L&T MHPS Boilers Internship Report and Thermal Power Plant Overview

S M URUF NEZAMI (15017004021)
B.TECH (MECHANICAL) |, DEENBANDHU CHHOTU RAM UNIVERSITY OF
SCIENCE AND TECHNOLOGY, MURTHAL
L&T MHPS Boilers
Pvt Ltd
INTERNSHIP REPORT

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L&T MHPS BOILERS PVT LTD
ACKNOWLEDGEMENT
I take the opportunity to convey my thanks to the management, executives
and non-executives of Larsen & Toubro (L&T) in general, and to those of L&T-
MHPS Boilers Pvt. Ltd. Engineering Office, in particular, for providing me with
an opportunity for doing six weeks Internship (1st January – 12th February
2018) in the Pressure Parts Department. I am also grateful to the Pressure
Parts team for familiarizing me with Boilers and introducing me to 3-D
Modelling and Finite Element (FE) analysis in Solid Edge, which will be very
helpful in my career and will enhance my skill set.
I would like to express my sincere gratitude to my supervisor, Mr. S.
Chandrasekhar, Joint General Manager (Engineering), without whose
guidance, neither my internship would have been fruitful, nor would my
project have seen the light of the day. He constantly guided me through my
internship and project and gave his valuable advice, as and when the need
arose, in spite of his extremely busy schedule.
I would also like to express my deepest thanks to Mr. Anup Kumar Singh,
Mr. Gulshan S and Mr. Rohan Mishra of Pressure Parts Department, for
assisting and guiding me on a day to day basis throughout my internship.
Despite their busy schedules, they took out time to familiarize and brief me
with the intricacies of my project and to assist me during my progress,
whenever required. Further, I owe my gratitude to the whole of Pressure Part
Department, for providing such an amiable environment for work and for
promptly addressing all of my queries to my satisfaction. I would like to convey
my heartfelt gratitude to the entire faculty of engineering.
Any omission in this brief acknowledgement does not mean lack of gratitude.
S M Uruf Nezami (15017004021)
B.Tech. Mechanical Engineering

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TABLE OF FIGURES
Figure 1: Total World Energy Consumption (2010).............................................. 5
Figure 2: World Total Primary Energy Production (2015) ..................................... 6
Figure 3: All India Installed Capacity (2016)....................................................... 7
Figure 4: Joint Venture of L&T-MHPS.............................................................. 15
Figure 5: LMB's Scope Of Business ................................................................. 15
Figure 6: LMB Offices, Manufacturing And Project Site Locations....................... 16
Figure 7: Boiler ............................................................................................. 19
Figure 8: Rough sketch Of Natural Circulation and Forced Circulation System.... 23
Figure 9: Schematic Flow Diagram Of Super Critical (Once Through) Boiler
Technology ................................................................................................... 24
Figure 10: Idealized Rankine Cycle.................................................................. 27
Figure 11: P-V Diagram Of Rankine Power Cycle .............................................. 27
Figure 12: T-s Diagram Of Rankine Power Cycle............................................... 28
Figure 13: H-s Diagram Of Rankine Power Cycle .............................................. 28
Figure 14: Reheat Rankine Cycle .................................................................... 29
Figure 15: Regenerative Rankine cycle............................................................. 29
Figure 16: Rankine Cycle With Reheat And Regeneration .................................. 30
Figure 17: Simple Super Critical Cycle ............................................................ 31
Figure 18: Two Way Boiler Used In Industry .................................................... 33
Figure 19: Location of Economizer .................................................................. 34
Figure 20: Location of Primary Superheater ..................................................... 35
Figure 21: Location of Secondary Superheater.................................................. 35
Figure 22: Location of Tertiary Superheater ..................................................... 36
Figure 23: Location of the Primary Reheater..................................................... 36
Figure 24: Location of Secondary Reheater ...................................................... 37
Figure 25: MRS (Mitsubishi Rotary Separator) Pulveriser................................... 39
Figure 26: Types Of Pulveriser........................................................................ 40
Figure 27: Example of Designing in Part Module............................................... 42
Figure 28: Example of Designing in Assembly Module....................................... 45
Figure 29: Incomplete Draft............................................................................ 46
Figure 30: Complete Draft.............................................................................. 46
Figure 31: Box Type Transportation Frame ...................................................... 47
Figure 32: Stanchion Type Transportation Frame ............................................. 48
Figure 33: Rough Sketch of Final Result.......................................................... 49
Figure 34: Final Result After Sketching ........................................................... 50
Figure 35: Butt1 Joint ................................................................................... 51
Figure 36: Complete Transportation Frame...................................................... 52
Figure 37: Square Beam of Given Dimensions.................................................. 56
Figure 38: Material Used................................................................................ 57
Figure 39: Analysis of Displacement................................................................ 59
Figure 40: Analysis of Stress .......................................................................... 59
Figure 41: Material Used................................................................................ 60
Figure 42: Stress Analysis of The Model........................................................... 61
Figure 43: Displacement Analysis of the Model................................................. 61
Figure 44: 3-D Model of Pipe .......................................................................... 61

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Table of Contents
INTRODUCTION TO POWER INDUSTRY.....................................................5
1.1 World Power Organizations..................................................................5
1.2 Indian Power Industry .........................................................................6
1.2.1 Introduction ...................................................................................6
1.2.2 Market Size ....................................................................................7
1.2.3 Investments ...................................................................................8
1.2.4 Government Initiatives...................................................................8
1.2.5 Road Ahead....................................................................................9
1.3 Future of Power Industry .....................................................................9
THERMAL POWER PLANT.........................................................................10
2.1 Current Trends..................................................................................10
2.2 Importance of Steam..........................................................................10
2.3 Summary ...........................................................................................11
ORGANIZATION .........................................................................................13
3.1 L&T (LARSEN & TOUBRO).................................................................13
3.2 MHPS (Mitsubishi Hitachi Power System)..........................................14
OVERVIEW - L&T–MHPS BOILER PVT. LTD. ...........................................15
4.1 L&T-MHPS Boilers PVT. LTD. ............................................................15
4.2 LMB OVERVIEW ................................................................................16
INTRODUCTION TO PRESSURE PARTS DEPT.........................................18
5.1 Inputs required by a Pressure Parts designer ....................................18
5.2 What does a PP designer do? .............................................................18
BOILER ......................................................................................................19
6.1 What is a boiler? ................................................................................20
6.2 Functions of a Boiler:.........................................................................20
CLASSIFICATION OF BOILERS.................................................................21
7.1 According to Relative Passage of water and hot gases:.......................21
7.2 According to Water Circulation Arrangement:....................................23
7.3 According to the Position of Furnace..................................................25
7.4 According to Pressure of steam generated..........................................25
Basic Working Principle of a Boiler (RANKINE CYCLE) ..........................27
8.1 Rankine cycle with reheat..................................................................28

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8.2 Regenerative Rankine cycle................................................................29
8.3 Reheat Regenerative Rankine Cycle ...................................................30
MODERN SUPERCRITICAL BOILER .........................................................31
9.1 Advantages of Super Critical Technology ...........................................32
MAJOR COMPONENTS OF A BOILER.......................................................33
10.1 Economizer......................................................................................34
10.2 Superheaters ...................................................................................34
10.2.1 Primary Superheater..................................................................35
10.2.2 Secondary Superheater..............................................................35
10.2.3 Tertiary Superheater..................................................................36
10.3 Reheaters .....................................................................................36
FLOW OF AIR IN THE BOILER..................................................................38
11.1 Wind Box .........................................................................................38
COAL SYSTEM...........................................................................................39
INTRODUCTION TO 3D MODELLING .......................................................41
13.1 Solid edge.........................................................................................41
13.2 Features of Solid Edge .....................................................................41
TRANSPORTATION FRAME ......................................................................47
14.1 Types of Transportation Frame ........................................................47
14.2 Requirements...................................................................................48
14.3 Transportation Frame Design ..........................................................49
14.3.1 Part Modelling............................................................................49
14.3.2 Assembly....................................................................................50
FINITE ELEMENT ANALYSIS (FEA) ..........................................................53
15.1 Introduction.....................................................................................53
15.2 What is Finite Element Analysis (FEA)? ...........................................53
15.3 Areas of FEA Application..................................................................54
ANALYSIS IN SOLID EDGE........................................................................55
16.1 Important Guidelines.......................................................................55
16.2 Analysis of Cantilever Beam.............................................................56
16.3 Analysis of Pipes..............................................................................59
REFERENCE ..............................................................................................62

