Operators Manual

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TUTORIAL FOR BOILER OPERATORS COMPETENCY EXAMINATION
DTP/BOT/ VI/030502
p*v<B*(mki. (Pre Requisite)

p|Ativni (Preamble)
pivr jnr[Sn t[mj p\i\[s[s)>g kiy< miT[ vriL bi[ylrni[ upyi[g bhi[Li p\miNmi> k[ yipkpN[
Yti[ [vi mL[ C[. (vXinni (vkisn) siY[ siY[ bi[ylrn) rcni t[mj kiy< krvin) p(tmi> pN an[k
s&Firi-vFiriai[ [vi mL[ C[. pivr jnr[Sn miT[ upyi[gmi> l[viti bi[ylri[ mi[Ti Big[ hiE-p\[sr
p\kirni> bi[ylri[ hi[y C[, yir[ p\i[s\[s kiy< miT[ li[-p\[sr bi[ylri[ni[ upyi[g Yti[ hi[y C[.
bi[ylri[ an[k p\kirni hi[y C[ a[Tl[ t[mn[ fiyr krvin) r)ti[ pN alg alg hi[y C[.
bi[ylri[mi> mi[Ti Big[ f)D-vi[Trni l)F[ mi[Ti Bign) upi(Fai[ Yt) hi[y C[. td&pri>t uwi[gi[mi>
upyi[gmi> l[viti> bi[ylri[ p\[sr v[ssn) p(rBiPimi> aivti> hi[viY) t[mn[ srkir oiri GD[l (nymi[
(I.B.R. 1991) n) kiydik)y [gvie p\miN[ clivvini> hi[y C[. ai miT[ bi[ylri[n&> riy-srkirmi>
r(jAT^[Snn[ tij&> kriv)n[ t[ a>g[n&> s(T<(fk[T m[Lvv&> pD[ C[.
upr m&jbn) j$(ryiti[n[ lxmi> riK)n[ bi[ylrn[ clivvi miT[ riy srkiri[a[ bi[ylr
a[T[DT tr)k[ni> Fi[rNi[ n) kyi< C[. bi[ylr a[T[D[T tr)k[n) liykit m[Lvvi miT[ t[ miNs[ s[kD
lis t[mj fAT< lis bi[ylr a[T[D[T ki[p)Ts) pr)xi pis kr[[l) hi[v) [ea[.
1.
1.1
pr)xi aipvi miT[ [et&> j$r) Xin:

s[kD lis bi[ylr a[T[D[Tn) pr)xi aipvi miT[ [et& j$r) Xin:
{1}
j&di j&di p\kirn) vriL bi[ylri[n) rcni s>b>F) Nkir) t[mj v(k<>gn) Nkir) hi[v)
[ea[. td&pri>t t[n) sirs>BiL k[v) r)t[ krvimi> aivS[ t[n) pN Nkir) hi[v) [ea[.
bi[ylrmi> xiri[ jmi Yy[l hi[y ti[ t[mn[ sif krvi miT[n&> t[mj d*r krvi miT[n&> Xin hi[v&>
[ea[.
{3} bi[ylrmi> k[v) r)t[ diKl Yv&> [ea[ aYvi ti[ si[e b) miNsn[ diKl krvmi> aiv[
ti[ t[ k[v) r)t[ diKl Yiy t[ miT[n&> p*rt&> Xin hi[v&> [ea[.
{4} bi[ylrn[ (nr)xN miT[ k[v) r)t[ t]yir krv&> [ea[ t[mj t[ s>b>F) l[v) [et)
kiLJai[ vg[r[n&> p*rt&> Xin hi[v&> [ea[.
{5} bi[ylrn) (cmn)ai[mi>Y) kiLi[ F&miDi[ n (nkL[ ti[ t[n[ (nvirvi miT[ k[vi pgli> Brvi
[ea[ t[ miT[n&> Xin hi[v&> [ea[.
{6} bi[ylr upr miuT krvimi> aivti> j&di j&di miu(T>s (vP[n&> Xig hi[v&> [ea[ an[
Kis kr)n[ n)c[ m&jbn) bibti[ p\Ry[ p*rt&> yin aipv&> [ea[.
(i)
vi[Trg[jn) ckisN) k[v) r)t[ krv) [ea[.
(ii) vi[Trg[jn) lis T&b t*T) y Ryir[ l[v) [et) sivc[t) t[mj t[n[ k[v) r)t[
bdlv) [ea[ t[n&> Xin hi[v&> [ea[.
(iii) p\[sr g[jn&> vi>cn k[v) r)t[ krv&> [ea[ t[n&> Xin hi[v&> [ea[.
(iv) slimt) vivn[ ckisvin&> t[mj t[mn[ s[T krvin&> Xin hi[v&> [ea[.
{2}
{7} s&prh)Tr t[mj eki[ni[miezrn) LvN) k[v) r)t[ krv) [ea[ t[n&> Xin hi[v&> [ea[.
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{8} bi[ylr cil&hi[y Ryir[ eki[ni[miezr k[v) r)t[ ai[pr[Snmi> m&kv&> [ea[ t[mj t[n[
ai[pr[Sn mi>Y) k[v) r)t[ alg krv&> [ea[ t[ s>b>Fn&> Xig hi[v&> [ea[.
{9} ej[`Tr t[mj f)D pp yir[ m&k[l) UBi krti> hi[y Ryir[ k[v) r)t[ t[mn[ Ki[l)n[
m&k[l) d*r krv) [ea[ t[ miT[n&> Xin hi[v&> [ea[.
{10} bi[ylrmi> bLtN k[v) r)t[ diKl krv&> t[ s>b>F) Xin hi[v&> [ea[. td&pri>t bi[ylrn[
fiyr)>g krvi dryin l[v) [et) tk[dir)ai[ t[mj vriLn&> uRpidn krt) v[Li l[v) [et)
tk[dir)ai[ni[ yil hi[vi[ [ea[.
{11} bi[ylri[n[ b[Tr)mi> k[v) r)t[ [Dvi t[mj j[ t[ bi[ylrn[ b[Tr)Y) k[v) r)t[ C*T&> piDv&> t[
m&jbn&> Xin hi[v&> [ea[.
1.2
fAT< lis bi[ylr a[T[D[Tn) pr)xi aipvi miT[ [et&> j$r) Xin:
fAT< lisn) pr)xi aipvi \miT[ [eti j$r) Xin upri>t n)c[ m&jbn) bibti[n&> vFirin&> Xin hi[v&>
[ea[:
{1}
ej[`Tr t[mj f)D ppn) rcni s>b>F) Xin hi[v&> [es[.
{2}
(cmn)mi>Y) n)kLti kiLi F&miDin[ aTkivvi miT[ upyi[gmi l[viti siFni[n&> Xin t[mj t[mni
s>b>F) mih)t) hi[v) [ea[.
{3}
f)D vi[Tr T^)Tm[T s>b>F) Xin hi[v&> [ea[.
{4}
s&prh)Tr t[mj eki[ni[miezrn) rcnin&> Xin hi[v&> [ea[.
{5}
f)T vi[Tr h)Ts<, f)D-viT r[y&l[Ts< vg[r[n) rcni t[mj t[mni upyi[g sb>F) Xin hi[v&>
[ea[.
{6}
bi[ylr DîfT a>g[n&> Xin hi[v&> [ea[ t[mj eDy&AT DîfT an[ fi[AD< DîfT miT[ upyi[gmi>
l[viti p>Kiai[n) rcni t[mj t[mni upyi[g s>b>F) Xin hi[v&> [ea[.
2.
2.1
pr)xi aipvi miT[ um[dvirn) liykiti[

s[kD lis bi[ylr a[T[DTn) pr)xi aipvi miT[ um[dvirmi> [et) j$r) liykiti[:
{1} um[dvirn) u>mr 20 vP<Y) ai[C) n hi[v) [ea[.
{2} um[dvir[ vriL bi[ylr upr aYvi vriL a[(jn miT[ni> vriL bi[ylr upr ai[Cimi>
ai[Ci #iN vP< s&F) fiyrm[n aYvi ai(sATT fiyrm[n tr)k[ kim kr[l&> hi[v&> [ea[. aYvi
{2} um[dvir[ vriL bi[ylr aYvi vriL a[(jn yi> t[ a>g[n&> (rp[r)>g kiy< Yt&> Ryi>
ai[Cimi> ai[Ci #iN vP< miT[ bi[ylr f)Tr k[ a[(jn f)Tr tr)k[ kim kr[l&> hi[v&> [ea[. AYvi
{2} srkir[ miy kr[l eDAT^)yl aYvi T[`(nkl EAT)T&Tmi> #iN vP<ni[ a[p\[T)s ki[P<
kr[li[ hi[vi[ [ea[ an[ t[ miT[n&> aYvi T[n)kl EAT)T&Tni vDin) sh) siY[n&> s(T<f)k[T hi[v&>
[ea[. #iN vP<ni a[p\[T)s ki[P<mi> ai[Cimi> ai[Ci a[k vP< miT[ f[Tr) aYvi (mlni AT)m pivr
liTmi> aYvi bi[ylr bnivt) a[(j(nyr)>g vk<Si[pmi> aYvi bi[ylr m[ET[s miT[n)
a[(j(nyr)>>g vk<\Si[pmi> kim kr[l&> hi[v&> [ea[.
2.2
fAT< lis bi[ylr a[T[DTn) pr)xi aipvi miT[ um[dvirmi> hi[v) [et) j$r)
liykiti[:
{1}
um[dvirn) u>mr 21 vP<Y) ai[C) n hi[v) [ea[.
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{2} s[kD lis bi[ylr a[T[D[Tn) pr)xi pis kr[l) hi[v) [ea[.
{3} s[kD lis a[T[DTn) aYvi t[n) smkx pr)xi pis kr) l)Fi pC) a[Tl[ k[ t[n[
ligt&> sT)<f)k[T m[Lv) l)Fi pC) bi[ylrni[ upyi[g krt) m)l aYvi f[Tr)mi> Avt>#\i r)t[
bi[ylr a[T[DT tr)k[ ai[Cimi> ai[Ci b[ vP< miT[ kim kr[l&> hi[v&> [ea[.bi[ulrn) h)T)>g spiT)
140 ci[rs m)TrY) ai[C) hi[v) [ea[ nh)> t[mj kim kyi< p\miN tr)k[ f[Tr)ni c)f
a[(j(nyr aYvi m[n[jrn&> sh)> viL&> s(T<(fk[T hi[v&> [ea[.
aYvi
{3} srkir[ miy kr[l EDAT^)yl aYvi T[k`(nkl EAT)T&Tmi> #iN vP<ni[ a[p\[T)s ki[P<
kr[li[ hi[vi[ [ea[ an[ t[ miT[n&> EDAT^)yl aYvi T[k`(nkl EAT)T&Tni vDin) sh)> siY[n&>
s(T<(fk[T hi[v&> [ea[. #iN vP<ni a[p\[T)s ki[P<mi> ai[Cimi> ai[Ci a[k vP< miT[ f[Tr) aYvi
(mlni AT)m pivr liTmi> aYvi ti[ bi[ylr m[ET[s an[ (rp[r krt) aYvi ti[ bi[elr
bnivt) a[(j(nyr)>g vk<Si[pmi> a[p\[T)s tr)k[ kim kr[l&> hi[v&> [ea[. td&pri>t ai[Cimi> ai[Ci
a[k vP< miT[ bi[ylr a[T[D[T aYvi ti[ t[n) pr)xi pis kr) l)Fi pC) Avt>#i r)t[ 140 ci[rs
m)TrY) ai[C) h)T)>g spiT) n hi[y t[vi bi[ylr upr bi[ylr a[T[D[T tr)k[ kim kr[l&> hi[v&>
[ea[.
ni[>F: ki[epN y(ta[ d[Sni ki[epN riyn) bi[ylr a[T[D[Tn) pr)xi aYvi ti[ t[n)
smkx pr)xi pis kr[l) hi[y ti[ t[ s(T<(fk[Tn[ g&jrit srkir oiri miy krvi miT[n) arJ
kr) Sk[ C[. g&jrit srkirn&> ligt&> vLgt&> Kit&> s(T<(fl[T upr t[ a>g[ni[ pi[tini[ S[ri[ kr)
aip[ C[.
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vriLni> g&NFmi[< (Properties of Steam)

p|Ativni
vriL a[ vriL a[(jn (Steam Engine) an[ vriL Tbi<enmi> (Steam Turbine) mi> mi[Ti piy[
Upyi[gmi> l[viy C[. t[ upri>t j&d) j&d) k[m)kl p\(k|yiai[mi> t[mj fT)<liezs< uwi[gi[mi> vriLni[
upyi[g Yiy C[.
vriL an[ t[ni> g&NFmi[< (vS[ (vgtvir smjti ph[li aipN[ Yi[D)k p\iY(mk Nkir) m[Lv) lea[.
1.0
pdiY< an[ t[ni> Av$pi[
pdiY<ni> m&yRv[ #iN Av$pi[ C[.

{1} Gn Av$p
{2} p\vih) Av$p
{3} viy& Av$p
1.1 pdiYi[< dbiN t[mj tipminn) (AY(t p\miN[ Gn, p\vih) k[ viy& Av$pmi> s>Bv) Sk[ C[ j[mk[
brf a[ Gn Av$p, piN) a[ p\vih) Av$p an[ vriL {biOp} a[ viy& Av$p C[.
1.2 yi2[ pdiY<n&> tipmin aYvi t[ni> prn&> dbiN aYvi b>n[ bdlvimi> aiv[ Ryir[ am&k ci[ks
dbiN[ an[ tipmin[ pdiY<n&> a[k Av$pmi>Y) b) Av$pmi> $pi>tr Yiy C[.
j[m k[, piN) n[ grm krti am&k ci[ks dbiN[ an[ tipmin[ t[n&> $pi>tr vriL k[ viy&mi> Yiy C[.
n)c[ dSi<v[l aikZ(t n> -1 mi> pdiY<ni j&di j&di Av$p smvvimi> aiv[l C[.
T
Temperature
Tsup
ts
00 c
c
H
aigL dSi<v[l aikZ(t n> -1 mi> AB j[Tl) grm) aipviY) Gn pdiY< (a) ni tipminmi> vFiri[ Yiy C[
an[ t[n&> Av$p a mi>Y) b Yiy C[. hv[ b Av$p[Y) vGir[ grm) aipviY) t[n&> GnAv$pmi>Y) F)m[ F)m[
p\vih) Av$pmi> $pi>tr Yvi mi>D[ C[ an[ (b>d& c a[ t[ s>p&N< p\vih) bn) y C[. Av$p b Y) Av$p c
s&F) aipv) pDt) grm) BC vD[ dSi<v[l C[ j[n[ glng&t grm) kh[ C[. ah) b Y) c s&F) aipv)
pDt) grm)Y) t[ni tipminmi> vFiri[ Yti[ nY) pr>t& pdiY<n&> acL tipmin[ Av$p bdlie y C[. hv[,
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acL dbiN[ grm) aipviY) pdiY<n&> Av$p f[rfir pim)n[ (b>d& d s&F) phi[c[ C[ yi t[n&> tipmin Dd
Yiy C[ an[ t[ miT[ t[n[ aip[l vFirin) grm) CD vD[ dSi<v[l C[. ai tipmin[ p\vih) ukLvi mi>D[ C[
an[ t[n& p\vih)mi>Y) biOpmi> $pi>tr Yiy C[. a[k (kli[g\im p\vih)n&. biOpmi> s>p*N< $pi>tr krvi miT[
aipv) pDt) grm) De vD[ dSi<v[l C[ai $pi>tr acL tipmin[ Yiy C[ an[ t[ dryin grm) aipvi
Cti p\vih)ni tipminmi> f[rfir n Yti[ hi[viY) aip[l) uOmin[ (DEn[) biOp)krNn) g&t grm) kh[ C[.
(Latent Heat of Evaporation) ai biOpn[ hj& vF& grm) aipviY) t[n&> tipmin vF[ C[ j[
aikZ(tmi> ef r[Ki vD[ dSi<v[l C[ an[ ai tipmin[ (Ff) pdiY< t[ni> a(ttt Av$p[ (Superheated
Stage) phi[>c[ C[ an[ t[ miT[ aipv) pDt) grm) EF vD[ dSi<v[l C[ j[n[ a(ttip (Uperheat) kh[
C[.
n)c[n) aikZ(t n> - 2 mi> piN)/vriLni> (v(vF Av$pi[ an[ t[ni g&NFmi[< dSi<v[l C[.
Temperature
Tsup
Ts
D
Liquid
Vapour
B
Evaporation
Sensible
Heat
Gas
Latent Heat
Super
Heat
Heat Added
2.0 vriLni> (v(vF g&NFmi[< (vS[ smjti ph[li> vriLn) j&d) j&d) (AY(tai[ (vS[ Nv&> K*b j
j$r) C[.
vriLn) (Steam) n) k&l cir (AY(tai[ vN<v) Skiy.
{1} B)n) vriL (Wet Steam)
{2} s*k) s>tZt vriL (Dry Saturated Steam)
{3} a(ttZt vriL (Superheated Steam)
{1} B)n) vriL (Wet Steam) : j[ vriLmi> piN)ni> (b>d&ai[n&> a(At_v rh[l&> hi[y C[ t[n[ B)n)
vriL kh[ C[. B)n) vriL m&yRv[ j&d) j&d) p\(k|yiai[mi> a[k GTk tr)k[ vpriy C[.
{2} s*k) s>tZt vriL (Dry Saturated Steam) : j[ vriLmi> piN)n&> a[k pN (b>d& a(At_v
n Frivt&> hi[y t[n[ s*k) s>tZt vriLni[ Big Ws (k.g\i. an[ piN)ni[ Big Ww (k.g|i hi[y ti[,
B)n) vriLni[ S&Oki>k = s*k) s>tZt vriLn&> vjn
B)n) vriLn&> k&l vjn
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j[n[ x vD[ dSi<vvimi> aiv[ C[.

x = Ws / Ws +Ww
{3} a(ttZt vriL (Superheated Steam) : s*k) s>tZt vriLn[ grm) aipvimi> aiv[ ti[
t[n&> tipmin t[ni> uRkln(b>d& krti> vFir[ hi[y t[n[ a(ttZt vriL kh[vimi> aiv[ C[.
a(ttZt vriLn&> tipmin t[n[ aipvimi> aiv[l a(ttipn a>S (Degree of Superheat) pr
aiFir riK[ C[. j[n) yiyi ai m&jb C[.
a(ttZt vriLni> tipmin an[ uRkln (b>d& vc[ni> tfivtn[ a(ttipn a>S kh[ C[ an[ t[n[ miT[
aip[l grm)n[ a(ttip kh[viy C[.
3.0 vriLni g&NFmi[< (Properties of Steam):
vriLni (v(vF g&NFmi[< n)c[ p\miN[ C[.
{1} vriLn&> dbiN (Steam Pressure)
{2} vriLn&> tipmin (Steam temperature)
{3} uRkln (b>d& (Boiling Point)
{4} qirN(b>d& (Saturation Point)
{5} (v(S kd (Specific Volume)
{6} s>v[w uOmi (Sensible Heat)
{7} biOp)Bvnn) g&tgrm) (Latent Heat of Evaporation)
{8} k&l uOmi (Enthalpy)
{9} a[Tî[p) (Entropy)
{1} vriLn&> dbiN (Steam Pressure) : vriLni ki[epN Av$p[ a[km x[#ifL ligti bLn[
dbiN kh[ C[. j[ni[ a[km (k.g\i/s[m)2 (kg/cm2) aYvi (bar)
{2} vriLn&> tipmin (Steam temperature) : vriLni ki[epN Av$p[ t[mi> rh[l grm) aYvi
q>D)n) t)v\ti aYvi mipn[ vriLn&> tipmin kh[ C[ j[n[ a>S s[(SyS (0C) mi> mipvimi aiv[ C[.
{3} uRkln (b>d& (Boiling Point) : j[ tipmin[ p\vih)n&> {piN)n&>} biOpmi> $pi>tr Yiy C[ t[n[
piN)n&> uRkln (b>d& kh[ C[.
{4} qirN(b>d& (Saturation Point) : j[ tipmin[ biOpn&. p\vih)mi> $pi>tr Yiy C[ t[n[ qirN(b>d&
kh[vimi> aiv[ C[.
ai b>n[ tipmin a[k j hi[y C[ miT[ t[n[ s>tZt tipmin (Saturated Temperature) kh[ C[.
a[Tl[,
piN)n[ yir[ 00s[ Y) grm) aipvimi> miv[ C[ Ryir[ yi s&F) piN) ukLvi n lig[ Ryi s&F) piN)ni
tipminmi> vFiri[ Yiy C[. j[ tipmin[ piN) ukLvi lig[ C[ t[ tipminn[ piN)n&> uRkln
(b>d& aYvi s>tZt tipmin (Saturation Temperature) kh[vimi> aiv[ C[. ai tipmin dbiN pr
aiFir)t C[ j[m dbiN vF[ C[ t[m s>tZt tipmin vF[ C[.
piN)n&> s>tZt tipmin d(ryin) spiT)a[ an[ vitivrNni dbiN[ (1.0332 kg/cm2) 1000C hi[y
C[.
aim, uprn) smj*t) prY) tirv) Skiy k[,
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piN) aYvi p\vih) t[ni uRkln (b>d&a[ viy&mi> $pi>tr Yiy an[ t[mi> [ p\vih) aN&ai[ rh[li
hi[y ti[ t[n[ p\vih)n) biOp kh[vimi> aiv[ C[. an[,
piN) aYvi p\vih)ni t[ni uRkln(b>d&Y) GNi j U>ci tipminn) (AY(tn[ viy& Av$p kh[vimi>
aiv[ C[. viy& Av$pmi> p\vih)ni aN&ai[ (blk&l hi[ti nY) an[ a[Tl[ t[ viy&ni> (v(vF (nymi[n[ an&sr[
C[.
{5} vriLn&> (v(S kd (Specific Volume of Steam) : aip[l vriLni a[km vjnni> kdn[
t[n&> (v(S kd kh[ C[. s*k) s>tZt vriLn&> (v(S kd vriLni> ki[qi (Steam Tables) mi>Y) mL[ C[
j[n[ Vs m)Tr3/(k.g\i vD[ C[.
yir[ B)n) vriL (Wet Steam)n&> (v(S kd n)c[ p\miN[ Si[F) Skiy C[.
B)n) vriLn&> (v(S kd V = s*k) vriLn&> kd + piN)ni> (b>d&ai[n&> kd
=
xVs + (1-x) Vw m)3/(k.g\i.
ah)> x = B)n) vriLni[ S&Oki>k
Vw = aip[l dbiN[ piN)n& (v(S kd {m)Tr3/(k.g\i}
Vs = aip[l dbiN[ s*k) s>tZt vriLn&> (v(S kd {m)Tr3/(k.g\i}
simiy r)t[ piN)n&> (v(S kd a[ s>tZt vriLni (v(S kd Vs ni p\miNmi nh)vt hi[y C[ miT[ t[n[
avgN) Skiy C[ a[Tl[
B)n) vriLn&> (v(S kd V = X Vs m)Tr/ (k.g\i Yiy C[.
a[ j p\miN[ a(ttt vriL (Superheated steam) n&> (v(S kd n)c[ni sm)krNY) Si[F)
Skiy C[.
Vsup = Vs x Tsup/Ts m)Tr3/ (k.g\i.
j[mi>, Tsup = a(ttt vriLn&> tipmin (0K mi. a>S k[9v)nmi>)
Ts = s*k) an[ s>tZt vriLn&> 0K mi> uRkln (b>d&
Vsup = a(ttt vriLn&> (v(S kd
Vs = s*k) s>tZt vriLn&> (v(S kd
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AF[.,Z ( Boilers )
5|:TFJGF o
AM.,Z V[S NAF6 WZFJT]\ A\W J[;, (Pressure Vessel) K[ H[DF\ 5F6LDF\YL JZF/ pt5F
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!P
X[, (Shell) VG[ 0=D (Drum) o V[S VYJF TM V[SYL JWFZ[ :8L,GL %,[8MG[ G/FSFZ
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
;5F84 AlCUM"/ VFSFZJF/F C[0 YL A\W SZJFDF\ VFJ[ K[P G/FSFZ[ JF/[,L %,[8MG[ X[, SC[ K[ HIFZ[
X[,G[ C[0 J0[ A\W SZJFDF\ VFJ[ K[ tIFZ[ T[G[ 0=D SC[JFI K[P
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VF Z:TFG[ Flues 56 SC[JFI K[P S[8,FS AM.,ZDF\ ;[8L\UA AM.,ZGF\ (Support) VFWFZ TZLS[
56 SFD SZ[ K[P
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EL (Furnace) o S[8,F\S AM.,Z DF8[ T[G[ OFIZAMS; 56 SC[JFDF\ VFJ[ K[P T[ U|[8 GL p5ZGL
VG[ AM.,ZGF\ X[,GL GLR[GL HuIF K[ HIF\ A/T6 A/[ K[P
5P
ELG]\ SN (Furnace Volume) o AM.,ZGF S[ EFUDF\ 3G4 5|JFCL S[ JFI]~5 A/T6G]\ NCG
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&P
pQDF ;5F8L (Heating Surface) o AM.,ZGL 8I]AM4 OFIZAMS; S[ OZG[;4 X[,4 8I]A %,[8M
VG[ AM.,ZGF\ AL EFUMGL ;5F8L S[ H[GL V[S AFH] VluG sOFIZf VYJF UZD JFI]VM 5;FZ YTF\
CMI VG[ ALH AFH] sV\NZGL AFH]f 5F6L S[ JZF/ 5;FZ YTF CMI T[ ;5F8LGF\ S], O/G[ AM.,ZGL
pQDF ;5F8L SC[ K[P T[G[ AM.,Z Z[8L\U TZLS[ 56 VM/BJFDF\ VFJ[ K[P
*P
5F6L VG[ JZF/GL HuIF (Water space & steam space) o X[, S[ 0=DGF\ S[ EFUDF\ 5F6L
CMI K[P T[ EFUG[ water space SC[ K[P 5F6L VG[ 8I]AM l;JFIGL 0=DDF\ ZC[,L HuIFG[
Steam space SC[JFI K[P
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5F6LGL Gl/IM (Water walls) o OZG[;DF\ NCG R[dAZGL RFZ[ AFH] 8I]AMG[ AFH]AFH]DF\ pEL V[
ZLT[ OL8 SZJFDF\ VFJ[ K[ H[YL SZLG[ T[ OZG[;DF\ NCG R[dAZGL NLJF,M ZR[4 H[G[ SC[JFI K[P
VF 8I]AMDF\ 5F6LGM 5|JFC GLR[GL p5Z TZO HTM CMI K[ VFYL T[G[ ZF.hZ 8I]AM Riser tubes
56 SC[ K[P OZG[;DF\ A/TF A/T/6DF\YL pt5F YTL Z[l0Ig0 UZDL 56 VF 8I]AM U|C6 SZ[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
[ JM8Z JM,GL ;5F8L AM.,ZGL S], pQDF ;5F8L (Heating Surface) 10%GF\ CMI TM
NCGYL pt5F YTL UZDL JM8ZJM, 8I]AMDF\ ZC[, 5F6L U|C6 SZ[ K[P VFYL H VF8I]AMDF\YL 5;FZ
YTF\ OL8JM8ZGL U]6JF4 h05 VG[ HyYM 5}ZFTF\ 5|DF6DF\ CMJM [.V[P
VFJL 8I]AMG[ ;LWL 0=D ;FY[ VYJF JM8ZC[0Z DFZOT[ [0JFDF\ VFJ[ K[P VF 8I]AM GL ACFZGL
AFH]V[4 VFS'lTDF\ NXF"jIF 5|DF6[4 pQDF VJZMWS J:T] (Insulation) ,UFJJFDF\ VFJ[ K[ H[YL
UZDL JFTFJZ6DF\ HTL G ZC[P
VFD4 JM8ZJM,G]\ D]bI SFI" OZG[;DF\ NCGYL pt5F YTL Z[l0Ig8 UZDL U|C6 YI[, UZDLG[
JFTFJZ6DF\ HTL V8SFJJL4 OZG[;G[ ,LS[H5|S (Air Tight) AGFJJL VG[ OZG[;GL lNJF,MG[ 9\0L
ZFBL T[G[ G]S;FG G YJF N[JFG]\ K[P
JM8ZJM, C[0ZDF\ 0[=.G JF<J (Drain Valve) 56 VF5JFDF\ VFJ[ K[P T[GM p5IMU DFT
AM.,ZDF\ 5F6L EZJF DF8[ VG[ AM.,Z HIFZ[ A\W VG[ 90]\ CMI tIFZ[ AM.,ZDF\YL 5F6L SF-L
GFBJF DF8[ YFI K[P RF,] AM.,ZDF\ VF 0=[.GJF<J SIFZ[S 56 BM,JM GCL\ VG[ AM.,Z RF,] SZTF\
5C[,F4 VG[ 0=[.GJF<J A\W K[ S[ GlC4 T[GL RSF;6L VJxI SZL ,[JLP [ RF,] AM.,ZDF\ VF JF<J
BM,LV[ TM JM8ZJM,GL 8I]AMDF\ 5F6GM 5|JFC V8SL I4 T[G]\ ;FDFgI JCGG ZC[ VFYL
JM8ZJM,GL S],L\U V;Z 38L I H[YL JM8ZJM,GL 8I]AM JWFZ[ 50TL UZD Y.G[ SF\ TM A[0M/ Y.
I4 O],F. I S[ SIFZ[S OF8L 56 I V G[ AM.,ZG[ DM8]\ G]S;FG YFIP
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5F6LGL 0=DDF\ ;5F8L (Water Level) o AM.,ZDF\ 0=DDF\ H[ ;5F8L (Level) ;]WL 5F6L ZC[ K[ S[
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(Steam Space) SC[ K[[P
!_P
AO<; (Baffles) o DM8[ EFU[ JM8Z 8I]A AM.,ZMDF\ NCGGL AFH]DF\ ACFZ HTF\ UZD JFI]VMDF\YL
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!!P
:8[ (Stays) o OFIZ8I]A AM.,ZGL ;5F8 ;5F8L H[JL S[ 8I]AXL84 X[,GF\ K[0F4 H[G[ UZDL VG[
NAF6 ,FUT]\ CMI T[ ACFZGL AFH]V[ J/L GF I T[ DF8[ T[JL ;5F8 ;5F8LG[ DFZOT[ VFWFZ VF5L
DHA]T SZJFDF\ VFJ[ K[P
:8GF\ D]bI RFZ 5|SFZ K[P

