STEAM GENERATOR

STEAM GENERATOR

Generate steam at desired rate at desired pr and temp by burning fuel in furnace. Controlled circulation with Rifled Tubing, Dry bottom, Radiant Reheat, Single drum,Top Supported, Balanced draft furnace & Tilting tangential firing Designation : 19177 16115 291-51 CC + 245-51

Consists furnace, superheater, reheater, water tubes or evaporators, economiser and air-preheater.

Consists of various auxilliaries such as Feeders, bunkers, Pulverizers, burners, ESP, Fans, ash-handling equipments and chimney.

STEAM GENERATION PRINCIPLE

Steam power plants operate on modified Rankine Cycle, DM water as working fluid. Sensible heat is added in economiser +furnace Steam generation takes place in waterwall. Superheating takes place at superheaters. Heat transfer in furnace and enclosed superheater takes place thru radiation.

HPT SH w/w HPH+Eco

BFP

RH IPT

LPT LPH

CEP

condenser

BOILER COMPONENTS

Economizers Boiler drum Water wall Superheaters (LTSH, DPSH, Platen) Re-heaters Safety Valves Wind Box & Air Dampers: SADC, FAD Etc. Burners Air pre-heaters Boiler Supporting Structures

M.S

C.R.H

H. R. H

500mw

FROM F.R.S BOTTOM RNG HDR & Z-PANEL 1ST PASS W.W O/L HDRS 1ST PASS W.W

ROOF I/L HEADER 2nd PASS LOWER C-HDRS LTSH O/L HEADER D.P.O/L HEADER R.H.HEADER ECONOMISER

2ND PASS UPPER C-HDR LTSH I/L HEADER D.P.I/L HEADER S.H. HEADER 2ND PASS ROOF O/L HDR(REAR

Feed Water & Steam temp

DRUM 323 C 391C 463C 334C 490C 568C 398C 540C RH-I FSH FRH

DPSH

LTSH

364C

1300-1400

ECO

323C

251.8C

1400C

APH
ID fan

ESP

FLOW OF AIR
TOTAL AIR

SA 60-70%

PA 30-40%

COLD SA

APH HOT SA

COLD PA

APH HOT PA MILL

SCANNER AIR FAN AUX AIR 60-70%

MILL

SEAL AIR FAN

FUEL AIR 30-40%

FLUE GAS PATH

DPSH FSH RH-I FRH

LTSH

ECO

CHIMNEY

1400C
SAPH (2)

Fuel+Air
PAPH (2)

ESP
ID FAN

Flue gas temp

DRUM DPSH FSH RH-I FRH

1118C

1016C

837C

659C 1400C LTSH

538C

1300-1400
332C

ECO

O2 = 3.6%

1400C

APH
131-136C ID fan

ESP

HEAT DISTRIBUTION
Heat gained by Boiling water 38% Heat gained by Superheater& Reheater 38%

Loss due to moisture in air. Loss due to moisture in fuel. Loss due to combustion generated moisture. Dry Exhaust Gas Losses~ 4.5%

Fuel energy 100%

Furnace

Hot gas

Flue gas

Heat loss from furnace surface.

Unburned carbon losses.

Heat gained by economizer & air preheater 10%

BOILER EFFICIENCY

Direct method
Steam Output

Flue Gas

Fuel Input 100% + Air

Boiler

Efficiency =

Heat addition to Steam x 100 Gross Heat in Fuel

Steam flow rate *(steam enthalpy-feed water enthalpy) Boiler Efficiency= +steam flow rate in RH*Heat added in RH *100 Fuel firing rate*Gross calorific value

Water

Indirect method
Steam Output
6. Surface loss

1. Dry Flue gas loss 2. H2 loss 3. Moisture in fuel 4. Moisture in air 5. CO loss

Fuel Input, 100%

Boiler

Flue gas sample

Air
7. Bottom ash loss

Efficiency = 100 (1+2+3+4+5+6+7) (by Indirect Method)

EFFICIENCY
Dry Gas : 4.163 %

Moisture in fuel
H2 in fuel H2O in Air Unburnt Carbon Radiation Sensible heat losses Unaccounted

: 2.656 %
: 5.635 % : 0.108 % : 1.50 % : 0.110 % : 0.585 % : 0.176 %

Efficiency = 85.47%

DESIGNATION: 19177 16115 Furnace Volume : 17599 m3 Drum elevation: 76.552 m

291-51 CC + 245-51

Fuel Heat input: 1224.8 x 106 KCal/hr. Main Steam pr & temp: 177.5kg/cm2 & 540C Reheat Steam pr & temp: 41.09kg/cm2 & 568C

Super heater flow : 1448.9 t/h

Reheater flow : 1295.1 t/h

CONTD
Total air flow Total heating surface area Superheater Reheater Economiser : 2013 t/h :12083 m2 : 9250 m2 : 9000 m2

Minimum load at which steam generator can be : 30% BMCR operated continuously with complete flame stability without oil support Minimum load at which steam generator can be : 20% BMCR operated continuously with complete flame stability with oil support when firing coal Maximum continous output with one FD fan and one ID fan in operation : 60% BMCR