Tanjung Jati B Training

BOILER OVERVIEW
Coal Fired Boiler Design & Performance.1
 Coal Fired Boiler
Design & Performance

BOILER OVERVIEW

Coal Fired Boiler Design & Performance.2

P.T. Central Java Power
Tanjung Jati B Units 1 & 2

2 x 660MW (net)

Boiler Precipitator FGD Absorber

Tanjung
Coal Fired Jati& B
Boiler Design Training
Performance.3
Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.4

Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.5

In the beginning. . .
Heros Aelopile - 200 BC

Coal Fired Boiler Design & Performance.6

18 Centuries later (1600)
Brancas Steam Turbine Novelty

Coal Fired Boiler Design & Performance.7

The Newcomen Beam Engine (1711)
Replaced the Savery Engine improved pumping technology

Coal Fired Boiler Design & Performance.8

The Shell or Haycock Boiler
Steam power for Newcomens Engine

Coal Fired Boiler Design & Performance.9

The Waggon Boiler

Coal Fired Boiler Design & Performance.10

Improving the technology
The Trevithick Boiler - 1804

A cylindrical
shell for
improved
strength
Increased
contact of flue
gas with water
Cast iron
construction vs.
copper plates
Higher Pressure
available

Coal Fired Boiler Design & Performance.11

B&W is Born - 1866
George Babcock & Steven Wilcox

The B&W
Safety Boiler

Coal Fired Boiler Design & Performance.12

Tanjung Jati B (2005)
Carolina-Type
660 MW (net)
Radiant Boiler
for Pulverized
Coal

Coal FiredTanjung Jati

Boiler Design B Training
& Performance.13
Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.14

The Boiler

Tanjung Jati B Units 1 & 2 are natural-circulation,

single drum, single reheat, and top-supported
Babcock & Wilcox Carolina Radiant Boilers.

The RB is a high pressure, high-temperature,

high-capacity, drum type boiler.

Coal Fired Boiler Design & Performance.15

The Boiler

Each boiler is a 660 MW (net), balanced draft,

pulverized coal fired unit with 10% oil (ignitor)
capability.

Coal Fired Boiler Design & Performance.16

The Boiler
Boiler Maximum Continuous Rating (BMCR)

Firing Bengalon Coal at 1% Sulfur:

Main Steam Flow: 2313 Mkg/hr (5099 Mlb/hr)

Main Steam Temp: 541oC (1006oF)
Main Steam Pressure: 174.2 barg (2527 psig)

Reheater Outlet Flow: 1895 Mkg/hr (4178 Mlb/hr)

Reheater Outlet Temp: 539oC (1001oF)
Reheater Outlet Press: 37.9 barg (549 psig)

Coal Fired Boiler Design & Performance.17

 Introduction
Boiler components we need to remember
(Part 1)
Furnace
Downcomers
Economizer
Steam Drum
Primary Superheater I
Primary Superheater II
Secondary Superheater
Reheater
Spray Attemperators
Safety Valves

Coal Fired Boiler Design & Performance.18

 Primary Secondary
Superheater Reheater
Superheater II

Steam Drum

Primary
Superheater I

Downcomers
Economizer

Furnace

Coal Fired Boiler Design & Performance.19

Steam
Steam Drum Internals
Drum
Steam Outlet

Primary Steam
Separators

Secondary Steam
Separators

Feed Water
Cyclone Piping
Separators
or cans

Vortex Feed Water

Eliminator Downcomers (x3) Inlet (at end of Drum)

Coal Fired Boiler Design

Ta n j u&ngPerformance.20
J a ti B Tra i ni n g
Attemperators Crossover Piping
1st Stage
2nd Stage Attemperator (x2)
Attemperator (x2)

Note: The Reheat Attemperator is located in the cold reheat

piping between the HP Turbine outlet & the cold reheat
inlet header

Coal Fired Boiler Design & Performance.21

Attemperators
Locations

STEAM DRUM PSH-I PSH-II SSH

HP TURBINE

TO IP TURBINE
REHEATER

Coal Fired Boiler Design & Performance.22

Typical Spray Attemperator

Coal Fired Boiler Design & Performance.23

Safety Valves

The Boiler and related Steam Piping have the following

number of safety valves

Steam Drum: Seven (7)

