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Boiler And Auxiliaries

Lalit Birla
Deputy Manager
(Operation)
What is Boiler?

 IBR Steam Boilers means any closed vessel exceeding 22.75 liters in capacity and which is used
expressively for generating steam under pressure and includes any mounting or other fitting attached
to such vessel, which is wholly, or partly under pressure when the steam is shut off.

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What is Boiler?

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What is Boiler?

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FUNDAMENTALS
 What happens when you heat water at normal atmospheric pressure?
 There are three stages.

• As you go on heating the water, the temperature of water increases till it reaches 100 deg C. This is
the Sensible Heat addition.

• Further heating does not increase the temperature; instead small bubbles of steam start to form. The
temperature remains constant at 100 deg C till all the water becomes steam. The water absorbs the
heat without temperature change for conversion to steam. At atmospheric pressure the Latent Heat of
vaporization is 2256 kJ/kg.
• Further heating called superheating will increase the temperature of the steam. How high one can go
depends on the withstanding capacity of the vessel

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FUNDAMENTALS

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 What happens when the water is at a higher
pressure, say, at 100 bar? Then the boiling takes
place at 311 deg C and the latent heat of
vaporisation is 1318 kJ/kg.

 If the water pressure is 200 bar then the boiling

takes place at 366 deg C and the latent heat of
vaporisation is 584 kJ/kg.

 As the pressure increases the boiling temperature

increases and the latent heat of vaporisation
decreases.

 A further increase in pressure and temperature leads

us to a point at which the latent heat of vaporisation
is zero, or there is no boiling. Water directly
becomes steam. This is the Critical Pressure and the
Critical Temperature. For steam this occurs at 374
deg C and 220.6 bar.
SUBCRICAL VS SUPERCRITICAL
568 DEG
596 DEG

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Fundamentals

 Conventional steam power plants operate at a steam pressures in the range of 170
bar. These are Subcritical power plants. The new generation of power plants operate
at pressures higher than the critical pressure. These are Supercritical power plants.
The operating pressures are in the range of 230 to 265 bar.

 The efficiency of the Rankine cycle depends on the pressure at which it operates. Higher
pressure and temperature increase the efficiency of the thermal cycle and power plant.
This is the reason for operating at higher steam pressures.

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EFFICIENCY
Solapur Super Critical Thermal Plant Efficiency?

What is Heat Rate?

 Heat rate is the heat energy input per unit of electrical energy
output.

 Unit kCal/kWh

 GROSS TURBINE CYCLE HEAT RATE (GTCHR) (kCal/kWh)

 Cycle Heat Rate (kCal/kWh)

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 ISGS
INPUT HEAT 1 kWh
1832 kCal
SOLAPUR Design GROSS TURBINE HEAT RATE is 1832 kCal/kWh

1832/.857 BOILER TURBINE 1 kWh

= 2137.69 kCal 1832 kCal
Boiler Design Efficiency
85.7 %

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EFFICIENCY

SOLAPUR 1 kWh
2137.69 kWh
PLANT

Design Gross Cycle Heat Rate 2137.69 kCal/kWh

Solapur Plant Efficiency ?

• Efficiency = Output/Input
• Output = 1 kWh = 860 kCal Designed Plant Efficiency is 40.23%
• Input = 2137.69 kCal

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NTPC SOLAPUR: 660MW RATED CAPACITY OEM: BGR HITACHI

Boiler is  Water Tube Boiler

 Tower Type Boiler

 Supercritical Boiler

 Balanced Draft
Boiler Parts

 Furnace: Made up of boiler tubes

 Water Wall tubes: Spiral and vertical

 Superheater

 Reheater

 Economiser

 Safety Valves

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Furnace

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Water Wall Tube

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Water Wall Tube

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Water Wall Tube

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Superheater, Reheater, Economiser

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 Solapur Boiler
ECO 1 FEEDWATER AND STEAM PATH IN BOILER ?
ECO 2 FEED
86 M WATE THROUGH
RH 1 R ECO 1 ECO 2 SPIRAL WW
DOWNCOMER
SH 2
RH 2 SH 3 SH 2 SH 1
VERTICAL
SH 3 WW
SEP
SH 1
58 M HPT IPT LPT
RH
RH 2
1

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DESIGN OF WATER STEAM SYSTEM

• Economiser - Plain Tube type - 2

sections
• Spiral + Vertical water walls
• Separators - 2 no.
• Collecting vessel - 1no.
• Boiler Water Circulating Pump - 1
no.
• Superheater - 3 sections
• Reheater - 2 sections

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Main Systems in Water – Steam Cycle:
• Eco-Evaporator System
• Super Heater System
• Reheater System
• Start Up System
• Circulation System
• Discharge System
• Condensate System
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ECONOMISER

• Two stage
• Parallel Flow

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ECONOMISER

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EVAPORATOR (WATER WALLS)

• Membrane
wall
construction.
• Spiral wall
• Vertical Wall

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EVAPORATOR (WATER WALLS)

• The hopper and furnace are

designed as spiral-wound tube wall
(helical coil)

• After the spiral-wound tubing, the

furnace outlet and convection pass
are provided with a vertical tubing.

