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    Vol 2 Boiler and Auxillaries PDF Free

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    Shashank Prasad

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    THERMAL POWER PLANT FAMILIARISATION ATRL CUO ee Peer WAT) el aay Le 7; rn B®) Neti Complex, Sector - 33, Faridabad - 121 003, India ‘THERMAL POWER PLANT FAMILIARISATION VOLUME - It (BOILER AND AUXILIARIES) SNISWANATHAN DIRECTO! NPTLSR, NI NATIONAL POWER TRAINING An ISO 9001:2000 & ISO 14001 Organisation (Ministry of Power, Govt. of India) NPTI Complex, Sector-33, Fari MAY, 2006 SANTOSH, INSTITUTE, 121003 (INDIA) PREFACE TO THE THIRD EDITION \Volume-tt of the manual on ‘Thermal Power Plant Familieisation” which deals with Boller and Auxtiaries was fist pubished in December, 1999 as a general text for the trainees atending Graduate Engineers Course at NPTI. It was well received by the trainees, faculty ‘and others concerned with Human Rescurce Development in the Power Sector. “The Second Elion of ths volume was brought out in March-2003 which incorporates the suggeetions received from the users of the earlier tecition and was designed to sult the need of the students of One Year Post Graduate Diploma Course in Thermal Power Plant Engineering ‘conducted by NPTI ‘This manual has now been updated and revised with necessary ‘corrections and modfiations to make it more users friendly. This manual ‘wil serve as a valusble roference to the Engineers working in Power Stations | acknowledge the contribution of Shri SVishwanathan, Director, NPTI (SR), Neyveil in updating this manual [Any suggestions for improving this ecition ae cordially welcome ore, Te[aiae? (Or. N.S.Saxena) oe hos shych asticatronar nbieg bebe reals Faridabad ~ 121 003 PREFACE “Thermal Power Prants play a preminont role inthe tolst power generation inthe country. The eral component of the nsaled capacty at on cate ie about 75% and coal ie and wil ‘contrive tobe the basic ful fox most ofthe Thormal Power Szhemes a2 tha other sources Ihe. ‘land gas are imied. The stuaion a iti, vith the Woroace n coal requirements of Thermal Power Stations, the ually f coal ae gradually datorerated The average calorific value hes ‘come down fo about 3000°3600 heals and the ash contethas gone up as highes 45% As ‘oalis being produced in open caet mining, adopted ov alge Seale toincrease the roducion in ho shortest posable time, it has zandincusions shale, stones et, with dsastcus effect on {el preparation equpment and Boler components and auxliay equpments. The ash in fhe nian Coal contains a high percentage of Sica and Atrrina, wfich ae Nighy abiasve. Use of ‘uch coal leads fo excessive wear and tear of CHP equipments, Coal Mis Nol piping, Bumer 32008, Bojer funaces & tubular panels, casings of 1D fans and ash handing isposal ‘machinery affeciing fer avalablly and ife anc caus substantal increase in © & N costs, thus decreasing the overalulisaten ofthe installed capacty.altough he Indian coals have sdvaniage of low sulphur content, not excaading 0.5% and comparaively high ash fusion Temperatures which are conducive to economic Bellr design, thelr nigh Inen Content Nave posed dificur problems on account of highly abraswve nature In view of the large reserves of low.rade coal found in India, a debetate pokoy docision was taken to use hase low-grade coaster power generation. Power?Process Industy Bollers have. accordingly been designed over the fast to bur those Low grade Coals, Therefore the design (Ftho Boar and ls ausilares ie great infuenced by the quay of Coal ond sesh conten, ‘esutng inthe substantial neroase in tho cost of the equipment and every elf has to Bs ‘made bacod en tho experiance, food back and the avaiable Technology. These are the ‘comoeling reasons to undorsand the nlrate design ofthe Boker, is pressure pars and the line of equipments inthe ercut ight upto the chimney [NPT has brought out 2 compendium of 6 volames on “Thermal Power Plant Famiiastin’ Updating them fice time time 10 "use in wih the relevant upgraded technologies in Mor Subsequent edions. The author of Vat in he seres, Shn S. Vewanathan ta Dy Dvector at [NPTTs Southern Region sie at Heyvat. She Viewanathar, a very ave faccly member land protessona:raner is vigerousty associated wih tho furtherng of the sites dierso ‘cts contnoutng towards, is qualtatve progress and fostenng wnowedge base Iheps that the esta outreacn etfons of Sit Viswanathan