BOILER

A boiler (or steam generator) is a closed vessel in which water, under pressure is converted into steam. It is one of the major components of a thermal power plant. A boiler is always designed to absorb maximum amount of heat released in process of combustion. This is transferred to the boiler by all the three modes of heat transfer i.e. conduction, convection and radiation.

Boilers are classified as

1. Fire tube boiler
In this type the products of combustion pass through the tubes which are surrounded by water. These are economical for low pressure only.

2. Water tube boiler

In this type of boiler water flows inside the tubes and hot gases flow outside the tubes. These tubes are interconnected to common water channels and to steam outlet. y y y y y y he water tube boilers have many advantages over the fire tube boilers High evaporation capacity due to availability of large heating surface. Better heat transfer to the mass of water. Better efficiency of plant owing to rapid and uniform circulation of water . Better overall control. Easy removal of scale from inside the tubes. In KSTPS, Natural circulation, tangentially fired, over hanged type, Water tube boilers are used. Oil burners are provided between coal burners for initial start up and flame

stabilization. Firstly, light oil (diesel oil) is sprayed for initialization then heavy oil (high speed diesel oil) is used for stabilization of flame. Pulverized coal is directly fed from the coal mills to the burners at the four corners of the furnace through coal pipes with the help of heated air coming from PA fan. Four nos. of ball mills of 34MT/hr. capacity each have been installed for each boiler. The pressure inside boiler is -ive so as to minimized the pollution and looses & to prevent the accidents outside the boiler.

GENERAL DESCRIPTION
Boilers are tangentially fired, balance draft, natural circulation , radiant type, dry bottom with direct fired pulverized coal from bowl mills. They are designed for burning low grade coal with high ash content. Oil burners are located between coal burners for flame stabilization.

Pulverized coal is directly fed from the coal mills to the burners at the four corners of the furnace through coal pipes. ESP with collection efficiency of 99.8% have been provided to reduce environmental pollution and to minimize induce draft fan wear. Two boiler feed pumps each of 100 % capacity are driven by AC motor through hyd. coupling with scoop tube arrangement for regulating feed water pressure for each unit. The air required for combustion is supplied by two forced draft fans.

Due to anticipated high abrasion of ID fans impellers. Three ID fans each of 60% capacity have been provided one ID fan to serve as standby. Oil preheating arrangement is provided on the tanks floors for the heavy oil tanks.Superheated steam temperature is controlled by attemperation. Re-heater steam temperature is primarily by tilting fuel burners through + 30o and further control if necessary is done by attemperation.

TECHNICAL SPECIFICATION OF BOILER

1.Type : Direct fired, natural circulation balance draft water tube boiler. 2. No. of Units. 3.Make : : Two. BHEL.

4.Capacity. 5.Steam Pressure. 6.Efficiency 7.No. of fans in service. a) ID fans. b) FD fans. c) PA fans. 8. Steam Temperature 9. No. of coal mills in FUEL :a) COAL:Type Quantity consumed Type of handing. Ash disposal B) OIL:Type. Quantity.

: : :

375 tonnes per hour. 139 Kg./Cm2 86.6 %.

: : : : :

2 Nos. 2 Nos. 2 Nos. 540oC. 3 Nos. service.

: : : :

Slack Coal. 3074 tones per day. Conveyor. Wet system.

: :

HSD and fuel oil. a) HSD 5520 KL per year. * b) Furnace Oil : 28800 KL per year.

No. of chimney / stack. Height of Chimney. Volume of flue Gas/ Temp. of flue gas.

: : : :

1 / 2. 180 Meters. 198 M3/ Sec. Air emitted. 140oC.

Furnace

Furnace is primary part of the boiler where the chemical energy available in the fuel is converted into thermal energy by combustion. Furnace is designed for efficient and complete combustion. Major factors that assist for efficient combustion are the temperature inside the furnace and turbulance, which causes rapid mixing of fuel and air. In modern boilers, water-cooled furnaces are used.

PULVERISED FUEL SYSTEM

The boiler fuel firing system is tangentially firing system in which the fuel is introduced from wind nozzle located in the four corners inside the boiler. The crushed coal from the coal crusher is transferred into the unit coalbunkers where the coal is stored for feeding into pulverizing mill through rotary feeder The rotary feeders feed the coal to pulverize mill at a definite rate. Then coal burners are employed to fire the pulverized coal along with primary air into furnace.

FIG. 5 TANGENTIAL FIRING These burners are placed in the corners of the furnace and they send horizontal streams of air and fuel tangent to an imaginary circle in the center of the furnace.

Boiler Drum:The drum is a pressure vessel. Its function is to separate water and steam from tmixture (of steam & water) generated in the furnace walls. It provides water storage for preventing the saturation of tubes. It also houses the equipment needed for purification of steam. The steam

purification primarily depends on the extent of moisture removal, since solids in steam are carried by the moisture associated with it. Drum is made up of two halves of carbon steel plates having thickness of 133 mm. The top half and bottom half are heated in a plate heating furnace at a very high temperature and are pressured to form a semi cylindrical shape. The top and bottom semi cylinders with hemispherical dished ends are fusion welded to form the

FIG. 6 STEAM DRUM boiler drum. Boiler drum is located at a height of 53m from ground. Main parts of boiler drum are Feed pipe, Riser tube, own corner, Baffle plate, Chemical dosing pipe, Turbo separation, Screen dryer, drum level guage.