BOILER- O&M
WELCOME PARTICIPANTS
Put your Mike & video - off
Arun Tewari
9910049818
1
Stay healthy , Stay blessed 2
BOILER BASIC
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Role of Boiler Pilot
The Prime duty of Boiler operator is to control…..
A. Load
B. Pressure
[Link]
D. All of above
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BOILER – A TALE OF TWO ENEMIES
4/24/2022
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BOILER – A TALE OF TWO ENEMIES
CORROSION
SLAGGING
CORROSION
PITTING
GOUGING
EROSION
FOULING
SCALING
4/24/2022
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FEW FUNDAMENTALS
EVEN HOLDS GOOD
OF LIFE
FOR BOILER
Life in Air
Fire is Power 7
FEW FUNDAMENTALS
STEAM WHY??
High Great
Critical Expansion
Temp Power
What For ??
PROCESS HEATING Cheap Safe
High Heat
Available
Capacity
Transporta
Reusable
tion
4/24/2022
PRIME MOVER 8
TRANSFORMATION OF ENERGY IN POWER PLANT
The picture can't be display ed.
Thermal Energy
Chemical Energy Heat Energy In steam
Of fuel After combustion
Electrical Energy Rotational Energy Kinetic/Potential Energy
At Generator At turbine outlet At turbine inlet 9
TYPE OF BOILER
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TYPE OF BOILER
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TYPE OF CFBC BOILER
IR- CFBC Cyclone
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HOT CYCLONE & COLD CYCLONE
TYPE OF BOILER
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TYPE OF BOILER
• Sponge Iron DRI
Kiln
• Cement Kiln
• Sinter Cooler
• Hot Strip Mill
• Coke Oven Batteries
• Coke Dry Quenching
(CDQ) plant
• Metallurgical /
Chemical Process
• Flue Gas Coolers
• Engine Exhaust
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HOW TO SPECIFY A BOILER
• Capacity/ Pressure\ Temperature\FW Eco in T
• Single Drum/Bi Drum/ No Drum
• Water Tube/ Fire Tube/ Mixed
• Natural/Forced/Mixed Circulation
• Balance/Forced/Induced Draft
• Membrane/ Space Furnace construction
• Top/Bottom/ Girth Support
• Fuel Firing System/Type of technology
• Outdoor/Indoor
• Equipped with Eco
KNOW AT LEAST THESE, IF NOT ALL • Original Equipment Manufacturer 15
DRAFT SYSTEM
No Induced Fan
Induced Fan Induced Fan
Waste Hot Gases
Pressure Fan
Pressure Fan No Pressure Fan
Balance Draft Positive Draft Negative Draft 16
NATURAL CIRCULATION
Superheated
Superheat
Heat
HEAT
Steam
SENSIBLE LATENT SUPERHEAT Latent
Subcooled
Sensible
water
Economizer Water Walls Superheater
Thumb Tule
Saturation Temperature =
√√ Drum Pressure X 100
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NATURAL CIRCULATION
ρwsgh FORCED
NARTURAL
ρwgH 18
NATURAL CIRCULATION
ρwsgh
STEAM DRUM
ρwgH 19
2nd Pass
Boiler Pressure Part
Arrangement
FURNACE/
1st Pass
3rd Pass
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NATURAL CIRCULATION
FURNACE/ 2nd Pass
1st Pass
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NATURAL CIRCULATION
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STEAM CIRCUIT
PSH1
SSH PSH 3 PSH2
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Difference in density
Saturated water & Saturated Steam
Two phase flow in inclined tube
Rifle bore tube 24
Saturated Steam
Pressure
Circulation Ratio: Circulation ratio
Mass of steam + Water in Riser
-----------------------------------------
Mass % of steam in Riser
Subcooled water Mix of Saturated
( Feed Water) Steam& Water
Riser
Consider drum pressure
100 Kg/Cm2/95/105
Saturation Temperature
316 Deg C/312/320
FW Eco Inlet temperature :
290 DegC
Saturated Water ( Boiler Water)
Downcomer 25
Heating Surface Area Requirement
As we move towards high
Pressure……
• Latent heat requirement
reduces so heating
surface area of
generating tube reduces
• More scope of Sensible
heat requirement , hence
LPH, High Pressure
deaerator, HPH & more
Eco area can be added
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Rankine Cycle
ENTROPY
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System Efficiency:
ηoverall = ηboilerxη
ηturbinexη
ηgeneratorxη
ηauxiliariesxη
ηcycle
ηboiler = 0.9
ηturbine = 0.94
ηgenerator = 0.95
ηauxiliaries=0.94
ηcycle = 0.42
ηoverall = 0.9 x 0.94 x 0.95 x 0.94 x 0.42 = 0.35
The efficiency of Rankine cycle is around 35%.A large amount of heat is
rejected in condensor.
