Boiler: Brief Introduction

BOILER
Brief Introduction
Satyakam
Mohapatra
Engineer(Mechanic
al)
Monnet Power Company Ltd
BOILER
In General, Aboileris a closed pressure vesselstrongly
constructed of steel or iron where water is converted to steam
by application of heat.
According Indian Boilers Act, 1923, Boiler" means a pressure vessel in which steam is generated for
use external to itself by application of heat which is wholly or
partly under pressure when steam is shut off but does not
include a pressure vessel,(i) with capacity less than 25 litres (such capacity being measured
from the feed check valve to the main steam stop valve);
(ii) with less than one kilogram per centimetre square design
gauge pressure and working gauge pressure; or
(iii) in which water is heated below one hundred degrees centigrade;
Usage of Boiler
In Power Sectors
In Independent Power Plant(IPP)
& Captive Power Plant(CPP).
In Process Plants
In Oil Refineries, Paper Industry,
Sugar Industry, Chemical

Industry, Rice mill, Steel Industry
etc.
Classification of Boiler
Criteria
Types
Content of Tube
Fire Tube Boiler, Water Tube Boiler
Type of firing
Solid, Liquid & Gas Fired
Type of Circulation
Natural Circulation, Natural

Assisted or Controlled Circulation,
Forced Circulation
Steam Pressure
Sub Critical Boiler, Super Critical

Boiler
Draught
Natural Draught, Mechanized

Draught(Forced, Induced,
Balanced)
Content of Tubes
Fire Tube
Water Tube
In fire tube boiler hot

flue gas will be moved
inside the tubes &
water outside the tube.
In fire tube boiler mode
of firing is generally
internally fired.
In fire tube boiler
operating pressure
limited to 25 kg/cm
In water tube boiler

water will be moved
inside the tube & hot
flue gases outside
the tubes.
Mode of firing is
externally fired.
Operating pressure
can exceed 125
kg/cm or more
5
FIRE TUBE
BOILER
WATER
TUBE
BOILER
Type of Firing
Solid
AFBC
Atmospheric
Atmospheric
Fluidized
Fluidized Bed
Bed
Combustion
Combustion
Bed
Bed Material
Material
Used
Used Crushed
Crushed
Refractory(
Refractory( +
+
0.8
mm
to
-2.8
0.8 mm to -2.8
mm)
mm)
Velocity
Velocity 3-5
3-5
m/sec
m/sec
Coal
Coal F-Grade,
F-Grade,
Washery
Washery Reject
Reject
Combustion
Combustion
EffEff- 80-85%
80-85%
Liquid
CFBC
Circulating
Circulating
Fluidized
Fluidized Bed
Bed
Combustion
Combustion
Bed
Bed Material
Material
Used
Used -- Crushed
Crushed
Refractory
Refractory (( +
+ 0.8
0.8
mm
to
-2.8
mm)
mm to -2.8 mm)
Velocity
Velocity 7-8
7-8
m/s.
m/s.
Coal
Coal F-Grade,
F-Grade,
Washery
Washery Reject
Reject
Combustion
Combustion Eff.Eff.95
%
95 %
Gas
PC
Fired
Pulverized
Coal Fired
Boiler.
Coal : F
Grade(30003500
Kcal/Kg) Size
is 65to 80.
No Bed is
Required
Combustion
Eff : 99 %
WHRB
Waste Heat
Recovery
Boiler
Waste Heat
from Flue
Gas of Other
process used
in boiler for
Steam
generation
AFBC
WHRB
CFBC
PC
Fired
Type of Circulation
Natural
Natural
Circulation
Circulation
Density
Difference is
the driving
force.
Limited to
boiler with
drum operating
pressure
around 175
kg/cm2(g).
Assisted/Controll
Assisted/Controll
ed
ed Circulation
Circulation
Beyond
Beyond 175
175 kg/cm2(g)
kg/cm2(g)
pressure
pressure in
in a
a re
re
circulation
system,
circulation system,
circulation
circulation through
through the
the
evaporator
is
to
be
evaporator is to be
assisted
assisted with
with
mechanical
mechanical pumps
pumps to
to
overcome
frictional
overcome frictional
losses
losses in
in the
the tubes.
tubes. A
A
pump
pump called
called boiler
boiler
circulation
circulation pump
pump will
will
be
be placed
placed in
in the
the down
down
comer
between
the
comer between the
Drum
Drum &
& water
water wall
wall
ring
header
to
ring header to do
do this
this
function
is
called
function
is Ltd
called
Monnet Power
Company
controlled
circulation.
controlled circulation.
Forced
Forced
Circulatio
Circulatio
n
n
Mechanical
pumps are
used to over
come the
frictional
losses
Operating
pressure is
above 224.6
kg/cm2(g)
9
SH
SH
SH
SH
SH
SH
Separator
ECO
ECO
Drum
ECO
ECO
Water
from
Feed
Statio
n
Drum
Furnac
e Wall
Furnac
e Wall
BCP
BCP
W
W
W
W
CC
CC
Pump
Pump
Distributio
Distributio
n
n Header
Header
Natural
Circulation
Distributio
Distributio
n
n Header
Header
Assisted
Circulation
Economiser
Economiser
Forced
Circulation
10
Steam Pressure
Sub Critical
Boiler
Super Critical
Boiler
Boilers Operating below