!P
Longitudinal Stays * A[ K[0FGL %,[8MG[ VFWFZ VF5JF DF8[
ZP
Gusset of Diagonal Stays * AM.,Z X[, VG[ T[GF K[0FGL %,[8MG[ VFWFZ VF5JF DF8[P
#P
Radial Stays
$P
Short Staybars
!ZP
AM.,ZGF\ DF pg8L\u; (Boiler Mountings) o AM.,ZGL ;]Z1FF4 VG[ JZF/ pt5F SZJFGL
;\5}6" 5|lSIFG[ ;FZL ZLT[\ lGI\T SZJF DF8[ AM.,Z 5Z H[ lO8L\u; ZFBJFDF\ VFJ[ K T[G[ Boiler
INDIABOILER DOT COM

DTP/BOT/ VI/030502
mounting SC[ K[P AM.,Z VF AWF\ DFpg8L\u; JUZ ;]Z1FF ;FY[ SFI" SZL XST]\ GYLP AM.,ZGF\
DFpg8L\u;DF\ D]bItJ[4
s!f ;[O8L JF<J; sZf JM8Z ,[J, .g0LS[8Z VYJF U[H s#f CF. :8LD ,M JM8Z V[,FD; s$f
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VYJF JF<J lJU[Z[GL ;DFJ[X YFI K[P
!#P
AM.,ZGL V[;[;ZLh ( Boiler Accessories ) o T[ AM.,ZGF\ V[JF ;FWGM K[ H[ AM.,ZGL

SFI"N1FTF JWFZ[ K[ VG[ AM.,Z %,Fg8 SM. 56 D]xS[,L lJGF ;Z/ ZLT[ R,FJJFDF\ DNN SZ[ K[P VF
EFUMG[ AM.,Z 5Z ;LWF OL8 SZJFDF\ VFJTF\ GYLP AM.,ZGL V[;[;ZLhDF\ D]bItJ[4
s!f ;]5ZCL8Z sZf .SMGMDF.hZ s#f V[Z 5|L CL8Z s$f OL8 JM8Z 5\5 VYJF .gH[S8Z GM ;DFJ[X
YFI K[P s5f OL8 JM8Z CL8Z
ZP_
AM.,ZG]\ JUL"SZ6 ( Classification of Boilers )
ZP!
AM.,ZG]\ JUL"SZ6 GLR[ D]HA SZJFDF\ VFJ[ K[P
!P
AM.,ZDF\ X[,GL WZL 5|DF6[ VF0]\ S[ pE]\ AM.,Z ( Horizontal or Vertical Boilers )
ZP
5F6L VG[ UZD JFI]VMGL ;F5[1F l:YlT 5|DF6[ ( Firetube or water tube Boiler )
#P
OZG[;GL l:YlT 5|DF6[ ( Internally fired or Externally fired )
$P
AM.,ZGM p5IMU SIF\ VG[ S[JL ZLT[ YFI K[ T[GF\ 5|DF6[ ( Stationary Boilers, Marine
Boilers, Portable Boilers & Locomotive Boilers )
Stationary Boilers : :8[XGZL AM.,ZG[ SFID DF8[ HDLG 5Z .g0=:8LhGF\ AM.,ZGF\ ~5DF\
D}SJFDF\ VFJ[ K[P
Marine Boilers : VF AM.,ZGM p5IMU 5[;[gHZ AM8 VG[ DM8L SFUM" :8LDZDF\ YFI K[P
Portable Boilers : 8==[S8Z VG[ ZM0ZM,ZDF\ OL8 SZJFDF\ VFJ[ K[P
Locomotive Boilers : Z[<J[GF\ :8LD V[lgHG R,FJJF DF8[ T[GL ;FY[ D}SJFDF\ VFJTF AM.,ZP
ZPZ
!P
CJ[ VF56[ H]NF\ H]NF\ 5|SFZGF\ AM.,ZM lJUT[ [.X]\P

OFIZ 8I]A AM.,Z ( Firetube Boiler) o OFIZ 8I]A 5|SFZGF\ AM.,ZDF\ A/T6GF\ NCGYL
pt5F YTF\ UZD JFI]VM ( Flue gases ) 8I]AMGL V\NZYL 5;FZ YFI K[ HIFZ[ VF 8I]AMGL
ACFZ 5F6L CMI K[ H[G]\ JZF/DF\ ~5F\TZ YFI K[P OFIZ 8I]A AM.,Z HIF\ JZF/G]\ NAF6
10kg/cm2g YL JWFZ[ H~Z G CMI VG[ HIF\ VMKL S[ DwID 5|DF6DF\ JZF/GL H~Z CMI tIF\
p5IMUDF\ ,[JFDF\ VFJ[ K[P OFIZ 8I]A AM.,ZM CJ[ H}GF\ 5|SFZGF\ AM.,ZM U6FI KTF\ 56 VFH[
T[GM p5IMU p5Z H6FJ[, l:YlT CMI TM SZJFDF\ VFJ[ K[ T[GF D]bI OFINFDF\ T[G[ R,FJJFGM BR"
VMKM VFJ[ K[ VG[ T[GL Compact Design G[ SFZ6[ T[ 36L VMKL HuIF ZMS[ K[P OFIZ 8I]A
AM.,ZMGL JZF/ pt5FNGGM NZ Z__ YL #___ lSPU|FP 5|lT S,FS (kg/hr) GM CMI K[P VG[ T[DGL
INDIABOILER DOT COM

DTP/BOT/ VI/030502
YD", VMlO;LIg;L (Thermal Efficiency ) 65% YL 68% sHIFZ[ T[ ;FDFgI l:YlTDF\

RF,T]\ CMIf CMI K[P
VFJF AM.,ZG]\ SN 5|DF6DF\ GFG]\ CMJFYL T[G[ ;C[,F.YL V[S HuIFV[ YL ALH HuIFV[ ,.
H. XSFI K[P VFJF AM.,ZG[ VMKL HuIFGL H~Z 50 K[ VG[ T[DGL JZF/ pt5FNG 1FDTF 5|DF6DF\
36L JWFZ[ K[ VG[ T[DF\ B}A H VMKF ;DIDF\ JZF/G]\ H~Z NAF6 D[/JL XSFI K[P OFIZ 8I]A
AM.,ZMDF\ D]bItJ[4
(a)
Simple Vertical Boiler
(b)
Cochran Boiler
(c)
Locomotive Boiler
(d)
Cornish Boiler
(e)
Lancashire Boiler
(f)
Scotch Marine Boiler lJU[Z[GM ;DFJ[X YFI K[P
VF NZ[S AM.,Z lJX[ 56 VF56[ 8}\SF6DF\ D[/JLX]\P

(a)
Simple Vertical Boiler : VF AM.,Z ;F.hDF\ B}A H GFG]\ VG[ T[GL ZRGF B}A H ;Z/ CMI
K[P VF AM.,Z ;F.hDF\ B}A H GFG]\ VG[ T[GL ZRGF B}A H ;Z/ K[P VF AM.,Z HIF\ VMKL JZF/
VG[ XlSTGL H~Z 50TK CMI tIF\ VG[ HIF\ HuIF VMKL CMI tIF\ JF5ZJFDF\ VFJ[ K[P T[G]\ DCD
NAF6 10kg/cm2g H[8,]\ H CMI K[P
(b)
Cochran Boiler : V[ pEF V[S ZTF JW] OFIZ 8I]A WZFJTF\ AM.,ZMDF\ ;FZFDFG]\ V[S K[P T[
36L ZRGFVM VG[ ;F.hDF\ pt5,aW K[P T[GL JZF/ pt5FNG 1FDFTF 150 to 3000 kg/hr VG[
T[G]\ DCD NAF6 17.5kg/cm2g H[8,]\ K[P
VF AM.,ZGL YD", VMlO;LIg;L4 [ SM,;M AF.JFDF\ VFJ[ TM 70% VG[ [ VM.,
AF/JFDF\ VFJ[ TM 75% H[8,L CMI K[P
(c)
Locomotive Boiler : ,MSM DMl8J AM.,Z V[ VF0]\ OFIZ 8I]A 5|SFZG]\ ( Horizontal
fire-tube type ) AM.,Z K[ H[DF\ OFIZ AMS; V\NZ H CMI K[P T[GM ACM/M p5IMU Z[<J[
V[lgHGDF\ YFI K[P ,MSM DMl8J AM.,ZGF\ OFINFVMDF\4
s!f
T[ SMd5[S8 K[ V[8,[ S[ 36L VMKL HuIF ZMS[ K[P
sZf
T[GL JZF/ pt5F SZJFGL 1FDTF JWFZ[ K[P
s#f
T[ VMKL lS\DTDF\ T{IFZ YFI K[P
s$f
T[G[ V[S HuIFV[YL ALH HuIFV[ ;C[,F.YL ,. H. XSFI K[P

,MSM DMl8J AM.,ZGF\ U[ZOFINFVMDF\4
INDIABOILER DOT COM

DTP/BOT/ VI/030502
s!f
T[DF\ ;LWL ;5F8LVM ( Flat Surfaces ) JWFZ[ CMJFYL 5}ZTF\ 5|DF6DF\ VFWFZM ( Supports )
GL H~Z 50 K[P
sZf
T[G[ V\NZ H.G[ ;OF. SZJFG]\ B}A D]xS[, K[P
(d)
Cornish Boiler : V[S SMlG\; .HG[Z VFGL XMW SZ[, CMJFYL T[G]\ VF GFD 5F0JFDF\ VFjI]\ K[P
T[ S,FSDF\ 2000kg H[8,L JZF/ ,UEU 11kg/cm2g GF\ NAF6YL pt5F SZL XS[ K[P HIFZ[
:DMS 8I]AJF/F\ GJF ;]WFZ[,F SMlG"X AM.,ZM S,FS[ 3000kg H[8,L JZF/ ,UEU 14kg/cm2g
GF\ NAF6YL pt5F SZL XS[ K[P VFD4 SMlG"X AM.,Z V[ ;Z/ K[ VG[ ;FZL /J6LYL T[ V;ZSFZ
AM.,Z 5}ZJFZ YFI K[P
(e)
Lancashire Boiler : VF :8[XGZL AM.,Z TZLS[ ;F{YL JW] J5ZFT]\ AM.,Z K[4 SFZ6 S[ T[GL
JZF/ pt5F SZJFGL 1FDTF B}A H U]6JF JF/L K[ VG[ T[DF\ GLRL TGM SM,;M 56 ;C[,F.YL
AGL XS[ K[P VF AM.,Z V[ SMlG"X AM.,ZDF\ H~Z ;]WFZF JWFZF ( modification ) SZLG[ H
AGFJJFDF\ VFJ[, K[P SMlG\; AM.,Z VG[ T[GL JrR[GM D]bI TOFJT V[ K[ S[ T[DF\ A[ OZG[; VYJF A[
O,]8I]a; K[P SMlG"X AM.,ZGL H[D VFDF\ 56 OZG[; 8I]AGL ,\AF. 38F0LG[ 36L AWL :DMS 8I]a;
ZFBL XSFI K[P VFD SZSFYL VF A\G[ AM.,ZMDF\ T[DGL S], pQDF ;5F8L ( Heating Surface )
DF\ 36M JWFZM YFI K[P
VF AM.,ZGM p5IMU D]bItJ[ JCF6DF\ YFI K[P BF; SZLG[ JCF6 JHGDF\ C,S]\ CMI VG[
T[DF\ JWFZ[vUlTGL H~Z CMI tIFZ[ VF AM.,Z J5ZFI K[P T[GF\ D]bI A[ 5|SFZ K[P
s!f Single Ended Scotch Marine Boiler
sZf Double Ended Scotch Marine Boiler
AL\ 5|SFZDF\ T[GF AG[\ K[0[ V[S V[S OZG[; CMI K[P TN p5ZF\T T[ 5C[,F\ 5|SFZ SZTF\ JHGDF\ C,S]\4
;:T] VG[ 5|DF6DF\ 36L VMKL HuIF ZMS[ K[P
V[S JFT BF; GMWL\ ,[[ S[ JCF6DF\ OF8Z 8I]A T[DH JM8Z8I]A V[D A\G[ 5|SFZGF\ AM.,ZMGM
p5IMU Y. XS[ K[P EFZ[ JHGNFZ JCF6MDF\ HIF\ AM.,ZG]\ C,SF56]\ VG[ JCF6GL JW] UlT H~ZL G CMI
tIF\ OFIZ 8I]A 5|SFZGF\ AM.,Z J5ZFI K[P HIFZ[4 H[DF\ JZF/ pt5F SZJFGL h05 JWFZ[ [.TL CMI VG[
JZF/G]\ p\R]\ NAF6 [.T]\CMI T[JF\ h05L 5[ZMgHZ JCF6MDF\ JM8Z8I]A 5|SFZGF\ AM.,Z J5ZFI K[P
ZP JM8Z 8I]A AM.,Z ( Water Tube Boiler )
JM8Z8I]A AM.,ZDF\ A/T6DF\ NCGYL pt5F YTF\ JFI]VM sO,[U[;f 8I]AGL ACFZGL ;5F8L p5ZYL
5;FZ YFI K[ VG[ 5F6L 8I]AGL V\NZGL 5;FZ YFI K[P
JM8Z8I]A AM.,ZMG]\ JUL"SZ6 GLR[ 5|DF6[ SZL XSFI K[P
(a)
T[GF\ p5IMU 5|DF6[ AM.,Z i.e. Stationary Marine
(b)
T[GF\ 0=DGL l:YlT 5|DF6[ i.e. Vertical, Cross Longitudinal
INDIABOILER DOT COM

DTP/BOT/ VI/030502
(c)
T[GL 8I]AMGF\ 5|SFZ 5|DF6[ i.e. Straight tube Bent tube
(d)
T[DF\ 5F6LDF\ JCG 5|DF6[ i.e. Natural Circulation Forced Circulation
(e) T[GF\ NAF6 5|DF6[ i.e. Low Pressure, High Pressure Super Cirtical
Pressure
JM8Z 8I]A AM.,ZGF\ OFINFVM
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JM8Z8I]A AM.,ZDF\ ;OF.4 DZFDT lJU[Z OFIZ8I]A AM.,ZGL ;ZBFD6LDF\ ;C[,F.YL YFI K[P
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pQDF ;5F8LG[ SFZ6[ JWFZ[ 50TF YD", O[ZOFZM ( Thermal Stresses) pt5F YIF JUZ h05L
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JM8Z8I]A AM.,ZDF\ Z[l0Ig8 hMGDF\ pQDF\ ;5F8L ( Heating Surface ) JWFZ[ CMJFYL SFI"N
SFDULZL ( Effective Operation ) VG[ ;J,TTF ( Flexibility ) JWFZ[ D/[ K[P
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JM8Z8I]A AM.,Z H]NL H]NL DTFVMDF\ T[DH H]NF\ H]NF\ JZF/DF\ NAF6 VG[ TF5DFG DF8[ AGFJL
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AM.,ZGF\ VR/ sTF5DFG[ NAF6[f 5F6LGL lNXF ;FZL ZLT[ VF5L XSFI K[P VG[ 5F6LG]\ JCG h05L
AGFJL XSFI K[ T[YL ( Heat Transfer Efficiency ) ;FZL D/[ K[P
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JM8Z8I]A AM.,ZGF\ U[ZOFINF

JM8Z8I]A AM.,ZGF\ U[ZOFINF\ GLR[ 5|DF6[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
!P
VFJF AM.,ZDF\ VX]wW S[ SRZFJF/F 5F6LGF p5IMU Y. XSTM GYLP [ 5F6LDF\ ZS[, pt5F SZ[
T[JL VX]lwWVM CMI TM YM0F 56 :S[, D[ TM Heat Transfer 38L I K[ VG[ SIFZ[S 8I]A
JWFZ[ 50TL UZD Y.G[ A/L I K[P
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VFJF AM.,ZG[ R,FJJF DF8[ B}A H ;FZL ZLT[ T{IFZ YI[,F VFJ0T 3ZFJTF ( Qualified )
DF6;MGL H~Z 50 K[ VG[ B}A H RMS;F.YL T[G]\ wIFG ZFBJ]\ 50 K[4 R,FJJDF\ ;FJR[TL ZFBJL 50[
K[P J/L4 VFJF AM.,Z R,FJJF BRF"/ K[P OFI8I]A AM.,Z VG[ JM8Z8I]A AM.,Z lJX[ 6IF
AFN VF56[ V[D SCL XSLV[ S[4 HIF\ JZF/G]\ NAF6 30 kg/cmg ;]WLG]\ [.T]\ CMI VG[ V[S
S,FSDF\ #_ 8G YL VMKL JZF/GL H~Z CMI tIF\ JM8Z8I]A AM.,Z SZTF\ OFIZ8I]A AM.,Z JWFZ[
;:TF 50[ K[P VF l,lD8GL p5ZGL DTF VG[ NAF6 DF8[ JM8Z8I]A 5|SFZGF\ AM.,Z JWFZ[ VG]S]/ 50[
K[P lJW]T p5FNG ( Power Generation ) DF8[ 5FJZ%,Fg8DF\ H[ VFW]lGS ( High
Pressure Boiler ) GM p5IMU YFI K[ T[GL DFTF #_ YL &5_ Tonnes / hour sS,FS[ #_
YL &5_ 8Gf VG[ T[YL 56 JWFZ[4 NAF6 !&_ VG[ TF5DFG 540C ;]WLGF\ CMI K[P
#P
;]5Z lSl8S, AM.,Z ( Supercritical Boiler ) o H[D H[D A/T6GL lS\DTDF\ JWFZM YFI K[
T[D T[D lJW]T .HGZM lJW]T pt5FNGGL 5wWlT JWFZ[ SZS;ZI]ST AG[ T[ DF8[ VMK]\ A/T6 J5ZFI
T[D lJRFZTF Y. UIF K[P CF,DF\ ;]5Z lSl8S, :8LD ;FIS, ( Supercritical Steam Cycle
) GF\ p5IMU DFZOTP SZS;Z JF/L lJW]T pt5FNGGL 5wWlTGM p5IMU Y. ZCIM K[P 125 atm
AF6 510C VG[ TF5DFG YL #__ NAF6 VG[ 600C TF5DFGGL Working Range DF\
36F AWF\ AM.,ZGL ZRGF SZJFDF\ VFJL K[ H[G[ Sub Critical VG[ Super Critical AM.,Z
SC[ K[P ;FDFgI ZLT[ Sub Critical Boiler DF\ .SMGMDF.hZ4 .J[5MZ[8Z VG[ ;]5ZCL8Z CMI K[P
HIFZ[ lS8LS, AM.,ZDF\ DF 5|LCLS, VG[ ;]5ZCL8Z H CMI K[P
;]5Z lSl8S, AM.,ZDF\ OFINF o
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Sub Critical AM.,ZGL ;ZBFD6LDF\ Heat Transfer Rate B}A H JWFZ[ CMI K[P
;AlSl8S, AM.,ZDF\ Heat Transfer Co-efficient 4000 kcal/m-hr-C CMI K[P
sHIFZ[ JZF/G]\ NAF6 VG[ TF5DFG 183 atm VG[ 538C CMI K[ tIFZ[f Super Critical
AM.,ZDF\ HIFZ[ JZF/ 240C GL pt5F YTL CMI tIFZ[ JZF/ AFH]GM Heat Transfer Coefficient 50000 kcal/m-hr-C CMI K[P
ZP
;]5Z lSl8S, JZF/GM p5IMU SZJFYL 5FJZ %,Fg8GL SFI"NTF 40 - 42% ;]WLGL p\RL CMI K[P
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;]5Z lSl8S, AM.,ZDF\ 5F6LqJZF/G]\ ;\lDz6 ( Two Phase Mixture ) G CMJFYL

Erosion VG[ GL Corrosion D]xS[,L VMKL Y. I K[P
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
$P
5|[XZF.h0 O,]0F.hZ A[0 S\AXG AM.,Z ( PFBC Boiler ) o VF 5|SFZGF\ AM.,ZDF\4 HIF\
NCG YFI K[P T[ R[dAZGL V\NZ U|[8 p5Z Z[TL Sand VG[ Ash GF\ GFGF GFGF ZHS6M Particles
CMI K[P VF ZGHS6MGL GLR[GF EFUDF\YL NCG DF8[GL CJF NFB, YFI K[P VG[ ZHS6MG[ p\RS[ K[
VG[ Aa,L\U A[0 ( Bubbling Bed ) G]\ :J~5 ZR[ K[4 T[ pS/TF 5|JFCLGL H[D JT[" K[P AG"Z VF
A[0G[ 800 YL 900C TF5DFG ;]WL UZD SZ[ K[ 5KL T[DF\ H NCGXL, 5NFY" DMS,JFDF\ VFJ[ K[
T[ T]ZT H A/JF ,FU[ K[P
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SF-L GFB[, ( Waste ) A/T6 56 ;C[,F.YL AF/L XSFI K[P A/T6 AF/JFYL H[ UZDL pt5F YFI K[ T[
A[0 s5YFZLf G]\ TF5DFG /JL XS[ K[ VG[ 8U]A,g8 A[0G]\ TF5DFG V[S ;ZB]\ ZFB[ K[P DM8F EFUGL pt5F
YTL UZDL 5F6L VYJF TM JZF/DF\ U|C6 Y. I K[ FBC AM.,ZDF\ NCGG]\ TF5DFG AL AM.,ZMDF\
NCGGLP 5|lS|IFYL pt5F YTF TF5DFG SZTF\ VMK]\ CMI K[ T[YL T[DF\ NOX VG[So2 G]\ pt5FNG 90% H[8,]\
VMK]\ YFI K[P
PFBC l;:8ZDF\ ,F.D:8MG SM,MDF.8 H[JF Sorbant GM p5IMU SM,;FGF NCGYL K]8F\ 50TF\
;<OZG[ 5S0JF DF8[ SZJFDF\ VFJ[ K[P
PFBC l;:8D4 SM,;FYL RF,TF 5FJZ %,Fg8GL SFI"N1FTF JWFZ[ K[ VG[ NOX SO2 H[JFG]\
Emission 56 38F0[ K[P
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CTLP
5P
J[:8 CL8 AM.,Z o ( Waste Heat Boiler )

VFJF AM.,ZMDF\ A/T6G[ AF/JFDF\ VFJT]\ GYLP VFJF AM.,ZMDF\ pWMUMGL V\NZGF\
5|M;[; %,Fg8DF\YL ACFZ GLS/TF UZD JFI]VM ( Hot Gases ) GM A/T6 TZLS[ p5IMU SZJFDF\
VFJ[ K[P UZD JFI]VMDF\YL UZDL 5F6LDF\ NFB, SZL JZF/ pt5F SZJFDF\ VFJ[ K[ :8LDGL lD,M4
l;D[g8 %,Fg8GL OZG[;M4 l0h, V[lgHG TYF U[; 8AF".GGF\ V[ShM:8DF\YL TYF 5[5ZlD,MDF\ a,[S
l,SZDF\YL ACFZ GLS/TF UZD JFI]VMGL UZLDLGM p5IMU J[:8 CL8 AM.,ZDF\ CMI K[P VFD 5|M;[;
%,Fg8DF\ 5|M;[;DF\YL pt5F YTF UZD JFI]VMDF\GL UZDLGM p5IMU SZL JZF/G[ By product
TZLS[ pt5F SZL UZDLGM jII V8SFJJFDF\ VFJ[ K[P
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#P! IBR v!)5_ 5|DF6[ JZF/ AM.,ZDF\ GLR[ H6FJ[, DFpg8L\u; VG[ ;[O8L GF\ ;FWGM T[DH
V[;[;ZLhGL H~ZL AG[ K[ S[4
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H[ AM.,ZDF\ ;]5ZCL8Z G CMI T[JF AM.,ZDF\ VMKFDF\ VMKF\ A[ ;[O8LJF<J CMJF [.V[4
;[O8LJF<JGL ;L8 (Seat ) GM AMZ sJZF/G[ 5;FZ YJF DF8[GL HuIFf SM. 56 ;\[UMDF\ 19
lDl,DL8ZYL VMKM G CMJM [.V[P [ AM.,ZDF\ ;]5ZCL8Z VF5[, CMI TM ;]5Z CL8Z VFp8,[8
5F.5 5Z V[S JWFZFGM ;[O8LJF<J ,UF0[, CMJM [.V[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
ZP
AM.,Z VG[ T[GF\ 0=DDF\ ZC[, 5F6LGL ;5F8L ( Water Level ) ATFJJF VMKFDF\ VMKF\ A[ ,[J,
.g0LS[8Z CMJF [.V[P
#P
JZF/GF\ NAF6 DF8[GM 5|[XZU[H S[ H[GL Z[gH AM.,ZGF\ JlS\U 5|[XZ SZTF\ A[ 67L CMJL [.V[P s[
JlS"U 5|[XZ 37 kg/cmg CMI TM T[GL Z[gH 0 YL 75kg/cmg CMJL [.V[f
$P
AM.,ZGL ACFZ VFJTL D]bI JZF/ 5F.5GM JF<J ( Steam Stop Valve ) T[ H 5F.5 5Z
OL8 SZ[,M CMJM [.V[P :8M5 JF<JGL TC[,FYL SM.56 AL 5F.5 :8LD 5F.5 [0[ [0[,L G CMJL
[.V[[P
HIFZ[ A[ AM.,ZMG[ V[S ;FDFgI D]bI JZF/ G/L ( Steam Common Header )
;FY[ [0JFGF\ CMI tIFZ[ NZ[S AM.,ZGL VFp8,[8 5F.5 5Z :8M5JF<J VG[ GMG lZ8"G JF<J NRV
D}S[,F CMJF [.V[P
5P
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OL8 JM8Z 5\5 VYJF .gH[S8Z U6JFDF\ VFJ[ K[P 5Z\T] [ pQDF ;5F8L 18.58m YL JWFZ[ CMI TM
A[ ;ZBL DTFJF/F OL8JM8Z 5\5 S[ H[GM lJW]T ;%,FI A[ H]NF\ H]NF\ ;M;" ( Source ) DF\YL CMI4
T[JL UM9J6 SZ[, CMJL [.V[P NZ[S OL8JM8Z 5\5 GL 1FDTF AM.,ZG[ JWFZ[ DF\ JWFZ[ ;TT RF,]\
ZFBL XSLV[ T[ DTFYL VMKL G CMJL [.V[P
&P
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Level ) G]\ V[,FD" VF5JFDF\ VFjI]\ CMI TM OI]A, %,U OL8 SZJFDF\ VFJTM GYLP
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AM.,Z .g:5[S8ZGM 8[:8U[H H ,UF0JFGL ;UJ0TF VF5[,L CMJKL [.V[P
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AM.,ZGL ;OF. ( Cleaning ) ;FZL ZLT Y. XS[ T[ DF8[ IMuI DF5GM D[G CM, ( Man - hole
) 4D0 CF[, ( Mud hole ) T[DH HF[JF DF8[ ;F.8 CF[, ( Sight hole ) CMJM [.V[P
CJ[ VF56[ AM.,ZGF\ DFpg8L\u; VG[ V[;[;ZLh lJX[ lJUT[ [.X]\P
AM.,ZGF\ DFpg8L\u; ( Boiler Mountings )

;[O8LJF<J ( Safety Valve )
;[O8LJF<J V[ AM.,ZG]\ B}A H VUtIG]= DFpg8L\U K[4 H[GF lJGF SM.56 AM.,Z SIFZ[I
56 RF,] SZL XSFI GlCP AM.,ZGF\ ;[O8LJF<JG]\ D]bI SFI" AM.,ZGF\ VUFpYL GSSL SZ[, NAF6 (
Pre determined Max Working Pressures ) SZTF\ JWFZ[ NAF6 G Y. I T[D T[G[
V8SFJJFG]\ K[4 H[GF\ DF8[ ;[O8LJF<J T[ GSSL SZ[, NAF6 VF5 D[/[ ( Automatically ) B},L
I K[ VG[ JZF/GM ACFZ SF-L GFBLG[ OZLYL NAF6G[ ;FDFgI SZ[ K[P SM.57 ;[O8LJF<J sV[S S[
V[SYL JWFZ[f GL JZF/ ACFZ O[\SJFGL 1FDTF AM.,ZGL DCTD pt5FNG DTL H[8,L CMJL [.V[4
GlC TM NAF6 JWTF ZC[JFGL XSITF JWL I K[P [ ;[O8LJF<J T[GF\ GSSL SZ[, NAF6[ ( at set
pressure ) B},L G I VG[ AM.,ZDFG]\ NAF6 T[GL l,lD8 SZTF\ JWL I TM SIFZ[S AM.,Z
INDIABOILER DOT COM

