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BASICS OF BOILER
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Session Objectives
This session is intended to discuss the following :
Session Objectives
BOILER CLASSIFICATION
Fire tube or flue tube or shell type when flue gases are inside and
water is outside.
Water tube when water is inside the tubes and flue gases are
outside.
Combination type (combo boiler) when flue gas and water flow
both outside and inside the tubes in a boiler that contains an
external furnace and shell-type boiler in a sequence.
• Industrial boilers.
• Utility boilers.
• Marine boilers.
• Nuclear boilers.
• Top-supported boilers
• Bottom-supported boilers
• Middle-/girdle-supported boilers
Two-pass boilers
• 1½ pass boilers
• Single or tower-type boilers
• Down shot or Arch fired boilers
Session Objectives
COMBUSTION REQUIREMENTS
Sufficient
Combustion Air
Temperature Combustion
Fuel Mixing within Time
above
is Flammable Temperature
Ignition
Gasified Range Turbulence
Point
3 T’s of Combustion
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
FUNDAMENTALS OF COMBUSTION
Heat
Complete
(Air) Oxygen Fuel
Products Flue Gas
O2 H2 H2O
+
C CO2
Heat
Incomplete
Oxygen Fuel Flue Gas
Products
H2 H2O
O2 +
C CO2
CO
H2
• Other Combustibles - Sulphur to Sulphur Oxides C
• Non-combustible - Nitrogen to Nitrogen+Nitrous Oxides
• Ash
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Session Objectives
1. Boiler and its classification.
2. Fundamentals of Combustion and heat transfer.
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Stack
COOLING TOWER
Steam
Air
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Steam
Water Steam / Water System
Blowdown
Fuel
Mixing of Furnace Heat Transfer Flue Gas
Fuel & Air Surface
Ash
Air
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Hot Reheat
Steam
Spray
Water Main Steam
Drum
Attemperator
Attemperator
Cold
Reheat
Platen Final Primary Final Primary
Steam
Super Re Re Super Super Spray
Heater Heater Heater Heater Heater Water
Down
Comers Flue Gas
Economiser
Feed Water
Furnace
Flue Gas
Water Wall Out to
Risers Air Heater
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
1
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
ID Fan ID Fan
AIR & FLUE GAS PATH
PA Fan FD Fan FD Fan PA Fan
S S
C C
Cold PA A A Cold PA
ESP P P
H
ESP
H
Scanner
Air Fan
Pri Sec Sec Pri
Flue Air Flue Air
Air Air
Gas Side Gas Side
Side Side Seal Air
Fan
Hot PA Hot PA
Wind Box
Mill Mill
Furnace
To Hot PA
Other
Coal Feeder Mills
Coal+Air
to Burners
Mill A Cold PA
To
Other
Mills
Atomising
Steam/Air
PCV
Fuel Oil
Return
Short Long
Recirc Recirc
PCV
Fuel Oil
Oil Heater To Burners
Supply
FCV FOTV
Steam
Fuel Oil Pumps
FUEL OIL
Hydrazine
T o APRDS
Dosing Spray
Ammonia Recirculation
Dosing Valve
M
Discharge Valve
2
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Session Objectives
5. Boiler Safety.
6. Operation Standards and Codes.
7. Control & Safety for automatically fired boilers.
8. Inspection and Maintenance of Boilers.
9. Boiler and burner efficiency.
10. Troubleshooting.
2
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Session Objectives
2
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
BOILER SAFETY
Session Objectives
2
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler
Rules of Safety concerned with the safety aspects of the boilers to prevent
the occurrence of disastrous explosions that marked the early period of boiler history.
ASME boiler and pressure vessel (BPV) codes are the most widely accepted and used worldwide.
These codes deal with the safety aspects in all areas of boiler making and operation and thus cover
• Mechanical design
• Manufacturing and workmanship
• Materials and stresses
• Inspection and testing
• Documentation and marking
• Care and operation
• Welder qualifications
Session Objectives
1. Boiler and its classification.
2. Fundamentals of Combustion and heat transfer.
3. Boiler system details and their importance.
4. Boiler operation and control.
5. Boiler Safety.
6. Operation Standards and Codes.
2
POWER SECTOR - TECHNICAL SERVICES
BHARAT HEAVY ELECTRICALS LIMITED Basics of Boiler