the Critical
Pressure(224.6
kg/cm2(g)).
These are recirculation
type or once through .
Steam Drum is required
to separate water &
steam.
Boilers Operating above

Critical Pressure (224.6
kg/cm2(g)) & Critical Temp
(374 00C)
These are only Once
Through Type.
Drum is not required as
cycle medium is a single
phase fluid having
homogenous property.
11
DRAUGHT
Natural
Draught
Mechanized
Draught
Forced
The draught
required for the
flow of air & gas
inside the boiler
is created by
chimney alone
Here
Here Fans
Fans are
are
used
to
draw
used to draw
air
air from
from
atmosphere
atmosphere &
&
push
into
the
push into the
furnace.
furnace.
The
The entire
entire
boiler
boiler will
will be
be
kept
above
kept above
atmospheric
atmospheric
pressure
pressure
Induce
d
Fans
Fans installed
installed
at
at the
the outlet
outlet of
of
boiler,
boiler,
evacuate
evacuate the
the
gases
from
gases from
furnace.
furnace. So
So a
a
negative
Pr.
negative Pr. Is
Is
developed
in
developed in
furnace
furnace &
& air
air
from
from
atmosphere
atmosphere
enters
enters the
the
furnace
furnace
Balanc
ed
Both
Forced &
Induced
draught
fans are
used to
derive the
benefits of
both
systems.
12
Boiler Mountings
Safety Valves
Feed Check Valves
Pressure Gauge
Drum Water Level gauge
Blow Down Valve
Main Stop Valveetc
Boiler Mounting are basically used for safe

operation of Boiler.
13
Description of Boiler Mountings

Safety Valve : The Function of a safety valve is to blow off steam
when the pressure in the boiler exceeds the working pressure.

Feed Check Valve : A feed check valve is used to control the supply
of feed water to boiler & also to act as a non-return valve.

Pressure Gauge : Pressure gauge indicates the pressure of steam in
a boiler.
Drum Water Level Gauge : The Function of water gauge glass is to
indicate the water level in the Drum.

Blow Down Valve : Blow down Valves are designed for continuous
use to control the concentration of dissolved solids in boiler water.

Main Stop Valve : Function of a steam stop valve is to stop or allow
the flow of steam from the boiler to Main Steam line.
14
Specification of Boiler
(Monnet Power Company Ltd)
Maker :
Bharat Heavy Electricals Ltd
Boiler Maker No :
Type :
Controlled Circulation, Sub Critical, Two Pass, Single
Reheat,
Balance draught, Tangential PC Fired.
0675,0676
Boiler Rating :
51793 m 2
Boiler Drum Design Pressure :
Boiler Hydrotest Pressure :
315 kg/cm2(g) ,(For RH-78 kg/cm2(g) )
Boiler Drum Design Temp :
369 OC
Steam flow at SHO:
Steam pressure at SHO:
Steam temperature at SHO:
Reheat Steam flow:
Steam pressure at RHI:
Steam temperature at RHI:
Steam pressure at RHO:
Steam temperature at RHO:
Boiler Efficiency:
210 kg/cm2(g)
1700TPH
192.2 kg/cm2(g)
540OC
1468.1TPH
52.4 kg/cm2(g)
337 OC
52.4 kg/cm2(g)
540OC
Monnet Power
86 %Company Ltd
15
Boiler Pressure parts

The Following parts generally comes under this
category
Drum
Economiser
Water Walls
Radiant Roof Tubes
Steam Cooled Walls
LTSH Coil
Div Panelette SH
Platen SH
Rehaeter Coil Assy.
16
RH O/L Hdr
17
18
Water Circuit
Feed
Water
Statio
n
ECO
Feed
Pipe
Water
Wall
Outlet
Headers
ECO I/L
Header
Water
Wall
Tubes
ECO
Coil
Botto
m Ring
Header
ECO O/L
Header
Down
Comer
ECO
Link
DRUM
19
BOILER DRUM
In
Separation
a Sub-Critical re-circulation boiler, the

drum plays an important role. In the
erection of a Power Boiler, the lifting of the
Boiler Drum is the first mile stone activity.
The Functions of Drum are
of saturated steam from the steamwater mixture produced by evaporating tubes.

