TRAINING MODULE ON

BOILER BASICS

What is Steam Boiler.?

Boiler is an closed vessel in which water is heated to produce steam.

STEAM

This steam shall be used for process / Power Generation.

BOILER

WATER

AIR + FUEL

IBR Indian Boiler Regulations

Steam boilers under IBR means any closed vessel which is used for
generating steam

Exceeding 22.75 liters in capacity.

Having pressure > 1 Kg/cm2.

Includes any mounting or other fitting attached to such vessel which

is wholly or partly under pressure when the steam is shut off.

Boiler Classification
Boilers are classified into different types based on Type of combustor,
Steam pressure, Fuel fired etc., Main two classifications are

Fire or Smoke Tube boiler.

- Low Pressure system.

Water Tube boiler.

- Low & High Pressure system.

Fire or Smoke Tube Boiler:

Water gets heated outside the tubes while the hot gases flows inside the
tubes.

Water Tube Boiler:

Water flows inside the tubes and the hot flue gases flow outside the
tubes.

Basics of Steam

Steam - Basics

If we take 1 Kg of water at 0C and if we add

100 Kcal of heat then the temperature of water
will increases to 100C.

This rise in temperature can be detected and is

called Sensible Heat (Specific Enthalpy - Water)

Steam Basics (Contd)

At normal atmospheric pressure, any further

addition of heat to water at 100C will not
increase the temperature but will convert some
of the water into steam.

In order to convert water into steam 539Kcal/kg

of additional heat must be added.

This cannot be detected as a rise in temperature

and is called the Latent Heat of Vaporization
(Specific Enthalpy - Evaporation).

Specific weight of steam and water

At atmospheric condition

Specific weight of water at saturation point =

958.38 Kg/m3.

Specific weight of steam at saturation point =

0.58 Kg/m3.

The volume of water expands 1650 times when it is converted into steam at
atmospheric condition.

Importance of Fuel

Reporting Fuel Analysis

Air Dried Basis (ADB):
Samples sent to lab are kept open to lab ambient condition for equilibrium
moisture. Datas reported on this basis is ADB basis.
As Received Basis (ARB):
Data reported on the basis of as received moisture at laboratory. Such
samples are sent to lab in a tightly packed covers.
As Fired Basis (AFB):
This has relevance to boiler performance. The sample is collected in feeder
area just before it enters into furnace. The data reported is AFB.
Dry Basis (DB):
Data expressed on moisture removed basis is called Dry basis.

Calorific Value
Calorific value is the heat produced by the combustion of a unit quantity of
fuel in a bomb calorimeter with oxygen under a specified set of conditions.

GCV Gross Calorific Value:

In GCV all the vapor produced in combustion process is fully condensed. The
latent heat is added to GCV and thus GCV is higher to NCV.

NCV Net Calorific Value:

Net calorific value informs that the water is removed as vapor with the
combustion products.

Moisture
Surface Moisture:
- The moisture which is present on the surface of the fuel particle.
- Can be removed easily when it is exposed to atmosphere.

Inherent Moisture (IM):

- The moisture which is held inside the molecular structure of the fuel.
- Difficult to remove.

Total Moisture (TM):

- Surface Moisture + Inherent Moisture.
Higher the moisture, lower will be the GCV

Calorific Value Conversion

Calorific Value Conversion - Example

1. Find the AS FIRED GCV:
GCVADB

= 5300 Kcal/Kg.

Total Moisture

= 30 %.

Inherent Moisture
GCVAFB

= 10 %.
= .. Kcal/Kg.?

2. Find the AS FIRED GCV:

GCVDB

= 5888.89 Kcal/Kg.

Total Moisture

= 30 %.

GCVAFB

= .. Kcal/Kg.?

Effects of Moisture in Fuel

Higher the moisture, lower the efficiency of boiler.
Creates jamming problem in bunker chutes and in feeders.
It chokes the APH tubes and starts corroding from inside the tubes.
Corrodes the back hand equipments like Dust collecting system, ID fan
flue gas ducting & steel chimney when it condenses.

