Page |1

A
INDUSTRIAL ORIENTED MINI PROJECT REPORT ON

“BOILER AUXILIARIES & IT’S PROTECTION”

A Dissertation Submitted in the Partial Fulfillment of the Academic Requirements
For the Award of the Degree of
BACHELOR OF TECHNOLOGY
in
ELECTRICAL & ELECTRONICS ENGINEERING
By
1. G.HARISH HT.NO. 09TR1A0215
2. M.BABU HT.NO. 09TR1AO227
3. P.UDAYKUMAR HT.NO. 09TR1A0237
4. S.MAHENDER HT.NO.09TR1A0245

Under the esteemed guidance of

Sri V. DAVID sir M.Tech

Associate/Assistant Professor

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

SREE CHAITANYA INSTITUTE OF TECHNOLOGICAL SCIENCES

(Approved by AICTE, New Delhi, Affiliated to JNTU, Hyderabad )
LMD Colony, Thimmapoor, Karimnagar-505 527. (A.P)
2012
 Page |2

ANDHRA PRADESH POWER GENERATION

CORPORATION
RAMAGUNDAM THERMAL STATION:: RAMAGUNDAM.

From To
The Superintending Enigneer, The principal,
Operation & Maintenance, SCITS,Karimnagar.
RTS-B, Ramagundam.

Sir,
Sub:-APGENCO-RTS-B Station Mini project completion-Regarding
Ref: Lr.NO.SE/O&M/RTS/TECH/F.203/D.NO.941/12,Dt.2.06.2012.

This is to certify that the following students of

“SREE CHAITHANYA INSTITUTE OF TECHNOLOGICAL SCIENCES”

have undergone project work on “BOILER AUXILIARIES& IT’S

PROTECTION” at RTS.B, Ramagundam during the period 22.05.2012

to 03.06.2012 under the guidance of Sri.B.RAMAKRISHNA REDDY

Assistant Divisional EngineeR/Boiler Maintenance.

1. G.HARISH 09TR1A0215

2. M.BABU 09TR1A0227

3. P.UDAYKUMAR 09TR1A0237

4. S.MAHENDER 09TR1A0245

Their conduct during this period is found satisfactory.

SUPERINTENDING ENGINEER/O&M,

Ramagundam.
 Page |3

ACKNOWLEDGMENT

We are very thankful to P.V.NARASIMHA RAO, Superintending

Engineer R.T.S B’ STATION RAMAGUNDAM, for giving this
opportunity of doing mini project work.

We are very grateful to Sri. G.Venkateshwar Rao, Divisional

Engineer M/M Division R.T.S B Station and Sri P.Vijendar D/E AT&P
under whose guidance we are able to complete the project.

We are also grateful to Engg. Staff members of B/M, especially

Sri. B.RAMA KRISHNA REDDY, Assistant Divisional Engineer/BM,
Mr. K.RAJ KUMAR(AE)/BM who gave their valuable suggestions and
co-operation.

We are very grateful to our principal Sri A.PRASADA RAJU sir

and our H.O.D Sri. G.BALRAM sir Associate Professor, “SREE
CHAITHANYA INSTITUTE OF TECHNOLOGICAL SCIENCES” Who
have their co-operation and allowed us to do the project outside the
college campus.

BY

1. G.HARISH 09TR1A0215

2. M.BABU 09TR1A0227

3. P.UDAYKUMAR 09TR1A0237

4. S.MAHENDER 09TR1A0245
 Page |4

SREE CHAITANYA INSTITUTE OF TECHNOLOGICAL SCIENCES

(Approved by AICTE, New Delhi, Affiliated to JNTU, Hyderabad)
LMD Colony, Thimmapoor, Karimnagar-505 527. (A.P)

CERTIFICATE
.
This is to certify that the Project report entitled “BOILER AUXILIARIES & IT’S PROTECTION” is
being submitted by G.HARISH bearing Roll No.09TR1A0215 in partial fulfillment of the requirements for

the award of Bachelor of Technology in Electrical and Electronics Engineering at Sree Chaitanya
Institute of Technological Sciences, Karimnagar is a bonafide work carried out by him/her.

Sri V.DAVID sir Sri G.BALRAM sir

Project Guide Head of the Department

External Examiner
 Page |5

ACKNOWLEDGEMENT

I wish to thank the Management of Sree Chaitanya Institutions for providing the
facilities to complete my project work.

At the very outset, we wish to place on record our sincere thanks and gratitude to our
beloved Head of the Institution, Sri.A.PRASAD RAJU, Principal, Sree Chaitanya Institute
of Technological and Sciences, who allowed us to complete this endeavour successfully.

I would like to express my sincere and deep sense of gratitude to Sri G.BALRAM,
Associate Professor & HOD, Electrical Engineering Department, for his significant
suggestions and helping us in every respect to accomplish the project work. His persisting
encouragement, everlasting patience and keen interest in discussions have benefited us to the
extent that cannot be spanned by words. He has been the continuous source of inspiration for
us throughout the work.

I would especially like to express my extreme gratitude and sincere thanks to my

Project Guide, Sri V.DAVID , Assistant Professor, Electrical and Electronics Engineering
for his enthusiastic, innovative guidance and support through provoking discussion and
invigorating suggestions extended to us with immense care, zeal throughout our work.

I would like to sincerely thank to our teaching and non-teaching Staff-Members of

Department of EEE for their goodwill gestures towards us.

Last but not least I would also like to thank my family &friends, without their support
this project work would remain unfulfilled.
 Page |6

CONTENTS

LIST PAGE NO.