DTP/BOT/ VI/030502
30FSF ;FY[ OF8L I H[ lD<STG[ G]S;FG VG[ GCFlG 56 SZ[P VFYL DF5GM ZMO8LJF<J ,UF0JM
B}A H~ZL K[P
[ ;[O8LJF<JG[ ;FZL l:YlTDF\ ZFBJM CMI TM VD]S ;DIGF\ V\TZ[ T[G[ RSF;JM [.V[P [
JF<JGL ;L8 VG[ JF<J 0L; p5Z AL[ SRZM DL I VYJF TM T[DF\ BJF6 YFI TM ;[O8LJF<J
IMuI ZLT[ SFI" SZL XS[ GlC4 VG[ AM.,Z EIHGS l:YlTDF\ VFJL I4 ;[O8LJF<JG]\ lJ\U S,LIZg;
( Wing clearance ) RSF;J]\ [.V[ VG[ Wing AMZ ( Bore) G[ V0SJ]\ [.V[ GlC VG[
T[G]\ ;C[,F.YL C,GR,G YJ]\ [.V[P [ VFD GF CMI TM ;[O8LJF<J a,M YFI GCL\P
VFYL ;[O8LJF<JG[ VD]S ;DIGF\ V\TZ[ T[GF\ GSSL SZ[, ( set pressure ) ;]WL NFAF6
JWFZLG[ RSF;JM [.V[ VYJF TM VF ;[8 5|[XZGF\ ,UEU H[8,]\ NAF6 AM.,ZDF\ VFJ[ tIFZ[ T[GF\
,LJZG[ WLDL UlTG[ p\RSLG[ a,M SZJM [.V[P ( Manual Blowing ) p\RF NAF6 VG[ JWFZ[
1FDTFJF/F AM.,ZGF\ ;[O8LJF<J DlCG[ S[ JZ;[ V[SJFZ ;[O8LJF<J AGFJGFZ SC[ T[ 5|DF6[ RSF;JM
[.V[P [ ;[O8LJF<JDF\YL YM0L JZF/ ;/\U GLS/IF SZTL CMI s;[O8LJF<J 5F; YTM CMIf TM YM0F
;DI DF8[ T[G[ ,LJZ p\RSLG[ a,M SZJM [.V[ H[YL SZLG[ T[DF\ [ S\.S SRZM E[UM YIM CMI TM T[ N}Z
Y. IP
[ ;[O8LJF<J a,M YIF 5KL A\W G YFI TM A/T6 VMK]\ SZLG[ ;[O8LJF<JGM l:5g8, (
Spindle ) p5Z C/J[SYL CYM0L DFZJL ( Hammering ) [ VF ZLT[ 56 ;[O8LJF<J A\W G
YFI TM AM.,ZGM TFtSFl,S A\W SZL N[JFG]\ VG[ tIFZAFN ;[O8LJF<J BM,LG[ T[G]\ H~ZL
5lZ1F6qDZFDT SZJLP
SM.56 ;DI[ HIFZ[ ;[O8LJF<JG[ ;[8 SZTF CM.V[ tIFZ[ T[GL l:5|\UGL SM., ( Coil )
V[SALG[ V0JL [.V[ GlC4 T[GF\ JrR[ HuIF ( Gap) ZC[JL H [.V[ GlCTZ JF<J SFI" GCL\
SZ[P HIFZ[ ;[O8LJF<JGP DZFDT ( repairing ) DF8[ ,LWM CMI tIFZ[ T[GL l0:S ( disc ) GL
Seat 5Z ,[5L\U SZJ]\ [.V[ VG[ V[D SZLG[ JZF/G]\ 5F;L\U V8SFJJ]\ [.V[ SFZ6 S[ JZF/
AGFJJFG]\ BRF"/ K[P J/L4 T[ JF<JGL G[ 56 G]S;FG 5CM\\RF0[ K[P
;[O8LJF<JDF\YL ACFZ GLS/TL JZF/GL 5F.5G]\ DF5 IMuI CMJ]\ [.V[P [ T[ GFGF DF5GL
CMI TM HIFZ[ ;[O8LJF<J a,M YFI tIFZ[ lJ~wW lNXFDF\ A/ pt5F lNXFDF\ A/ pt5F YFI K[ H[ O,[\H
[.g8; G[ G]S;FG 5CM\RF0[ K[ VG[ G [.T]\ B[\RF6 ( Strain ) JF<JGL AM0LDF\ pt5F [.g8;G[
G]S;FG 5CM\RF0[ K[ VG[ G [.T]\ B[\RF6 ( Strain ) JF<JGL AM0LDF\ pt5F YFI K[P
[ ;[O8LJF<JDF\YL ACFZ GLS/TF 5F.5G[ KTGL ACFZ ,. HJFDF\ VFJ[ TM T[DF\ V[S 0=[.G
( Drain) GL jIJ:YF SZJL [.V[ H[YL SZLG[ ;[O8LJF<JGL V[ 5F.5DF\ E[U]\ YI[,]\ 5F6L SF-L
XSFIP
;[O8L JF<JGF\ D]bI A[ 5|SFZ 5F0L XSFI K[P
(a)
J[.8 ,M0[0 ;[O8LJF<J ( Weight Loaded Safety Valve )
(b)
l:5|\U ,M0[0 ;[O8LJF<J ( Spring Loaded Safety Valve )
INDIABOILER DOT COM

DTP/BOT/ VI/030502
(a)
Weight Loaded Safety Valve T[GF\ 56 A[ 5|SFZ 5F0L XSFI

!P 0[0 J[.0 ;[O8LJF<J ( Dead Weight Safety Valve )
ZP l,JZ V[g0 J[.0 ;[O8LJF<J ( Lever & Weight safety Valve )
(1)
Dead & Weight Safety Valve : VF B}A H ;FNF 5|SFZGM ;[O8LJF<J K[P H[DF\ JF<JGL
p5Z ;LW[;LWF JHGM ( Weight ) D}SLG[ T[G[ ,M0[0 SZJFDF\ VFJ[ K[P JF<J p5Z S[8,]\ :Y}/ JHG
( Dead Weight) D}SJ]\ T[GL U6TZL GLR[ 5|DF6[ SZJFDF\ VFJ[ K[P [ JF<JGM jIF; 8 ;[PDLPGM
CMI VG[ T[G[ 10 lSPU|Fq;[PDLPGF\ NAF6[ a,M SZJFGM CMI TM4
H~ZL 0[0 J[.8 JF<JG]\ O/ s;[DLf2 JZF/G]\ NZF6 slSPU|Fq;[PDLf
( Dead Weights = Area of valve in cm x Pressure of steam in
kg/cm2)
W = /4 D x p = /4 x (8) x 10
W = 502.4 kg VF8,]\ JHG D}SJ]\ [.V[P
VF ;[O8LJF<J B}A H lJ`JF;5F+ ( Reliable ) K[ VG[ T[ T[GL SFDULZL ;\TMQFSFZS ZLT[
AJ[ K[P 5Z\T] VF JF<JGF\ U[ZOFINF 56 36F\ K[P ,MSMDM8LJ VG[ DZLG 5|SFZGF\ AM.,ZM S[ H[DF\
;TT C,GR,G ZC[T]\ CMI ( Vibration ) tIF\ T[GM p5IMU Y. XSTM GYLP ALH]\ p\RF NAF6 JF/F
AM.,ZMDF\ 50TF\ JHGM D}SJF 50TF CMJFYL JF<JGL ;F.h B}A H JWL HTL CMJFYL4 T[GM p5IMU
Y. XSTM GYLP VF p5ZF\T4 H[D NAF6 JWFZ[ CMI T[D T[D H[ T[ AM.,ZGL 1FDTF 56 JWFZ[ CMI4
VFYL JF<JDF\ JZF/ ACFZ SF-JFGL 1FDTF 56 JWFZJL 50[P CJ[ JF<J 5Z ,UF0JFDF\ VFJT]\ JHG
JF<JGF\ jIF;GF JU"GF\ 5|DF6DF\ K[4 JF<JGL JZF/ ACFZ SF-JFGL 1FDTF [ JWFZJL CMI TM
JF<JGM jIF; JWFZJM 50[4 T[YL JHGM 56 JWFZ[ ,UF0JF 50[P VFYL4 VF 5|SFZGM ;[O8LJF<J VMKF\
NAF6 VG[ VMKL DTFJF/F AM.,ZM H[JF\ S[ SMlG"X VG[ ,[S[XFIZDF\ J5ZFI K[ H[VM :8[XGZL 56 K[P
(2)
Liver and Weight Safety Valve :
INDIABOILER DOT COM

DTP/BOT/ VI/030502
VFS'lTDF ATFjIF 5|DF6[ VF 5|SFZGF\ JF<JG[ l,JZ ( Lever ) VG[ J[.8 ( Weight ) YL ,M0 SZJFDF\
VFJ[ K[P VF ,M0 Lever Ratio b/a 5Z VFWFZ ZFB[ K[P DF8[ BZ[BZ ,UF0J]\ 50T]\ JHG L GLR[GF\ ;}T
5|DF6[ YX[P
L = W x b/a YX[4
CJ[4 ,LJZDF\ AL\ K[0[ ,UF0JF 50TF\ JHG W GL lS\DT4 VF5[, JZF/GF\ NAF64 ,LJZ Z[lXIM
b/a VG[ JF<JGF\ O/ 5|DF6[4
Moment of Downward Pressure = Moment of Upward Pressure
W x b = ( /4 d x p ) x a ;}YL XMWL XSFI K[P
HIF\4 d
p
= JF<JGM 0FIFDL8Z4 ;[DL

= JZF/G]\ NAF6 lSPU|FPq;[PDLP
w = H~ZL JHG4 lSPU|FP

b/a = l,JZ Z[lXIM
sVCL\ JF<J VG[ l,JZG]\ JHG4 5|DF6DF\ B}A H VMKF\ CMJFYL U6TZLDF\ ,LW[, GYLPf
VF5|SFZGM ;[O8LJF<J 56 Dead Weight Safety Valve GL H[D H VMKF\ NAF6 VG[ VMKL
1FDTF WZFJTF\ :8[XGZL AM.,ZMDF\ H J5ZFI K[P T[G[ 56 Vibration GL V;Z YFI K[P 5|;\UM5FT T[GM
p5IMU 40 kg/cmg NAF6 ;]WL Y. XS[ K[P
VF JF<JGM DM8FDF\ DM8M U|[ZOFINM V[ K[ S[ T[DF\ A[ l5JM8L\U 5M.g8 ( Pivoting Points )
VFJTF CMJFYL4 tIF\ ,FUTF 3QF"6 ( Friction ) G[ SFZ6[ 36LJFZ VF JF<J T[GF\ ;[8 SZ[,F\ NAF6[ a,M YTM
GYLP
(a)
l:5|\U ,M0[0 ;[O8LJF<J ( Spring Loaded Safety Valve ) o VF 5|SFZGF\ JF<JG[

C,GR,G GL HZFI[ V;Z YTL GYLP T[YL T[ ,MSM DM8LJ VG[ DZLG AM.,ZMDF\ JF5ZL XSFI K[P TN
p5ZF\T T[ p\RF NAF6JF/F AM.,ZMDF\ 56 JF5ZL XSFI K[P JF<J p5ZYL l:5\UG]\ B[\RF6 (
Tension ) VMK]\ J]\ SZLG[ JF<JG]\ a,M 5|[XZ ;[8 SZL XSFI K[P VF 5|SFZGF\ JF<JDF\ V[S GFG]\
,LJZ 56 VF5[, CMI K[ G[GL DNNYL JF<JG[ D[gI]V,L a,M SZLG[4 T[GL ;L8 K[ S[ GlC4 T[ RSF;L
XSFI K[P
(b)
JM8Z ,[J, .g0LS[8Z VYJF U[H ( Water Level Indicator ) o AM.,ZGF\ 5lZA/M (
Parameters ) DF\ 0=DDF\ 5F6LGL ;5F8L ( Water Level ) B}A H VUtIG]\ 5lZA/ K[P
AM.,ZDF\ 5F6LGL ;5F8L B}A H VUtIG]\ 5lZA/ K[P AM.,ZDF\ 5F6LGL ;5F8L AZFAZ H/JFJL
[.V[ VG[ T[ K[ S[ GlC T[GL BAZ Water Level Indicator YL 50[ K[P AM.,ZDF\ [ 5F6L GF
ZC[ sHIFZ[ AM.,Z SFD SZT]\ CMIf TM X]\ YFI T[ S<5L XSFI K[P ;FDFgI ZLT[ NZ[S AM.,ZDF\ :8LD
INDIABOILER DOT COM

DTP/BOT/ VI/030502
0=D Steam Drum GL AG[\ AFH]V[ V[S V[S Level Indicator VYJF Level Gauge
Glass D}SJFDF\ VFJ[ K[P HIF\ AM.,ZDF\ 0=DG[ 36L p\RF. 5Z ZFBJFDF\ VFJ[, CMI tIF\ Level
Gauge Glass G[ +;] D}SJFDF\ VFJ[ K[4 H[YL SM. 56 HuIFV[YL 0=DDF\G]\ 5F6LGL ;5F8L [.
XSFI K[P S[8,F\S DM8F VFW]lGS AM.,ZDF\ CF.0=Ml,S VG[ lJW]TYL SFD SZTF\ Level Indicator
GM p5IMU YFI K[4 VG[ T[DH AM.,ZGF\ VM5Z[8L\U O,MZ 5Z D}SJFDF\ VFJ[ K[P p\RF NAF6JF/F
AM.,ZDF\ VF U[H O,[8 l5hD[l8 u,F;DF\YL AGFJJFDF\ VFJ[ K[P
Water Level Gauge G[ ;lJ";DF\ D}SJFGL 5wWlTVM o
!P
HIFZ[ AM.,Z ;FDFgI l:YlTDF\ RF,T]\ CMI tIFZ[ GJM VYJF DZFDT SZ[, U[H G[ ;lJ";DF\ D}SJFGL
5wWlT o B}A H JWFZ[ 50TM YD", XMS ( Thermal Shock ) GF,FU[ T[ DF8[ GLR[ 5|DF6[
;FJR[TL ZFBJLP
(a)
AWF\ H JF<JG[ A\W SZMP X~VFTDF\ VFD TM AWF JF<J A\W H CMI K[ KTF\ 56 T[ A\W K[ S[
GlC T[ RSF;MP
(b)
0=[.G JF<J 5}Z[ 5}ZM BM,MP
(c)
U[HGL p5ZGM sJZF/ AFH]GMf JF<J H[G[ Steam Side Isolation Valve SC[JFI K[
T[G[ B}A H VMKM BM,MP
(d)
CJ[ U[HGL GLR[GM s5F6L AFH]GMf JF<J H[G[ Water Side Isolation Valve SC[JFI
K[ T[G[ B}A H VMKF BM,MP
(e)
15 YL 20 lDlG8 ;]WL U[HDF\ NAF6 JWFIF" lJGF H U[HG[ UZD YJF NMP
(f)
WLD[ WLD[ 0=[.G JF<J A\W SZM VG[ U[HDF\ NAF6 JWFZTF\ J
(g)
U[HGF\ 0=[.G JF<JG[ ;\5}6"56[ A\W SZMP
(h)
U[HGL p5ZGM VG[ GLR[GM JF<J CJ[ ;\5}6" 56[ BM,L GFBM H[YL H ;lJ";DF\ VFJL HX[P
(i)
U[HDF\ SM.56 HuIFV[ ,LS[H TM GYL G[ m T[ RSF;MP
ZP AM.,Z 9\0] CMI tIFZ[ GJM VYJF DZFDT SZ[, U[HG[ ;lJ";DF\ D}SJFGL 5wWlT
(a)
0=[.G JF<J B]<,M ZFBLG[4 p5ZGM JF<J 5C[,F BM,MP
(b)
GLR[G JF<JG[ B]<,M SZMP
(c)
0=[.G JF<JG[ A\W SZMP
(d)
U[HDFG]\ NAF6 AM.,ZGF\ NAF6 ;FY[ ;FY[ JWJF NMP
(e)
U[HDF\ SM. 56 HuIFV[ ,LS[H TM GYL YI]\ G[ m T[ [TF\ ZCMP
INDIABOILER DOT COM

DTP/BOT/ VI/030502
ZMlH"NF SFI"SDDF\4 Water Level Gauge GF\ DM.SM XL8qu,F; 5Z WLD[ WLD[ SRZM sZMf
DJFGL 5F6LGL ;5F8L RMbBL N[BFTL V8SL I K[P H[G[ V\NZ ZC[, JZF/GL DNNYL H4 O,X SZL ;FO SZL
XSFI K[PPH[G[ DF8[4
!P
JZF/ VG[ 5F6LGL AFH]GF\ JF<J B}<,F\ ZFBMP
ZP
0=[.G JF<J ;C[H BM,M VG[ U[Z[H T[DH T[G[ [0TF\ TF.5 AZFAZ ;FO G Y. I tIF\ ;]WL a,M YJF
NMP
#P
VF ZLTG]\ a,M."S B}A H WLD[ WLD[ YFI T[GL BF; ;FJR[TL ZFBMP VG[ U[H B}A H U\NM G Y. I T[
DF8[ NZ[S lXO8 s5F/Lf DF\ p5ZGL ZLT[ a,M0FpG VF5LG[ U[HG[ ;FO ZFBL XSFI K[P
AM.,ZDF\ HIFZ[ 56 VF<SAL AM., VFp8 ( Alkali Boil out ) VG[ V[l;0 S,LlG\U (
Acid Cleaning ) SZJFG]\ CMI4 TIFZ[ U[HG[ A\W sVF.;M,[8f ZFBMP
(C)
High Steam and Low Water alarm Or Valve : JZF/G]\ JW] NAF6 VG[ 0=DDF\
5F6LGL GLRL ;F5F8L VF AG[\G]\ bIF, ZFBJF DF8[ ,[S[XFIZ VG[ AL\ V\NZYL OFIZ SZJFDF\ VFJTF\
AM.,ZMDF\ VF 5|SFZGM ;[O8LJF<J D}SJFDF\ VFJ[ K[P T[ AG[\ SFI" SZTM CMJFYL T[G[ S\5Fpg0
;[O8LJF<J 56 SC[JFDF\ VFJ[ K[P T[ OST :8[XGZL AM.,Z DF8[ H IMuI K[P
VFW]lGS AM.,ZMDF\ sD]bItJ[ JM8ZI]ST 5|SFZGF\f 0=DDF\ 5F6LGL ;5F8L GLRL I TM T[GL
6 DF8[ ,M JM8Z V[,FD" ( Drum Level Low ) CMI K[ H[YL AM.,Z R,FJGFZ 0=DDF\ 5F6LGL
;5F8L ;FDFgI SZJF DF8[ H~ZL 5U,F\ tJlZT56[ ,. ,[ VG[ T[D KTF\ 56 [ 5F6LGL ;5F8L 38TL
H I TM JZL ,M JM8Z l8=5 Trip Drum Level Very Low Trip GL UM9J6 SZ[, K[ H[YL
AM.,ZDF\ A/T6G]\ NCG V8SL I VG[ AM.,Z TZT H A\W Y. IP V[H 5|DF6[ AM.,ZDF\ HIFZ[
JZF/G]\ NAF6 JWL I tIFZ[ Steam Pressure High G]\ V[,FD" 56 VF5JFDF\ VFJ[ K[ H[YL
SZLG[ R,FJGFZ A/T6 38F0LG[ S[ H~ZL 5U,F\ ,.G[ JZF/G]\ NAF6 ;FDFgI SZL XS[P
(D)
OI]A, %,U ( Fusible Plug ) o

OFIZ 8I]A AM.,ZGL OZG[;GF\ SFpG ( Crown ) DF\ OI]A, WFT] ( Metal ) VYJF
V[,MI ( Alloy ) GM %,U OL8 SZJFDF\ VFJ[ K[P VF %,U ;FDFgI 5lZl:YlTDF\
sV[8,[ S[ HuIFZ[ AM.,ZDF\ 5F6LGL ;5F8L AZFAZ CMI tIFZ[f 5F6LYL -\SFI[, CMI K[P H[YL
OI]A, WFT]G]\ TF5DFG T[GF\ U,GlA\N] SZTF\ VMK]\ ZC[ K[P
5Z\T] HIFZ[ AM.,ZDF\ 5F6LGL ;5F8L JWFZ[ 50TL VMKL Y. IP tIFZ[ VF %,UGL p5Z
5F6L G ZC[JFYL T[G]\ TF5DFG h05YL JWL I K[ VG[ OI]A, WFT] 5LU/L I K[ V G[ T[ 50L
I K[ VG[ tIF\ HuIF YJFYL JZF/ GLS/JF ,FU[ K[P H[ OZG[;DF\YL VFUG[ CM,JL GFB[ K[P VG[
AM.,ZG[ JWFZ[ 50T]\ G]S;FG YT]\ V8SFJ[ K[P
(E)
JZF/GM 5|[XZ U[H ( Steam Pressure Guage ) o AM.,ZDF\ S[8,]\ NAF6 K[ T[ [JF DF8[
NZ[S AM.,ZDF\ :8LD 5|[XZ U[H ZFBJFDF\ VFJ[ K[P ;FDFgI ZLT[ 5|[XZ U[H X[, VYJF 0=DGL p5Z
INDIABOILER DOT COM

DTP/BOT/ VI/030502
,UF0JFDF\ VFJ[ K[P VG[ AG"Z O,MZ 5ZYL T[G[ ;C[,F.YL [. XSFI T[ ZLT[ ZFBJFDF\ VFJ[ K[P
U|[HG]\ 0FI, V[ ZLT[ AGFJ[,q,B[, CMI K[ S[ H[ AM.,ZG]\ S[ JZF/ G]\ NAF6 kg/cmg DF\
JFTFJFZ6GF\ NAF6 SZTF\ JWFZ[ ATFJ[ K[P AZ0F"G 5|[XZ U[H ( Bourdon Pressure Guage
) V[ ;F{YL JW] p5IMUDF\ ,[JFDF\ VFJTM 5|SFZ K[P 5|[XZ U[HG[ v 8I]A ;FIOG wJFZF AM.,ZDF\
,UF0JFDF\ VFJ[ K[P AM.,ZDF\ [ ;]5ZCL8Z CMI TM T[GL VFp8,[8 5F.5 5Z 56 V[S 5|[XZ U[H
,UFJFI K[P U[HGL 8I]AGL V\NZ JZF/ 9\0L 50LG[ 5F6L AGL I K[ VG[ VF 5F6L U[HDF\ JZF/GF\
NAF6G[ 5CM\RF0[ K[Ps Transmit S\Z[ K[f G[ A0"G U[HGL 8I]ADF\ JZF/G[ HJF N[T]\ GYLP [ E},[R}S[
JZF/ VF 8I]ADF\ HTL ZC[ TM T[G]\ V[S;5g;G YFI K[ VG[ U[H BM8]\ ZL0L\\U ATFJ[ K[ VG[ 8I]AG[
G]S;FG YFI K[P
(F)
:8LD :8M5 JF,J q H\SXG JF<J ( Steam Stop Valve OR Junction Valve ) o
AM.,Z [0[ OL8 SZJFDF\ VFJ[ K[P Steam space GL p5Z p\RFDF\ pRF\ 5F.5 5Z HIF\YL
AM.,ZDF\YL JZF/ ACFZ ,. HJFGL CMI tIF\ VYJF TM [ AM.,ZDF\ ;]5ZCL8Z CMI TM
;]5ZCL8DF\YL ACFZ GLS/TL D]bI 5F.5 5Z T[G[ ,UF0JFDF\ VFJ[ K[P HIFZ[ JZF/GL G~Z G CMI
tIFZ[ AM.,ZG[ A\W SZL4 VF JF<JG[ 56 A\W SZL AM.,ZDF\YL ACFZ HTL JZF/ G[ V8SFJL N[JFI K[P
VF JF<J A\W SZJFYL AM.,ZG]\ NAF6 ,F\AM ;DI ;]WL /JL XSFI K[P
VF JF<J CFY J0[ ( Manual ) VYJF DM8Z wJFZF operate SZL XSFI K[P H[
AM.,ZDF\YL ACFZ HTL JZF/GF\ HyYFG[ lGI\T SZJFG]\ VG[ H~Z 50[ TM ;\5}6" A\W SZJF G]\ SFI" SZ[
K[P VF JF<J VG[ AM.,ZGL JrR[YL AL SM.56 5F.5 T [.g8YL [0JFDF\ VFJTL GYLP
(G)
OL8 R[S JF<J ( Feed Check Valve ) o OL8 5\5DF\YL AM.,ZDF\ 5F6L ,. HTL 5F.5
,F.GDF\ AM.,ZDF\ 5F6L NFB, YFI T[ 5C[,F\ VF JF<JG[ ,UF0JFDF\\ 5F6L ,. HTL 5F.5 ,F.GDF\
AM.,ZDF\ 5F6L NFB, YFI T[ 5C[,F\ VF JF<JG[ ,UF0JFDF\ VFJ[ K[P VF JF<J GMG lZ8"G (NRV)
5|SFZGM CMI K[4 T[ AM.,ZDF\ HTF\ 5F6L (Feed Water ) GF\ 5|JFCG[ lGI\lT SZJF VYJF ;\5}6"
56[ A\W SZJF DF8[ J5ZFI K[P HIFZ[ OL8 5\5 A\W CMI IFZ[ AM.,ZDF\YL 5F6L VMK]\ G VFJ[ T[ DF8[
VM8MD[l8S VF JF<J 5|[XZGF\ TOFJTG[ SFZ6M A\W Y. I K[P VFW]lGS JWFZ[ DTFJF/F AM.,ZMDF\
OL8R[S JF<J p5ZF\T gI]D[l8S VM5Z[8[0 S\8=M, JF<J CMI K[P sV[S SZTF\ JW]f H[G[ AM.,Z 5[G, 5ZYL
VM5Z[8 SZL XSFI K[ VG[ T[ VM8MD[l8S SFD 56 SZ[ K[P
(H)
a,M VMO SMS ( Blow off cock ) o a,M VMO SMS AM.,ZGF\ GLRFDF\ GLR[GF EFUDF\YL HDF
YI[, ,}h D0 VG[ ;[l0D[g8; ( Loose mud & Sediments ) G[ ACFZ SF-JF DF8[ ZFBJFDF\
VFJ[ K[P V[ p5ZF\T SIFZ[S AM.,ZG[ ;\5}6"56[ BF,L SZJ]\ CMI tIFZ[ 56 p5IMUDF+ VFJ[ K[P
VFW]lGS AM.,ZDF\ VF DF8[GL VF8MD[l8S jIJ:YF 56 SZJFDF\ VFJ[ K[P
(I)
V[g8L 5|>\lD\U 5F.5 ( Anti Priming Pipe ) o HIFZ[ AM.,Z h05YL JZF/ pt5F SZT]\ CMI
tIFZ[ 5F6L 8L5F :J~5[ JZF/ ;FY[ O[SFI K[P H[ :8LD V[lgHGDF\ I K[P VF 38GFG[ 5|F.lD\U SC[ K[P
VG[ [ AM.,ZDF\ ;]5ZCL8 56 CMI TM T[ 8L5F ;]5ZCL8DF\ NFB, Y. XS[ K[P VG[ T[GL DFZOT[
5F6LGL ZC[,L VX]lwWVM 56 I K[ H[G[ S[ZLVMJ SC[ K[P VF VX]lwWVM ;]5ZCL8DF\ 8I]AMGL V\NZ
INDIABOILER DOT COM

DTP/BOT/ VI/030502
:S[, pt5F SZ[ K[ Anti Priming pipe JZF/ ;FY[ 5F6LGF\ 8L5F HTF V8SFJJF DF8[G]\ ;FWG
K[P T[G[ AM.,ZGF\ X[,DF\ Steam Space GL HZF p5Z VG[ Steam Stop Valve GL GLR[
OL8 SZJFDF\ VFJ[ K[P T[ K[0F\ A\W CMI T[J]\ VFIGG]\ AF"S; K[P T[GF p5ZGF\ V0WFEFUDF\ 36FAWF
,\ARMZ; SF6F\ CMI K[P H[DF\YL JZF/ 5;FZ Y. \I K[P HIFZ[ VF SF\6F DF\YL JZF/ 5;FZ YFI tIFZ[
T[GM 5|JFC T}8[ K[ VG[ T[YL T[DF\ ZC[,F\ 5F6LGF\ JHGNFZ 8L5F\ K}8F 50[ K[ VG[ 5FKF AM.,ZDF\ 50L
I K[P
#P#
AM.,ZGL V[;[;ZLh ( Boiler Accessories ) o

