K Karthikeyan Manager Controls & Instrumentation BHEL, Tiruchirappalli

1. Boiler Controls & Instrumentation K Karthikeyan Manager Controls & Instrumentation BHEL, Tiruchirappalli Email : karthi@bheltry.co.in

2. Boiler C&I INTRODUCTION PART I - BOILER PART 2 - INSTRUMENTATION PART 3 - CONTROLS Bharat Heavy Electricals Limited - Tiruchirappalli

3. Boiler C&I Boiler Controls & Instrumentation Bharat Heavy Electricals Limited - Tiruchirappalli

4. Boiler C&I Boiler C&I -Functions Bharat Heavy Electricals Limited - Tiruchirappalli

5. Boiler C&I Broad engineering activities Boiler Controls & Instrumentation • Control systems engineering • Instrumentation engineering • Electrical systems engineering • New product development Bharat Heavy Electricals Limited - Tiruchirappalli

6. Boiler C&I Functions Boiler Controls & Instrumentation • Proposal Engineering • Contract Engineering • Product Engineering • Quality Assurance & Control • Field Engineering • Research & Development Bharat Heavy Electricals Limited - Tiruchirappalli

7. Boiler C&I Boiler Controls & Instrumentation ProposalEngineering Bharat Heavy Electricals Limited - Tiruchirappalli

8. Boiler C&I Boiler Controls & Instrumentation Proposal Engineering • Scope of Work • Project Estimate • Offer submission • Offer evaluation by customer • Award of contract Bharat Heavy Electricals Limited - Tiruchirappalli

9. Boiler C&I Boiler Controls & Instrumentation Proposal Engineering • In summary, the purpose is to draw-up - Scope of Work - Project Estimate of the project.Deliverables : - Estimable quantity(BOM)- main and spares - Datasheets - Descriptive offers of packages & - Preliminary design sketches(P&IDs, GA). Bharat Heavy Electricals Limited - Tiruchirappalli

10. Boiler C&I Boiler Controls & Instrumentation Scope of Work • Arrived based on a broad specification prepared by the customer/consultant. • Individual system scope identified gets recompiled into a project scope of work . • Project scope document includes scope of work , terminal points & exclusions Bharat Heavy Electricals Limited - Tiruchirappalli

11. Boiler C&I Boiler Controls & Instrumentation Scope of Work • The typical scope covered in Boiler C&I discipline include • Furnace safeguard Supervisory system • Secondary Air Damper control system • Soot blower control system • Boiler area field instruments • Associated cable & accessories. • Electricals(MCC, elevator etc.) Bharat Heavy Electricals Limited - Tiruchirappalli

12. Boiler C&I Boiler Controls & Instrumentation Offer evaluation • The offers get evaluated at the customer end. • Customer awards the contract on a technically qualified bid with the lowest price. • The award of contract is indicated by a ‘Letter of Intent’ received from the customer. Bharat Heavy Electricals Limited - Tiruchirappalli

13. Boiler C&I Boiler Controls & Instrumentation Award of contract • The offers get evaluated at the customer end. • Customer awards the contract on a technically qualified bid with the lowest price. • The award of contract is indicated by a ‘Letter of Intent’ received from the customer. Bharat Heavy Electricals Limited - Tiruchirappalli

14. Boiler C&I Boiler Controls & Instrumentation Contract Engineering Bharat Heavy Electricals Limited - Tiruchirappalli

15. Boiler C&I Contract Engineering Packages • SG integral C&I(Trichy) • Station C&I(PEM or customer)- in case of BTG or Turnkey • SG integral electricals(Trichy) • Station Electricals(PEM or customer)- in case of BTG or Turnkey Bharat Heavy Electricals Limited - Tiruchirappalli

16. Boiler C&I Contract Engineering The role involves system level contract coordination for the boiler C&I area. • Applicable PGMA List • Sub Delivery check list. • Boiler Contract Regular activity(BCR) schedule • ‘00’ PG list(erection documents). • Applicable O&M documents. Bharat Heavy Electricals Limited - Tiruchirappalli

