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    Boilers: by M.Rajasekara Babu

    Uploaded by

    Muthu Kumar
    The document provides information about boilers, including: 1) Boilers are enclosed vessels that use combustion heat to transfer heat into water and generate steam under pressure for uses like power generation and heating. 2) Boilers must meet certain criteria to fall under Indian Boiler Regulations, such as holding over 25 liters of water or operating above 1 kg/cm2 pressure or 100 degrees C temperature. 3) Boilers consist of various systems like feedwater, fuel, combustion, steam generation, and blowdown systems to generate and control steam production.

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    © All Rights Reserved
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    Boilers: by M.Rajasekara Babu

    Uploaded by

    Muthu Kumar
    148 views29 pages
    The document provides information about boilers, including: 1) Boilers are enclosed vessels that use combustion heat to transfer heat into water and generate steam under pressure for uses like power generation and heating. 2) Boilers must meet certain criteria to fall under Indian Boiler Regulations, such as holding over 25 liters of water or operating above 1 kg/cm2 pressure or 100 degrees C temperature. 3) Boilers consist of various systems like feedwater, fuel, combustion, steam generation, and blowdown systems to generate and control steam production.

    Original Description:

    A brief presentation on boilers used in process industry

    Original Title

    Boilers

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    The document provides information about boilers, including: 1) Boilers are enclosed vessels that use combustion heat to transfer heat into water and generate steam under pressure for uses like power generation and heating. 2) Boilers must meet certain criteria to fall under Indian Boiler Regulations, such as holding over 25 liters of water or operating above 1 kg/cm2 pressure or 100 degrees C temperature. 3) Boilers consist of various systems like feedwater, fuel, combustion, steam generation, and blowdown systems to generate and control steam production.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    148 views29 pages

    Boilers: by M.Rajasekara Babu

    Uploaded by

    Muthu Kumar
    The document provides information about boilers, including: 1) Boilers are enclosed vessels that use combustion heat to transfer heat into water and generate steam under pressure for uses like power generation and heating. 2) Boilers must meet certain criteria to fall under Indian Boiler Regulations, such as holding over 25 liters of water or operating above 1 kg/cm2 pressure or 100 degrees C temperature. 3) Boilers consist of various systems like feedwater, fuel, combustion, steam generation, and blowdown systems to generate and control steam production.

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    BOILERS

    By
    M.Rajasekara babu
    BOILERS

    ► Boilers is an enclosed vessel including mounting &


    fittings that provides a means for combustion heat
    to be transferred into water until it becomes steam
    partially or wholly under pressure.
    ► Used to generate steam for the purpose of
     Power Generation
     Prime Movers
     Process
     Heating
     Ejectors
    IBR
    ► Indian Boiler Regulation
    ► As per IBR Boiler means
     Holding capacity exceeding 25 liters
     Pressure above 1 Kg/Sq.cm
     Temperature above 100 Deg C
    ► As per IBR Steam Pipe means
     Pipe exceeds 3.5 Kg/Sq.cm Pressure below
    10”NB Pipe sizes.
     Pipe exceeds 1 Kg/Sq.cm pressure above &
    including 10”NB Pipe sizes.
    TYPES OF BOILERS
    ► Fire Tube Boiler
    ► Water Tube Boiler
    ► Packaged Boiler
    ► Stoker Feed Boiler
    ► Fluidized Bed Boiler
    ► Super Critical Boiler (221 Bar of 375 Deg C)
    ► Based on Fuel
    ► Based on Pressure
    BOILER CONSISTS
    ► Feed Water System
    ► Fuel System
    ► Combustion Air & Flue Gas or Draft System
    ► Fuel Combustion System
    ► Steam Generation System
    ► Blow Down System
    ► De-super heater system
    ► Steam System
    ► Dosing System
    Feed Water
    ► Factors for water quality
     Deposits
     Impurities causes deposits
    ►Ca & Mg (Hardness Salt)
    ►Ca & Mg bicarbonate (Temporary Hardness)
    ►Ca & Mg Sulphates, Chlorides & Nitrate (Permanent
    Hardness)
     Silica
    Water Treatment
    ► External Water Treatment
     Filters (Control of Solid Deposits)
     Ion Exchange Process (Convert Soluble Salts by
    softening. Replace Ca & Mg with Na)
     De-mineralization (Removal of all salts)
    ►Cation
    ►Anion

     De-aeration (Removal of dissolved Gases)


