You are on page 1of 61

REPORT ON THEORITICAL ANALYSIS ON AFBC(ATMOSPHERIC FLUIDIZED BED COMBUSTION) BOILER

Submitted by

CHHATRAVALA AMIT A. (080160119013) BARAIYA RAMESH P. (090163119002) SANGANI JAYVANT B. (090163119101)


In fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
In

MECHANICAL

GOVERNMENT ENGINEERING COLLEGE MODASA Gujarat Technological University, Ahmedabad


December, 2011

Government Engineering College Modasa Mechanical Engineering Department 2012

Page | 1

CERTIFICATE Date: 25-4-2012 This is to certify that the dissertation entitled Theoritical analysis on AFBC(Atmospheric Fluidized Bed Combustion) Boiler has been carried out by BARAIYA RAMESH P. under my guidance in fulfillment of the degree of Bachelor of Engineering in Mechanical engineering (8th Semester) of Gujarat Technological University, Ahmedabad during the academic year 2011-12.

Guides:
Prof. R.J. Jani

Head of the Department

Page | 2

Government Engineering College Modasa Mechanical Engineering Department 2012 CERTIFICATE Date:25-4-2012 This is to certify that the dissertation entitled Theoritical analysis on AFBC(Atmospheric Fluidized Bed Combustion) Boiler has been carried out by CHHATRAVALA AMIT A. under my guidance in fulfillment of the degree of Bachelor of Engineering in Mechanical engineering (8th Semester) of Gujarat Technological University, Ahmedabad during the academic year 2011-12.

Guides:
Prof. R.J. Jani

Head of the Department

Page | 3

Government Engineering College Modasa Mechanical Engineering Department 2012 CERTIFICATE Date:25-4-2012 This is to certify that the dissertation entitled Theoritical analysis on AFBC(Atmospheric Fluidized Bed Combustion) Boiler has been carried out by SANGANI JAYVANT B. under my guidance in fulfillment of the degree of Bachelor of Engineering in Mechanical engineering (8th Semester) of Gujarat Technological University, Ahmedabad during the academic year 2011-12.

Guides:
Prof. R.J. Jani

Head of the Department

Page | 4

Table of content
Acknowledgement Abstract List of figure Title of chapter

Chapter no 1. 1.1 1.2 1.3

Introduction Introduction Main components of plant Rankine cycle and its analysis

page 10 14 15

Chapter no 2.

Raw water treatment plant

2.1 2.2 2.3

D.M Plant Circuit D.M.Plant Deaerator

19 20 22

Chapter no.3 3.1

Coal handling plant Coal Handling Process description 25

Chapter no. 4 4.1 4.2 4.3 4.4

Boiler AFBC Boiler Waste Heat Recovry Boiler Boiler Specification Boiler Safty 28 39 39 40

Chapter no 5 Boiler mountings and accesories


5.1 5.2 Mountings Accessories 41 44

General Problems In boiler Emegencies in Boiler Do & Donts Features & Benefits Conclusion

56 56 58 60 61

Page | 5

Acknowledgement
we are the students of government engineering college modasa, we has take industrial training in varrasana ispat ltd at varrasana nearby gandhidham. when a good thing comes to end, memories are left behind, in this regard, I amindebted to respected chairman S.P. Patel for giving us this wonderful opportunity to a project in a organization, we are highly obliged to varrasana ispat ltd. where we have done our summer training.we are thankful to S.P.Patel for giving us permission for doing summer training.We are also thankful to Prof. R.J. Jani for supporting us throughout the entire project.

Page | 6

ABSTRACT

With teaching our knowledge become good, traning is developing our habbit.It assure that technical studies cannot perform adroit without practical training. Hence the practical training is exorbitant for engineering student. The actual objective of plant training is to get all detail about organization and main enance about all operation and procrss, which are caried out practical knowledge. Its inviting feature is to learn industrial management and discipline. In this report of training we include all the details related to our project as well as company.

In this report we have include AFBC boiler detail and try to get knowledge about AFBC Boiler.

Page | 7

List of figures Fig no. fig. description page

1.1 1.2 2.1 2.2 3.1 4.1 4.2 5.1 5.2 5.3

Over View of plant Physical layout of rankine cycle D.M Plant Deaerator Grab Bucket Conveyer AFBC Boiler Mechanism of FBC Boiler Mountings & Accesories Economiser Air-Preheater

11 15 21 22 28 28 32 41 46 47

Page | 8

PREFACE

In developing economy that is ours, development inputs remain constant demand necessitating use of resources. Electric by virtue of its being the most convenient form of inputs, has proved to be one of the most powerful vehicles for promoting economic well being of the society through industrial growth.

Electric power has thus come to be considered as the most important input in the nations endeavors towards industrialization as well as in attaining the growth rate that our development plans aim to achieve. It is thus only natural that the per capita of electricity has come to be considered as a measure of the countrys industrial accomplishment as also the standard of living of the society.

The country has made tremendous progress in the field of electric power in the past three decades. The installed capacity has steadily increased to 45000 MW. From this generation was from coal fired power plant.

Indian has reserves of the order of 13000 million tones/ much of reserves is not of high quality and contains appreciable amount of incombustible matter. It is only rational to utilize these large reserves of coal by converting this primary source of energy to process and more concentrated forms, which makes it easy for transportation and use. Conversion of electric power is one such processing on which the country has rightly placed the emphasis upon.

Chapter 1
Page | 9

INTRODUCTION

This section briefly describes the Boiler and various auxiliaries in the Boiler Room. A boiler is an enclosed vessel that provides a means for combustion heat to be transferred to water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and inexpensive medium for transferring heat to a process. When water at atmospheric pressure is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be an equipment that must be treated with utmost care.