in reshaping tho entre material rie ke New foxmal, systematcaly piecing together af relevant infomation would reach a wide culation of me engnsenng raterty tus tating the man cbyacives cf Lewy piscing the nireaie apees foreay assmiction and conceptual understanding, ‘Suvi M. Arunachalam, Principal Drecior, NPTI, Southem Region, Neyveli has been @ guiding force extoncing his good ofces erthusstcall in bringing cut ths eon, ‘Suggestions fom ai the usore emboh Pieced Eoejth (008K Ncw) Fandabod rector General est waloome. THERMAL POWER PLANT FAMILIARISATION - VOL.I (BOILER AND AUXILIARIES) CONTENTS sLNo, ‘Toric i Principles of Steam Generation 1 2 Development of Boilers - Types " & Boller Pressure Parts 2s ‘4 Draught System 8s s. Soot Blowers 140 6 Pulveriser Plant 4s B ue Firing System 176 8 Burner Management System 197 %. Emission Control System 204 CHAPTER 1 PRINCIPLES OF STEAM GENERATION 1.0 STEAM GENERATION + ‘Steam Generation is the process of converting water into steam, a vapor exhibiting the properties ofa gas by application of heat Heating water ot any ‘pressure evertslly will use it to boll and steam willbe released. 11 SENSIBLE HEAT: ‘The heat requced to tring the water from O°C 10 the boiling point is the enthalpy crest content ofthe liquid measured i Kealty. This also known as sensible heat, The sensible host required to bring the water to the boiling point depends on the pressure at which the water is heated. Higher the pressure, higher willbe the requirement of sensible hes 1.2 SATURATION TEMPERATURE ‘When required sensible hea is added to water, it starts boiling with the ‘comtinvation of hestadition, But both water and the seam remains tthe same ‘temperature though beats continued to be added tl he entire water is converted Imus seam, ‘This temperate ic the eataaion teraperatuee. For each beiling pressare there is only one saturation temperature and vice-versa, ‘The water and Steam at this temperature are termed saturated water and saturated. steam respectively. 13) LATENT HEAT: Daring the boing process that is after the water analns the saturation temperature, even though heat is being added the Lenpersture remains constant ‘This beat is being used to change the water from liquid to vapor state, This het is ‘the enthalpy of evaporation or the latent heat: Thus te latent heat isthe heat ‘equied to convert the saturaed water into saturated steam. Like sensible het the latent heat required also depends on the pressure at which boiling oscurs. Latent heat requirement decreses with increase in pressure. 14 CRITICAL POINT: Te can be seen in Fig. 1.1 with the increate in pressure for steam {eneraton, the sensible heat required increases with decease in latent heat. AL every pressure between saturated water and situated seam a phase called wet steam exists. However atone point the water turns into steam on addition of ‘rerenarunee Fig ht Sensible heat alone without going through the phase of wet seam. This occurs at ‘temperature of 374°C and 224.6 kg/cm’ absolute pressure, This pont is called as eitica! point ant pressure and saturation temperature corespending to this Point are the critical pressure and critical temperature. At critical point the density of water and steam remains the same 18 SUPER HEAT: ‘When the stam is heated out of contact wit water, the soar temperature Increases above saturation temperature. Such aheaing i known as super heating. (On superheatng of the seam, the enthalpy (hes! content) of the stm will Increase by the amount the hest Is aed and the temperature of sear alsa will ‘se. The rte at which the tempecsture rises depends to some degree on pressure, 2.0 HEAT TRANSFES For effecting steam generation, it is essential to transfer heat from a source {othe water. In an equipment like boiler where steam is generated all modes of| ‘heat transir viz. conduction, convection and radiation havea part in wansetring ‘the heat released during combustion to the bole water to make Hea 2.1 CONDUCTION ere ihe eat i ranfered ftom one part of ihe material the another or suas material through the molecules. Substances differ greatly in their bility to conduct heat. Gases and vapors ae the poorest conductors, igus ae ‘much beter ar metas are the best In boilers heat transfer through conduction thes plac from the outer to inner surface ofthe tubes carrying water for steam ‘zeneration or steam for supetbeating. 