17. Boiler C&I Contract Engineering System Engg. Documents involved : • Piping&Instrumentation Diagrams(P&IDs) • Measurement & control recommendations • Automatic control schemes • Interlock & protection schemes Bharat Heavy Electricals Limited - Tiruchirappalli

18. Boiler C&I P & I Diagram- Air & flue gas (portion) Bharat Heavy Electricals Limited - Tiruchirappalli

19. Boiler C&I Instrument schedule steam & water (sample) Bharat Heavy Electricals Limited - Tiruchirappalli

20. Boiler C&I Product Engineering Bharat Heavy Electricals Limited - Tiruchirappalli

21. Boiler C&I Product Engineering Detailed design of Boiler C&I products & systems • Digital controls • Analog controls • Electrical systems & cables • Field instruments • Special instruments • Actuators Bharat Heavy Electricals Limited - Tiruchirappalli

22. Boiler C&I Product Engineering • Digital Controls Burner management system. Soot Blower control system • Analog Controls Secondary air damper control system. Auxiliary PRDS control system. Bharat Heavy Electricals Limited - Tiruchirappalli

23. Boiler C&I Product Engineering • Electrical systems Control supply panels LT Motor control centres Power distribution panels • Field instruments Switches & gauges for Pressure,Level & temperature Thermocouples Flow elements Bharat Heavy Electricals Limited - Tiruchirappalli

24. Boiler C&I Product Engineering Special instruments • Flame scanner system • Acoustic steam leak detection system. • Electronic water level indicator. • Closed circuit television system. • Vibration monitoring system. • Flue gas analysers. • Steam and water analysers. Bharat Heavy Electricals Limited - Tiruchirappalli

25. Boiler C&I Product Engineering • Electrical and C & I engineering design • Release of indents for C & I sub-delivery items. • Evaluation of technical offers for bought-out items • Technical Delivery Conditions (TDC) Bharat Heavy Electricals Limited - Tiruchirappalli

26. Boiler C&I Boiler Controls & Instrumentation Quality Control & Assurance Bharat Heavy Electricals Limited - Tiruchirappalli

27. Boiler C&I Quality Control & Assurance The role involves preparation/review of following activity w.r.t C&I products & systems • Prepare Standard Quality Plans (SQP) • Prepare Contract Quality Plans (CQP) • Review/Approve Vendor Quality Plans (VQP) • Issue Reference Quality Plans (RQP) • Prepare Inspection Check Lists (ICL) Bharat Heavy Electricals Limited - Tiruchirappalli

28. Boiler C&I Quality Control & Assurance • Performing inspection at vendor works for CI products & systems - bought-out items • Review & dispose Site Action Requests on CI products & systems Bharat Heavy Electricals Limited - Tiruchirappalli

29. Boiler C&I Field Engineering Bharat Heavy Electricals Limited - Tiruchirappalli

30. Boiler C&I Field Engineering The role involves • Providing technical support / trouble shooting of C&I products / system during - Erection & commissioning stage of project - Operation after handing over to customer • Review & dispose Commissioning action requests • Review & dispose Contract closing pending issues • Visiting sites to ensure smooth progress of C&I site activity Bharat Heavy Electricals Limited - Tiruchirappalli

31. Boiler C&I Boiler Controls & Instrumentation Research & Development Bharat Heavy Electricals Limited - Tiruchirappalli

32. Boiler C&I Research & Development • Microprocessor based Gravimetric coal feeder controls - BHELFEED • Microcontroller based Flame moniotirng system - BHELSCAN • Acoustic steam leak detection system – BHELSONIC • Electronic water level Indicator system- BHELVISION In-house developed C&I systems & products Bharat Heavy Electricals Limited - Tiruchirappalli

33. Boiler C&I Boiler Basics Bharat Heavy Electricals Limited - Tiruchirappalli

34. Boiler C&I BOILER CLASSIFICATION Bharat Heavy Electricals Limited - Tiruchirappalli

35. Boiler C&I BHEL BOILERS • Power Boilers Up to 600 MW rating(Coal, oil and gas fired - Subcritical) Up to 800 MW - Supercritical • Nuclear steam generators Up to 235 MW rating • Industrial boilers Up to 450 Tonnes/hour rating Fertilisers, Petrochemical, Steel & Paper industries Wide range of fuels- Oil, Gas, BFG, Bagasse, Black liquor. Bharat Heavy Electricals Limited - Tiruchirappalli