Superheat
sensible
Latent
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As the pressure increases…
• More scope of sensible heat
• Less requirement of Latent heat
Steam Press
45 66 87 105
( Kg/Cm2)
Steam Temp
415 480 515 545
(Deg C)
FW Eco In 105 150 170 220
( Deg C) 0 HPH 1 HPH 1 HPH 2 HPH
Steam Fuel
2.29 2.39 2.42 2.59
Ratio
High Pressure /Temp Cycle Gross output
(MW)
24.8 26.5 28.0 29.0
• High SFR
SSC
• Low SSC (Kg/Kw-hr)
4.03 3.77 3.57 3.44
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100 TPH TG boiler with 69% efficiency ,Tubine exhaust at 0.1 kg/cm2 (a)
STEAM FORMATION – NUCLEATE BOILING
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STEAM FORMATION
Pressure 30 bar 100 bar 240 bar
Steam % 2.5% 10% 100%
Circulation 100/2.5 100/10 100/100
Ratio =40 =10 =1
Water
liberal strict strict
chemistry
Tube Metal 234+26 316+26
???
temperature = 260 =342
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TUBE METAL TEMPERATURES
For Economiser coils :
Feed Water Eco outlet temperature + Thumb Tule
13 Deg C Material Max Temp
°C
For Steam generating Pressure Part ASME (tubes):
Saturation temperature at Pressure + SA-210 A-1 427
26 Deg C SA-213 T11 552
For Convective Superheaters SA-213 T22 580
Superheater Outlet temperature of that section +
39 Deg C SA-213 T91
SA-213 TP
649
304H
For Radiant Type Superheaters 750
310H
Superheater Outlet temperature of that section +
347H
52 Deg C
For Bed superheaters
Superheater Outlet temperature of that section +
65 Deg C 33
Weld & Heat Affected Zone
Weakest Zone out of
Base metal, Weld Metal & HAZ
Most of crack initiate from HAZ
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STEAM SEPARATION
Down comers
Risers
WATER STEAM SEPERATION
• With out any physical equipment
(Density Difference)
• Baffle Separation
• Cyclonic action separation
Moisture Trapping
• Chevrons
• Demisters
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SUPEARHEAT STEAM
Primary Secondary
Superheater Superheater
Why?
Location of Attemperator
Constructional Features
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SUPPORTS AND EXPANSION
Top Support Bottom Support Girth Support
Thumb Rule : 1 mtr length of steel at 100 Deg C metal temp will expand 1 mm 37
Combustion
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Heat Transfer
Convection Conduction
Radiation
Conduction Convection Radiation
• Furnace tubes • Furnace tubes
• Furnace tubes • Convective Super heater
• Bed coils • Radiant Super heater
• Bank Tubes
• Bed Super heater • Economizer
• Air heater 39
Fuel
Proximate & Ultimate Analysis
N
• More carbon –more heating value, difficult to burn O
C
• More VM – Easy to combust A
S
• FC/VM Ratio (close to 1.5)
H
Coal
Wood
Biomass
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Fuel
2C + O2 → 2 CO + 2430 Kcals / kg of Carbon
Theoretical Air reqd for combustion
Exothermic reaction
C + O2 → CO 2 + 8084 Kcals / kg of Carbon
11.61 C + 4.35 S - 34.78(H-O/8)
2CO + O2 → CO 2 + 5654 Kcals / kg of Carbon
2H 2 + O2 → 2H2O + 28,922 Kcals / kg of Hydrogen Excess Air = O2 / (21 – O2) x 100%
S + O2 → SO2 + 2,224 Kcals / kg of Sulphur
To burn 1 kg Bagasse with 4% O2
Bagasse Combustion @ 2.8 Kg Theoretical air
@ 3.5 Kg Actual air
@ 4.0 Kg Dry Flue gas
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Fuel
ULTIMATE ASH
SLOP
ANALYSIS SLOP (60
BAGASSE Alkali ( Na,K) ANALYSIS (%
(60 Brix)
BAGASSE
% WT (As Brix) by Weight)
High fouling
fired basis)
SiO2 2.50 69.88
Carbon 22.22 23.50
Fe2O3 2.0 6.49
Hydrogen 2.15 3.25
CaO 14.0 4.75
Nitrogen 1.85 0.00
MgO 6.5 2.83
Oxygen 14.50 21.75
Chloride & Sulfur
Corrosion SO3 16.5 0.08
Moisture 40.00 50.00
P2O5 10.0 2.01
Sulphur 0.62 0.00
K2O 47.0 2.79
Ash 18.66 1.50
Quartz & Silca NaO 0.5 1.22
Total 100.00 100.00 Erosion
Cl 1.0 -
GCV(Kcals/K
1860 2272
g)
Al2O3 - 9.10
Limitation of high steam temperature with biomass 42
Fuel- Slop
Sludge :
Ideal Requirement : As low as possible
Control:
Run all decanters on full effiiciency mode
Use Pits to settle down Sludge for the max time
Brix : Temperature :
Ideal Requirement : 68-72
Ideal Requirement : 56-60
Control:
Control through evaporator
Control: Use of Steam coil heater/electrical heater
Efficient utilization of Evaporator 43
Fuel- Bagasse
Moisture :
Ideal Requirement : As low as possible
Control:
Run all decanters on full efficiency mode
Use Pits to settle down Sludge for the max time
No Fermented Bagasse
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STRESS & DESIGN
[Link] Stress:
Stress that results from the application
Of external load
• Internal pressurization,
• Thermal Expansion & Contraction
• Vibration LONGITUDIONAL STRESS HOOP STRESS
PD/2T PD/4T
[Link] Stress:
Stress that remains in the material even
when it is free from external forces or
• Thermal gradients.
