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Project Dwg. No: G101-25-1723.

09-L070

Boiler
MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT

Boiler Maintenance
Manual No. MM-M01.01
Revision 004

Note
This mechanical maintenance manual is intended to provide the Paiton Expansion Project
mechanical maintenance personnel with the basic understanding required to perform preventive,
routine, corrective and overhaul maintenance activities on the subject equipment.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and Paiton Expansion Project.

Boiler
Maintenance

Be sure to read this manual.


Contents
Safety

General

Specifications

Preventive Maintenance

Disassembly and Reassembly

Corrective Maintenance

Water Washing Method

Appendixes

Contents

Contents
Revision Record i
Important Information iii
Warranty vi
Limitation of Liability viii
Copyright x
Personnel to whom the Manual is Directed xi
Contact Address xii
Abbreviations xiii
List of Vendor Manuals xiv
Arrangement of the System Maintenance Manual xv

Chapter1

Safety ____________________________

1.1

Feature of Boiler Safety 1-1

1.2

Warnings Description 1-2


1.2.1

Definitions of Serious Injury, Minor Injury, Serious


Damage to Property, and Minor Damage to Property 1-3

1.2.2

Symbols 1-4

1.2.3

Hazards Warning Label 1-5

1.2.4

Hazard Area 1-7

1.3

Risk Assessment Standard 1-8

1.4

Safety Measures 1-10


1.4.1

Work Permit System (Lockout/Tagout) 1-10

1.4.2

General Cautions on Personnel in Working Area 1-11

1.4.2.1 Cautions against Rotating Equipment 1-11


1.4.2.2 Cautions against Electrical Equipment 1-12
1.4.2.3 Cautions against High Temperature Sections 1-13
1.4.2.4 Cautions against Steam Leak in the Plant 1-14
1.4.2.5 Cautions against Oil / Coal Leak in the Plant 1-14
1.4.2.6 Cautions against Chemicals 1-15
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-15
1.4.2.8 Cautions against Lack of Oxygen 1-16
1.4.2.9 Cautions against Lifting Heavy Object 1-16
1.4.2.10 Cautions against Sharp Objects 1-17
1.4.2.11 Cautions using Fork Lift 1-17
1.4.2.12 Cautions using Crane 1-18
Boiler
Mitsubishi

Contents

Chapter1

Safety (Continued from previous page)


1.4.2.13 Disposal 1-19

1.5

Emergency Measure 1-20


1.5.1

Evacuation on Emergency Case 1-20

1.5.1.1 Evacuation Route 1-20


1.5.1.2 Evacuation of Disabled Persons, Who Cannot Walk
by Themselves 1-20
1.5.1.3 Evacuation from Power House 1-21
1.5.2

Fire Accident 1-22

1.5.3

Earthquake 1-23

1.5.4

Explosion Accident 1-23

1.6

Qualification and Training 1-24

Chapter2

General ___________________________

2.1

Purpose 2-1

2.2

References 2-1

2.3

Overview of the Boiler and Auxiliaries 2-2

2.4

Boiler Components 2-12


2.4.1

Furnace Pass Wall, Passage Side Wall and 2RY Pass


Walls Tubes and Roof Tubes 2-12

2.4.2

Water Separator and Water Separator Drain Tank 2-15

2.4.3

Superheaters 2-16

2.4.4

Reheaters 2-20

2.4.5

Desuperheaters 2-23

2.4.6

Economizer 2-24

2.4.7

Boiler Supports 2-25

2.4.8

Casing and Insulation 2-26

2.4.9

Safety Valves 2-26

Chapter3

Specifications _____________________

Chapter4

Preventive Maintenance _____________

4.1

Prerequisites 4-1

4.2

Boiler
Mitsubishi

4.1.1

Scheduling 4-1

4.1.2

Interdepartmental Cooperation and Communication 4-2

4.1.3

Isolation of Equipment 4-2

4.1.4

Safety Precautions 4-2

Routine Maintenance 4-4

Contents

Chapter4

Preventive Maintenance
(Continued from previous page)

4.3

4.2.1

Preparation 4-4

4.2.2

Inspection and Maintenance 4-5

Outage Maintenance 4-14


4.3.1

Preparation 4-14

4.3.2

Inspection and Maintenance 4-15

Chapter5

Disassembly and Reassembly ________

5.1

Water Wall Tubes, Roof Tubes, Headers and Manifolds 5-1


5.1.1

5.2

Superheater Headers, Tubes and Desuperheaters 5-9


5.2.1

5.3

Recommended 10 Year Inspection 5-12

Reheater Headers, Tubes and Desuperheater 5-15


5.3.1

5.4

Recommended 10 Year Inspection 5-3

Recommended 10 Year Inspection 5-17

Economizer Headers and Tubes 5-19


5.4.1

Recommended 10 Year Inspection 5-20

5.5

Sample Tube Removal 5-22

Chapter6

Corrective Maintenance _____________

6.1

Prerequisites 6-1

6.2

Preparation 6-2

6.3

Boiler Tube Repair 6-2

6.4

Troubleshooting 6-2

Appendixes

Boiler
Mitsubishi

Appendix A

Torque Chart A-1

Appendix B

Recommended Spare Parts B-1

Appendix C

Special Tools C-1

Appendix D

Applicable Vendor Drawings D-1

Appendix E

Details of Refractory, Insulation, etc. E-1

Appendix F

Reference Drawings F-1

Contents

List of Figures

Boiler
Mitsubishi

Figure1-1

Types of Hazard Warning Labels 1-6

Figure 1-2

Boiler Mapping for Hazard Areas 1-9

Figure 2-1

Overview of Boiler & Auxiliaries 2-7

Figure 2-2

Cutaway View of Boiler 2-8

Figure 2-3

Flow Path up to the Water Separator 2-9

Figure 2-4

Flow Path of Superheated Steam 2-10

Figure 2-5

Flow Path of Reheat Steam 2-11

Figure 2-6

Pressure Parts Arrangement (Upper side) 2-28

Figure 2-7

Pressure Parts Arrangement (Upper side A-A of Fig. 2-6) 2-29

Figure 2-8

Pressure Parts Arrangement (Upper side B-B of Fig. 2-6)2-30

Figure 2-9

Pressure Parts Arrangement (Upper side C-C of Fig. 2-6)2-31

Figure 2-10

Pressure Parts Arrangement (Upper side D1-D1,


D2-D2 of Fig. 2-6) 2-32

Figure 2-11

Pressure Parts Arrangement (Upper side E-E of Fig. 2-6)2-33

Figure 2-12

Pressure Parts Arrangement (Upper side F-F of Fig. 2-6) 2-34

Figure 2-13

Pressure Parts Arrangement (Upper side G-G of Fig. 2-6))2-35

Figure 2-14

Pressure Parts Arrangement (Lower side) 2-36

Figure 2-15

Arrangement of Furnace Intermediate Headers 2-37

Figure 2-16

Sectional View of Rifle Tube 2-38

Figure 2-17

Rifle Tube Location in Furnace Wall 2-39

Figure 2-18

Arrangement of Spacer Tube & Girdling Tube 2-40

Figure 2-19

Pressure Parts Arrangement around Boiler (1/3) 2-41

Figure 2-20

Pressure Parts Arrangement around Boiler (2/3) 2-42

Figure 2-21

Pressure Parts Arrangement around Boiler (3/3) 2-43

Figure 2-22

Basic Plan of Water Wall Panels

Figure 2-23

Basic Plan of Water Wall Panels (2/3) 2-45

Figure 2-24

Basic Plan of Water Wall Panels (3/3)) 2-46

Figure 2-25

Typical Arrangement of Furnace Buckstay &


Boiler Stopper 2-47

Figure 2-26

General Arrangement of Buckstay-1/3 2-48

Figure 2-27

General Arrangement of Buckstay-2/3 2-49

Figure 2-28

General Arrangement of Buckstay-3/3 2-50

(1/3) 2-44

Contents

List of Figures (continued from previous page)