The boiler system comprises of: a feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system.

The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returned from the processes and (2) Makeup water (treated raw water) which must come from outside the boiler room and plant processes. For higher boiler efficiencies, an economizer preheats the feed water using the waste heat in the flue gas.

1.1) OVERVIEW OF THE PLANT


Page | 10

1.1 Fig. captive power plant at Electrotherm ( AFBC type.)

OVERVIEW OF THE PLANT


Page | 11

SR NO. 1. 2. 3. 4. 5. 6. 7. 8.

NAME Location Capacity Fuel type Boiler type Nos. of boiler Turbine Condenser Coling tower

DESCRIPTION Varrsana(gujarat) 36MW Indonesian coal , char coal , lignite A.F.B.C & W.H.R.B Four Impuls reaction turbine Surface type Cross flow Coling tower

The power plant of ELECTROTHERM has a maximum generation capacity of 25MW with the help of two Turbine each of 15MW capacity.

Now the generator according to its principle converts the mechanical energy of rotational into electrical energy which is varied according to use by the transformers.

The coal to the boiler is supplied from the coal bunker with the help of the conveyor belt. The coal is crushed in between crusher and is transferred to the boiler furnace, with a requirement size. The size of the coal feed to the boiler should not be more than 6mm.

Limestone is also added to lignite during feeding to furnace to control the Sox and NOx emission.

During this the primary air is supplied from the nozzles below bed and the secondary air is supplied from the walls of furnace.

Due to fluidization the flue gas and fly ash with unburnt particles goes to cyclone separator. Now the fly ash below the 60-micron size is separate and flue gas goes to super heater and unburnt particles are entered into the seal pot.

One particle of the lignite recycles about 50,000 times, so it is obvious that the total combustion of lignite takes place in furnace, so the efficiency is increased. Page | 12

The ash product is of two types. They are bottom ash and fly ash. The fly ash is removed by ESP and the bottom ash is removed by mechanical ash handling system.

1.2) THE MAIN COMPONENT OF A POWER PLANT :


Boiler Page | 13

Turbine Alternator, generator Coal handling system Ash handling system Condenser Pumps Fans Raw water treatment plant. Cooling tower

1.3) RANKINE CYCLE AND ITS ANALYSIS

Page | 14

Rankine cycle is the idealized cycle for steam power plants. This cycle is shown on p-v, ts, h-s, diagram in the below figures. It consists of following processes:

(A)Physical layout of the four main devices used in the Rankine cycle

The different process involved in rankine cycle is explained below:

Process 1-2: Water from the condenser at low pressure is pumped into the boiler at high pressure. This process is reversible adiabatic.

Process 2-3: Water is converted into steam at constant pressure by the addition of heat in the boiler.

Process 3-4: Reversible adiabatic expansion of steam in the steam turbine.

Process 4-1:Constant pressure heat rejection in the condenser to convert condensate in to water. Page | 15

1.3.1) THERMAL EFFICIENCY OF RANKINE CYCLE


Page | 16

Consider one kg of working fluid, and applying first law to flow system to various processes with the assumption of neglecting changes in potential and kinetic energy, we can write,

Page | 17

1.3.2) REASONS FOR COSIDERING RANKINE CYCLE AS AN IDEAL CYCLE FOR STEAM POWER PLANT
1. It is very difficult to build a pump that will handle a mixture of liquid and vapor at state 1 (refer T-s diagram) and deliver saturated liquid at state 2. It is much easier to completely condense the vapor and handle only liquid in the pump. 2. In the rankine cycle, the vapor may be superheated at constant pressure from 3 to 3 without difficulty. In a Carnot cycle using superheated steam, the superheating will have to be done at constant temperature along path 3-5. During this process, the pressure has to be dropped. This means that heat is transferred to the vapor as it undergoes expansion doing work. This is difficult to achieve in practice.

Chapter 2
Page | 18

RAW WATER TREATMENT PLANT

2.1.) D.M. PLANT CIRCUIT


Raw water

D.M.F. (de-media filter)

U.F. membrance (ultra filter )

S.A.C. (stronge acid catayan )

Degasser tank

W.B.A (week base anayen )

S.B.A. (stronge base anayen )

M.B. (mix bed )

D.M. water tank

Boiler

Page | 19

2.2) DEMINERALISATION PLANT (D.M. PLANT):Ion exchange units can be used to remove any charged (ionic) substance from water, but are usually used to remove hardness and nitrate from groundwater. Water is pretreated to reduce the suspended solids and total dissolved solids (TDS) load to the ion-exchange unit. Methods of pretreatment include: Filtration, Coagulation and filtration, Cold lime with or without soda ash, Hot lime with or without soda ash, Evaporation or distillation, Electrodialysis, RO (reverse osmosis).

Ion exchange:Ion exchange effectively removes more than 90 percent of barium, cadmium, chromium (III), silver, radium, nitrites, selenium, arsenic (V), chromium (VI), and nitrate. Ion exchange is usually the best choice for small systems that need to remove radionuclides.

Procedure:Procedure for demineralization are given below, Water from filter are passed through the carbon filter and remove chlorine from it.

Cation exchanger:Water from carbon filter is passed from upper side the cation exchanger tank and discharge from bottom outlet water in cation exchanger process with in tanks and remove the all positive from the water.

Dessenger :To remove O2 & CO2 from water then fallen from top of dessenger And is given from bottom of the dessenger, This remove CO2 from water.

Water base exchanger:Water is then passed through the water base anion exchanger to remove chlorine and ion from it.