List of Figures 8

Nomenclature 9

CHAPTER 1 INTRODUCTION 10

1.1 PROFILE OF RTS-B STATION 10

1.2 INTRODUCTION TO THERMAL POWER PLANTS 12
1.3 OVERVIEW OF THERMAL POWER PLANT WORKING 13
1.4 PRINCIPLE OF OPERATION 14
1.5 INTRODUCTION TO BOILERS 14
1.5.1 GENERAL CLASSIFICATION OF BOILERS 15
1.5.2 PRESERVATION OF BOILERS 18
1.6 BOILER IN RAMAGUNDAM THERMAL POWER STATION 19
1.6.1 SPECIFICATIONS OF BOILER 19
1.6.2 BOILER 20
1.6.3 TANGENTIAL FIRING 22
1.6.4 COAL 22

CHAPTER 2 BOILER AUXILIARIES 24

2.1 AIR PRE HEATERS 24

2.1.1 TUBULAR AIR PRE HEATER 25
2.1.2 LJUGSTORM AIR PRE HEATER 27
2.2 ECONOMISER 29
2.2.1 VERTICAL FINNED TUBE ECONOMIZER 29
 Page |7

2.3 SUPER HEATERS 31

2.4 FANS IN THERMAL POWER STATION 32
2.4.1 INDUCED DRAFT FAN 33
2.4.2 FORCED DRAFT FAN 34
2.5 ELECTRO STATIC PRESPITATOR 35
2.6 COALMILLS 37

CHAPTER 3 BOILER PROTECTION 39

3.1 INTRODUCTION 39
3.2 TRIPPING OF ID FAN 39
3.3 TRIPPING OF FD FAN 40
3.4 FURNACE PRESSURE UNSAFE 41

CHAPTER 4 CONCLUSIONS 43
 Page |8

LIST OF FIGURES

FIG.NO TITLE PAGE

Fig.1.1 Sectional view of a Fire Tube Boiler 16

Fig.1.2 Simple Diagram of Water Tube Boiler 17
Fig.1.3 Typical arrangement of steam drum internals 21
Fig.1.4 Typical diagram of tangential fired furnace 23
Fig.2.1 Ljungstorm air pre heater 28
Fig.2.2 Tubes arrangement in economizer 30
Fig.2.3 Typical Tubes arrangement in super heater 32
Fig.2.4 Induced draft fan 34
Fig.2.5 Forced draft fan 35
Fig.2.6 Electostatic precipitater 36
Fig.2.7 Typical Coal mill 37
Fig.3.1 RTS-B unit interlock schematic 40
Fig.3.2 Relay used for MFT 42
 Page |9

NOMENCLATURE

LAPH : Ljuungstorm air pre heater

TAPH : Tubular air pre heater

LPT : Low pressure steam turbine

HPT : High pressure steam turbine

ID FAN : Induced draft fan

FD FAN : Forced draft fan

ESP : Electo static precipitator

CE : Collecting electrodes

EE : Emitting electrodes

MFT : Master fuel trip

ESV : Emergency steam valve

MSV : Main steam valve

 P a g e | 10

CHAPTER-1
INTRODUCTION

1.1 PROFILE OF R.T.S ‘B’ STATION

Ramagundam thermal power station (R.T.P.S) of Andhra

Pradesh State Electricity Board (APSEB) is situated at Ramagundam in the district of
Karimnagar. The plant is situated at 60km from Karimnagar
and 4km from Ramagundam railway station. The station is 0.5km from the state highway
connecting Hyderabad-Mancherial. The power station has only one unit of 62.5MW.
The unit was commissioned in 1972.The plant was financed Under AID
scheme unit comprises of boiler of CE USA and turbine generator of GE USA.
The raw water to the plant is drawn from the river Godavari situated about 8km
from the plant. The water from the river is pumped to a reservoir on the top of hill near the
plant. Water is supplied by gravity to DM Plant through clarifier and directly to CW to
cooling tower basins as make up.
The coal is received at the power station by road and rail from godavarikhani of
singareni collieries. Adequate facilities are provided for unloading coal from wagons.
However at present the entire coal requirement is received at plant by road ways by means of
trucks.
The ash from the boiler is disposed to the ash disposal area situated about 1km
from the plant towards east of the plant. This are is getting filled up and extension of the area
has to be developed.
The boiler was designed for coal quality of 4050kcal/kg with ash content of
38.7%. The present coal quality as reported is about 3700kcal/kg with ash content of 42%.
Due to ageing deterioration of equipment, controls and non-availability of spares the
performance has deteriorated. At present the unit is operating at a PLF of 65% and heat rate
has been reported to be 2660-2730kcal/kwh, while the design heat rate is 2616kcal/kwh. The
unit has been adequate residual life and also for improving the performance by implementing
renovation and modernization works. Therefore APSEB has decided to carry out renovation
and modernization (R&B) works on the unit to restore the unit to operate at its rated capacity
and at design efficiency. Before taking up such a major R&M works, APSEB desired to
carry out a study to identify the deficient and problem areas and evolve techno-economic
feasibility for implementation.
 P a g e | 11

RAMAGUNDAM THERMAL STATION “B”

SALIENT FEATURES
1. LOCATION : Ramagundam,Karimnagar Dist

2. CAPACITY : 62.5 MW

3. COST OF PROJECT : Rs.14.8 crores.

4. SOURCE OF WATER SUPPLY : Godavari River

5. SOURCE OF FUEL : Indian Bituminous coal of Singareni

Coal mines.
6. BOILERS
a) Type : CE Type, vu-40boiler
b) No. of units : One
c) Make : Combustion Engineering Inc, U.S.A
d) Capacity : 281,500 kg/hr
e) Steam pressure : 91.4
f) Steam Temperature : 516 C
g) Efficiency :85.8%
7. No. of Draft Fans
Forced : One
Induced : One
8. No. of Coal Mills : 4
9. No. of Soot blowers : 20+1 No. LAPH Soot Blower
10. FUEL
COAL
a) Type : High ash content low grade bituminous coal
b) Colorific Value (K.cal/kg) : 4055
c) Qty. used/day : 900-1000Mt
d) Ash content percent : 38.7
e) Sulphur content : 0.7%
f) Type of Disposal of Fly Ash : In slurry form
OIL
1) Type : Furnance oil and special kerosene oil
2) Qty. used/year : 1200
11. TURBINES
a) Type : Non-reheat single cylinder impulse reaction
turbine
b) No. of units : One
c) Capacity : 62,500 kw
d) Speed : 3000 r.p.m
e) No. of stages : 17
 P a g e | 12

1.2 INTRODUCTION TO THERMAL POWER PLANTS

The electricity has become essential commodity rather than luxury now-a-days. In state
or region thermal power stations will become important, as hydroresources are inadequate.
The concept of a modern thermal station is that it should be situated at such a place that the
basic requirements of fuel, water and land should be satisfied. Basically thermal
stations are two types.