Other Parameters
Ash
- Higher the ash content lower the GCV & high ash handling cost.

Sulphur Content
- Corrodes the back hand equipments due to Sulphur condensation.

Fuel Size
- Lower the fuel size, higher the surface exposed to flame and better the
combustion.
- Higher the fines, more will be the carryover of fuel with ash.

What is the fuel used in 16 TPH

boiler.?

Imported Coal:

Coffee Spent:

GCV (AFB)

: <5000 Kcal/Kg.

GCV (AFB)

: <3000 Kcal/Kg.

Total Moisture

: <30 %.

Total Moisture

: >50 %.

Boiler - Working

Moving Grate Boiler Air & Flue Gas Circuit

Flue Gas flow
Air flow

ESP

ID Fan
SA Fan

FD Fan

Moving Grate Boiler Water & Steam Circuit

TO PROCESS

MU WATER

CONDENSATE

DEAERATOR STORAGE
TANK

F.P:01

F.P:02

DOSING

STEAM

CHEMICAL

ECONOMISER

Deaerator

Deaerator is used
for the removal of
oxygen (O2) and non
condensable gases.

Oxygen promotes
pitting corossion. It
affects the heat
transfer
in
equipment

Deaerator (Contd)

As the temperature increases, the solubility of oxygen in water decreases.

The concentration of dissolved oxygen in water is very less at 100 Deg C. Hence the
temperature is maintained more than 100 Deg C in Deaerator.

Economiser

Heat Recovery Equipment.

It adds sensible heat to the incoming feed water.
It enhances the efficiency of the boiler by abstracting the heat from flue gases.

Boiler Bank
It is the tube nest
connecting
Steam
drum and Mud drum.
In this zone some
quantity of water is
converted into steam.
Water is transferred to
waterwall
panels
through Downcomer.

Membrane/Waterwall Panel
It is the zone where water
partially converted into steam.
The arrangement is of tube and
fin construction so that it forms a
gas tight chamber.
It ensures the flue gas gets
cooled down before entering
boiler bank zone.

Air Preheater

Air In

Air Out

The Air Preheater is the last heat recovery equipment which is situated last in the flue
gas path.
It is a cross flow heat exchanger which provides hot air for combustion.

Boiler Mountings & Accessories

Fittings or Devices which are necessary for safety and controls are known as
Mountings.

Fittings or Devices which are provided to increase the efficiency of boiler and
help in smooth running of boiler is known as Accessories.

Boiler Mountings
Safety Valve.
Water Level Gauge.
Pressure Gauge.
Fusible Plug.
Blowdown Valve.
Feed Check valve.
Air Vent Valve.

Boiler Accessories
Economiser.
Air Preheater.
Superheater.
Boiler Feed Water Pumps.
Pressure Reducing Valve.
Moisture Separator.
Steam Traps.

Boiler Basic Calculation

Feed water consumption:

Make Up Water

Steam to Deaerator
Feed Water

Condensate

Feed Water Consumption = Make Up Water + Condensate + Steam (To Deaerator)

Percentage of Blowdown:

Example : 01
Feed water TDS

: 250 PPM.

Boiler water TDS maintained

: 2500 PPM.

Blowdown %

: .%

Example : 02
Feed water TDS

: 100 PPM.

Boiler water TDS maintained

: 2500 PPM.

Blowdown %

: .%

Evaporation Ratio:

Example:
Steam Generated

: 200 Tons/Day.

Fuel Consumed

: 38500 Kg/Day.

Evaporation Ratio

: ..

Boiler Direct Efficiency:

Boiler Indirect Efficiency:

Boiler Indirect Efficiency = 100 Total Heat Losses.
Heat Losses:
HL 1

: Heat loss in dry flue gas.

HL 2

: Heat loss due to formation of water from H2 in fuel.