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INTRODUCTION TO POWER INDUSTRY
The power industry is the generation, transmission, distribution and sale of
electric power to the general public. The electrical industry started with
introduction of electric lighting in 1882. Throughout the 1880s and 1890s,
growing economic and safety concerns lead to the regulation of the industry.
Once an expensive novelty limited to the most densely populated areas,
reliable and economical electric power has become a requirement for normal
operation of all elements of developed economies.
By the middle of the 20th century, electric power was seen as natural
monopoly", only efficient if a restricted number of organizations participated
in the market; in some areas, vertically-integrated companies provides all
stages from generation to retail, and only governmental supervision regulated
the rate of return and cost structure.
Since the 1990s, many regions have opened up the generation and
distribution of electric power to provide a more competitive electricity market.
While such markets can be abusively manipulated with consequent adverse
price and reliability impact to consumers, generally competitive production of
electrical energy leads to worthwhile improvements in efficiency. However,
transmission and distribution are harder problems since returns on
investment are not as easy to find.
1.1 World Power Organizations
The electric power industry is commonly split up into four processes. These
are electricity generation such as a power station, electric power
transmission, electricity distribution and electricity retailing. In many
countries, electric power companies own the whole infrastructure from
FIGURE 1: TOTAL WORLD ENERGY CONSUMPTION (2010)FIGURE 1: TOTAL WORLD ENERGY CONSUMPTION (2010)

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generating stations to transmission and distribution infrastructure. For this
reason, electric power is viewed as a natural monopoly. The industry is
generally heavily regulated, often with price controls and is frequently
government - owned and operated.
The nature and state of market reform of the electricity market often
determines whether electric companies are able to be involved in just some of
these processes without having to own the entire infrastructure, or citizens
choose which components of infrastructure to patronize. In countries where
electricity provision is deregulated, end-users of electricity may opt for more
costly green electricity.
1.2 Indian Power Industry
1.2.1 Introduction
The Indian power sector is one of the most diversified in the world. Sources
for power generation range from commercial ones such as coal, lignite,
natural gas, oil, hydro and nuclear power to other viable non-conventional
sources such as wind, solar, and agriculture and domestic waste. The demand
for electricity in the country has been growing at a rapid rate and is expected
to grow further in the years to come. In order to meet the increasing
requirement of electricity, massive addition to the installed generating
capacity in the country is required.
FIGURE 2: WORLD TOTAL PRIMARY ENERGY PRODUCTION (2015)

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1.2.2 MarketSize
As per the International Energy Agency (IEA) publication on World Energy
Statistics 2013, India ranks 5th in Electricity production and 110th in the
per-capita consumption of electricity.
The Indian power sector is undergoing a significant change that is redefining
the industry outlook. Sustained economic growth continues to drive power
demand in India. The Government of India’s focus to attain ‘Power For All’ has
accelerated capacity addition in the country. At the same time, the competitive
intensity is increasing on both market side as well as supply side (fuel,
logistics, finances and manpower).
Electricity production in India (excluding captive generation) stood at 911.6
TWH in FY13, a 4 per cent growth over the previous fiscal. During FY14,
electricity production stood at 967 TWH. Over FY07–14, electricity production
expanded at a compound annual growth rate (CAGR) of 5.6 per cent.
As of April 2014, total thermal installed capacity stood at 168.4 gigawatt (GW),
while hydro and renewable energy installed capacity totalled 40.5 GW and
31.7 GW, respectively. At 4.8 GW, nuclear energy capacity remained broadly
constant from that in the previous year.
Indian solar installations are forecasted to be approximately 1,000 megawatt
(MW) in 2014, according to Mercom Capital Group, a global clean energy
communications and consulting firm.
Wind energy market of India is expected to attract about INR 20,000 crore
(US$ 3.24 billion) of investments next year, as companies across sectors plan
to add 3,000 MW of capacity powered by wind energy.
FIGURE 3: ALL INDIA INSTALLED CAPACITY (2016)

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1.2.3 Investments
The investment climate is positive in the power sector. Due to the policy of
liberalisation, the sector has witnessed higher investment flows than
envisaged. The Ministry of Power has sent its proposal for the addition of
76,000 MW of power capacity in the 12th Five Year plan (2012-17), to the
Planning Commission. The Ministry has set a target of adding 93,000 MW in
the 13th Five Year Plan (2017-2022).
The industry has attracted FDI worth US$ 9,309.96 million during the period
April 2000 to September 2014.
1.2.4 Government Initiatives
The Government of India has identified the power sector as a key sector of
focus to promote sustained industrial growth. Some of the initiatives taken by
the Government of India to boost the power sector of India are as follows:
 India and Bhutan have signed a power project pact to provide a major boost
to the 600 MW Kholongchu hydroelectric project. It will be the first
hydroelectric project to be developed by a joint venture (JV) between public
sector units (PSUs) of the two countries.
 India and Nepal have signed the power trade agreement (PTA). The
agreement will be effective for the next 25 years and deals with power trade,
cross-border transmission lines and grid connectivity.
 The Ministry of New and Renewable Energy (MNRE) has initiated scheme
for setting up of 25 Solar Parks, each with the capacity of 500 MW and
above, to be developed over the next 5 years in various states.
 Indian Renewable Energy Development Agency Ltd (IREDA) has signed a
MOU with the US Exim Bank with respect to cooperation on clean energy
investment.
 In line with the government’s plans to boost domestic output of coal, India’s
largest thermal power producer, NTPC Ltd, could soon become one of the
major coal-producers of the country as well. NTPC plans to produce up to
300 million tonnes (MT) of coal within the next four to five years, said Mr
Arup Roy Choudhury, Chairman and MD, NTPC.
 The Competition Commission of India (CCI) has given its approval to Adani
Power's deal with Lanco Infratech to buy the latter's 1,200 MW imported
coal-fired power plant at Udupi in Karnataka for more than Rs 6,000 crore
(US$ 973.79 million).

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1.2.5 Road Ahead
The government is targeting capacity addition of around 89 GW under the
12th (2012–17) and around 100 GW under the 13th (2017–22) Five-Year Plan.
The expected investments in the power sector during the 12th Plan (2012–17)
is US$ 223.9 billion. There is a tangible shift in policy focus on the sources of
power. The government is keen on promotion of hydro, renewable and gas-
based projects, as well as adoption of clean coal technology.
Wind energy is the largest source of renewable energy in India; it accounts for
an estimated 87 per cent of total installed capacity (18.3 GW). There are plans
to double wind power generation capacity to 20 GW by 2022.
Biomass is the second largest source of renewable energy, accounting for 12
per cent of total installed capacity in renewable energy. There is a strong
upside potential in biomass in the coming years.
1.3 Future of Power Industry
The power industry is growing with a decent rate because the need of today
is electricity generation. But today also we did not produce sufficient
electricity in several underdevelopment and undeveloped countries .i.e. why
power production is the need of today and the future.
In the future, civilization will be forced to research and develop alternative
energy sources. Our current rate of fossil fuel usage will lead to an energy
crisis this century. In order to survive the energy crisis many companies in
the energy industry are inventing new ways to extract energy from renewable
sources. While the rate of development is slow, mainstream awareness and
government pressures are growing.
The non-conventional sources of energy are introducing today. The technology
will be definitely helpful to generate electricity by using these sources.