Superheater Outlet Piping: Two (2) Spring-Type

Two (2) Electromatic

Cold Reheat Piping: Seven (7) Spring-Type

Hot Reheat Piping: Two (2) Spring-Type

Coal Fired Boiler Design & Performance.24

Safety Valves
Locations

7 4

STEAM DRUM PSH-I PSH-II SSH

HP TURBINE

2 7
TO IP TURBINE
REHEATER

Coal Fired Boiler Design & Performance.25

 Introduction
Boiler components we need to remember
(Part 2)
Coal Feeder
Coal Pulverizer
Coal Burner
Ignitor (or Lighter)
Burner Windbox
Primary Air Fan
Forced Draft Fan
Seal Air Fan
Steam Coil Air Heater (SCAH)
Tri-Sector Air Heater

Coal Fired Boiler Design & Performance.26

 Burner
Windbox
Burner with
Ignitor

Tri-Sector
Airheater

Coal Feeder

Coal Pulverizer

Seal Air Fan Forced

Primary Air Fan SCAH
Draft Fan
Coal Fired Boiler Design & Performance.27
Introduction
Coal Feeders, Pulverizers & Burners

Coal Feeders regulate the coal flow from the coal

silos to the Pulverizers.

Coal Pulverizers act to Grind, Classify & Dry

the coal prior to introduction to the Burners.

Coal Burners are Low NOx DRB-XCL type burners

TM

designed to produce stable flames while minimizing

NOx & CO emissions .

Coal Fired Boiler Design & Performance.28

Introduction
Ignitors & Burner Windbox

Ignitors provide a source of ignition and help

stabilize burner flames at relatively low coal input.

The Windbox segregates the air flow of each burner

level (called a Compartmented windbox).

Coal Fired Boiler Design & Performance.29

Introduction
Primary Air, Forced Draft & Seal Air Fans

Primary Air Fans provide the required air flow to

the pulverizers to function properly and allow for
the transport of pulverized coal to the burners.

Forced Draft Fans provide the necessary amount

of combustion air for the burners.

Seal Air Fans provide the required amount of static

air pressure to the pulverizers and the coal feeders.

Coal Fired Boiler Design & Performance.30

Introduction
Steam Coil Air Heater & Air Heater

Steam Coil Air Heater (SCAH) provides extra heat

to the secondary air in order to control or maintain
the air heaters average cold end temperature above
the acid dew point.

The Tri-Sector Air Heater transfers heat from the

hot flue gasses exiting the boiler to both the cold
primary & secondary air streams.

Coal Fired Boiler Design & Performance.31

 Introduction
Boiler components we need to remember
(Part 3)
Sootblowers
Thermoprobes

Coal Fired Boiler Design & Performance.32

Sootblowers

The Sootblowers which utilize steam from the

boiler are intended to remove slag and ash
from boiler tube surfaces.

Steam is taken from the Primary Superheater II

Outlet Header. From there, the pressure is
reduced at the Sootblower Blower Reducing
Station to 500 psig or 34.5 barg.

Coal Fired Boiler Design & Performance.33

Sootblowers
Steam Source TO BOILER & AIR HEATER
SOOTBLOWER
REDUCING STATIONS

STEAM DRUM PSH-I PSH-II SSH

HP TURBINE

TO IP TURBINE
REHEATER

Coal Fired Boiler Design & Performance.34

Sootblowers

There are three (3) types of Sootblowers

62 - Long retractable (IK) PSH-I, PSH-2, SSH & RH

8 - Extended Lance (IKEL) Economizer

36 - Short Retract (IR) Furnace Walls

Coal Fired Boiler Design & Performance.35

Thermoprobes

Two (2) thermoprobes are supplied, one on each

convection pass sidewall, and are located immediately
upstream of the rear furnace wall screen tubes.

Their function is to monitor the gas temperature

within the convection pass during start-up to
prevent overheating the superheater and reheater
tubes.

The maximum flue gas temperature is 510oC (950oF)

at a boiler load of <10%.