Mixing feed water from economiser and water
separated from steam-water mixture, and recirculate through the evaporating tubes
Carrying out blow down for reduction of boiler
water dissolved solid concentration.
Treatment of Boiler Water by chemicals
20
TECHNICAL DATA OF DRUM

210 kg/cm2(g)
Operating Pressure
197 kg/cm2(g)
Water Holding Capacity
60 m3
Design Temperature
369 0C
No of Cyclone Separator
92(46X2)
No of Secondary Drier
124
OD of Drum
1778 mm
Thickness
155 mm
(Straight Portion/Dished Portion)
Weight of Drum without Internals 214.7 MT
Design Pressure
21
SH
Conn
Pipe
Stubs
4
5
2
Taping No
Safety
Valve
Stub
Riser
Stub
Feed
Nozzle
Details
Qty(In Nos)
DWLG & EWLI
15 (Both Side)
Test Tapings
Air Vent
Chemical Feed Nozzle
DWLG & EWLI
15 (Both Side)
DC
Nozzle
22
STAGES OF STEAM & WATER SEPARATION :
Separation takes place in the concentric cylinder of Turbo

separator.
The second stage of separation takes place in the
corrugated sheets connected to the top of the Turbo
separator.
The third and final stage of separation takes place in
Screen Driers.
The Anti Vertex spider is provided at the inlet of Down
comer to avoid whirl formation in DC.
The main components of Boiler Drum:

Turbo separator
Screen Dryer
Baffle Plate
Anti Vertex Spider
23
Drier
Drier Assembly(62X2)
Assembly(62X2)
Drum Internals of MPCL

Boiler
Turbo
Turbo
Separat
Separat
or(2X46
or(2X46
))
Separatin
Separatin
g
g
Chamber
Chamber
Feed
Feed Header
Header
DC Nozzle
Feed
Feed Nozzle
Nozzle
24
TURBO SEPERATOR
25
Economiser System
O Application of economisers is to capture the heat
from flue gas and transfer it to the feed water.

This raises the temperature of the boiler feed
water, lowering the needed energy input, in turn
increases efficiency.
O Total System Consists of ECO feed line, Eco I/L
Header, ECO Coil Assy, ECO O/L Hdr, ECO Link to
Drum.
TECHNICAL DATA
No of Banks
3 Banks( 92 Sets)
Total Heating Surface

of ECO System
20,000 Sq. Mtr
Total Water Holding

Capacity
150 m3
26
Description
Size
(DiaXThick)
(In mm)
Design
Temp( 0C)
Design Pressure
(kg/cm2(g))
ECO Feed Pipe
457.2X50
283
219.7
ECO Inlet
Header
508X65
283
215
ECO Coil
38.1X4.5
336
215
ECO Outlet
Header
406.4X60
353
210.8
ECO Link to
Drum
368X40
323.9X36
357
210.8
27
ECONOMISER COIL
28
Water Wall System

O The water walls are tube panels through which
the water for steam generation will be

circulated. In Water Wall only heat is added to
evaporate the feed water to steam.
O It also forms the major part of furnace
enclosure.
TECHNICAL DATA
Design Temp & Pr. at WW
Inlet Hdr
3680C & 212 kg/cm2(g)
Design Temp & Pr. at WW

Outlet Hdr
3680C & 209 kg/cm2(g)
Total Heating Surface of WW

Tubes
7000 Sq.Mtr
Water Holding Capacity of

Circulating
System Ltd
Monnet
Power Company
170 m3
29
Description
Size
(DiaXThck)
(In mm)
Design Temp( 0C) Design Pressure

(kg/cm2(g))
Down Comer
368X36
368
212
Bottom Ring
Header
914X85
368
212
WW Tubes
51X5.6/6.0/7.1
63.5X7.1
396
214
Front, Hanger Tube

