Boiler

Refresher

What will we cover..?

Basic

Concept of Steam Boiler Boiler Pressure Parts Boiler Operation Principles

Basic Concept of Steam Boiler

Boiler System

What is Boiler..?
A

closed vessel that safely, reliably and efficiently transfers heat released during combustion of fuel in which water and steam are heated under pressure. The steam or hot fluid is then circulated out of the boiler for use in various processes and heating.

Boiler Function

To release the energy in the fuel as efficiently as possible. To transfer the released energy to the water and to generate steam as efficiently as possible. To separate steam from the water where the energy can be transferred to the process as efficiently as possible.

Boiler Function
Changes of Water Phase inside a Boiler

Types of Boiler
Fire-Tube

Boiler Water-Tube Boiler, including HRSG Tubeless Boiler Electric Boiler

Fire Tube Boiler

A cylindrical vessel with the flame in the furnace and the combustion gas inside the tubes. The furnace and tubes are within a larger vessel, which contains the water and steam. Also known as Shell Boiler and Package Boiler in modern time Lancashire Boiler, Scotch Marine, Cornish

Fire Tube Boiler

Stoker Boiler

Modern Fire Tube Boiler

Steam Outlet Safety Valve Chimney

Burner

Blowdown

Combustion Air Control Panel

Fire Tube Boiler

Fire Tube Boiler

Water Tube Boiler

Water and steam are inside the tube, and the hot gas is in contact with the outer tube surfaces. Normally operates on a principle of natural circulation. Babcock & Wilcox Boiler

Water Tube Boiler

Comparison
Water-Tube
Pressure can be as high as 350 bar

Fire-Tube
Pressure limited to 27 bar & 27 t/h of flow.

Fast response time

Requires on-site fabrication High capital cost due to its complexity High maintenance cost & requires sophisticated DCS

Low response time

Everything is factory packed, ready for use Relatively cheaper and uses less space Simple maintenance and control

Other Types

Fulton Boiler

Can be classified into sub-critical and super-critical boiler. Capacity as high as 1,300MW Triple fuel capability Double Reheat Demand high quality water Higher efficiency Opposed-fired design is more preferable with efficient burner design

Modern Power Generation Boiler

Boiler for Power Generation

Boiler Heat Transfer Zones

Furnace Zone high temperature gases of Convection Zone medium temperature

gases can be used for heating steam with medium to high superheat.

combustion can be used for heating water and steam with low to medium superheat.

HRA Zone with cool gases, heat can only be

extracted effectively by cool liquid.

Firing Configuration

Firing Configuration (Opposed-Fired)

Firing Configuration (Tangential-Fired)

Firing Configuration (U-Flame)

Boiler Essential Fittings

1. 2. 3. 4. 5. 6. 7. 8. 9.

Safety Valves Two Water Gauges Steam Pressure Gauge Blow-down Valve Feed Pumps Boiler Stop Valve Feedwater Check Valve Inspectors test pressure gauge attachment Fusible Plug

Boiler Essential Fittings

10. 11. 12. 13.

Low water alarm Low water fuel cut out Manufacturers or maker plate A registration plate

Boiler Essential Fittings

Water Gauge Glass

Blowdown

Boiler Essential Fittings

Manufacturers Plate

Pressure Gauge

Safety Valve

Boiler Stop Valve

Feedwater Check Valve

xx 700MW Boiler
IHI natural circulation with single reheat and single drum design. Coal as Main Fuel with LFO as back-up Boiler outlet pressure of 171.9 bar Boiler outlet temperature 541 C Reheat Pressure 39 bar @ 566 C Balanced Draught Design

Feedwater Flow in Boiler

Boiler Sections Arrangement
Primary Superheater T=386 C P=181 b Secondary Superheater T=379 C P=180 b T=429 C P=177 b T=450 C P=178 b Final Superheater T=541 C P=171 b

T=365 C P=182 b

Furnace Roof

HRA Roof HRA Rear Wall

HRA Partition Wall

HRA Sidewalls T=566 C P=39 b

T=538 C P=166 b

T=338 C P=42.5 b

Steam Drum
T=360 C P=185 b

T=301 C P=185 b

Reheater T=338 C P=41.9 b

Furnace Side Wall (R)

Furnace Rear Wall

Furnace Front Wall

Furnace Side Wall (L)