22 CONVECTION : Convection heat transfer takes place by the movement of the heated ‘medium. When Mid is heated its density decreases. If part of a uid mass i heated, the cooler, Heavier portion acts to displace the hested portion. Cooler portions become heated in tum atid are displaced. Result is continuous flow of cooler hid 10 the heated area and of heated Maid swey from i, setting up a convection cument, The moving bot fluid becomes the hest transfer medium. 3 The convection flow when caused by density difference alone is netural convection and if aided by a fan or pump it i freed convection. In a boiler ‘mostly the tutes receive the het fem the convectiond flow of hot gees from ‘combustion chamber Tumace). Also within theres te water or steam picks Up ‘he hea from inner sufsce ofthe tubes by convection. 23 RADIATION: All heated bodies radiate heat energy. Radiation does not require a Uuansmission medium and it travels through vacuum a well a8 through a. ga. Radiation taels lke light waves. The amount of energy a body radiates depends to some degree on is size, shape and substance but mainly on the fourth power of the body's absolute tmperature, Within a boiler all the tbe sections surrounding ‘he combustion chamber or nthe vicinity of face receive heat by raat 30 BOILING: ‘When a contsiner of water is heated, steam forms in bubbles a the ested surface. These bubbles are displaced by heavier — stam free water and ‘relation currents bring bubbles 1 the surface where seam is released. This proces, boiling, can take place in to ways i) Nucleate Boiling 1) Film Boning ‘M_—NUCLEATE BOILING: Fig 1.2), When the water doples. adhered t0 the inner surface of a container heated upon. receive the heat from the inner wall and the droplets ae individually ‘comerted imo steam babbles. As these bubbles grow in ie, they pet themselves ‘eth frm the wall and move up through the waterbody duet low density: Fig12. (Other water droples occupy their space and tis process continues as Tong 8 the container is heated, This proces of incividl bubble formation is termed 1s Nuclete Boiling, Under this condition the iner walls are always in contact ‘with water droplets snd sa the inner wall temperate nomally remain around the auction temperatre cocresponding to the presser. 32 FILM BOILING: Fig 3) 1 the heat fax (heat added per anit aten in unit ime) to the container is arvatly increased before individual bubbles detch from the wall more steam [bubbles uljacene 6 each aber Hl be Forme, These ajucens bubIeS of seam coalesce to form a steam film on the inner wall of the heating surfsce. ‘That i ‘ecween the inner wall and waterbody steam film, which isa poor conductor of het, wil be feemed. This ecuces the neat bw fom the heating surface to water ‘but the steam film gets superheated and so the metal temperature iezeases, This phenomenon is called Film boiling. The deviation of boiling process from Nuceate boiling condition to film boing is termed as Departre from Nucleste Boiling (DNB), Occurrence of DNB in steam generation provess leads 10 overheating ofthe meta Figi3 40° HEATING SURFACE: For evaporation of water ino steam, esentilly the water needs tobe held ina container, which has to be heated, The walls ofthe coataner, through wich heat is transferred to wate, fori the heating surface. boiler, which provides stoum of large quantity, must have sufficient hecting surface. Though the arrangement of heating surface ina boiler depends on the typeof boiler, for more practical purpose and in large capacity boilers generating steam for Power Generation or Industral applications the hscting suufees are in the form of round tubes. Through these tubes placed in beating zones water or steam will be circulated to receive sensible heat, latent heat and superbe. A boiler wil have number of cicuits of Resting surfaces sich as economiser, water walls, boiler bank, super heater and ze heater for effcielly sand seam. They may absorb eat Uransfrsing the hea of combustion othe wat either by radiation, convection or both, 6 30 CIRCULATION: Flow of water, steam or both through the the circuits of a boiler is termed as the Circulation. An adequste ciculatin is necessary fr all the cicuts to remove the heat and cool the heating surfaces thereby keeping the surfeces within the temperature Hits ofthe material Ta circuits where ware is evaporated into steam suficiert circulation wil be needed to avoid the deposit of salts fom water ‘on the surfaces (scaling). Ina circuit if the