& Screen Tube O/L
Header
273X40
368
209
Side WW O/L
Header
273X50
368
209
Riser Pipes
159X18
368
209
30
Plate
n SH
WW
Panel
s
Div
SH
Pan
el
31
CC PUMP
Boiler water circulating pump is used in
high capacity boiler (Super critical or Sub
critical), It assists the circulation of water, to
overcome the friction losses in Boiler.
Make :
Torishima
Type :
Single Suction-Double discharge
No of Pumps :
Three
Design pressure :
210 kg/cm2(g)
Hydr0 test pressure : 315 kg/cm2(g)
Design Temperature : 366 oC
Motor Rating :
350 KW
Full Load Speed :
1450 rpm
Suction Pressure :
197kg/cm2(g)
Quantity Pumped : 48453 l/min(2850 tph)
Wt. of Motor :
7300 kg
Wt. of Pump casing :
5200 kg
32
Riser
Riser
s
s
Saturated Steam Circuit

Sat Steam
DRUM
SH
SH Rear
Rear
Roof
Roof
Tubes
Tubes
Junctio
n Hdr
BP
BP
Upper
Upper
Rear
Rear
Wall
Wall
SH
Conn
Pipes
Rad
Rad
Roof
Roof I/L
I/L
Hdr
Hdr
Fur
Fur
Roof
Roof
Panel
Panel
SH
SH
Roof
Roof
O/L
O/L Hdr
Hdr
BP
BP L/R
L/R
Side
Side Upp
Upp
Hdr
Hdr
BP
BP
Front
Front
Wall
Wall
BP
BP
Front
Front
Lower
Lower
Hdr
Hdr
SH
SH BP
BP
Lower
Lower
Side
Side
Front
Front
Hdr
Hdr
BP
BP L/R
L/R
Side
Side
Wall
Wall
Panel
Panel
SH
SH
Rear
Rear
Hanger
Hanger
Tube
Tube
SH
SH
Rear
Rear
Int.
Int.
Hdr
Hdr
LTSH
I/L Hdr
ECO
ECO
Support
Support
Tube
Tube
BP
BP
Lower
Lower
Rear
Rear
Wall
Wall
BP
BP
Lower
Lower
Rear
Rear
Hdr
Hdr
BP
BP
Lower
Lower
Side
Side
Rear
Rear
Hdr
Hdr
33
Saturated Steam Circulation System

Description
Size
(DiaXThick)
(In mm)
Design Temp
( 0C)
Design Pressure
(kg/cm2(g))
Rad Roof Inlet Header
273X50
369
208.8
Fur Roof Panel
57X6.0
414
208.8
Rad Roof O/L Hdr
406.4X55
369
208.2
BP L/R Side I/L. Hdr
368X48
368
208.0
BP L/R Side Panel
63.5X6.3/7.1.
51.0X5.0/5.6
393
208.0
SH BP Lower Side
Front Hdr
406.4X60
393
207.4
SH BP Front Lower Hdr
406.4X60
393
207.4
BP Front Wall
51X5.0/5.6
63.5/6.3
393
207.4
BP Front Hanger Tubes
51X6.3
394
207.4
Contd..
34
Description
Size
(DiaXThck)
(In mm)
Design Temp
( 0C)
Design Pressure
(kg/cm2(g))
SH Rear Roof Panel
51X5
394
206.8
SH Rear Junction Hdr
273X50
395
206.7
BP Rear Upper Wall
51X5
395
206.7
BP Lower Side Rear Hdr
323.9X50
393
206.3
BP Lower Rear Hdr
323.9X45
393
206.3
BP Rear Lower Panel
44.5X5
394
206.3
ECO Support Tubes
44.5X7.1
393
207.4
SH Inter. Hdr
219.1X28
393
207.3
SH Hanger Tubes
51X11
394
207.2
Total Heating Surface of SH Roof 830 Sq Mtr

Total Heating Surface of Steam Cooled Wall 2010 Sq. Mtr
35
Superheated Steam Circuit

LTSH
I/L Hdr
LTSH
Coil
LTSH
O/L Hdr
SH DESH
Link
Div SH
I/L Hdr
SH Vertical
Platen I/L
Hdr
SH Div
Panel O/L
Links
Div SH
O/L Hdr
SH Div
Panelette
Assy
MS Line
SH Vertical
Platen Assy
HP
Turbine
SH Platen
O/L Hdr
MS Line
36
Super Heater System

O Superheater is a component of a boiler that superheats
steam i.e. heats steam above its saturation temperature.