Page | 20

Strong base anion exchanger:Water then passed through the strong base exchanger to remove silica from it.

Mixed bed exchanger:Finally water is passed through the mixed bed to remove residual ion and silica from it. Then deminaralized water is stored in storage tank.

Fig : 2.1 D.M Plant

Page | 21

D.M. pumps specifications


SR. NO. DESCRIPTION 1 2 3 4 5 6 Make No. of pumps Water temperature Rated flow design Head at design condition Rated speed Nos.
o

UNIT Beacon weir Ltd. 2 (1 working + 1 standby) 45 253 75 1470

m3/hr M Rpm

2.3) DEAERATOR:-

A steam generating boiler requires that the boiler feed water should be devoid of air and other dissolved gases, particularly corrosive ones, in order to avoid corrosion of the metal.

Page | 22

DEARATOR SPECIFICATIONS
MAKE QUANTITY TYPE DEARATOR CAPACITY OPERATING PRESSURE TEMP. OF INCOMING WATER TEMP. OF DEARATOR WATER DISSOLVED O2 IN WATER NORMAL WATER LEEVEL EAS system Hyderabad One Spray cum tray- counter flow 150 TPH 1.5 kg/cm2 55 oc 120 oc 0.005 ppm +1125 mm

Generally, power stations use a deaerator to provide for the removal of air and other dissolved gases from the boiler feedwater. A deaerator typically includes a vertical, domed deaeration section mounted on top of a horizontal cylindrical vessel which serves as the deaerated boiler feedwater storage tank. There are many different designs for a deaerator and the designs will vary from one manufacturer to another. The adjacent diagram depicts a typical conventional trayed deaerator. If operated properly, most deaerator manufacturers will guarantee that oxygen in the deaerated water will not exceed 7 ppb by weight (0.005 cm/L).

Page | 23

Chapter 3 COAL HANDLING PLANT


Coal handling system contains unloading, transferring, crushing and storage of coal and finally supplying quantity to the boiler plant.

Properties:Coals are ranked according to their carbon content. Under mild conditions of heat and pressure, the lowest rank coals were formed, consisting of brown coal and lignite. At higher temperatures and pressures, sub-bituminous and bituminous coals were formed, and under very high pressures, the highest rank coals, called anthracites, were formed. The anthracites contain more than 92% carbon, 23% hydrogen together with oxygen, volatile matter and impurities. Bituminous coal contains about 5% hydrogen and has a carbon content of 7080%. The lowest ranks of lignite and brown coal may have less than 50% carbon content. Sulfur is an important impurity as it appears in combustion products as oxides of sulfur (SO2), which pollutes the environment.

COAL SPECIFICATIONS
COAL MOISTUR E (%) ASH (%) VOLATILE MATTER (%) CARBON (%) CALORIFIC VALUE (kcal/kg) SULPHURE (%)

pet-coke Indonesian South African Chinese Australian High ash Lignite

5-8 10-12 9.59 8.08 8.75 8.22 30

0.6 3-10 23.67 12.83 13.4 31.79 15.20

9-11 38-40 22.9 29.3 25.2 25.8 30-34

70-80 40 44-55 49-79 52-62 34-45 23-30

8200 5410 4760 6335 6348 4505 3500-4000

0.65-0.80 0.89 0.48 0.66 0.70 084 ----Page | 24

3.1 COAL HANDLING PROCESS DESCRIPTION:


Coal handling process is mainly divided into three process according to the path of coal. 1. Staking 2. Direct bunkering 3. Reclaiming

1.) STAKING In this process coal from the coal hopper is go to the belt conveyor 1. On belt conveyor-1 one magnetic separator placed to separate the metal particles from the coal. Then coal is gone to the crusher and crushed in size of 5 to 6mm. This crushed coal is gone to storage through the belt conveyor-5.

2.) DIRECT BUNKERING: As given above process, coal come at crusher from hopper and after crushing the coal in 5 to 6mm size is gone on belt conveyor-2 as requirement in boiler plant. From belt conveyor-2 coal gone on belt conveyor-3. On belt conveyor-3also one magnetic separator is placed to find out the metallic particle from coal. Then coal is gone on the belt conveyor-4 from which coal is feed in bunker. This process is called direct bunkering because coal from wagon trippler is directly comes to the bunker.

Page | 25

3.) RECLAIMING: Process of transferring coal from storage to the coal bunker at boiler plant is called reclaiming. Coal storage from conveyor receiving hopper goes on the belt conveyor-6 On belt conveyor-6 magnetic pulley and magnetic separator are placed to separate the magnetic particles. Then this coal is gone on the belt conveyor-2, belt conveyor-3 and belt conveyor-4 and finally in bunker as direct bunkering.

STORAGE OF COAL The purpose of coal storage is two fold, first fuel storage is an insurance against complete shutdown of a power plant occurring from failure of normal supplies. Second, the storage permits the choice of the date of purchase allowing the management to take advantages of seasonal market condition. Storage of coal protects the plant failure in case of coal strikes, failure of the transportation system and general coal storage of coal. Coal is undesirable, because its cost more as there is risk of spontaneous combustion, possibility of loss and deterioration during storage, interest on capital costs of coal lying dormant cost of insurance, cost required to protect the storage coal deterioration and many others.

Fig.3.1grab bucket conveyor

Page | 26

FUEL CIRCUIT

Pure coal

bunker

pocket feeder

drag chain feeder

P.A. Line

Furnace

Page | 27

Chapter 4

BOILERS
Boiler is designed as a heart of TPS because it is the component in which due to burning of fuel, heat is produced which in turn is used to heat the water so as to produced steam, at rated pressure which rotates the turbine rotor. The turbine is coupled with the generator, which produced the electricity. Not only is this, the steam produces also utilized for the process.