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THERMAL POWER PLANT
The theory of thermal power station or working of thermal power station is
very simple. A power generation plant mainly consists of alternator runs with
help of steam turbine. The steam is obtained from high pressure boilers.
Generally in India, bituminous coal, brown coal and peat are used as fuel of
boiler. The bituminous coal is used as boiler fuel has volatile matter from 8 to
33% and ash content 5 to 16%. To increase the thermal efficiency, the coal is
used in the boiler in powder form.
In coal thermal power plant, the steam is produced in high pressure in the
steam boiler due to burning of fuel (pulverized coal) in boiler furnaces. This
steam is further super heated in a super heater. This super heated steam then
enters into the turbine and rotates the turbine blades. The turbine is
mechanically so coupled with alternator that its rotor will rotate with the
rotation of turbine blades. After entering in turbine the steam pressure
suddenly falls and corresponding volume of the steam increases.
2.1 Current Trends
There are two distinct aspects driving changes in power plant technology. One
is environmental considerations. The other is financing of new installations.
With regard to the environment there has, in recent years, been an effort to
reduce the emission of sulphur oxides and nitrogen oxides. This can be done
by appropriate selection of the fuel or proper choice of clean-up technology
for the exhaust gases. Since the demand for electricity is ever increasing it
follows that new plants must have reduced emission criteria just to maintain
total emissions at the current level.
The aspect of financing is related to reduced economic growth and reduced
government spending on large scale projects in recent years. Generally private
enterprise is less willing to invest in projects with a low return and a long pay-
back period. There is thus an incentive to build plants with a lower capital
cost and a shorter construction period and to refurbish older plants. There
are various ways of achieving this but a combined cycle plant is a ready
solution.
2.2 Importance of Steam
All thermal power plants, by definition, produce work, in the form of
electricity, from heat. The heat is generated mostly by combustion of a
chemical fuel or fission of a nuclear fuel. In rare cases heat may be supplied
from a natural source such as the earth (geothermal) or the sun (solar) but
the scale of this is practically negligible at the present time. The process of
producing work from heat requires a thermodynamic cycle with a working

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fluid to convey the heat from the heat source, at an elevated temperature, to
the heat sink, at a lower temperature. For large scale applications this fluid
must be relatively cheap and abundant and have desirable heat transport
properties. Water fits these requirements very well particularly as the change
in phase from liquid to vapour and back to liquid is accompanied respectively
by a large absorption and rejection of heat. This enables this fluid to transport
much larger quantities of heat per unit mass than other working fluids such
as, for example, air. As a result water-steam is the working fluid of choice and
is used in the majority of thermal power cycles for the production of electricity.
Steam is generated from water in fossil fuelled boilers and in nuclear fuelled
reactors and then utilized in steam turbines to produce electrical power. The
production of steam is thus a key element in the production of electrical
power.
Gas turbines utilize air as the working fluid in their thermodynamic cycles.
Air is convenient to use, as the combustion process and the thermodynamic
cycle can be combined thus simplifying enormously the structure of the plant.
This is a big advantage but constraints in fuel cost and availability as well as
in overall cycle efficiency and plant capacity make gas cycles less attractive
than the steam cycle for large scale applications. The advent of combined
cycles with their high thermal efficiency has however made them very
attractive for certain applications. A combined cycle however reverts back to
steam as the working fluid for part of the combined cycle. Thus even such
installations make use of water to generate steam.
2.3 Summary
In order to extract heat from fuel it must first be processed and then burned.
Most solid fuels such as coal require specific processing to ensure proper
mixing with the combustion air while liquid and gaseous fuels are more
readily combustible. Most processing requires crushing and grinding to
produce small quickly combustible particles but for certain applications
gasification is an alternative method of preparation.
Fuel may be burned in various ways which ensure intimate mixing of the fuel
and air but the most common method is to burn it in suspension where the
fuel and air are mixed in a turbulent flame. This promotes rapid combustion
and a high rate of heat release. Suspension firing is suitable for solid, liquid
and gaseous fuels.
Following combustion, the exhaust gas usually requires some treatment to
minimize the release of ash in particulate form and of certain combustion
products. Most plants burning solid fuels and heavy liquids have electrostatic
precipitators or baghouses to trap the flyash while plants burning fuels having
high sulphur contents have more recently been fitted with desulfurization
units.

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Heat may be obtained directly, without combustion of a fuel, from below the
earth or from the sun. The main problem with such resources is lack of
concentration of the energy. An extensive collection system is required and
this adds enormously to the cost of handling what is often perceived as free
energy.
Nuclear energy on the other hand is extremely concentrated. Only a tiny
amount of fuel is required to produce a large amount of power. This makes it
very desirable for the production of heat on a large scale in central generating
plants. A distinct advantage of nuclear energy is that there are no combustion
gases released to the atmosphere and hence no atmospheric pollution. On the
other hand the radioactive spent fuel products have to be stored indefinitely
in secure areas. The amount to be stored however is relatively small and safe
methods of disposal have been devised.
The overall safety of nuclear plants is of concern following the accidents at
Three Mile Island and Chernobyl. These concerns have been addressed in
some advanced nuclear reactor designs where passive safety is a feature. This
concept ensures that a nuclear reactor remains in a safe condition without
operator intervention following various postulated accidents.

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ORGANIZATION
3.1 L&T (LARSEN & TOUBRO)
L&T was founded in Mumbai in 1938 by two Danish engineers, Henning
Holck-Larsen and Soren Kristian Toubro. Both of them strongly committed to
developing India’s engineering capabilities to meet the demands of the
industry. Beginning with the import of machinery from Europe, L&T rapidly
took on engineering and construction assignments of increasing
sophistications. Larsen & Toubro is a technology-driven USD 12.8 billion
company that infuses engineering with imagination.
With its steady hold in the Indian industry in fields ranging from engineering,
construction, information technology, financial services and manufacturing
goods, Larsen & Toubro, headquartered in Mumbai, India, have delivered
quality products and services that have established it on the global scene.
L&T currently holds the title of the largest engineering and constructional
MNC in India with its roots spread throughout infrastructure, power,
hydrocarbon, machinery, ship building and railway sectors. It has received
several recognition at a national and global level with the ‘Golden Peacock
National Quality Award’ a 23rd World Congress on ‘Leadership and Quality of
Governance’ being its latest achievement.
Other accomplishments over the years includes being ranked 4th in the global
list of the Green Companies in the industrial sector and the more recent
inclusion of the company at the 500 spots in the Forbes list of 2000 of the
‘‘World’s largest and Most powerful Companies’’. It was ranked in 2012 above
contending companies like Google and Apple Inc. at the 9th spot in the list of
the most innovative company by Forbes magazine.
Various Operating Divisions:
 Constructions: With over 60 years of experience behind it, L&T
Construction is India’s largest construction enterprise with immense
expertise in the field to back it.
 Power: It consists of the various offerings of L&T in the power sector of
the Indian Industry.
 Information technology: L&T Infotech is an IT solutions and service
provider at a global stage.
 Machinery and Industrial Projects: Either with its house manufacturing
or with partnership with world leaders, a wide range of industrial
machinery and products are designed and developed by the company.

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 Hydrocarbon: L&T’s Hydrocarbon Business delivers ‘build to guide’
world class engineering and construction solutions on turnkey basis in
oil & gas, petroleum refining, chemicals & petrochemicals and fertilizers
sectors.
 Electrical and Automation: L&T offers business solutions low to
medium voltage categories, consisting mostly of electrical systems,
switch gears, automation systems, medical equipment, energy meters,
etc.
 Heavy Engineering: L&T’s state of the art manufacturing techniques
have achieved global recognition in delivering quality products. Its
strong engineering and innovation capabilities are no news to its
clients.
3.2 MHPS (Mitsubishi Hitachi Power System)
Mitsubishi Hitachi Power Systems (MHPS), Japan is one of the world’s leading
heavy machinery manufactures, with consolidated sales of over USD 34bn.
Its diverse line up of products and services encompasses energy, material
handling & transportation equipment, aerospace, machinery & steel
structures and ship building & ocean development. MHPS has over five
decades in experience in manufacturing supercritical boilers and turbine
generators. It possesses state of the art of technology and has the world’s most
extensive references of large capacity supercritical boilers and turbines

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OVERVIEW - L&T–MHPS BOILER PVT. LTD.
4.1 L&T-MHPS Boilers PVT. LTD.
L&T-MHPS Boilers Pvt. Ltd. is a 51:49 Joint Venture Company formed on 16th
April, 2007 in India between Larsen and Toubro (L&T), India and Mitsubishi
Hitachi Power Systems (MHPS), Japan for engaging in the business of design,
engineering, manufacturing, selling, maintenance and servicing of
Supercritical Boilers and Pulverisers in India.
FIGURE 4: JOINT VENTURE OF L&T-MHPS
FIGURE 5: LMB'S SCOPE OF BUSINESS

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The company has established manufacturing facility that can manufacture
pressure parts and pulverisers at Hazira, near Surat in the state of Gujarat
with the technological support from Mitsubishi Hitachi Power Systems.
4.2 LMB OVERVIEW
Completed Projects:
 JAYPEE GROUP, NIGRIE
 MAHAGENCO, KORADI
 NABHAPOWER, RAJPURA
FIGURE 6: LMB OFFICES, MANUFACTURING AND PROJECT SITE LOCATIONS