Superheated steam contains more thermal energy and
increases the overall efficiency of the cycle.
O There are 3 stages of Super Heaters LTSH, Divisional
Panelette SH & Platen Super Heater.
TECHNICAL DATA
No of Sets
LTSH-62 Sets, Divisional

SH- 24 Sets, Platen SH 25
Sets
Total Heating Surface
LTSH -10,100 m2, Div SH

-2025 m2, Platen SH 2200
m2
Total Water Holding

Capacity of SH system
130 m3
37
Superheater System
Description
Size
(DiaXThick)
(In mm)
Design Temp( 0C) Design Pressure

(kg/cm2(g))
LTSH I/L Hdr
323.9X50
395
205.8
LTSH Horizontal
Assy.
47.63X5.6
445
205.8
LTSH Terminal Tube

Assy
47.63X5.6
464
205.8
LTSH O/L Hdr
457.2x65
435
204.2
SH DESH Link
508x60
558x60
440
426
204.0
SH Div I/L Hdr
406.4X60
419
202.8
Contd..
38
Description
Size
(DiaXThick)
(In mm)
Design Temp( 0C)
Design Pressure
(kg/cm2(g))
SH Div. Panelette
Assy
44.5X5
44.5X7.1
483/
522
202.8
Div. SH O/L Hdr
406.4X70
487
198.9
SH Div Panel O/L

Link
508X60
487
198.6
SH Vertical Platen
I/L Hdr
406.4X60
487
197.4
SH Vertical Platen
Assy
63.5X6.3/12
51X6.3/11
476/533
476/551
197.4
SH Platen O/L Hdr
508X110
540
192.2
39
LTSH COIL
40
Div SH Panel
41
Platen SH
42
Reheater Circuit
CRH
Line
From
HP
Turbin
e
Exhau
st
RH I/L
Hdr
RH Coil
Assy
IP
Turbin
e
RH O/L Hdr
(F)
RH O/L Hdr (R)
HRH
Line
43
Reheater System
O Reheater is a boiler component in which heat is
added to intermediate-pressure steam, which

has lost some of its energy in expansion through
the high-pressure turbine.
O Reheater System comprises of : RH Inlet Header,
RH Front Platen Coil
Assy, DATA
RH Rear Spaced Assy,
TECHNICAL
RH
Outlet
Header
No of
RH Coil Assy
74 Sets (Both Front & Rear)
Total Heating Surface of RH Coils
7628 Sq. Mtr
Total Water Holding Capacity of RH
105 m3
Design Temp. & Pr. at RH Inlet Hdr
361 0C ,52.4 kg/cm2(g)
Design Temp. & Pr. at RH Outlet Hdr
540 0C,52.4 kg/cm2(g)
Size of RH front Coil Assy
63.5 mm Dia X 4 mm Thck

54 mm Dia X 4.5 mm Thck
Size of RH Rear Coil Assy
54 mm Dia X 4.5 mm Thck
44
RH Coil Assy
45
H.
R.
H
C.R.H
M.S
Boiler
Drum
Platen
SH
RH
Coil
Assy
DC
LTSH
CC
Pump
Div SH
ECO Coil
Furnace Wall
FROM F.C.S
WATER
SATURATED STEAM
SUPER HEATED STEAM

Bottom Ring Header
46
REHEATED STEAM
Air Flow path

PA Fan
FD Fan
Col
d
PA
to
Mill
FD Fan
SCAPH
SCAPH
Pri.
Sid
e
Hot PA
to Mill
Flu
Flu
e
e
Gas
Gas
APH
Sec
Sid
e
Col
d
PA
to
Mill
SCAPH
SCAPH
Scann
er Air
fan
Wind Box
PA Fan
Sec
.
Sid
e
Flu
Flu
e
e
Gas
Gas
APH
Pri.
Sid
e
Hot PA
to Mill
47
Forced Draught Fan

These fans supply air necessary for fuel combustion for
proper burning of the specific fuel. These are generally

axial type.
The FD fans supply secondary & over fire air, which is
preheated in secondary sector APH.
Over fire air can be admitted to the furnace through the
upper levels of furnace wind box nozzle to assist in
reducing the amount of NOx formed in furnace.
Control of airflow to WB is effected by FD fan blade pitch
control & distribution of secondary air to WB
compartments is controlled by secondary air damper.
Steam Coil Air Pre Heater(SCAPH) are provided in the by
pass ducts before each APH to prevent corrosion of cold
end of APH normally at start up & low load operation.
48
Suction
Chamber
Blades
Forced Draught Fan
Diffuser
49
50
Primary air fan

These fans supply the air needed to dry & transport coal from
coal mills to the furnace. These fans are generally axial type of
fan.
To achieve the required temperature at mill inlets(For Proper
Drying of Coal) , part of air(Tempering air) by passes the APH &
is mixed with hot air coming out of APH.
The PA Fan blade pitch is modulated to maintain a pre
determined pressure in pulveriser hot air bus duct.

