Air & Gas

Boiler Area
Air & Gas

System
Presented By:
Ali Rehman
Saad Akhlaq
Nawaz Mustafa
Contents to be discussed today:
 System Introduction
 FDF
 Gas Air heater
 GRF
 Introduction of Combustion Air and
Aux Air
 System set points and Trips
 System Emergencies and Runback
 System startup and shut down
 Operational Procedures
 VVVF Drive
GRF Outlet Damper Inlet Guide Vane
Tempering Air
Gas Air Heater
Steam Air Heater FDF Silencer
GRF GAH Air Outlet Damper
FDF Outlet Damper Inlet Guide Vane
GAH Flue Gas Inlet Damper GAH Flue Gas Outlet Damper
Furnace Secondary Stack

Pass
GAH Flue Gas Inlet Damper GAH Flue Gas Outlet Damper
Inlet Guide Vane

FDF Outlet Damper
GRF GAH Air Outlet Damper

FDF Silencer
Gas Air Heater Steam Air Heater
Tempering Air
GRF Outlet Damper Inlet Guide Vane
Forced Draft Fan
 Type Horizontal Single stage
double suction centrifugal type
 Capacity (volume) 12620 m3/min
 Suction pressure 1040 mmAq
 Delivery pressure 1100 mmAq
 Control system inlet vane system
 Speed 980 rpm
 Motor capacity 3000 KW
Steam Air Heater
 Its purpose is to control the cold end metal temperature
 The steam air heater starts working at 20 bars pressure, as
on this pressure supply of steam from auxiliary header

becomes available.
 The two sources of steam supply for the steam air heater
are:
◦ Auxiliary header From
Extraction 5 (9.0-9.5 kg/cm2)
◦ Extraction no. 5 SAH (A)

PCV(Set point: 5.5 TCV
kg/cm2)
From Aux. Header
SAH (B)
TCV
 Condensate returns to LP Heater 2/ Hot well.

Gas Air Heater
 Absorbs waste heat from flue gases and
transfers heat to cold air.
 Revolution: 1.424
 Air Heater DP: 180 mm Aq
 Bearing Oil pump : 50C (Cut in) & 45C (Cut
Out)
Internal Structure of Baskets illustrated
Material: Cold Rolled Carbon Steel
Material: Corrosion Resistant Low Alloy Steel

Gas Air Heater
 Driving mechanism of Gas Air Heater:
◦ Electric Motor
◦ Air Motor
◦ Hand Driven
 AH Washing
Average Cold End Metal Temperature
 Average temperature: 125C at Min load &
111C at Max load
 Temperature is maintained by SAH TCV
Example:
Gas Air Heater At Max. Load
Flue Gas
TFlue Gas inlet TFlue Gas Outlet Tflue Gas Outlet = 158.1 C
Then
TCold Air Outlet TCold Air inlet Cold Air

Tcold Air Inlet = 64.3 C
Set Points
 Average Cold End Metal Temperature: 125
(At Min.)
 Average Cold End Metal Temperature: 111
(At Max.)
 Bearing Oil Pump on: 50C
 Bearing Oil Pump off: 45C
Wind Box
 Wind box Damper Types:
◦ Fuel Air Dampers (20-100%)
◦ Aux Air Dampers (20-100%)
◦ Over fire Dampers (20-40%)
 Igniter Wind box Dampers
 Furnace Wind box DP: 180mm

 Ignitor Wind Box DP: 150mm
Fuel and Auxiliary Air Dampers illustrated
Complete combustion and over fire damper illustrated
Gas Recirculation Fan
 Main purpose is to maintain the reheat steam
temperature and control Nox production.
 2 GRF installed (Each has 50% of MCR
capacity).
 Takes gases from secondary pass and blows
back into furnace

 Controlled by VVVF Drive
Soot Blower
GRF
Soot Blower
Air Heater
FDF
Peep Hole Peep Hole
Wind Box
Wind Box
Cooling
Detector
Cooling
Burner
Igniter
Burner
Igniter Fan
Flame
AC Cooling Fan
Flame Detector Cooling Air

Damper Shaft Seal
Burner Cooling Air
Combustion Air For Igniter
Air Heater
DC Cooling Fan
TV Camera
FDF
GRF
Combustion Air for Igniter
 Igniter Fan is used when the Load is less than
50% of full Load.
 Uses direct air from FDF when the load is
above 50%.
 Stabilizer is used for mixing of combustion
air in Igniter
Startup of Air and Gas System
Description Status
Gas Air-A heater motor drive Starts
Gas Air-B heater motor drive Starts
FD Fan A Starts
FD Fan B Starts
AC cooling air fan Starts
Igniter air fan Starts
GRF A Starts
GRF A Turning gear motor OFF
GRF B Starts
GRF B Turning gear motor OFF

VVVF Drives
 Installed in GRF and FDF in our Boiler
 Due to Varying output Demands in prime
movers i.e Motors

 It controls the rotational speed and the
frequency of the electrical power supplied to

the motor according to the requirements.
 VVVF Drives also known as adjustable-
frequency drives (AFD), variable-speed drives

(VSD),
FDF VVVF
Operating principle
 Variable frequency drives operate under the principle that
the synchronous speed of an AC motor is determined by the
frequency of the AC supply and the number of poles in the
stator winding, according to the relation:
Where,
RPM = Revolutions per minute
f = AC power frequency (Hertz)
p = Number of poles
 Example
A 4-pole motor that is connected directly to 50 Hz utility

(mains) power would have a synchronous speed of 1500 RPM:
120 x 50 = 1500 rpm
4
VVVFD system
 A variable frequency drive system
generally consists of an AC motor, a
controller and an operator interface.
VVVFD controller
 It contains six diodes, These diodes convert AC power to
DC power.
 The DC bus section filters and smoothes out the
waveform sees a fixed DC voltage.

 Inverter inverts the DC voltage back to AC. But, it does
so in a variable voltage and frequency output.

 Inverters use Insulated Gate Bipolar Transistors (IGBTs)
to switch the DC bus on and off at specific intervals. In

doing so, the inverter actually creates a variable AC
voltage and frequency output.
 Embedded microprocessor governs controller and the
specific parameters are accessible for programing to the

user to suit the motor equipment requirements

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Boiler Area

Air & Gas

FDF Outlet Damper Inlet Guide Vane

Furnace Secondary Stack

Inlet Guide Vane

GRF GAH Air Outlet Damper

on this pressure supply of steam from auxiliary header

◦ Extraction no. 5 SAH (A)

From Aux. Header

 Condensate returns to LP Heater 2/ Hot well.

Material: Cold Rolled Carbon Steel

Material: Corrosion Resistant Low Alloy Steel

 Temperature is maintained by SAH TCV

TCold Air Outlet TCold Air inlet Cold Air

 Furnace Wind box DP: 180mm

back into furnace

Flame Detector Cooling Air

Combustion Air For Igniter

Gas Air-A heater motor drive Starts

Gas Air-B heater motor drive Starts

AC cooling air fan Starts

Igniter air fan Starts

GRF A Turning gear motor OFF

GRF B Turning gear motor OFF

movers i.e Motors

frequency of the electrical power supplied to

frequency drives (AFD), variable-speed drives

A 4-pole motor that is connected directly to 50 Hz utility

waveform sees a fixed DC voltage.

so in a variable voltage and frequency output.

to switch the DC bus on and off at specific intervals. In

specific parameters are accessible for programing to the

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