Boiler
Mitsubishi

Figure 2-29

Sectional View of Water Separator 2-51

Figure 2-30

Sectional View of Water Separator Drain Tank 2-52

Figure 2-31

Boiler Expansion Movement Diagram - 1/2 2-53

Figure 2-32

Boiler Expansion Movement Diagram 2/2 2-54

Figure 2-33

Arrangement of Boiler Header Supports 2-55

Figure 2-34

Typical Arrangement of Boiler Element Supports 2-56

Figure 2-35

Insulation of Finned Tube Walls 2-57

Figure 2-36

Insulation of Membrane Tube Walls 2-58

Figure 2-37

Insulation of Boiler Mountings 2-59

Figure 2-38

Boiler Access Door Insulation 2-60

Figure 2-39

Application of Refractory and Insulation for


Boiler and Pipes 2-61

Figure 2-40

Sectional View of a Typical Boiler Safety Valve 2-62

Figure 4-1

Criteria for Cleaning - Superheater Tube 4-19

Figure 4-2

Criteria for Cleaning - Reheater Tube 4-22

Figure 4-3

Damage to Refractory & Castable by Falling Clinker 4-25

Figure 4-4

Identification of Water Wall Tube Sample Location 4-30

Figure 5-1

Inspection Areas of Boiler 5-24

Figure 5-2

Overview of Furnace Walls 5-25

Figure 5-3

Furnace Wall Tube Panel Arrangement 1/2 5-26

Figure 5-4

Furnace Wall Tube Panel Arrangement 2/2 5-27

Figure 5-5

Overview of Passage Walls 5-28

Figure 5-6

Passage Wall Panel Arrangement 5-29

Figure 5-7

Overview of 2ry Pass Wall 5-30

Figure 5-8

2ry Pass Wall Panel Arrangement (1/3) 5-31

Figure 5-9

2ry Pass Wall Panel Arrangement (2/3) 5-32

Figure 5-10

2ry Pass Wall Panel Arrangement (3/3) 5-33

Figure 5-11

Overview of Economizer Assembly 5-34

Figure 5-12

Economizer Bank Arrangement 5-35

Figure 5-13

Overview of Roof Tube Walls 5-36

Figure 5-14

Arrangement of Roof Penetration Sealing 5-37

Figure 5-15

Overview of 1ry Superheater Assembly 5-38

Contents

List of Figures (continued from previous page)

Boiler
Mitsubishi

Figure 5-16

1ry Superheater Bank Arrangement 5-39

Figure 5-17

Overview of 2ry Superheater Assembly 5-40

Figure 5-18

2ry Superheater Bank Arrangement 5-41

Figure 5-19

Overview of 3ry Superheater Assembly 5-42

Figure 5-20

3ry Superheater Bank Arrangement 5-43

Figure 5-21

Overview of 1ry Reheater Assembly 5-44

Figure 5-22

1ry Reheater Bank Arrangement 5-45

Figure 5-23

Overview of 2ry Reheater Assembly 5-46

Figure 5-24

2ry Reheater Bank Arrangement 5-47

Figure 5-25

Sectional View of Desuperheater for Superheaters 5-48

Figure 5-26

Sectional View of Desuperheater for Reheater 5-49

Figure 5-27

Cable Opening Arrangement for Boiler Tubes 5-50

Figure 5-28

Ash Protector Arrangement for Boiler Tubes 5-51

Figure 5-29

Arrangement of Orifices in the Furnace Lower 5-52


Header Tubes

Contents

List of Tables

Boiler
Mitsubishi

Table 1-1

Risk Assessment Standard as per MIL STD822 1-8

Table 3-1

Boiler Specifications 3-1

Table 3-2

Water Wall Tube 3-2

Table 3-3

Water Separator 3-2

Table 3-4

Water Separator Drain Tank 3-3

Table 3-5

Roof Tubes 3-3

Table 3-6

Back Pass and Passage Wall Tubes 3-3

Table 3-7

Primary Superheater 3-4

Table 3-8

Secondary Superheater 3-4

Table 3-9

Tertiary Superheater 3-5

Table 3-10

Primary Reheater 3-5

Table 3-11

Secondary Reheater 3-6

Table 3-12

Desuperheater 3-6

Table 3-13

Economizer (Spiral Finned Tube) 3-6

Table 3-14

Economizer (Hanger Tube) 3-6

Table 3-15

Specification of Headers 3-7

Table 4-1

Routine Maintenance Check list 4-12

Table 4-2

Outage Maintenance Check list 4-26

Table 6-1

Troubleshooting Furnace, Superheater,


Reheater, Economizer 6-3

Table A-1

Torque Chart A-1

Table B-1

Recommended Spare Parts B-1

Table F-1

Boiler Pressure Parts Reference Drawings List F-1

Revision Record
Page Number
Page B-5

Description of Revision

Revision Issue
Date

Additional spare parts

Date Revised

Pages
Inserted

2011/06/13

2011/06/13

199

included.
Page E-1

Appendix E - Attached

~E-199

Assembly and Details of


Refractory & Insulations

Page 2-2

Chapter 2 Section 2-3 SH

2012/03/19

2012/03/01

2012/03/19

2012/03/01

2012/03/19

2012/03/01

2012/03/19

2012/03/02

steam & RH steam pressures


and temperatures values
corrected.
Page 4-15,

Chapter 4 Sub-Section 4.3.2

4-17, 4-20,

clause a), c), d) & e) para 1,

4-22,

added information related to


thickness survey.

Page 4-18,

Chapter 4 Sub-section 4.3.2

4-20

clause c) para 9 added


clearances between liner
DeSH body (1ry & 2ry DeSH),
clause d) para 8 RH clearance
DeSH between liner added.

Page 4-18,

Chapter 4 Sub-section 4.3.2

4-20

clause c) para 9, d) para 8


added inspection of
counterbore of positioning
/support bolt and fillet welding
part by ultrasonic test.

Boiler
Mitsubishi

Continued from previous page.


Page Number

Description of Revision

Revision Issue

Date Revised

Date
Page 4-18,

Chapter 4 Sub-section 4.3.2.

4-21

clause c) & d) Inspection &

Pages
Inserted

2012/03/19

2012/03/02

2012/03/19

2012/03/05

2012/03/19

2012/03/05

2012/03/19

2012/03/06

2012/03/19

2012/03/06

2012/03/19

2012/03/07

186

2012/03/19

2012/03/07

2012/03/19

2012/03/08

180

2012/09/19

2012/09/19

2012/09/19

Maintenance procedure for the


removal of exfoliated scale
inside SH & RH tubes added.
Page 4-24

Chapter 4 Table 4-2 Outage

~4-27

Maintenance Check list


updated.

Page 5-29,

Chapter 5 Figures 5-6, 5-8,

5-31, 5-32,

5-9, 5-10, 5-12, 5-16, 5-18,

5-33, 5-35,

5-20, 5-22 and 5-24 (corrected

5-39, 5-41,

tsr to ts and t-tsr to tsr)

5-43, 5-45,
5-47
E-6 ~ E-135

Figure 5-28 revised and added


table of materials.
Detail of Refractory and
Insulation replaced with latest
Revision 2

E-136 ~201

Insulation Procedure Detail


replaced with latest Revision 1

F-1 to F-186

Appendix F Reference
Drawings added

F-1 ~ F-6

Table F-1 Boiler Pressure


Parts Reference Drawings List
added

F-7 ~ F-186

Boiler Pressure Parts


Drawings added in Appendix F

4-23 ~ 4-24

Chapter 4, Sub-Section 4.3.2,


clause (g) revised

4-25

Added Figure 4-3 Damage to


Refractory & Castable by
Falling Clinker.

4-30

Figure number 4-3 changed to


Figure 4-4

Boiler
Mitsubishi

ii

Important Information
Purpose of the Plant Usage
This boiler is designed to generate steam at supercritical pressure and high steam
for producing net electric power of 815MW by the steam turbine generator.
The boiler is used only for electric power generation purpose that supports stable
and reliable electric power supply to the power grid and supplying steam for
auxiliary equipment in the power station.

General
1.

To satisfy the purpose mentioned above the following points must be strictly
observed,
a)

The operation, maintenance and inspection of the Boiler must be


performed by the persons who have basic technical knowledge and
have been trained concerning the hazard of the Boiler and the
avoidance of the hazard.

b)

The operators and maintainers must read and understand these


manuals before starting the operation, maintenance or inspection.
It is often experienced that serious damages to the equipment or
personnel have occurred by the unexpected action of operators or
maintainers who do not understand well about the equipment.

c)

The modification or change of operational specification must be


performed under MHI supervision or as per the written acceptances of
MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The customer is requested to discuss with MHI about any modification
or changes before the work actually starts.
The address for MHI to be contacted is shown in this chapter.