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TRANSITION HEADER

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EVAPORATOR (WATER WALLS)

• The steam or steam – water mixture

coming from the two evaporator outlet
headers is connected to two radial
distributor.
• The fluid is mixed up here and distributed
to the two separators.
• Steam & Water is separated in separator.
• The separated water is passed to the
water collecting vessel and steam is
passed to Superheater.
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SUPER HEATER

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SUPER HEATER

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SUPER HEATER

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SUPER HEATER

• The separated steam flows to superheater 1 (SH1) consisting of

tubes and platen tube bundle.
• SH1 is Counter flow type.
• SH2 is arranged in counter flow between the two reheater
groups
• Attemperator – 1 is located between SH1 & SH2
• Attemperator – 2 is located between SH2 & SH3
• SH3 is connected in parallel flow to the flue gas.
• The spray water is extracted from the feedwater line upstream
of Economizer.
• The first attemperator stage controls the temperature difference over the
second attemperator stage and the second stage controls the main steam 33
REHEATER

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REHEATER

• RH1 & RH2 are arranged in

counter flow to the flue gas.
• Attemperator is located between
RH1 & RH2
• The spray water is extracted from
the intermediate stage of the
feedwater pump.

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 RH VENT SH VENT
EVO VENT RH DRAIN SH DRAIN

MS HRH CRH DRAIN

SOOT BLOWING DRAIN

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Material
Material
Component
Specification
Economiser SA-210M Gr. C
Evaporator Wall SA-213M T12
SA-213M T22
Superheater-1
SA-213M T91
Superheater-2 SA-213M T91
SA-213M T91
Superheater-3
SA-213M UNS S30432
SA-213M T12
Reheater-1
SA-213M T22
SA-213M T91
Reheater-2
SA-213M UNS S30432 SP

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39
 70 80

50 60

30 40

10 20
11 13
12 14

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BURNER

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BURNER

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 24
23
22
21 14
13
12
11

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Oil Guns

HFO( Heavy Fuel Oil) and LDO(Light Diesel Oil)

Purpose of the oil Firing System

• Start-up boiler
• Shut-down boiler
• Support firing

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Oil Guns

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Oil Guns

 LDO – Elevation 10 and 20

 HFO – Elevation 10,20,30,40,50,60,70,80
 LDO Atomization – with Service Air
 HFO Atomization – with Steam

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OIL GUNS

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Mill Arrangement
70 80

50 60

30 40

10 20

20 60
70 30

80
40
10
50

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Mill Designation
TOP VIEW

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Boiler Auxiliaries

 Oil Guns: HFO and LDO  Coal Mills

 SG ECW pumps  Coal Feeders
 CC (BRP) pump  Coal Bunkers
 Seal Air Fans
 FD Fans
 ESP
 ID Fans  Bottom Ash Hopper
 APH  Chimney
 PA Fans

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SGECW

 Steam Generator Equipment Cooling Water

 Used To cool down lube oil of auxiliary equipment.
 Fans Lube oil
 Mills Lube Oil and Hydraulic Oil
 APH Bearing Lube oil.
 Fans Winding cooler.
 BRP Motor Cooler
 BRP Heat Barrier cooling

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Boiler Circulation Pump

• Pump in operation During start

up(Low load condition/ wet
mode)

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 FD Fans

 Forced Draft Fan

 2 Nos.
 FD fan, is forced draft fan, is used basically
for providing the required quantity of hot air
to the furnace for smooth and uniform
combustion of fuel. FD fan will produce the
positive pressure inside the system i.e.
furnace.

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ID FAN

 Induced Draft Fan

 2 Nos
 ID fan is Induced draft fan and ID fan is located between ESP and chimney.
ID fan will take the hot flue gases from furnace via ESP and will deliver to
chimney. ID fan will handle the flue gases i.e. hot air.
 ID fan will produce the pressure lower than the atmospheric pressure in the
system or we may say that ID fan will produce the negative pressure in the
furnace to remove the flue gases from furnace via electrostatic precipitators
and to push the flue gases to chimney.

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PA FAN

 Primary Air Fan

 2 Nos
 Primary Air Fans or PA Fans. The
main function of the Primary
air fan or PA fan is to carry the
pulverized coal to the furnace as
fuel for combustion.

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 Air Preheater
 4 Nos Air Preheater
 2 SAPH(Secondary Air Preheater)
 2 PAPH (Primary Air Preheater)

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Mill/Pulveriser

 8 Nos of Bowl Mills

 Tasks of the mill system:
 Grinding
 Drying
 Transportation
 Classification
 Distribution of the coal

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How Mill Works?

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Coal Feeder

Regulate Feeding to Mill.

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RATED PARAMETERS

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Boiler Protection - MFT

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Boiler Protection- MFT

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 NTPC Ramagundam NTPC Talcher Kaniha NTPC Tanda

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