rotating so that it cleans the sweeping area covered by the
circular travel of the nozzle. The lance is then retracted back.
There are 4 LRSB installed on the superheater coils zone.
Technical Parameters
Temperature range = 320 340 0C
Steam consumption = 2-2.25 tons (18) /shift
Blowing pressure = 15 -40 kg/cm2
Blowers operating time = 1 min 42 sec

TECHNICAL DETAILS OF STEAM GENERATOR

FUEL SPECIFICATION
S. N.
1
2
3

Fuel
Imported Coal (Sub bituminous)
Bagasse
Biogas

Gross calorific value (kJ/kg)

20,580
9240
16000

AVERAGE FUEL CONSUMPTION RATE

S. N.

Fuel

Consumption rate (TPH)

Imported Coal (Sub bituminous)

Bagasse

43

Biogas

Loss of Ignition (LOI) % ANALYSIS

S. N.

ASH

LOI %

Bottom ash

8.43

APH ash

20.60

ESP ash

13.82

ASH COLLECTION DATA

S. N.

ASH

COLLECTION RATE

Bottom ash ( kg/hour)

416

FLy ash (kg/hour )

564

CONDENSATE EXTRACTION PUMP

The condensate extraction pump (CEP) of vertical centrifugal type pumps the feed water from
the condensate hot well to the Deaerator. Three number (each 50%) capacity in parallel supplies
the feed water to the deaerator. (1 working and 2 stand by).The discharge from each CEP
connects to a header and is supplied to deaerator.
The technical specification of the CEP is tabulated below.
S.No.
1
2
3
4
5

Parameters
Pump Type
Number
Liquid Temperature
Liquid specific gravity
Capacity(max)

Value
Centrifugal, vertical
3(1W +2 S)
45.450C
1
50 m3/hr

Discharge pressure

7.7 kg/cm2a

Suction pressure

0.1 kg/cm2

Number of stage

Pump speed

Approx 2950

10

Gland packing

Mechanical seal

11

MOC of impeller

Stainless steel

BOILER FEED PUMP