DM8FEFUGF\ AM.,ZDF\ V[;[;ZLh ,UF0JFDF\ VFJ[ K[ T[GF\ D]bI SFIF[" GLR[ 5|DF6[ K[P
!P AM.,Z %,Fg8GL SFI"MNTF JWFZJL
ZP AM.,Z %,Fg8GL SFDULZL ;Z/ AGFJJFDF\ DNN SZJLP
CJ[ VF56[ V[S 5KL V[S V[;[;ZLh lJX[ lJUT[ [.X]\P
(A)
OL8 JM8Z 5\5 ( Feed water pump ) o OL8 JM8Z 5\5GM p5IMU AM.,ZDF\ H[8,F 5|DF6DF\
JZF/ pt5F YFI K[ T[8,F 5|DF6DF\ OL8JM8Z DMS,JF DF8[ YFI K[P OL8 JM8Z 5\5 SF\ TM ZM8ZL
Rotary VYJF TM Z[;L5|MS[l8\U Reciprocating 5|SFZGF\ CMI K[P J/L T[ JZF/YL RF,TF
VYJF DM8Z lJW]Tf YL RF,TF 56 CMI K[ Z[;L5|LS[l8\U 5\5 DM8[EFU[ JZF/YL RF,TF CMI K[ H[G[
;LWF H :8LD V[lgHG [0[ ,UF0[, CMI K[P ZM8ZL 5\5 JZF/ 8AF".G S[.,[S8=LS DM8ZYL RF,TF CMI
K[P ZM8ZL 5\5 ;FDFgI ZLT[ JWFZ[ UlT Speed JF/F ;[g8=LOI]U, Centrifugal 5|SFZGF\ CMI K[P
J/L4 T[ V[S .d5[,Z S[ V\SYL JWFZ[ .d5[,Z WZFJTF\ CMI K[ ( Single Stage Multi
Stage) VFW]lGS AM.,ZM S[ H[DF\ OL0JM8ZG]\ JWFZ[ 5IMU SZJFDF\ VFJ[ K[P
(B)
.gH[S8Z ( Injector ) o .gH[S8Z V[ V[S ;Z/ ;FWG K[ S[ H[GM p5IMU V[ H AM.,ZGL pt5F
YTL JZF/GM p5IMU SZL OL8JM8ZG[ AM.,ZDF\ DMS,JF DF8[ YFI K[P VF ;FWGDF\ SM.56 EFU
C,GR,G SZTM CMTM GYLP ( No moving Parts ) 5F6LG[ Trpering Nozzle DF\YL 5;FZ
YTL JZF/GF\ NZF6YL A/5}J"S AM.,ZDF\ DMS,JFDF\ VFJ[ K[P VFGM p5IMU B}A H GFGF AM.,ZM
VG[ ,MSM DM8LJ AM.,ZDF\ H YFI K[P T[ B}A H ;:T]\ VG[ R,FJJFDF\ ;Z/ CMJFYL T[G[ 36LJFZ
:8[g0 AFI Stand By TZLS[ ZFBJFDF\ VFJ[ K[P [ .gH[S8ZG[ OL8JM8Z 5\5 ;FY[ ;ZBFJJFDF\ VFJ[
TM .gJ[S8Z B}A H lSOFITL 50[ K[ H[D S[ JZF/DF\ ZC[,L AWL H UZDL 5FKL AM.,ZDF\ H I K[P
VFD .gH[S8Z OL8JM8Z OL8ZVG[ OL8JM8Z 5\5G]\ SFD SZ[ K[P 5Z\T] T[VM GYLP T[YL DZLG VG[ DM8F
AM.,ZM HIF\ JWFZ[ HyYFDF\ 5F6L DMS,JFGL H~Z 50[ K[ tIF\ T[GM p5IMU Y. XS TM GYLP
OL8ZJM8Z 5\5 T[GF\ SZTF\ JWFZ[ K[ VG[ T[GF 5Z VMK]\ wIFG VF5JFGL H~Z 50[ K[P VF p5ZF\T T[GL
AL V[S DIF"NF V[ 56 K[ S[ TD[ AM.,ZDF\ UZD 5F6LG[ DMS,L XSTF GYLP SFZ6 S[ JZF/
GMh,DF\YL 5;FZ Y.G[ .gH[S8ZGL lDS;L\U R[dAZDF\ 9Z[ K[P [ 5F6L H UZD CMI TM T[ 9\0L 50L
XSTL GYL VG[ .gH[S8Z SFD SZT]\ A\W Y. I K[ VFD4 .gH[S8ZGL DNNYL AM.,ZDF\ DMS,JFDF\
VFJT]\ 5F6L 9\0] CMJ]\ VFJxIS K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
(C)
OL8 JM8Z CL8;" ( Feed water Heaters ) o AM.,ZDF\ 5F6L DMS,TF 5C[,F H[ ;FWGDF\ T[G[
H~ZL TF5DFG ;]WL UZD SZJFDF\ VFJ[ K[ T[G[ OL8JM8Z CL8Z SC[JFDF\ VFJ[ K[P OL8JM8Z CL8Z
D]bItJ[ A[ 5|SFZGF\ CMI K[P
!P
CL8Z4 H[ UZDL :8LD V[lgHGDF\YL ACFZ GLS/L JZF/ S[ :8LD8AF".GGF\ VD]S :8[H 5KLYL VD]S
HyYFDF\ GLS/TL JZF/ S[ H[GM 0=FIG[; O[SXG VMKM CMI K[ T[DF\YL D[/J[
ZP
CL8Z4 H[ UZDL AM.,ZDF\YL ACFZ GLS/TF UZD JFI]VM DF\YL D[/J[P VF AL 5|SFZGF\ OL8 JM8Z
CL8ZG[ .SMGMDF.hZ SC[JFI K[P
(D)
.SMGM DF.hZ ( Economiser ) o AM.,Z %,Fg8DF\ ;F{YL JWFZ[ UZDLGM jII AM.,ZDF\YL
RDGL JF8[ ACFZ GLS/TF JFI]VM ( Flue gases ) DF\ YFI K[P AM.,Z VG[ RLDGLGL JrR[ VF
JFI]VMGF\ Z:TFDF\ D}SJFDF\ VFJT]\ ;FWG S[ H[ VF JFI]VMDF\ ZC[,L UZDLG[ XMQFLG[ AM.,ZDF\ HT
D]HA 36L AWL VF0L S[ pEL 8I]AM VFJ[, CMI K[ S[ H[DF\ YL AM.,ZDF\ HT]\ OL8ZJM8Z 5;FZ YFI K[
VG[ VF8I]AMGL ACFZGL ;5F8L p5ZDL HTF\ Ash VG[ AL\ SRZF G[ ( Shoot Blower )
DFZOT[ N}Z SZJFDF\ VFJ[ K[P NZ[S .SMGMDF.hZDF\ 5|[XZ U[H4 ;[O8LJF<J4 0=[.GJF<J4 V[Z lZl,h
JF<J VG[ TF5DFG DF5JF DF8[ A[ YDM"DL8Z S[ U[H sV[S .G,[8 5Z VG[ V[S VFp8,[8 5Zf
ZFBJFDF\ VFJ[ K[P UZDJFI]VM GF\ Z:TFDF\ 56 VF H 5|DF6[ A[ YDMDL8Z S[ U[H ZFBJFDF\ VFJ[ K[P
.SMGMDF.hZGL ;F.h VYJF T[GL pQDF ;5F8L T[GL ACFZ GLS/TF JFI]VMGF\ TF5DFG 5ZYL GSSL
SZJFDF\ VFJ[ K[P
.SMGMDF.hZDF\ Heat Transfer ;FZL ZLT[ YFI T[ DF8[ T[GL 8I]AM Fins JF/L AGFJJFDF\ VFJ[
K[P .SMGMDF.hZDF\YL 5;FZ YTF\ JFI]VMG]\ TF5DFG Dew Point T[GL V\NZ ZC[, JZF/ s5F6Lf GF\
Dew Point YL JWFZ[ ZC[J]\ [.V[P [ TF5DFG SZTF\ GLR]\ I TM JZF/G]\ H[ 5F6L YFI T[
.SMGMDF.hZGL 8I]AM p5Z JFI]VMDF\ ZC[,F So2 / So3 ;FY[ D/LG[ ;<II]lZS V[l;0 ( H2So4) AGFJ[
K[ H[G[ ,LW[ 8I]AMG]\ BJF6 ( Corrosion ) YFI K[P [ JFI]VMDF\ ;<OZG]\ 5|SF6 JWFZ[ CMI TM (
Corrosion rate ) JW[ K[P VMKF\ NAF6JF/F AM.,ZDF\ .SMGMDF.hZGL 8I]AM4 SF:8 VFIG"GL
AGFJJFDF\ VFJ[ K[ sH[G]\ JSL"U 5|[XZ 22.84 kg/cmg SZTF\ VMK]\ CMIf p\WF NAF6JF/F AM.,ZDF\
:8L,GL VYJF V[,MI :8L,GL 8I]AMGL p5IMU SZJFDF\ VFJ[ K[P
.SMGMDF.hZG]\ JUL"SZ6 GLR[ 5|DF6[ SZJFDF\ VFJ[ K[P
!P
ACFZ GLS/TF JFI]VMGL lNXF 5|DF6[ Horizontal Vertical
ZP
YD", SFDULZL 5|DF6[ Steaming Non-Steaming

s Steaming .SMGMDF.hZGL Heating Surface AM.,ZGL Heating Surface DF\
U6JFDF\ VFJ[ K[f
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DTP/BOT/ VI/030502
#P
JFI]GF\ 5|JFCGL ;F5[DF\ OL0JM8ZGF\ 5|JFC 5|DF6[ Counter Flow S[ Parallel Flow GMG
:8LDL\U .SMGMDF.hZ V[ AM.,ZGM V\TUT" EFU U6FTM GYL GF\ lGIDM 5|DF6[ VFJF .SMGMDF.hZ
;ZSFZL AM.,Z .g:5[S8Z wJFZF ZlH:8Z SZJFDF\ VG[ RSF;JFDF\ VFJ[ K[ VG[ NZ JQF[" T[G[ p5IMUDF\
,[JF DF8[G]\ H~ZL ;l8"lOS[8 SF-L VF5[ K[P
.SMGMDF.hZGF\ OFINF o ( Advantages of Economiser )
!P
.SMGMDF.hZ UZD JFI]VMDF\YL H[ UZDL U|C6 SZ[ K[ T[ Heat Energy GL V[S 5|SFZ[ ART SZ[
K[P [ VF UZDLGM p5IMU G SZJFDF\ VFJ[ TM T[ JFTFJZ6DF\ RF,L I VG[ 3CJFGF 5|N}QF6DF\
JWFZM SZ[P VFD4 V\T[ TM T[ AC]D}<I A/T6G]\ ;[lJ"U K[P VFYL AM.,Z %,Fg8GL SFI"NTF JW[ K[P
5F6G\] TF5DFG 60C JW[ TM 1% A/T6GL ART YFI K[P
ZP
.SMGMDF.hZ AM.,ZGL Heating Surface JWFZ[ K[ T[YL AM.,ZGL JZF/ pt5F SZJFGL
1FDTF Evaporative Capacity JW[ K[P JZF/ pt5FNG h05L AG[ K[ H[ 5F6LGF\ JCGGM NZ
56 JWFZ[ K[ VG[ AWL H Heating Surface G[ JWFZ[ SFI"N AGFJ[ K[P
#P
AM.,ZDF\ 9\0] 5F6L DMS,JFYL AM.,ZGL WFT] 9\0L YFI K[P OL8JM8ZG[ .SMGMDF.hZ DF\ UZD
SZJFYL AM.,ZGF\ H]NF H]NF\ EFUMGF\ TF5DFG JrR[GM TOFJT VMKM YFI K[ H[YL V;DFG
expension SFZ6[ pt5F YTL VMKL YFI K[ VG[ AM.,ZGL VFJZNF JW[ K[P
(E)
V[Z l5| CL8Z ( Air Pre-Heater ) o JFTFJZ6DF\ E/L HTF\ AM.,ZGF\ UZD JFI]VMDF\YL UZDL
U|C6 SZL Heat Energy GM ARFJ SZJF DF8[G]\ VF ALH]\ ;FWG K[P T[G[ .SMGMDF.hZ VG[
RLDGL JrR[ UZD JFI]VMGF\ Z:TFDF\ D}SJFDF\ VFJ[ K[P H[ CJF G[ OZG[;DF\ A/T6GF\ NCG DF8[
JF5ZJFGL CMI K[ T[G[ l5| CL8ZDF\ UZD SZJFDF\ VFJ[ K[P 9\0L CJF UZD JFI]VMDF\YL UZDL U|C6 SZ[
K[P CJF 8I]AMGL V\NZYL VG[ UZD JFI]VM 8I]AMGL ACFZYL 5;FZ YFI K[P SM.S V[Z l5| CL8ZDF\
VFGFYL p<8L UM9J6 56 CMI K[P
V[Z l5| CL8ZGF\ D]bI A[ 5|SFZ K[P

1.
Tubular Air Pre-heater
2.
Regenerative Air Pre-heater
!P
Tubular Air Pre-heater DF\ 5FT/L 8I]AMDF\YL CJF 5;FZ YFI K[ VG[ T[GL ACFZYL JFI]VM
5;FZ YFI K[ S[ SIFZ[S ZRGF p,8L 56 CMI K[P
ZP
Regenerative Air Pre-heater V[ ZM8ZL 8F.5G]\ CL8Z K[4 H[G]\ ZM8Z G]\ CMI K[P ZM8Z
Corrugated Metal lDlG8[ Z YL # JFZ OZT]\ CMI K[P UZD JFI]VM CL8ZDF\ V0WF EFUDF\YL
5;FZ YFI K[ VG[ CJF CL8ZGF\ AFSLGF\ V0WF EFUDF\YL 5;FZ YFI K[P Corrugated Metal
UZD JFI]VMDF\YL UZDL U|C6 SZ[ K[ VG[ HIFZ[ T[9\0L CJFGF\ ;\;U"DF\ VFJ[ K[ tIFZ[ U|C6 SZ[,L
UZDL 9\0L CJFG[ VF5[ K[P VF 5|SFZG]\ V[Z l5|CL8Z DM8L DTFJF/F AM.,ZDF\ J5ZFI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
V[Z l5| CL8ZGF\ OFINFVM o ( Advantage of Air Pre-heater )

!P
UZD YI[, CJFYL OZG[;G]\ TF5DFG JWFZ[ ZC[ K[ H[YL 5F6LDF\ UZDL JW] 5|DF6DF\ XMQFFI K[P
ZP
A/T6G]\ NCG ;FZL ZLT[ Y. XS[ K[ S[D S[ UZD CJFGM VMlS;HG A/T6DF\ ZC[, SFA"G (C)4
CF.0=MHG (H) VG[ ;<OZ (S) [0[ YTF\ S[lDS, lZV[SXGGL h05 JWFZ[ K[ T[YL ACFZ GLS/TF
JFI]VMDF\ CO2 G]\ 5|DF6 JW[ K[P
#P
UZD YI[, CJF O,[D sHIMTf G[ 8}\SL VG[ JWFZ[ :YFIL (Stable) AGFJ[ K[ H[YL W]DF0F (Smoke
) G]\ pt5FNG 38[ K[P
$P
UZD CJFG[ ,LW[ VMKL JWFZFGL CJF Excess air ;FY[ GLRL TGM SM,;M 56 AF/L XSFI K[P
5P
HIFZ[ VFGL UZD YI[, CJFGM p5IMU SZJFDF\ VFJ[ K[ tIFZ[ AM.,Z %,Fg8GL SFI" NTF JW[ K[ S[D S[
p5Z D]HAGF\ OFINF p5ZF\T UZDJFI]VMDF\YL JFTFJZ6DF\ HTL GSFDL UZDLGM p5IMU SZL Heat
Energy GL ART SZL XSFI K[[P
(F) ;]5ZCL8Z ( Superheater ) o AM.,ZGF\ 0=DDF\YL GLS/TL ;\T'%T JZF/ ( Saturated

Steam ) G[ ;}SL ;\T'%T ( Dry Saturated ) VYJF TM VlTT%T ( Superheate ) JZF/
AGFJJF DF8[ ;]5ZCL8ZGM p5IMU SZJFDF\ VFJ[ K[P ;]5ZCL8Z V[ A[ C[0ZM ( Headers ) ;FY[ [0[, U
VFSFZGL 8I]AMGM DF/M K[ H[DF\YL AM.,Z 0=DDF\YL ACFZ GLS/TL JZF/ 5;FZ SZJFDF\ VFJ[ K[P
;]Z5ZCL8ZG[ ;FDFgI ZLT[ OZG[;DF\YL GLS/TF JFI]VMGF\ Z:TF (Gas path ) DF\ D}SJFDF\ VFJ[ K[
H[YL T[ UZD JFI]VMDF\YL ;FZF V[JF 5|FDF6DF\ UZDL U|C6 SZL XS[P UZD JFI]VMGF\ Z:TFDF\YL UZDL
D[/JLG[ HIFZ[ ;\T'%T JZF/G[ VlTT%T JZF/DF\ O[ZJJF DF\ VFJ[ K[ tIFZ[ T[JF ;]5ZCL8ZG[ SgJ[SXG
;]5ZCL8Z ( Convection Superheater ) SC[JFDF\ VFJ[ K[ HIFZ[ ;]5ZCL8G[ ;LW[;LW]\ OZG[;DF\
AG"ZGL VFUGL ;FD[ H D}SJFDF\ VFJ[ K[ tIFZ[ T[ VFUDF\YL Z[l0V[XG UZDL D[/J[ K[P VFYL T[G[ Z[l0Ig8
;]5ZCL8 ( Rediant Superheater ) SC[JFDF\ VFJ[ K[P HIF\ High degree of Superheater
GL H~Z 50[ K[ tIF\ VF 5|SFZG]\ ;]5ZCL8Z J5ZFI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
p\RF NAF6 WZFJTF\ VFW]lGS AM.,ZMDF\ AG[\ 5|SFZGF\ ;]5ZCL8Z J5ZFI K[ H[YL VR/ TF5DFG D[/JL XSFI
K[P
;]5ZCL8ZDF\ ,M0 VMKM CMI tIFZ[ TF5DFG JWFZ[ CMI K[4 VG[ H[D ,M0 JW[ T[D TF5DFG DF\ 38F0M YFI K[P
VFYL [ VF AG[\ 5|SFZGF\ ;]5ZCL8Z ;FY[ JF5ZLV[ TM T[DGL ;lCIFZL V;Z ( Combined effect ) G[
SFZ6[ VR/ TF5DFG D[/JL XSFI K[P
Convection ;]5ZCL8ZG[ ;FDFgI ZLT[ AM.,ZGL 5FK/ HIF ACFZ HTF\ JFI]VMG]\ TF5DFG
560C YL VMK]\ GF CMI T[ hMGDF\ D}SJFDF\ VFJ[ K[ AM.,ZDF\ ;]5ZCL8ZGL ZRGF VG[ AF\WSFD V[ ZLT[
SZJFDF\ VFJ[ K[ S[ T[DF\ JFI]VMDF\YL JZF/DF\ h05YL UZDL 5;FZ Y. XS[4 T[GL 8I]AMGL ;OF. ;C[,F.YL
Y. XS[ VG[ 8I]AM VMJZCL8 Y. A/L G IP HIFZ[ JFI]VMG]\ TF5DFG 550C YL JWFZ[ G CMI tIFZ[
8I]AM A/JFGM EI ZC[TM GYLP 5ZT]\ 550C YL JWFZ[ TF5DFG CMI TM 8I]AMGL ;FJR[TL DF8[GL jIJ:YF
SZJFDF\ VFJ[ K[P VF 8I]AMG]\ TF5DFG DF5JF DF8[ YDM"S5<; ,UF0JFDF\ VFJ[ K[ H[YL AM.,Z X~ SZTF\4
T[GL ;FDFgI SFDULZL NZdIFG T[DH AM.,Z A\W SZTF T[GF 5Z ;FZL ZLT[ wIFG VF5L\ XSFIP RF,]
AM.,ZDF\YL [ 8I]AMDF\YL JZF/GM 5|JFC ( Flow ) V8SL I TM :8F"J[XG ,LW[ 8I]AMG]\ TF5DFG JWL I
VG[ 8I]AMA/L HJFGL XSITF ZC[ K[P AM.,Z RF,] SZTF\ 5C[,F\ ;]5ZCL8ZG[ 5F6LYL EZJ]\ [.V[ VG[ :8F8"
V[ JBT[ T[DF\YL 5}ZTF\ 5|DF6DF\ JZF/GM 5|JFC ZC[ T[ DF8[ T[GF C[0Z 0=[.G VG[ J[g8JF<J B]<,F ZFBJF
[.V[P UZD JFI]VMGM Z:TM AN,LG[ 56 ;]5ZCL8Z JWFZ[ 50T]\ UZD G YFI T[JL jIJ:YF 56 VD]S AM.,Z
DF\ SZJFDF\ VFJ[ K[P ;]5ZCL8ZDF\YL ACFZ GLS/TL JZF/GL 5F.5 5Z D}SJFDF\ VF J[, ;[O8LJF, ;[8 5|[XZ
0=[DGF\ V[S S[ AG[ ;[O8LJF\<JGF ;[8L\U SZTF\ VMK]\ ZFBJFDF\ VFJ[ K[ H[YL AM.,ZDF\ 5|[XZ JW[ T[ 5C[,F\ H
;]5ZCL8ZGM ;[O8LJF<J AM,[ K[P SM.S SFZ6 ;Z [ 0=DGM ;[O8LJF<J 5C[,F\ AM,[ TM ;]5Z CL8ZDF\ HTL
JZF/GF\ 5|JFC 5Z U\ELZ V;Z 50[ S[ V0SL I H[YL ;]5ZCL8ZGL 8I]AMGL WFT]G]\ TF5DFG B}A JWL I
VG[ JWFZ[ UZD YJFYL 8I]AM A/L I VYJF TM OF8L IP ( Bulging or Rapture )
INDIABOILER DOT COM

DTP/BOT/ VI/030502
#P$ GLR[ J6"J[, ;FWGMG]\ 56 AM.,Z DF8[ V[8,]\ H DCtJ K[P

(A)
:8LD 0=FI;" VYJF ;[5Z[8;" ( Steam Driers or Spearators ) o AM.,ZDF\YL ACFZ

GLS/TL JZF/ ;FY[ YTF\ 5F6LGF\ EFU G[ N}Z SZJF DF8[ GM p5IMU YFI K[P
AM.,ZDF\ ACFZ GLS/TL VG[ :8LDV[lgHG S[ 8AF".G DF\ HTL 5F.5DF\ T[G[ V[lgHG S[
8AF".GGL GS D}SJFDF\ VFJ[ K[P ;FDFgI 5|SFZGF\ Separator DF\ Baffle plates CMI K[P
JZF/ VFGL ;FY[ VY0FI K[P T[YL T[GM J[U 38[ K[P VG[ lNXF AN,F. I K[P 5F6LGF S6M T[GF JW]
JHG VG[ Inertia GF\ SFZ6[ VF %,[8M ;FY[ VY0F.G[ GLR[GF EFUDF\ 50[ K[ HIF\YL T[ 0=[.G 8=[5
(Drain Trap ) DFZOT[ ACFZ GLS/L I K[P
(B)
:8LD 8=[5 (Steam Traps ) o JZF/GF\ VF\lXS 9\0F 50JFG[ SFZ6[ H[ 5F6L AG[ T[G[ V[S9]\ SZLG[4
:JI\ ;\RFl,T ZLT[4 JZF/ G GLS/[ T[ ZLT[ ACFZ SF-JFG]\ SFI" Steam Traps SZ[ K[P
Steam Traps V[JL HuIFV[ JZF/GL 5F.5DF\ D}SJFDF\ VFJ[ K[ H[YL SZLG[ JZF/DF\ ZC[, S\0[g;[8
U]Z]tJFSQF"6 Gravity YL T[DF\ E[U]\ YFIP Steam Traps V[ V[JL ;FNL ZRGF K[ S[ HIFZ[
Trap DF\ 5F6LGL ;5F8L VD]S SZTF\ JW[P V[8,[ Trap GM JF<J 5MTFGL D[/[ B},[ VG[ 5F6L ACFZ
GLS/L I VG[ H[J]\ 5F6L GLS/L I K[ S[ TZT H JF<J T[GL T[ A\W Y. IP VFD4 JZF.GM
HZF56 jII YTM GYLP
Steam Traps GF\ D]bI A[ 5|SFZ K[P
1.
Expansion Steam Traps :

UZDLG[ SFZ6[ H[ T[ WFT]GF\ YFI T[ l;wWF\T p5Z VF 8=[5 SFD SZ[ K[P
2.
Bucket Traps & Float Steam Traps :

VF Traps DF\ ZC[, Float VYJF Bucket wJFZF Traps DF\ 5F6LGL JW38 YFI T[GF\ 5|DF6DF\
T[ SFI" SZ[ K[P Float VYJF Bucket 5F6GL ;5F8L 5Z TZTF CMJFYL 5F6LGL ;5F8L JW38 YFI
T[ 5|DF6[ p5Z GLR[ YFI K[ VG[ VF Float VYJF Bucket [0[ Spindle wJFZF JF<J [0[, CMI
K[ H[ B},[ K[ VG[ A\W YFI K[P
(C)
;}8 a,MV;" (Shoot Blowers ) o

AM.,Z 8I]VMG[ VG[ AL ;5F8LVM S[ H[ 5;FZ YTF\ JFI]VMGF\ DFU"DF\ CMI4 T[GF 5Z Shoot G]\
50 (Layer ) AFhL I K[P VF AFh[, 50 Heat Transfer GM NZ 38F0[ K[P VFYL Shoot
Blowers GM p5IMU SZLG[ VF Shoot G[ N}Z SZJFDF\ VFJ[ K[P Shoot Blower GL SFDULZL
DF8[ JZF/GM p5IMU YFI K[ H[ T[ AM.,ZDF\YL H
$P_
AM.,ZGL ZRGF SZTL JBT[ wIFGDF\ ZFBJFGF\ D]NFVM o

AM.,ZGL OZG[;G]\ SN (Volume) VG[ 0=FO8 GL ( Draught ) V[ ZLT[ ZRGF SZJL [.V[ S[
H[YL JW]DF\ JW] NCGGL SFI"1FDTF D/[P DFZOT[ JW]DF\ JW] pQDFGL VF5[ ,[ q JCG YFI4 H[JL SZLG[
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AM.,ZDF\ YL ACFZ GLS/TF JFI]VMG]\ TFDFG Optimum ZC[ AM.,Z 0=D .g8ZG[<1FIMuI ZLT[
,UFJ[, CMJ]\ [.V[P AM.,ZDF\ H]NF\ H]NF\ ,MS[ T[G[ SFDULZL ;FZL D/[ TDF8[ DHA}T DFpg8L\u;4
OL8L\u;4 V[S;[;ZLh VG[ .g:8]D[G[8[XG ,UF0, CMJF [.V[P
AM.,ZGL ;OF. ( Cleaning ) T5F; (Inspection) VG[ DZFDT ( Repair ) IMuI ZLT[ Y. XS[ T[
DF8[GL HuIF VG[ V5|MI CMJM [.V[P
(B)
AM.,ZGL 5;\NUL ( Selection ) SZJF DF8[ wIFGDF\ ZFBJFGF D]NFVM o
!P
AM.,Z S[8,F NAF6YL R,FJJFG]\ K[ m S[JF 5|SFZGL JZF/GL H~Z K[4 ELGL4 ;\T'%T4 ;}SL S[
VlTT%T m
ZP
V[S S,FSDF\ S[8,L JZF/ pt5F SZJFGL K[ m V[8,[ S[ AM.,ZGL DTF S[8,L [.V[ m
#P
AM.,Z DF8[GL HuIF S[8,L K[ m
$P
SIF AM.,ZDF\YL SFI"NTF JWFZ[ K[ m
5P
AM.,ZGL ;OF.4 DZFDT VG[ RSF;6L DF8[GL RJ,TTF VG[ V[5|MI S[JM K[ m
&P
AM.,ZGL XZ]VFTGL lS\DT S[8,L K[ m
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AM.,ZDF\ JF5ZJFDF\ VFJGFZ A/T6 ;C[,F.YL p5,aW K[ S[ GlC m
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AM.,Z pE]\ SZJ]\ ;C[,]\ K[ S[ U}\RJ6EU]" m JU[Z[ JU[Z[
5P_
AM.,Z 5F6LG]\ JCG o ( Water Circulation in Boiler )
AM.,ZGL V\NZ 5F6LG]\ ;ZSI],[XG A[ ZLT[ Y. XS[ K[P

!P
5F6LGL 3GTFGF TOFJTG[ SFZ6[ YT]\ ;ZSI],[XG H[G[ Natural Circulation SC[ K[P
ZP
5\5GM p5IMU SZLG[ SZJFDF\ VFJT]\ ;ZSI],[XG H[G[ Forced Circulation SC[ K[P
;AlSl8S, ( Subcritical ) VFW]lGS p\RF NAF6JF/F AM.,ZDF\ Natural Circulation CMI
K[P
HIFZ[4 lSl8S, ( Critical ) AM.,ZDF\ 5\5GM p5IMU SZLG[ 5F6L G]\ ;ZSI],[XG SZJFDF\ VFJ[ K[
H[G[ Forced Circulation SC[ K[P
!P
Natural Circulation : VF 5|SFZG]\ ;ZSI],[XG ;ZHJF DF8[ GLR[GL VFS'lT NMZMP 8I]ADF\
5F6GM VFU|C pt5F SZT]\ A/ F = ( HL H2 ) 4 HIF\ VG[ V[ 9\0F VG[ CJ[ U6LV[ TM H[D
5F6L p5Z I K[ T[D T[DF\YL VD]S EFU JZF/ AG[ K[ VG[ T[ 0=DDF\ K}8L 50[ K[ 0=DG SC[JFDF\
Criculation Ratio VFJ[ K[P
AM.,ZDF\ H[D NAF6 JW[ T[D OL8JM8ZG]\ TF5DFG 5Z pR]\ CMI K[P Natural
Circulation YDM"l;OMlGS C[0 p5Z VFWFZ ZFB[ K[P 5ZT]\ H[D JZF/G]\ NAF6 JW[ T[D T[GL 3GTF
(Density) 56 JW[ HIFZ[ AG[ AFH]GF\ O[ZOFZG[ SFZ6[ YDM"l;OMlGS C[0DF\ 38F0M YFI K[P VFD
INDIABOILER DOT COM

