Boiler and Aux

120 MW X 8
PRESENTATION ON
“BOILER & AUXILIARY ”
BY R.S.DAS,CHIEF MANAGER(MECH)
RAW WATER HP D/A LP HEATER GRIDCO
HEATER BFP
WATER TREATMENT
HPT IPT LPT GENERATOR
SMELTER
COOLING 10.5 KV 220 KV
TOWER
CEP
CW PUMP 6.6 KV
CONDENSER UAT
REHEATED STEAM
GT 6.6 KV
SAT
CONDENSATE CHIMNEY
STORAGE TANK
BOILER
COAL BUNKERS
ECONOMISER
ELECTRO STATIC
PRECIPITATOR
FUEL OIL TANK
MILL ID FAN
FD FANS
PA FAN
COAL CRUSHER
ASH SLURRY PUMPS
PULVERISED FUEL BOILER
The coal is ground (pulverised) to a fine powder,
so that less than 2% is +300 µm and 70-75% is
below 75 µm, for a bituminous coal. The pulverised
coal is blown with part of the combustion air into
the boiler plant through a series of burner nozzles.
Secondary and tertiary air may also be added.
Combustion takes place at temperatures from
1300-1700°C, depending largely on coal rank.
Steam is generated, driving a steam generator and
turbine. Particle residence time in the boiler is
typically 2-5 seconds, and the particles must be
small enough for complete burnout to have taken
place during this time.
CONTD.
Two broadly different boiler designs are
used. One is the traditional two-pass
layout where there is a furnace chamber,
topped by some heat transfer tubing to
reduce the FEGT. The flue gases then turn
through 180°, and pass downwards
through the main heat transfer and
economiser sections.
The other design is to use a tower boiler,
where virtually all the heat transfer
sections are mounted vertically above each
other, over the combustion chamber.
CONTD.
There are variations in the positioning of the
burners in the combustion chamber, and
designs are offered which use:
1.wall-mounted burners on one side,
2.opposed-fired wall mounted burners, .
3.tangential burners in the corners or on the
walls.
Most PCC boilers operate with what is called a

dry bottom. Combustion temperatures (with
bituminous coal) are held at 1500-1700°C.
With lower rank coals the range is 1300-
1600°C. Most of the ash passes out with the
flue gases as fine solid particles to be
collected in ESPs or fabric filters before the
stack.
SPECIFICATION OF NALCO 120 MW
BOILER
MAKE BHEL
CIRCULATION NATURAL
TYPE PF,WATER
TUBE,REHEAT
DRAFT BALANCED
FLOW CAPACITY 430 T/HR-400 T/HR
TOTAL HEATING SURFACE AREA 13,844 M2 -1 –5
15683 M2 -6
17400 M2 - 7 & 8
FURNACE SIZE- WIDTH 11201MM
-DEPTH 7696 MM
DESIGN PRESSURE 158.2 Kg/m2
EFFICIENCY 87.36% (MCR
87.33% (NCR)
BOILER AND AUXILIARIES
 MAIN BOILER
 FANS
 MILLS & FEEDERS
 AIR HEATERS
 ELECTROSTATIC PRECIPITATOR
 VALVES
 SOOT BLOWERS
CIRCULATION
NATURAL
Q
HEAT TRANSFER MODE
1. CONDUCTION
2. CONVECTION
3. RADIATION
4. COMBINATION ALL ABOVE
BOILER PARTS
1. BOILER DRUM
2. SUPER HEATERS
3. REHEATERS
4. WATER WALLS
5. DOWN COMERS
6. STEAM HEADERS
7. SAFETY VALVES AND VALVES
safety_valve.exe
8. ECONOMISER
9. FUEL FIRING EQUIPMENTS
BOILER TUBE MATERIALS
THE TUBES SHALL BE SEAMLESS AND

MANUFACTURED FROM CARBON
STEEL /ALLOY STEEL /SS
RH
LTSH
PLSH
ECO
WW
SOOT BLOWERS
• FUNCTION :- TO CLEAN THE
HEATING SURFACE BY STEAM
BLOWING.
• 40 NOS. OF WALL SOOT BLOWERS
AND 16 NOS. OF LRSB (LONG
RETRACTABLE SOOT BLOWERS) /
BOILER.
MILLS
1 INPUT COAL SIZE <40MM
2 OUTPUT COAL SIZE FINENESS OF
COAL POWDER
70-80% - THROUGH 200 MESH
98-99%- THROUGH 50 MESH
3 NAME OF XRP-763/XRP-803 (FOR
PULVERISER UNIT#7 & 8)
4 NO. OF 5 NOS. / 120 MW
PULVERISERS
5 CAPACITY 31.4T/HR(XRP-763)
36.5T/HR(XRP-803)
6 MAKE BHEL
ADVANTAGE OF BOWL MILL
• LOW POWER CONSUMPTION
• HIGH RELIABILITY
• MINIMUM MAINTENANCE
• WIDE CAPACITY
• QUIET AND VIBRATION LESS
OPERATION
• ABILITY TO HANDLE WIDE RANGE
OF COAL
COAL FEEDERS
• RAW COAL FEEDERS ARE EITHER
VOLUMETRIC OR GRAVIMETRIC TYPE.
• IT FEEDS COAL IN A CONTROLLED WAY

FROM BUNKERS TO THE BOWL MILLS.
• COAL FLOW IS CONTROLLED EITHER

BY PIV (POSITIVE INFINITE VARIABLE)
GEAR BOXES OR DYNO DRIVE.
AIR HEATERS
• AIR HEATER IS A HEAT EXCHANGER IN
WHICH TEMPERATURE OF PRIMARY AIR
AND SECONDARY AIR IS RAISED BY
TRANSFERRING HEAT FROM FLUE GASES
COMING OUT FROM THE FURNACE.
• MOTOR CAPACITY-7.5 KW
• THERE ARE TWO TRISECTOR ROTARY