Coal Fired Boiler Design & Performance.36

Sootblowers & Thermoprobes
Locations

Thermoprobe

IK Long Retract IK Long Retract

Blowers Blowers

IR Short Retract IKEL Short

Wall Blowers Retract Blowers

Coal Fired Boiler Design & Performance.37

Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.38

Customer Supplied Information
Performance Related

Turbine heat balance

Fuel (coal) analysis
Pressure drop limitations
Emission limits & other government guidelines (SO2, CO, NOx)
Site information
- Location, seasonal, etc. (Humidity and ambient temperatures)
Boiler use information
- Cycling, extra capacity, etc.

Coal Fired Boiler Design & Performance.39

Steam Cycle Information
Firing Bengalon Coal (at 1% sulfur)
ECR BMCR
Load Load
Main steam flow, Mlb/hr 4783 5099
Main steam temperature leaving SSH, F 1006 1006
Main steam pressure leaving SSH, psig 2513 2527
Reheat steam flow, Mlb/hr 3943 4178
Reheat inlet steam temperature, F 620 632
Reheat inlet steam pressure, psig 538 570
Reheat outlet steam temperature, F 1001 1001
Reheat outlet steam pressure, psig 519 549
Feedwater temperature, F 550 557
Water leaving the Economizer, F 585 593

Coal Fired Boiler Design & Performance.40

Customer Specifications
Bengalon Coal Information

As-Dried Dry Ash Free

Proximate Analysis Ultimate Analysis
Percent Percent
by Weight by Weight
Moisture (inherent) 13.5 Carbon 76.3
Volatile matter 40.0 Hydrogen 5.4
Fixed Carbon 42.0 Nitrogen 1.5
Ash 4.5 Oxygen 15.8
100.0 Sulfur 1.0
100.0
High heating value = 5900 kcal/kg (10,536 BTU/lb)

Coal Fired Boiler Design & Performance.41

Need to Calculate
Boiler output (Turbine steam requirements)

Efficiency (Rupiah)

Fuel Quality (Volatiles, Carbon, Water, Ash)

Fuel Rate (Number of Pulverizers & Burners)

Combustion Air Weight (PA & FD Fan sizing)

Wet Flue Gas Weight (ID fan sizing)

Coal Fired Boiler Design & Performance.42

Efficiency
Heat Loss Method
Dry gas loss
Moisture in air loss
H2 and H2O in fuel loss
Unburned combustible loss (unburned carbon)
Radiation loss
Manufacturers margin
Unaccounted for loss
Efficiency (%) = 100 - Losses (%)

Coal Fired Boiler Design & Performance.43

Combustion Air
Total air required for the burning equipment.

Theoretical air + Excess air = Combustion air

Theoretical air:
- Minimum air required for conversion of C, H, and S in fuel to
standard products of combustion

Excess air:
- Required because air and fuel mixing is not perfect

Combustion air determines the sizing of FD fans, ducts,

windboxes, and air heaters.

Coal Fired Boiler Design & Performance.44

Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.45

Furnace Design Goal

Provide sufficient volume and proper geometry to

completely burn the fuel and contain the fireball

Produce the required amount of steam from the

heat of combustion

Coal Fired Boiler Design & Performance.46

Furnace Design Constraints
Fuel Quality:
Heating Value (BTU or kcal/kg)
Volatiles (gases)
Fixed Carbon
Ash
Moisture or Water in the Coal

Fuel Ash Characteristics

Furnace Slagging
Convection Pass Fouling
Corrosion Properties

Coal Fired Boiler Design & Performance.47

Fouling & Slagging
Convection
Pass Fouling

Furnace
Slagging

Coal Fired Boiler Design & Performance.48

Furnace Design Constraints
Emissions formed during combustion
Carbon Monoxide (CO)
Nitrogen Oxides (NOx)

Mechanics & Economics

Physical Size of the Boiler

Coal Fired Boiler Design & Performance.49

Furnace Construction
Membrane

Smooth and Ribbed Tubes

Coal Fired Boiler Design & Performance.50

Furnace Membrane Panel

Coal Fired Boiler Design & Performance.51

Ribbed Furnace Wall Tube
(creates centrifugal force)

Coal Fired Boiler Design & Performance.52

Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.53

Superheater Types

Pendant (shielded from radiant heat from combustion)

Platen (subject to radiant heat from combustion)