DTP/BOT/ VI/030502
VFU/ HTF V[S ANF6 V[J]\ VFJ[ K[P HIFZ[ Forced Circulation GL H~Z pEL YFI K[P NAF6
HIFZ[ lSl8S, CMI ( Critical Pressure of Steam ) ( 225 atm ) tIFZ[ YDM"l;OMlGS C[0
VYJF A/ X}gI Y. I K[4 VFD4 Natural Circulation ST;A lOl8S, AM.,ZM 5]ZT]\ H
DIF"lNT K[P
ZP
Forced Circulation : 140 kg/cmg NAF6GL JW] NAF6JF/F lSl8S, VG[ ;]5Z lSl8S,
AM.,ZMDF\ Forced Circulation ZFBJ]\ 50[ K[P VFW]lGS AM.,ZMDF\ 36LAWL ;DF\TZ ;ZlS8
CMI K[P VFYL Natural Circulation AM.,ZDF\ V[S ;ZBL VG[ 5}ZTF 5|DF6DF\ NZ[S ;lS"8DF\
JC[\R6L SZJL D]xS[,L 50[ K[ SFZ6 S[ Heat Transfer DF\ YTL JW38G[ SFZ6[ ;ZSI],[XGDF\ 56
JW38 YFI K[P
Heat Transfer GM NZ JWFZJF DF8[ JFI] VG[ 5F6LGL UlT 56 JWFZJL 50[P JFI]GL
UlT SZTF 5F6LGL UlT JWFZJL ;C[,L VG[ VMKL BRF"/ K[ SFZ6 S[ 5F6LG]\ SN JFI]GF SNGF\
5|DF6DF\ B}A H VMK]\ CMI K[4 H[YL ;C[,F.YL 5F6LG]\ NAF6 JWFZL XSFI K[P NAF6 JWFZL XSFT]\
CMJFYL T[GM J[U sUlTf 56 JWFZL XSFI K[P
Forced Circulation YL YTF\ VgI OFINFVM o

!P
HuIFV[ VG]S]/ 50[ T[ ZLT[ ZRGF SZL XSFI K[P SFZ6 S[ T[GL Heating Surface UZDJFI]VMGF\
;\;U"DF\ ,FJJF DF8[ JWFZ[ Output VG]S]/TF CMI K[P VFD4 VF5[, HuIF DF\YL JWFZ[ D[/JL XSFI
K[P
ZP
5F6LGM J[U B}A H CMJFYL 8I]AMYL 8I]AMGL ;F.h GFGL ZFBL XSFI K[P VG[ T[ 8I]AMGL NLJF, (
Thickness ) 56 5FT/L ZFBL XSFI K[P VF p5ZF\T 0=DGL ;\bIF VMKL SZL XSFI K[ HIFZ[
Pass through Boiler DF\ 0=DGL H~Z ZC[TL HYLP VFG[ SFZ6[ VF5[, Output DF8[ VMKL
WFT]GL H~Z 50[ K[P 5F6LGM ;\U|C VMKM CMJFYL 0=DG]\ SN VMK]\ ZFBL XSFI K[P NFPTP 100
8GqS,FS DTFJF/F Natural Circulation AM.,ZDF\ VFXZ[ 7000 lSPU|FP 5F6LGL H~Z 50[ K[
HIFZ[ Forced Circulation AM.,ZDF\ OST 1700 lSPU|FP 5F6LGM HyYM CMI K[P JHG VMK]\
YJFYL OFpg0[XGGM BR" 56 VMKM YFI K[P
#P
Forced Circulation AM.,Z h05YL AN,FTF AM.,Z ,M0G[ 5CM\RL J/[ K[P 9\0F AM.,ZG[ 56
h05YL ,M0 5Z ,. XSFI K[P T[ p5FZF\T T[ l5S ,M0 ( Peak Load ) l:YlT DF8[ 56 IMuI K[
VYJF CF.0=M,[S8=S :8[XGDF\ Stand-by AM.,Z TZLS[ IMuI K[P
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;ZSI],[XGGL UlT B}A H CMJFYL :S[l,\U YT]\ GYLP
5P
AM.,ZGF\ AWF\ H EFUM V[S ;ZBF UZD YFI K[ T[YL YJFGM EI 38[ K[ VG[ Thermal Stress
pt5F YTL GYLP
&P
V[S ;ZB]\ TF5DFG JWJFYL Differential Expansion VMK]\ YFI K[ VFYL UZD JFI]VM VG[
CJFGF l,S[HGL XSITF 38[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
*P
AM.,ZGF\ EFUMG[ VF0F ( Horizontal ) UM9JL XSFI K[ S[D S[ Natural Circulation GL

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Benson, Loeffler VG[ Velox lJU[Z[ AM.,ZMV[ p\RF NAF6JF/F AM.,ZM K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
(Boiler Start-up)
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
20.
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,ZGL SFI"X{,L ( Boiler Performance )

!P_
5|:TFJGF o
;FDFgI ZLT[ AM.,ZGM ,M0 ( Boiler Load ) AN,FTM ZC[TM CMI K[P AM.,Z ,M0DF\
YTF\ JW38GM VFWFZ JZF/ ( Steam ) D]bItJ[ SIF\ J5ZFI K[4 T[GF p5Z ZC[,M K[P S[8,FS
AM.,ZDF\ ,M0DF\ JW38 36L H VMKL CMI K[P HIFZ[ 5|JFCL VYJF JFI]~5 A/T6 JF5ZJFDF\ VFJ[
K[ tIFZ[ JZF/GF\ pt5FNGDF\ [.TL JW38 36L h05YL D[/JL XSFI K[P HIFZ[ 3G 5NFY" VYJF
SM,;M JF5ZJFDF\ VFJ[ TIFZ[ JZF/ pT5FNGDF\ O[ZOFZ SZTF\ ;DI ,FU[ K[P
AM.,ZGM ,M0 V[SWFZM H/JF. ZC[ T[ H~ZL K[P SFZ6 S[ AM.,Z p5Z JZF/ pt5FNGGM
EFZ AN,FIF SZTM CMI TM AM.,ZGL SFI"X{,L ( Boiler Performance ) p5Z T[GL ;LWL
V;Z 50[ K[P
ZP_
AM.,ZGL JZF/ pT5FNG 1FDTF ( Boiler Capacity )

GLR[GFDF\YL V[S 5|SFZ[ NXF"J[, K[P
!P
CL8L\U ;ZO[; o
VF 1F[+O/ GSSL SZTL JBT[ ;FDFgI ZLT[ H[ AFH]V[ UZD JFI] ZC[TF CMI T[ 1F[+O/
U6TZLDF\ ,[JFDF\ VFJFDF\ VFJ[ K[P VFBF AM.,Z %,Fg8GL CL8L\U ;ZO[; GSSL SZTL JBT[ ;]5Z
CL8Z VG[ .0MGMDF.hZGF\ 1F[+O/G[ 56 ;DFJL ,[JFDF\ VFJ[ K[P T[G[ RMZ;DL8ZDF\ NXF"JJFDF\ VFJ[
K[P ;FDFgI ZLT[ AM.,ZGL CL8L\U ;ZO[; AM.,Z pt5FNSM 5F;[YL 5|F%T YFI K[P H~ZL 50[ TM
AM.,ZGF\ DF5 p5ZYL 56 GSSL YFI K[P
AM.,Z CM;" 5FJZ o
AM.,ZDF\ CM;" 5FJZ T[GL CL8L\U ;ZO[; VG[ 5|SFZ p5Z VFWFZ ZFB[ K[ T[GF CM;"5FJZ GLR[
5|DF6[ GSSL SZL XSFI K[P
ZP
#P
AM.,Z CM;" 5FJZ = CL8L\U ;ZO[; q VR/F\S

VR/F\S AM.,ZGF\ 5|SFZ p5Z VFWFZ ZFB[ K[P
VFW]lGS AM.,ZDF\ AM.,ZGL NZ S,FS[ JZF/ pt5F SZJFGL 1FDTFG[ pt5FlNT 1FDTF TZLS[ ,[JFI
K[P
AM.,ZGL JF:T:JS JZF/ pt5F SZJFGL 1FDTF
( Actual evaporisation ) = Wa = total evaporisation per hour
sS,FS[ pt5F YTL JZF/f / Fuel used per hour sS,FSDF\ J5ZFI[, A/T6f
= V[S lS,MU|FD A/T6 AF/TF\ pt5F YTL JZF/
;DFG pt5FNG 1FDTF s.SJLJ[,g8 .J[5MZF.h[XGf o
INDIABOILER DOT COM

DTP/BOT/ VI/030502
NZ[S AM.,ZDF\ JZF/ V[S ;ZBF NAF6[ V[S;ZB]\ CMT]\ GYL T[DH AM.,ZDF\YL pt5F YTL JZF/GL
l:YTL 56 ;ZBL CMTL GYL VF +6[ AFATM H]NF H]NF 5|SFZGF\ AM.,ZDF\ H]NL H]NL CMI K[P DF8[ A[ H]NF
H]NF AM.,ZGL T],GF SZJF DF8[ AM.,ZGL S,FSGL JZF/ pt5F SZJFGL XlST VYJF V[SD A/T6YL
pt5F YI[,L JZF/ V[ IMuI DF5 GYP
VF IMuI DF5 DF8[ AM.,ZDF\ NFB, YTF\ 5F6LG]\ TF5DFG 100C DFGJFDF\ VFJ[ K[P VG[ VF H
pQ6TFDFG[ ;\T'%T JZF/ T{IFZ SZJF DF8[ OZT NZ lS,MU|FD NL9 U]%T UZDL H AM.,ZDF\ VF5JL 50[ K[P
VFJL l:YTGL WFZ6F SZL JZF/GM H[ HyYM D/[ T[G[ ;ZBFJJFDF\ VFJ[ K[P
We = 1kg A/T6 AF/TF\ 100C
TF5DFGGF\ 5F6LDF\YL T[H TF5DFG[ pt5F YTL JZF/P
H =
JF:T:JS JlS"U l:YlTDF\ pt5F YTL JZF/GL S], UZDL ( Enthalpy)
h =
AM.,ZDF\ NFB, YTF\ 5F6LGL S], UZDL
Ls =
100C TF5DFG[ pt5F YTL 1 kg JZF/GL U'%T UZDL
( 538.9 kcal / kg )
CJ[ 1 kg 5F6LDF\YL JZF/ pt5F SZJF DF8[ [.TL UZDLP

=
H -h lS,MS[,ZL
JF:TlJS JlS"U 5lZl:YTDF\ lS,MU|FD JZF/ pt5F SZJF DF8[ H~ZL UZDL
=
Wa [ H h ] lS,MS[,ZL
We, .SJLJ[,g8 .J[5MZF.h[XG
= Wa = [ H h ] / Ls
= Wa = [ H h ] / 538.9
= V[SD A/T6YL D/TL JZF/GL UZDL / 538.9

VYJF
= V[S S,FSDF\ pt5FlNT JZF/GL UZDL / 538.9
;DFG pt5FNG VF\S ( Factor of equivalent evaporisation )
JF:TlJS JlS"U 5lZ:YlTDF\ 1 kg 5F6LDF\YL JZF/ AGFJJF HF[.TL UZDL
= lGID 5lZl:YT V[8,[ 100C TF5DFGJF/F 5F6LDF\YL V[ H TF5DFG[ JZF/ AGFJJF DF8[ H~ZL
UZDL
=
H h / Ls
= H h / 538.9
V[S RMZ;DL8Z CL8L\\U ;ZO[;YL YT]\ .J[5MZ[XG o

=1
S,FSDF\ 5F6LG]\ JZF/DF\ YT]\ ~5F\TZ CL8L\U ;ZO[;G]\ 1F[+O/ sRMP DL8ZDF\f H[ GM V[SD lS,MU|FD
5|lTS,FS 5|lT RMPDLP ( kg / hr / m ) K[P
AM.,ZGL SFI"N1FTF o ( Boiler efficiency )
INDIABOILER DOT COM

DTP/BOT/ VI/030502
JZF/ AGJF J5ZFTL UZDLGM HyYM VG[ T[H ;DIDF\ VF5[,F\ A/T6DF\YL pt5F YTL UZDLGF\
HyYFGF\ U]6MZ G[ AM.,ZGL SFI"1FDTF SC[ K[P
AM.,ZGL SFI"N1FTF
= Output sD/TL UZDLf / Input sJ5ZFTL UZDLf

= Wa ( H h ) / C.V.
HIF\ C.V.
= A/T6G]\ pQDLI D}<I Kcal / kg
Wa = 1 kg
A/T6 AF/TF\ 5F6LG]\ JF:TlJS 5lZl:YTDF\ YT]\ JZF/DF\ ~5FTZ
H h=
1kg 5F6L slOSJM8Zf G]\ JZF/DF\ ~5F\TZ YJF4 DF8[ H~ZL UZDL
JZF/GL S], UZDL ( Enthalpy of Steam )
AM.,ZDF\ NFB, YTF\ 5F6LGL S], UZDL

( Enthalpy of Feed water ) ( Kcal / kg)
pNFCZ6 o
WFZM S[ AM.,ZGL K S,FSGL 8=FI, JBT[ GLR[GL DFlCTL V[S9L SZJFDF\ VFJL K[P
s!f pt5F YTL JZF/G]\ NAF6
= 14 kg / cm slG5["1Ff
sZf pt5F YI[, JZF/G]\ JHG
= 48,000 kg
s#f JZF/GM ;Z[ZFX X]QSF\S
= 0.9
s$f OL0 JM8ZG]\ ;Z[ZFX TF5DFG
= 28C
s5f J5ZFI[, SM,;FG]\ JHG
= 4800 kg
s&f SM,;FGL pQDLI lS\DT
= 8100 kg
s!f
p5Z VF5[, DFlCTL 5Z6L

;DFG pt5FNG VF\S sO[S8Z VMO .SJLJ[,g8 .J[5MZF.h[XGf
sZf
AM.,ZGL BZ[BZL pt5FNG 1FDTF ( Actual evaporisation )
s#f
AM.,ZGL ;DFG pt5FNG 1FDTF ( Equivalent evaporisation )
s$f
AM.,ZGL SFI"N1FTF ( Boiler efficiency ) XMWMP

JZF/ SM9FDF\YL ( Steam table ) 14 kg / cm ab NAF6[
h = 197.0 Kcal / kg
L = 468.9 Kcal / kg
1 kg ELGL JZF/GL UZDL
= H wet = h + XL = 197.1 + ( 0.9 + 468.9 )

= 619.11 Kcal / kg
1 kg 5F6LDF\YL JZF/ AGFJJF DF8[ VF5JL 50[, UZDL

= Hwet h1 = 619.11 28 Kcal / kg
INDIABOILER DOT COM

DTP/BOT/ VI/030502
VlC h1 = ( 28 0 ) = 28 Kcal
= ;DFG pt5FNG VF\S
= Hwet h / 538.9
= 619.11 28 / 538.9
= 1.097
HJFA 1
AM.,ZGL BZ[BZL pT5FNG 1FDTF Per kg of coal

( Actual Evaporisation Per kg of coal )
Wa = 48,000 / 4800 = 10 kg per kg of coal
HJFA - 2
AM.,ZGL ;DFG pt5FNG 1FDTF ( Equivalent evaporisation )

in kg of water from and at 100C
We = Wa x [ Hwet h ] / 538.9 = 10 ( 619.11 28 ) / 538.9
= 10.97 kg / kg of coal
HJFA - 3
AM.,ZGL SFI"1FDTF ( Boiler efficiency )

= Wa [ Hwet h] / CV
= 10 x ( 619.11 28 ) / 8100
= 0.73 or 76%
#P_
HJFA - 4
AM.,Z %,Fg8DF\ YTM UZDLGM jII ( Heat losses in Boiler Plant )
V[S ;FZF 5|SFZGF\ JM8Z8I]A AM.,ZGL YD", VMKFDF\ VMKL 80% H[8,L CMI K[ ,[S[XFIZ AM.,Z
S[ H[DF\ :JI\ ;\RFl,T :8MS;" ( Stokers ) CMI VG[ H[G]\ ( Brick work ) ;FZL ZLT[ H/JFT]\ CMI TM T[
,UEU 75% H[8,L efficiency VF5[ K[ TM ;JF, V[ YFI S[ VF AFSLGL 20 YL 25% UZDL SIF\ I
K[ m S[D S[4 VF UZDLGM AM.,ZDF\ 5|F6LDF\YL AZF/ AGFJJF DF8[ p5IMU Y. XSTM GYL4 VFYL T[G[ jII (
Losses ) TZLS[ U6JFDF\ VFJ[ K[P
AF[.,ZDF\
A/T6DF\
NCGYL
pt5gG YTL
UZDL
jII YTL UZDL
( Heat Losses )
5F6LDF\YL H~ZL 5|DF6[GL

JZF/ AGFJJF DF8[
J5ZFTL UZDL
( Useful Heat )
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AM.,Z %,Fg8DF\ YTF UZDLGF jII ( Heat Losses ) G[ D]bItJ[ RFZ EFUDF\ JC[\RL XSFI K[P
!P
AM.,ZDF\YL ACFZ GLS/TF UZDJFI]VMDF\ YTM jII
ZP
( Heat lost to chimney gases or Flue gases )

A/T6GF\ V5}6" NCGYL YTM UZDLGM jII
#P
( Heat lost due to incomplete combustion )

U|[8GF\ ;l/IFDF\YL GLR[ 50[, VG[ G A/[, A/T6GL YTM jII
( Heat lost due to unburnt fuel falling through the grate bars or
unburnt fuel falling in the furnace )
$P
lJlSZ6YL YTM UZDLGM jIJ

( Heat lost to external radiation )
CJ[ VF56[ JZFOZTL p5Z H6FJ[, UZDLGF jII ( Heat losses ) G[ lJUT[ [.X]\P
!P
AM.,ZDF\YL sRLDGLDF\YLf ACFZ GLS/TF UZDJFI]VMDF\ YTM jII
( Heat lost to chimney gases or Flue gases )
AM.,ZGL RLDGLDF\YL ACFZ O[\SFTF JFI]VM A[ EFUDF\ AG[,F CMI K[P
(a)
;}SF UZDJFI]VM ( Dry Flue gases )
(b)
JFI]VMDF\ ZC[,L JZF/ ( Steam in Flue gases )

(a)
;}SF UZD JFI]VMDF\ YTM UZDLGM jII GLR[ 5|DF6[ U6L XSFI q V[S lS,MU|FD A/T6DF\
;}SF JFI]VMDF\ YTM UZDLGM jIJ ( Heat lost to dry flue gases per kg of
fuel burnt )
= V[S lS,MU|FD A/T6 AF/JFYL pt5F YTF\ JFI]VMG]\ JHG VF JFI]VMGL lJlXQ8 pQDF (
Kp) X
ACFZ GL/STF JFI]VM VG[ JFTFJZ6GF\ TF5DFG JrR[GM TOFJT ( t1 t2 )
Heat lost to dry flue gases per kg of fuel = Wg x Kp (t1 t2)
p5ZGF\ ;DLSZ6YL V[ :5Q8 YFI K[ S[ TF5DFGGM TOFJT H[8,M JW] T[8,M UZDLGM jII JW]
YFI K[P TN p5ZF\T H[D JWFZ[ A/T6 AF/JFDF\ VFJ[ T[D jII 56 JWFZ[ CMI K[P
(b)
JFI]VMDF\ ZC[,L JZF/DF\ YTM UZDLGM jII GLR[ 5|DF6[ Y6L XSFIP
V[S JFTG]\ BF; wIFG ZC[ S[ JFI]VMDF\ ZC[,L JZF/ V[ A/T6DF\ ZC[,F\ CF.0=MHG
GF\ NCGGF SFZ6[ pNEJ[ K[P
CJ[4 V[S lS,MU|FD A/T6DF\YL pt5F YTL JZF/G]\ JHG
= gH2 + V[S lS,MU|FD A/T6DF\ ZC[,L Mositure G]\ JHG (W)
INDIABOILER DOT COM

DTP/BOT/ VI/030502
VF56[ V[D WFZL ,.X]\ S[ JFI]VMDF\ ZC[,L JZF/ JFTFJZ6DF\ NAF6 VG[ JFI]GF\
TF5DFGGL 5lZl:UlTDF\ VlTT%T ( Super heated ) :J~5[ K[P V[ lS,MU|FD A/T6
AF/JFYL JZF/DF\ YTM UZDLGM jII
( Heat lost to steam in flue gases per kg of fuel burnt
[ gH2 + w ]
[ Hsup h]
Heat losss = [gH2 + w ] [ 100 + 538.9 + Kp ( t-100) - h

HIF\4 t =
AM.,ZGL ACFZ GLS/TF\ UZDJFI]VMG]\ TF5DFG
Hsup =
V[S lSPU|FP VlTT%T JZF/GL JFTFJZ6GF\ NAF6[ VG[ JFI]VMGF\ TF5DFG[ sS],
UZDLf
ZP
#P
kp
VlTT%T JZF/GL lJlXQ8 pQDF
lSPU|FP 5F6LGL JFTFJZ6GF TF5DFG[ Enthalpy
lSPU|FP A/T6DF\ ZC[, Moisture G]\ JHG
H2
lSPU|FP A/T6DF\ ZC[, CF.0=MHGG]\ JHG
VFD4 RLDGL JF8[ AM.,ZDF\YL ACFZ GLS/TF JFI]VM ( Flue gases ) DF\ YTM UZDLGM
jII 36M JWFZ[ CMI K[P UZDLGF\ VF jIIG[ VMKM SZJF DF8[4 VF W]lGS GJF AM.,ZDF\4 AM.,Z
VG[ RLDGL JrR[4 .SMGMDF.hZ VG[ V[Z l5| CL8Z D}SJFDF\ VFJ[ K[ S[ H[VM ACFZ HTF\ VF
JFI]VMDF\YL 36LAWL UZDL XMQFL ,[ K[ VG[ VF 5|SFZGM UZDLGM jII V8SFJ[[ K[P
TN p5ZF\T T[VM AM.,ZGL SFI"N1FTF 56 JWFZ[ K[ H[ VF56[ VFU/GF\ 5|SZ6MDF\ lJUTJFZ
[. UIF KLV[P
A/T6GF\ V5}6" NCGYL YTM UZDLGM jII
V5}ZTL CJFG[ SFZ6[4 A/T6G]\ V5}6" NCG YFI K[ H[G[ 5lZ6FD[ Co sSFA"G DMGMS;F.0f
AG[ K[P A/T6GF\ ;5}6" NCG DF8[ 5}Z[5}ZF SFA"G (C) G]\ SFA"G0FIMS;F.0 (Co2) DF\ ~5F\TZ YJ]\
HZL K[P S[D S[4 HIFZ[ 1 lS,MU|FD SFA"G A/LG[ Co2 AG[ K[ tIFZ[ 8080 Kcal T[ H[8,L UZDL
5[NF SZ[ K[ VG[ [ 1 lS,MU|FD SFA"G A/LG[Co AG[ K[ tIFZ[ TP OST 2420 Kcal H[8,L H UZDL
5[NF SZL XS[ K[P VFD4 8080 2420 = 5666 Kcal H[8,L UZDLGM jII YFI K[4 H[ 36M H
DM8M K[PDF8[4 AM.,ZDF\ A/T6G]\ ;5}6" NCG YFI T[ H~ZL K[P T[ DF8[ AM.,ZDF\ NCG DF8[
DMS,JFDF\ VFJTL CJFGM 5}ZTM HyYM CD[\XF /JJM [.V[ VG[ T[G[ ,UTF\ ;FWGM H[JF S[ 5\BF4
0S8 lJU[Z[G[ IMuI l:YlTDF\ /JJF [.V[P VG[ lGIlDT T[ GL RSF;6L VG[ H~ZL ;DFZSFD YJ]\
[.V[P JFI]~5 SZTF\ 5|JFCL VG[ 3G A/T6 DF\ VF 5|SFZGM UZDLGM jII JW] YJFGL XSITFVM
ZC[TL K[P
U|8GF\ ;l/IFVMDF\YL GLR[ 50[, VG[ GA A/[, A/T6YL YTM jII o
HIFZ[ 56 3G A/T6 JF5ZJFDF\ VFJ[ K[ tIFZ[ NCGGL 5|lSIF NZdIFG T[GF\ GFGF GFGF
8]S0FVM YFI K[P H[DF\GF VD]S U|[8GF\ ;l/IFVMDF\YL GLR[ 50L I K[ VG[ T[G]\ NCG Y. XST]\ GYL H[
V[ 5|SFZGM UZDLGM H jII K[P VF jII4 U|8GF\ ;l/IFVMDF\ GLR[ 50[, A/T6GF\ JHGG[ T[GL
S,MlZlOS J[<I] ( C.V.) ;FY[ U]6FSFZ SZLG[ D[/JFI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
Heat loss = GLR[ 50L UI[, A/T6G]\ JHG (w) x A/T6GL S,MlZlOS J[<I] ( C.V.)
$P
lJlSZ6YL YTM UZLDLGM jII o ( Heat lost to External Radiation )

AM.,Z VG[ T[GF OZG[;GL H]NL H]NL ;5F8LVM 5Z V;DZSFZ ,[UL\U ( Lagging ) GF\
SZ[, CMI TM VF 5|SFZ[ UZDLGM jII YFI K[P lJlSZ6YL YTM UZDLGM jII S], UZDLGF\ jIIDF\YL
p5Z H6FJ[, +6 5|SFZGF\ UZDLGM jIIG[ AFN SZJFYL D/[ K[P UZDLGF\ jIIDF\YL p5Z H6FJ[,
+6 5|SFZGF\ UZDLGM jIIG[ AFN SZJFYL D/[ K[P S], UZDLGM jII v sAM.,ZDF\YL ACFZ GLS/TF\
UZDJFI]VMDF\
Heat Loss =
$P_
!P
UZDLG[ jII - s A/T6DF\ V5}6" NCGYL YTM UZDLGM jII + A/T6GF\

;\5}6" NCGYL YTF[ UZDLGF[ jII + U|[8GF\ ;l/IFV,DF\YL GLR[ 50[, VG[
G A/[, A/T6YL YTM UZDLGM jII f
AM.,Z VG[ T[GL V[;[;ZLhGL SFI"N1FTF
AM.,ZGL SFI"N1FTF ( Boiler efficiency Or Thermal efficiency of ther
Boiler )
AM.,ZDF\ OL8JM8ZDF\YL H~ZL l:YlTJF/L JZF/ AGFJJF DF8[ p5IMUDF\ VFJTL UZDL VG[
V[8,F\ H ;DIDF\ H T[ A/T6GF\ ;\5}6" NCGYL K}8L 50TL UZDLGF\ U]6F[ZG[ AF[.,ZGL SFI"N1FTF
SC[ K[P i.e. it is output divided by the input to the boiler
VFD4 AM.,ZGL SFI"N1FTF = Wa ( H h ) / C. V.
HIF\4 C.V. = A/T6GL S[,MlZlOS J[<I] Kcal / kg
Wa = V[S lS,MU|FD A/T6 AF/JFYL D/T]\ BZ[BZ]\ pt5FNG4 kg
H h = V[S lS,MU|FD OL8JM8ZDF\ NFB, Y.G[ JZF/ AGFJJF DF8[ J5ZFI[,L UZDLP
[ AM.,Z %,Fg8DF\ .SMGMDF.hZ VG[ ;]5ZCL8Z 56 CMI TM T[ NZ[SGL SFI" N1FTF V,U
U6JFDF\ VFJ[ K[P VG[ [ VF +6[I G[ V[S H EFU ( Single Unit ) TZLS[ U6JFDF\ VFJ[ TM T[
ZLT[ U6JFDF\ VFJTL SFI"N1FTF G[ VYJF SC[JFI K[P
ZP
.SMGMDF.hZGL SFI"N1FTF o
.SMGMDF.hZDF\YL 5;FZ YTF\ OL0JM8Z wJFZF D[/JFI[, UZDL VG[ UZDJFI]VMGL VF5[,L
UZDLGF\ U]6MZG[ .SMGMDF.hZGL SFI"N1FTF Over all efficiency VYJF efficiency of
combined boiler plantSC[JFI K[P
VFD4
.SSMGMDF.hZGL SFI"N1FTF = Wa ( t2 t1 ) / W1 x Cp ( tt1 tt2 )
HIF\4
t1
.SF[GF[DF.hZDF\ NFB, YTF\ OL8JF[8ZG]\ TF5DFG
t2
.SMGMAF.HZDF\YL ACFZ GLS/TF OL8JM8ZG]\ TF5DFG
tt1
.SMGMDF.hZDF\ NFB, YTF\ UZDJFI]VMG]\ TF5DFG
INDIABOILER DOT COM