4.1.) Atmospheric Fluidized Bed Combustion. (AFBC) Boiler

Fig:4.1 AFBC Boiler

4.1.1) Introduction to FBC Boilers This section briefly describes the Boiler and various auxiliaries in the Boiler Room. A boiler is an enclosed vessel that provides a means for combustion heat to be transferred to water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and inexpensive medium for transferring heat to a process. When water at atmospheric pressure is boiled into steam its Page | 28

volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be an equipment that must be treated with utmost care. The boiler system comprises of: a feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system. The water supplied to the boiler that is converted into steam is called feed water. The two sources of feed water are: (1) Condensate or condensed steam returned from the processes and (2) Makeup water (treated raw water) which must come from outside the boiler room and plant processes. For higher boiler efficiencies, an economizer preheats the feed water using the waste heat in the flue gas.

Page | 29

The traditional grate fuel firing systems have several limitations and hence are techno economically unviable to meet the challenges of the future. FBC has emerged as a viable alternative as it has significant advantages over conventional firing system. FBC offers multiple benefits, such as: compact boiler design, flexibility with fuel used, higher combustion efficiency and reduced emissions of noxious pollutants such as SOx and NOx. The fuels burnt in these boilers include coal, washery rejects, rice husk, bagasse and other agricultural wastes. The fluidized bed boilers have a wide capacity range- 0.5 T/hr to over 100 T/hr.

Page | 30

WATER CRICUIT

Raw water

D.M.plant

Dearator

Feed pump

Economiser

Steam drum

Down chamber

Bed coil

Water wall

Riser tube

Steam drum

Primory superheater

Secondray superheater

Main steam line

Turbine

Page | 31

4.1.2.) Mechanism of Fluidized Bed Combustion

When an evenly distributed air or gas is passed upward through a finely divided bed of solid particles such as sand supported on a fine mesh, the particles remain undisturbed at low velocities. As the air velocity is gradually increased, a stage is reached when the individual particles are suspended in the air stream and the bed is called fluidized. With further increase in air velocity, there is bubble formation, vigorous turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid

particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid bubbling fluidized bed. At higher velocities, bubbles disappear, and particles are blown out of the bed. Therefore, some amounts of particles have to be re-circulated to maintain a stable system and is called as Atmospheric fluidized bed". This principle of fluidization is illustrated in Figure.

Fig:4.2 Mechanism of FBC Boiler

Page | 32

Fluidization depends largely on the particle size and the air velocity. The mean solids velocity increases at a slower rate than does the gas velocity. The difference between the mean solid velocity and mean gas velocity is called as slip velocity.

Maximum slip velocity between the solids and the gas is desirable for good heat transfer and intimate contact. If sand particles in fluidized state are heated to the ignition temperatures of fuel (rice husk, coal or bagasse), and fuel is injected continuously into the bed, the fuel will burn rapidly and the bed attains a uniform temperature.

The fluidized bed combustion (FBC) takes place at about 840C to 950C. Since this temperature is much below the ash fusion temperature, melting of ash and associated problems are avoided. The lower combustion temperature is achieved because of high coefficient of heat transfer due to rapid mixing in the fluidized bed and effective extraction of heat from the bed through in-bed heat transfer tubes and walls of the bed. The gas velocity is maintained between minimum fluidization velocity and particle entrainment velocity. This ensures a stable operation of the bed and avoids particle entrainment in the gas stream.

Any combustion process requires three Ts - that is Time, Temperature and Turbulence. In FBC, turbulence is promoted by fluidization. Improved mixing generates evenly distributed heat at lower temperature. Residence time is many times higher than conventional grate firing. Thus an FBC system releases heat more efficiently at lower temperatures. Since limestone can also be used as particle bed (in case the fuel with sulphur content is used), control of SOx and NOx emissions in the combustion chamber is achieved without any additional control equipment. This is one of the major advantages over conventional boilers.

Page | 33

AIR CIRCUIT

Atmospheric air

F.D. fan

F.D. header

Air box

P.A. fan suction

Furnace

P.A.fan

Furnace

Page | 34

PROCESS AND PLANT STRUCTURE:The plant basically consist of two boiler, two electrostatic precipitator, one ID fan, one primary air fan, one secondary air fan, and two hot gas generators and cyclones and siphons are provided for circulating the ash.

FIG. Atmospheric Fluidized Bed Combustion System

AFBC is one of the most important types of FBC boilers as it can be used for variety of fuels - such as agricultural residues like rice husk or bagasse and even low quality coal. This type of boiler find use in industries where there is a possibility of having a combined heat and power generation application. In AFBC boilers the fuel is sized depending on the type of fuel (in case of coal, the coal is crushed to a size of 1 10 mm depending on the grade of coal) and the type of fuel feeding system and is fed into the combustion chamber. The atmospheric air, which acts as both the fluidization air and combustion air, is delivered at a pressure and flows through the bed after being preheated by the exhaust flue gases. The velocity of fluidizing air is in the range of 1.2 to 3.7 m /sec. The rate at which air is blown through the bed determines the amount of fuel that can be reacted.

Page | 35

Almost all AFBC/ bubbling bed boilers use in-bed evaporator tubes in the bed of limestone, sand and fuel for extracting the heat from the bed to maintain the bed temperature. The bed depth is usually 0.9 m to 1.5 m deep and the pressure drop averages about 1 inch of water per inch of bed depth. Very little material leaves the bubbling bed only about 2 to 4 kg of solids is recycled per ton of fuel burned. Typical fluidized bed combustors of this type are shown in Figures 5 and 6.

