Boiler PressureHigh.pptxUnit II: High Pressure Boilers

Unit II: High Pressure BoilersUnit II: High Pressure Boilers

1. U n i t II : H i g h P r e ss u r e B o i l e r s

2. 03 U n i t II : H i g h P r e ss u r e B o i l e r s T OP I C S C O V E R E D I N P R E V I OU S L E C T U R E ( 6 ) : - F l u i d i z e d B e d C o m bu s t i o n B o i l e r Various Arrangements of FBC Boiler 6 . R a m s i n b o i l e r T OP I C S T O B E C O V E R E D I N T H I S L E C T U R E ( 7 ) : - 2 . 4 . 4 C o n t r o l S y s t e m i n F B C B o i l e r s C o m p a r i s o n b e t w ee n v a r i o u s B o i l e r s I n d i a n B o i l e r R e g u l at i o n ( I B R ) A c t M a i n t e n a n c e o f H i g h P r e s s u r e B o i l e r s www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

3. 04 U n i t II : H i g h P r e ss u r e B o i l e r s 2.4.4.1 : CONTROL SYSTEM TYPES- 1. Pressure Control System Pressure control loops may be used for the control of boiler pressure or fuel oil pressure. For the control of boiler pressure, the final control element regulates fuel flow to the boiler in response to boiler drum steam pressure. For the control of fuel oil pressure, the final control element is usually a pressure reducing control valve that regulates in response to downstream pressure. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

4. 05 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 4 . 4 . 1 : C O N T R OL S Y S T E M T Y P E S - 2 . L e v e l C on tr o l S y s t e m Liquid level control loops may be used for the control of boiler drum water level. A typical level control loop is shown in Figure. 3 . T e m p e r a t u r e C on tr o l S y s t e m Temperature control loops may be used for the control of steam temperature from boilers or fuel oil temperature from fuel oil heaters. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

5. 06 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 4 . 4 . 1 : C O N T R OL S Y S T E M T Y P E S - 4 . F l o w C on tr o l S y s t e m Flow control loops may be used for the control of fuel flow into the boiler burners, burner draft airflow, feed water into a boiler or steam flow out of a boiler. A typical flow control loop is shown in Figure. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

6. 07 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 4 . 4 . 1 : C O N T R OL S Y S T E M T Y P E S - 5 . F ee d w a t e r C on tr o l S y s t e m The mass of the water flow and the steam flow must be regulated so mass water flow equals the mass steam flow to maintain drum level. The feed water control regulates the mass water flow to the boiler. It affects the steam pressure, which is the final arbiter of firing rate demand. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

7. 08 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 4 . 5 : F B C B O I L E R S : A D V A N T A G E S Fully Automatic, hence ensures safe operations even at extreme temperatures H i g h t h e r m a l e ff i c i e n c y Fluidized Bed Furnace at l o w e r t e m p . h e l p s i n r e d u c i n g Air-Pollution. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik Reduced requirement of Coal crushing. Easy Ash removal and Short commissioning & erection period

8. 09 U n i t II : H i g h P r e ss u r e B o i l e r s S t o r a g e D r u m Cost B u bb l e f o r m a t i on C a p a c i t y of S t e a m i n tons/ hr Drum-less Moderate D o no t o cc u r 135 Required L o w O n Inn e r W a ll s 4 5 – 5 2 . 5 : C O M P A R I S O N O F H I G H P R E SS R E B O I L E R S V S L A - M O N T BOILER B E N S O N BOILER www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

9. 10 U n i t II : H i g h P r e ss u r e B o i l e r s S t a rt i n g S y s t e m Q u i c k S l o w 2 . 5 : C O M P A R I S O N O F H I G H P R E SS R E B O I L E R S V S L O - EFF L E R BOILER VELOX B O I L E R H e a t T r a n s f e r R a t e L i m i t a t i on on S i z e C a p a c i t y of S t e a m i n tons/ hr High C e r t a i n 130 www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik L o w Z e r o 1 00

10. 11 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 6 : I N D I A N B O I L E R R EG U L A T I O N ( I B R ) A C T I t g o v e r n s d e s i g n , m a nu f a c t u r e , installation and operation of all s t e a m p r o d u c i n g v e ss e l s w h i c h f a l l un d e r i t s p u r v i e w . I n d i a n B o i l e r R e g u l a t i o n s i s t h e l a w o f I n d i a , w h i c h w a s c r e a t e d i n 15 t h S e p t e m b e r 1 9 5 I t e x t e n d s t o t h e w h o l e o f I n d i a e x c e p t t h e S t a t e o f J a mm u a n d K a s h m i r . www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik A n A c t t o c o n s o l i d a t e a n d a m e n d t h e l a w r e l a t i n g t o steam-boilers I n e x e r c i s e o f t h e p o w e r s conferred by section 28 and 29 of t h e I n d i a n B o i l e r s A c t .