1. Pit Head stations.

2. Load Demand stations.

Pit head stations are those which are nearer to the source of fuel and load demand stations
are those which are nearer to the load centers.

The thermal power station is just like any industry.

The basic requirements are:

a. Supply of raw materials at competitive cost. Coal and oil are the raw
materials required for thermal plants.
b. Access to the markets for its products.
c. Labour force of the size and quantity required.
d. Means of disposal for any trade effluents that is by-products.

The other factores to be considered for selecting the site are:

1. Load demand.
2. Land
3. Site requirements
4. Access for construction
5. Transmission Lines
6. Clearances
7. Environmental factors

The layout of Thermal power station is shown in the block diagram

 P a g e | 13

1.3 OVERVIEW OF THERMAL POWER PLANT WORKING

At present 54.09% or 93918.38 MW (Data Source CEA, as on 31/03/2011) of total

electricity production in India is from Coal Based Thermal Power Station. A coal based
thermal power plant converts the chemical energy of the coal into electrical energy. This is
achieved by raising the steam in the boilers, expanding it through the turbine and coupling
the turbines to the generators which converts mechanical energy into electrical energy.

In a coal based power plant coal is transported from coal mines to the
power plant by railway in wagons or in a merry-go-round system. Coal is unloaded from the
wagons to a moving underground conveyor belt. This coal from the mines is of no uniform
size. So it is taken to the Crusher house and crushed to a size of 20mm. From the crusher
house the coal is either stored in dead storage( generally 40 days coal supply) which serves
as coal supply in case of coal supply bottleneck or to the live storage(8 hours coal supply) in
the raw coal bunker in the boiler house. Raw coal from the raw coal bunker is supplied to the
Coal Mills by a Raw Coal Feeder. The Coal Mills or pulverizer pulverizes the coal to 200
mesh size. The powdered coal from the coal mills is carried to the boiler in coal pipes by
high pressure hot air. The pulverized coal air mixture is burnt in the boiler in the
combustionzone.Generally in modern boilers tangential firing system is used i.e. the coal
nozzles/ guns form tangent to a circle. The temperature in fire ball is of the order of 1300
deg.C. The boiler is a water tube boiler hanging from the top. Water is converted to steam in
the boiler and steam is separated from water in the boiler Drum. The saturated steam from
the boiler drum is taken to the Low Temperature Superheater, Platen Superheater and Final
Superheater respectively for superheating. The superheated steam from the final superheater
is taken to the turbine which is mechanically connected to generator Then is sent to the
condenser for condensing back to water by a cooling water system. This condensed water is
collected in the Hotwell and is again sent to the boiler in a closed cycle. The rotational
energy imparted to the turbine by high pressure steam is converted to electrical energy in the
Generator.
 P a g e | 14

1.4 PRINCIPLE OF OPERATION:

The fundamental forms of energy with which thermal stations are principally concerned are
heat and work. Heat produces work and this work is further converted into electrical energy
through a medium
i.e. electrical generator. For the purpose of understanding of thermal plants, the phenomenon
of the thermodynamic vapour power cycles explained below

RANKINE CYCLE: This is the simplest theoretical vapour cycle which is the basis for
operation of a steam plant. Super heated steam from the boiler is fed to the prime mover
(Turbine) and is expanded there. After which enters the condenser emerging as condensate is
again fed into the boiler. This rotaion of water cycle is called Rankin cycle.

The main purpose of superheating steam and supplying it to the prime moves is to
avoid too much wetness at the end of expansion. Moisture content of steam would result in
undue blade erosion. The maximum wetness in the final stage of steam that may be tolerated
without any appreciable harm to the turbine blades is about 12%.also the use of super heater
in a boiler helps in reducing the stack temperature by extracting heat from the flue gases
before these are passed out of chimney.

1.5 INTRODUCTION TO BOILERS:

In a modern steam generator, various components are arranged to efficiently absorb heat
from the products of combustion and provide steam at the rated temperature, pressure and
capacity. These components include the boiler, superheater, reheater, economiser and air
heaters. They are supplemented by systems for steam-water separation and the control of
steam outlet temperature. The entire boiler system can be divided into two general sections,
the furnace and convection pass. The furnace provides a large open volume with water
cooled enclosure walls where combustion takes place and the combustion products are
cooled to an appropriate furnace exist gas temperature (FEGT). The convection pass contains
tube bundles which consist of the superheater, reheater, boiler bank and economiser.

Boiler is a device for generating steam for power, processing or heating purposes. Boilers are
designed to transmit heat from an external combustion source contained within the boiler
itself. Boilers surface is defined as tubes, drums and shells which are a part of the steam-
water circulation system and which are in contact with the hot gases. Although the term
boiler now frequently refers to the overall steam generating system, the term boiler surface
excludes the economiser, superheater, reheater or any component other than the steam-water
circulation system it self.
 P a g e | 15

1.5.1 GENERAL CLASSIFICATION OF BOILERS:

Boilers are generally categorized as follows:

Steel boilers, Fire tube boilers, Water tube boilers, Horizontal straight tube boilers, Bent
tube boilers, nuclear circulation, Positive circulation, shell circulation.

Among the above classification Water tube boilers and Fire tube boilers are generally
used. Modern high capacity boilers are water tube boilers.

If the hot combustion gases are restricted out side the tubes and the water is surrounded
is called Fire tube boilers.