Boiler
Mitsubishi

2.

The operation and maintenance must be performed according to the


applicable laws and regulations at the location of the power station.

3.

Disposal from the power station must be treated to satisfy the local
regulations.

4.

The copyright of software, drawings and other documents provided by MHI


at all times, is still reserved by MHI.

iii

5.

Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.

Important General Notice for Safety


1.

The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.

2.

The protection measures must satisfy all of the operational functions.

3.

The safety activity must be planned systematically as Safety and Health


management system and operate continuously.
Safety and Health management system must include the following points,
a) Instruction for the use and the maintenance of the personal protective
equipment issued to operators and maintainers
b) The establishment of a work management organization to make clear
the operation directives and work procedures
c) Implementation of training for operator and maintainer

4.

The customer must train the operators and maintainers to act positively and
to prevent the occurrence of an accident by using their knowledge of the
power plant.

5.

The customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.

6.

To prevent accidents involving personnel and equipment, it is necessary to


observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operators and the maintainers:

7.

a)

Risk of a fatal accident

b)

Danger to lose their health and fitness

c)

Danger of damage to the equipment

MHI can not forecast all possible dangers existing in the plant such as
danger due to human error and/or dangers caused by the operating
environment.
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.

Boiler
Mitsubishi

iv

8.

MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.

Instruction of this Manual

Boiler
Mitsubishi

1.

This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must train him specially.

2.

The warning labels are to be expressed in the English language.

3.

This manual contains optional matters.

4.

Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.

5.

MHI may change the content of this manual without notice.

6.

This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.

7.

If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.

Warranty
The provisions set forth in this section are in addition to all liability and
warranty disclaimers and limitations set forth in the Contract, whether arising
under law or from course of performance, course of dealing, or usage of trade.
Nothing in these provisions shall constitute or be deemed to constitute any
additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and
commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing
in the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents,
partial or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and
other equipment), or any other liability (collectively, Accidents and Damages)
in the case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.

In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;

Boiler
Mitsubishi

vi

Accidents and Damages caused by the modification or re-installation of the


Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during
transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in
accordance with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing
performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other
equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of
the damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect
references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or
storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.

Boiler
Mitsubishi

vii

Limitation of Liability
Use and Disposal
Nothing in this Limitation of Liability section or manual shall constitute or be
deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.

For Documents and Safety Training


Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.

For Damage to the Plant


The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety
training prior to the start of their work. Persons who have not received such
safety training are not permitted to work on the installed Plant. This initial
training, however, is merely the minimum requirements prior to allowing any
personnel to work on the installed Plant. The Customer must, on a continual
and regular schedule, give up-to-date training to its personnel on safety
requirements, provide testing or other methods to confirm their understanding
of the safety training, and confirm that they have the physical and mental
capability to perform their respective roles. The Customers obligation for
safety training and personnel supervision is an ongoing obligation and must
be continuously performed and kept current throughout the operation of the
Plant. Accidents, partial or total failure of the Plant, damage to personnel or
property, loss, injuries, and other liability (collectively, Liability) caused by
inadequate safety training or the Customers personnels failure to abide by
the documents provided by MHI are expressly excluded from the coverage of
any warranty provided by MHI and are the sole and exclusive responsibility of
the Customer.
Boiler
Mitsubishi

viii

MHI will NOT be liable for any Liability caused by modification or changes
made in Plant-related documents (including any Safety Manual) by anyone
other than MHI.

For Damage to the Plant


Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected
by MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or
fault, in material or Equipment that was used during a repair, even when such
repair was performed by or under an instruction given by MHI.

Boiler
Mitsubishi

ix

Copyright
COPYRIGHT 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED.
ANY REPRODUCTION IS EXPRESSLY PROHIBITED.
All of the content contained in this manual is protected by Japanese, International
and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property rights in
the documents provided by Mitsubishi Heavy Industries, Ltd.(MHI) (including
safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject
to your compliance with the restrictions set forth below, MHI grants to you a limited,
non-exclusive license in the copyright for the sole purpose of allowing you to use,
operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents provided by
MHI (including safety-and-instruction manuals) for any purpose other than the
purpose described above without MHIs prior written consent is strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,
uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, estoppel or otherwise, is
being granted or otherwise transferred.

Boiler
Mitsubishi

Personnel to whom the


Manual is directed
This Manual was prepared for all personnel who will participate in the operation
and maintenance of the plant, and other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed
to perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.

Operator

Operators following the instructions of their supervisor or the Shift Charge


Engineer are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to emergency stop devices following instructions
given by their superior when dangerous or hazardous situations are recognized.

Maintainer

Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work
if MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.

Boiler
Mitsubishi

xi

Contact Address
For any question or any clarification required, please do not hesitate to contact MHI
through the following address (es).

For Support before Operation:


MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
1-1, Akunoura Machi, Nagasaki 850-063

For Support after Commissioning and in an Emergency


(later)

Boiler
Mitsubishi

xii

Abbreviations
Abb.

Expanded Form

Abb.

Expanded Form

1RY

Primary

IP

Intermediate Pressure

2RY

Secondary

ID

Induced Draft

3RY

Tertiary

IDF

Induced Draft Fan

AC

Alternating Current

LP

Low Pressure

AA

Additional Air

SP

Secondary Pass

AVT

All Volatile Treatment

MSDS

Material Safety Data Sheet

BCP

Boiler Circulating Pump

MW

Mega Watt

BMCR

Boiler Maximum Continuous


Rating

NDT

Non Destructive Test

DCS

Distributed Control System

OD

Outside Diameter

DeSH/DSH

Desuperheater

OJT

On Job Training

Eco.

Economizer

PAF

Primary Air Fan

ESP

Electrostatic Precipitator

P&ID

Piping and Instrumentation


Diagram

FD

Forced Draft

PPE

Personal Protective Equipment

FDF

Forced Draft Fan

PTW

Permit to Work

FGD

Flue Gas Desulphurization

PVC

Polyvinyl Chloride

GRF

Gas Recirculation Fan

RH

Reheater

HDR

Header

SH

Superheater

HP

High Pressure

WB

Wind Box

I&C

Instrument and Control

WW

Water Wall

CWT

Combined Water Treatment

WS

Water Separator

MOV

Motor Operated Valve

WSDT

Water Separator Drain Tank

DC

Direct Current

TV

Television

OD

Outer Diameter

Boiler
Mitsubishi

xiii

List of Vendor Manuals


NIL

Boiler
Mitsubishi

xiv

A r r a n g e me n t o f t h e S y s t e m
Maintenance Manual
This manual is arranged as follows.

Chapter 1
Describes health and safety issues during maintenance, disassembly and reassembly
of the Boiler.

Chapter 2
Describes the construction, purpose, and function of the Boiler and the associated
parts.

Chapter 3
Describes the Boiler parts, using the relevant Data Sheets.

Chapter 4
Describes the Preventive, Routine, and Outage Maintenance.

Chapter 5
Describes the disassembly and reassembly procedures, necessary to obtain access
to internal parts for inspection and repair during Boiler overhaul.

Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.

Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents

Boiler
Mitsubishi

xv

Chapter 1

Safety

C h a p t er

1 Safety
1.1

Feature of Boiler Safety


The boiler produces high pressure and high temperature steam during the
combustion of pulverized coal in the furnace. The boiler while in service is
subjected to furnace pressure fluctuations including extreme conditions of
explosion or implosion.
To maintain the boiler operating conditions under control, all equipment
provided in the fuel firing system must operate correctly. That means, the fuel
burners and associated equipment are maintained in good condition.
As the boiler is operated at super critical pressure and high superheated steam
temperature, the pressure parts of the boiler and steam pipes are subjected to
high stress during operation. The boiler being a large structure, the several parts
of the boiler are subjected to unequal temperature distribution. Thus the boiler
encounters severe stress conditions and there is a risk of failure of pressure
parts causing steam / water leak. Leaking water and/or steam from the failed
parts of the boiler can cause injury to person working near the failed area.
The high temperature steam leaking from cracks is not visible, but produces
noise. Hence, all persons working in the boiler area must move cautiously
around the boiler in case any abnormal noise is heard.
Coal burned in the boiler produces a huge amount of ash. The abrasive ash
causes wear on the boiler tubes located in the gas path leading to another type
of tube failure under high stress condition.
Some ash with traces of combustibles embedded form clinkers and stick on the
furnace walls forming big lumps known as clinkers. When the clinker becomes
large enough, they tend to fall to the furnace bottom. Be aware of these clinkers
while doing maintenance jobs in the furnace bottom.
As the boiler is a very tall structure, there is the danger due to falling or tripping
over boiler parts or materials being transported for both operation and
maintenance works. Hence utmost care is to be taken while handling materials
at the various levels around the boiler.
All operators and maintainers must realize these dangers and keep themselves
alert without jeopardizing safety, following the instructions written in this chapter.
The operator and maintainer are requested to strictly observe the warning signs
and the instructions provided to avoid endangering their own or their colleagues
lives.