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Major Projects Under execution:
 RRVUNL, RAJASTHAN
 NTPC TANDA
 NTPC KHARGONE
 MPPGCL KHANDWA
 NUPPL GHATAMPUR
Major Export Orders:
 Rabigh IWPP Phase II Project, RAWEC, Jeddah, Saudi Arabia.–
Completed
 Pagbilao Unit 3 Expansion Project, Pagbilao Energy, Quezon,
Philippines.- Completed
 Walidia Power Plant (WPP), UEEPC, Walidia, Egypt.-Completed
 Tanjungjati B Unit 5&6 Expansion Project, PT Bhumi Jati Power (BJP),
Central Java, Indonesia.
 USC, Central Java Project, PT Bhimasena Power, Batang, Central Java,
Indonesia.
 Hitachinaka Kyudou Karyoku 1 Project, Hitachinaka Generation Co.,
Hitachinaka, Japan

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INTRODUCTION TO PRESSURE PARTS DEPT.
Pressure parts – The main purpose of the pressure parts department is to
provide sufficient heating surfaces for effecting the heat transfer from the
hot flue gases to the fluid inside the tubes.
5.1 Inputs required by a Pressure Parts designer
 Process Datasheets
 Basic boiler layout with arrangement of heating surfaces
 Operating pressures and temperatures
 Metal temperature profile
5.2 What does a Pressure Part designer do?
 Detail the pressure parts
 Determine the design pressures and design temperatures
 Select the material based on design metal temperatures
 Calculate the thicknesses of all pressure parts based on pressure and
external induced loads
 Carry out flexibility analysis where required
 Design of supports for heating surfaces and headers/manifolds
 Finalize all pressure part attachments
 Calculate and communicate boiler loads to the Structural department
 Raise material requisitions and specifications for ordering the
pressure parts
 Preparation of the 3D models for pressure part assemblies and release
2D shop drawings.
 Coordinate with the plant SP-3D model

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BOILER
FIGURE 7: BOILER

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6.1 What is a boiler?
A boiler is a closed vessel, which is made by metal, in which water is converted
into steam by using the heat energy of fuel. It can generate steam at desire
temperature, pressure and the heat generation rate.
According to the A.S.M.E. (American Society of Mechanical Engineers) the
boiler is define as " A combination of apparatus for producing, finishing and
recovering heat together with the apparatus for the transferring the heat so
made available for the fluid being heated and vaporized."
6.2 Functions of a Boiler:
The main function of a boiler is to generate steam at desire pressure and
desire steam generation rate. A boiler has to provide the space for water,
steam, furnace, and safely perform the following function.
1. Generate the steam at desired pressure.
2. The steam generation rate is high.
3. Provide an appropriate surface area to transfer heat from gas to water.
4. Safe operation.
5. Convert steam into super-heated steam if desire.
6. Avoid the explosion due to high pressure inside the boiler.

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CLASSIFICATION OF BOILERS
7.1 According to Relative Passage of water and hot gases:
a) Water Tube Boiler: A boiler in which the water flows through some
small tubes which are surrounded by hot combustion gases, e.g.,
Babcock and Wilcox, Stirling, Benson boilers, etc.
b) Fire-tube Boiler: The hot combustion gases pass through the boiler
tubes, which are surrounded by water, e.g., Lancashire, Cochran,
locomotive boilers, etc.
TABLE 1: DIFFERENCE BETWEEN WATER TUBE AND FIRE TUBE BOILERS
Serial
No.
Fire tube boiler Water tube boiler
1
In Fire-tube boilers hot flue gases
pass through tubes and water
surrounds them.
In Water-tube boilers water
passes through tubes and hot
flue gasses surround them.
2
These are operated at low
pressures up to 20 bar.
The working pressure is high
enough, up to 250 bar in super
critical boilers.
3
The rate of steam generation and
quality of steam are very low,
therefore, not suitable for power
generation.
The rate of steam generation
and quality of steam are better
and suitable for power
generation.
4
Load fluctuations cannot be
handled.
Load fluctuations can be easily
handled.

22
5
It requires more floor area for a
given output.
It requires less floor area for a
given output
6
These are bulky and difficult to
transport.
These are light in weight, hence
transportation is not a problem.
7 Overall efficiency is up to 75%.
Overall efficiency with an
economizer is up to 90%.
8
Water doesn’t circulate in a
definite direction.
Direction of water circulated is
well defined.
9
The drum size is large and
damage caused by bursting is
large.
If any water tube is damaged, it
can be easily replaced or
repaired.
10
Simple in design, easy to erect
and low maintenance cost.
Complex, design, difficult to
erect and high maintenance
cost.
11
Even less skill operators are
sufficient for efficient operation.
Skilled operators are required
for operation.
12 Used in process industry. Used in large power plants.

23
7.2 According to Water Circulation Arrangement:
a) Natural Circulation Boiler: Water circulates in the boiler due to
density difference of hot and water, e.g., Babcock and Wilcox boilers,
Lancashire boilers, Cochran, locomotive boilers, etc.
The natural circulation is one of the oldest principles for steam/water
circulation in boilers. Its use has decreased during the last decades due
to technology advances in other circulation types. Natural circulation
principle is usually implemented on small and medium sized boilers.
Typically the pressure drop for a natural circulation boiler is about 5-
10 % of the steam pressure in the steam drum and the maximum steam
temperature varies from 540 to 560 °C.
b) Forced Circulation Boiler: A water pump forces the water along its
path, therefore, the steam generation rate increases, Eg: Benson, La
Mont, Velox boilers, etc.
In contrast to natural circulation boilers, forced circulation is based on
pump-assisted internal Water/steam circulation. The circulation pump
FIGURE 8: ROUGH SKETCH OF NATURAL CIRCULATION AND FORCED
CIRCULATION SYSTEM

24
is the main difference between natural and forced circulation boilers. In
the most common forced circulation boiler type, the Lamont boiler, the
principles of forced circulation is basically the same as for natural
circulation, except for the circulation pump.
Thanks to the circulation pump, the operation pressure level of forced
circulation boiler can be slightly higher than a natural circulation
boiler, but since the steam/water separation in the steam drum is
based on the density difference between steam and water, these boilers
are not either suitable for supercritical pressures (>221 bar). Practically
the maximum operation pressure for a forced circulation boiler is 190
bar and the pressure drop in the boiler is about 2-3 bar.
Once Through Boiler: A once-through (or universal pressure) boiler
can be simplified as a long, externally heated tube. There is no internal
circulation in the boiler, thus the circulation ratio for once-through
boilers is 1. In contrast to other water tube boiler types (natural and
controlled circulation), once through boilers do not have a steam drum.
Thus, the length of the evaporator part (where saturated water boils
into steam) is not fixed for once through boilers. Once-through boilers
are also called universal pressure boilers because they are applicable
for all pressures and
temperatures.
However, once
through boilers are
usually large sized
boilers with high
subcritical or
supercritical steam
pressure. A large
modern power plant
unit (about 900 MW)
based on the once-
through design can
be over 160 m high
with a furnace height
of 100 m. The once
through boiler type
is the only boiler type
suited for
supercritical pressures (nowadays they can reach 250-300 bars). The
available temperature range for once through type is currently 560-600
°C. Pressure losses can be as high as 40-50 bar. Once-through boilers
need advanced automation and control systems because of their
relatively small water/steam volume. They do not either have a buffer
for capacity changes as other water tube boiler types do.
FIGURE 9: SCHEMATIC FLOW DIAGRAM OF SUPER
CRITICAL (ONCE THROUGH) BOILER TECHNOLOGY

25
7.3 According to the Position of Furnace
a) Internally fired: The furnace is located inside the shell, e.g., Cochran,
Lancashire boilers, etc.
b) Externally fired: The furnace is located outside the boiler shell, e.g.,
Babcock and Wilcox, Stirling boilers, etc.
7.4 According to Pressure of steam generated
a) Low-pressure boiler: a boiler which produces steam at a pressure of
15-20 bar is called a low-pressure boiler. This steam is used for process
heating.
b) Medium-pressure boiler: It has a working pressure of steam from 20
bars to 80 bars and is used for power generation or combined use of
power generation and process heating.
c) High-pressure boiler: It produces steam at a pressure of more than 80
bars.
d) Sub-critical boiler: If a boiler produces steam at a pressure which is
less than the critical pressure, it is called as a subcritical boiler.
e) Supercritical boiler: These boilers provide steam at a pressure greater
than the critical pressure. These boilers do not have an evaporator and
the water directly flashes into steam, and thus they are called once
through boilers.
TABLE 2: COMPARISON BETWEEN SUB CRITICAL AND SUPER CRITICAL BOILERS
S. No. Parameters Subcritical
boilers
Supercritical
boilers
1. Pressure (bar) < 220 ~220 to 300
2. Temperature(⁰C) <565 ~565 to 600
3. Efficiency ~30 to 37% ~40 to 42%
4. Emission levels Higher CO2,
NOx, Sox
emissions
CO2 emission 5%
lower. NOx/Sox
lower.

