BOILERS

By
M.Rajasekara babu
 BOILERS

► Boilers is an enclosed vessel including mounting &

fittings that provides a means for combustion heat
to be transferred into water until it becomes steam
partially or wholly under pressure.
► Used to generate steam for the purpose of
 Power Generation
 Prime Movers
 Process
 Heating
 Ejectors
 IBR
► Indian Boiler Regulation
► As per IBR Boiler means
 Holding capacity exceeding 25 liters
 Pressure above 1 Kg/Sq.cm
 Temperature above 100 Deg C
► As per IBR Steam Pipe means
 Pipe exceeds 3.5 Kg/Sq.cm Pressure below
10”NB Pipe sizes.
 Pipe exceeds 1 Kg/Sq.cm pressure above &
including 10”NB Pipe sizes.
 TYPES OF BOILERS
► Fire Tube Boiler
► Water Tube Boiler
► Packaged Boiler
► Stoker Feed Boiler
► Fluidized Bed Boiler
► Super Critical Boiler (221 Bar of 375 Deg C)
► Based on Fuel
► Based on Pressure
 BOILER CONSISTS
► Feed Water System
► Fuel System
► Combustion Air & Flue Gas or Draft System
► Fuel Combustion System
► Steam Generation System
► Blow Down System
► De-super heater system
► Steam System
► Dosing System
 Feed Water
► Factors for water quality
 Deposits
 Impurities causes deposits
►Ca & Mg (Hardness Salt)
►Ca & Mg bicarbonate (Temporary Hardness)
►Ca & Mg Sulphates, Chlorides & Nitrate (Permanent
Hardness)
 Silica
 Water Treatment
► External Water Treatment
 Filters (Control of Solid Deposits)
 Ion Exchange Process (Convert Soluble Salts by
softening. Replace Ca & Mg with Na)
 De-mineralization (Removal of all salts)
►Cation
►Anion

 De-aeration (Removal of dissolved Gases)

 Reverse Osmosis
 FUEL SYSTEM
► Fuel Storage
► Heating of Oil to correct viscosity
► Removal of contaminants (Strainers)
► Pumping
► Day Tanks
► Oil heaters
 DRAFT SYSTEM
► Natural
Draft
► Mechanical Draft
 Forced Draft
 Induced Draft
 Balanced Draft
 COMBUSTION
► Rapid oxidation of fuel
► Fuel Atomization
 Steam atomization
 Air atomization
 Mechanical atomization
► Oil Firing Burners
► 3 T’s of Combustion
 Temperature (Ignition)
 Turbulence (Fuel Mixing)
 Time (Complete combustion)
 Steam Generation
► Boiler Heat Transfer Surface
 Generation Tubes
 Down Comer / Up raiser Tube
 Water wall tubes
 Roof panel tubes
 Floor Panel tubes
► Super Heater
 LT / Primary Super Heater
 HT / Secondary Super Heater
 Steam Generation
► Steam Drum
 Baffles
 Feed pipe
 Dosing pipe
 Demister / mist separator
► Mud Drum
► Headers
► Soot blowing
 BLOW DOWN SYSTEM
► Dissolved solids contained in the water
remain in the boiler to control and removed
by blow down process. Conductivity as
indicator of contamination in the boiler
water.
 Continuous Blow Down
 Intermediate Blow Down
 De-super heater
► To reduce the exit steam temperature when
necessary and to maintain it within the
limits.
► Fitted with a spray tube located horizontally
to maintain uniform distribution of water at
extremely low flow.
 Steam System
► Steam Distribution
 Steam Pipe Layout
 Pipe size
 Condensate removal (steam trap)
►Thermostatic steam trap
►Mechanical steam trap
►Thermodynamic steam trap

 Insulation
 Dosing System
► Internal water treatment
 To prevent formation of scale – forming
compounds to free flowing sludge, which can be
removed by blow down.
 Sodium Phosphate, Sodium sulphate, Sodium
aluminates & Sodium carbonate
BOILER MOUNTINGS

► Pressure gauges
► Safety valves (3Nos)
► Water level indicators (2 Nos.)
► Feed check valve
► Steam stop valve
► Fusible plug
 AUXILLARIES
► Air preheater ► Mechanical separators
► Economizer ► deaerator
► Super heaters ► chemical dosing
► Desuperheaters system
► Boiler feed pumps ► Pressure reduction

► FD & ID Fans valves

 QUALITIES OF BOILER
► QUICK START UP
► LESS MAITENANCE
► LESS FLOOR SPACE
► ABLE TO MEET LOAD FLUCTUATION
► LESS FUEL
► MAXIMUM EFFICIENCY
► EASY FOR MAITENANCE
 Losses in Boilers
► Heat loss from flue gas (stack temperature)
► Heat loss from moisture in the fuel
► Loss from incomplete combustion
► Radiation & convection heat loss from wall
► Blow down loss
► Loss from excess air
 Tube Failure
► Mechanical Damage
 Fly ash erosion
 Impingement
 Clinkers
► Chemical Causes
 Caustic gouging
 Hydrogen embrittlement
 Pitting
 Cold end corrosion
► Metallurgical Causes
 Creep damage / stress rupture
 Short time over heating
 Long time over heating
 Fatigue
 Preservation
► Boiler preservation is required to protect the internal
surface from corrosion during shutdown time.
► Wet Method
 Hydrazine (200 ppm) / Sodium sulphite (300 ~ 400 ppm)
 pH 10.5 to 11
► Dry Method
 Silica gel / activated alumina (0.25 Kg / Sq.m)
 Un-slacked lime (0.098 Kg / Sq.m)
 Positive pressure with pure Nitrogen
 Statutory
► Annual Inspection
► RLA Study & Testing
► Hot work permission & Approval
► Part replacement permission & Approval
► Boiler Parts procurement & certifications
► Authorities for approvals
 SPECIFICATION
Description Aux. Boiler ASGU RGB OSB
Make BHEL Thermax L&T BHEL
Code IBR IBR IBR IBR
Water Tube Water Tube Fire Tube Water Tube
Type
Bi-drum Single drum Single drum Bi-drum
Firing Oil fired Oil fired Oil fired
Draft FD FD WHB FD
MCR 90 TPH 120 TPH 149 TPH 85 TPH
P-design 120 Ksc 123 Ksc 125.5 Ksc 50 Ksc
P-working 106 Ksc 106 Ksc 106 Ksc 45 Ksc
P-hydro 150 Ksc 155 Ksc 153 Ksc 67.5 Ksc
Steam Temp 482 Deg C 482 Deg C 482 Deg C 382 Deg C
Heating Area 2278 Sq.m 1715 Sq.m 1962 Sq.m 1620 Sq.m
AUX. BOILER
ASGU
OSB
THANK YOU