DTP/BOT/ VI/030502
tt2
.SMGMDF.hZDF\YL ACFZ GLS/TF\ UZDJFI]VMG]\ TF5DFG
W1
NZ lS,MU|FD A/T6 NL9 pt5F YTF UZD JFI]VMG]\ JHG
Wa
NZ lS,MU|FD A/T6 T{IFZ YI[,L JZF/G]\ JHG
Cp
ACFZ HTF JFI]VMGL lJlXQ8 pQDF
VCL\4 5F6LGL lJlXQ8 pQDF (Cp) V[S CMJFYL ;}+DF\ U6TZLDF\ ,LW[, GYL VFW]lGS GJF
NZ[S AM.,ZMDF\ AM.,Z AGFJGFZ T[GL ZRGF V[JL ZLT[ SZ[ K[P H[YL .SMGMDF.hZ AM.,ZGL V\NZ
H CMI T[D ,FU[ 6[ S[ AM.,ZMGM H V\TUT" EFU CMIP
TN p5ZF\T .SMGMDF.hZGL SFI"N1FTF JWFZJF DF8[ T[DF\ 8I]AMGL ;\bIF H[D AG[ T[D JW]
ZFBJFDF\ VFJ[ K[ VG[ 8I]AM ( Fins ) ;FY[( Finned Tubes ) AGFJJFDF\ VFJ[ K[P
VFD SZJFYL .SMGMDF.hZGL S], Heating Surface JW[ K[ VG[ T[GL SFI"N1FTFDF\ 56 JWFZM
YFI K[P
$P_ ;]5ZCL8Z o
;]5ZCL8Z ;FDFgI ZLT[ OZG[;DF\YL VFU/ JWTF JFI]VM ( Flue gas ) GF\ Z:TFDF\
D}SJFDF\ VFJ[ K[ H[YL T[ UZD JFI]VMDF\YL UZDL U|C6 SZL XS[P [ JWFZ[ TF5DFGGL H~Z CMI TM
SIFZPS ;]5ZCL8ZG[ OZG[;GF\ p5ZGF\ EFUDF\ 56 D}SJFDF\ VFJ[ K[P
AM.,Z 0=DDF\YL GLS/TL ;}SL ;\T'%T JZF/G[ ;]5ZCL8ZGL G/LVM ( Tubes ) DF\YL 5;FZ
SZJFDF\ VFJ[ K[P VF G/LVMG]\ U}\R/]\ ( Coils ) JFI]GF\ Z:TFDF\ ZFBJFDF VFJ[ K[P JFI]DF\YL UZDL
JZF/DF\ I K[4 VG[ JZF/G[ VR/ NAF6[ VlTT%T JZF/DF\ ~5F\TZ SZ[ K[P
;]5ZCL8ZGL SFI"N1FTF GLR[ D]HA U6TZL SZLG[ D[/JL XSFI K[P ;]5ZCL8ZDF\ JZF/ wJFZF
JFI]DF\YL D[/J[, UZDL VG[ UZDJFI]VMGL VF5[,L UZDLGF\ U]6MZ G[ ;]5ZCL8ZGL SFI"N1FTF
SC[JFI K[P
;]5ZCL8ZGL SFI"N1FTF = Wa ( H + Cps ( tsup tsat)) / Wf Cpf ( tt1 tt2)
VF ;}+DF\
Wa
NZ lS,MU|FD A/T6 NL9 T{IFZ YI[,L JZF/G]\ JHG
Wf
NZ lS,MU|FD A/T6 NL9 T{IFZ YTF UZD JFI]G]\ JHG
tsat =
;]5ZCL8ZDF\ NFB, YTL JZF/G]\ TF5DFG
tsup =
;]5ZCL8ZDF\YL ACFZ GLS/TL VlTT%T JZF/G]\ TF5DFG
tt1
;]5ZCL8ZDF\ NFB, YTF\ JFI]G]\ TF5DFG
t12
;]5ZCL8ZDF\YL ACFZ GLS/TF\ JFI]G]\ TF5DFG
CPf =
VR/ NAF6[ JFI]GL lJlXQ8 pQDF
Cps =
VR/ NAF6[ JZF/GL lJlXQ8 pQDF
H[ AM.,ZDF\ T[DF\YL GLS/TL JZF/G]\ TF5DFG B}A H p\R] [.T]\ CMI T[DF\ ;]5ZCL8Z A[ EFUDF\
JC[\RFI[,]\ CMI K[ H[D S[4 %,[8G ;]5ZCL8Z VG[ OF.G, ;]5ZCL8Z VF ZLT[ JZF/GF TF5DFGG]\ lGIDG JW]
;FZL ZLT[ SZL XSFI K[4 H[DF\ 0L ;]5ZCL8ZGL jIJ:YF 56 CMI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,ZG]\ lGIDG ( Boiler Control )

5|:TFJGF o
AM.,ZGF\ lGIDG ( Boiler Control ) GM D]bI pN[X VMKFDF\ VMKF\ BR"[ ;,FDTL5}J"S JZF/ (
Steam ) pt5FNG SZJFGM K[4 H[ DF8[ AM.,ZGF\ H]NF H]NF D]bI 5lZA/MG[ wIFGDF\ ZFBJFDF\ VFJ[ K[P
AM.,ZGF\ ,F\AF VFI]QI DF8[4 SM.57 D]xS[,L JUZ ,F\AM ;DI ;TT R,FJJF DF8[4 T[GL /J6L (
Preservation ) S[ DZFDT ( Maintenance ) GM BR" T[DH T[DH T[G[ R,FJJF GM BR" T[DH T[G[
R,FJJFGM BR" 56 BMKFDF\ VMKM YFI VG[ pD SFI"N1FTF D/[ T[ DF8[4 AM.,Z HIFZ[ RF,] CMI4 TIFZ[
GLR[GF ( Parameters ) B}A H RMS;F.5}J"S lGI\+6 SZJF [.V[P
s!f
AM.,ZDF\\ DMS,JFDF\ VFJTF 5F6LG\] lGIDG VYJF AM.,Z 0=DGL ;5F8LG]\ lGIDG
( Feed water control Or Drum level control )
sZf
A/T6G]\ lGIDG (Fuel Control or Combustion Control)
s#f
AM.,ZDF\ pt5F YTL JZF/GF\ NAF6G]\ lGIDG ( Steam Pressure Control or Master
Pressure Control )
s$f
AM.,ZDF\ pt5F YTL JZF/GF\ TF5DFGG]\ lGIDG ( Boiler outlet steam Temperature
Control )
s5f
CJFGF\ 5|JFCG]\ lGIDG ( Air Flow Control )
s&f
OZG[;DF\GF NAF6G]\ lGIDG ( Furnace Pressure Control )
CJ[ VF56[ JFZF OZTL p5ZGF\ lJUTJFZ [.X]\P

!P_
AM.,ZDF\ DMS,JFDF\ VFJTF 5F6LG]\ lGIDG VYJF AM.,Z 0DGL ;5F8LG]\ lGIDG
( Feed water control or Drum level control )
VF 5|SFZGF\ lGIDGG[ D]bItJ[ 0=D ,[J, Sg8=M, TZLS[ VM/BJFDF\ VFJ[ K[P 0=D ,[J, Sg8=M, D]bItJ[
ZLT[ SZJFDF\ VFJ[ K[[
(a)
V[S V[,LD[g8 Sg8=M, ( Single element control )
(b)
A[ V[,LD[g8 Sg8=M, ( Double element control )
(c)
+6 V[,LD[g8 Sg8=M, ( Three element control )

AM.,ZGF\ 0=D DF\ 5F6LGL ;5F8L ( Level )
B}A H RMS;F.5}J"S /JJ]\ [.V[ sD[.g8[.G SZJ]\ [.V[f H[YL SZLG[ JZF/ VG[ 5F6L
JWFZ[DF\ JWFZ[ K}8F\ 50[P 0=D DF\ 5F6LGL ;5F8L AZFAZ ZFBLG[ VF56[ AM.,ZGL G/LVMG[ (
Tubes ) 9\0L ZFB[ K[ T[ GSSL SZL XSLV[ KLV[P [ AM.,Z 0=DDF\ 5F6L G ZC[ TM T[GM VY" V[JM
INDIABOILER DOT COM

DTP/BOT/ VI/030502
Y. XS[ S[ AM.,ZGL G/LVMDF\ 56 5F6LGM 5|JFC G CMI TM AM.,ZGL G/LVM JWFZ[ UZD (
overheat ) Y. I VG[ SIFZ[S T[ VFU/LG[ OF8L I VYJF T[G[ G]S;FG 56 Y. XS[P CJ[
VF56[ V[S 5KL V[S 0=D ,[J, Sg8=M, lJUT ;DX]\P
!P!
l;\U, sV[Sf V[,LD[g8 S\8=M, ( Single element control )

l;\U, V[,LD[g8 S\8=M,DF\ D]bI V[,LD[g8 0=D ,[J, K[P 0=D ,[J, 0=Fg;DL8Z wJFZF 0=DDF\
5F6LG]\ ,[J, S[8,]\ K[ T[ 6L XSFI K[P VF 0=D ,[J,G]\ D}<I sDF5f 0=D ,[J, S\8=M,ZDF\ [0JFDF\
VFJ[ K[P 0=D ,[J, S\8=M,ZDF\ Z[OZg; J[<I] V[8,[ S[ GSSL SZJFDF\ VFJ[ K[P ;[8 J[<I] SZTF\ 0=D
,[J,DF\ JWFZM S[ 38F0M YFI TM VF S\8=M,Z4 ;FRL ;5F8L ( Actual level ) VG[ ;[8 5M.g8 (
set point ) JrR[GF\ TOFJT 5|DF6[ U6TZL SZLG[ E}, ( error ) l;uG, S\8=M, JF<J 5Z DMS,[
K[ VF E}, l;uG, ( Single error ) OL0 JM8Z S\8=M, JF<J B},[ K[ VYJF TM A\W YFI K[ sV[8,[
S[ JF<JG]\ VM5GL\U VMK]\ S[ JWFZ[ YFI K[Pf JF<JGF\ VM5GL\U 5|DF6[ 5F6L 0=DDF\ NFB, YFI K[P
l;\U, V[,LD[g8 0=D ,[J, RMS;F. 5}J"S S\8=M, YT]\ GYL SFZ6 S[ ,[J, JW38GL lS|IF AM.,Z ,M0GF\
JW38GF\ 5|DF6DF\ WLDL CMI K[P VFYL HIFZ[ AM.,ZGM ,M0 JW[ K[ T[GF\ 5|DF6DF\ 5F7LGM 5|JFC
sO,Mf J3TF JFZ ,FU[ K[P VFYL 0=D ,[J, VR/ ( Constant set point ) H/JFT]\ GYL VG[
,[J,DF\ JW38 ZCIF H SZ[ K[P
!PZ
0A, sA[f V[,LD[g8 S\8=M, o ( Double element control )

VF 5wWlTDF\ 0=D,[J,DF\ D}<I p5ZF\T JZF/DF\ 5|JFC ( Steam flow ) G]\ D]<I (
Value ) 56 ,[JFDF\ VFJ[ K[P T[YL HIFZ[ AM.,ZGF\ ,M0DF\ ( Boiler outlet steam flow
DF\f JWFZM YFI T[GL ;FY[ H Sg8=M, VFp85]8 l;uG, ( Output signal ) DF\ JWFZM SZ[ K[PVFD4
VFp8Z5]8G]\ D}<O H[JM AM.,Z ,M0 JW[ T[GL ;FY[ H 5F6LGF\ S\8=M, JF<JG[ BM,LG[ JZF/GF\ 5|JFC (
Steam flow ) GF\ 5|DF6DF\ h05YL 5F6LGF\ 5|JFCDF\ JWFZM SZ[ K[P T[ H 5|DF6[ HIFZ[ AM.,Z
,M0 38[ tIFZ[ S\8=M,Z JZF/GF\ 5|JFCDF\ 38F0FGF\ 5|DF6 DF\ VFp85]8GF\ D}<IDF\ 38F0M SZ[ K[ H[
5F6LGF S\8=M, JF<JG[ h05YL JZF/GF\ 5|JFCGF\ 5|DF6DF\ A\W SZL K[<,[ H~ZL 0=D ,[J, H/JFI T[
ZLT[ B]<,M ZFB[ K[ VG[ H~ZL 5F6LGM 5|JFC D/L ZC[ K[P
!P#
Y|L s+6f V[,LD[g8 S\8=M, o ( Three element control )

0=DGL V\NZ AM.,Z ,M0 JWJFYL 1Fl6S 5F6LGM pEZM VFJ[ K[ H[G[ Swell s:J[,f 56 SC[
K[4 H[ 0=D ,[J,DF\ D}<IDF\ 1Fl6S JWFZM ATFJ[ K[P V[ H ZLT[ HIFZ[ h05YL AM.,Z ,M0 38JFYL VG[
0=DDF\ 9\0F5F6LGM pD[ZM YJFYL 0=D,[J,DF\ 1Fl6S 38F0M YFI K[4 H[G[ Shrink szL\Sf 56 SC[ K[P
VF 5|DF6[ 0=DDF\4 HIFZ[ AM.,Z ,M0 JW[ K[ tIFZ[ 5F6LGL GL DF\U JWJL [.V[ 5Z\T] GL lS|IFG[
SFZ6[ DF\U 38JFG[ AN,[ JW[ K[P VF D]xS[,L N}Z SZJF DF8[ Y|L V[,LD[g8 S\8=M, ( Three element
control ) 5wWlTGM p5IMU SZJFDF\ VFJ[ K[P H[DF\ 0=D ,[J,4 JZF/GM 5|JFC Steam flow
VG[ 5F6LGM 5|JFC Feed water flow GF\ D}<IM ( Value ) GM p5IMU SZJFDF\ VFJ[ K[P VF
DF8[ H~ZL 5F6LGM 5|JFC4 JZF/DF\ 5|JFCG]\ OL8 OMZJ0" (FF) VG[ 0=D ,[J, V[ S\8=M,Z GSSL SZ[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
VG[ JZF/GM 5|JFC JWTF\ T[ 5F6LGM 5|JFC JWFZ[ K[ VG[ V[H 5|DF6[ 38F0[ K[[P 0=D ,[J, V[ S\8=M,Z
GlCJT O[ZOFZM ( Negligible changes ) VG[ ,M;L; ( Losses ) 5|DF6[ 5F6LDF\ 5|JFCGL
DF\U GSSL SZL ;FR]\ VR/ 0=D ,[J, /jIF\ SZ[ K[P VF ZLTYL 0=D ,[J,4 AM.,ZGF\ ,M0DF\ l;JFI S[
B}A H DM8M JWFZM S[ 38F0M YFI4 B}A H VR/ ( Constant ) VG[ ,FAF\ ;DI ;]WL H/JFI K[P
ZP_
A/T/ VYJF NCGlS|IFG]\ lGIDG o ( Flue control or Combustion control )

AM.,ZDF\ T[GF 5|SFZ 5|DF6[ A/T6 ( Natural Gas or any other Gas ) TZLS[
JFI] A/T6 5|JFCL A/T6 sSM.56 5|SFZG]\ Oil f S[ 3G A/T6 sH]NF\ H]\NF 5|SFZGM SM,;M4
JG:5lTGM SRZM S[ ,FS0]\ lJPf JF5ZJFDF\ VFJ[ K[P
JFI]~5 VG[ 5|JFCL A/T6G]\ lGIDG ( Control ) ;C[,M K[ S[D S[ T[ ;C[,F.YL JCL XS[
K[ q UlT SZL XS[ K[ VG[ T[GM 5|JFC ;C[,F.YL DF5L XSFI K[P HIFZ[ 3GA/T6GF\ J5ZFXG]\ DF5
VG[ T[G]\ lGIDG SZJFGL ZLT[ H]NL CMI K[P HIFZ[ 3GA/T6GF\ J5ZFXG]\ DF5 VG[ T[G]\ lGIDG
SZJFGL ZLT[ H]NL CMI K[P ;FDFgI ZLT[4 VFHGF\ VFW]lGS p\RF NAF6 VG[ p\RF TF5DFGJF/F
AM.,ZDF\ S[ H[GL 1FDTF ( Capacity ) 56 5|DF6DF\ JWFZ[ CMI K[4 T[DF\ A/T6 TZLS[ JFI]~5
VYJF 5|JFCL A/T6 H JF5ZJFDF\ VFJ[ K[ DF8[ T[GL H RRF" VCL SZ[, K[PP
AM.,ZDF\ 5|JFCL A/T6 IMuI TF5DFG ,FjIF AFN 5\5GL G/L ( Pipe ) JF8[ D[GL
OM<0DF\ ,. HJFDF\ VFJ[ K[ VG[ tIF\YL T[G[ AM.,ZGL ;F.8 5Z D}SJFDF\ q OL8 SZJFDF\ VFJ[, AG"Z
sV[S SZTF\ JW] 56 CM. XS[ K[f DF\ DMS,JFDF\ VFJ[ K[P V[ 5C[,F\ IMuI 5|SFZGF\ 5\BF ( Fan ) GL
DNNYL CJFGL 0S8 ( Air Duct ) DFZOT[ CJFG[ AM.,ZGL OZG[; ;]WL 5CM\RF0JFDF\ VFJ[ K[P HIF\
VluGGM :+MT VF5JFYL T[ A/T6 ;FY[ E/LG[ T[G[ AF/[ K[P NCGDF\YL pt5F YTL UZDL OZG[;GL
VFH]AFH] TYF ACFZ H TF\ UZD JFI]VM ( Flue Gases ) GF\ DFU"DF\ VFJ[, G/LVM ( Tubes
) DF\ ZC[,F q OZTF\ 5F6 q JZF/ ( Water / Steam ) DF\ XMQFFI K[P G/LVMDF\ ZC[, 5F6L UZD
Y.G[ JZF/ AG[ H[ HIFZ[ K[<,[ JWTF\ UZD GSFDF\ ( Flue gases ) JFI]VM G[ RLDGL (
Chimney ) DFZOT[ JFTFJZ6DF\ O[\SJFDF\ VFJ[ K[P
CJ[4 AM.,ZDF\ JZF/G]\ NAF6 ( Steam Pressure ) B}A H VUtIG]\ 5F;] (
Critical Parameter ) K[ T[YL NAF6 VR/ ( Constant ) /JJ]\ B}A H H~ZL K[P VR/
NAF6 6JJF DF8[ AM.,ZGF OZG[;DF\ AF/JFDF\ VFJTF A/T6YL pt5F YTL UZDLGF NZG]\
lGI\+6 SZJ]\ B}A H H~ZL K[P UZDL pt5F SZJFGM NZ A/T6 ( Fuel ) VG[ CJFGF\ 5|JFC ( Air
Flow ) G[ H~ZL 5|DF6[ JW38 SZLG[ SZL XSFI K[P NCGGL SFI"N1FTF JWFZJF DF8[ V[Z OI]V,
Z[lXIM ( Air Fuel Ratio ) V[ ZLT[ IMuI 5|JFCDF\ ZFBJM 50[ S[ H[YL A/T6G[ A/JF DF8[ 5}ZTF
5|DF6DF\ H~ZL VMlS;HG D/L XS[P [ 5}ZTF 5|DF6DF\ CJF (O2) G D/[ TM A?IF lJGFG]\ A/T6
ACFZ HTF\ JFI]VM ( Flue gases ) ;FY[ I VG[ NCGGL SFI"N1FTF 38[ H[ BM8M A/T6GM BR" (
Flue cost ) JWFZ[P VF p5ZF\T A?IF lJGFG]\ VF NCGXL, A/T6 AM.,ZDF\ VFU/ HTF\ SM.
SFZ6;Z A/JF ,FU[ TM T[ HuIFV[ W0FSM ( Explosion ) YJFGM EI 56 ZC[ K[P JWFZ[ 50TF
INDIABOILER DOT COM

DTP/BOT/ VI/030502
CJF sJWFZJF CJF Excess air f 56 A/T6DF\YL pt5F YTL UZDL U|C6 SZ[ K[ SZF6 S[ T[
JFTFJZ6DF\ TF5DFGYL AM.,ZDF\GF TF5DFG ;]WL UZD YFI K[ VG[ VF U|C6 SZ[, UZDL K[J8[
RLDGL DFZOT[ ACFZ HTF\ JFI]VM ;FY[ GSFDL J[0OF. I K[P VFD4 SFI"N1F NCG DF8[ A/T6
CJFGF\ 5|DF6 AZFAZ H/JFJ]\ [.V[P
#P_
AM.,ZDF\ pt5F YTL JZF/GF\ NAF6G]\ lGIDG o ( Steam Pressure control or

Master Pressure control )
VF 5|SFZGF\ lGIDGDF\ V[8,[ S[ Master pressure control ( Pressure
control ) DF\ AM.,ZGF\ Tt5}ZTF NAF6 ( Actual pressure ) VG[ S\8=M,ZGL ;[8 J[<I] ( Set
value ) GF\ TOFJT 5ZYL PIC 4 A/T6GL DF\U ( Fuel demand ) U6TZLYL pEL SZX[ q
U6FX[ VG[ OI]V,O,M S\8=M,ZG]\ ;[8 5M.g8 GSSL SZX[P VFD VF ,}5 ( Loop ) HZL JZF/GF\
NAF6G[ VR/ ZFBJF VR/ ( Constant ) OI]V,O,M /JX[P HIFZ[ NAF6DF\ O[ZOFZ YX[ tIFZ[
JZF/DF\ NAF6 ( Steam pressure ) G[ T[GF\ ;[8J[<I] H[8,]\ SZJF OI]V,GF\ O,MG[ S\8=M,
SZJFDF\ VFJX[ VG[ SF:S[8 ,}5 ( Cascade Loop ) OZL OI]V,O,MG[4 :8LD 5|[XZ VR/
ZFBJF VR/ ZFBX[P DF+ JZF/G]\ NAF6 V[ V[SH 5lZA/ ( Parameter ) Master
pressure /JJF DF8[ WLDM 5|lT;FN ( Slow response ) VF5X[ SFZ6 S[ 5C[,F\
AM.,ZDF\ CJF JWX[4 tIFZ AFN A/T6 JWX[ T[G]\ NCG YJFYL UZDL ( Heat ) pt5F YX[4 H[
UZDL 5F6LDF\ XMQFF.G T[GL JZF/ AF[ VFD VF AWL H lS|IF YTF\ JFZ ,FU[ K[P DF8[ VF D]xS[,LG[ N}Z
SZJF DF8[ JZF/GF\ 5|JFC ( Steam flow ) G[ OL8 OMZJ0" (FF) TZLS[ ,[JFDF\ VFJ[ K[ SFZ6 S[
NAF6DF\ [ S\. 56 JW38 YX[ T[GL 5C[,L V;Z JZF/GF\ 5|JFC ( Steam flow ) 5Z YX[ VG[
NAF6DF\ DM8L JW38 X~ YFIP T[GF\ 5C[,F\ H JZF/GF\ 5|JFC wJFZF S\8=M,Z TFtSFl,S IMuI ;]WFZM SZL
A/T6 ( Fuel Flow ) GL JW38 SZX[ VG[ 5KLYL PIC K[<,[ ;FZF S\8=M, DF8[ SFD SZX[P
$P_
CJFGF\ 5|JFCG]\ lGIDG o ( Air flow control )

AM.,ZDF\ H[8,L VUtITF A/T6 GF\ 5|JFCG[ /JJFGL K[ T[8,L H CJFGF\ 5|JFCG[ (Air
Flow Control ) 56 /JJFGL K[P
PIC wJFZF pt5F YTL CJF Air VG[ A/Y6 Fuel GF\ DF\UG]\ l;uG, Air flow
controller VG[ Fuel Flow controller GL ;[8J[<I] AGX[P DF\YL GLS/[, l;uG, Air
Flow controller DF\ Fuel air ratio device U]6MZ ( Ratio ) ;FY[ U]6FSFZ Y. CJFGF\
5|JFCGL DF\U ( Air Flow Demand ) GSSL YFI K[P VF Air Flow Demand V[ Air
Flow Controller DF\ ;[8J[<I] AG[ K[P
Air Flow Controller VF ;[8J[<I] VG[ ;FRF CJFGF\ 5|JFCGF\ ( Actual Air Flow ) TOFJT
5|DF6[ Error Signal 5\BF ( FD Fan ) GF\ Inlet vanes control Actuator DF\ I K[
VG[ T[GF\ VM5GL\UDF\ O[ZOFZ YX[ VG[ H~ZL CJFGM 5|JFC ( Air Flow ) HIF\ ;]WL GJL DF\U
pt5F G YFI tIF\ ;]WL VR/ ZFBX[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
$P!
D}/E}T A/T6 CJFG]\ lGIDG o ( Basic Fuel Air Control )

V[S OI]V, Z[lXIM JWFZFGL CJF ( Excess air ) GL U6TZL SZLG[ GSSL SZJFDF\ VFJ[
K[P DF\YL GLS/T]\ l;uG, VF Z[lXIM ;FY[ U]6FSFZ Y.G[ CJFGL DF\U GSSL YFI K[P VFDF\ 36LJFZ
JWFZ[ Excess air HJFGL XSITF ZC[ K[P JWFZFGL CJF S[8,L K[ T[ GSSL SZJF DF8[ VMG ,F.G
VMlS;HG V[G[,F.hZ D}SJFDF\ VFJ[ K[P VF V[G,F.hZ ACFZ GLS/TF JFI]VMDF\ outlet fuel
gases DF\ S[8,F\ 8SF VMlS;HGG]\ 5|DF6 K[ T[ ATFJ[ K[P VG]EJ 5ZYL ;FZFDF\ ;FZF NCG (
Optimum Combustion ) DF8[ S[8,F 8SF VMlS;HG ACFZ GLS/TF JFI]VMDF\ ZFBJM [.V[
T[ GSSL SZJFDF\ VFJ[ K[P
VMlS;HGG]\ 5|DF6 8SF s@f DF\ VF5JFDF\ VFJ[ K[ VG[ VF DF5GM p5IMU VMlS;HG
S\8=M,ZDF\ SZ[ K[P VMlS;HG H[8,F 8SF ZFBJ]\ CMI T[8,F 8SF ;[8 J[<I] S\8=M,ZDF\ D}SJFDF\ VFJ[ K[P
VF S\8=M,DF\YL GLS/T]\ +}l8 l;uG, V[Z OI]V, Z[lXIFGM lS\DT ( Value ) DF\ O[ZOFZ SZ[ K[P VF
J[<I]GL DF:8Z 5|[XZ S\8=M,ZDF\YL GLS/TF l;uG, ;FY[ U]6FSFZ Y. CJFGL DF\U GSSL YFI K[P
AM.,ZG[ H]NF\ H]NF\ ,M0 5Z R,FJTL JBT[ ;FZFDF\ ;FZ]\ ( Optimum ) VMlS;HG 5|DF6 D[/JJF
DF8[ JZF/GF\ 5|JFCGF\ DF5GM 56 VMlS;HG S\8=M,ZDF\ p5IMU SZJFDF\ VFJ[ K[P JZF/GM 5|JFC
VMlS;HG S\8=M,ZGL ;[8J[<I] GSSL SZ[ K[P CJ[4 ACFZ GLS/TF JFI]VMDF\ D5FTL VMlS;HGGL J[<I]
5Z AM.,ZDF\YL ACFZ GLS/TF JFI]VMGF\ Z:TFDF\ (Gas Duct ) YTL V[Z ,LS[H V;Z SZ[ K[P VF
,LS[H G[ SFZ6[ AG"ZM 5F;[ H[8,L JWFZFGL CJF [.V[ T[8,L D/TL GYLP VF D]xS[,LG[ N}Z SZJF DF8[
AM.,ZDF\YL ACFZ GLS/TF JFI]VMDF\ S[8,F\ 5|DF6DF\ Co K[ T[ DF5JFDF\ VFJ[ K[ H[GF DF8[ Co
V[G[,F.hZ D}SJFDF\ VFJ[ K[P AM.,Z VMKF\ ,M0 5Z RF,T]\ CMI tIFZ[ CJF VG[ A/T6G]\ AZFAZ
lDz6 YT]\ GYLP T[DH AG"ZG]\ 5ZOMD"g; AU0[ tIFZ[ CJF VG[ A/T6G]\ 5}Z[5]Z]\ NCG G Co YJFYL
G]\ 5|DF6 JWL I K[P VF GL J[<I]GM p5IMU S\8=M,Z DF\ VFJ[ K[P V S\8=M,ZDF\ VG]AJ 5ZYL ACFZ
HTF\ JFI]VMDF\ S[8,M Co CMI TM pD NCG YI]\ U6FI T[ GSSL SZLG[ T[ J[<I]G[ ;[8J[<I] TZLS[
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ZlXIMGL J[<I] 5|[XZ S\8=,ZDF\YL GLS/TF +}l8 l;uG, [0[ U]6FSFZ Y.G[ CJFGL DF\U AG[ K[ H[ Air
controller GL ;[8J[<I] AG[ K[P VF ;[8J[<I] T[DH TtSFl,G CJFGF\ 5|JFCGF\ TOFJT p5ZYL H[ +}l8
l;uG, AG[ K[ FD Fan T[ GF\ J[g; S\8=M, V[:rI]V[8Z DF\ I K[P OI]V, V[Z S\8=M,ZDF\ ;,FDlT
DF8[ CJFG]\ sV[Zf .g8Z,MS D}SJFDF\ VFJ[ K[ [ AM.,ZDF\ A?IF lJGFG]\ A/T6 ( Unburnt
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JZF/G]\ NAF6 VMK]\ YFI VG[ A/T6 VG[ CJFGL DF\U JW[ tIFZ[ [ A/T6 JW[ VG[ SM.S SFZ6;Z
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O,MS\8=M,ZDF\ V[Z OI]V, O,M S\8=M,Z A/T6 tIF\ ;]WL G JWJF N[ HIF\ ;]WL BZ[BZ CJFGF\ 5|JFCDF\
INDIABOILER DOT COM