36. Boiler C&I Bharat Heavy Electricals Limited - Tiruchirappalli

37. Schematic of a boiler

38. Boiler C&I UTILITY BOILERS - ESSENTIAL COMPONENTS • Furnace & Circulation system • Superheaters • Reheaters • Economiser • Airheaters • Fans • Pulverisers • Raw coal feeders • Fuel firing system • Sootblowers Bharat Heavy Electricals Limited - Tiruchirappalli

39. Boiler C&I CIRCULATION SYSTEMS • Natural circulation • Controlled circulation • Once through Circulation ratio : Mass rate of water fed to the steam generating tubes to the mass rate of steam generated. Natural circulation 6 Controlled circ 4 Once through 1 Bharat Heavy Electricals Limited - Tiruchirappalli

40. Boiler C&I BOILER CIRCULATION SYSTEMS Bharat Heavy Electricals Limited - Tiruchirappalli

41. Boiler C&I Fans 1. Axial • Impulse type - IGV Control. • Reaction type - Blade pitch Control. 2. Radial Inlet damper control, Variable speed control; Variable speed control by two speed motor, Hydraulic coupling or Variable frequency drive. Bharat Heavy Electricals Limited - Tiruchirappalli

42. Boiler C&I Radial Fan Bharat Heavy Electricals Limited - Tiruchirappalli

43. Boiler C&I Axial Reaction Bharat Heavy Electricals Limited - Tiruchirappalli

44. Boiler C&I RADIAL FANS - SPEED CONTROL • Flow proportional to Speed • Flow proportional to (Impeller Dia) 3 • Head proportional to (Speed) 2 • Head proportional to (Impeller Dia) 2 Hence Variation in speed alters the performance Bharat Heavy Electricals Limited - Tiruchirappalli

45. Boiler C&I FANS IN BOILER - SCOPE • Primary air fans - Dries & transports Pulverised coal • Forced draft fans - Supplies Combustion air • Induced draft fans - Sucks Flue gas out of furnace Bharat Heavy Electricals Limited - Tiruchirappalli

46. Boiler C&I MILL - GRINDS COAL • Slowspeed mills (Tube mills - 15 to 25 RPM) • Mediumspeed mills (Bowl mill, Ball and race mill etc.- 50 to 100 RPM) • High speed mills (hammer mills directly coupled to motor - 750 to 1000 RPM) Bharat Heavy Electricals Limited - Tiruchirappalli

47. Boiler C&I RAW COAL FEEDERS • Volumetric - Rotary and drag link, • Gravimetric – Endless belt type Scope : CONVEY RAW COAL TO MILL Types : Bharat Heavy Electricals Limited - Tiruchirappalli

48. Boiler C&I AIRHEATER Heat recovery equipment Extract heat from Flue gas to heat primary & secy. Air • Regenerative type ( Rotating drive ) • Tubular type Types : Bharat Heavy Electricals Limited - Tiruchirappalli

49. Boiler C&I SOOTBLOWERS Remove ash & slag from pressure part tubes Types • Long retractable sootblowers - traverse & rotary motors • Half retractable sootblowers- traverse & rotary motors • Rotary blowers - rotary motor • Wall blowers - traverse & rotary motors • Furnace temperature probe - Used during boiler start up Bharat Heavy Electricals Limited - Tiruchirappalli

50. Boiler C&I FUELS & COMBUSTION Fuels : Coal Oil Gas H/C ratio • Natural gas 0.3 Fuel oil 0.1 Coal 0.07 Calorific value (kcal/kg ) • Gas 10000 Oil 8000 • Bituminous coal 3000-3500 Lignite 2500 Coal burning methods • "On grate" “In suspension" Fluidised bed Three 'T's of combustion • Time • Temperature and • Turbulence. Bharat Heavy Electricals Limited - Tiruchirappalli