uid enters atthe inlet and leaves the outlet tothe next Circuit itis a once throagh system. If par of the Mud from the outlet of the circuit is returned fo the inlet ofthe same circuit it isa re circulation system. In boiler the following circuits always adopt once through system, })— Beoromiser i) Superheaters Rehesters Tn these civcits the inlet pressure of the fll effects the creation, The water wall or evaporator circuits of a boiler will have ether a ence through oF re Circulation system, Many boilers for these cixwits opt only recirculation system S41 CIRCULATION TYPES + In the evaporating circuits of a steam-generatng uit the circulation may iy by means of pamps or by a combination of the two, Accordingly there are thee be produced mau hy the action of the force of gravity, mechani 'ypes of cinelaion as flo: 1) Natural circulation ‘iy Forced circulation ii) Assisted creutation. SUL NATURAL CIRCULATION : NATURAL CIRCLLATION Fig 1. “Ths is adopted in recirculation systems. Inthe Fig. 4 water fom the ‘conomise circuit enters a drum and joins tbe creation system. Water sting the drum flows down through the dowa comer pipes kept in non heating zone an érters the bottom of the ater wall tobe, that isthe evaporator section. AS these tubes ae hese! by furnace radiation. a par of the water converte to stam and the misture flows back to the drum, In the drum the steam is. sept Rema ser and the Water mines with the incoming water from the evo «yet is repeated Thi som of steam generation is adopted to ji) preven the dissolved salts in water, pesipitating and depositing seale om the surface of tes shen all the water in the tubes evaporated te stam, fi) encase the inner alls OF the tubes are convinuously wetted with “water sa to have nile boing throughout the thes. “The circulation in this case takes place om the therm-siphon principle; “The dyn cenmers comin teatvely Gokd water, whereas the water wall thes contain seam water mixture, whose density is comparatively less. This density difference is the driving force for the mixture to over come the fictional resistance. Circulation thes place at such a rate thatthe driving force and ‘ictonal resistance are balanced Fig 1s. ‘As the prossue increases the difference in density between water and ‘steam seduces as shown in Fig 1. Thus the hydrostatic fead available will wot be able to ovoreome the fictional resisance for 4 How corresponding 10 the minivans requirement of cooling of water wall tubes. Therefore natural ‘tealation is Timite to boiler with drum operating pressure around 175 kyfem™ S12 ASSISTED CIRCULATION: Beyood 175 kglem? of pressure in a te circulation system, circulation Atreugh the evaporator is 10 be assed with mechanical pumps w9 overcome frictional losses im the tubes. A pump call Boiler ciulaion pump will be placed betwen the drum nd water wall abe inlet to do this faneton. In such a system some times to regulate the low through various tubes in sccondance tothe srnount of heat received orifice plates willbe used atthe inet of| the tuber, Such asystom is known as Controlled Circulation. S13 FORCED CIRCULATION ‘Inthe once through sysems of sub critical pressure or in bilers operating shove critical prestue, the water from the feed supply is pumped to the inlet end or ends of the heat absorbing circuits. This i called forced circulation, Evaporation or change of state gradually takes place along the length of he circuit and when evaporation is compet, further progress though the heated circuits resulls in superneating the vapor. Conventionally this type of forced circulation requires no steam and water érum. 52 CIRCULATION NUMBER ‘The cicaation namber isthe rao ofthe quantity of watersteam mixture ‘owing tough the circuit 1 the quantity of steam produced in the circuit. In oer won circulation number is 10, ‘The circu 11-10 kg of water is circuited for each hy of steam generated, the J mamber fora hoi willbe decided considering many factors especially t ensure nucleate boiling is maintained fr all operating conditions Higher circulation umber reduces the chnce of scale formation in evaporating tubes and DNS but eds more evaporating surface “The general practic opted for circulation number in varios boilers is Nawal Ciculaion Intstial boiler = 100 1S ii) Natural Circulation UityRoier 7109 iii) Assisted Citcuation boilers 2tod iv) Femsed CirculatensOnce through boiler ' 10 CHAPTER 2 DEVELOPMENT OF BOILERS ~ TYPES 19 INTRODUCTION “The wie of steam can be traced back as far as 150 BC. At about that time Hero of ‘Alexandre in his ueatise Pneumatica described about devices which wed the expansive forse aren to aise water above its natural level. The Egyptians may have used iteven crler but {owas ot antl 1712 tht ary development ofan Industrial nature took place. 