TYPE AIR HEATER PER BOILER.
ADVANTAGES OF AIR HEATERS
1. INCREASE IN BOILER EFFICIENCY
2. STABILITY OF COMBUSTION IMPROVED
BY HOT AIR
3. INTENSIFIED AND IMPROVED
COMBUSTION
4. HELP IN BURNING POOR QUALITY FUEL
EFFICIENTLY
5. THE AREA OF HEAT TRANSFER GETS
REDUCED.
ELECTRO STATIC
PRECIPITATORS
COMBUSTION GASES LADEN WITH ASH

IS PASSED THROUGH ESPs, WHICH
HAS A COLLECTION EFFICIENCY OF
99.74%.
DUST INLET – 63.7 gm/Nm3
DUST OUTLET-150 mgm/Nm3
ESP
HOW A ESP FUNCTIONS
Charging
Particles are given strong negative
charge by ionizing corona produced
by high-voltage electrodes
Collection
The electric field causes charged
particles to migrate and precipitate on
the grounded plates, where they
agglomerate and are held by the
electric field
Removal
The particulate matter is
mechanically rapped off the plates
in large ‘clumps’, falling into
hoppers for removal
SUSPENSION AND RAPPING MECHANISM
The collecting electrodes are fixed loosely to
suspension beams on pins. They are joined
together in the bottom rapping beam. Both,
the firm bottom and the top loose
attachment provide a perfect transfer of
energy from the rapping hammers to the
entire row of collecting electrodes. The
rapping is carried out in regular,
programmed intervals and guarantees
removal of deposited dust from the
electrodes to the hoppers.
Tumbling Hammers Strike the collecting
plates and rigid electrodes directly, so that
all areas receive proper rapping acceleration
and no energy is lost to support structure.
FOUR STAGES OF
PRECIPITATION
1. IONIZATION OF GASES AND CHARGING
OF DUST PARTICLES.
2. MIGRATION OF THE PARTICLES TO THE
COLLECTOR
3. DEPOSITION OF CHARGED PARTICLES
ON THE COLLECTING SURFACE
4. DISLODGING OF PARTICLES FROM THE
COLLECTING SURFACE
ESP - PARTICLE CHARGING
• The -ve charges of ions and free electrons travel towards +ve electrode
and the +ve charges of ions travel towards -ve electrodes.
• When -ve ions travel towards +ve electrodes, the -ve charges get
attached to the dust particles and thus the dust particles are electrically
charged,
ESP - PARTICLE COLLECTION
ELECTROSTATIC PRECIPITATOR
AS PER STATUTORY
NORM, SPM FROM THE
CHIMNEY SHOULD NOT
BE MORE THAN
100mg/Nm3.
FANS
1 ID FAN INDUCED DRAFT FAN
2 FD FAN FORCED DRAFT FAN
3 PA FAN PRIMARY AIR FAN
4 SEAL AIR SEAL AIR FAN

FAN
FD FANS
 TO SUPPLY SECONDARY AIR FOR
COMPLETE COMBUSTION.
 THERE ARE TWO FD FANS OF CAPACITY
58.4 M3/SEC EACH. TYPE-AXIAL , DESIGN-
KKK, GERMANY,KW-400,HEAD-450 mmWC
 THE FLOW OF FD FAN IS REGULATED
THROUGH BLADE PITCH CONTROL. THE
SPEED OF THE FAN IS 1500 RPM
FD FAN ASSEMBLY
ID FANS
 TO REMOVE THE FLUE GAS AND PRODUCT
OF COMBUSTION FROM BOILER.
 THERE ARE 2 NOS. OF ID FANS OF

CAPACITY 137.2 M3/SEC. TYPE-
RADIAL,KW-900, HEAD-342 mmWC
 THE FLOW IN ID FAN IS CONTROLLED BY

VARYING SPEED OF HYDRAULIC
COUPLING.
ID FAN ASSEMBLY
Air out
Air in
PRIMARY AIR FANS
 PRIMARY AIR IS REQUIRED FOR DRYING OF
COAL IN MILLS AND CONVEY THE SAME TO
BOILER FOR COMBUSTION
 THERE ARE TWO PRIMARY AIR FANS EACH

OF CAPACITY 55 M3/SEC. TYPE-RADIAL,KW-
900, HEAD-1212 mmWC
 THE FLOW OF FAN IS CONTROLLED BY

INLET GUIDE VANE.
PA FAN ASSEMBLY
SEAL AIR FANS
 TO SUPPLY HIGH PRESSURE

AIR i.e ABOVE PRIMARY AIR
PRESSURE TO STOP FINE COAL
DUST ENTRY INTO BEARINGS ETC.
IN THE MILLS.

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120 MW X 8

Most PCC boilers operate with what is called a

THE TUBES SHALL BE SEAMLESS AND

• IT FEEDS COAL IN A CONTROLLED WAY

• COAL FLOW IS CONTROLLED EITHER

• THERE ARE TWO TRISECTOR ROTARY

COMBUSTION GASES LADEN WITH ASH

2 FD FAN FORCED DRAFT FAN

3 PA FAN PRIMARY AIR FAN

4 SEAL AIR SEAL AIR FAN

 THERE ARE 2 NOS. OF ID FANS OF

 THE FLOW IN ID FAN IS CONTROLLED BY

 THERE ARE TWO PRIMARY AIR FANS EACH

 THE FLOW OF FAN IS CONTROLLED BY

 TO SUPPLY HIGH PRESSURE

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