Académique Documents
Professionnel Documents
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Amit Prakash
20%
Stack Lake Steam 6% Aux. Power + Losses 34% Electricity 100% Fuel Air
Boiler
Steam Turbine
Generator
Transmission
Steam
Boiler
Steam Turbine
Generator
Transmission
57-62%
100% Fuel
Stack
Combuster
Compressor
Turbine
Generator
Transmission
Process Steam
Process Plant
Combuster
Exhaust Gas
Air
Compressor
Turbine
Generator
Transmission
Amit Prakash
28%
Air
35-40% Electricity
Compressor
Turbine
Generator
Transmission
Boiler Steam & Water System Air & Flue Gas System
BOILER
Fuel Preparation System Fuel Firing System Boiler Miscellaneous Systems Boiler Feed Pumps & Deaerator System Turbine Steam System
UNIT#2
TURBINEGENERATOR
HP & LP Heaters System Turbine Supervisory & Control System Generator & Electrical System Turbine Miscellaneous Systems Turbine Bypass System
DM Plant
Steam & Water Air & Flue Gas BOILER Fuel Preparation Fuel Firing
Steam
UNIT#2
UNIT#3
TG
HP & LP Heaters
Supervisory & Control Generator & Electrical
Miscellaneous Systems
DM Plant
BOILER FUNDAMENTALS
Amit Prakash
Blowdown
Air
Ash
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COMBUSTION REQUIREMENTS
Fuel is Gasified
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Heat
Flue Gas Products H2O CO2
O2
H2 C
Heat
Flue Gas
Products H2O CO2 CO H2 C
O2
Other Combustibles - Sulphur to Sulphur Oxides Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides Ash
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Attemperator Platen Super Heater Down Comers Final Re Heater Primary Re Heater Final Super Heater Primary Super Heater Cold Reheat Steam Spray Water
Flue Gas
Economiser
Feed Water
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Process Regulation Drum Level - Regulation of Feed Water flow Drum Water Quality - Blow down / Chemical Dozing Fouling of Heat Transfer Surfaces - Blowdown / Soot Blowing Main Steam Temperature - Attemperation / Burner Tilt Hot Reheat Steam Temperature - Burner Tilt / Attemperation Main Steam Pressure - Regulation of Combustion
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From FD Fans
To Hot PA Header
To Cold PA Header
PA FAN A
PA FAN B
FURNACE
FD FAN B
18
Process Performance Highlights Generation of Draft - Natural / Induced / Forced / Balanced Supply of Air for Transport of Pulverised Coal Pre-heating of Air Distribution of Air in Combustion Chamber Recirculation of Gas Fan capacity depends on Flow, Density & System Resistance Fan performance is affected by temperature, density, barometric pressure and speed Flue Gas Cleaning Gas flow is restricted by ash deposits on boiler surfaces
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Major Equipment
Air Path - Forced Draft Fans, Steam Coil Air Pre-heater, Regenerative Air Pre-heater & Wind-box
Gas Path - Induced Draft Fans and Stack Gas Recirculation - Gas Recirculating Fans Flue Gas Cleaning - Mechanical Precipitator, Electrostatic Precipitator and Gas Scrubber Dampers
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Process Regulation Furnace Draft - ID Fan Inlet Vane Control and/or Variable Speed Secondary Air Flow - FD Fan Variable Pitch Control PA Header Pressure - PA Fan Inlet Vane Control RAPH Cold End Temperature - SCAPH Control Gas Recirculation - Damper Control
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Coal Feeder
Coal+Air to Burners
Mill A
To Other Mills
Cold PA
To Other Mills
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FUEL GAS
Atomising Steam/Air PCV Fuel Oil Return PCV Short Recirc Long Recirc
To Burners
FUEL OIL
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Process Performance Highlights Coal Pulverizing - Direct / Indirect Firing Coal Transport and Drying Fuel Gas Pressure Regulation Fuel Oil Pumping & Filtering Fuel Oil Pressure & Viscosity Regulation Gas Pressure & Oil Pressure/Temperature affect Boiler Load
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27
Air Distribution
Fuel Combustion
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Major Equipment Burners Ignitors Flame Scanners Burner Tilt Mechanism Wind Box Dampers
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Process Regulation
Emergency Shutdown
Flame Monitoring Oil Support for Coal Flame Stability