Horizontal (physical orientation)

Coal Fired Boiler Design & Performance.54

Platens Pendant SSH
Pendants Pendant RH
Horizontal Surface
Steam Drum
Horizontal RH

Steam Drum
Horizontal PSH I

Platen PSH II Horizontal

Economizer

Coal Fired Boiler Design & Performance.55

 Steam/Water
Steam Cycle
Drum Internals
Steam Drum Steam Outlet

Primary Steam
Separators

Secondary Steam
Separators

Feed Water
Cyclone Piping
Separators
or cans

Vortex Feed Water

Eliminator Downcomers (x3) Inlet (at end of Drum)

Coal Fired Boiler Design

Ta n j u&ngPerformance.56
J a ti B Tra i ni n g
 SECOND STAGE SSH INLET

Steam Cycle ATEMPERATOR

PSH II OUTLET
HEADERS SSH OUTLET
HEADER

HEADER FIRST STAGE

Superheater ATTEMPERATOR
STEAM DRUM
PSH I OUTLET
HEADER
ROOF INLET
HEADER

CONVECTION PASS
RING HEADER
PSH II INLET
HEADER

To HP
Turbine

Coal Fired Boiler Design & Performance.57

 REHEAT

Steam Cycle SUPERHEATER

OUTLET HEADER

Reheater

Note: RH Attemperator
is located between the HP
turbine outlet & the Cold
RH Inlet Header.
REHEATER
INLET HEADER

Coal Fired Boiler Design & Performance.58

Steam Temperature Control

Attemperation (from Feed Water)

Excess Air (from FD Fans)

Parallel Back-end Control (Gas Biasing Dampers)

Coal Fired Boiler Design & Performance.59

Spray Attemperator

Coal Fired Boiler Design & Performance.60

Attemperators
Location

STEAM DRUM PSH-I PSH-II SSH

HP TURBINE

TO IP TURBINE
REHEATER

Coal Fired Boiler Design & Performance.61

Excess Air
Affect on Spray Attemperation

Too much excess air will tend to increase

Attemperator spray flow

More gas (mass) flow & higher furnace exit

gas temperature (FEGT) will result if excess air
is too high.

Coal Fired Boiler Design & Performance.62

Gas Biasing Dampers

The boiler has what is called a parallel flow

back pass or convection pass. Reheater surface
is located in one section & Primary Superheater
surface is in the other.

A set of Gas Biasing Dampers is located in

both sections located downstream of the
economizer.

Coal Fired Boiler Design & Performance.63

Gas Biasing Dampers

Primary Superheater I

Reheater Gas Biasing

Damper Location
Baffle Wall

Coal Fired Boiler Design & Performance.64

Agenda
I. History
II. Introduction
III. Heat and Material Balances
V. Furnace Design
VI. Convection Pass Design
VII. Boiler Circulation

Coal Fired Boiler Design & Performance.65

Boiler Circulation Goal

The goal is to generate the required steam flow at

the required outlet conditions while providing
adequate cooling to protect the furnace.

Coal Fired Boiler Design & Performance.66

Why Adequate Boiler Circulation is Important

Boiler tubes to last as long as possible

Boiler to operate as efficiently as possible

Do not want the tubes to scale, plug or fail

Coal Fired Boiler Design & Performance.67

How do we achieve our goal?

1. Maintain a good water treatment program.

2. Do not overfire boiler under certain steam load

conditions. Over-firing at low boiler pressures
and low boiler load (start-up) is a common
mistake.

Coal Fired Boiler Design & Performance.68

Natural Circulation Principle

Coal Fired Boiler Design & Performance.69

The Circulation Loop

Coal Fired Boiler Design & Performance.70

Boiling

(Good) (Bad)

Coal Fired Boiler Design & Performance.71

 FURNACE
REARWALL ECONOMIZER
Water STEAM DRUM
HEADER OUTLET
HEADERS

Cycle FURNACE
FRONT WALL
HEADER

ECONOMIZER
DOWNCOMERS INLET
HEADERS

Coal Fired Boiler Design & Performance.72

 Coal Fired Boiler
Design & Performance

BOILER OVERVIEW
(END)

Coal Fired Boiler Design & Performance.73