The combustion gases pass over the super heater sections of the boiler, flow past the economizer, the dust collectors and the air pre-heaters before being exhausted to atmosphere. The main special feature of atmospheric fluidized bed combustion is the constraint imposed by the relatively narrow temperature range within which the bed must be operated. With coal, there is risk of clinker formation in the bed if the temperature exceeds 950C and loss of combustion efficiency if the temperature falls below 800C. For efficient sulphur retention, the temperature should be in the range of 800C to 850C.

Page | 36

General Arrangements of AFBC Boiler

AFBC boilers comprise of following systems: Fuel feeding system Air distributor Bed & In-bed heat transfer surface Ash handling system.

Many of these are common to all types of FBC boilers.

Page | 37

Page | 38

4.2.) Waste Heat Recovery Boiler Wherever the waste heat is available at medium or high temperatures, a waste heat boiler can be installed economically. Wherever the steam demand is more than the steam generated during waste heat, auxiliary fuel burners are also used. If there is no direct use of steam, the steam may be let down in a steam turbinegenerator set and power produced from it. It is widely used in the heat recovery from exhaust gases from gas turbines and diesel engines.

4.3.) BOILER SPECIFICATIONS


BOILER NO. AND NAME TYPE OF COAL USED STEAM PRE.AND QUANTITY, TEMP. A.F.B.C-1 Atmosperic combustion A.F.B.C-2 Atmosperic combustion W.H.R.B-1 West heat recovery boiler W.H.R.B-2 West heat recovery boiler ___ 36 TPH, 66.5 Kg/cm2, 4900 C ___ 28 TPH, 66.5 Kg/cm2, 4900 C Fluidized Indonesian+ char Coal+ bed Lignit 65 TPH, 66.5 Kg/cm2, 4900 C Fluidized Indonesian+ char Coal+ bed Lignit 65 TPH, 66.5 Kg/cm2, 4900 C

Page | 39

4.4) BOILER SAFETY


Historically, boilers were a source of many serious injuries and property destruction due to poorly understood engineering principles. Thin and brittle metal shells can rupture, while poorly welded or riveted seams could open up, leading to a violent eruption of the pressurized steam. Collapsed or dislodged boiler tubes could also spray scalding-hot steam and smoke out of the air intake and firing chute, injuring the firemen who loaded coal into the fire chamber. Extremely large boilers providing hundreds of horsepower to operate factories could demolish entire buildings. A boiler that has a loss of feed water and is permitted to boil dry can be extremely dangerous. If feed water is then sent into the empty boiler, the small cascade of incoming water instantly boils on contact with the superheated metal shell and leads to a violent explosion that cannot be controlled even by safety steam valves. Draining of the boiler could also occur if a leak occurred in the steam supply lines that was larger than the make-up water supply could replace. The Hartford Loop was invented in 1919 by the Hartford Steam Boiler and Insurance Company as a method to help prevent this condition from occurring, and thereby reduce their insurance claims.

Page | 40

Chapter 5 BOILER MOUNTINGS AND ASSESORIES

5.1) Mountings:
Boiler mountings are the machine components that are mounted over the body of the boiler itself for the safety of the boiler and for complete control of the process of steam generation. Various boiler mountings are as under: 1.) Safety valve 2.) Pressure gauge. 3) Fusible plug. 4) Steam stop valve 5) Feed check valve 6) Blow off cock 7) Man and mud holes. 8.) Water level indicators: 9.) Low- water cutoff: 10.) Bottom blow down valves: 11.) Surface blowdown line 12.) De-superheater tubes or bundles:

Page | 41

1.) Safety valve: It is used to relieve pressure and prevent possible explosion of a boiler.

2.) Pressure gauge: Function: To record the steam pressure at which the steam is generated in the boiler. A bourden pressure gauge in its simplest form consists of elliptical elastic tube bent into an arc. This bent up tube is called as BOURDENS tube. One end of tube gauge is fixed and connected to the steam space in the boiler. The other end is connected to a sector through a link. 3.) Fusible plug: Function: To extinguish fire in the event of water level in the boiler shell falling below a certain specified limit. It protects fire tubes from burning when the level of the water in the water shell falls abnormally low and the fire tube or crown plate which is normally submerged in the water, gets exposed to steam space which may not be able to keep it cool. It is installed below boiler's water level. When the water level in the shell falls below the top of the plug, the steam cannot keep it cool and the fusible metal melts due to over heating. Thus the copper plug drops down and is held within the gunmetal body by the ribs. Thus the steam space gets communicated to the firebox and extinguishes the fire. Thus damage to fire box which could burn up is avoided. By removing the gun metal plug and copper plug the fusible plug can be put in position again by interposing the fusible metal usually lead or a metal alloy.

4.) Steam stop valve A valve is a device that regulates the flow of a fluid (gases, fluidized solids, slurries, or liquids) by opening, closing, or partially obstructing various passageways Function: to shut off or regulate the flow of steam from the boiler to the steam pipe or steam from the steam pipe to the engine. When the hand wheel is turned, the spindle which is screwed through the nut is raised or lowered depending upon the sense of rotation of wheel. The passage for flow of steam is set on opening of the valve.

5.) Feed check valve: i) To allow the feed water to pass into the boiler. ii) To prevent the back flow of water from the boiler in the event of the failure of the feed pump.

Page | 42

6.) Blow off cock. Function: To drain out the water from the boiler for internal cleaning, inspection or other purposes.