     Reverse Osmosis
    FUEL SYSTEM
    ► Fuel Storage
    ► Heating of Oil to correct viscosity
    ► Removal of contaminants (Strainers)
    ► Pumping
    ► Day Tanks
    ► Oil heaters
    DRAFT SYSTEM
    ► Natural
    Draft
    ► Mechanical Draft
     Forced Draft
     Induced Draft
     Balanced Draft
    COMBUSTION
    ► Rapid oxidation of fuel
    ► Fuel Atomization
     Steam atomization
     Air atomization
     Mechanical atomization
    ► Oil Firing Burners
    ► 3 T’s of Combustion
     Temperature (Ignition)
     Turbulence (Fuel Mixing)
     Time (Complete combustion)
    Steam Generation
    ► Boiler Heat Transfer Surface
     Generation Tubes
     Down Comer / Up raiser Tube
     Water wall tubes
     Roof panel tubes
     Floor Panel tubes
    ► Super Heater
     LT / Primary Super Heater
     HT / Secondary Super Heater
    Steam Generation
    ► Steam Drum
     Baffles
     Feed pipe
     Dosing pipe
     Demister / mist separator
    ► Mud Drum
    ► Headers
    ► Soot blowing
    BLOW DOWN SYSTEM
    ► Dissolved solids contained in the water
    remain in the boiler to control and removed
    by blow down process. Conductivity as
    indicator of contamination in the boiler
    water.
     Continuous Blow Down
     Intermediate Blow Down
    De-super heater
    ► To reduce the exit steam temperature when
    necessary and to maintain it within the
    limits.
    ► Fitted with a spray tube located horizontally
    to maintain uniform distribution of water at
    extremely low flow.
    Steam System
    ► Steam Distribution
     Steam Pipe Layout
     Pipe size
     Condensate removal (steam trap)
    ►Thermostatic steam trap
    ►Mechanical steam trap
    ►Thermodynamic steam trap

     Insulation
    Dosing System
    ► Internal water treatment
     To prevent formation of scale – forming
    compounds to free flowing sludge, which can be
    removed by blow down.
     Sodium Phosphate, Sodium sulphate, Sodium
    aluminates & Sodium carbonate
    BOILER MOUNTINGS

    ► Pressure gauges
    ► Safety valves (3Nos)
    ► Water level indicators (2 Nos.)
    ► Feed check valve
    ► Steam stop valve
    ► Fusible plug
    AUXILLARIES
    ► Air preheater ► Mechanical separators
    ► Economizer ► deaerator
    ► Super heaters ► chemical dosing
    ► Desuperheaters system
    ► Boiler feed pumps ► Pressure reduction

    ► FD & ID Fans valves


    QUALITIES OF BOILER
    ► QUICK START UP
    ► LESS MAITENANCE
    ► LESS FLOOR SPACE
    ► ABLE TO MEET LOAD FLUCTUATION
    ► LESS FUEL
    ► MAXIMUM EFFICIENCY
    ► EASY FOR MAITENANCE
    Losses in Boilers
    ► Heat loss from flue gas (stack temperature)
    ► Heat loss from moisture in the fuel
    ► Loss from incomplete combustion
    ► Radiation & convection heat loss from wall
    ► Blow down loss
    ► Loss from excess air
    Tube Failure
    ► Mechanical Damage
     Fly ash erosion
     Impingement
     Clinkers
    ► Chemical Causes
     Caustic gouging
     Hydrogen embrittlement
     Pitting
     Cold end corrosion
    ► Metallurgical Causes
     Creep damage / stress rupture
     Short time over heating
     Long time over heating
     Fatigue
    Preservation
    ► Boiler preservation is required to protect the internal
    surface from corrosion during shutdown time.
    ► Wet Method
     Hydrazine (200 ppm) / Sodium sulphite (300 ~ 400 ppm)
     pH 10.5 to 11
    ► Dry Method
     Silica gel / activated alumina (0.25 Kg / Sq.m)
     Un-slacked lime (0.098 Kg / Sq.m)
     Positive pressure with pure Nitrogen
    Statutory
    ► Annual Inspection
    ► RLA Study & Testing
    ► Hot work permission & Approval
    ► Part replacement permission & Approval
    ► Boiler Parts procurement & certifications
    ► Authorities for approvals
    SPECIFICATION
    Description Aux. Boiler ASGU RGB OSB
    Make BHEL Thermax L&T BHEL
    Code IBR IBR IBR IBR
    Water Tube Water Tube Fire Tube Water Tube
    Type
    Bi-drum Single drum Single drum Bi-drum
    Firing Oil fired Oil fired Oil fired
    Draft FD FD WHB FD
    MCR 90 TPH 120 TPH 149 TPH 85 TPH
    P-design 120 Ksc 123 Ksc 125.5 Ksc 50 Ksc
    P-working 106 Ksc 106 Ksc 106 Ksc 45 Ksc
    P-hydro 150 Ksc 155 Ksc 153 Ksc 67.5 Ksc
    Steam Temp 482 Deg C 482 Deg C 482 Deg C 382 Deg C
    Heating Area 2278 Sq.m 1715 Sq.m 1962 Sq.m 1620 Sq.m
    AUX. BOILER
    ASGU
    OSB
    THANK YOU

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