Boiler
Mitsubishi

1-1

Chapter 1

1.2

Safety

Warnings Description
Safety of personnel working in the power plant is the most important matter. MHI
have taken all steps to avoid the risks of danger in the design of the power plant.
However, certain risks are unavoidable due to the nature of the plant.
This manual classifies the severity and hazard level of such risks by two
categories, DANGER and CAUTION. Read and understand the indications
thoroughly before operation or maintenance of the plant.
The contents of wordings, DANGER and CAUTION are described as follows;
Kinds

Meaning of Warnings
DANGER indicates an imminently hazardous situation
during use of the Boiler, which, if not avoided, could
result in death or serious injury, or serious damage to
the property or environment.
CAUTION indicates a potentially hazardous situation

CAUTION

during use of the Boiler, which, if not avoided, may result


in minor injury or minor damage to the property or
environment.

This manual also uses the following indicators in addition to the hazard level
indications described so far.

Kinds

Meaning of Warnings
IMPORTANT describes the particular information or

IMPORTANT

items that personnel must know during operation and


maintenance of the Boiler, and that, if not heeded, may
result in an accident of an in-assessable hazard level.

Notice

Boiler
Mitsubishi

NOTICE describes useful information and tips for


operation and maintenance of the Boiler.

1-2

Chapter 1

Safety

1.2.1 Definitions of Serious Injury, Minor Injury,


Serious Damage to Property, and Minor Damage to
Property
Serious Injury
This term describes injuries, which leave after effects such as loss of
eye sight, permanent disability, bone fracture or breakage, gas
inhalation, asphyxiation, electric shock, hospitalization or prolonged
hospital visits for treatment.

Minor Injury
This term describes injuries, which do not require hospitalization or
prolonged attention at a hospital (injuries other than the serious
injuries described above).

Serious Damage to Property


This term describes damages, which require a suspension of
productive activity for one day or more due to restoration of the
damaged property.

Minor Damage to Property


This term describes damage, which does not require any suspension
of productive activity due to restoration of the damaged property.

Boiler
Mitsubishi

1-3

Chapter 1

Safety

1.2.2 Symbols
In this manual, the following symbols are added for easy understanding
of the contents of warnings and are found next to DANGER,
CAUTION and other indications.
These symbols are in compliance with ISO 3684.
Symbol

Description
This symbol indicates the possible presence of high voltage, and
warns of a hazard which may result in system shock, burn or
death by electric shock if safety precautions are neglected or the
system is handled incorrectly.
This symbol indicates a movable section that is inside a safety
cover or is exposed.
Movable parts may inflict laceration or bone fracture to body parts
such as a hand by pinching the hand and/or clothing.
This symbol indicates the presence of parts the surface of which
could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place
your feet when moving around the area.
Risk of injury by tripping is present near this symbol due to
factors such as a location with an unstable surface, or
obstructions such as scaffolding, temporary pipe lines, or other
protrusions.
This symbol indicates the possible presence of gas(es) harmful or
asphyxiant to personnel.
Be sure to ventilate fully before work commences.
This symbol indicates caution against the handling of a heavy
object or working in an abnormal position.
Do not work in an abnormal posture which may damage your back
or waist.

This symbol indicates prohibited items or actions during the


operation and maintenance of the Boiler.

This symbol indicates a movable section that is inside a safety


cover or exposed.
Do NOT touch any equipment where this symbol is displayed.

Boiler
Mitsubishi

1-4

Chapter 1

1.2.2

Safety

Symbols (Continued from previous page)

Symbol

Description
This symbol indicates that personnel must not touch since the
surface is hot.
Do NOT enter any area where this symbol is displayed.

This symbol indicates that the entry of personnel is prohibited.


Do NOT enter any area where this symbol is displayed.

This symbol indicates that physical contact is prohibited.


Do NOT touch or enter a location or enclosure where this symbol
is displayed.
This symbol indicates that the stated items or actions in the
warning notices relative to operation and maintenance of the
Boiler are mandatory.

1.2.3 Hazards Warning Label


Hazard warning labels are applied where potential hazards are present
during operation and maintenance activities.
Hazard warning labels will be in appropriate sizes and colors that will
catch the eye and the attention of personnel. They also have symbols
that show the hazard types, in addition to the descriptions of warning
contents.

IMPORTANT
Personnel are requested to confirm the location of, and to read, and
thoroughly understand the contents of all hazard warning labels
applied to this Boiler. If any of the hazard warning labels peel off/wear
out or become unreadable, install a new label in the original location
without delay.

Boiler
Mitsubishi

1-5

Chapter 1

WARNING

Safety

DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION

PINCH POINT

STEEP
DROP

DO NOT
ENTER

DO NOT
TOUCH

DO NOT
TOUCH

TB0001_A

FIGURE 1-1
Boiler
Mitsubishi

TYPES OF HAZARD WARNING LABELS

1-6

Chapter 1

1.2.4

Safety

Hazard Area

IMPORTANT
Only trained maintainers or operators are allowed to enter the
maintenance work area. Entry to the area by personnel untrained
could cause not only injury but also serious damage to the Boiler.

Boiler
Mitsubishi

1-7

Chapter 1

1.3

Safety

Risk Assessment Standard


As prepared by the Design Section as per MIL STD822D.
TABLE 1-1

RISK ASSESSMENT STANDARD


Detailed Description of Impact on each Object

Category

Safety

Catastrophic

II

Critical

III

Marginal

VI

Negligible

Health

- Unit shutdown (unit cannot be


operated)
- More than 4 days for repairing
- Unit shutdown (can not be
operated)
- Within 3 days for repairing
- Unit shutdown (can not be
operated)
- Can be repaired by Customer

TABLE 1-1

Environment

- Death

- Harmful gas, coal or oil leakage


- High pressure and temperature
material leakage such as steam,
water, air and gas, oil, coal etc.
- Low oxygen

- Serious Injury

- Same as the above

- Minor Injury
(with
hospitalization)
- Minor Injury
(without
hospitalization)

- Same as the above


- High temperature surface
- High elevation or unstable
- Not harmful and high pressure
& temperature leakage
-Mechanical protected

RISK ASSESSMENT STANDARD (CONTINUED)

Definition

Description

Category

Detailed

(A)

Frequent

Repeating occurrence

1 time / 1 or 2 months

(B)

Probable

Known to occur, or, it has happened

1 time / 1 year

(C)

Occasional

Could occur

1 time / 5 years

(D)

Remote

Not likely to occur

1 time / 10 years

(E)

Improbable

Practically Impossible

1 or 2 times / total life

TABLE 1-1
Hazard
Categories
Frequency
of Occurrence

RISK ASSESSMENT STANDARD (CONTINUED)


I

II

III

VI

Catastrophic

Critical

Marginal

Negligible

(A)

Frequent

13

(B)

Probable

16

(C)

Occasional

11

18

(D)

Remote

10

14

19

(E)

Improbable

12

15

17

20

Boiler
Mitsubishi

1-8

Chapter 1

Safety

DANGER ZONE
(Contains the high temperature
& high pressure medium such
as steam, water, air and gas,
coal, oil etc)

MM-M01.01

Rev.004

WORKING FLOOR

MPTD-3-0536

Boiler
Mitsubishi

FIGURE 1-2

BOILER MAPPING FOR HAZARDOUS AREAS


1-9

Chapter 1

1.4

Safety

Safety Measures
1.4.1 Work Permit System (Lockout / Tagout)
Work permit system is applied when equipment is shutdown for
maintenance work, to complete the maintenance work under a safe
condition. The outline of the work permit system is as follows:
(1)

The Maintenance Engineer applies for the work permit clearly


indicating the content of the maintenance work that he wants to
do, and submits it to the Shift Charge Engineer.