7.) Man and mud holes: To allow men to enter inside the boiler for inspection and repair 8.) Water level indicators: They

show the operator the level of fluid in the boiler, also known as a sight glass, water gauge or water column is provided. 9.) Low- water cutoff: It is a mechanical means (usually a float switch) that is used to turn off the burner or shut off fuel to the boiler to prevent it from running once the water goes below a certain point. If a boiler is "dry-fired" (burned without water in it) it can cause rupture or catastrophic failure 10.) Bottom blow down valves: They provide a means for removing solid particulates that condense and lay on the bottom of a boiler. As the name implies, this valve is usually located directly on the bottom of the boiler, and is occasionally opened to use the pressure in the boiler to push these particulates out. 11.) Surface blowdown line: t provides a means for removing foam or other lightweight non-condensible substances that tend to float on top of the water inside the boiler

12.) Desuperheater tubes or bundles: A series of tubes or bundles of tubes in the water drum or the steam drum designed to cool superheated steam. Thus is to supply auxiliary equipment that doesn't need, or may be damaged by, dry steam.

Page | 43

5.2) Accessories:
Boiler accessories are those components which are installed either inside or outside the boiler to increase the efficiency of the plant and to help in the proper working of the plant. Various boiler accessories are: 1) Air Preheater 2) Economizer 3) Superheater

1. Air preheater: Waste heat recovery device in which the air to on its way to the furnace is heated utilizing the heat of exhaust gases 2. Economiser: Function: To recover some of the heat being carried over by exhaust gases (This heat is used to raise the temperature of feed water supplied to the boiler. 3. Superheater : To superheat the steam generated by boiler Super heaters are heat exchangers in which heat is transferred to the saturated steam to increase its temperature. Fossil fuel power plants can have a superheater and/or reheater section in the steam generating furnace. Nuclear-powered steam plants do not have such sections but produce steam at essentially saturated conditions. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the superheater, which has

an elaborate set up of tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine.

Page | 44

ACCESSORIES:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Economiser Superheater Air pre-heater (APH) Feed pump Eletrostasic precipitator (ESP) Deaerator Bed Ash Cooler Drum Mechanical Dust collect

ECONOMISER : An economiser is a device in which the waste heat of the flue gas is utilized for heating the feed water.Economiser is generally of two types: independent and integral type. Former is installed in chamber a part from the boiler setting. The chamber is suited at the passage of flow of the gases from the boiler or boiler to chimney. Latter is part of the boiler heating surface and is installed within the boiler setting.

SUPERHEATER: The function of the superheater is to increase the temperature of the steam above its saturation point.They are located in the path of the furnace gases so that heat is recovered by the supreheater from the gases. They are two types of superheaters: convective and radiant.

Page | 45

Fig 5.2: Economiser

Fig 5.3: Super heater

Page | 46

AIR PRE-HEATER: Air for combustion purposes may be preheated before it enter the boiler furnace by passing it through banks of tubes placed in the flue leading from boiler to the chimney. It thus uses some heat of leaving flue gases, that would otherwise passed to waste.

Fig 5.4: Air preheater

Page | 47

ELECTROSTATIC PRECIPIRATOR: An electrostatic precipitator (ESP), or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that minimally impede the flow of gases through the device, and can easily remove fine particulate matter such as dust and smoke from the air stream. In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy.

S.no 1. 2. 3. 4. 5. 8.

Description Design Gas Volume Temperature Dust Type Max. Inlet Dust loading Outlet Emission (all fields in service) Collection Area

Unit AM3/Sec Deg cen. GM/NM3 MG/NM3 M3

BHAVNAGA R LIGNITE 76.11 150 Fly Ash 50

KUTCH LIGNIT E 74.22 150 Fly Ash 48 <50 8748 114.93 117.78 140.19

IMPORTE D COAL 62.4 140 Fly Ash 49

9.

Specific Collection rates

M2/m3/sec

10. 11. 12. 13. 14.

No. of Gas passes Velocity through ESP No. of Fields in Series Design Pressure Flange to Flange Pressure Drop

M/Sec Mmwc Mmwc

28 0.52 4 Electrical & 4 Mechanical -420 -28

Page | 48

Fig 5.4: Electrostatic precipitator

Page | 49

ESP SPECIFICATIONS
SR. NO. 1 2 3 4 5 6 7 Number of streams Make Design flow of flue gases Temperature of flue gases Dust loading at ESP inlet Dust loading at ESP outlet System pressure Nm3/sec
o

DESCRIPTION

UNIT

Nos.

1 Alstom Projects India Ltd. 90 160 120 50 (-)600

gm/Nm3 gm/Nm3 mm of WC

Through gas discharge theory, it is known that breakdown of non-uniform electric field (as ESP electric field breakdown) are all due to the formation and extension of streamer.

Definition of streamer: In some parts in the gas, the formed mixing zone of positive and negative ions which possesses high conductance passage is called as streamer. It is one of the gas discharge ways (corona discharge and streamer discharge) of non-uniform electric field.