In the water tube boilers, the water and steam flow inside the tubes and the hot gases
flow over the outside surfaces. The boiler circulation system is constructed of tubes, headers
and drums joined in such a way that water flow is provided to generate steam while cooling
all the parts. The water tube construction allows greater boiler capacity and higher pressure
than shell or fire tube designs. Also, the water tube boilers offers greater versatility in
arrangement; this permits the most efficient use of the furnace, superheater, reheater and
other heat recovery components.

Fire Tube Boiler

In a fire tube boiler, hot gases pass through the tubes and boiler feed water in the shell side is
converted into steam.Fire tube boilers are generally used for relatively small steam capacities
and low to medium steam pressures.
 P a g e | 16

Figure 1.1.Sectional view of a Fire Tube Boiler

Water Tube Boiler

In a water tube boiler, boiler feed water flows through the tubes and enters the boiler drum.
The circulated water is heated by the combustion gases and converted into steam at the
vapour space in the drum. These boilers are selected when the steam demand as well as
steam pressure requirements are high as in the case of process cum power boiler /power
boilers.

Most modern water boiler tube designs are within the capacity range 4,500 – 120,000
kg/hour of steam, at very high pressures. Many water tube boilers are of “packaged”
construction if oil and /or gas are to be used as fuel. Solid fuel fired water tube designs
are available but packaged designs are less common.
 P a g e | 17

The features of water tube boilers are:

􀂃 Forced, induced and balanced draft provisions help to improve combustion efficiency.
􀂃 Less tolerance for water quality calls for water treatment plant.
􀂃 Higher thermal efficiency levels are possible

Figure 1.2 Simple Diagram of Water Tube Boiler

 P a g e | 18

1.5.2 PRESERVATION OF BOILERS:

Preservation of Boilers is carried out to protect the interior of heating surfaces from
corrosion. When the boiler is streaming all the efforts and precautions are taken to prevent
the boiler heating parts, which come in contact with water or air. But for effective follow-up
during the outage period the preservation is carried out

During the shut down period if the preservation is not carried out, oxide of iron
(Fe2O3) is formed on the surfaces due to pressure of moisture and oxygen. During the
starting of boiler even if the deaerated water is used the corrosion continues to take place on
account of already formed. Fe2O3 which decomposes into Fe3O4 and free oxygen.

12Fe2O3 = 8 Fe3O4 +2O2

The free oxygen released will react with the metal.

3 Fe2 + 2O2 = Fe3O4

Due to this, corrosion formation of pitting takes place on the surfaces, which leads to
fracture of the tubes.

For minimizing the corrosion in boilers, when the boiler is shutdown the boiler
internals can be dried completely.
 P a g e | 19

1.6 BOILER IN RAMAGUNDAM THERMAL POWER STATION:

Ramagundam thermal power station located at Ramagundam having a capacity of 62.5

MW and the cost of the project is 14.8 crores. The source of supply of water is from
Godavari River which is 8km away from the power station

1.6.1 SPECIFICATIONS OF BOILER:

1 Type CE Type, VU-40 boiler

2. No of units one

3 Make Combustion engineering inc.

U.S.A.

4 Capacity 281. 500Kgs/hr.

5 Steam pressure(Kg/cm² ) 91.4

6 Steam temperature 516ºc

7 Efficiency 85.8%

8 No of draft fans
a) Forced 1
b) Induced 1

9 No of air fans Nill

a) Primary -
b) Seal -
c) scanner -

10 No of coal mills 4

11 No of soot blowers 20+1 No of LAPH soot blowers

 P a g e | 20

1.6.2 BOILER :

CE make VU-40 Boiler was commissioned during 1972. The boiler consists of
water wall tubes around the walls. Total number of water wall tubes front side 101nos and
rear side 101nos and north side and south side 98×2=196nos. During burning of the fuel in
furnace, cleaning of water wall tubes from ash was carried out with soot blowers. The OD of
the water wall tube is 3” and thickness 0.18”. The water walls are connected from lower ring
header to the top drum and some of the tubes to the mud drum.

1.6.2.1 BOILER DRUMS:

The lower drum & upper drum (Reg. No. AP 828) were commissioned during
1972. Some of the Water Wall tubes are connected to the upper drum and lower drum.
Bank tubes are connected between upper drum and lower drum. Four No.s down comers
are connected from mud drum to the bottom ring header. The upper drum consists of 53 Nos
turbo separators. The turbo separator consists of primary stage & secondary, through which
steam water mixture is separated. The upper drum consists of two No.s safety valves, one at
south side and other north side. Chemical dazing line was connected to the upper drum to
maintain the dissolved solids contents below 1 PPM CBD pipe were connected to the drum.

STEAM DRUM INTERNALS:

The function of the steam drum internals is to separate the water from the steam generated in
the furnace walls and to reduce the dissolved solids contents of the steam to below the
prescribed limit of I ppm. Wet steam entering the drum from the riser tubes and furnace
walls is collected in a compartment, formed by internal baffles. From this compartment the
steam 8;I is first led through two rows of turbo separators. Each turbo separator consists of a
primary stage and a secondary stage. The primary stage is formed by two concentric cans.
Spinner blades Impart a centrifugal motion to the mixture of steam and water, flowing
upward through the inner can, thereby throwing the water to the outside and forcing the
steam to the inside. The water is arrested by a skim-off lip above the spinner blades and
returned to the lower part of the drum through the annulus between the two cans. The steam
proceeds up to the secondary separator stage. The secondary stage consists of two opposed
banks of closely spaced thin corrugated sheets which direct the steam through a tortuous path
and force remaining entrained water against the corrugated plates. Since the velocity is
relatively low, this water does not get picked up again, but runs down the plates and off the
second stage lips at the two steam outlets. From the secondary separators the steam flows
uniformly and with relatively low velocity upward to the series of screen dryers, extending in
layers across the length of the drum. These screens perform the final stage of separation. CD
 P a g e | 21