26
5. Steam drum Required for
steam
separation
None
6. Start-up time
required
Higher Lower
7. Water circulation Natural or
Forced
Once-through
8. Engineering Comparatively
simple
Complex
9. Capital cost Lower Higher
10. Availability &
Operating cost
Comparable
availability but
higher
operating costs
Comparable
availability but
lower operating
costs due to
higher efficiency

27
Basic Working Principle of Boiler
Or
RANKINE CYCLE
The Rankine cycle is the fundamental operating cycle of all power plants
where an operating fluid is continuously evaporated and condensed. The
selection of operating fluid depends mainly on the available temperature
range.
The Rankine cycle
operates in the following
steps:
 1-2-3 Isobaric Heat
Transfer. High pressure
liquid enters the boiler from
the feed pump (1) and is
heated to the saturation
temperature (2). Further
addition of energy causes
evaporation of the liquid
until it is fully converted to
saturated steam (3).
FIGURE 10: IDEALIZED RANKINE CYCLE
FIGURE 11: P-V DIAGRAM OF RANKINE POWER
CYCLE

28
 3-4 Isentropic Expansion. The
vapor is expanded in the turbine,
thus producing work which may
be converted to electricity. In
practice, the expansion is limited
by the temperature of the cooling
medium and by the erosion of the
turbine blades by liquid
entrainment in the vapor stream
as the process moves further into
the two-phase region. Exit vapor
qualities should be greater than
90%.
 4-5 Isobaric Heat Rejection. The vapor-liquid mixture leaving the
turbine (4) is condensed at low pressure, usually in a surface condenser
using cooling water. In well designed
and maintained condensers, the
pressure of the vapor is well below
atmospheric pressure, approaching
the saturation pressure of the
operating fluid at the cooling water
temperature.
 5-1 Isentropic Compression. The
pressure of the condensate is raised
in the feed pump. Because of the low
specific volume of liquids, the pump
work is relatively small and often
neglected in thermodynamic
calculations.
8.1 Rankine cycle with reheat
The purpose of a reheating cycle is to remove the moisture carried by the
steam at the final stages of the expansion process. In this variation, two
turbines work in series. The first accepts vapor from the boiler at high
pressure. After the vapor has passed through the first turbine, it re-enters the
boiler and is reheated before passing through a second, lower-pressure and
turbine. The reheat temperatures are very close or equal to the inlet
temperatures, whereas the optimal reheat pressure needed is only one fourth
of the original boiler pressure. Among other advantages, this prevents the
vapor from condensing during its expansion and thereby damaging the
FIGURE 12: T-S DIAGRAM OF
RANKINE POWER CYCLE
FIGURE 13: H-S DIAGRAM OF RANKINE
POWER CYCLE

29
turbine blades, and improves the efficiency of the cycle, because more of the
heat flow into the cycle occurs at higher temperature.
The reheat cycle was
first introduced in the
1920s, but was not
operational for long
due to technical
difficulties. In the
1940s, it was
reintroduced with the
increasing
manufacture of high-
pressure boilers, and
eventually double
reheating was
introduced in the
1950s. The idea behind
double reheating is to
increase the average
temperature. It was observed that more than two stages of reheating are
unnecessary, since the next stage increases the cycle efficiency only half as
much as the preceding stage. Today, double reheating is commonly used in
power plants that operate under supercritical pressure.
8.2 Regenerative Rankine cycle
The regenerative Rankine cycle is so
named because after emerging from
the condenser (possibly as a subcooled
liquid) the working fluid is heated by
steam tapped from the hot portion of
the cycle. On the diagram shown, the
fluid at 2 is mixed with the fluid at 4
(both at the same pressure) to end up
with the saturated liquid at 7. This is
called "direct-contact heating". The
Regenerative Rankine cycle (with minor
variants) is commonly used in real
power station.
Another variation sends bleed steam
from between turbine stages to feed
water heaters to preheat the water on
its way from the condenser to the
boiler. These heaters do not mix the
FIGURE 14: REHEAT RANKINE CYCLE
FIGURE 15: REGENERATIVE RANKINE
CYCLE

30
input steam and condensate, function as an ordinary tubular heat exchanger,
and are named "closed feed water heaters".
Regeneration increases the cycle heat input temperature by eliminating the
addition of heat from the boiler/fuel source at the relatively low feed water
temperatures that would exist without regenerative feed water heating. This
improves the efficiency of the cycle, as more of the heat flow into the cycle
occurs at higher temperature.
8.3 Reheat Regenerative Rankine Cycle
These days, modern
steam power units
are operated with
the Reheat-
regenerative cycle
and we will see here
the basic concept of
Reheat-regenerative
cycle. As we can see
in block diagram,
high pressure and
high temperature
steam enters to the
high pressure
turbine at state 1
and as we are also
considering here the
concept of regeneration hence we must note it here that all steam will not be
expanded through the high pressure turbine up to pressure corresponding to
state 3 but also certain quantity of steam will be extracted from the high
pressure turbine and its state is displayed by state 2
FIGURE 16: RANKINE CYCLE WITH REHEAT AND
REGENERATION

31
MODERN SUPERCRITICAL BOILER
The term "supercritical" refers to main steam operating conditions, being
above the critical pressure of water (221.5 bar). The significance of the critical
point is the difference in density between steam and water. Above the critical
pressure there is no distinction between steam and water, i.e. above 221.5
bar, water is a fluid.
In supercritical cycle, equipment is designed to operate above the critical
pressure of water. Supercritical boilers are once-through where in the feed
water enters the economiser and flows through one path and main steam exits
the circuit. Typically current supercritical units operate at 242 bar main
FIGURE 17: SIMPLE SUPER CRITICAL CYCLE

32
steam pressure, 565ºC main steam temperature and 593ºC reheat steam
temperature.
9.1 Advantages of Super Critical Technology
1. Higher Efficiency:
Supercritical steam conditions improve the turbine cycle heat rate
significantly over subcritical steam conditions. The extents of improvement
depend on the main steam and reheat. Steam temperature for the given
supercritical pressure. A typical supercritical cycle having turbine throttle
pressure of 242 bar with temperatures for main steam and reheat steam as
565ºC and 593ºC respectively, will improve station heat rate by more than
5%. This results in fuel savings to the extent of 5%. Overall supercritical power
plant efficiency of 42% is achievable with current supercritical parameters.
2. Emissions:
Improved heat rate results in 5% reduction in fuel consumption and hence
5% reduction in CO2 emissions per MWh energy output. Typically for 800 MW
supercritical unit the annual reduction in CO2 emission will be about 725,000
tonnes of CO2 with respect to baseline emission established by CEA for 2008
– 2009.
3. Operational Flexibility:
Supercritical technology units also offer flexibility of plant operation such as:
 Shorter start-up times.
 Faster load change flexibility and better temperature control.
 Better efficiency even at part load due to variable pressure operation.
 High reliability and availability of power plant.