DTP/BOT/ VI/030502
JWFZM G YJF ,FU[P VF DF8[ OI]V, O,M S\8=M,ZDF\ HTF\A/T6GF\ DFUGF\ 5|DF6DF\ HIF\ ;]WL BZ[BZ
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K[P V[SO,M 8=Fg;DL8ZDF\YL GLS/TF l;uG,G[ [.TF V[Z OI]V,GL 0LDFg0 JW[ TM OI]V,GL
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V[H ZLT[ HIFZ[ OI]V, 0LDFg0 38[ TIFZ[ VMS;LgIZ H[ V[Z S\8=M,ZDF\ HTF\ 0LDFg0 l;uG,GL
;lS"8DF\ D}SJFDF\ VFJ[, K[ T[ V[SI]V, O,M S[8,M K[ T[GL [0[ ;ZBFD6L SZLG[ H[ JWFZ[ CX[ T[
l;,[S8 Y. V[Z OI]V, Z[lXIM T0[ ;]WFZFJWFZM Y.G[ V[Z S\8=M,ZDF\ HX[ VG[ V[ZG[ H[ V[rI]V,
OI]V, O,M CMI T[G[ H~ZL [.TL CJF SZTF\ VMKL CJF YJF N[X[ GlCP
5P_
OZG[;DF\GF NAF6G]\ lGIDG o ( Furnace Pressure Control )

VF S\8=M, ,}5DF\ OZG[; 5|[XZ 8=Fg;DL8ZDF\YL GLS/T] l;uG, OZG[; 5|[XZ S\8=M,ZDF\ I K[P
S\8=M,ZGL ;[8J[<I] ;FY[ VF DF5JFDF\ VFJ[, J[<I] ;FY[ ;ZBFD6L SZL +]l8 ( Error ) l;uG, ID
Fan GF\ .G,[8J[GGF\ V[ZrI]V[8ZDF\ I K[ VG[ ID Fan GF\ .G,[8 J[GG[ H~lZIFT 5|DF6[ AM,
A\W SZ[ K[P ( Open / Close ) JWFZ[ ;FZL ZLT[ S\8=M, YFI T[ DF8[ ID Fan 0[dAZDF\ HJ]\ l;uG,
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H[D AG[ T[D VR/ H/JFI K[P VM5[l;8L DL8Z ( Opacity meter ), Co DL8Z4 O2 DL8Z
lJU[Z[ OZG[;DF\ A/T6 AZFAZ AG[ K[ S[ S[D T[GL VF+L SZJF DF8[ ACFZ GLS/TF\ JFI]VM ( Flue
gases ) GF\ lJ`J,[QF SZJF DF8[ JFI]VMGF\ Z:TFDF\ ( Flue gas path ) D}SJF H~ZL K[P VF
AWF\ DL8ZMwJFZF A/T6 D?IF lJGF HT]\ GYL G[ m JWFZFGL CJF IMuI 5|DF6DF\ K[ S[ GlC m lJU[Z[
GSSL YFI K[ T[DH A/T6GF\ S\8=M,DF\ OL0A[S TZLS[ p5IMUDF\ VFJ[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,Z cc 0=FO8cc s 5|JFC f

AF.,ZGF[ JZF/ pt5gG SZJFGF[ NZ A/T6 A/JFGF\ NZ 5Z VFWFZ ZFB[ K[P A/T6
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:8[8LS ( Static ) NAF6 ( Pressure ) GF\ TOFJT p5Z VFWFZ ZFB[ K[P VF :8[8LS NAF6GF\
TOFJTG[ 0=FO8 ( Draught ) SC[ K[P
AF[.,ZGF 0=FO8 pt5gG SZJFGF[ C[T]\
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#P
RLDGL DFZOT[ pt5gG YI[, O,]U[;G[ JFTFJZ6DF\ O[\SJF

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K[P
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
5FT/L VG[ VF[KL WGTF CF[JFG[ SFZ6[ RLDGLG[ Tl/I[ NAF6 VF[K]\ CF[I K[P VFYL JFTFJZ6GL CJF
tIF\ W;L HJFGF[ 5|ItG SZ[ K[P
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%,Fg8DF\ UZD JFI]G[ JFTFJZ6DF\ p\RF.V[ KF[0JF DF8[ H T[GF[ p5IF[U YFI K[P VFD SZJFYL
VF;5F;G]\ JFTFJZ6 :JrK ZC[ K[P
H~ZL 0=FO8 5[NF SZJF DF8[ RLDGLGL p\RF.G]\ ;]+
h = 353 H [ 1 (w+1) 1] 5F6LGF\ DLPDL
Ta
Tf
W = 1 kg fuel AF/JF DF8[ HF[.TL CJFG]\ JHG

Tf = Average absoulte Temp of Chimney fuel gas K
Ta = Absolute Temp of air outside the Chiney K
W+1 = O,]U[; pt5gG YTF\ T[G]\ JHG kg per kg of fuel burnt
H = RLDGLGL p\RF.
INDIABOILER DOT COM

DTP/BOT/ VI/030502
I = Static draught s :8[8LS 0=FO8 f

p5ZGF\ ;}+ FZF D/TF[ 0=FO8 V[ YLIF[ZL8LS, K[P JF:TlJS ZLT[ D/TF\ Static draught G]\ D]<I
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V[lgHGDF\YL ACFZ GLS/TL JZF/GF\ H[8 FZF 0=FO8 pt5gG SZJFDF\ VFJ[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
S]l+D 0=FO8 GF OFINF

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A/5|[lZT 0=FO8 o ( Forced Draught )

VF 5|SFZGF\ 0=FO8DF\ A/T6 DF8[ VF5JFDF\ VFJTL CJF JFTFJZ6GF\ NAF6 SZTF\ JWFZ[
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5|JFCL S[ JFI]~5 A/T6 J5ZFT]\ CF[I tIF\ 5|[lZT 0=FO8 ;F~ SFD VF5[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
5|[lZT 0=FO8 5\BF[ R,FJJF A/5|[lZT 5\BF[ R,FJJF DF8[ J5ZFTL XlST SZTF\ JWFZ[ XlSTGL H~Z 50[
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,ZGF\ 5F6LG]\ X]lSZ6

( BOILER FEED WATER TREATMENT )
5|:TFJGF o
SF[.56 AF[.,Z %,Fg8DF\ JZF/ ( Steam ) pt5gG SZJF DF8[ B}A H H~ZL VG[ VUtIGF[ SFRF[ 5NFY" (
Raw Material ) V[ 5F6L (Water) K[P VF H~ZL 5F6L VF56G[ H]NF H]NF :+F[T H[JF\ S[ GNL4 S]JF4
;ZF[JZ4 0[D lJU[Z[ DF\YL D/[ K[P VF 5F6LDF\ H[ T[ :Y/ D]HA T[DF\ W6L AWL VX]lVF[ CF[I K[P AF[.,ZDF\
5F6L VF VX]lVF[ N}Z SIF" AFN H JF5ZJ]\ B}A H H~ZL K[P 5F6LDF\ ZC[,L VF VX]lVF[ H]NL H]NL 5lT FZF
N}Z SZL XSFI K[P ;F{ 5|YD VF56[ H]NF H]NF 5|SFZGL VX]lVF[ VG[ T[ VX]lVF[ ;FY[G]\ 5F6L JF5ZJFYL X]\
G]SXFG YFI K[ T[ HF[.X]\P
!P_
5F6LDF\ ZC[,L VX]lVF[ VG[ T[GFYL YTF G]SXFG
!P!
5F6LDF\ ZC[,L VX]lVF[ D]bItJ[ GLR[ D]HA JC[\RL XSFIP
(A)
xI VX]lVF[ ( Visible Impurities ) H[GF A[ 5|SFZ K[P

(a)
;]1D ;JF[GL VX]l ( Microbiological Growth ) (b) VFjI VX]lVF[ VG[

0F[C/FX ( Sediments & Turbidity )
(B)
FjI VX]lVF[ ( Dissolved Gases )
(C)
WFT] VG[ 1FFZGL VX]lVF[ ( Metal & Salt Impurities )
(D)
S[l<XID VG[ D[uG[lXIDGL VX]lVF[ ( Hardness )
(E)
WFT]DI V[l;0 ( Mineral Acids )
!PZ
CJ[ VF56[ V[S 5KL V[S VX]lVF[ lJUT[ HF[.X]\ T[DH T[ VX]lVF[ ;FY[G]\ 5F6L AF[.,ZDF\
JF5ZJFYL X]\ G]SXFG YFI T[ 56 HF[.X]\P
(A)
NxI VX]lVF[ ( Visible Impurities ) H[GF A[ 5|SFZ GLR[ D]HA K[P
(a)
;]1D ;JF[GL VX]l ( Micro biological Growth )

BF; SZLG[ l:YZ ;5F8L WZFJTF\ 5F6LDF\ V[8,[ T/FJ4 ;ZF[JZ S[ VF[KF JC[6 JF/L GNLGF\ 5F6LDF\
DF.S|F[ VF[U["lGhD s ;]1D JF6]VF[ f H[JF\ S[ VF<UL4 A[S8[ZLIF4 :,Ld;4 0FI[8d;4 ;<OZ4 ;<OZ
ZL0I];L\U A[S8[lZIF lJU[Z[ pt5gG Y. T[GF[ lJSF; YFI K[P VF VX]lVF[GL CFHZL C\D[XF
Clogging GL TS,LO pEL SZ[ K[P
(b)
VFjI VX]lVF[ VG[ 0F[C/FX ( Sediments & Turbiaity )

8lA"8L0L V[ TZTL VFjI VX]lVF[ K[ HIFZ[ ;[l0D[g8; V[ :YFIL 5F6LDF\ GLR[ Tl/I[ A[;L HFI T[JF
H[JF S[ DF8L4 Z[TL SF\SZF lJU[Z[ H[JL JHGNFZ VX]lVF[ K[P VF VX]lVF[ 5F6LGF\ AWF\ H p5IF[UDF\
JF\WFHGS K[P
(B)
FjI JFI]VF[ ( Dissolved Gases ) : H[ D]bItJ[ GLR[ D]HAGF\ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
s!f
SFA"G0FIF[S;F.0 ( Co2) o S]JFGF\ 5F6LDF\ GLCFHZL JWFZ[ Co2 GL CFHZL JWFZ[ CF[I K[P ;5F8L
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sZf
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DF[8[EFU[ O2 GL CFHZL HF[JF D/[ K[P VF[KF TF5DFG[ VF[hF[GGL CFHZLG[ SFZ6[ 56 T[ 5F6LDF\ CF[I
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CF[I K[P
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T[GF ;/UL p9JFGF\ U]6WD"G[ SFZ6[ HF6L XSFI K[P T[GL CFHZLYL SIFZ[S VFU ,FU[ K[ VG[ W0FSF[
56 YFI K[P
s5f
CF.0=F[HG ;<OF.0 (H2S) o T[GL BF; 5|SFZGL U\WG[ SFZ6[ T[ 5F6LDF\ K[ S[ GlC T[GL HF6SFZL D/[
K[P AF[.,ZGF\ 5F6LDF\ T[GL CFHZLYL YTL ZF;FIl6S 5|lS|IFG[ SFZ6[ D]xS[,L pEL YFI K[P
(C)
(a)
(b)
(c)
(d)
(D)
WFT] VG[ 1FFZGL VX]lVF[ ( Minerals & Salts )

Iron s VFIG" f o ;FDFgI ZLT[ 5F6LDF\ O[Z; AFISFAF["G[8GF\ :J~5DF\ CFHZL CF[I K[4 H[ 5F6LDF\
FjI K[P D[U[\GLh 56 5F6F\ VFIG" SZTF\ VF[KF\ 5|DF6DF\ CFHZ CF[I K[ KTF\ 56 T[ 5F.5,F.GF[DF\
0L5F[hL8 YFI K[P sRF[\8L HFI K[Pf
;F[l0ID VG[ 5F[8FlXID ;F[<8; ( Sodium & Potassium Salts ) VF ;F[<8; 5F6LDF\
FjI K[ H[GL CFHZL AF[.,ZDF\ D]xS[,L pt5gG SZ[ K[P
S,F[ZF.0; (Florides ) o AF[.,Z DF8[GF\ 5F6LDF\ ZC[, S,F[ZF.0; V[8,]\ AW]\ SXF SZTF\ YL T[D
KTF\ T[GL CFHZL G CF[JL T[ .rKGLI K[P
l;l,SF ( Silica ) S]NZTL 5F6LDF\ l;l,SFG]\ 5|DF6 VF[KF JF 5|DF6DF\ HF[JF D/[ K[P p\RF NAF6
s 65 kg / cm2 S[ T[YL JW] f JF/F AF[.,ZF[DF\4 5F6LDF\ ZC[,L l;l,SF4 :8LDGL ;FY[ 8AF".GDF\
HFI K[P VG[ tIF\ T[ p\RF NAF6 VG[ TF5DFGG[ SFZ6[ ;BT :S[, pt5gG SZ[ K[P VG[ 8AF".GGL
a,[0L; VG[ GF[h, 5Z RF[\8L HFI K[P VG[ JZF/G[ 5;FZ YJF DF8[GF[ DFU" ;F\S0F[ SZL GFB[ K[P H[YL
8AF".GGL SFI" 1FDTF W8[ K[P ,F\AF UF/[4 a,[0G]\ Dl8lZI, lA|8, YJFG[ SFZ6[ a,[0DF\ G]ZXFG YJFGL
XSITFVF[ 56 ZC[ K[P
S[l<XID VG[ D[uG[lXIDGL VX]lVF[ ( Hardness ) :
S[l<XID VG[ D[uG[lXIDGF\ ;F[<8; s VX]lVF[ f4 SFAF["G[84 AFISFAF["G[84 S,F[ZF.0;4 ;<O[8 lJU[Z[
GF\ ~5DF\ D]bItJ[ CF[I K[4 H[ B]A H ;BT :S[, (Hard Scale ) pt5gG SZ[ K[P
VF :S[, pQDFGF\ JCG ( Heat Transfer ) DF\ VJZF[W pt5gG SZ[ K[P VF :S[, 5F.5 ,F.GGL
V\NZ HFDL HFI K[P VG[ JCGGF\ DFU"G[ ;F\S0F[ SZ[ K[P 5F6LDF\ ZC[, VF 1FFZF[GL CFHZLG[ CF0"G[;
(Hardness) SC[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
(E)
!P#
WFT]DI V[l;0 ( Mineral Acids ) AF[.,ZGF\ 5F6LDF\ T[GL CFHZLYL T[ WFT] HF[0L ZF;FIl6S
5|lS|IF SZ[ K[ VG[ WFT]G[ G]SXFG SZ[ K[P
AF[.,Z OL0 JF[8ZDF\ ;FDFgI ZLT[ HF[JFDF\ VFJTL ZF;FIl6S VX]lVF[4 T[GF\ 8[SlGS, GFD4
ZF;FIl6S ;\7FVF[4 ;FDFgI GFD T[DH T[GFYL YTL lJlJW V;ZF[ GLR[ VF5[, 8[A,DF\ NXF"J[, K[P
T[DF\ HF[. XSFX[ S[ :S[, (Scale ) AGFJTL D]bI VX]lVF[ ,F.D VG[ D[uG[lXIDGF\ S,F[ZF.0;
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;F[O8 :S[, (Soft Scale ) AGFJ[ K[P l;l,SF B}A H ;bT :S[, ( Very Hard Scale )
pt5gG SZ[ K[P VG[ H[ ;ZO[; 5Z ;F[O8:S[, CF[I T[G[ ;BT AGFJJFDF\ DNN SZ[ K[P
TABLE
G\
GFD
;\7F
;FDFgI GFD
V;ZF[
S[l<XID SFAF["G8
CaCo3
RF[S4 ,F.D
D:8F[G
;F[O8 :S[,
S[l<XID AFISFAF["G8
Ca ( HCo3)2
---
;F[O8 :S[,
S[l<XID ;<O[8
CaSo4
%;D %,F:8Z
;F[O8 5[lZ;
;BT :S[,
D[uG[lXID SFAF["G8
MgCo3
D[uG[;F.8
;F[O8 :S[,
l;l,SF[G 0FIF[S;F.0
SiO2
l;l,SF
;BT :S[,
D[uG[lXID ;<IO[8
MgSo4
Epson Salts
SZF[hG
( Corrosion
)
S[l<XID S,F[ZF.0
CaCl2
---
SZF[hG
D[\uG[lXID ;<O[8
Mg ( HCo3)2
---
:S[,4 SZF[hG
D[uG[lXID AFISFAF["G8
MgCl2
---
SZF[hG
10
;F[l0ID S,F[ZF.0
NaCl
;FDFgI DL9]\
.,[S8=F[l,l;;
11
;F[l0ID SFAF["G8
NaCo3
VYJF ;F[0F V[X
VF<SFl,lG8L
12
;F[l0ID AFISFAF["G8
NaHCo3
A[SL\U ;F[0F
5|F.lD\U4
OF[lD\U4
VF<Sl,lG8L
13
;F[l0ID CF.0=F[S;F.0
NaOH
SF[l:8S ;F[0F
V[DlA|8,D[g8
14
;F[l0ID ;<O[8
Na2So4
!P$
lJlJW VX]lVF[GL D]bI V;ZF[
VF<Sl,lG8L
INDIABOILER DOT COM

DTP/BOT/ VI/030502
!P
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!P
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!P
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p5Z H6FJ[, H]NF H]NF 5|SFZGL VX]lVF[GL D]bI V;ZF[ GLR[ 5|DF6[ K[P
:S[,G]\ pt5FNG ( Scale Formation )
SZF[hG ( Corrosion ) BJF6
OF[lD\U4 5|F.lD\U VG[ S[ZL VF[JZ ( Foaming, Priming and Carfyover )
SF[l:8S V[DlA|8,D[g8Z ( Caustic Embrittlement )
CJ[ VF56[ VF VX]lVF[GL V;ZF[ lJUTJFZ HF[.X]\
Scale Formation o OL0JF[8ZG]\ TF5DFG JWJFYL S[ S[l<XID VG[ D[uG[lXID ;<O[8 H[JF
1FFZF[GL FjITF W8[ K[ VG[ Scale Formation YJFGF[ NZ JW[ K[P
D]bItJ[ :S[, S[l<XID VG[ D[uG[lXIDGF\ 1FFZF[G[ SFZ6[ AFh[ K[P T[DH S[8,LSJFZ VFH :S[, l;l,SFGL
CFHZL G[ SFZ6[ l;D[g8GL H[D B}A H ;BT ZLT[ HFDL HFI K[P ZF;FIl6S 5|lS|IF GLR[ 5|DF6[ YFI K[P
Ca ( HCo3)2 + UZDL (Heat ) -------> CaCo3 s ;F[O8 :S[, f+ Co2 + H2O
Mg ( HCo3)2 + UZDL (Heat ) -------> MgCo3 s ;F[O8 :,H f+ Co2 + H2O
VFH VFjI :,H s S[l<XID VG[ D[uG[lXID SFAF["G[8 f WG:J~5[ HDF ( Settle ) YFI K[P H[
AF[.,ZGF\ GF[ZD, VF5[Z[XGDF\ U\ELZ ZLT[ D]xS[,L pEL SZ[ K[P 5F6LDF\ ZC[, VF[U["lGS 5NFYF[" H[JF S[
VF[.,4 U|L; JU[Z[ VF VFjI WG ZHS6F[G[ HFDJFDF\ AF.g0G]\ SFD SZ[ K[ VG[ VF AWF H ZHS6F[
l;D[g8GL H[D RF[\8L HFI K[P
Scale Formation o D]bItJ[ AF[.,ZGL 5F.5F[ VG[ 8I]AF[DF\ YFI K[[ T[GL V;ZF[ GLR[ D]HA K[P
AF[.,ZGL 8I]AF[DF\ T[ RF[SL\U ( Chocking ) SZLG[ JCGGF[ DFU" ;F\S0F[ SZL GFB[ K[ V[ T[G[ SFZ6[
5F6LG[ AF[.,ZDF\ DF[S,JF DF8[ JWFZ[ NAF6 VF5J]\ 50[ K[P
Scale Formation pQDFGF JCGG[ VJZF[W[ K[ VFYL AF[.,ZGL 8I]AF[DF\YL JCT[ 5F6LG[ JFI]VF[
(Flue Gases ) 5]Z[5]ZL UZDL D/L XSTL GYL VG[ AF.,ZGL 8I]AGL WFT] UZD YFI K[ VG[ V[
WFT] A/L 50L HFI K[ J/L A/L 50[,L 8I}A SIFZ[S O},L HFI K[P V[ Bag SC[ K[ H[DF\ SRZF[ s
:S[,f HDF YFI K[ VG[ K[J8[ V[ AF[.,Z 8I}A OF8L HFI K[P AF[.,ZGF\ Z[l0Ig8 CL8 hF[G S[ HFI
5F6LGL 8I}AF[ A/T6GF\ NCGGL ;FD[ H CF[I K[ tIF\ Scale Formation JWFZ[DF\ JWFZ[ YJFGL
XSITF CF[I K[P
AF[.,ZDF\ OL0 JF[8Z 5CF[\R[ T[ 5C[,F\ T[DF\ ZC[, S[l<XID VG[ D[uG[lXID VYJF l;l,SFG]\ 5|DF6
V[FK]\ VYJF N]Z SZL Scale Formation VF[K] SZL XSFI K[P AF[.,ZGL V\NZ Internal
Treatment FZF S[l<XID4 D[uG[lXID VG[ l;l,SF N}Z SZL XSFI K[P VYJF VF[KL SZL XSFI K[P
Internal Treatment 5lTDF\ OL0JF[8ZDF\ S[lDS, pD[ZJFDF\ VFJ[ K[P FjI VX]lVF[G[ RF[\8[
GlC T[JL GZD :,H (Sludge) AGFJL a,F[v0FpG (Blow-Down) DFZOT[ ACFZ SF-L
GFBJFDF\ VFJ[ K[P
AF[.,Z OL0JF[8ZG]\ p\R] TF5DFG h05L S[lDS, ZLV[SXG VG[ 8I}AF[G]\ p\R] TF5DFG pt5gG SZ[ K[
H[YL 8I}AG]\ Metal Sagging Point GL GS VFJL HFI K[ T[YL :S[, 5F[D["XG4 A[UL\U4
a,L:8ZL\U VG[ Z[%RZ JW] h05L SZ[ K[P B}AH p\RF NAF6 JF/F AF[.,ZF[DF\ OL0JF[8ZGL X]TF
(Purity) p\RL ZFBJFG]\ D]bI SFZ6 VF K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
ZP
CORROSION sBJF6f o SZF[hG V[8,[ WFG]\ BJF6 it is called as eating away

process of metal P BJF6G[ SFZ6[ WFG] GA/L 50[ K[P VG[ GSFDL AGL HFI K[P H[ DF[8]\
;DFZSFD S[ BRF"/ X8v0FpG (Shut-Down) VYJF EFUF[ AN,JF TZO NF[ZL HFI K[P
BJF6 (Corrosion) YJF DF8[GF\ SFZ6F[ GLR[ D]HA K[P
AF[.,Z OL0JF[8ZGL VF[KL pH s V[8,[ S[ Acidic Water f p5ZF\T T[DF\ ZC[, O2 VG[ Co2 GF\
SFZ6[ AF[.,Z4 .SF[GF[DF.hZ4 OL0JF[8Z CL8Z VG[ 5F.5F[DF\ S[ZF[HG YFI K[P
(a)
VF[lS;HG (O2) o OL0JF[8ZDF\ O2 GL DFgI DIF"NF ( Permissible Limit ) < 0.007 ppm
K[P p\RF 5|[XZ VG[ TF5DFG[ O2 GL V;Z h05L AG[ K[P V[ O2 A\W l;:8DDF\ D[SvV5 JF[8Z4
Sg0[G;Z ,LS[H VG[ Sg0[G;[8 5\5GL u,[g0 DFZOT[ NFB, YFI K[P
(b)
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VF V[l;0 WLD[ WLD[ Iron VG[ AL D[8, HF[0[ 5|lS|IF SZL T[VF[GF SFAF["G[8 AGFJ[ K[P VF GJF
pt5gG YI[, D[8,GF\ Bicarbonate UZDLYL HDF YFI K[P VG[ OZL V[SJFZ Co2 K}8F[ 5F0[ K[P
SFAF["lGS V[l;0G[ SFZ6[ SZF[hG YFI K[P
SZF[hG D[8, ;ZO[; p5Z 5L8L\U (pitting) VG[ U|]JL\U (grooving) pt5gG SZ[ K[ H[ D[8,GL
DHA}TF.G[ VF[KL SZ[ K[P VG[ H[GL V;Z l;:8DG[ lGQO/ AGFJ[ K[P
BJF6 (Corrosion) V8SFJJFGL q VF[K]\ SZJFGL ZLTF[ o
5F6LGL pH4 VF<S,L ;F[<8 V[l;l0S JF[8ZDF\ pD[ZL JWFZJFDF\ VFJ[ K[P pH JWFZJFYL SZF[hG W8[
K[P
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VFJ[ K[P
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(Deaeration) DFZOT[ N}Z SZJFDF\ VFJ[ K[P
CF.0=FlHS ( Hydrazine ) 4 8[lGG ( Trannin ) VG[ ;F[l0ID ;<O[8 ( Sodium
Sulphate ) H[JF lZ0I];L\U V[Hg8 DFZOT[ 56 O2 VF[KF[ SZL XSFI K[P
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Corrosion ) V8SFJL XSFI K[P
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OF[lD\U4 5|F.lD\U VG[ S[ZL VF[JZ ( Foaming, Priming & Carryover )
AF[.,ZDF\YL :8LD HF[0[ 5F6LGF\ h05YL O\SFJFGLq ;FY[ HJFGL lS|IFG[ 5|F.lD\U ( Priming )
SC[JFI K[P 5|F.lD\UDF\ B}A H h05L 5F6LG]\ ,[J, JWW8 YFI K[P VG[ 5F6LGF\ 5Z5F[8F h05YL O}8[
K[P H[ h05YL 5F6LG[ :8LD ;FY[ ,. HFI K[P VFYL AF[.,Z JF[8ZDF\ ZC[, :,H 56 :8LD ;FY[ O\[SFI
K[P
5|F.lD\U YJFGF\ SFZ6F[ GLR[ D]HA K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,ZGL VIF[uI ZRGF sl0hF.Gf
A/T6 AF/JFGL VIF[uI 5lTP
AF[.,ZG[ T[GL lGIT 1FDTF SZTF JWFZ[ 1FDTFYL R,FJJ]\P
AF[.,ZGF\ JZF/ pt5FNG SZJFGF\ 5|DF6DF\ h05L JWW8 SZJFYLP
AF[.,ZGF 5F6LGL ;5F8L 5Z GFGF :YFIL 5Z5F[8F4 ( Stable Bubbles ) pt5gG YJFGL lS|IFG[
OF[lD\U ( Foaming ) SC[JFI K[P
OF[lD\U YJFGF SFZ6F[ GLR[ D]HA K[P
JWFZ[ 50TF WG FjI 5NFYF[" ( High % of dissolved Solids )
JWFZ[ 50TL VFd,TF ( Excessive Alkalinity )
5F6LDF\ T{,L 5NFY"GL CFHZL ( Presence of oil in water )

OF[lD\UGL D]bI V;Z ~5[4 T[GF\ SFZ6[ JZF/ ;FY[ 5F6L VG[ 1FFZF[ HFI K[P VFU/ HTF\ JZF/GL
5F.5F[DF\ VF 1FFZF[ AFh[ K[ VG[ :S,[ pt5gG SZ[ K[P
5|F.lD\U S[ OF[lD\U G CF[I TF[ 56 JZF/GL V\NZ ZC[, 5F6LGF\ EFUG[ SFZ6[ VFjI 1FFZF[ JZF/ ;FY[
HFI K[ H[G[ S[ZL VF[JZ ( Carryover ) SC[ K[P
S[ZL VF[JZ YJFG]\ SFZ6[ 50% lDS[lGS, VG[ 50% S[lDS, D]xS[,LVF[ K[P
lDS[lGS, SFZ6F[DF AF[.,ZGL ZRGF4 5F6LGL JWFZ[ p\RL ;5F8L4 AF[.,ZG[ JWFZ[ 1FDTF 5Z R,FJJ]\
T[DH AF[.,ZGL pt5FNSTF (Load) DF\ h05L JWW8 SZJL lJU[Z[ D]bI K[P
HF[ AF[.,ZDF\ 5F6LGL ;5F8LGL p5Z :8LD :5[; ( Steam Space ) 5]ZTF\ 5|DF6DF\ CF[I TF[
AF[.,ZDF\YL ACFZ GLS.TL JZF/ ;FY[ 5F6L S[ ALHF\ VFjI WG 5NFYF[" HJFGL XSITF W6L W8L
HFI K[ S[ GlCJT Y. HFI K[[P HF[ :8LD:5[; VF[KL CF[I TF[ S[ZLVF[JZ YFI K[P
AF[.,ZG[ T[GL 1FDTF SZTF\ JWFZ[ 1FDTF 5Z R,FJJ]\4 AF[.,Z VFp8,[8 :8LD:8F[5 JF<J h05YL
BF[,JF[ VG[ B}AH h05YL JZF/G]\ NAF6 ( Steam Pressure ) JWFZJ]\ lJU[Z[ AAl,\U (
Bubbling) VG[ SZ[L (Carryover) VF[JZ GF SFZ6F[ AG[ K[P
5|F.lD\U4 OF[lD\ VG[ S[ZL VF[JZGL V;ZF[
JZF/ ;FY[ HTF\ 5F6LGF\ S6F[DF\ FjI VG[ VFjI :,H CF[I K[P VF :,H GF\ S6F[ JZF/GL 5F.5F[DF\4
JF<JDF\4 ;]5ZCL8ZDF\ VG[ V\T[ 8AF".GGL a,[0F[ p5Z HDF YFI K[P VF HDF YI[,F S6F[ JZF/GF\ 5|JFCG]\
1F[+O/ W8F0[ K[P 8AF".G VG[ ;]5ZCL8ZDF\ W;FZF[ pt5gG SZ[ K[ VG[ 8AF".GGL SFI"1FDTF W8F0[ K[P
5|F.lD\U4 OF[lD\ VG[ S[ZL VF[JZ VF[K]\ SZJFGL q V8SFJJFGL ZLTF[
AF[.,Z 0=DDF\ :8LD JF[XZ ( Steam Washer ) VG[ D[lSlGS, ;[5Z[8Z ( Mechanical
Separator ) S[ZLVF[JZG[ ;FZL ZLT[ lGI\+6DF\ ZFB[ K[P IF[uI DFJHT ( Internal
Treatment ) VG[ IF[uI ;DI[ a,F[0FpG ( Blow Down ) VF5LG[ S[ZLVF[ JZ W8F0L
XSFI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
5F6LDF\YL V[FU["lGS 5NFY" VG[ VF[., lJU[Z[G[ N}Z SZJFYL 56 S[ZL VF[JZ4 5F.lD\U VG[ OF[lD\U
W8F0L XSFI K[P
$P
Caustic Embrittlement sSF[l:8S V[DlA|8,D[g8 f