Figure 1.3 Typical arrangement of steam drum internals

1.6.2.2 BOILER OPERATION:

All steam generating equipment, from the simple fire-tube boiler to the large
generator equipped with a water-cooled furnace, superheater and economizer, is designed for
specific performance. When supplied with feedwater at the specified temperature, the
boiler is built to deliver a definite quantity of steam at the required pressure. If a superheater
is included in the installation, the temperature of the steam is computed also. These
performance limitations should not be exceeded.
The moisture content of the steam leaving the boiler and the concentration of solids
entrained therein will depend to a great extent upon the quality of the feed water, the use of a
suitable feedwater treatment and adequate blow downs to maintain the boiler ran water
alkalinity and concentration of dissolved and suspended solids below a determined point.
 P a g e | 22

1.6.3 TANGENTIAL FIRING :

In a tangentially fired furnace, the burners are located near the furnace corners. The
fud and air streams from the burners are directed to a firing circle in the center of the
furnace. The rotative or cyclonic mixing action that is characteristic of this type of firing is
most effective in redistributing the burning fuel into a constantly changing gas and air
atmosphere. The air and fuel streams are vertically adjustable by means of movable air
deflectors and nozzle tips, which can be tilted upward or downward through a total angle of
60 degrees. This movement is effected through connecting rods and tilting mechanisms for
each compartment, all of which are connected to a drive unit at each corner operated by
automatic control. The deflection of all adjustable burners at the four corners of each furnace
is regulated in unison by the master control and drive units.

1.6.4 COAL:

1 Type High ash content low

grade bituminous coal.

2 Calorific value (k cal/kg) 4055

3 Quantity used per day 900-1000Mt

4 Ash content percent 38.7

5 Sulphur content 0.7%

6 Type of handling equipment Conveyor belt system

7 Type of disposal of Slurry form

a) Fly ash Slurry form
b) Bottom ash
 P a g e | 23

Figure 1.4
 P a g e | 24

CHAPTER-2
BOILER AUXILIARIES

2. BOILER AUXILIARIES IN RTPS:

2.1 AIR HEATERS:

Air heaters are used in steam generating plants to heat the combustion air and
enhance the combustion process. Most of frequently, the flue gas is the source of energy and
the air heaters serves as a heat trap to collect and use waste heat from the flue gas stream.
This can increase the overall boiler efficiency by 5 to 10%. Air heaters can also use
extraction steam or other sources of energy depending up on the particular application. These
units are usually employed to control air and gas temperatures by pre heating air entering the
main gas-air heaters.

Super heaters, Economizers generally cannot fully extract the heat from flue
gases. Therefore Pre-heaters are employed which recover some of the heat from the flue
gases.

Air heaters are classified as recuperative and regenerative types based on their
operating principle.

In Recuperative type, heating medium is on one side and air is on the other side
of tube or plate and heat transfer is by conduction through the material which separates the
media. These are of static construction and hence there is only nominal leakage through
expansion joints, access doors, casings etc. Tubular air heaters , cast iron air heaters, plate air
heaters, steam air heaters, heat pipe are comes under this category.

In Regenerative type air heaters the heating medium flows through a closely
packed matrix to raise its temperature and then air is passed through the matrix to pick up
the heat . Either the matrix or the hoods are rotated to achieve this and hence leakage
through sealing arrangements at the moving surfaces is high. LjungstrÖm, Rothemühle
are comes under this category.
 P a g e | 25

AIR HEATER SPECIFICATIONS:

1 SPECIFICATION AIR PREHEATER

2 Type LJUSTROME-Air preheater

3 Size 23 VIR

4 No. of heaters 1

5 No. of sectors. 12

6 Gear box. 4 APC

7 Speed ratio. 104.9:1

8 Motor(kw) 5.6

9 Support Bearing SKF 29468E

10 Guide Bearing SKF23034

11 Lubrication Type Natural

2.1.1 TUBULAR AIR HEATER

GENERAL

The function of the Tubular Air Heater (2nd stage air heater) is to increase the temperature of
the air from the Ljungstrom Air Heater (1st stage air heater) when required for mill drying
during periods of high moisture coal.
 P a g e | 26

DAMPER OPERATION

Dampers No. 1 - Coltrol the air from the Tubular Air Heater to the burner
windboxes, allowing a cooling air flow through the tubular air heater when thereis little or no
demand for hot air from the tubular air heater to the pulverizers (see Note 1). These dampers
should be fully open whenever Dampers No. 2 are closed, throttled when Dampers No. 2 are
throttled and closed when Dampers No- 2 are fully open. When no coal is fired (oil start-up)
Dampers No. 1 should be fully open. Dampers No. 2 - Control the air from the Tubular Air
Heater to the pulverizers. These dampers will be fully open when maximum mill drying is
required. With moderate or low moisture coal or reduced mill capacity these dampers are
throttled as required (see Note 2). When no coal is fired (oil start-up) Dampers No. 2 should
be closed. Dampers No. 3 - Control the air from the Ljungstrom Air Heater going directly to
the pulverizers. These dampers are operated in conjunction with but in the opposite direction
of Dampers No. 2. They should be completely closed when Dampers
No. 2 are fully open and must seal tightly. During start-ups (no coal firing) Dampers No. 3
are fully closed.
Dampers No. 4 - Control the main secondary air from the Ljungstrom Air Heater to the
burner windboxes. They are throttled in conjunction with Dampers No. I to provide
sufficient resistance in the ducts and allow flow of air through the tubular air heater when
Dampers No. 1 are open. They should never be completely closed. During oil start-up
Dampers No. 4 should be throttled.

NOTES:

1. Some air flow is required through the tubular air heater at all times to
keep the metal below the oxidation temperature.

2. For boiler efficiency purposes the temperature of the hot air to the
pulverizers should not greatly exceed mill drying requirements. Unnecessary hot air requires
more temperating air, which reduces boiler efficiency. Dampers No. 2 should be positioned
to keep the mill tempering dampers onlyopen sufficiently, within the control range.