T=301 C P=188 b
Economizer

Flow=2259t/h T=301 C P=185 b T=283 C P=190 b

BF
100.00 150.00 200.00 250.00 50.00

Af te rH P Af
0.00

P D is ch H P

Pressure (bar)

te r

he

Af

Feedwater & Steam P-T Diagram

Location 0.0 100.0

Pressure Temperature

ar g he e at te er r H ate 7/ r5 Bo P h ea ile H te rF P St ee r 6 H ea P dw H m S P at af Ex tea er te m H tra P be r bo Tu ctio fo ile n rb r (to re t in ur e H bi ex P n it (to hea e C te H ol r P d he 7) R H at er be H fo 6) H re ot ot R IP Bo R H T ile a Ex H b r ef fter tra or Bo ct IP e io ile IP T n ex (to Tu r it rb H (to P i he ne Fe LP at ed T er Ex w at 5) LP tra er ct T Ta Ex ion nk ) LP trac 1 (t LPT o tio T en LP Ex n he try tra 2 ( to a ct io LP ter n he 3) 3( to at er LP LP he 2) T ex a C C on ond it/C ter 1) o de e ns nsa nde C at ns te on e a de e a fte fter r ns C rL C at on E e P af F e de he P at ed nsa ter er LP w at t e a 1 er fte he af r L ate te rF Ph r2 e ee dw ater at 3 er Ta nk

200.0

Temperature (C)

300.0

400.0

500.0

600.0

Boiler Heat Absorption

Furnace -48%. Boiler bank (convection section) 20%. Superheaters 15%. Air Heaters -10%. Economiser -7%

Boiler Pressure Parts

1. Economiser 2. Steam Drum 3. Furnace Wall 4. HRA 5. Superheater 6. Reheater

Radiant Superheater

To HPT

Feedwater Flow in Boiler

Final Superheater Secondary Superheater Primary Superheater

To IPT

Reheater

From HPT exhaust

Water wall Economizer

From HP Heater 7

Economiser
Absorb low quality heat from the flue gases in the form of sensible heat, to the boiler feedwater before entering steam drum. Located after primary superheater and reheater but before the RAPH Reduce flue gas temperature to a satisfactory level for the RAPH Can be Plain Tube type or Welded Fin Tube

Economiser

1. 368 tubes 2. Inlet temperature 283 degree C @ 190.6 bar 3. Outlet temperature 301 degree C @ 188.6 bar

Steam Drum
Receives feedwater from the economiser Contain saturated steam and water which act as a buffer during sudden load change Steam is separated and dried from entrained water before further heating in the superheaters. Blow-down of dissolved solid from boiler water takes place Location of some statutory safety equipment

Steam Drum

Steam Drum

Steam Drum
Horizontal Separator
First Stage Drying Relies on principle of centrifugal action to separate substance of different density Eliminates steam content in steam/water mixture so that only water will pass to downcomers 234 units

Steam Drum
Chevron Dryer
2nd. Stage Drying Plating out moisture in steam onto metallic surface. The film of water adhering to the dryer surface drain by gravity to the bottom of the dryer and falls back into the water. 76 units

Steam Drum Fittings

Furnace Wall
Panels

of welded fin tubes form walls of rectangular furnace of steam generator. Place where steam is generated in the boiler Bottom of furnace hopper connected to ash receiving hopper via a water seal. Rear wall of furnace has a nose section to assist distribution of gas flow to SH section located above the nose.

Furnace
Large water-cooled chamber in which fuel and air are mixed and burned in suspension. Houses the firing equipment and confines the combustion process by having a gas tight enclosure.

Furnace Wall

Furnace Wall

Furnace Wall

Superheaters

Superheats the dry steam out of the drum to few hundred degrees as to eliminate high moisture content after LP turbines expansion. Design can be 2 types:

Radiant Superheater consists of division wall and Platen Superheater Convection Superheater consists of Primary and Secondary Superheater either pendant or horizontal type.

Radiant Superheater

Platen Superheater utilises the radiant heat left in the flue gas before they enter the convection zone. Consists of closed pitched tubes welded together to form a platen section. Surface parallel to the gas flow and with spaces at least 600mm between platen elements.

Convection Superheater

Primary Superheater
Consists

of horizontal & vertical loop tubes located in the HRA gas path parallel to reheater. Flue gas flowing at right angles to the tubes, creating turbulence and thus maximise heat transfer rate. Outlet steam temperature is controlled by primary attemperator before entering the Secondary Superheater

Convection Superheater

Secondary Superheater*
Located

(can be radiant)

close to the furnace outlet and protected from the intense radiation by water wall nose. Consists of vertical elements (pendant type) arranged across the furnace width. The outlet steam temperature is controlled by second stage attemperator before entering the Final Superheater

Convection Superheater

Final Superheater
Located

at furnace exit above the nose section of the furnace rear wall. Consists of vertical elements, arranged across the furnace width. Final part of the boiler where final superheated steam leaves the boiler before entering the HP Turbine.

Reheater
Receives exhausted steam from HP turbine through Cold Reheat Pipe Consists of 4 sections

Lower,

intermediate, upper & vertical sections

Steam flows upward through the horizontal banks by counter flow to flue gas flow. Outlet steam leaves the reheater to IP turbine inlet through Hot Reheat Pipe.

Other tubes in HRA

1. 2. 3.

4.
5.

Furnace Roof HRA Rear Wall HRA Front Wall HRA Side Wall Partition Wall