20° BOILER: |A boiler or steam generator essentially i a container into which water can be fed and steam can be taken eut at desired presse, ermpeature and flow, Ths call for eppliation of Tesron the container, For that the boiler should havea facility to bum a fuel apd release the feat. "The function of a biker or steam generator thus can be staed.as i) to convert chemical nergy ofthe fe! into heat energy (i) 4 transfer this est energy to water for evaporation as ‘Jello steam for super heating. The working of blr is represented as a block diagram ia Fig2l FEED WATER srcaucrnerarion | > HEAT 4 HEAT GENERATION TRANSFER, 1 1 1 s 1 1 una one ont rucceuwans —H Byaporrive oats equipwenT Super EATER n Reenter f teoxomeer Saatheara AuAILIARIES &. ACCESSORIES EL PREPARATION RAIMT SYSTEM "Ast REMOVAL AS TRUMENTATIONETC. Fig 30 THREE GENERATIONS OF BOILER; Boiler design has teen an evolutionary process over the part three centuries, Verious {¥pes of Bclers have been developed to suit the requirements ofthe day. Developer one riented towards increased seam generating capability, efficieney. safety ct and Woutle fee Qpention. Though many types of boilers were developed almost ding tame Poros for somenience sake the development of boilers can be taken into broadly three pensrotions or follows FirstGeneraton = Shell Type Boiters Second Generaion - _ FreSmoke Tube Boilers Third Generation Water Tube Boilers, 341 SHELL TYPE BOWER: This sth earliest typeof boiler. Is a simple shell witha feed pipe and steam outlet, mounted ona trick sting called fumice. Fuel is barat on « grte within the sewing andthe heat released was directed over the lower shell sutfae before mcs Of It Went out Ue fing ‘Thete are many variants in this type basically on the shape ofthe shell. The shells are made of riveted wrought ion plates, SHELL TYPE BOILER, Fig.22. ira ‘The major disadvantage of shel type boiler is ts very low heat transfer area compared to the sll seating « single large vessel of water is emarkably inefficient. Further for {oe Sng seam generating capability the Size of the sell nly hast be incressed which has incre Limitations. ‘These boilers are generaing seam al very Jow pressures close to stmospherie pressure only 32. FIRE/SMOKE TUBE BOILER: Invention of steam engines in the 18% century called for better boilers of higher steaming copblides. To nee this requirement FreSmcke tube beers were devcloped. Here Stenptis rade to bring mote ofthe water into cese cont with the heat. This bole also faving a abel containing water ss shown in Fig.23. The hot combustion progucts (Fue gs) Fonte furnce are directed through the tubes within the sell and immersed in water, “The a ie niving provision forthe admission of feed water and to take out steam, ‘The water in {Pe ancl cools the hot geses passing through the tubes. The gases coming out ofthe totes are vos geal in-a smoke ex and et out ito the chimney. Such fire fube design not only Stoel more beating surface, but ako helps to dist seam fomnatin more uiformly rooghout the ms of water These types of Kolesar tli sein instil applications having a low steam demand. FUEGAS OUTLET. Sreqyeourter waTeRLewE —ARETUOES FIRE TUBE BOILER Pig23 ‘Thovgh the fire tbe boilers are heter than shell ype boilers stil there are certain ‘iicuies, Fire tabe boiler also needs a shel te hold the water for steam generation, the size of which has to be increased with inerease in steaming eepacky, The solid residues of ‘combustion present in the ho gases will sete inside the tues, thereby redace the heat transfer 1s well chote the tubes. Hence these boilers also will not be euitable for applications like Power generation where a large quantity of stam wil be recured, 33° WATER TUBE BOILERS : Development of water tube boilers in the late past of 18 century and early pat of 19° centary brought in evolutionary charges in boiler design. An early water tube teiler is shoan in Fig 24. Here feed water fom a lover drum is eicalated though a bundle of tubes called tobe ‘bank_‘The hot products of combustion from the famace pais over this tabe bank and heat is \rarsferred