3. Exact positioning of the dampers for all loads and fuel conditions must be determined
from experience.

INSTRUCTIONS FOR THE OPERATION AND MAINTENANCE

OF C-E TUBUL-AR AIR PREHEATERS:

The preheating of air for combustion is not a new or recently developed idea, It has been
done to limited extent both in this country and abroad for many years. Prior to 1920, the use
of preheated air in boiler furnaces received more serious consideration in Europe than here,
mainly on account of the relatively high cost of coal in European countries. The increasing
cost of fuel here has, however, greatly stimulated the interest of American operators,
 P a g e | 27

particularly in the central station field, and as a consequence a great many installations have
been made. The advantages of this method of heat recovery and utilization have now become
so well
established that it is practical certainity that most of the future power plants and a large
number of existing plants will use preheated air. At first it was thought that a choice would
have to be made between economizers and air heaters, but it has now been proven that in
many cases, sufficient heat recovery can be effected through boiler mediums to amply justify
their combined use. Where economizers are not used, the savings and advantages of air
preheating are so apparent that no argument is needed to demonstrate them. A net increase in
efficiency of from 4 to 8 per cent represents a saving that cannot be overlooked. At the
present time, there are several types of air heaters in use. They may be classified
from a construction standpoint under the following main headings, Plate Type – Rotative
Type - Tubular Type.

Construction of C-E Tubular Air Heater

The arrangement of the counterflow type tubular air heater is shown in the attached drawing.
The travel of the flue gases is shown with red arrows and travel of the air with blue. The air
side of the air heater consists of a number of horizontal, straight tubes rolled into a tube sheet
at each end and enclosed in a casing. Flue gases enter at the top travel downward across
horizontal air tubes and through the bottom gas outlet to the economizer. The air enters from
the both ends and passes around the ends of the gas chamber to the back side where it enters
the tube bank. A partition in the rear and front air passage divides the air portion into two
sections. The air passes through the flue gas touched tubes to the front air passage and exits
through the two at each end.

Operating Attention

Very little routine attention is necessary to maintain satisfactory performance of the heater
because it has no moving elements. The heater is so designed that the gas velocities are
usually high enough to prevent excessive collection of soot or flue dust and for this reason
only occasional cleaning of the heater will be necessary.

2.1.2 LJUNGSTORM AIR PRE HEATER

DESCRIPTION HOW THE LJUNGSTROM WORKS

The Ljungstrom air preheater absorbs waste heat from flue gas, then transfers this heat to
incoming cold air by means of continuously rotating heat transfer elements of specially
formed metal plates. Thousands of these high efficiency elements are spaced and compactly
arranged within twelve sector-shaped compartments of a radially divided cylindrical shell,
 P a g e | 28

called the rotor. The housing surrounding the rotor is provided with duct connections at both
ends, and is ade-quately sealed by radial and circumferential sealing members – forming an
air passage through one half of the preheater, and a gas passage through the other. As the
rotor slowly revolves the mass of elements alternately through the gas and air passages, heat
is absorbed by the element surfaces passing through the hot gas stream; then, as these same
surfaces are carried through the air stream, they release the stored up heat – thus greatly
increasing the temperature of the incoming combustion or process air.

Figure 2.1 LJUNGSTORM AIR PRE HEATER

 P a g e | 29

2.2 ECONOMISER:

Economisers are basically tubular heat transfer surfaces used to pre heat boiler
feed water before it enters the drum (recalculating units) or furnaces surfaces (once through
units ).The term Economizer comes from early use of such heat exchangers to reduce
operating costs or economize on fuel by recovering extra energy from flue gas. Economizers
also reduce the potential of thermal shock and strong water temperature fluctuations as the
feed water enters the boiler drum or water walls. Economisers are classified into two types
based on its construction. They are (a) Plain tube and (b) Welded Fin tube

In RTPS 62.5MW thermal power station they use vertical finned tube type economiser

2.2.1 VERTICAL FINNED TUBE ECONOMIZER:

The function of the economizer is to preheat the boiler feedwater before It is introduced into
the steam drum, and to recover some of the heat from the flue gases leaving the boiler. The
economizer is located in the gas pass to the rear of the boiler. It is composed of a number of
parallel tube circuits, arranged in horizontal rows in such a manner that each row is
staggered in relation to the row above and below it. All tube circuits originate from the inlet
header and discharge Into the outlet header. The economizer tubes are finned to increase the
amount of effective heating surface and also strengthen the economizer tube construction.
Feedwater is supplied to the economizer Inlet header via the feed stop and check valves. A
drain is provided on the bottom of lower header to facilitate draining of the elements. The
feedwater flow is upward through the economizer, that is, in counter flow to the hot flue
gases. Most efficient heat transfer is hereby accomplished. Any difficulty with steam
generation within the economizer is eliminated by the upward water flow. From the outlet
headers and feedwater is led to the drum via the economizer outlet link.

OPERATION:

1. Before starting up the boiler, the economizer should be inspected externally and if
necessary cleaned. Especially if the installation is new, accumulation of erection material
(wood, insulation, welding rods, etc.) is not unusual. Large debris should be removed
manually, followed by washing down the economizer banks by means of hose and water.
2. All joints in the economizer casing should be examined occasionally for tightness in order
that air infiltration be kept to a minimum.

3. Any exposed insulation should be kept in good condition at all times.

4. The end doors should be bolted tight. Check the doors occasionally for tightness.
 P a g e | 30

5. The frequency with which soot blowers are used depends entirely on local Conditions.
When the economizer is first placed in operation, the economizer soot blowers should be
blown about once every shift. Observations of the increase in draft loss between bowings
will determine how long an Interval may be set as a Standard. In many cases it has been
found that blowing the economizer soot blowers Once a day or less is sufficient. For further
details, refer to soot blower section.

Figure 2.2 Tubes arrangement in economizer

 P a g e | 31

2.3 SUPERHEATERS:

Superheaters are meant to rise the steam temperature above the saturation temperature by
absorbing heat from flue gas. By increasing the temperature of the steam efficiency of the
cycle also. Super heating eliminates the formation of condensate during transporting of
steam in pipe lines and inside the early stages of turbine which is harmful to the turbine
blades and pipe lines.