Page | 50

is at the corona outer region and forms even more extricated electron avalanche(no Cause of streamer formation: Normal negative corona is electron-avalanche-like extrication in corona zone. However when the bared voltage of the ESP electric fields rises continually, the photon will be discharged at the electron avalanche head as a result of the compounding of the positive and negative ions or that the excitonic atom regains normal state. The generated electron extricated by photon is entitled as photoelectron, which longer extricate through the high field intensity of the sharp electrode, while extricate through photoelectron), this even more extricated electron avalanche converges with the avalanche head of the main electron avalanche and in some parts of the gas of corona outer region forms mixing zone with high conductance of positive and negative ions. The mixing zone is called as streamer. After streamer forms, by the effect of basic electric field, the charges in streamer section are to part and go ahead the both ends of the section, hence to weaken electric field in the streamer. Thus, although streamer occurs at the edge of the corona zone, the potential from it to opposite electrode is almost the same with that to the sharp electrode, because the interior electric field intensity of streamer is very weak (i.e. streamer obtains the ability to transmit potential), which is equivalent to that the sharp electrode extends forward and makes extrication develop at the depth of the electric field gap (corona outer region) and results in breakdown (spark.) Thus, the breakdown course of ESP electric fields is finished in three segments, i.e., corona zone electron avalanche (corona)-corona outer

region streamer-electric field breakdown. Therefore the formation of streamer is premonition of electric field breakdown; it is also acceptable to say that the streamer formation is the sufficient condition of electric field breakdown. As for conven- tional ESP with single zone and negative corona, this kind of pre-breakdown streamer is unfavorable, in respect that streamer will speed up discharge development and make breakdown voltage decrease. What is more important, streamer formation makes cation

and positive dust charged by cation appear in corona outer region (in the streamer, the appearance of cation at corona outer region will enhance DE ionization making the corona current increase, streamer tend to develop and breakdown voltage fall. At the same time, as for the dust, cation reduces the charge capacity of negatively charged

dust and even charges the dust positively to make positive corpuscles form at corona outer region of the electric fields.) Whereas ESP with single zone and negative corona can not collect positive Page | 51

corpuscle dust charged by the cation in the streamer, therefore dust leakage rate increases, the deposited dust layer on the corona wire will become thick, which brings the ESP operation exacerbation. At corona outer region of conventional ESP, cation and positive corpuscle dust charged by cation also exist. One of the sources is before electric field breakdown gas discharges and forms streamer, which is the mixing zone of the positive and negative ions. Its second source is cation and positive corpuscle dust charged by cation formed because of back corona. Its third source is the carbon in the dust with much fly ash combustible substance, which tends to be charged positively and form cation and positive corpuscle dust charged by cation. Since the cation and positive corpuscle dust charged by cation exist at corona outer region, then these ions and dust must have an escape hatch, therefore a sort of structure needs to be designed to collect them. It is common knowledge that dust charge requires high corona current in the electric field, while collection of charged dust requires high field intensity but not high current. Thereby, charge and dust collection is contradictory at the corona current aspect. Especially for collection of high specific resistance dust, too high current will give birth to highelectric field on the collected dust layer and cones- quently result in dust layer gap breakdown, back corona and dust removal efficiency drop. As against double-zone ESP, the charge zone and dust collection zone of the double-zone electric field are structurally completely separated and is able to be intensified respectively.

Through variant wire-plate tests, Longking has developed a new model of double-zone ESP mechanical and electronic multiplex double-zone ESP (hereinafter referred to as double- zone ESP.). It is composed of charge zone structure of the conventional needle bared wire & flat plate type BE plate and the dust collection zone structure of tube type auxiliary electrode & flat plate type BE plate. These two structures is configured alternatively, each of which is energized by independent power supply. Thus, charge and dust collection functions are intensified respectively and forms a sort of mechanical and electronic multiplex structure. In no-load electric pressure build-up test, no spark over appears in the fields composed of tube type auxiliary electrode and flat plate type BE plate with the gas passage spacing of 400 mm, when the electric field intensity reach 4.2 kV/cm. During actual operation, its secondary voltage is able to reach 80 kV in general, which intensifies enormously dust collection function.

Page | 52

Electricity Consumption:-

The charge zone and collection zone of the double-zone ESP are energized separately by independent HV power supply. The charge zone employs power supply according to conventional plate current density. However, since in the collection zone the on-site operation voltage is very high and the current is very low, when the gas passage spacing is 400mm, the voltage is chosen as 80 kV. For the dust with not too high specific resistance, 90 kV level can be chosen; the plate current density is general between 0.05 mA-0.08 mA/m2. Compared to conventional ESP fro 300MW unit, to reach the same dust removal efficiency, the double ESP can save 15%-18% electricity consumption.

In double-zone electric fields, the wire-plate form of the charge zone is almost the same with the conventional electric fields, which not only charges the dust, but also collect the negatively charged dust. The collection zone is composed of the tube type auxiliary electrodes and ordinary plate type CE plates, which possesses characteristics of high electric voltage, low current and more uniform plate current density distribution. The industrial application results show when collecting coal burnt boiler dust, the double-zone ESP can be adaptable to comparatively wide scale of coal without back corona in the dust collection zone and with more stable operation. Besides the dust removal efficiency, dust migration speed and value-cost ratio are all higher than the conventional horizontal ESP. The last but not the least, it can reduce the flue dust emission concentration below 50 mg/DNm3 thereby to reduce the fine dust emission, which is favorable to protect atmosphere environment and human health.

Page | 53

FLUE GAS CIRCUIT

Furnace

Economiser

Air preheater

I.D. fan

Chimeny

5.6)Boiler efficiency
Thermal efficiency of a boiler is defined as the percentage of (heat) energy input that is effectively useful in the generated steam. This is also known as input-output method due to the fact that it needs only the useful output (steam) and the heat input (i.e. fuel) for evaluating the efficiency. This efficiency can be evaluated using the formula:

Page | 54

Parameters to be monitored for the calculation of boiler efficiency by direct method are: Quantity of steam generated per hour (Q) in kg/hr. Quantity of fuel used per hour (q) in

kg/hr. The working pressure (in kg/cm2(g)) and superheat temperature (oC), if any The temperature of feed water (oC) Type of fuel and gross calorific value of the fuel (GCV) in kcal/kg of fuel

And where hg Enthalpy of saturated steam in kcal/kg of steam hf Enthalpy of feed water in kcal/kg of water

Page | 55

GENERAL PROBLEMS IN POWER PLANT

EMERGENCY CASES REQUIREING SHUT DOWN OF BOILER: Very high drum level Fall in drum level Pressure rise in boiler furnace Flame failure Both I.D & F.D. fans trip.