(2)

The Shift Charge Engineer passes the work permit form to the
operator to study and decide the isolation method from the line in
operation on the mechanical and electrical view point and then
report to the Shift Charge Engineer with his comments on the
hazard conditions for the work.

(3)

The Shift Charge Engineer gives work permit number and


prepares necessary tags to show the work permit number and
the situation of isolation by valves and power supply. He will then
instruct the operators to set the isolation condition following the
work permit form.

(4)

The operators will open the breaker and set the valves to the
specified condition, they will drain and vent the equipment to be
worked on, and the breaker and the valves are then locked. The
operators return the work permit to the Shift Charge Engineer.

(5)

The Shift Charge Engineer checks the isolation and will issue the
signed work permit to the Maintenance Engineer, or his
representative.

(6)

The Maintenance Engineer orders the start of the maintenance


work to the personnel nominated.

(7)

The Maintenance Engineer or his representative will then return


the signed work permit to the Shift Charge Engineer after making
sure the maintenance work is completed.

(8)

The Shift Charge Engineer will then send operators to release the
locks and return to the original situation.

(9)

The operators check the situation and report that the system is
now back to the normal condition when signing off the work
permit.

(10) The Shift Charge Engineer makes sure that the work under the
permit is completed and files details in the log book.
The work permit system is to clarify responsibility for the works on each
step and to ensure that the work is performed safely.

Boiler
Mitsubishi

1-10

Chapter 1

Safety

1.4.2 General Cautions on Personnel in Working Area


1.4.2.1

Cautions against Rotating Equipment


All couplings on rotating machines are covered by the
coupling cover but whole parts of the shaft are not fully
covered. It is recommended that the following warning is
observed strictly.

Do not approach or operate the equipment where protective


covers have been removed. Get additional supervisor
assistance.
Make sure that the breaker for the motor is opened when you
are required to remove the cover.
Care must be taken of the exposed rotating parts especially in
the area between the casing and the coupling.
All shafting, coupling and other rotating parts must be guarded
in order to prevent accidental contact.

Boiler
Mitsubishi

1-11

Chapter 1

1.4.2.2

Safety

Cautions against Electrical Equipment


The electrical equipment covered under this section
includes all the concerned plant equipment and the
maintenance tools like grinders, lamps, welding equipment
etc. though live parts of the plant equipment or
maintenance tools are insulated, be sure to observe the
following cautions. Failure to observe them may cause
fatal accidents, personal injuries and damage to the
electrical equipment.

Always, confirm that power supply is disconnected at the


up-stream side of power supply system and it is locked
according to the Work Permit.
Do not remove or open panels or doors labeled with high
voltage live part warning label not included in the Work Permit.
Ensure the proper earthing is provided for all electrically
operated tools and equipment used for maintenance works.
When using lamps for internal inspection, ensure that a low
voltage system (24volts) is available.
Make sure that no materials or Parts remain in the Panel or
terminal box before closing them finally.

Boiler
Mitsubishi

1-12

Chapter 1

1.4.2.3

Safety

Cautions against High Temperature Sections


Various equipment and pipelines contain high temperature
fluid in the plant and they are insulated on their surface.
Even though several hot spots exist in the wide area of
insulated surface, some specified equipment and pipe
lines are not insulated for cooling purpose. Since the
temperature is very high and you could get burned,
observe the following caution to avoid burn injury.

CAUTION
Suitable working wear is always available and should be worn,
including gloves, to avoid direct contact to hot spots in the
plant.
Level gauges of pressure vessels including connecting pipes
are not insulated to cool down the steam to drain.
Sampling piping is not insulated to cool down the steam to a
suitable temperature for the analyzer except on the places
located close to the working areas.
All exhaust pipes of the safety valves and the exhaust pipe of
the boiler flush pipe are not insulated.
Always wear gloves.

Boiler
Mitsubishi

1-13

Chapter 1

1.4.2.4

Safety

Cautions against Steam Leak in the Plant


The steam leak especially from high temperature steam
may cause serious injury to the personnel and it must be
repaired at an early stage of the leakage. The following
pre-cautions must be followed to find leakage at an early
stage.

Water drips may occur at the insulated parts such as the


connected part of the lagging. The leaking point can be found
by removing insulation partially using great care.
As you approach the leakage, the water will change to visible
steam. It is now too dangerous to remove the insulation.
Leakage of the superheated steam only makes whistling
noise without generating white steam. It is very dangerous to
approach the noise area.
Contact the Charge Engineer to obtain a Permit to Work
before repairing the damage.
Be well aware of the steam. The steam could leak from the
water system containing water at 100C or higher even if it is
a low pressure type water system.
High temperature drain or steam could leak from the flush
pipe during start-up.
If not avoided, the steam or vapor can enter the inside of your
working wear through the small gap between the body and
the clothing.

1.4.2.5 Cautions against Oil / Coal Leak in the Plant

CAUTION
Oil / Coal leakage is very dangerous. It is a potential fire
hazard.
Any oil spillage must be reported to the Shift Charge
Engineer.
Oil leaks make the area slippery and people are advised to
move around these areas carefully.
Boiler
Mitsubishi

1-14

Chapter 1

1.4.2.6

Safety

Cautions against Chemicals


Pay attention to the items listed below to prevent any
accident related to the chemicals in the plant.

IMPORTANT
Precaution against chemicals:
Operate chemical injection systems by strictly following the
instruction of the chemist. The operator must use suitable
protective tools.
Disposal:
Observe the rules and regulation of the installation site.
Material safety data sheet (hereafter MSDS):
Always understand the content of applicable MSDS in
advance, and observe the notified instructions when
handling.
Emergency response:
Solution against emergency must be thoroughly instructed
to all personnel involved so that the fullest measures can be
taken against any situation.

1.4.2.7

Cautions against Combustible Materials/


Storage Areas

IMPORTANT
Storage containers must be clearly marked to indicate the
content.
Bunding must be provided for bulk tanks.
Suitable fire protection must be provided for each area.
Do not store bulk combustible materials on the site.
Small quantities of combustible materials must be stored in
fire resistant cupboards.
Combustible materials must be segregated from other
equipment.

Boiler
Mitsubishi

1-15

Chapter 1

1.4.2.7

Safety

Cautions against Combustible Materials /


Storage Areas (Continued)

IMPORTANT
Leakage of gasoline has the risk of fire. Maximum storage
quantity of gasoline outside of the dispensing pump is five
liters.
Emergency response:
Personnel directly involved in combustible materials MUST
be properly trained and thoroughly instructed. Other
personnel in the vicinity must be aware of the dangers and
take precautions in all situations.

1.4.2.8

Cautions against Lack of Oxygen

Check that the oxygen content in the equipment vessel or in


the confined space is between 18~22% before entering, and
ensure sufficient ventilation.
Continue monitoring oxygen and ventilation during
inspection.
It is recommended that you do not enter the equipment,
vessel or confined space alone but if the situation demands
that you must enter, take the necessary preventive safety
measure provided, breathing system etc, and find a partner
who will wait for your return at the point of entry, keeping in
verbal contact throughout.
Make complete arrangements for rescue.

1.4.2.9

Cautions against Lifting Heavy Object


Be careful during the removal/installation of any
equipment during maintenance.

CAUTION
Do NOT attempt to move or lift equipment in an abnormal
posture. ALWAYS install/remove equipment, using a forklift
or a crane. A normal lift without mechanical aid should be
done using two or more persons.
Failure to observe the above may cause injury due to
dropped equipment, back or waist injury or damage to the
equipment.
Boiler
Mitsubishi

1-16

Chapter 1

Safety

1.4.2.10 Cautions against Sharp Objects

CAUTION
Use leather gloves when handling parts with sharp edges.

1.4.2.11 Cautions using Fork Lift

CAUTION
Do NOT permit anyone to stand below any item being lifted
under any circumstance.
Failure to observe this may cause fatal accidents.