33
MAJOR COMPONENTS OF A BOILER
 Economizers
 Superheaters
 Reheaters
 Water wall
 Desuperheaters
FIGURE 18: TWO WAY BOILER USED IN INDUSTRY

34
10.1 Economizer
Use: In Boilers, economizers are heat
exchange devices that heat fluids, usually
water, up to but not normally beyond the
boiling point of that fluid. They are a device
fitted to a boiler which saves energy by using
the exhaust gases from the boiler to preheat
the cold water used to fill it (the feed water).
Working Principle of Economizer: The flue
gases coming out of the steam boiler furnace
carry a lot of heat. Function of economiser in
boiler is to recover some of the heat from the
heat carried away in the flue gases up the
chimney and utilize for heating the feed
water to the boiler. It is simply a heat ex-
changer with hot flue gas on shell side and
water on tube side with extended heating
surface like Fins or Gills. Economisers in
thermal power plant must be sized for the
volume and temperature of flue gas, the
maximum pressure drop passed the stack, what kind of fuel is used in the
boiler and how much energy needs to be recovered.
Advantages: The use of economizer results in saving fuel consumption,
increases steaming rate and boiler efficiency.
10.2 Superheaters
Use: The superheater is a heat exchanger that overheats (superheats) the
saturated steam. By superheating saturated steam, the temperature of the
steam is increased beyond the temperature of the saturated steam, and thus
the efficiency of the energy production process can be raised.
Types:
 Radiation Superheaters: They are located directly within the
combustion chamber of the boiler itself. Radiation based superheaters
are used to gain higher steam temperatures and the heat is mainly by
radiation.
 Convection Superheaters: They are most commonly found on
locomotives. Convection superheaters are the most common
superheaters in steam boilers. Convection based superheaters are used
FIGURE 19: LOCATION OF
ECONOMIZER

35
with relatively low steam temperature, and the heat from the flue gases
is mainly transferred by convection.
According to the requirement of the boiler three or more than three
superheaters are provided in a boiler. In L&T MHPS Boiler Pvt. Ltd. we usually
use three superheater namely primary superheater, secondary superheater
and tertiary superheater.
10.2.1 Primary Superheater
A superheater is a device used to convert saturated
steam or wet steam into dry steam. There are three
types of superheaters namely: radiant, convection,
and separately fired.
The fluid with 100% steam moves from water
separator to primary super heater inlet header in
convection area. This steam moves to Outlet
header of primary super heater through banks.
Then from this outlet header the steam has to pass
through Primary De-Superheater which allows
lowering the temperature of steam if it has reached
above the desired temperature.
10.2.2 Secondary Superheater
After passing through primary de-
superheater the steam reaches secondary
superheater inlet header in radiation area.
This superheater has tubes where heat gain
up takes place. The steam then reaches
secondary superheater Outlet header.
Here heat gain up is more due to radiation
factor.
The steam then has to pass through
secondary de-superheater which again
allows to reduce the steam temperature if it
has increased above desired temperature.
PRIMARY SUPERHEATER
SECONDARY SUPERHEATER

36
10.2.3 Tertiary Superheater
The steam from secondary de-superheater reaches
the inlet header of tertiary superheater. This
superheater lies in radiation and convection area
and it also has pendants.
From here steam goes to High Pressure Turbine.
After rotating the High Pressure Turbine the steam
then reaches the inlet header of primary Reheater.
Advantages:
The main advantages of using a superheater are
reduced fuel and water consumption but there is
a price to pay in increased maintenance costs. In
most cases the benefits outweighed the costs and
superheaters were widely used.
10.3Reheaters
Design consideration for Reheaters are same as Superheaters. Although the
outlet temperature are same or higher as superheaters but the pressure is
low compared to the superheater.
Reheaters can be organized in vertical or horizontal position and are usually
located in conductive zone. Steam comes from H.P turbine exhaust and goes
to L.P turbine inlet after getting reheated.
In L&T usually use two stage Reheaters namely
Primary Reheater and Secondary Reheater is
used.
10.3.1 Primary Reheater
In a reheat turbine the steam first enters high
speed turbine so its temperature and pressure
reduces before entering low speed turbine so a
Reheater is used to reheat the cooled steam.
The steam from high pressure turbine reaches
the inlet header of primary reheater. The
primary reheater has banks in convection
section and heat gain up is large.
TERTIARY SUPERHEATER
FIGURE 23: LOCATION OF THE
PRIMARY REHEATER

37
The steam reaches the outlet header of primary
Reheater. Then this steam passes through de-
superheater of primary reheater.
10.3.2 Secondary Reheater
The steam from de-superheater of primary
reheater reaches to inlet header of secondary
reheater. This reheater lies in radiation and
convection area (combination) and has pendants
where heat gain up takes place.
The steam then reaches the Outlet headers of
secondary reheater. The steam then passes to
Medium Pressure Turbine and then to Low
Pressure Turbine rotating them all which in turn
is used to produce electricity. The steam then
goes to condenser.
SECONDARY REHEATER

38
FLOW OF AIR IN THE BOILER
1. Air is brought in the system from atmosphere by two fans.
a) Primary Air Fan (PA) which supplies about 15% of needed air.
b) Forced Air Fan (FA) which gives 85% of needed air.
The outlet of these two fans is connected to Air Pre Heater through pipes.
2. The air from air pre heater leaves from two outlets at about 250°C. One
outlet is connected by a pipe directly to the furnace. This provides hot air
which helps during combustion of coal. The other outlet is connected to the
coal pulverizer and is useful to remove all the moisture content in coal and
make it dry before it reaches the furnace.
3. The outlet of PA fan has one additional branch pipe which is connected to
the pipe which connects air pre heater and pulverizer. This pipe meets the hot
air pipe before it reaches pulverizer. It is used to control the temperature of
hot air entering the pulverizer so that coal does not start burning before it
reaches the furnace.
4. The hot air goes from pulverizer to furnace via pipe at 90°C.
5. This air in furnace is used to reach combustion temperature easily and
then there is release of flue gases.
6. The temperature of the boiler can be controlled by controlling the
temperature of air entering the furnace. The temperature of furnace should
be below IDT-Initial Deformation Temperature of coal because at this
temperature melting of coal will start and the molten coal will stick to the
walls of the furnace and on solidification will tend to develop cracks in the
furnace wall.
11.1 Wind Box
There are a number of pulverizers in one power plant. Each pulverizer can
transfer dry coal to a specific level of burner. One wind box is required by two
levels of burner. A wind box is a very important part placed after pulverizer
just before the coal enters the furnace. This wind box has various parts. It is
connected to air pre heater which provides it with secondary air. It is
connected to pulverizer which supplies dry coal with hot air. It has an oil gun
which supplies oil which low ignition temperature. The wind box now provides
hot air, dry coal and oil to the furnace. The oil can be burnt easily using the
hot air temperature and this ignited oil can be used to reach the high ignition
temperature of coal.

39
COAL SYSTEM
1. Conveyor belt / bucket - A conveyor belt (or belt conveyor) consists of two
or more pulleys, with a continuous loop of material - the conveyor belt - that
rotates about them. One or both of the pulleys are powered, moving the belt
and the material on the belt forward.
2. Tripper floor - Tripper floor is equipment which carries the coal from
conveyor belt to the bunker and fills the bunker.
3. Coal Bunker - It is a big storage area for coal. It takes up coal from the
Tripper floor and passes it to the coal pulverizer through coal feeder. The coal
bunker is circular at top of radius about 10 m and about 15 m height, after
this height it becomes conical and goes down till 16 m. Total height of the
FIGURE 25: MRS (MITSUBISHI ROTARY SEPARATOR) PULVERISER

40
bunker is approximately 30 m. The bunker transfers stored coal to coal feeder.
The main use of coal bunker is storage of coal and to maintain continuous
supply of coal whenever needed.
4. Coal Feeder - The function of a coal feeder is to control the coal entering
the pulverizer at various loading conditions. There are two types of feeders:
i) Gravimetric Feeder - By weight
ii) Volumetric Feeder
5. Coal Pulverizer - A pulverizer or grinder is a mechanical device for the
grinding of many different types of materials. For example, they are used to
pulverize coal for combustion in the steam-generating furnaces of fossil fuel
power plant. There are different types of pulverizers:
FIGURE 26: TYPES OF PULVERISER
Coal Pulverizer receives hot air from air pre heater which takes up air from
FD fan and PA fan and heats this atmospheric air by exchanging heat with
outgoing flue gases. This pre heated air is used in pulverizer to remove all the
moisture in the coal.
6. Coal Pipes - These are the pipes that carry coal from pulverizer to the
burner.
7. Coal Burner - This is the equipment which provides area for burning of
fuel to desired temperature to release required amount of heat.
PULVERIZER
Vertical Horizontal
Bowl Type Ball Type Tubular