to water through the tube metal." Depending of ti amount of heat aed either all the water the tubes wll be evaporaced into steam bythe time it comes out of the tubes or part ‘ofthe water wil be converted ito steam witha water stem mixture coming oat ofthe tubes Inthe later ease the mixture from the tubes will be collectodina drum and ater separating the steam the remaining water wll be returned back to the inet ofthe wives. EARLY WATER TUBE BOILER 2. Compared to fire tube boilers, in water tube boilers hee is no problem of choking of the tabes bythe sold product of combustion. Any soot dept over the tubes ct be cleaned casily even during service. AS no single shell to hold the wer for evaporation fe reqpired and 4 the neam pneratn uke ce in sub-division (wes), itmakes posse fo eign Pole of Try large capacities and nigh pressures ‘osdy most oie biles wed fr industrial alewions and lost lth Doi ed fee eoccty pecan ace war be dain only, Many develonmest ave es BS 8 fer cle Sete bales over the lst two hundred years rake tem ow oS ae ely Than of mode power blr fom he esl water tab lk suse fn subsequent paragraphs. 40. EVOLUTION OF MODERN POWER BOILER sSimutaneous developments have taken place on all the specs of bles Wo, Stam enc ae’ Comaricn Charset, Ful abd Ait admisden, Fuel Fring System Flor coer ee, For eonvenence each one of thems dicussedsepartly 41 STEAM GENERATING CIRCUITS + “The amor developments in steam generating cits of a early simple water robe boiler ae the ieroducion of "Becnomiser, Re circulation Concept Boiler Dram with Steam Separators ‘Water walled furnace Sper beaters Re beats 4d ECONOMISER: Insp: water ae bier te ot gsc avg he tbe hank ae ving subg) 0am ats ot wo amspere I the pes det let otf he chimney, Te azovnt of he Aru of heat fem these. aces beeen te Hier bank tes 2 recover 0 goed Pir ae ioduced. Te fed wert te tlle f Gt passed oa tine. oo ete to the bank tabs. This prcheas te feed wae and consider these cil bet gon ery recone ago ant fest, whch RET aN ‘These coils of tes are named as Ezonomiser 412. RECIRCULATION CONCH: navwater tube boiler if the eat ation 10 te tubes isi sch 8 way to evaPert af oe 0A AT Gi to tam by te tine homes ont of bet iS called once, eee tha to ras the dsled salts mwa pes deste imide hess No 22 ead This depo called sele a por contr of hea Dus 0 the wate i apr air trace of ibe can not be ansered fly wo water. This 1 904 tea ee am eneton in tubes bet lctese he ube etal wma bobo hamper Fates To ener come this the het adion 10 he tbs wall Bm SU A ares and ahi ama acon of wart seam and aie ust of he besa mire of 5 vwatersteam only be received. This mincure directed into & seam separator is separated into steam and water. The water will be retumed back to the boiler tubes. This is called 8 1 circulation concept, Here the sats of weter will aot immediately deposit on the tes but sradully teir concentration build up in the boiler water. However by stable blow down procedures their concentation can he lowered te tolerable levels, Since, in the eerly days of boiler development and for that mater even til very recently no suitable meihod of water ieatment was available to provide totally a salt free water to boilers ost of the boters adopt only this re circulation concept to over come the scale ‘eposits in bole tubes, 4.3 DRUM WITH STAM SEPARATORS ‘With the introduction of recirculation concept, there is aeed for steam separation. These steam separators ae housed in a boiler drum, which collet the steam water mintre from the boiler tubes, Also the drum facilitates the mixing of water separated from the mintare with the ater from the economiser before returning the same to bole tubes 44 WATER WALLED FURNACE: BOILER WITH BANK TUBES Wig2s arly water tube boilers hat evaporating tubes (bank tes) placed seross the flue gas pth as in Fig.25, In this arrangement asthe gases moves form one buak of tube To anxber he a of heat transfer reduces du othe reducion in temperature grade. This call for increased est. transfer are at Iter stages tha will Rave practic limits and als increase cos. Fantr in sch 6 a type of othe combustion chamber sul wp with fie bik which is iefcee it many ae oy ee o produce mre eficet snd ecnemical eum gers tbe free we bait up with tbe walls called water walls. ‘The water for seam generation is eecloa ‘tough ths water wall ties, which recive. eat, ty radiation. With such

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