Superheaters are usually classified according to the shape of the tube banks and the
position of the header; also according to where they; receive heat by radiation or convention,
although in some instance it may; be a combination of both methods

Types of superheaters depending on the firing method, fuel fired etc., the superheaters
are replaced in the boiler flue passes, horizontally, vertically or combined.

General classifications of superheaters are shown below:

a) Pendent Type superheater.

b) Horizontal Type superheater.
c) Radiant Superheater.
d) Convection Superheater.
e) Combined Superheater.

Inspite of above classification pendent type superheaters are used in RTPS.

THE SUPERHEATER DESUPERHEATER

A desuperheater is installed in the connecting link between the Low Temperature and
High Temperature superheater. Steam enters the desuperheater from the outlet header of the
low temperature superheater and passes on through to the inlet header of the high
temperature superheater. Located in this manner, the temperatures to which the
desuperheater will be subjected are considerably less than if it were posi-
tioned after the high temperature stage. Likewise, the possibility of carrying spray water over
to the turbine will be eliminated when operating according to the outlined procedure. A
steam assisted water spray nozzle is fitted in the entering end of the desuperheater to make it
possible to reduce the steam temperature, when necessary, and maintain
the same at its design value within the limits of the nozzle capacity. Steam for assisting the
atomization of the spray water flows continuously from the steam drum whether there is a
desuperheater water flow or not.
A control valve, linked to an automatic control drive unit, regulates the flow of spray water
supplied to the desuperheater. A manually operated valve is provided on each side of the
 P a g e | 32

control valve to permit isolation when required. A manual control valve in the by-pass line
around the automatic control valve and the two isolating valves is to be used only in the
event of an emergency, and when the automatic control valve may require maintenance. The
source of spray water is from the feedwater system. It is important that the take-off line be
located upstream from any chemical injection lines. It is essential that the spray water be
chemically pure and free of solids in order to prevent both chemical deposition in the
superheater and carryover to the turbine. The desuperheater is fitted with a renewable liner to
take the wear of erosion from the spray water stream, thus protecting the main desuperheater
shell. Excessive noise from within the desuperheater usually indicates a worn liner, and the
Service Department of this Company should be contacted when this or any such abnormal
conditions may arise. Sufficient clearances should be provided around the desuper-heater for
replacing the liner.

Figure 2.3 Typical Tubes arrangement in super heater

2.4 FANS IN THERMAL POWER STATION:

The purpose of the fan is to move air/gas continuously against moderate pressure.
Even though a little amount of compression occurs, it is customary to consider air/gas in fans
as being incompressible. Fans can also be used for gases with dust particles in suspension.
Fans are used in boiler for different applications such as supplying air for combustion,
removal of combustion, removal of combustion products, air for cooling of equipment
 P a g e | 33

working in hot zones etc. Fans are designated according to the function they do in the boiler,
e.g. Induced draught fan, Forced draught fan, Primary Air fan etc.

CLASSIFICATION OF FANS BASED ON FLOW OF MEDIUM:

Depending upon the direction of flow of the medium at outlet with respect of
rotational axis, fans are broadly classified into axial and radial (centrifugal) fans.

2.4.1 INDUCED DRAFT FAN:

The function of Induced Draft fan is to suck the gases out of furnaces and
throw into the stack. Boiler is provided with one no. of Induced Draft Fan. ID fan is
provided with regulating damper control and scoop control for controlling the loading on
fans, Inlet/Outlet gates for isolation to facilitate startup/maintenance of fan. Flue gas
interconnection with damper is provided before ESP in order to maintain balanced flow
through both the APH/second pass when only one ID fan is running.

a) Air ingress across air heater and in flue gas duct from APH outlet to ID fan inlet
should be arrested. Air ingress of about 65 Ton is taking place across air pre heater
and in the flue gas path. The calculated energy saving potential is about 1.345Mus or
approximately Rs22.9 Lakh annually.
b) Exit temperature of flue gas should be reduced. Observed exit temperature is 180ºC
which is higher than design temperature of 150°C. It indicates that by reducing exit
temperature if flue gas to 150°C, 0.395MUs of energy can be saved annually due to
reduction in induced draft fan power. In monetary term it can result in saving of
approximately Rs6.72 Lakh.

c) Possibility may be explored to replace sharp bends with the smooth profile bends in
the flue gas path. This will reduce ID fan power consumption.
d) As ID fan is running in full load condition and there is only one ID fan, this left little
scope for furnace control. Practically in case of flame disturbances, wide fluctuation in
furnace draft is observed. Therefore considering the ID fan loading condition, the
availability of flame scanners will help in better stability and safety of boiler. The
availability of flame scanners will help operation staff in early detection and action in
case of furnace instability and will reduce number of unit tripping. Therefore
availability of flame scanners will help in lowering the Apc.
e) As a long term measure possibility may be explored for providing variable frequency
drive in place of present motor.

Annual savings potential is 0.99Mus or Rs.17Lakh with a simple payback period of 6

years.
 P a g e | 34

Figure 2.4 Induced draft fan

2.4.2 FORCED DRAFT FAN:

The function of FD fan is to supply excess air recquired for complete combustion.
Boiler with one no. of Forced Draft Fans. FD fan is provided with blade pitch control for
controlling the loading on fans. Outlet damper for isolation to star up /maintenance of fan.

Boilers operating with both forced and induced draft use the forced draft fan to push air
through the combustion air supply system into furnace. The fan must have a discharge
pressure high enough to equal the total resistance of air ducts, air heater, burners or fuel bed
and any other resistance between the fan discharge and the furnace. This makes the furnace
the point of balanced draft or zero pressure. Volume out put of the forced draft fan must
equal the total quantity of air required for combustion plus air heater leakage. In many
installations, greater reliability is obtained by dividing the total fan capacity between two
fans operating in parallel. If fan is out of service, the other usually can carry 60% or more of
full boiler load, depending on how the fans are sized.
 P a g e | 35

Figure 2.5 Forced draft fan

2.5 ELECTROSTATIC PRECIPITATORS:

There are two kinds of equipment used to remove grit and dust from boiler flue
gases. There are the Cyclone grit Arrestors (Mechanical Collectors) and the Electrostatic
Precipitators.