When using a forklift, ALWAYS lift the objects parallel to the


ground while considering the center of gravity.
Otherwise, lifted objects may fall and serious damage could
occur.
A forklift is often used to transfer small machines. Check fork
insertion position for the forklift prior to use. Be careful, as
marks which indicate the fork insertion positions are
sometimes hidden by wraps or packing materials.

Boiler
Mitsubishi

1-17

Chapter 1

Safety

1.4.2.12 Cautions using Crane

CAUTION
A crane is often used to transfer heavy parts. Check for any
possible risks which could occur during hoisting and
transportation before operating the crane.
Check of the equipment:
Check the crane, the crane hook and all related items before
use. Use wire ropes which can withstand the weight of the
parts multiplied by a safety factor.
Inspect the shackles, eyebolts, jigs and wire ropes provided
for the hoisting work prior to the actual hoisting.
Perform periodical inspection (dye penetrant test) of hoisting
tools at least once a year.
Rigging / Slinging work:
Only authorized personnel can perform slinging work and
operation of the crane.
Work area:
Before hoisting, secure a working area around the part to be
lifted and prohibit the entry of unrelated personnel.

Hoisting method:
Hoist the part parallel to the ground while paying attention to
the center of gravity.
Do NOT permit any person to stand under the part being
lifted.
Pay attention to and ensure that all persons are clear of the
equipment being lifted.
Hoisting point:
Do NOT hoist any parts from a position other than the
specified hoisting points.
Unpacking:
Do NOT unpack any part until it is located in the designated
location.
Protection of machine:
Avoid any impact to the unpacked parts.

Boiler
Mitsubishi

1-18

Chapter 1

1.4.2.13
a)

Safety

Disposal
Water disposal including oily drain
The water is disposed to the plant drain system. The water
must be carefully disposed according to the materials
contained in the water. The water drain system is
separated into three categories that are rain water,
chemical water and oily water.
The waste waters are treated and then discharged into the
public drain system.

b)

Chemical disposal
Chemicals must be handled following the instruction of the
MSDS and disposed to the chemical drain system.

c)

Solid disposal made by maintenance work


For disposal from the site, observe the local legal
regulations.

Boiler
Mitsubishi

1-19

Chapter 1

1.5

Safety

Emergency Measure
1.5.1 Evacuation on Emergency Case
1.5.1.1

Evacuation Route
Following items are considered on design and installation
of emergency evacuation.

IMPORTANT
Each building installed in the plant is provided with at least two
exits. A clear indication of the exits can be seen from anywhere
in the building as the exit sign is illuminated using the
emergency power supply.
Evacuation routes are indicated on each floor of the building,
directing personnel to the exits.
Keep the evacuation routes completely free from materials and
tools.

1.5.1.2

Evacuation of Disabled Persons, Who Cannot


Walk by Themselves
The following are necessary items, prepared for emergency
evacuation.

IMPORTANT
It is recommended to keep a stretcher available for emergency
use at a place that is known by all personnel.
If you find this kind of accident, inform the rescue team, and
attempt to bring the collapsed person to the first aid station.

Boiler
Mitsubishi

1-20

Chapter 1

1.5.1.3

Safety

Evacuation from Power House


Following are guidance for the evacuation from the power
house.

IMPORTANT
An evacuation place for personnel to gather in after evacuation
from the power house in an emergency must be predetermined
and explained beforehand in the emergency training.
Evacuation directive must be given by the responsible person
such as Shift Charge Engineer, and all personnel must be
alerted in the power house repeatedly with an available
broadcast facility.
All people working in the power house must stop their work
immediately and leave the power house to the gathering place.
When evacuated to the evacuation place, make sure
that there is no one missing.

Boiler
Mitsubishi

1-21

Chapter 1

Safety

1.5.2 Fire Accident

IMPORTANT
Clearly show the location of the fire alarm push button and the
nearest fire extinguisher to make everybody take the first step
at fire protection.
Inform everyone concerned that a fire has now started if you
discover a fire.
Start fire fighting using the fire extinguisher located near the
fire site.
The operators must check the plant is ready for trip, and wait
for order from the responsible person.
The operator and other personnel must transfer the fire
fighting to the fire fighting team when they arrive at the fire site
and the operators must wait for instruction from the Shift
Charge Engineer. All other personnel must immediately start
evacuation.
If unit trip is decided, the operator must trip the plant manually.
The operators must evacuate from the power house according
to the instruction of the responsible person immediately after
shutdown of the unit.
If the fire is extinguished successfully, the operators should
return to the power house as required by the Shift Charge
Engineer and start inspection of the equipment for restart of
the unit.
Based on the inspection, the responsible person should
decide whether to operate the unit again or shutdown for
repairing.
After the inspection or repair, and then checking the
equipment and/or system, start up the unit again.

Boiler
Mitsubishi

1-22

Chapter 1

Safety

1.5.3 Earthquake
In the case of an earthquake, the shift charge engineer or operator
must judge whether the unit trip is necessary according to the intensity
of the earthquake, and immediately trip the unit manually. If the unit is
tripped, all equipment must be carefully checked on its operation status
and tripped if abnormal phenomena are found.
In the local area, mechanical and/or thermal shocks may be given to
the equipment, piping, instruments and electrical panels. Be sure to
observe the following when completing the inspection.

Check that the lubricating oil pump is running. Bearings of the


equipment will be damaged if lubricating oil is not supplied.
Check the piping and equipment for steam and water leakage. The
steam or high temperature water leakage may cause serious
injury to the personnel and it must be repaired at an early stage of
the leakage.
Check the pulverizers and /or coal silos for signs of a fire. If a coal
fire does start, make sure that CO2 fire fighting system is properly
operated.
Check the position of boiler seismic stopper. Since the boiler
seismic stopper must be anchored at the original position, boiler
cannot be re-started if the slippage is found. If the stopper is not
at the original position, please contact MHI.

CAUTION
Check the piping and equipment for the breaking and the falling
down of insulation. Since the exposure of hot surface may cause
burn injury, it must be repaired by a worker fully dressed in
Personal Protective Equipment.

1.5.4 Explosion Accident

Do not use a fire in a hazardous area where the combustibles


(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or
handled. Use of a fire in a hazardous area could cause serious
injury to personnel and serious damage to equipment due to an
explosion.

Boiler
Mitsubishi

1-23

Chapter 1

1.6

Safety

Qualification and Training


The system must be operated only by authorized operators & maintenance
supervisors.
The customer shall authorize all operators and maintainers, who are involved in
the operation and maintenance of this plant, either by the training course given
by Mitsubishi, or by the customers own personnel assessment.
Operator and maintainer training course {both classroom training and On the
Job Training (OJT)} will be provided by Mitsubishi before the handing over of
this plant. The customer must train and assess new operators and maintainers
who join after the turn-over, according to his own procedure and standard,
(Mitsubishi training course may still be available if required).
As a minimum, operator and maintainer must satisfy the following:
Operator and Maintainer can read and fully understand the description of
this manual.
Operator and Maintainer can understand the related P & ID, logic diagram.
Operator and Maintainer know the location of the system equipment
including pipe routes, valves and instruments.
Operators and Maintainers have fundamental knowledge of the function of
each equipment.
Operator can operate the equipment and the system manually at local
stations.
Operator can operate the system remotely using the DCS system.
Operator can respond suitably for any kind of alarm.
Operator knows the location of emergency exit on the power house and is
available to provide first aid treatment.
Operator knows emergency communication system operation.
Operator and Maintainer, following the Charge Engineers instruction are
aware of the isolation method for mechanical, electrical and instrumental
equipment being prepared for safe maintenance while the unit is in
operation.
Maintainer must also be able to handle the maintenance tools provided by
the owner and those supplied by the manufacturer.

Boiler
Mitsubishi

1-24

Chapter 2

General

C ha pte r

2 General
2.1

Purpose
The purpose of this maintenance manual is to provide specific information to the
Paiton Expansion Project operators and maintaining personnel.
Although this document will convey a good knowledge and direction regarding
maintenance of the boiler, the operator / maintainer must seek assistance or
instruction from the manufacturer when a problem not covered in this document
occurs.

