CONTROL

AND
INSTRUMENTATION IN
SUPER CRITICAL
BOILERS

Types of boilers
Drum type
Once-through type

THE CONCEPT
The mass flow rate thru all heat
transfer circuits from Eco. inlet to SH
outlet is kept same except at low
loads wherein recirculation is
resorted to protect the water wall
system

Once-thru Boiler
Major differences from Drum type boiler :

Evaporator system
Low load circulation system
Separator

Once -thru Boiler

Evaporator system :
Formed by a number of parallel tubes
Tubes spirally wound around the furnace to
reduce number of tubes and to increase the
mass flow rate thru the tubes
Small tube diameter
Arrangement ensures high mass velocity
thru the tubes

Once -thru Boiler

Low load circulation system :
At part loads once -thru flow not adequate to
cool the tubes
To maintain required mass velocities boiler
operates on circulating mode at low loads

Once -thru Boiler

Low load circulation system :
The excess flow over the once-thru
flow separated in separator and
Returned to the condenser or de-aerator
thru a heat exchanger
or
Recirculated back to the boiler directly by
a dedicated circulating pump

Once -thru Boiler

Separator :

Separates steam and water during the

circulating mode operation

Runs dry during once-thru flow mode

Smaller in size compared to drum in a
drum type boiler

Once -thru Boiler

Advantages:
Better suited for sliding pressure operation
Steam temperature can be maintained over
wider load range under sliding pressure
Quick response to load changes
Shorter start up time
Higher tolerance to varying coal quality
Suitable for sub critical & super critical
pressures

Once -thru Boiler

Requirements :

Stringent water quality

Sophisticated control system

Low load circulation system
Special design to support the spiral furnace wall weight
High pressure drop in pressure parts
Higher design pressure for components from feed pump to
separator

Effect on Boiler Components

Evaporator (Furnace) walls
Super-heaters
Thick walled boiler components
Steam piping

Effect on Boiler Components

Higher pressure & temperature lead to
increased thickness of :
Shells of separator, start-up system
components, SHO header..
Main steam piping.

Higher thickness results in larger

temperature gradients across walls

Feedwater Control
Natural circulation boiler

Once-through boiler

Steam flow

T
Enthalpy

Level

Eco

Feedwater
control

Eva
Feedwater
control

Eva

Eco
Feedwater

Feedwater

THANK
YOU