Discussion about Construction and

Working Principle of Boiler, its

Auxiliaries and Boiler Mountings.
(FD, ID Fan, Economizer, De-aerator,
Super heater & Feed Pump)

Engr. Kshirod Mohan Bose

Executive Engineer (Boiler), Ghorashal Power Station
Mobile No. 01711076856, E-mail: kshirod124@yahoo.com
 Boiler Fundamentals
• What is Boiler ?
o STEAM GENERATOR
o Steam Pressure is Pre-set

o Steam Temperature is Pre-set

o DEFINITION OF BOILER
o A Boiler is a closed vessel in which water or other fluid is heated.
The fluid does not necessarily boil.

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 2

 Phenomenon Water (Steam
Generation)
Sensible Latent Heat Sensible Latent Heat Sensible
Heat of fusion Heat of vaporization or condensation Heat
150oC

Water boiling
Temperature oC

100oC
Steam Condensing

Steam
Water Change of State
Ice Melting
0oC
Ice Freezing
ICE
Change of State
-17.77oC
37 kJ 334 kJ 418 kJ 2250 kJ 97.4 kJ
Heat (kJ) per kg of Water
 Specific Latent Heat of Fusion and Solidification for Water

Receives FORMS 1 kg of
1 kg of Ice 334.9 kJ of
Water at
at 0OC Heat
FORMS GIVES UP 0OC

Specific Latent Heat of Evaporation and Condensation for Water

1 kg of Receives FORMS 1 kg of
2256.9 kJ of
Water at Steam at
Heat
100OC FORMS GIVES UP 100OC

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com

 Pressure Temperature
Relationship for Water
Temperature °C

400 374.15°C
CRITICAL POINT
350° 22123 kPa
15000 kPa
300° 10000 kPa
250° 5000 kPa
3000 kPa
200°

150° 600 kPa

100° 100 kPa

50°

0° Pressure kPa
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
BASIC FACTORS TO SELECT
BOILER
Power required to be generated
Operating Pressure
Fuel-quality and type
Water availibility and its quality
Probable load factor
Location of the power house or process plants
Cost of operations and maintenance
Cost of installations and erection
Availibility of floor space
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ESSENTIAL QUALITY CRITERIA OF GOOD BOILER
It should be capable of quick start-up

Should meet large load fluctuations

Occupy less floor space

Should afford easy maintenance and inspection

Should essentially posses the capacity of producing maximum steam with minimum fuel
consumption

Light and simple in construction

Various joints should be accessible for inspection and should be away from direct flame impact
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 7
Classification of Boiler
On the basis of Use: For power
Plant
For Utility
Stationary
Power
Boiler
Plant
For Plant
Boiler Process

Locomotive
Mobile
boiler
Marine
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 8
 On the basis of
On the basis of
furnace Position
Tube of Boiler
of Boiler

Externally
Water Tube
Fired

Internally
Fire Tube
Fired

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

9
kshirod124@yahoo.com
On the basis of Heat Source/Fuel
Coal Fired Boiler

Oil Fired Boiler

Solid/Liquid/Gaseous
Fuel
Gas Fired Boiler
Electrical Energy
Boiler
Gas & Oil/Duel Fuel
Boiler
Nuclear Energy
HRSG without Burner
Hot Waste Gases as
By-product of Process
HRSG with Burner

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 10

 On the basis of Steam On the basis of
Circulation Draught

Natural Natural Draught

Circulation Boiler Boiler

Forced Forced Draught

Circulation Boiler Boiler

Induced Draught
Boiler

Balanced
© Kshirod Mohan Bose, XEN, GPS Draught Boiler
+8801711076856, kshirod124@yahoo.com 11
On the basis of Pressure
Boiler

Sub Critical Super Critical

Pressure boiler Pressure boiler
(P<16.67 MPa) (P>22.13 MPa)

Low Pressure Medium High Pressure Super High

boiler Pressure boiler boiler Pressure boiler
(P<1.275 MPa) (P<3.82 MPa) (P<9.8 MPa) (P<13.73 MPa)
© Kshirod Mohan Bose, XEN, GPS +8801711076856,
12
kshirod124@yahoo.com
Fire Tubes Boiler
• Application: hotel,
heater, small industrial
process
• Fuel: Oil, Gas
• Steam capacity up to 5
Ton/h
• Saturated
temperature
• Design pressure up to
2.5 Bar
• Fully shop assembly
© Kshirod Mohan Bose, XEN, GPS
+8801711076856,
kshirod124@yahoo.com 13
Package Boiler

• Application: Auxiliary
boiler, industrial
process
• Fuel: Oil and Gas only
• Steam Capacity up to
220 Ton/hr
• Design Pressure up to
110 Bar
• Design Temperature up
to 500o C
• Mainly shop assembly,
very minimum site
works
 Marine Boiler
• Application: Steam turbine drive
(turbine propulsion) in the shipboard
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 70 Ton/hr
• Design Pressure up to 58 Bar
• Design Temperature up to 500o C
• Limited spaces, compact arrangement
• Dynamic behavior