2.2

Boiler
Mitsubishi

References
a)

Boiler P & I Diagram


MHI Dwg. No. P10-0600A
Project Dwg No. P101-74-3-BB-BS-J001

b)

Boiler General Arrangement


MHI Dwg. No. P10-4001A to 4003A Rev.
Project Dwg No. P101-36-BB-LO11 TO LO13

c)

Pressure Part Arrangement


MHI Dwg. No. P10-4101 to 4108
Project Dwg No. P101-36-BB-LO14

d)

Basic Plan for Water Wall Panel


MHI Dwg. No. P12-4001 to 4003

2-1

Chapter 2

2.3

General

Overview of the Boiler and Auxiliaries


Refer to the Figures 2-1 to 2-5.
The boiler facilitates the transfer of heat released during the combustion of the
fuel to the feed water and steam.
This heat transfer produces superheated main steam at a pressure of 25.3
MPa(g) and a temperature of 542oC as required by the HP steam turbine.
This heat transfer also occurs in the reheater section where the temperature of
the cold reheat steam at a pressure of 4.89 MPa (g) is increased from 304oC to
568oC at a pressure of 4.73 MPa(a) as required at the inlet to the IP steam
turbine.
The boiler supplied for the Paiton Expansion Project is of the outdoor, once
through, balanced draft, and reheat type suitable for firing pulverized coal and
generating steam at supercritical conditions.
The following systems/components are associated with the boiler:
Boiler heat transfer banks and insulation
Desuperheaters
Water Separators and Water Separator Drain Tank
Boiler water Circulation Pump
Drafting system
Air Heater
Pulverizer
Burners
Soot Blowers
Electrostatic Precipitators
Flue Gas Desulphurization System
Chimney
The boiler heat transfer banks consist of economizer, furnace water walls,
ceiling (roof) pipes, rear gas (2RY pass) duct water walls, superheaters and
reheaters.
The furnace water walls made of membrane panels minimizes the need for
refractory and ensures gas tightness. Similarly, the water cooled 2RY pass
water walls and roof composed of fin-welded tubes minimizes the need for
refractory and ensures gas tightness.

Boiler
Mitsubishi

2-2

Chapter 2

General

The economizer, superheater and reheater assemblies are housed inside the
box formed by the furnace, roof and 2RY pass water walls.
Each assembly consists of either one or two sections known as tube bank. The
construction of each tube bank is different.
The boiler outer surfaces are provided with thermal insulation to reduce heat
loss and to provide safety to the operator. The outer surface of the insulation
material exposed to the atmosphere is covered with ribbed hot dipped
aluminium coated steel sheets. Setting bars located at the upper and lower ends
of these sheets securely set them in position.
The high pressure (HP) feed water from the outlet of the HP feed water heaters
flows through the economizer banks located at the bottom of the secondary
pass and recovers heat from the outgoing flue gas.
The heated feed water, from the outlet of the economizer, then passes through
the water walls of the boiler to absorb the heat produced by the combustion of
pulverized coal in the furnace.
The water wall tubes in the upper and lower furnace area mainly absorb the
heat by thermal radiation from the fire in the furnace. The roof tubes, passage
side wall tubes, 2RY pass and division wall tubes absorb the heat by convection
from the hot flue gas.
During low load operation (less than 20%), water particles are contained in the
steam at the outlet of the roof and 2RY pass heat transfer banks. Water and
steam mixture from the outlet of the 2RY pass walls/roof tubes is passed
through the two water separators (WS) where mixture is separated. The steam
is passed through other heat transfer banks for superheating. The water is
drained into the water separator drain tank (WSDT) and pumped back to the
economizer by the boiler circulation pump (BCP).
The BCP is of the leak-free glandless type and its bearings are water lubricated.
For full details of the BCP, refer to the Boiler Circulation Pump vendor operation
and maintenance manual (OM-01.01).
Two bypass pipes with motor operated valves (MOV) connect the two roof outlet
headers to the two WS. This bypass arrangement helps to reduce the flow
through the 2RY pass tubes and thus the pressure drop in the boiler is
minimized during normal supercritical operation. The flow stability is very good
at supercritical pressures when the fluid is only in one phase and this property is
used to reduce the flow through the 2RY pass tubes.
The three stage superheater consisting of 1RY, 2RY and 3RY superheater
banks superheat the steam either by radiation or convection heat transfer
depending on their arrangement in the boiler.
The spacer tubes maintain the alignment of the 2RY reheater panels and 3RY
superheater panels. Required spacer tubes for maintaining the alignment of the
panels are drawn from the 1RY superheater inlet headers and connected to the
2RY superheater outlet headers.
Boiler
Mitsubishi

2-3

Chapter 2

General

Similarly girdling tubes are drawn from the 2RY superheater inlet headers and
terminated at the 3RY superheater outlet headers. The girdling tubes maintain
the alignment of tubes of 2RY and 3RY superheater banks which are exposed
to the furnace radiation heat.
Two sets of desuperheaters are placed in between each 1RY and 2RY SH
circuits and 2RY and 3RY SH circuits for steam temperature control.
The two stage reheater consisting of 1RY and 2RY stages of reheater banks are
arranged to provide convective heat transfer surfaces. One set of
desuperheater is placed in between the 1RY and 2RY RH banks for steam
temperature control. During normal operation of the boiler no spray water is
injected. Only under emergency conditions spray water is injected. Hence, a
steam cooling line is provided for the reheater desuperheaters to avoid any
thermal shock during water injection. This cooling line is drawn from the 1RY
RH inlet header and connected to the desuperheater.
The draft system consists of two induced draft fans (IDF), two forced draft fans
(FDF), two primary air fans (PAF) and the associated ducts. For cooling air and
sealing air requirements two sets of AC/DC fans and two sets of AC fans are
provided, respectively.
In order to maintain furnace stability and to obtain the maximum combustion
efficiency, combustion air and additional air are supplied by the FD fans to the
individual burner assemblies.
The PA fans draw air from the atmosphere and its discharge is divided into two
sections, one passing through the air heater to provide hot primary air and the
other bypassing the air heater to provide tempering air.
The hot and the cold primary air are mixed at the pulverizer inlet and the
required inlet air temperature is maintained. This primary air dries the pulverized
coal and then transports the pulverized coal to the coal burners at the desired
temperature.
The two ID fans maintain a balanced draft in the furnace and help to evacuate
the products of combustion in the furnace. The flue gas system is designed to
provide passage for the products of combustion from the boiler to the chimney,
while allowing the gas to transfer its heat energy effectively to the water cooled
tubes and steam cooled tubes installed in the flue gas path.
Two, 50% BMCR duty tri-sector, vertical shaft, counter flow, air heaters are
installed in each stream of air and flue gas path to improve the boiler efficiency.
The air heater recovers a portion of heat from the outgoing flue gas, and imparts
it to the incoming combustion air/primary air from the FD fans / PA fans. Each
air heater is equipped with a power actuated soot blower, and a water washing
device. The air heater has a dual drive arrangement-using an electric AC motor
and an air motor. Bearing lubrication with a water cooling system ensures stable
operation. Fire fighting water is also available. In the case of an emergency both
fire fighting and water wash water are used to put out an air heater fire.
Boiler
Mitsubishi

2-4

Chapter 2

General

Coal is used as the primary fuel and Light oil is the startup fuel in the steam
boiler prepared to provide steam to the steam generators provided for the
Paiton Expansion Project.
Coal delivered to the site is stored, and then it is delivered to the six coal
bunkers serving the six installed coal pulverizers.
Five of the six installed pulverizers are necessary to produce the steam required
to produce the 865900kW of Electric Power required.
From the coal bunker, coal is delivered to the coal feeder then through a coal
feed pipe to the Pulverizer in which the coal is crushed and prepared for firing
into the boiler through the coal burners.
Twenty four sets of tilting type burner assemblies and their accompanying start
up burners are installed on the front and the rear side of the lower furnace walls.
These burners provide efficient and stable combustion of the fuel, formed to
produce two sets of fire balls inside of the furnace.
Oil burners are provided in the burners assemblies only for start up and coal
burner stabilization purposes.
Combustion air to the burners is provided through control dampers located in
the wind boxes connected to each set of burner assembly.
Flame detectors and closed TV cameras are installed in the furnace to monitor
the condition of the flame and to ensure safe operation of the boiler.
Tilting type additional air (AA) port assemblies are provided above the top
burner on the front and rear water wall. The purpose of this additional air is to
cool the furnace outlet gas thereby reducing the NOx emission in the exit flue
gas.
Cooling and sealing air from the Cooling and Sealing Air System is provided to
the flame detectors, furnace TV camera,burners,pulverzers,wind box etc. to
protect this equipment from high temperature and to reduce hot air and dust
leakage.
Thirty long retractable soot blowers, ten half retractable soot blowers and sixty
eight deslaggers are strategically located on the boiler to dislodge any slag or
soot deposited on the heat transfer surfaces.
One swivel type soot blower is provided at the cold end of each air heater for
cleaning the air heater elements.
Superheated steam to the soot blowers is drawn from the 2RY superheater inlet
header.
The auxiliary steam header supplies blowing steam to the air heater soot
blowers to perform soot blowing during a cold startup when superheated steam
from the 2RY superheater inlet header is not available.