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Boiler Auxiliary Cooling Water System Ensures continuous supply of cooling water to Boiler & its auxiliaries Consists of Overhead Tank, Pumps & Heat Exchangers Chemical Dosing System Prepares & supplies chemicals for treatment of Boiler Water Consists of Preparation Tanks, Mixers & Metering Pumps
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31
To HP Heaters
Discharge Valve
32
Process Performance Highlights Boiler Water pre-heating & air removal Maintain positive Suction Pressure for Feed Pumps Feed Water Pumping to Boiler
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Process Regulation
Deaerator Pressure
Deaerator Level BFP Minimum Recirculation
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LAWS OF THERMODYNAMICS
Conservation of Energy - Heat may be converted in to work and work may be converted in to heat, in accordance with a certain natural proportionality constant (ENERGY CAN NOT BE DESTROYED)
Not all of a given quantity of Heat can be converted in to useful Work, because of irreversbility in the process (ENTROPY OF THE UNIVERSE IS INCREASING)
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37
T
Heat Available for Work
Unavailable Heat
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Condensing Turbine Back Pressure Turbine Regenerative Turbine Controlled Extraction No. of Cylinders Speed - Constant / Variable Single / Double Flow
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LP
Turbine
41
Major Equipment
Condenser
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HP HTR
LP HTR
44
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Hotwell Level
Heater Level Minimum Flow through CEP & GSC
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Turning Gear
OIL SYSTEMS
WARM UP SYSTEM
48
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Process Regulation
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Condenser Cooling Water System Supplies Cooling Water Condensation of Turbine Exhaust Steam Turbine Auxiliary Cooling Water System Ensures continuous supply of cooling water to Turbine & its auxiliaries Consists of Overhead Tank, Pumps & Heat Exchangers Chemical Dosing System Prepares & supplies chemicals for treatment of Condensate Consists of Preparation Tanks, Mixers & Metering Pumps
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52
To Unit#2
Condenser Waterbox A B
CW Makeup Water
CW Supply Header
53
Process Performance Highlights Steam Condensation Cooling of Condenser CW - Cooling Tower / Lake Process Regulation
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54
PRV
HRH
To IPT
Condensate Condenser
55
Enable Boiler Operation for Quick Re-start after Boiler Trip and during Turbine Start-up
Control MS Pressure after Turbine Trip or Sudden Load Throw-off
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GENERATOR FUNDAMENTALS
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WORKING PRINCIPLE
Converts Mechanical Energy in to Electrical Energy Based on Electro-magnetic Induction E = 4.44 O FN volts E - e. m. f. O - Strength of Magnetic Field F - Frequency N - No. of Turns in a Stator Winding Coil F = Pn/120 P - No. of Poles n - Revolution per second of Rotor
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Losses - Bearing Loss, Copper Loss & Iron Loss Typically Efficiency is 90-97%
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Generator Transformer
ELECTRICAL SYSTEMS
MECHANICAL SYSTEMS
61
132 KV Bus II
Circuit Breaker
GT
Unit Auxiliary Transformer From Station Bus From Station Bus 6.6 kV Unit Bus B
11 kV
62
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Field Excitation
Generator Synchrinisation Voltage Regulation
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Wall Blowers
Long Retractable Blowers Air Heater Blowers
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Automatic Turbine Run-up System Oil Supply Control - Turning Gear, Auxiliary Oil Pumps, Emergency Oil Pump, Jacking Oil Pump and Lube Oil Temperature Condensate & Evacuation Control - Condensate Extraction Pumps, Gland Steam Pressure, Vacuum Pumps and Vacuum Breaker Valve Turbine Control - Steam & Metal Temperature Matching, Warming up of HP ESV & CV, Steam Rolling & Acceleration and Auto Synchroniser
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