41
INTRODUCTION TO 3D MODELLING
13.1 Solid edge
Solid Edge is a 3D CAD, parametric feature (history based) and synchronous
technology solid modeling software. It runs on Microsoft Windows and
provides solid modeling, assembly modelling and 2D orthographic view
functionality for mechanical designers. Through third party applications it
has links to many other Product Lifecycle Management (PLM) technologies.
Siemens Solid Edge is an industry-leading mechanical design system with
exceptional tools for creating and managing 3D digital prototypes. With
superior core Modeling and process workflows, a unique focus on the needs
of specific industries, and fully integrated design management, Solid Edge
guides projects toward an error free, accurate design solution.
Solid Edge is available in either Classic or Premium. The "Premium" package
includes all of the features of "Classic" in addition to mechanical and electrical
routing software, and powerful engineering simulation capabilities for CAE
(Computer Aided Engineering).
The ordered part option is used for the part design. After modelling of each
part, the assembly is created in the assembly environment. The various
commands used for the part designs are extrude, sweep, cut, revolve and etc.
After the assembly of the piston arrangement the draft drawing is created by
using the draft environment in the Solid Edge
13.2 Features of Solid Edge
There are various types of modules used in 3D modelling for various types
operation. Some important modules that are used mainly and are necessary
for the most of the 3D Modelling are:
1. Isometric Part Module
2. Isometric Sheet Metal Module
3. Isometric Assembly Module
4. Isometric Draft Module
5. Isometric Weldment Module
13.2.1 Isometric Part Module
The ordered modelling process begins with a base feature controlled by a 2D
sketch, which is either a linear, revolved, lofted, or swept extrusion. Each
subsequent feature is built on the previous feature. When editing, the model
is "rolled back" to the point where the feature was created so that the user

42
cannot try to apply constraints to geometry that does not yet exist. The
drawback is that the user does not see how the edit will interact with the
subsequent features. This is typically called "history" or "regeneration based"
modelling. In both ordered and synchronous mode Solid Edge offers very
powerful, easy yet stable modelling in hybrid surface/solid mode, where
"Rapid Blue" technology helps the user to create complex shapes in an
intuitive and easy way.
Home icon contains commands used for sketching:-
1. Click on the ‘sketch’ icon.
2. Select the suitable plane.
3. Select line, rectangle or circle as per the shape of component.
4. Give the suitable dimensions by clicking on ‘smart dimension’.
5. Click on close sketch command and then finish.
FIGURE 27: EXAMPLE OF DESIGNING IN PART MODULE

43
There are some commands to solidified and modify the part.
 EXTRUDE
 CUT
 REVOLVE
 REVOLVED CUT
 HOLE
 ROUND
 DRAFT
 SWEEP
Some commands and their uses are given:-
 Draw :-
 Line
A line can be drawn by clicking on “line’ icon. Click for the first point on the
plane and then click for the seecond and so on. The magnitude and direction
of the line may be defined by filling length and angle shows in a box icon.
 Rectangle
Draw a rectangle by clicking on rectangle command. Rectangle may be drawn
by:
 Rectangle by center
 Rectangle by 2 points
 Rectangle by 3 points
 Polygon by center
 Circle
Circle may be drawn after a click on circle command.
 Circle by centre
 Circle by 3 points
 Tangent circle
 Ellipse by centre points
 Ellipse by 3 points

44
 Tangent arc
An arc may be drawn after a click on the tangent arc command.
Arc may be drawn by:-
 Arc by three points
 Arc by centre point
 Other commands are:-
 Curve
 Fillet and chamfer
 Offset
 Mirror
 Trim
 Relate
Relate command is used to define a relation between two sketches.
It contains:
 Connect
 Parallel
 Equal
 Horizontal/vertical
 Tangent
 Symmetric
 Collinear
 Dimension
The command is used to give the dimension to a sketch. Dimensions given to
a sketch are:-
 Smart dimension
 Distance between
 Angular coordinates dimension
 Angle between etc.
 Planes
 Coincident plane
 Parallel
 Angled
 Perpendicular
 Normal to curve
 By three point
 Tangent

45
13.2.2 Isometric Assembly Module
An assembly is built from individual part documents connected by mating
constraints, as well as assembly features and directed parts like frames which
only exist in the Assembly context. Solid Edge supports large assemblies with
over 1,000,000 parts.
Basically Isometric Assembly module is used to assemble an object with the
help of parts that we have created in the Isometric Part Module.
FIGURE 28: EXAMPLE OF DESIGNING IN ASSEMBLY MODULE

46
13.2.3 Isometric Drafting Module
The draft drawing has to be create of all parts modelled individually. It gives
all dimensions of the parts for the further information. The example of the
draft drawing is as given below,
FIGURE 30: COMPLETE DRAFT
FIGURE 29: INCOMPLETE DRAFT

47
TRANSPORTATION FRAME
These are the frames which used as a casing for the parts of boiler to be
transported so that the parts may not be damaged during transportation and
handling.
14.1 Types of Transportation Frame
14.1.1 Based on Kind of Joint
 WELDED FRAME
The welded frames are those whose beams and columns are joined by
welding. Welded frames are preferred in current project.
 PIN JOINTED
This design is preferred as these can be used again after delivery of
consignment as they can be easily detached. But there are many
complications in it as the design has to be really accurate because there
have to be proper spacing between the pin jointed region and the bars.
14.1.2 Based on the Physical Structure
 BOX TYPE
The box type frame is a closed structure as shown in fig.
FIGURE 31: BOX TYPE TRANSPORTATION FRAME

48
 STANCHION TYPE
As the fig shows that there is no horizontal beam is provided at the top.
So the frame may be extended as required.
FIGURE 32: STANCHION TYPE TRANSPORTATION FRAME
14.2 Requirements
(1) Wooden blocks are placed under the finished goods like coil, panel, tube
and header so that the good may not be damage. It provides a base support
to the good and prevents it from rubbing.
(2) But in some cases like finned tubes wooden blocks cannot be placed under
the fin. So the blocks are provided under the plates.
(3) In case of panels one should look for the attachments and openings of
panel. These openings are avoided while placing the beam and wooden
support.
(4) The width of the frame should not more than 4.3 meter.
(5) The horizontal members called beams should not be separated by a
distance more than 3.5 meter.
(6) The overall weight i.e. frame + pressure part should not be more than 25
metric ton.
(7) Height of the frame should be less than 2.5 meter.

49
14.3 Transportation Frame Design
Output design will be created by using 3D software Solid Edge.
Solid Edge ST9 may be used for design the model. It was developed by
Siemens PLM software.
14.3.1 Part Modelling
In the part modelling environment the lug may be designed. Lug is a
mechanical part attached with the transportation frame for lifting and lashing
purpose. Steps to be followed:
 Open the solid edge software and click on ‘ISO Part’.
 Click on ‘sketch’. Now a new window will open. Select ‘Rectangle’ and
make a rectangle of required dimension.
 Click on ‘fillet’ and make fillet of required radius.
 Now click on ‘circle’ and make a circle of required radius.
 Now click on ‘close sketch’.
 Now select ‘extrude’ and create from ‘select by sketch’.
 Click on sketch and give the extrude according to given dimensions.
 Now click on the ‘chamfer’ and select by edge.
 Fill the setback 13 mm and then ‘finish’.
 Now click on ‘application button’ and select ‘property’.
 Go to ‘property manager’ and define the properties to the lug.
 Go to ‘material’ select carbon steel.
FIGURE 33: ROUGH SKETCH OF FINAL RESULT

50
 Weight of lug may be checked by clicking on ‘mv properties’.
 Save the file.
14.3.2 Assembly
For frame design we have to sketch a wire frame first.
SKETCHING
Steps to be followed:-
 Open assembly and click on ‘sketch’ and select front plane.
 Click on ‘line’ and start sketching as shown in fig.
 After sketching click on ‘close sketch’.
 Now again select side plane and start sketching as per the input.
 Select top base plane and sketch.
 The wire frame will look like as shown below.
FIGURE 34: FINAL RESULT AFTER SKETCHING

51
MODELLING
While doing modelling we follow these steps:-
1. First click on ‘Tools’.
2. Now select ‘Frame’.
3. The frame window will open then select again ‘Frame’ in window.
4. Select ‘butt1’ as corner treatment in the window as shown below.
5. Now select the type of beam required from library.
6. Set the method used for selection of element as ‘single’ or ‘chain’.
7. Click on the wire frame sketches alternatively and the modelling of the
frame will create.
8. The orientation can be changed.
9. Click on the frame and select ‘edit cross-section’.
10. Now change the orientation.
FIGURE 35: BUTT1 JOINT

