Lecture 07_PPE_Unit 2: High Pressure Boilers

Program: Diploma (Mechanical)
Class: TY (ME) Semester: V
Course: Power Plant Engineering
Code: 22566
LECTURE 07:LECTURE 07:
Unit: 2. High Pressure Boilers

02
wwwwwwwwwwww....ssssaaaannnnddddiiiippppffffoooouuuunnnnddddaaaattttiiiioooonnnn....oooorrrrggggMechanical Engineering Department, Sandip Polytechnic, NashikMechanical Engineering Department, Sandip Polytechnic, NashikMechanical Engineering Department, Sandip Polytechnic, NashikMechanical Engineering Department, Sandip Polytechnic, Nashik
Name of theName of theName of theName of the Trainer : Prof. Rushikesh Deoram SonarTrainer : Prof. Rushikesh Deoram SonarTrainer : Prof. Rushikesh Deoram SonarTrainer : Prof. Rushikesh Deoram Sonar
Years ofYears ofYears ofYears of Experience : 10Experience : 10Experience : 10Experience : 10
DomainDomainDomainDomain Expertise : Mechanical EngineeringExpertise : Mechanical EngineeringExpertise : Mechanical EngineeringExpertise : Mechanical Engineering
Qualification: M.E. (Design Engineering)Qualification: M.E. (Design Engineering)Qualification: M.E. (Design Engineering)Qualification: M.E. (Design Engineering)
Contact Details:Contact Details:Contact Details:Contact Details:
+91 9890481959+91 9890481959+91 9890481959+91 9890481959
rushikesh.sonar@sandippolytechnic.orgrushikesh.sonar@sandippolytechnic.orgrushikesh.sonar@sandippolytechnic.orgrushikesh.sonar@sandippolytechnic.org

03Unit II: High Pressure Boilers
TOPICS COVERED IN PREVIOUS LECTURE (06):-
2.4.1 Fluidized Bed Combustion Boiler
2.4.2 Various Arrangements of FBC Boiler
6. Ramsin boiler
TOPICS TO BE COVERED IN THIS LECTURE (07):-
2.4.4 Control System in FBC Boilers2.4.4 Control System in FBC Boilers2.4.4 Control System in FBC Boilers2.4.4 Control System in FBC Boilers
2.5 Comparison between various Boilers2.5 Comparison between various Boilers2.5 Comparison between various Boilers2.5 Comparison between various Boilers
2.6 Indian Boiler Regulation (IBR) Act2.6 Indian Boiler Regulation (IBR) Act2.6 Indian Boiler Regulation (IBR) Act2.6 Indian Boiler Regulation (IBR) Act
2.7 Maintenance of High Pressure Boilers2.7 Maintenance of High Pressure Boilers2.7 Maintenance of High Pressure Boilers2.7 Maintenance of High Pressure Boilers

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
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.

2.4.4.1 : CONTROL SYSTEM TYPES-
2. Level Control System
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. Temperature Control System
Temperature control loops may be used for the control of
steam temperature from boilers or fuel oil temperature
from fuel oil heaters.

4. Flow Control System
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.

5. Feed water Control System
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 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.

2.4.5: FBC BOILERS: ADVANTAGES
Fully Automatic, hence ensures
safe operations even at extreme
temperaturesHigh thermal efficiency
Fluidized Bed Furnace at
lower temp. helps in reducing
Air-Pollution.
Reduced requirement of
Coal crushing.
Easy Ash removal and Short
commissioning & erection
period

Storage Drum Drum-lessRequired
2.5: COMPARISON OF HIGH PRESSRE BOILERS
VS
LA - MONT
BOILER
BENSON
BOILER
Capacity of Steam in
tons/ hr
Bubble formation
Cost ModerateLow
Do not occurOn Inner Walls
13545 – 50

Starting System QuickSlow
2.5: COMPARISON OF HIGH PRESSRE BOILERS
VS
LO-EFFLER
BOILER
VELOX
BOILER
Capacity of Steam in
tons/ hr
Limitation on Size
Heat Transfer Rate
Starting System QuickSlow
HighLow
CertainZero
130100

2.6: INDIAN BOILER REGULATION (IBR) ACT
It governs design, manufacture,
installation and operation of all
steam producing vessels which
fall under its purview.
Indian Boiler Regulations is the
law of India, which was created
in 15th September 1950
An Act to consolidate and
It extends to the whole of India except
the State of Jammu and Kashmir.
An Act to consolidate and
amend the law relating to
steam-boilers
In exercise of the powers
conferred by section 28 and 29 of
the Indian Boilers Act.

2.6: Definitions: INDIAN BOILER REGULATION (IBR) ACT
21
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.
2. Boiler
means an explosion of a boiler or
steam-pipe or any damage to a boiler or
steam-pipe which is calculated to
weaken the strength thereof so as to
render it liable to explode.
1. Accident
35
4
means, respectively, a person appointed to be a Chief
Inspector, a Deputy Chief Inspector and an Inspector
under this Act.
4. “Chief Inspector”, “Deputy Chief Inspector”, and “Inspector”
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.
3. Economizer
means the Central Boilers Board
constituted under section 27 A;
5. Board

2.6: Definitions: INDIAN BOILER REGULATION (IBR) ACT
76
means any pipe through which steam
passes from a boiler to a prime mover
or other user or both.
7. Steam-pipe
means prescribed by regulations or
rules made under this Act.
6. Prescribed
8. Feed Pipe10. structural alteration, addition or
8
9
includes any person using a boiler as agent of the owner
thereof and any person using a boiler which he has hired
or obtained on loan from the owner thereof;
9. Owner
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
integral part thereof;
8. Feed Pipe
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.
10. structural alteration, addition or
renewal 10

2.6: IBR Act: Chief Inspector, Deputy Chief Inspectors and Inspectors
(1) 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.
(2) 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.
(3) 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
(3) 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.
(4) 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.

2.6: IBR Act: Chief Inspector, Deputy Chief Inspectors and Inspectors
(5) 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.
(6) 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.
(7) 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).

2.6: IBR Act: Additional Sections - 14. Duty of owner at examination
(1) On any date fixed under this Act for the examination of a boiler, the owner thereof shall be bound-
(a) to afford to the Inspector all reasonable facilities for the examination and all such information as may reasonably be
required of him;
(b) 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
(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.

2.6: IBR Act: Additional Sections - 16. Reports of accidents
(1) 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.
(2) Every person shall be bound to answer truly to the best of his knowledge and ability every question put to
(2) 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.

2.7: Maintenance of High Pressure Boilers
1. 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.

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.

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.

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.
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.

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.
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.

* 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

In this lesson, We have learnedIn this lesson, We have learnedIn this lesson, We have learnedIn this lesson, We have learned
2.5 Control System in FBC Coilers
2.6 Indian Boiler Regulation (IBR) Act
SUMMARY
2.6 Indian Boiler Regulation (IBR) Act
2.7 Maintenance of High Pressure Boilers

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UNIT III. STEAM AND GAS POWER PLANTS
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Lecture 07_PPE_Unit 2: High Pressure Boilers

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