POWER PLANT- BOILER OPERATIONS SIMULATOR

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1 POWER PLANT- BOILER OPERATIONS SIMULATOR The PS-5030 is a simulation software package is rigorous and detailed simulation models of POWER PLANT-Boiler Operations and processing facilities. The package consists of the following modules: PS-5031 PS-5032 PS-5033 PS-5034 PS-5035 PS-5036 Pulveriser Fuel System Oil Firing System Flue Gas and Air System Superheater and Reheater System Boiler Drum Water Treatment Plant Plant familiarization: Boiler Operations plant Simulator offers the best platform for learning process plant configuration, instrumentation, control system, critical parameters and their design values and normal plant operations. Ensure Smooth Start Ups: Boiler Operations Plant Simulator allows operators to become familiar with operation while they increase their familiarity with the controls and graphical scenes. Continued training ensures increasingly smooth start-ups in the future. Reduce Incidents and Downtime: Training personnel in a non-destructive environment enable you to validate emergency controls before actual use. Testing modifications to compressor controls can avoid damage from surges. One can purposely trigger malfunctions (such as a trip) to test operator reactions and improve response reactions. Maximize Performance: The Boiler Operations plant Simulators are based on rigorous first-principles models and actual controls, allowing you to troubleshoot actual process and control problems. They unlock the fundamental understanding required to modify, test, and improve processes and maximize plant performance.

2 Benefits to Academic Institutions: The Dynamic Simulator of Boiler Operations Plant helps to teach the students the fundamentals as well as complex process operations. It provides opportunity for the chemical / instrumentation engineering students to know what is happening in the industry. Simulator trained students will have edge over their counterparts in the competitive scenario with respect to their knowledge in Instrumentation & Control and Process operations.

3 PS-5031: PULVERSIER FUEL SYSTEM In Pulverized fuel firing system the coal is grinded to fine powder state with the help of grinding mill and then injected into the combustion chamber with the help of hot air. The coal is temporarily stored in the bunker from where it is fed into the mill at controlled quantity through feeder system which controls the coal flow. The hot air which is entering the mill at 10 Kpa & 300 deg C dries the coal and picks up the pulverized coal. The flow then is classified and the higher size coal is rejected and again sent back into the mill for grinding. Cold air at 35 deg C helps in maintaining the temperature of coal within deg C so that proper combustion can be attained inside boiler. Seal air which enters at 15 Kpa & 35 deg C helps in sealing of bearing and avoids mixing of coal and lubrication oil. Minimum DP must be maintained between hot air and seal air. Feed Flow Controller Hot Air Flow Controller Cold Air temperature Controller Hot air gate failure Cold Air gate failure Feeder trip Mill Trip

4 PS-5032: OIL FIRING SYSTEM Oil firing system consists of oil guns and igniter rods which help in boiler light-up and for support combustion during emergencies. Oil firing system consist of a root control valve which maintains oil pressure around 5 to 6 Kg/Cm2 & 100 deg C and flow at 5 T/hr, from there oil flows to the four corners of the boiler each consist of a oil valve control which controls the oil flow inside the boiler. Atomizing steam shut-off valve is provided to supply atomizing steam at about 6 to 7 Kg/Cm2 Pressure and 250 deg C to all the four corners of the boiler for helping in purging, scavenging and atomizing during taking oil gun in service. Oil firing system consists of a return hand control valve open at 50% which helps in continuous circulation of oil to maintain temperature and pressure. Feed Flow Controller Pressure Controller Oil flow to corner Buner 1 HC02 Oil recycle flow-hc01

5 PS-5033: FLUE GAS AND AIR SYSTEM Flue gas & air system maintains the draft of the boiler, it consist of Air Pre-Heater (APH) system and 2 Primary Air (PA), Forced Draft (FD), Induced Draft (ID) Fans respectively. PA fan sucks air from atmosphere and supplies it at 10 Kpa & 300 deg C through APH is fed into the pulverizer and carries the grinded coal into the boiler for combustion. FD fan sucks air from the atmosphere and supplies it at 1.5 Kpa & 320 deg C through APH supports direct combustion in boiler. ID fan is used to remove flue gas from the boiler through APH system and ESP and helps in maintaining furnace pressure at -10 Pa. APH system helps in transfer of heat from exit flue gas at 350 deg C to inlet PA and FD air (300 deg C and 320 deg C respectively). ID fan Pressure Controller PA fan Pressure Controller FD fan Pressure Controller Hot air gate failure Cold Air gate failure Feeder trip Mill Trip

6 PS-5034: SH & RH SYSTEM Super heater (SH) system consists of four stages in which steam is heated up gradually stage by stage from Low Temperature SH (LTSH) at 420 deg C to divisional SH (DIV SH) at 450 deg C to platen SH at 490 deg C and finally to final SH which is at 540 deg C.Two stages of De-superheating station is used to control SH temp, 1st stage is between LTSH and DIV SH which controls the temp at 385 deg C, 2nd stage is between Platen SH and Final SH which controls the temp at 485 deg C. Re-heater system consists of three stages in which steam is heated up gradually stage by stage from Wall RH at 380 deg C to platen RH at 470 deg C and finally to final SH which is at 540 deg C.Two stages of De-superheating station is used to control RH temp, both the attemperation line is given before Wall RH to maintain RH temp at 540 deg C. Temperature Controller Final SH Fouling DIV SH Fouling

7 PS-5035: BOILER DRUM Boiler feed water is pumped from deaerator to the steam drum by boiler feed water pump. The steam drum is controlled by a three element control system which balances the feed water and steam flows, using a flow ratio controller, for transient load changes. The steam is generated at about 160 kg/cm2 in the boiler. The Boiler has a rated capacity of 440 Tons/hr. The steam produced in the boiler is superheated to about 540 deg C. The solids in the boiler feed water make up, accumulates in the steam drums, so a continuous blow down is employed to maintain the solids concentration in the steam drums less than 150 mg/liter. Intermittent blow down is required to remove the sludge and this is let down to the intermittent blow down tank. Drum Level Controller CBD level controller Periodic Blow down Emergency Blow down

8 PS-5036: WATER TREATMENT PLANT Raw water enters Pressure Sand filter via raw water pump at rate of 200 m3/hr and design pressure of 4 Kg/cm2, where the Turbidity of raw water will be reduced below 2NTU. The raw water pass through Weak acid cation exchanger where the alkalinity of the raw water will be fully removed, and the alkaline free water will pass on through Strong acid cation exchanger (HCL), here the hardness of water will be removed and Sodium content will be brought below 1ppm.The water will be taken to Degasser Tower where Co2 will be vented with the help of Degassed air blower at the rate of 4150 m3/hr. The water from Degassed tower will have CO2 below 5ppm and is stored in degassed storage tank. Exchanger Level Controller Feed flow controller Change in Feed water Content Feed Pump failure