15
BIOMASS BOILER

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

16
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Heat Recovery Steam Generator
(HRSG)

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

17
kshirod124@yahoo.com
 HRSG in Vertical Design HRSG in Horizontal Design
LP : Lowpressure

HP:Higpressure

1. Direction of exhaust gas flow

1. Direction of exhaust gas flow CSXA400311en_.cdr
2. Direction of heat exchanger tubes centerline
2. Direction of heat exchanger tubes centerline 3. Position of heat exchanger tube fins (if any)
3. Position of heat exchanger tube fins
Industrial Boiler
• Application: Industrial process, Steam
turbine drive (< 50 MW)
• Multi Fuels: Oil, Gas and Solid
• Steam Capacity up to 200 Ton/hr
• Design Pressure up to 120 Bar
• Design Temperature up to 500o C
• Site assembly
Consideration of Industrial Boiler:
– Multi-fuel Burning capability
– Waste Fuel Utilization (biomass, waste acid,
sludge, etc.)
– Cogeneration Potential to maximize heat
© Kshirod Mohan Bose, XEN, GPS +8801711076856,
from their fuel kshirod124@yahoo.com
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Utility Boiler

• Application: Electric Utility

(more than 50 MWe)
• Main Fuel: Coal
• Steam Capacity up to 1,850
Ton/hr (600 MW)
• Design Pressure up to 173 Bar
• Design Temperature up to 550o
C
• Site assembly

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

kshirod124@yahoo.com
20
 Drum
Final Super Heater
Down comer
Secondary Super Heater
Primary Super Heater
Water Wall Re- Heater

Burner Position
Economizer
Lower Header

Cross Sectional View of an

Utility Boiler © Kshirod Mohan Bose, XEN, GPS
+8801711076856, kshirod124@yahoo.com
 To IPC From HPC
To HPC Example of Utility Boiler
Stack
Platen SH

Con. SH 1

Con. SH 2

RH 1
RH 2
Econ.
Regenerative Air
Radiant SH FW Heater
FD Fan

FUEL Air
ID Fan
Furnace Boiler of 210 MW Ghorashal Power Station
Sub- critical, Super High Pressure, Water Tube,
Balanced Draft with Condensing Turbine
© kshirod124@yahoo.com 22
 Super Critical Boiler

• Application: Electric Utility

• Fuels: Pulverized Coal
• Steam Capacity up to 2,500 Ton/hr
(800 MW)
• Design Pressure up to 253 Bar
• Design Temperature up to 565o C
• Higher efficiency (no steam drum, no
blow-down system)
• Feed water quality is major concern
• Site assembly

23
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
 Supercritical Technology
What is Supercritical Pressure ?
• Critical point in water vapour
cycle is a thermodynamic state
where there is no clear
distinction between liquid and
gaseous state of water
• Water reaches to this state at a
critical pressure above 22.1
MPa and 374 oC

kshirod124@yahoo.com
PV Diagram of Water
© Kshirod Mohan Bose, XEN, GPS +8801711076856,
24
Comparison in Rankin Cycle
• Supercritical
Subcritical

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

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Features of Super Critical Boiler
• Latent heat for evaporation is not required
• Internally Ribbed Tube construction
• Increases heat transfer rate
• Spiral tube water wall construction
• Absence of nuclear boiling
• Maintenance free boiler
• Circulation is forced type
• Absence of Dozing, Condensate Polishing Unit (CPU) is applied for maintaining the
water quality
• Less emission
• Higher efficiency
• Less fuel consumption
• No Blow down (Less water consumption)

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 26

 Furnace Wall Designs

Spiral Wall Configuration Vertical Wall Configuration

27
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
 Efficiency and CO2 Emission

Steam Steam CO2

Plant type Efficiency
Pressure Temperature Emissions
with power rating (%)
(kg/cm2) (C) (g/kW-hr)

Sub Critical 170 540 35 900

(Maximum Capacity 500 MW)

# Super Critical 247 565 40 830

Up to Crip limit

Ultra Super Critical 250 600 42 784

Advanced Ultra Super

300 700 45 740
Critical

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 Unburnt &
Boiler Energy Flow
Unaccounted Loss Stack Loss & Radiation Loss AIR ENERGY IN

Hot Air

Water Wall &

Super Heater

Fuel
Air Heater
Energy
Re-Heater Economizer
In

STEAM Form HP To LP FEED WATER

ENERGY Turbine Turbine ENERGY IN 29
Heat Balance Diagram
Heat/ Energy Out Put &
Input Losses

Super heated and

Fuel (Chemical)
Re-heat Steam

Feed Water Stack/ Radiation

(Electrical) Loss

Unburnt &
Air (Electrical)
Unaccounted
Circulation of Water and Steam in Boiler
Natural Circulation • Forced Circulation