AF[.,ZGL WFT] ( Metal ) DF\ lS|:8,F.G lTZF0F[ ( Crystalline Crack ) pt5gG YJFYL
AF[.,ZGL WFT] sH[ DF[8[EFU[ :8L, CF[I K[Pf GA/L 50[ K[ VF 5|lS|IFG[ SF[l:8S V[DlA|8,D[g8 SC[ K[P
SF[.56 WFT]G[ ,F\AF[ ;DI ;]WL VF<S,F.G 5F6LDF\ ZFBJFG[ SFZ6[ T[DF\ Stress pt5gG YFI K[P
SF[l:8S V[DlA|8,D[g8 YJFGF SFZ6F[
!P
HIFZ[ AF[.,ZG]\ 5F6L Free Hydroxide Alkalinity VG[ YF[0L l;l,SF ( SiO2 ) WZFJT] CF[I
tIFZ[ Na2Co3 + HOH ------> Co2 + 2NaOH
ZP
lJlJW HF[.g8;DF\YL WLD]\ 5F6LG]\ l,S[H YT]\ CF[I tIFZ[
#P
H[ HuIFV[YL 5F6LG]\ l,S[H YT]\ CF[I T[ HuIFV[ HF[ AF[.,ZGL WFT]DF\ B}A H :8=[; pt5gG YI[, CF[I
tIFZ[ s Stress pt5gG YJFG]\ D]bI SFZ6 Faulty Riveting, misalignment VG[
Expansion K[ f
SF[l:8S V[DlA|8,D[g8 ZF[SJFYL q VF[K]\ SZJFGL 5lTVF[
!P
SF[l:8S V[DlA|8,D[g8 AF[.,ZGF\ 5F6LDF\ Causticity VF[KL SZLG[ VYJF TF[ Inhibiting
Agent pD[ZLG[ V8SFJL XSFIP
ZP
AF[.,ZGF\ 5F6LDF\ S[lDS, S\5F[hLXG AZFAZ HF/JLG[ T[DH 5F6LDF\YL AWF[ H Free NaOH N}Z
SZLG[ 56 SF[l:8S V[DlA|8,D[g8 W8F0L XSFI K[P
#P
OF[:O[8GF[ p5IF[U SZLG[ Free NaOH N}Z SZL XSFI K[P

HF[ OL0JF[8ZGL pH 8=F.;F[l0ID OF[:O[8 (Na3PO4) YL HF/JJFDF\ VFJTL CF[I VG[ H[ T[ HuIFV[
WFT]DF\ Stress pt5gG YI[, CF[I TF[ tIF\ Free NaOH GF\ AN,[ 8=F.;F[l0ID OF[:O[8 HDF YI[,
CF[I K[P
VFD4 OL0 JF[8ZDF\ Low Hydroxide Alkalinity HF/JJFYL4 H[ HuIFV[ Stress pt5gG
YI[, CF[I tIF\YL 5F6LG]\ l,S[H V8SFJJFYL VG[ Special Chemical Inhibiting Agents
H[JF S[ ;<O[8 l,SZ4 8[lGG VG[ ;F[l0ID GF.8=[8 lJU[Z[ pD[ZJFYL SF[l:8S V[DlA|8,D[g8 V8SFJL
XSFI K[ S[ VF[K]\ SZL XSFI K[P
ZP_
5F6LG]\ 5'yYSZ6 (ANALYSIS OF WATER )
ZP!
SF[.56 5F6LDF\ S[8,F 5|DF6DF\ S. S. VX]lVF[ K[ T[ 5F6LGL 5'yYSZ6GL DNNYL HF6L XSFI K[P
VF 5F6LGF[ ( Raw Water ) AF[.,Z JF[8Z sOL0 JF[8Zf TZLS[ p5IF[U SZTF\ 5C[,F\
T[DF\YL 8lA"l08L ( Turbidity ) VG[ ;[l0D[g8; ( Sediments ) H[JL VFjI VX]lVF[G[ 5[|;Z
lO<8Z4 U|[lJ8L lO<8Z VYJF TF[ SFl8"H lO<8Z FZF N}Z SZJFDF\ VFJ[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
HF[ 5F6LG[ VF[KF\ NAF6JF/F AF[.,ZF[DF\ p5IF[UDF\ ,[JFG]\ CF[I TF[ p5ZGF 5F6LG[ S[8FIG (
Cation ) lJSA[h V[GFIG ( Weak Base Anion ) VG[ :8=F[\U A[h V[GFIG ( Strong
Base Anion ) lJU[Z[DF\YL 5;FZ SZLG[ IF[uI 5lT D]HA 0LlDGZ,F.h JF[8Z ( D.M. water
) AGFJJFDF\ VFJ[ K[P
p\RF NAF6JF/F AF[.,ZF[DF\ JF5ZJF DF8[ D.M. Water DF\ ZC[, TDS VG[ SiO2 G]\
5|DF6 B}AH VF[K]\ SZJFDF\ VFJ[ K[P H[ DF8[ T[G[ lDS; A[0 ( Mixed Bed ) I]lG8DF\YL 5;FZ
SZJFDF\ VFJ[ K[P lDS; A[0 DF\YL ACFZ GLS/TF 5F6LG[ 5F[l,XJF[8Z ( Polish Water ) SC[JFDF\
VFJ[ K[P
ZPZ
D.M. Water VG[ Polish Water AGFJJF DF8[GF\ %,Fg8;G]\ ;FN]\ Z[BFlR+ ( Simple
Layout ) GLR[ NXF"J[, K[P
1.
D.M. Water Plant
3.
Polish Water Plant
INDIABOILER DOT COM

DTP/BOT/ VI/030502
ZP5
D.M. Water VG[ Polish Water AGFJJFGL 5|lS|IFG]\ 8}\SDF\ J6"G GLR[ D]HA K[P
!P
D.M. Water %,Fg8GF\ H]NF H]NF :8[H GLR[ H6FJ[, K[P
sVf
5|[;Z lO<8Z ( Pressure Filter ) o VFDF\ H]NL H]NL ;F.hGL Z[TLGF\ YZ CF[I K[ H[DF\YL 5;FZ
SZJFDF\ VFJ[ K[P 5F6LDF\ ZC[,L VFjI VX]lVF[ VF 5|[;Z lO<8ZDF\ N}Z YFI K[PHIFZ[ T[GL VFjI
5NFYF[" N}Z SZJFGL SFI"N1FTF W8L HFI tIFZ[ T[DF\ Back Wash s p\WF[ 5|JFC f VF5LG[ Z[TL ;FY[
RF\[8[,F[ VFjI VX]lVF[G[ N}Z SZL XSFI K[P
sAf
S[8FIG V[S;R[gHZ ( Cation Exchager ) o AWF\ H 5|SFZGF\ Cations H[JF\ S[ Na+, K+,
Ca+, Mg+, Al+ lJU[Z[ VFDF\ N}Z YFI K[P Cation Exchanger GL ACFZ VFJT]\ 5F6L
V[l;l0S CF[I K[P Cation N}Z SZJF DF8[ T[DF\ Zero Carb 225H+ GFDGF\ Z[lhGGF[ p5IF[U
SZJFDF\ VFJ[ K[P Cation N}Z SZJFGL SFI"N1FTF HIFZ[ W8L HFI tIFZ[ VF Exchanger G[ HCL
s CF.0=F[S,F[lZS V[l;0f J0[ lZHGZ[8 s OZLYL p5IF[UDF\ ,[JF IF[uI f SZJFD\F VFJ[ K[P
sSf
V[GFIG V[S;R[gHZ ( Anion Exchanger ) o T[GF A[ 5|SFZ K[ VYJF

1.
Weak Base Anion Exchanger
2.
Strong Base Anion Exchanger
Cation Exchanger DF\YL ACFZ VFJT]\ 5F6L 5|YD Weak Base Anion Exchanger
DF\ HFI K[ HIF\ Cl-, So4-, No3-, Co3-, HCo3-, Sio2-, lJU[Z[ Anion Z[lhG HF[0[ ;\IF[HFI
K[P VG[ N]Z YFI K[ VFDF\ Die Acidite FFIP VYJF H 8 R H[JF\ lZhg; J5ZFI K[P Weak
Base Anion Exchanger DF\YL ACFZ VFJT]\ 5F6L A[lhS CF[I K[P VFDF\YL ACFZ GLS/T]\
5F6L Degaser Unit DF\ HFI K[PHIF\ T[DF\ ZC[,F\ JFI]VF[ (Gases ) H[JF\ S[ O2, Co2, N2,
H2H lJU[Z[ N}Z YFI K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
Degaser Unit DF\YL ACFZ GLS/TF 5F6LG[ 5\5 DFZOT[ Strong Base Anion
Exchanger DF\ DF[S,JFDF\ VFJ[ K[4 HIF\ 5F6LDF\ ZC[,F\ Co2 - SiO2 N}Z YFI K[ P VF
V[S;R[HgZDF\ Die acidite HIP Z[lhGGF[ p5IF[U YFI K[P Anion GF\ lZHGZ[XG DF8[ SF[l:8S (
NaOH) J5ZFI K[P NaOH 5C[,FDF\ Strong Base Anion NFB, YFI K[P VG[ tIFZ 5KL
Weak Base Anion DF\ NFB, YFI K[P VFD AgG[ I]lG8F[G]\ lZHGZ[XG YFI K[P Strong
Base Anion DF\YL ACFZ GLS/TF 5F6LG[ TZLS[ VF[/BJFDF\ VFJ[ K[P
ZP
Polish Water : Polish water AGFJJF DF8[ D.M. Water G[ Mixed Bed Unit
DF\YL 5;FZ SZJFDF\ VFJ[ K[4 HIF\ AFSL ZC[, Cations ( + Ve Ions ) VG[ Anions ( -Ve
Ions ) N}Z YFI K[ VG[ JWFZ[ 5|DF6DF\ l;l,SF ( SiO2) 56 N}Z YFI K[P Mixed Bed Unit
DF\ A\G[ 5|SFZ GF lZhg; V[8,[ S[4 Cations N}Z SZJF DF8[Zero Carb 225H+ VG[ Anions
N}Z SZJF DF8[ Edie acidic HIP GF[ p5IF[U YFI K[P Mixed Bed DF\YL ACFZ GLS/TF
5F6LGL pH 6-7, conductivity 0.2 micro mho/cm, Sio2 0.01 ppm (
maxm_) VG[ TDS 0.1 ppm ( maxm_) CF[I K[P VF 5F6LDF\ Morpholine pD[ZL T[GL
pH J[<I] 8.8 9.0 H[8,L SZJFDF\ VFJ[ K[P VF 5F6LG[ Deaerator DF\ DF[S,JFDF\ VFJ[ K[P
HIF\ T[DF\YL FjI O2, Co2, H2s lJU[Z[ N}Z SZJFDF\ VFJ[ K[P VF FjI JFI]VF[4 5F6LG[ 105
110 ;[P H[8,]\ UZD SZL DF\ Deaerator :5|[ SZJFDF\ VFJ[ K[P H[YL JWFZFDF\ JWFZ[ 5F6LGL
;5F8L AG[ VG[ T[ JWFZ[ G[ JWFZ[ FjI JFI]VF[ K}8F 5F0[P Deaerator 5KL 5F6LDF\ AFSL ZC[,
VMlS;HG (O2) OL8 JM8Z 5\5GL ;S;G ,F.GDF\ CF.0=FlhG ( Hydrazine N2H4) G]\
0MhL\U SZJFYL N}Z YFI K[P
N2H4 + O2 = 2H2O + N2
VFD N2H4 V[ 0L VMS;LHGZ[8Z Z;FI6 K[ VG[ T[ FjI O2 G[ OL0JM8ZDF\YL N}Z SZ[ K[P T[ B}A H
XlSTXF/L GF.8=MHG AGFJ[ K[P JWFZFGF CF.0=MHGG]\ ;LW[;LW]\ 0LS\5MhLXG 56 YFI K[4 V[
V[DMlGIF VG[ N2 DF\ lJEFHG YFI K[P V[DMlGIF 5F6LGL pH J[<I]\ ;\TMQFSFZS ZLT[ /J[ K[P
#P_
5F6LGL pH J[<I] ( pH Value of Water ) :

pH J[<I] V[8,[ 5F6LDF\ ZC[,F 5MhL8LJ CF.0=MHGGF V6]G]\ 5|DF6P 5F6L T[GF\
V6]DF\YL K]8F 50[, CF.0=MHG (H+) VG[ CF.0=MS;L; (OH-) VFIG WZFJ[ K[P VF A\G[ VFIGDF\
5|DF6GM U]6FSFZ VR/ V[8,[ S[(10-14) CMI K[P X] 5F6LDF\ 25C TF5DFG[ AG[\ VFIGG]\ 5|DF6
;ZB]\ CMI K[4 V[8,[ S[(H+) G]\ 5|DF6 (10-7) U|FD V[S l,8Z 5F6LDF\ VG[(OH-) G]\ 5|DF6 56
(10-7)U|FD V[S l,8Z 5F6LDF\ CMI K[P HIFZ[ CF.0=MHG (H+) VFIGG]\ 5|DF6 JWFZ[ CMI tIFZ[
5F6L V[l;l0S SC[JFI K[P NFPTP pH J[<I] 5 GM VY V[ YFI S[ V[S l,8Z 5F6LDF\ (H+) VFIGG]\
5|DF6 (10-5) U|FD VG[(OH-)VFIGG]\ 5|DF6 (10-9) U|FD K[P V[H 5|DF6[pH J[<I] 9 V[8,[ 1
l,8Z 5F6DF\ (H+)VFIGG]\ 5|DF6 (10-9 ) U|FD VG[(OH-) VFIGG]\ 5|DF6 (10-5)U|FD VG[
5F6L A[lhS SC[JFI K[P VFD4 CF.0=MHG VFIGGF 5|DF6GF jI:TDF\ ,MU[lZWDG[ 5F6LGL pH J[<I]
INDIABOILER DOT COM

DTP/BOT/ VI/030502
SC[JFI K[P 5F6LGL pH 7 SZTF\ VMKL CMI TM 5F6L V[l;l0S VG[ 7 SZTF\ JWFZ[ CMI TM 5F6L
VF<S,F.G SC[JFIP VFD4 pH V[ TZ,5NFY sVYJF 5F6Lf GL V[l;l0STF VYJF A[lhS56]\
NXFJTM VF\S K[P
WFT]GF\ BJF6DF\ sVIlO\S .7l7lX71Ff DF\ 5F6LGL pH B}A H VUtIGM EFU EHJ[ K[P
VMlS;HGGL U[ZCFHZLDF\ VFIGGF SZMhGGM NZ 5F6LGL pH GF\ 5|DF6DF\ CMI K[P 9.6 pH J[<I]
V[ VF NZ B}A H VMKM Y. I K[ S[D S[ 9.6 pH J[<I] V[ CF.0=MHGJFI] pt5F YJFG]\ VG[ VFIG
5LU/JFG]\ A\W Y. I K[P H[D pH VMKL T[D SZMhGGM NZ JWFZ[P VF<S,LlG8L VG[ lO<D
OMD[XGGM ;\AW B}A H GSGM K[P lO<D OMD[XG tIFZ[ H YFI HIFZ[ VF<S,LlG8L VD]S Z[gHDF\
/JJFDF\ VFJ[P O[Z; CF.0=MS;F.8 ( Fc(OH)2) G]\ FJ6 9.6 pH V[ ;\T]%T AG[ K[P [ 9.6
pH SZTF JWFZ[ /JJFDF\ VFJ[ TM H~ZL VF<S,LlG8L VG[ VMYL ( Fc(OH)2) VFjI ZC[ K[
VG[ T[ Z1F6FtDS 50 TZLS[ SFD AJ[ K[P OL0JM8ZDF\ H~ZL VF<S,LlG8L ;M0FV[X4 SMl:8S ;M0F
VYJF 0=FI ;Ml0ID OM:O[8GM p5IMU SZL /JJFDF\ VFJ[ K[P
$P_
AM.,ZDF\ OL0JM8ZGL .g8ZG, l8=8D[g8 ( Internal Boiler Water Treatment )

AM.,Z HIFZ[ l:YlTDF\ CMI tIFZ[ T[GF\ 5F6LDF\YL VX]lVM N}Z SZJF DF8[ H[ ZF;FIl6S lS|IFVM
SZJFDF\ VFJ[ K[ T[G[ Internal Boiler Water Treatment SC[JFDF\ VFJ[ K[P
VFGM D]bIC[T] AM.,ZGF\ 5F6LGL U]6JF ;]WFZJFGM CMI K[P S[ H[YL SZLG[ :S[, OMD[XG4 SZMhG4
:8LD S\8FlDG[XG VG[ V[DlA|8,D[g8 V8SFJL XSFIP
AM.,ZGF\ 5F6LDF\ H[ T[ H~ZL S[lDS<;GM pD[ZM SZJFYL 5F6LDF\ ZC[,; VX]lVM 3G:J~5[ K}8L
50[ K[ H[G[ :,H ( Sludge ) :J~5[ ACFZ SF-L XSFI K[P SIFZ[S VX]lVM 1FFZMDF\ 5lZJlT"T YFI
K[P H[ G]SXFGSTF" CMTF GYLP
:8LD HGZ[XG %,Fg8 VG[ SF[vHGZ[XG %,Fg8;GF\ AWF\ H AF[.,ZF[DF\ 8=F.;F[l0ID OF[:O[8 (
Na3Po4) G[ AF[.,ZGF\ :8LD 0=DDF\ ;LW[ ;LW]\ pD[ZJFDF\ VFJ[ K[P
p\R]\ NAF6 VG[ TF5DFG S[ AF[.,ZF[DF\ CF[I T[DF\ ( Na3Po4) OL0JF[8ZDF\ pD[ZJFYL IF[uI 5|DF6DF\
VF<S,F.GGL l:YZTF D/[ K[P ( Na3Po4) T[GF\ VF<S,F.G :JEFJG[ SFZ6[ OL0JF[8Z 8=L8D[g8
DF8[ B}A H IF[uI K[P 5F6LDF\YL 9.5 SZTF\ JWFZ[ pH J[<I]V[ 1FFZF[ 3G:J~5DF\ JWFZ[ 5|DF6DF\ K}8F
5F0[ K[P 9.6 pH J[<I] V[ VF<S,LlG8L IF[uI 5|DF6DF\ H/JFI K[P VG[ VF VF<S,LlG8LV[
Fe(OH)2 G]\ Z1F6FtDS 50 ( Layer ) AG[ K[ H[ AF[.,ZGL WFT]G]\ BJF6 V8SFJ[ K[P
5.0
OL0JF[8Z VG[ AF[.,ZGF\ 5F6LGL DFgI DF+FVF[
5.1
OL0JF[8Z ( Recommanded Feed Water Limits )

OL0JF[8ZDF\ GLR[ H6FJ[, 8[A, 5|DF6[ H]NF H]NF 5[ZFDL8Z HF/JJF DF8[ E,FD6 SZJFDF\ VFJ[ K[P
No.
5[ZFDL8Z sU]6WDF["f
NAF6 &! YL NAF6 !_! VG[
INDIABOILER DOT COM

DTP/BOT/ VI/030502
!__ s AF[.,Z JWFZ[ s AF[.,Z

0=D kg / cmg 0=D kg / cmg
1
pH at 25C ( Copper alloy pre boiler 8.8 ~ 2

system )
8.8 ~ 9.2
pH at 25C ( Copper free pre boiler 9.9 ~ 9.2

system )
9.0 ~ 9.4
Oxygen ( maxm- ),. ppm
0.007
0.007
Total Iron ( maxm.) ppm
0.01
0.01
Total Copper ( maxm.), ppm
0.01
0.005
Total Co2
Nil
Nil
Total Silica ( maxm.), ppm
0.02
0.02
Hydrazine residual, ppm
0.01 ~ 0.02
0.01 ~ 0.02
Oil
Not allowed
Not allowed
5.2
AF[.,Z JF[8Z ( Recommanded Boiler Water Limits )

5[ZFDL8Z sU]6WDF["f
No.
AF[.,Z 0=D 5|[XZ AF[.,Z 0=D 5|[XZ

&! YL !__ kg / !_! VG[ JWFZ[
cmg
kg / cmg
Total Dissolved Solids ( TDS), ppm
Specific electrical
25C, rimhos / cm
Phosphat residual, ppm
15 ~ 25
5 ~ 10
pH at 25C
9.8 ~ 10.2
9.4 ~ 9.7
Silica ( maxim- ) ppm
To be conrolled
on the boiler
water and drum
pressure and
boiler water pH
relation
to
maintain less
that 0.02 ppm
in the steam
leaving
the
drum
Chlorides
Not allowed
conductivity
Not more that Not more that

100
50
at Not more that Not more that
200
100
Not allowed
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,Z OL0JF[8ZGL H~ZL pH V[DF[lGIF4 DF[OF[l,G H[JF AFQ5XL, ( Volatile ) S[lDS<; pD[ZLG[
HF/JJFDF\ VFJ[ K[P OL0JF[8ZDF\ VFJF AFQ5XL, S[lDS<;G]\ 5|DF6 1 ppm YL JWJ]\ HF[.V[ GCLP HF[ pH
T[GL recommanded range YL VF[KL YFI TF[ JZF/DF\ l;l,SF S[ZLVF[JZ YFI K[P VFYL AF[.,ZGF\
5F6LDF\ H[D A[G T[D l;l,SF VF[KL CF[JL HF[.V[ H[YL SZLG[ JZF/DF\ l;l,SFG]\ 5|DF6 0.02 ppm SZTF\
VF[K]\ ZC[P ALH]4 OL0JF[8ZDF\ VF[lS;HGG]\ 5|DF6 0.007 ppm SZTF\ VF[K]\ ZC[ T[ DF8[ IF[uI 5|DF6DF\
CF.0=F[hG ( N2H4) pD[ZJF[ HF[.V[P ;FDFgI ZLT[ OL0JF[8ZDF\ Z[;L0I]V, ( N2H4) 5|DF6 0.01 ~
0.02 ppm HF/JJF DF\ VFJ[ T[F VF[lS;HGG]\ 5|DF6 0.007 ppm SZTF\ VF[K]\ ZC[ K[P
INDIABOILER DOT COM

DTP/BOT/ VI/030502
AF[.,ZGL RSF;6L ( Boiler Inspection & IBR )
!P
ZP
#P
$P
5P
1923 GF\ EFZTLI AMI,ZDF\ lGIDM o ( IBR 1923 )

AMI,Z ;FDFgI 56 p\RF NAF6M s5|[;Z[f SFI" SZ[ K[ V[8,[ T[ NAF6 ;,FDTL GL DIF"NF DF\
ZC[ V[ AC] H~ZL K[P AMI,ZDF\ VS:DFTDF\ GCFlGGM VG[ DF,CFlG V[D A\G[ 5|SFZ GL CFlGGM
EI ZC[ K[ V[8,[ T[G]\ l:5[ZL\U SFI" VG[ 6J6LSFI" SF/5}J"S SZJFDF\ VFJ[ K[ AWF H N[XMDF\
SFINFSLI ZLT[ AMI,ZGL ;,FDTL DF8[GF\ VD]S lGIDM AGFJJFDF\ VFjIF K[P VF56F N[XDF\ VFJF
lGIDM ;J"5|YD 1923 DF\ AGFJJFDF\ VFjIF CTF VG[ tIFZ[ 5KL T[DF\ H~ZL ;]WFZFJWFZF 1961
DF\ SZJFDF\ VFjIF CTF\P H[G[ IBR 1923 SC[JFDF\ VFJ[ K[P s;]WFZFVMV[ DF\ SZ[, K[f VF IBR
5|DF6[ AWF H AM.,Z WZFJGFZFVMV[ SFINFSLI [UJF.VMGM S0S ZLT[ VD, SZJFGM ZC[ K[P
IBR GL D]bI [UJF.VM GLR[ D]HA K[P
AMI,ZG]\ Z:8=[XG RLO AM.,Z .g:5[S8Z 5F;[ SZFjIF 5KL H AMI,ZGM p5IMU SZL XSFI K[P
AMI,ZDF\ DCD NAF6 S[8,]\ ZFBL XSFI T[GM lG6"I AMI,Z .g:5[S8Z SZ[ K[P VG[ T[ DT,AG]\
;8L"O[S[8 56 YFI K[P AMI,Z WZFJGFZ jIlSTV[ UD[ T[JF SM.56 ;\[UMDF\ VF 5|DF6[GF\ ;}lRT
NAF6YL JWFZ[ NAF6[ AMI,ZG[ VM5Z[8 SZJFGL DGF. CMI K[P
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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INDIABOILER DOT COM

DTP/BOT/ VI/030502
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TUTORIAL FOR BOILER OPERATORS COMPETENCY EXAMINATION

p*v<B*(mki. (Pre Requisite)

pr)xi aipvi miT[ [et&> j$r) Xin:

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pr)xi aipvi miT[ um[dvirn) liykiti[

um[dvirn) u>mr 21 vP<Y) ai[C) n hi[v) [ea[.

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vriLni> g&NFmi[< (Properties of Steam)

pdiY< an[ t[ni> Av$pi[

pdiY<ni> m&yRv[ #iN Av$pi[ C[.

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j[n[ x vD[ dSi<vvimi> aiv[ C[.

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:8GF\ D]bI RFZ 5|SFZ K[P

Longitudinal Stays * A[ K[0FGL %,[8MG[ VFWFZ VF5JF DF8[

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AM.,ZGL V[;[;ZLh ( Boiler Accessories ) o T[ AM.,ZGF\ V[JF ;FWGM K[ H[ AM.,ZGL

AM.,ZG]\ JUL"SZ6 ( Classification of Boilers )

AM.,ZG]\ JUL"SZ6 GLR[ D]HA SZJFDF\ VFJ[ K[P

OZG[;GL l:YlT 5|DF6[ ( Internally fired or Externally fired )

CJ[ VF56[ H]NF\ H]NF\ 5|SFZGF\ AM.,ZM lJUT[ [.X]\P

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YD", VMlO;LIg;L (Thermal Efficiency ) 65% YL 68% sHIFZ[ T[ ;FDFgI l:YlTDF\

Simple Vertical Boiler

Scotch Marine Boiler lJU[Z[GM ;DFJ[X YFI K[P

VF NZ[S AM.,Z lJX[ 56 VF56[ 8}\SF6DF\ D[/JLX]\P

T[ SMd5[S8 K[ V[8,[ S[ 36L VMKL HuIF ZMS[ K[P

T[GL JZF/ pt5F SZJFGL 1FDTF JWFZ[ K[P

T[ VMKL lS\DTDF\ T{IFZ YFI K[P

T[G[ V[S HuIFV[YL ALH HuIFV[ ;C[,F.YL ,. H. XSFI K[P

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T[G[ V\NZ H.G[ ;OF. SZJFG]\ B}A D]xS[, K[P

T[GF\ p5IMU 5|DF6[ AM.,Z i.e. Stationary Marine

T[GF\ 0=DGL l:YlT 5|DF6[ i.e. Vertical, Cross Longitudinal

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T[GL 8I]AMGF\ 5|SFZ 5|DF6[ i.e. Straight tube Bent tube

T[DF\ 5F6LDF\ JCG 5|DF6[ i.e. Natural Circulation Forced Circulation

JM8Z8I]A AM.,ZGF\ U[ZOFINF

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;]5Z lSl8S, AM.,ZDF\ 5F6LqJZF/G]\ ;\lDz6 ( Two Phase Mixture ) G CMJFYL

T[G]\ VM5Z[XG B}A H ;Z/ K[P

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J[:8 CL8 AM.,Z o ( Waste Heat Boiler )

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AM.,Z .g:5[S8ZGM 8[:8U[H H ,UF0JFGL ;UJ0TF VF5[,L CMJKL [.V[P

AM.,ZGF\ DFpg8L\u; ( Boiler Mountings )

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J[.8 ,M0[0 ;[O8LJF<J ( Weight Loaded Safety Valve )

l:5|\U ,M0[0 ;[O8LJF<J ( Spring Loaded Safety Valve )

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Weight Loaded Safety Valve T[GF\ 56 A[ 5|SFZ 5F0L XSFI

Liver and Weight Safety Valve :

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= JF<JGM 0FIFDL8Z4 ;[DL

w = H~ZL JHG4 lSPU|FP

l:5|\U ,M0[0 ;[O8LJF<J ( Spring Loaded Safety Valve ) o VF 5|SFZGF\ JF<JG[

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0=[.G JF<J 5}Z[ 5}ZM BM,MP

pv<B(mki. (Pre Requisite)