Mill Air flow is maintained by adjusting the hot air regulating
damper while the mill outlet temp is maintained by adjusting

the cold air regulator damper. Venturi is provided in the mill
inlet duct to measure the individual mill air flow.
51
Suction
Chamber
Diffuser Assy.
Primary Air
Fan
Monnet
Power Company Ltd
52
1st
Stage
Blade
2nd
Stage
Blade
Primary Air Fan

53
Technical specification of Fans

Description
Unit
PA Fan
FD Fan
Make
N.A.
BHEL
BHEL
Type
N.A.
PAF 19/10.6-2
FAF 23/12.5-1
Motor Rating
KW
3600
1200
Capacity
M3/Hr
105
215
Speed
rpm
1490
990
Pressure
mmwc
1290
410
Temp of
Medium
Handled
50
50
Bearing
Lubrication
N.A.
Oil
Lubrication(ISO
VG68)
Oil
Lubrication(ISO
VG68)
54
Air Pre Heater
The purpose of APH is to recover heat from
the boiler flue gas & heat air before another

process and so as to increase the thermal
efficiency.
Ljungstrom (Regenerative) Air Pre Heater:
The basic component of Ljungstrom APH is a
continuously rotating cylinder, called rotor, that is

packed with thousands of square feet of specially
formed sheets of heat transfer surface.
As the Rotor revolves, waste heat is absorbed
from the hot flue gas passing through one half of
the structure. The heat transfer cycle is
continuous as the surface are alternatively
55
exposed to the outgoing gas & incoming air
56
Technical Data
Description
Value
Type
Regenerative, Trisector
No per Boiler
Two
Rotor Diameter
6789 mm
Arrangement
Vertical
Heating Surface Area
84200 M2
Main Drive
18.5 KW,1500 rpm
Aux. Drive
Air Motor with gear box & muffler, Air

consumption 8 Nm3/min at pressure 6.33
kg/cm2(g)
57
Soot blowers
As the flue gas moves over the heat transfer
areas of boiler, the ash deposits on the

heating surfaces. This is known as soot
deposit. Soot Blowers are installed to blow
away these soot deposits to facilitate smooth
heat transfer.
There are two types of Soot Blowers-Wall
Blowers & Long Retractable Soot Blowers.
Wall Blowers are used to blow off soots
deposited in water walls in furnace
LRSB are used in Super Heaters, Economiser
& Reheater Zone.
58
WALL
BLOWER
LRSB
59
WALL BLOWER
60
Technical Data
Description
Unit
Wall Blower
LRSB
No per Boiler
No.
88+16(Future)
40+18(Future)
Travel
mm
305
9700
Blowing Pressure
kg/cm2(g)
11
12.5/10.5
Blowing Steam Temp
383
383
Speed of Travel
mpm
6.1
1.55
Speed of Rotary
rpm
0.7
5.87
Blowing Rate per group
Kg/min
89
152/93/79
Blowing time per group
Min
1.4
12.04
Operating time per cycle
Min
66
75.12/325.52/100
.16
Steam Consumption per

cycle
Kg
5500
47708
Steam Consumption
/Cycle/Blower
Kg
62.5
1192
Total Steam Consumption per Day
Kg
Blowing Steam Temp &

Pr.
Cycles per Day
Monnet Power
No Company Ltd
3
159624
383 0C & 30 kg/cm2
3
61
14 kg/cm2(g)
250 0C
LDO & HFO Circuit
PRS
PRS
LDO cap.50m3/hr & Pr.- 2

Kg/cm2
HFO cap.HFO
50m3/hr & Pr.- 5
Pump
Kg/cm2
s
LDO
Pump
s
Unloadin
g Pump
House
4.5 kg/cm2(g)
232 0C
Tanker
Tanker 1
1
12KL
12KL
Tanker
Tanker 2
2
12KL
12KL
Tanker
Tanker 3
3
12KL
12KL
HFO
HFO
Tank
Tank #1
#1
3000
3000
3
m
m3
HFO
HFO
Tank
Tank #2
#2
3000
3000
3
m
m3
LDO
LDO
Tank#
Tank#
1
1
1000
1000
3
m
m3
LDO
LDO
Tank#
Tank#
2
2
1000
1000
3
m
m3
Contd
..
Tanker
Tanker 4
4
12KL
12KL
Tanker
Tanker 5
5
12KL
12KL
Tanker
Tanker 6
6
12KL
12KL
Monnet Power Condensate