SHUT DOWN OF THE UNIT REQUIRING USE OF VACCUM BREAKER:

Abrupt increase in axial shift up to critical limits. Rise in temperature of oil drum drain from seal and bearing. Emission of sparks from rear seals of turbine Sudden drop in turbine oil level and pressure.

OTHER EMERGENCIES IN BOILER Water wall tube failure Re-heater/super heater/economizer tube failure. High reheat steam temperature. Steam pressure rise Ignition of unburnt particles of coal in boiler flues. Plugged air heater. Slag in superheater Page | 56

Boiler water conductivity high. Impulse steam High smoke density. Boiler flue gas temperature low.

Page | 57

DOS AND DONT S:

DOS:

1. Maintain all instruments and interlocks in good working condition. 2. Maintain the instrument air free from moisture and oily matters and the pressure as recommended. 3. All dampers must be in smooth operating condition. 4. Maintain fuel as per the recommendation. 5. Use the bed material as per the specification. 6. Maintain bed chemistry as per the design limits. 7. Maintain feed and boiler water as per the design limits. 8. Use proper lubricants as per the manufacturer recommendation. 9. Clean all Ash hoppers, feed water and transfer pump suction strainers, Oil gun regularly. 10. Operate the boiler within the recommended operating limits and Maintain proper operation log sheets regularly. 11. Operation & Servicing of individual equipment should be done as per the manufacturers schedule. 12. Carry out regular cleaning of direct water level gauge glass on Feed water tank, Deaerator and Boiler drum. 13. Keep the stand by auxiliaries ready for operation. 14. Chemical dosing systems as per recommendation. 15. Boiler surroundings and equipment must be properly illuminated. 16. Cleared the bed material immediately to make room for emergency. 17. Use genuine spares.

Page | 58

DONTS: 1. Dont by pass any instruments and safety interlocks. 2. Dont run the Boiler with furnace in pressurized condition. 3. Dont throttle the feed water pump balancing leak off valve while the pump is in operation. 4. Dont operate the furnace wall header drain valves while the Boiler is in operation. 5. Dont leave the furnace door open while the boiler is in operation. 6. Do not open the furnace manhole without the permission from control room. 7. Dont leave the Instrument Control Panel unattended. 8. Dont allow unauthorized persons to operate the boiler and associated equipment. 9. Avoid continuous operation of boiler at low loads (low back end temperature) to protect economizer and air preheater corrosion. 10. Do not dose chemicals into the boiler in batch wise, they should be done on a continuous basis. 11. Do not slump the in-between compartments, it must be from the last compartment. Do not slump the start-up compartment

Page | 59

FEATURES AND BENEFITS:

A) Two-stage particle separation system 1. Greater than 99.8% particle collection efficiency 2. Provides a means to control particle size distribution in furnace, which results in improved carbon burnout, limestoneutilization, emissions and heat transfer 3. Reduces operating costs B) All-internal primary solids recirculation(U- beam) 1. Compact design requires 20-30% less building volume thancyclone-based CFBC boilers critical for repowering projects 2. Lowers auxiliary power consumption compared with cyclone-based CFBC boilers C) Low, uniform velocities at the furnace exitU-beam separators, and the super heater 1. Significantly reduces erosion in upper furnace andsuper heater compared with cyclone designs 2. To date, no U-beam erosion maintenance required in anyIR-CFBC unit 3. No high-maintenance vortex fi nders or hot expansion joints;therefore, no maintenance expenses for these items D) No thick refractory due to elimination of hotcyclones and hot return legs 1. Thin, cooled refractory places no restriction on boiler start-upor shutdown rate 2. Significantly reduces need for refractory maintenance 3. Virtually eliminates forced outages due to refractory failures 4. Requires only 10 to 25% of the total refractory comparedwith hot cyclone CFBC designs E) In-furnace heat transfer surface 1. Vertical, flat membraned tube panels within furnace performevaporative or superheat duty 2. Proven reliability and low maintenance F) Unique primary air nozzles (bubble caps) 1. Reduces back sifting of solids during low-load operation 2. Reduces need for periodic cleaning of nozzles and primary airwindbox 3. Minimises erosion inside nozzle caused by the re-entrainmentof back-sifted solids G) Soot blowers not required upstream of MDC 1. Eliminates steam consumption, maintenance costs and forcedoutages typically associated with sootblowers H) Gravity fuel feed and fl y ash recycle system 1. Reduces maintenance, forced outages and auxiliary powerrequirements by eliminating the mechanical fuel injection andpneumatic fl y ash recycle systems I) High turndown (up to 5:1) without auxiliary fuelsupport 1. Allows wider load swings 2. Reduces operating costs (no auxiliary fuel) during lowloadoperation

Page | 60

CONCLUSION After the study of the captive power generation the power plant as a whole and coal handling, boiler and turbine, it becomes very clear that the boiler work in efficiency range of 60-75% and the efficiency of the boiler depends upon the degree by which the heat recovered which is lost in the intermediate stage of the steam and electricity generation. Apart from the above conclusions a combined conclusion can be drawn that if the heat loosed are kept at kept at minimum and better quality fuel is used which is hydrogen and moisture content ( as these are the major causes of heat loss other then the dry gas loss). In the desired quantities and good preventive maintenance can boost the overall station efficiency of the plant.

Page | 61

You might also like