52
11. Give the desired properties to the frame.
12. Update the physical properties.
13. Save the file.
FIGURE 36: COMPLETE TRANSPORTATION FRAME

53
FINITE ELEMENT ANALYSIS (FEA)
15.1 Introduction
Before we delve into
Finite Element
Analysis (FEA), it is
necessary to
understand what
Finite Elemental
Method (FEM) means.
FEM is a precursor to
understanding FEA.
The basic concept
behind Finite Elemental Method is to replace any complex shape with the
summation of a large number of regular / simple shapes (like a rectangle,
triangle, etc.). These shapes are then combined to correctly model the original
part. These smaller, simpler shapes are called finite elements because each
such shape occupies a finite sub-space within the original, complex shape.
For example, it is easier to visualize an engine, airplane, a machine
component or skeleton as made up of smaller, simpler components. It makes
modelling easier. And unlike finite difference models, finite elements do not
overlap in space.
Traditionally, engineering analysis of mechanical
systems has been done by deriving differential
equations related to the variables involved. However,
solving the resulting mathematical models is often
impossible, especially when the resulting models are
non-linear partial differential equations. This is where
Finite Elemental Method steps in.
15.2 What is Finite Element Analysis (FEA)?
When FEM is applied to a specific field of analysis, it is referred to as Finite
Element Analysis (FEA). FEA is thus a numerical method that offers a means
to find approximate solutions to complex mechanical engineering problems.
FEA methods contrast to the infinitesimally small or differential elements
used for centuries to derive differential equations. FEA has traditionally been
a branch of Solid Mechanics. However, with the advent of sophisticated CAD
and CAE tools, FEA is now used to solve design problems in mechanical and
other engineering fields like aerospace and defence, automotive,

54
electromechanical and consumer goods, heavy engineering, industrial
machinery and power and energy.
Here are the steps involved in FEA:
1. Divide the interval of integration - the numerical result is an approximation
to exact solution.
2. In each sub-interval, choose proper simple functions to emulate the true
function - the accuracy of numerical result depends on the number of sub-
interval and approximate function.
A typical FEA on a software system requires the following information
 Nodal point spatial locations
 Elements connecting the nodal points
 Mass properties and boundary restraints
 Loading or forcing function details
 Analysis options
15.3 Areas of FEA Application
A FEA is the most common tool for stress and structural analysis. It can also
receive input data from other tools like kinematics analysis systems and
computation fluid dynamics systems. FEA software can be used in:
 Mechanical Engineering design
 Computer Aided Drafting (CAD) and engineering simulation services
 Structural Analysis
 Modal Analysis
 Solid mechanics
 Mould Flow Analysis
 Fatigue & Fracture Mechanics
 Thermal and Electrical analysis
 Sheet Metal forming analysis

55
ANALYSIS IN SOLID EDGE
The concept of a “Finite Element” was introduced by Prof. R.W. Clough of UC
Berkeley in 1960 at an ASCE Conference.
NASTRAN (NASA STRuctural ANalysis) was developed for NASA by a
consortium of several companies for the analysis of the Saturn V rocket.
 Siemens PLM Software acquired MSC. Nastran source code in 2003 and
has greatly improved the performance and capabilities of NX Nastran
through the latest release of NX Nastran 8.1
 Finite Element Modellers (Pre/Post Processors), the tools used to
generate Finite Element meshes and view results, were first
commercialized in the 1970s.
 Siemens PLM Software began the first commercial offering of FEM
software with the introduction of SDRC Super Tab in the 1970’s.
 Siemens continues to support the analysis community with Femap and
NX CAE pre/post-processors.
16.1 Important Guidelines
 Linear Analysis is small displacement, small angle theory
Must use nonlinear analysis if the displacement changes the stiffness or
loads.
Pressure loads on flat surfaces, have no membrane component unless
nonlinear large displacement solution performed. (Load carried by bending
stiffness only)
Linear contact is a misnomer, contact condition is iterative solution, but no
other nonlinear effects are considered.
 Mesh density required is a function of the desired answers
Must have enough nodes so model can deform smoothly like the real
structure.
In general, accurate stresses require more elements than accurate
displacements.
Goal is for a small stress gradient across any individual element.

56
 Normal modes should always be run before any dynamic solution.
Confirm model behaviour, stiffness and mass properties are correct.
16.2 Analysis of Cantilever Beam
Analysis of beam can be carried out in Solid Edge with the help of Stimulation
Express which is located at the right.
Let’s take a beam of 10×10×2000 dimension and apply a 1000 Newton point
load at the end of the beam in the downward direction.
FIGURE 37: SQUARE BEAM OF GIVEN DIMENSIONS

57
Manual Calculations
 For Max Deflection
We know that, max deflection is
δmax =
𝑷𝑳 𝟑
𝟑𝑬𝑰
……. Eq. 1
 For Max Bending Stress
We know that, max bending stress is
𝑴
𝑰
=
𝝈
𝒚
Then,
FIGURE 38: MATERIAL USED

58
σ =
𝑀×𝑦
𝐼
……. Eq. 2
Given,
P (Point Load) = 1000N
L (Length) = 2000mm
ν (Poisson’s Ratio) = 0.3
E (Modulus of Elasticity)= 210×103 N/mm2
a= (breadth) = (depth) = 10mm
I (Moment of Inertia) =
𝑏𝑑3
12
=
𝑎4
12
=
104
12
= 833.33 mm4
Now using given data in eq.1,
We get
δmax =
𝑷𝑳 𝟑
𝟑𝑬𝑰
=
1000×20003
3×210×103×833.33
= 1.52 × 104
mm
Max Deflection is 𝟏. 𝟓𝟐 × 𝟏𝟎 𝟒
mm
Now using given data in eq. 2,
We get,
σ =
𝑀×𝑦
𝐼
(we know that, moment = P × L)
=
2×106×
𝑎
2
𝑎4
12
=
2×106×5
833.33
= 1.2×104 N/mm2
Max Bending Stress is 1.2×104 N/mm2
Analysis Calculations
As we can see in the figures below that the value calculated by stimulation
express are:

59
Max Deflection is 𝟏. 𝟓𝟐 × 𝟏𝟎 𝟒
mm
Max Bending Stress is 1.2×104 N/mm2
16.3 Analysis of Pipes
Stimulation Express can be used in order to analyse not only solid and hollow
beams. But it can also be used to analyse other models too. For example let’s
FIGURE 40: ANALYSIS OF STRESS
FIGURE 39: ANALYSIS OF DISPLACEMENT

60
analyse a model of a hollow pipe with thickness of 76mm and outer diameter
and inner diameter are 406.4mm and 254.4mm respectively that’s going to
be used in the transportation of steam/water in a supercritical boiler.
Manual Calculations
Given,
P (Internal Pressure) = 300 kg/cm2 = 29419.95 KPa
L (Length) = 1000mm
Ν (Poisson’s Ratio) = 0.3
E (Modulus of Elasticity)= 200×103 MPa
Do (Outer Diameter) = 406.4 mm
Ro (Outer Radius) = 203.2 mm
Di (Inner Diameter) = 254.4 mm
Ri (Inner Radius) = 127.2 mm
T (Thickness) = 76 mm
FIGURE 41: MATERIAL USED

61
FIGURE 42: 3-D MODEL OF PIPE
FIGURE 43: DISPLACEMENT ANALYSIS OF THE MODEL
FIGURE 44: STRESS ANALYSIS OF THE MODEL

62
REFERENCE
1) Indian Power Ministry Official Site
2) UNESCO-EOLSS
3) L&T Official Site
4) LMB Official Site
5) NPTEL – Prof. USP Shet, Prof. T. Sundarranjan and Prof. J M Mallikarjuna
6) Wikipedia
7) PowerPoint Presentation – Anup Kumar Singh
8) Steam its generation and use – The Babcock and Wilcox Company
9) Supercritical steam generator technology – V Lakshmana Rao and R
Raghavan
10) Thermopedia
11) www.joshikandarp.webs.com
12) Heat Exchanger in Boilers – Sebastian Teir and Anne Jokivuori
13) GrabCad
14) Siemens PLM Automation Official Site
15) An Introduction to FEA via Solid Edge
16) MSC. FEA Introduction PDF – Pressure Parts Staff
17) Creating Structural Frame Design Presentation – Rahul Kulkarni
18) Etc.

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