HL 3

: Heat loss due to moisture in fuel.

HL 4

: Heat loss due to moisture in air.

HL 5

: Heat loss due to unburnt in bed / bottom ash.

HL 6

: Heat loss due to unburnt in fly ash.

HL 7

: Heat loss due to partial combustion of C to CO.

HL 8

: Heat loss due to radiation.

Dust Collecting System

Dust Collector
The purpose of dust collector is to trap the dust particles and to allow
only pure gases into the atmosphere.
Cyclone Separator

Wet Scrubber

Bag Filter

Electrostatic Precipitator (ESP)

Cyclone Separator
Gas
O/L

Gas
I/L

In cyclone separator, the dust particles are

removed by means of gravity and rotation.

The light weight particles travel at cyclone

path and the heavy weight particles will
get settle down in the hopper.

Wet Scrubber

The water is sprayed over the dust laden

gas particles which is flowing upward.

The heavy dust particles will acquire

weight and settles down.

Bag Filter

Bag filter consists of bags with cages.

The bags consists of micron size holes

which allows only minute size of gas
particle to pass inside.

Purging air supplied frequently to remove

that adhered particles on bag surface.

ELECTROSTATIC PRICIPITATORS (ESP)

The precipitation process involves the
following process.
High voltage is applied to electrode
plates.
The oppositely charged ions particles are
attracted by electrode plates.
Rapping is applied to remove the dust
particles which is adhered to electrode
plates.

ASH HANDLING SYSTEM

Ash

Bottom
Ash

Fly Ash

Bottom Ash

Hot Ash collected from traveling grate of Boiler furnace is collected directly in to water filled
trough, where in a moving belt is installed to take out Wet Ash from the trough.

Fly Ash

Pneumatic Handling is an effective method of conveying dry bulk material through

pipes by means of compressed Air as a conveying medium.

Boiler Water Quality

Water parameters to be maintained

Parameters

Feed Water

Boiler Water

Condensate

pH at 25 Deg C

8.5 9.5

10.5 - 11

6.5 7.5

Hardness

Nil

Nil

Nil

TDS

<50 PPM

<2000 PPM

Nil

Waterside problems in boilers

SCALING

Ca & Mg Hard scales,

Silica Scales
etc.

CORROSION

Low pH
Pitting Corrosion due to
Dissolved Gases,
Under Deposit corrosion,
Caustic Corrosion etc.

CARRYOVER

High TDS

pH

pH is the measure of degree of acidity or basicity of solution.

pH < 7 -

Acid

pH = 7 -

Neutral

pH > 7 -

Base

Chemical Dosing:
NaOH, Sodium hydroxide is used to elevate the pH in feed water.
Morpholine/Ammonia are volatile chemicals used for pH improvement in feedwater.

Dissolved Oxygen
Dissolved gases depend on source of water.
Dissolved gases such as oxygen and CO2 are naturally occurring.
It leads to pitting corrosion.
At high temperature, even a small O2 leads to high rate of corrosion.

The Dissolved oxygen can be removed by

Mechanical De aeration &
Chemical Dosing.

Chemical Dosing:
Hydrazine (Should be handled with care)
Sodium Sulphite.

Total Hardness
Hardness is composed primarily of calcium and Magnesium minerals.
These are primarily responsible for scale formation.

External Water Treatment:

Softener Plant.

Internal Water Treatment:

Can be controlled by dosing phosphate.

Total Dissolved Solids

When water is converted into steam only pure steam is formed and the dissolved
solids will settle down. Hence the dissolved solids concentration will increases
in the steam drum over a period of time.

It causes foaming and Carryover.

External Water Treatment:

RO Plant & DM Plant.

Internal Water Treatment:

By proper Blowdown.

Common problems in Pressure parts due to water quality

Hydrogen Attack Low pH

Corrosion Dissolved O2

Scale Deposit Hardness

Carryover TDS

Thank You