The electrostatic precipitators utilize electrostatic forces to separate dust particles from the
gas to be cleaned. The Electrostatic Precipitator essentially consists of two sets of electrodes
called ‘Collecting Electrodes’ and ‘Emitting Electrodes’ (also called discharge electrodes).
The collecting electrodes are made up of steel sheet pressed to a special profile and the
emitting electrode is a thin wire drawn to a helical form. A unidirectional high voltage is
applied between these electrodes, connecting its positive polarity to collecting electrodes
which are also earthed. The dust laden flue gas from Boiler passes between rows of
collecting and discharge electrodes.
 P a g e | 36

The high voltage induces ionization of gas molecules adjacent to the negatively
charged emitting electrodes. The positive charges of the ions create travel towards the
discharge electrodes and the negative charges towards the collecting electrodes. On their way
to the collecting electrodes, the negative charges get deposited on the dust particles. Thus the
dust particles experience a force, which causes the particles to move towards the collecting
Electrodes and finally get deposited on them. Minor proportions of the dust particles, which
have acquired positive charges, get deposited on the emitting electrodes also. Periodically
these are dislodged from the electrodes by a process called ‘rapping’. The particles then fall
into the hoppers at the bottom.

Figure 2.6 Electostatic precipitater

 P a g e | 37

2.6 COALMILLS

The key input to the coal fired power plant is the coal. Coal in the form that is available from
the mines is not suitable for efficient combustion in the boiler of the power plant. The
pulverizing system prepares the coal for combustion.

In coal fired power plant, coal mill is used to grind, pulverize and dry coal before the coal is
transmitted the boiler. The coal is feed into the coal mill via a inlet pipe so that the roller coal
mill such as Raymond mill and vertical mill can pulverize the coal into particles.

The hot air in the coal mill will lift the coal particles out of the Raymond mill or vertical mill
and into the boiler, if the coal particles are too heavy they will drop to the bottom of the coal
mill too and will be grind, pulverize again.

Figure 2.7 Typical Coal mill

 P a g e | 38

coal mill features

1 Compact design, Simple structure, easy maintenance.

2 Adaptable to specific process requirements .
3 High drying ability, reliable operation.
4 Long service life of grinding parts
 P a g e | 39

CHAPTER-3
BOILER PROTECTION

3.1 INTRODUCTION
Boiler is heart of the thermal power plants. Steam Generator (boiler) is very
important equipment at thermal power units, Boiler is used to supply steam for the unit to
rotate the turbine's rotor, hence produce electricity at Generator's stator. There are mainly
three causes which may cause severe damage to the boiler. They are

1. Tripping of ID FAN
2. Tripping of FD FAN
3. Furnace pressure unsafe

Boiler usually equipped with coal and Main gas firing equipments, and you can
imagine that huge boiler disappear in seconds unless operator take his precaution from
operation hazards., hence Boiler always equipped with a protection relays to trip the
boiler out of service if hazards conditions has happened, these relays are enclosed at huge
protection system is called (Master Fuel Trip).

So the protection for the Boiler can be done by using MFT protection method.
When a master fuel trip is initiated .it produces trip signal for fuel systems from operation ,
then trip the boiler out of service away from danger.

3.2 TRIPPING OF ID FAN

The ID FAN tipping is the most serious cause which may leads to shut down of entire
unit. Because it is the fan which is used to remove the flue gases from the boiler by applying
–ve draft . If the ID FAN is tripped because of any reason then there is no path for leaving
flue gases from the boiler so ther is a chance of melting of tubes in the boiler this is an
undesirable thing so we need to maintain the draft in boiler in safe limits.In situation of ID
FAN tripping the MFT will sense the faulty situation and will initiate the tripping of the unit
through DCS.
 P a g e | 40

3.3 TRIPPING OF FD FAN

The tripping of FD FAN can also leads to similar effect as that of ID FAN
tripping but the only difference is the even though the FD FAN is tripped the ID FAN should
be in running condition because the temperature in boiler is very high i.e., greater than 1000
degree Celsius therefore it is necessary that the ID FAN should be in working condition
when FD FAN is tripped. So In situation of FD FAN tripping the MFT relay will sense the
faulty situation and will send trip signal to DCS.

Figure 3.1 RTS-B unit interlock schematic

 P a g e | 41

3.4 FURNCE PRESSURE UNSAFE

There are many important parameters to be monitored during any Power plant
normal & emergency operations. Furnace pressure is one such very important parameter,
which needs continuous control, protection & monitoring against any furnace explosion
and implosion. The National Fire Protection Association (NFPA) codes, such as NFPA 85:
Boiler and Combustion Systems Hazards Code are dedicated to fire and furnace explosion
and implosion protection. The NFPA also requires some additional logic for the furnace
pressure control loop to ensure adequate operating safety margins. There should be high and
low furnace pressure logic to block the ID fan from increasing or decreasing speed, as is
appropriate. A high furnace pressure signal the fan should be blocked from decreasing
speed and on a low furnace pressure signal it should be blocked from increasing speed. A
main fuel trip (MFT) there should be MFT kicker logic. An MFT occurs when the burner
management system detects a dangerous condition and shuts down the boiler by securing the
fuel per NFPA and boiler manufacturer requirements.
 P a g e | 42

CHAPTER-4
CONCLUSION

So in the conclusion, we can say that the boiler is heart for any thermal power station.
So it is necessary that we must operate boiler with in safe limits of its operating
conditions. We must take care of all of its auxiliaries, the temperature inside the
boiler& whether the required amount of steam is generating or not otherwise the entire
unit will be shut down .So the protection of boiler will play a major role in thermal
power plants. So by maintaining all the safety conditions we can increase the plant
efficiency.