STEAM (Ms)
Ms

WATER M
(Mw)

COLD SIDE
w
Steam +
DOWNTAKE or
DOWNCOMER

Water

HOT SIDE
HOT SIDE
COLD SIDE

ORIFICE
CIRCULATING PUMP 31
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
Heat Transfer in the Boiler Pressure Parts

 Furnace
Furnace
–– radiation
radiationmode
mode

Spaced SH
Radiant SH

Evap.
 Radiant (Platen) Super-heater
Radiant (Platen) Super-heater
–– luminous
luminousradiation
radiationmode
mode
Econ. –– non-luminous
non-luminousradiation
radiationmode
mode
–– convection
convectionmode
mode
 Convective
Convective(Spaced)
(Spaced)Super-heater
Super-heater
–– non-luminous
non-luminousradiation
radiationmode
mode
–– convection
convectionmode
mode
 Evaporator (Boiler Bank)
Evaporator (Boiler Bank)
Furnace

–– convection
convectionmode
mode
 Economizer
Economizer
–– convection
convectionmode
mode
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© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
Boiler Drum Internals

Cyclone Separators

Water Level
 Boiler Main Component
Pressure Components (Mainly Water Circuit)

Economizer

Furnace and convection pass

Water Circuits, including drums and steam

separators and re-heater.

Attemparators

Connection Piping and Headers

© Kshirod Mohan Bose, XEN, GPS
+8801711076856, kshirod124@yahoo.com 34
Economizer
• Used for Feed Water
Heating.
• For adding heat at higher
temperature
• Use waste Heat
• Increases Efficiency.

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

kshirod124@yahoo.com 35
Water Wall
Construction
Tube & Tile

Tangential Tube

Studded Tube

Membrane Wall Studded Tube

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 36
Super heater

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

37
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ATTEMPERATOR / De-superheater

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

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kshirod124@yahoo.com
Boiler Auxiliaries
Non- pressure Boiler
Components Balance of Plant
Equipment
(Fuel & Air System)
• Fuel preparation • Fans
Equipments • Feed Pumps
• Burners • Pollution Control
• Air Heaters Equipment
• Duct works and supports. • Controls

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com 39

The function of Boiler Auxiliaries:
• Auxiliaries allow more heat to be produced.
• Minimizing heat loss is key to maximizing output.
• Efficiency is the key to generation.
• Combustion needs oxygen so airflow is key to heat production.
• Fuel type and size is key to combustion rate.
• Sizing of Auxiliaries is critical.

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

40
kshirod124@yahoo.com
Main role of Boiler Auxiliaries:

Power Output MW Steam Flow Temperature and

Turbine Pressure

Boiler Capacity Auxiliaries Optimum

Under Capacity Over Capacity

< Desired MW Wasted Costs

Maximum Operation Wasted Energy
© Kshirod Mohan Bose, XEN, GPS +8801711076856,
41
kshirod124@yahoo.com
Air Heaters

Tubular Air Heater Re- Generative Air Heater 42

 SAFETY VALVES & RELIEF VALVES

RELIEF VALVE

43
© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com
 WATER GAUGES and INDICATORS
CL

NWL FUNCTION
O
TO PROVIDE THE OPERATOR WITH A READILY
VISIBLE ( REMOT / LOCAL ) MEANS OF
MONITORING THE WATER LEVEL WITHIN THE
STEAM DRUM AT ALL TIMES

CRITICAL CONDITIONS
 TOO LOW A WATER LEVEL MAY CAUSE REDUCTION
AND / OR LOSS OF CIRCULATION IN THE FURNACE
WATERWALL TUBES.
 TOO HIGH LEVEL WILL REDUCE THE
EFFECTIVENESS OF THE STEAM SEPARATORS AND
DRYERS IN THE DRUM CAUSING WATER CARRY-
OVER TO THE SUPERHEATERS.

© Kshirod Mohan Bose, XEN, GPS +8801711076856,

44
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Draft System
• Natural Draft
• No fan used (not used for Power Plants)
• Forced Draft
• Fans are used to force air to Boiler
• Induced Draft
• Fans are used to suck air from Boiler, not commonly used)
• Balanced Draft
• Both Forced Draft & Induced Draft Fans are used
Natural Draft Boiler
 Forced Draft

AIR

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com

47
 Induced Draft

AIR

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com

48
 Balanced Draft

AIR

© Kshirod Mohan Bose, XEN, GPS +8801711076856, kshirod124@yahoo.com

49
Classification of Fans
• Radial Flow

• Axial Flow
Common Types of Fans
De-aerator
Feed Pump

• Multi- stage
centrifugal pump
• Driven by Motor or
Turbine
• May be configured as
1 100%, 2  100%, 3
 66%
Thank You…
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