11. 12 U n i t II : H i g h P r e ss u r e B o i l e r s 2.6: Definitions: INDIAN BOILER REGULATION (IBR) ACT 2 1 2 . B o i l e r means any closed vessel exceeding 22.75 liters in capacity which is used expressly for generating steam under pressure and includes any mounting or other fitting attached to such vessel, which is wholly or partly under pressure when is shut off. 1 . A cc i d e n t m e a n s a n e x p l o s i o n o f a b o i l e r o r s t e a m - p i p e o r a n y d a m a g e t o a b o i l e r o r s t e a m - p i p e w h i c h i s c a l c u l a t ed t o w e a k e n t h e s t r e n g t h t h e r e o f s o a s t o r e n d e r i t l i a b l e t o e x p l o d e . 3 www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik 5 4 4. “Chief Inspector”, “Deputy Chief Inspector”, and “Inspector” means, respectively, a person appointed to be a Chief Inspector, a Deputy Chief Inspector and an Inspector un d e r t h i s A c t . 3 . E c o n o m i z e r means any part of a feed-pipe that is wholly or partially exposed to the action of flue gases for the purpose of recovery of waste heat. 5 . B o a r d m e a n s t h e C e n t r a l B o i l e r s B o a r d c o n s t i t u t ed un d e r s e c t i o n 2 7 A ;

12. 13 U n i t II : H i g h P r e ss u r e B o i l e r s 2.6: Definitions: INDIAN BOILER REGULATION (IBR) ACT 7 6 7. S t e a m - p i p e means any pipe through which steam passes from a boiler to a prime mover o r o t h e r u s e r o r b o t h . 6 . P r e s c r i b e d means prescribed by regulations or rules made under this Act. 8 . F ee d P i p e 8 www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik 9 9 . O w n e r includes any person using a boiler as agent of the owner thereof and any person using a boiler which he has hired o r o b t a i n ed o n l o a n f r o m t h e o w n e r t h e r e o f ; means any pipe or connected fitting wholly or partly under pressure through which feed water passes directly to a boiler and which does not form an i n t e g r a l p a r t t h e r e o f ; 1 . s t r u c t u r a l a lt e r a t i o n , a dd i t i o n o r r e n e w a l shall not be deemed to include any renewal or replacement of a petty nature when the part or fitting used for replacement is not inferior in strength, efficiency or otherwise to the replaced part or fitting. 1

13. 14 U n i t II : H i g h P r e ss u r e B o i l e r s : IBR Act: Chief Inspector, Deputy Chief Inspectors and Inspectors The State Government may appoint such persons as it thinks fit to be Inspectors for the State for the purposes of this Act , and may define the local limits within which each Inspector shall exercise the powers and perform the duties conferred and imposed on Inspectors by or under this Act. The State Government may appoint such persons as it thinks fit to be Deputy Chief Inspectors for the State and may define the local limits within which each Deputy Chief Inspector shall exercise his powers and perform his duties under this Act. Every Deputy Chief Inspector may exercise the powers and perform the duties conferred and imposed on Inspectors by or under this Act and, in addition thereto, may exercise such powers or perform such duties conferred or imposed on the Chief Inspector by or under Act, as the State Government may assign to him. The State Government shall appoint a person to be Chief Inspector for the State who may, in addition to the powers and duties conferred and imposed on the Chief Inspector by or under this Act, exercise any power or perform any duty so conferred or imposed on Deputy Chief Inspector or Inspectors. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

14. 15 U n i t II : H i g h P r e ss u r e B o i l e r s : IBR Act: Chief Inspector, Deputy Chief Inspectors and Inspectors Subject to the provisions of this act, the Deputy Chief Inspectors and Inspectors shall exercise the powers and perform the duties conferred and imposed on them by or under the general Superintendence and control of the Chief Inspector . The Chief Inspector, Deputy Chief Inspectors and Inspectors may offer such advice as they think fit to owners regarding the proper maintenance and safe working of boilers. The Chief Inspector and all Deputy Chief Inspectors and Inspectors shall be deemed to be public servants within the meaning of section 21 of the Indian Penal Code (45 of 1860). www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

15. 16 U n i t II : H i g h P r e ss u r e B o i l e r s : IBR Act: Additional Sections - 14. Duty of owner at examination On any date fixed under this Act for the examination of a boiler, the owner thereof shall be bound- to afford to the Inspector all reasonable facilities for the examination and all such information as may reasonably be required of him; to have the boiler properly prepared and ready for examination in the prescribed manner; and (c) in the case of an application for the registration of a boiler, to provide such drawings, specifications, certificate and other particulars as may be prescribed. (2) If the Owner fails, without reasonable cause to comply with the provisions of subsection (l), the Inspector shall refuse to make the examination and shall report the case to the Chief Inspector who shall unless sufficient cause to the contrary is shown, require the owner to file a fresh application under section 7 or section 8, as the case may forbid him to use the boiler notwithstanding anything contained in section 10. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