• Welding
• Casting,
• Cold Forming
• Other manufacturing process
Stress Concentrator/Raiser : Location where applied stresses are amplified .
On surface: Pits, depressions, fissures, weld toes. Sharp angles
Internal surface : Por0sity 45
Know These also
Boiler Peak Rating
Operating
Pressure
Boiler Maximum Continuous Rating
Super heater (MCR)
Safety Valve
Set Pressure
Turbine Maximum Continuous Rating
(TMCR)
Maximum Allowable
Working pressure
Boiler Normal Continuous Rating
( NCR)
Design Pressure
Net Rating
Hydraulic pressure
Gross Rating
Boiler Water Holding Capacity : 0.8 X Steam Generating Capacity
1ppm = 1 mg/ltr = 1 mg/kg( for water)
To maintain a concentration of 20 ppm in 50 T boiler you will require 10 kg of material 46
CONFUSING PAIRS
Erosion Carry Over Vortex Finder Acid Cleaning Tube
Corrosion Carry Under Vortex Breaker Alkali cleaning Pipe
Mg/Ltr
ppm
Attemperator Purging Carbon loss Scaling NB
Desuperheater Scavenging LOI Fouling DNB 47
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WATER CHEMISTRY
Hardness
Combined
concentration of
Ca & Mg Salts
Leads to Scaling Alkalinity
Measure of
Dissolved Carbonates & Bi
Oxygen Carbonates
Leads to Foaming
& Carry over
Parameters pH
Suspended Measure of
Solids Acidity
Leads to
Corrosion
TDS
Silica
Measure of
Leads to
all dissolved
hard scale
solids
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WATER CHEMISTRY
UNDERSTAND
DIFFERENCE
FEED WATER
&
BOILER WATER
COC
50 50
Oxygen scavengers (L P DOSING)
WATER CHEMISTRY • Hydrazine (N2H4),
• DEHA(Di-ethyl-hydroxylamine) (CH3CH2)2NOH,
• Carbo-hydrazide (H6N4CO),
pH booster
• Methyl-ethyl-ketoxime (MEKO) H3C(C=N-OH)CH2CH3
Morpholine
Cyclo-hexylamine
add pH Booster to Deaerator
add L P Dosing
Dissolved
oxygen is
removed by
thermo-
mechanical
action up to 07
ppb
To Deaerator
add HP Dosing
From CEP to Turbine
Sludge
conditioner
(H P DOSING)
Tri Sodium Phosphate
Key Words 51
WATER CHEMISTRY
Solubility of Gases in water
Spray Nozzles
Tray
Scrubber
Dalton’s Partial pressure law
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WATER CHEMISTRY
WATER QUALITY REQUIREMENT
S. No Description Unit Feed Water Boiler Water
1 Total Hardness (Max.) PPM Nil Nil
2 pH Value at 25 Deg.C 8.5 - 9.5 9.8 - 10.5
3 Oxygen (Max.) PPM 0.007 Nil
4 Iron (Max.) PPM 0.01 --
5 Copper (Max.) PPM Nil Nil
6 Silica (Max.) PPM 0.02 4
7 Total CO2 (Max.) Nil Nil
8 Permanganate No. (Max.) Nil Nil
9 Total Dissolved Solids (Max.) PPM 0.1 150
10 Total Suspended Solids (Max.) PPM Nil Nil
11 Oil (Max.) PPM Nil Nil
Specific electrical conductivity at 25
12 Deg.C after degassing(max.) in micro 0.2 350
siemens/centimeter
13 Residual Hydrazine (Max.) PPM 0.02 0.1
14 Residual Phosphate (Max.) PPM Nil 10 - 15
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PRESERVATION
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