TRAINING ON

BOILER SYSTEM DISCRIPTION

BANGAAI AMMONIA PLANT (BAP)

By Mr. PRASHANT M. PATIL
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 BANGAAI AMMONIA PLANT (BAP)

 TRAING ON OPERTION AND MAINTENANCE

OF FM BOILER
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BOILER SALIENT FEATURES

 FM means Fully Modular
 Packaged, shop / site assembled & fully modular boilers
 Bi-drum, bottom supported design with
water cooled furnace.
 Suitable for firing : Natural gas firing
 Fully drainable super heater
 Drum coil pre-heater to increase feed water inlet
temperature to Economizer
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BOILER SALIENT FEATURES

• Fully drainable superheater

• High efficiency steam separators

• Drum coil pre-heater to increase feed water inlet

temperature to Economizer
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•MCR –68TPH

•Steam Pressure – 46.9 Kg/cm2 (g);

•Design Pressure – 57.5 Kg/cm2 (g);

•Steam Temperature – 387 °C

•Design – ASME SECTION I EDITION 2013

•Performance Testing – ASME PTC 4.1(Heat Loss Method)

•Design Fuel- Natural Gas

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Typical
Steam
Sectional View
Drum

Superheater

Convection bank

Membrane
Furnace Wall

Outer Casing
Water
Wind Box
Burner Drum
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Water Circulation circuit
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 Flue Gas Path

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P&ID DESCRIPTION:
Steam & Water:
Components:
 Boiler Feed Water Control Station
 Drum Coil Pre-heater
 Economizer
 Boiler (Steam Drum, Evaporator, Water Drum)
 Superheaters (HP & MP Superheaters)
 De-super heater
 Main Steam Piping
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Boiler Feed Water Control Station:

Function of feed water control station is to maintain the water level in
the boiler steam drum.
 Feed flow control station consist of
• 1 x 100% Control valve
• 1 x 30% Control valve
• Manual isolation valve at inlet and outlet for 30% and 100% control
valves.
• Manual bypass globe valves are provided at 30% control valves and
100% Control valves.
• Pressure and temperature indicators
• Flow measurement with transmitter
• One Nos Temperature Control valve is provided at Feed water
control station outlet to control Economizer inlet temperature.
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Drum Coil Pre-Heater:

 Boiler is provided with a drum coil heater inside the water drum. The
heater is a heat exchanger in which the feed water from the feed
water control station passes through the tubes picking up heat from
the drum water

 Heat that is picked up from the coil heater ensures that the feed
water temperature at the inlet to the economizer leads to a flue gas
temperature greater than the sulphur dew point temperature.
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Economizer:
 To recover economically feasible heat from the flue gas.

 It increases the temperature of feed water entering into the Steam

Drum.

 Counter flow design for optimum heat recovery

 The coils are made of SA 210 GrA1 material and of size mm OD

38.1 * 3.25 mm thick

 The headers are made of SA 106 Gr B material

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Steam Drum:
Steam drum Accommodates
 Feed pipe
 Continuous blow down line
 H.P. dosing pipe
 Cyclone Separators
 Primary and Secondary Scrubbers
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Steam drum Mountings

 Level Gauges (2 Nos.)
 Level Transmitter (4 Nos.)
 Pressure Gauges on Steam Drum Puppy Header
 Pressure Transmitter on Steam Drum Puppy Header
 Safety Valves (2 Nos.)
 Air Vent with isolation valve on Steam Drum
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Convection Bank :
 Convection section consists of Convection Banks . Each Convection
bank consists of set of SA 210 Gr A1 plain tubes (50.8 mm OD &
3.66 mm Thk.), with their ends fitted duly to the bottom and top
drums of the Evaporator (twin drum type)

Water drum:
 The Water or the Mud drum is provided with the intermittent blow
down (IBD) connection.
 Water drum accommodates:
 Intermittent Blow down Connection MOV
 Drum coil Pre-heater
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HP Superheater:
TheSuper heater section is divided into five passes:
HPSH pass I (SA 210M Gr A1 T22 & 50.8 mm OD / 4.5 mm Thk)
HPSH pass II &IV (SA 213M T11 & 50.8 mm OD / 4.5 mm Thk)
HPSH pass III &V (SA 213M T22 & 50.8 mm OD / 4.5 mm Thk)
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De-Superheater (Attemperator):
 Spray type Attemperator assembly is provided Between PSH &
SSH to control final stem temperature.
 Water is sprayed through the spray nozzle along the steam flow
direction.
 Construction of the sleeve along with the spray nozzle facilitates
proper mix up of water with steam.
 Spray water through temperature control valve.
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Main Steam Line:

 Temperature Elements
 Safety Valve (1-no.)
 Pressure Transmitters & Indicator
 Flow Element with Flow Transmitters
 Start up Vent
 Main Steam Stop Valve
 Non Return Valve
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Air & Flue Gas:

Components:
 FD Fans (Motor Driven & Turbine Driven)
 Air Duct
 Combustor
 Flue Duct
 Stack Inlet multi-lower damper
 Stack
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FD Fan:
 One Motor driven FD Fan with 100% capacity provided.
 Supply of combustion air to the boiler.
 Forcing product of combustion through the boiler, economizer & to
the stack.
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FD Fan (2631-ME-007-K1B) Motor Driven:

Duty conditions Unit FD Fan (Test Block Condition)
Make Howden Solyvent
Quantity No. 1 x 100%
Nature of medium Clean Air
Airflow Rate M3/sec 20.72
Static Head Inlet / Outlet Mmwc -35 / 715

Air Temperature at Fan Inlet Deg C 37

Inlet Density Kg/m3 1.11

Fan Shaft Power with Full
KW 199
Damper Opening
Fan Speed Rpm 1480

Bearing Lubrication ISO VG 46 or Equivalent Oil

225 kw, 4P 1411 RPM Crompton
Motor
Greaves motor
Coupling SPACER Type Metaflex – 80X SPL, Size
Model / Make 262
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 Scanner Air fan

Duty conditions Unit SC Fan (Test Block Condition)
Make Howden Solyvent
Quantity No. 1 Working + 1 Stand by
Nature of medium Clean Air
Airflow Rate M3/sec 0.1857
Static Head Inlet / Outlet Mmwc -43 / 740
Air Temperature at Fan Inlet Deg C 37
Inlet Density Kg/m3 1.293
Shaft Power (Damper Control) KW 3.69

Fan Speed Rpm 2900

Bearing Lubrication ISO VG 46 or Equivalent Oil
225 kw, 4P 1411 RPM Crompton
Motor
Greaves motor
Coupling SPACER Type Metaflex – 80X SPL, Size
Model / Make 262
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Air Ducts:
 FD fan Discharge connected wind box through air duct.
 One Para flow modulating damper provided at wind box inlet
 A pressure Transmitter is provided in Air duct and wind box to
measure the pressure.
 One Aerofoil is provided to measure the combustion air flow.
 Air flows into furnace through Air sleeve damper mounted on
burners.
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Flue Gas Duct:

 Flue gas from the furnace passes through Screen Tubes, SH coils,
Evaporator tubes, Boiler Feed Water Preheater (Economizer) coils
and finally on stack.
 Temperature and pressure indicators
• Pressure Indicator is provided at secondary SH outlet
• Temperature Transmitter with indicator provided at SH outlet
• Flue gas Temperature at Economizer Outlet
• Flue gas temperature at Economizer outlet
• O2 Measurement at Economizer outlet provided
• Multi lower damper at stack inlet.
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THANK YOU !!!