Company LtdLine to Flash
LDO Unloading
Header
HFO Unloading
Header
LDO Discharge Line
HFO Discharge 62
Line
LDO & HFO Circuit

LDO
LDO
Tan
Tan
k
k
2X1000
m3
HFO
HFO
Tank
Tank
2X3000
m3
1x100
LDO
LDO
%
Pump
Pump
Set(Both
Set(Both
Units)
Units)
Forwarding Pump
House
HFO
HFO
Pump
Pump
Set(Unit
Set(Unit
I)
2x100
I)
Boiler
I
Boiler
II
%
HFO
HFO
Pump
Pump
Set(Unit
Set(Unit
II)
II)
HFO
HFO
Heater-1
Heater-1
Steam
Tracin
g Line
HFO
HFO
Heater-2
Heater-2
HFO
HFO
Drain
Drain
System
System
14
kg/cm2(g)
210 0C
Steam
Tracin
g Line
Aux.
Steam
Condensate Line
63
to Nearest Trench
Technical specification of hfo & Ldo

Description
Unit
LDO
HFO
Standard
N.A.
IS 1460-1974
IS-1593/1971/Gr
HV/Oil
Flash Point
66
66
Pumping Temp.
35
55
Firing Temp.
35
120
Viscosity
cst
2 to 20 @Firing
Temp.
180 at 55 0C
Total Sulphur
N.A.
1.8 % by
weight
4.5 % by weight
GCV
Kcal/kg
10720
10270
Sp. Gravity at
15 0C
N.A.
0.85-0.87
0.85-0.95
64
Technical specification of HFO & LDO Forwarding Pumps

Description
Unit
LDO Pump
HFO Pump
Make
N.A.
Alekton
Alekton
No of Pump per Blr
No
01(Common for 01
Both Unit)
Model No.
N.A.
DH 330-770-3
DH 600-1400-3
SJ
Capacity at max cst
lpm
281(14.3 tph)
879(50.1 tph)
Speed
rpm
2920
1450
Suction Pressure
kg/cm2(g) -0.5
-0.5
Delivery Pressure
kg/cm2(g) 25
30
Motor rating
KW
18.5
75
Motor Make
N.A.
Crompton
Greaves
Crompton
Greaves
Bearing Lubrication
N.A.
Grease IS 719
Gr.3
Grease IS 719
Gr.3
Pump Efficiency(at min

%
78
cst)
83.7
65
TT burners assy.
OVER FIRE AIR
UPPER
HFO OIL BURNERS
OVER FIRE AIR

LOWER
HH
H
END
END
AIR
AIR
COAL
COAL
OIL+AI
OIL+AI
R
R
COAL
COAL
FG
AIR
AIR
COAL
COAL
OIL+AI
OIL+AI
R
R
COAL
COAL
DE
AIR
AIR
COAL
COAL
OIL+AI
OIL+AI
R
R
COAL
COAL
BC
AIR
AIR
COAL
COAL
OIL+AI
OIL+AI
R
R
COAL
COAL
GH
EF
CD
AB
A
AA
END
END
AIR
AIR
Service
Ignition of Pulverised Fuel, Stabilization

of Coal Flame at lower loads etc.
Capacity Maximum
30 % MCR
No of Oil Guns
16(4 per elevation)
Locations
Aux air nozzles AB,CD,EF & GH
HFO flow per Gun
2420 kg/hr(Max), 950 kg/hr(Min)
HFO Pressure
10.5 kg/cm2(g)(Max), 4.0 kg/cm2(g)

(Min)
Atm. Steam Flow/Gun
250 kg/Hr
At. Steam Pr.
5.25 kg/cm2(g)
LDO OIL BURNERS

Service
Initial startup & warm-up.
Capacity Maximum
7.5 % MCR
No of Oil Guns
4(In One Elevation)
Locations
Aux air nozzle AB
LDO flow per Gun
2420 kg/hr(Max), 950 kg/hr(Min)
LDO Pressure
10.0 kg/cm2(g)(Max), 3.5 kg/cm2(g)