16. 17 U n i t II : H i g h P r e ss u r e B o i l e r s : IBR Act: Additional Sections - 16. Reports of accidents If any accident occurs to a boiler or steam-pipe, the owner or person in charge thereof shall within twenty- four hours of the accident, report the same in writing to the Inspector. Every such report shall contain a true description of the nature of a accident and of the injury, if any, caused thereby to the boiler or to the steam- pipe or to any person, and shall be insufficient detail to enable the Inspector to judge of the gravity of the accident. Every person shall be bound to answer truly to the best of his knowledge and ability every question put to him in writing by the Inspector as to the cause, nature or extent of the accident. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

17. 18 U n i t II : H i g h P r e ss u r e B o i l e r s : M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s General Maintenance Even though the boiler has electrical and mechanical devices that make it automatic or semi-automatic in operation, these devices require systematic and periodic maintenance. Any "automatic" features do not relieve the operator from responsibility, but rather free him from certain repetitive chores, providing him with time to devote to upkeep and maintenance. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

18. 19 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 7 : M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s 2. Shift Maintenance It include checking the boiler water level in the gauge glass and the boiler steam pressure on the gauge. Operate the blow down valve to remove any accumulated solids in the mud drum . The valves on the water column and gauge glass should be operated to make sure these connections are clear. Monitor water chemistry to adjust the chemical feed treatment and continuous blow down as required, to remain within water treatment guidelines established by the Owner's water treatment consultant. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

19. 20 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 7 : M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s 3. Daily Maintenance Daily Maintenance should include a check of the burner operation, including fuel pressure, atomizing air or steam pressure, visual appearance, etc. Clean the observation ports during periods of low fire or shutdown. Test the boiler level alarms and low water cutoff. Maintain a daily schedule of soot blowing. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

20. 21 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 7 : M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s 4. Monthly Maintenance Follow the recommendations of you authorized inspector pertaining to safety valve inspection and testing. The frequency of testing , either by the use of the lifting lever or by raising the steam pressure, should be based on the recommendation of your authorized inspector. Test the boiler safety valves in accordance with the manufacturer's instructions to be absolutely sure that the valves have not corroded shut. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

21. 22 U n i t II : H i g h P r e ss u r e B o i l e r s 2 . 7 : M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s 5. Annual Maintenance Clean both the heating and heated sides of the boiler. Remove all man way and hand hole covers. Open all bottom blow down and drain valves . Hose the inside of the boiler with clean water under high pressure. Use a hand scraper to remove accumulated sludge and scale . After cleaning tube exteriors, inspect the tube surfaces for signs of overheating, such as bulging, blackened surfaces in the tubes, etc. www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

22. 23 U n i t II : H i g h P r e ss u r e B o i l e r s * IMPORTANT QUESTIONS FROM MSBTE PAPERS Sr. No. Question Marks 1 State the two types of FBC boiler. 2 2 Name any four components of FBC Boiler 2 3 Compare Lamont and Benson Boiler 4 4 Explain the maintenance procedure of major components of high pressure boiler. 4 5 Explain with neat sketch construction and working of Lamont boiler. 6 6 Explain with neat sketch construction and working of Benson boiler. 6 7 Explain with neat sketch construction and working of Loeffler boiler. 6 8 Explain with neat sketch working principle of Fluidized Bed Combustion (FBC) boiler. 6 9 Draw schematic diagram of boiler feed water control system. State its importance in thermal power plant. 6 10 Explain the Indian Boiler Regulation (IBR) act. Name the inspecting and competent authority suggested by IBR 6 www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

23. 24 U n i t II : H i g h P r e ss u r e B o i l e r s SUMMARY I n t h i s l e ss o n , W e h a v e l e a r n e d 2 . 5 C on tr o l S y s t e m i n F B C C o i l e r s 2 . 6 I n d i a n B o i l e r R e g u l a t i on ( I B R ) A c t 2 . 7 M a i n t e n a n c e o f H i g h P r e ss u r e B o i l e r s www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik

24. 25 U n i t II : H i g h P r e ss u r e B o i l e r s Our Next Video Lecture Topic U N I T III . S T E A M A N D G A S P O W E R P LA N T S T i l l T h e n S t a y C o nn e c t e d , T H A N K Y O U www.sandipfoundation.org Mechanical Engineering Department, Sandip Polytechnic, Nashik