(Min)
Atm. air Flow/Gun
241 kg/ Hr
At. air Pr.
5.25 kg/cm2(g)
66
Coal Circuit
Coal
From
CHP
To
four
corne
rs of
Boiler
Coal
Bunke
r
Feeder
Pulveriser
Pulveriser
67
Flue gas path
1404
0
C
Combusti
Combusti
on
on
Chamber
Chamber
1150
0
C
1040
0
C
Plate
n SH
Div
SH
904
0
C
7100C
RH
Coil
LTSH
Coil
ESP
ESP
Pass
Pass A
A
3340C
541
0
C
APH
1270C
ID
ID
Fa
Fa
n
n
ESP
ESP
Pass
Pass B
B
Economise
r
ESP
ESP
Pass
Pass C
C
3340C
APH
ID
ID
Fa
Fa
n
n
127
0
C
C
H
I
M
N
E
Y
ESP
ESP
Pass
Pass D
D
68
Flue Gas Path
-19 mmwc
-33 mmwc
-79
mmwc
-5 mmwc
ESP
-213
mmwc
-270
+32
mmwc mmwc
APH
69
C
H
I
M
N
E
Y
Electrostatic Precipitator : Anelectrostatic
precipitator(ESP) is a highly efficient filtration

device that removes fine particles, like dust and
smoke, from a flowing gas using the force of an
induced electrostatic charge minimally impeding
the flow of gases through the unit.
No of pass per boiler : 4
Gas flow at inlet : 566.7 Nm 3/s
Temp. at inlet : 127 0C
Dust concentration at inlet : 86.8 gm/Nm 3 (Worst
Coal), 70.69 gm/Nm3 (Design Coal)

Dust concentration at outlet : 50 mg/Nm 3(Worst
Coal)
Efficiency : 99.942 %
70
Induced Draught Fan : ID Fans evacuate
combustion products from the boiler furnace by

creating sufficient negative pressure to establish
a slight suction in furnace.
Make : BHEL
No per Boiler : Two
Model No. - NDZV 47 SIDOR
Fan Regulation : Inlet damper & VFD
Temp. of Medium : 150 0C
Motor Rating : 3800 KW
Flow : 565 m3/Hr
Draught at Inlet : -270 mmwc
Draught at Outlet : 32 mmwc
Bearing Lubrication : Oil Lubrication(ISO VG68)
71
INDUCED DRAUGHT FAN
Suction
Chambe
r
Motor
Rear
Side
Bearin
g
Discharge
Chamber
Front
Side
Bearin
g
Impelle
r
72
Thanks
73

Boiler: Brief Introduction

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Boiler: Brief Introduction

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BOILER

Monnet Power Company Ltd

Monnet Power Company Ltd

Sugar Industry, Chemical

Fire Tube Boiler, Water Tube Boiler

Solid, Liquid & Gas Fired

Natural Circulation, Natural

Sub Critical Boiler, Super Critical

Natural Draught, Mechanized

In fire tube boiler hot

Monnet Power Company Ltd

In water tube boiler

Monnet Power Company Ltd

Monnet Power Company Ltd

Boilers Operating below

Monnet Power Company Ltd

Boilers Operating above

Boiler Mounting are basically used for safe

Monnet Power Company Ltd

Description of Boiler Mountings

when the pressure in the boiler exceeds the working pressure.

of feed water to boiler & also to act as a non-return valve.

indicate the water level in the Drum.

use to control the concentration of dissolved solids in boiler water.

the flow of steam from the boiler to Main Steam line.

Bharat Heavy Electricals Ltd

Controlled Circulation, Sub Critical, Two Pass, Single

Balance draught, Tangential PC Fired.

Boiler Drum Design Pressure :

Boiler Hydrotest Pressure :

315 kg/cm2(g) ,(For RH-78 kg/cm2(g) )

Boiler Drum Design Temp :

Steam flow at SHO:

Steam pressure at SHO:

Steam temperature at SHO:

Reheat Steam flow:

Steam pressure at RHI:

Steam temperature at RHI:

Steam pressure at RHO:

Steam temperature at RHO:

Boiler Pressure parts

Monnet Power Company Ltd

Monnet Power Company Ltd

Monnet Power Company Ltd

Monnet Power Company Ltd

a Sub-Critical re-circulation boiler, the

of saturated steam from the steamwater mixture produced by evaporating tubes.

TECHNICAL DATA OF DRUM

Water Holding Capacity

(Straight Portion/Dished Portion)

Weight of Drum without Internals 214.7 MT

Monnet Power Company Ltd

DWLG & EWLI

Chemical Feed Nozzle

DWLG & EWLI

Monnet Power Company Ltd

STAGES OF STEAM & WATER SEPARATION :

Separation takes place in the concentric cylinder of Turbo

Monnet Power Company Ltd

The main components of Boiler Drum:

Drum Internals of MPCL

Monnet Power Company Ltd

from flue gas and transfer it to the feed water.