Boiler
Mitsubishi

2-5

Chapter 2

General

The Electrostatic Precipitators, installed between the air heaters and the ID fans
collect the fine ash particles present in the flue gas and maintain the particulate
emission within the permitted limits. An opacity measuring instrument is
installed in the flue gas duct ahead of the FGD absorber to measure the
emission level of ash particles in the gas. The SOx level is reduced in the FGD.
The clean flue gas is led to the atmosphere through the chimney. CO2, CO, O2,
SO2 and NOx measuring instruments are installed in the chimney to assist in the
confirmation of the emission level of the gas.
The purpose of this maintenance manual is to describe in detail all pressure
parts of boiler which include heat transfer banks and piping from the economizer
inlet to the 3RY superheater outlet, and the 1RY reheater inlet to the 2RY
reheater outlet.
Maintenance details of Ducts and Boiler Dampers, Forced Draft Fan, Primary
Air Fan, Induced Draft Fan, Pulverizer and Fuel Oil Burner are described in the
mechanical maintenance manuals MM-M-03, MM-M-01.02, MM-M-02.01, and
MM-M-04 respectively. Details of Boiler water Circulation Pump (OM-01.01), Air
Heater (OM-01.02), Soot Blowers (OM-01.03) and Electrostatic Precipitators
(OM-25) are provided in their respective vendor manuals.

Boiler
Mitsubishi

2-6

Chapter 2
BOILER FRONT

General

CEILING GIRDER

HANGER RODS

COAL CONVEYER AREA

LEGEND
RETRACTABLE
SOOT BLOWER

WATER SEPARATOR

WALL DESLAGGER
(T)

2RY SH

3RY SH

(T)

2RY RH

WATER SEPARATOR
DRAIN TANK
BS

COAL BUNKERS

INTERMEDIATE HEADER
& MANIFOLD

1RY RH

1RY SH

T.V

BS

GAS TEMPERATURE
PROBE
HALF RETRACTABLE
SOOT BLOWER
OBSERVATION PORT
100 250
ACCESS DOOR
610
ACCESS DOOR
800 800
ACCESS DOOR
500 800
HEAT EXHAUST DOOR
1000 1000
BUCKSTAY
BOILER STOPPER

ECON.

ECON.

HRSP

FLOWMETER
MSP
CRSP
WDC
FWP
FEEDERS

HIGH & MIDDLE TEMP.


BASKET ELEMENT
REMOVAL DOOR

FURNACE

PIPE &
CABLE SPACE

AIR HEATERS

SILENCER SILENCER
SILENCERS

LOW TEMP. BASKET


ELEMENT REMOVAL DOOR

BCP

FLUE GAS
TO EP, FGD& ID FAN

MM-M01.01

Rev.004

FORCED DRAFT FANS


MILLS

DCC
PRIMARY AIR FANS

MPTD-3-0080

FIGURE 2-1
Boiler
Mitsubishi

OVERVIEW OF BOILER & AUXILIARIES

2-7

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-2
Boiler
Mitsubishi

CUTAWAY VIEW OF BOILER

2-8

Chapter 2
REAR WALL HANGER TUBE
OUTLET HEADER

REAR WALL HANGER


TUBE INLET MANIFOLD

PASSAGE SIDE WALL


INLET MANIFOLD

REAR WALL OUTLET HEADER


PASSAGE SIDE WALL
INLET HEADER
1RY SH INLET HEADER

REAR WALL 2ND INTERMEDIATE HEADER


PASSAGE SIDE WALL
OUTLET HEADER
REAR WALL
INTERMEDIATE HEADER

PASSAGE SIDE WALL


INLET HEADER

REAR WALL INLET HEADER


PASSAGE SIDE WALL
OUTLET HEADER

FURNACE INLET MANIFOLD


SIDE WALL INLET HEADER
SIDE WALL
INTERMEDIATE HEADER

REAR WALL
INTERMEDIATE MANIFOLD
VENT

VENT

2RY PASS REAR WALL


INLET HEADER

2RY PASS INLET MANIFOLD


2RY PASS DIVISION WALL
OUTLET HEADER

SIDE WALL 2ND


INTERMEDIATE HEADER
SIDE WALL
INTERMEDIATE MANIFOLD

VENT

SIDE WALL
INLET HEADER

2RY PASS REAR WALL


OUTLET HEADER

VENT
N2

2RY PASS INLET MANIFOLD


SIDE WALL
OUTLET HEADER

VENT

1RY SH INLET HEADER

REAR WALL HANGER TUBE


INLET HEADER

2RY PASS SIDE WALL


INLET HEADER
2RY PASS DIVISION WALL
INLET HEADER

2RY PASS SIDE WALL


INLET HEADER

SIDE WALL 2ND


INTERMEDIATE
HEADER

TO REHEATER STEAM TEST

2RY PASS SIDE WALL


OUTLET HEADER

SIDE WALL
OUTLET HEADER

General

TO SILENCER

VENT
VENT

VENT
FOR CHEMICAL CLEANING
FRONT WALL INLET HEADER
FRONT WALL
INTERMEDIATE HEADER
VENT

FRONT WALL INTERMEDIATE


MANIFOLD

VENT

WATER
SEPARATOR

VENT

N2
ROOF INLET HEADER

VENT

N2

BCP WARMING

TO BCP

VENT

ROOF OUTLET HEADER

VENT

WATER
SEPARATOR

2RY PASS SIDE WALL


OUTLET HEADER

N2

N2

2RY PASS FRONT WALL


OUTLET HEADER

ROOF INLET MANIFOLD


VENT

N2

2RY PASS FRONT WALL


INLET HEADER

WATER SEPARATOR
DRAIN TANK

SH SPRAY LINE
M

N2
VENT
M

ECONOMIZER OUTLET HEADER


M

TO BOILER FLASH PIPE

MM-M01.01

Rev.004

FROM H.P. HEATERS


ECONOMIZER INTERMEDIATE HEADER
ECONOMIZER INLET HEADER
MPTD-3-0082

FIGURE 2-3
Boiler
Mitsubishi

FLOW PATH UP TO THE WATER SEPARATOR

2-9

Chapter 2

General

3 R Y S H O U T L ET H E A D E R
3 R Y S H O U T L ET H E A D E R

3R Y S U P E R H EA T E R

G IR D L IN G TU B E S

TO BOILER FLASH PIPE

3R Y S H IN LE T H E A D E R

TO BOILER FLASH PIPE

3R Y SU P E R H EA T E R
M A IN S T E A M P IP E 3A

3R Y S H IN LE T H E A D E R

T O H P T U R B IN E

G IR D L IN G T U B E S

M A IN S T E A M P IP E 3B

F O R S O O T B LO W E R

T O H P T U R B IN E

T O S ILE N C E R

VENT
T O S ILE N C E R

T O S ILE N C E R
N2

M
S

2ry S H D S H
2ry S H D S H
S

T O B O ILE R F LA S H P IP E
2 R Y S H O U T L ET H E A D E R

2R Y S H O U T L ET H E AD E R

2 R Y S U P E R H E A TE R

2R Y S U P E R H EA T E R

2R Y S H IN LE T H E A D E R

2R Y S H IN LE T H E A D E R
B C P W A R M IN G LIN E

T O A U X ILIA R Y S T E A M
VENT

TO REHEATER STEAM TEST


M

N2
1ry S H D S H
1ry S H D S H

T O B O ILE R F LA S H P IP E
1R Y S H O U T LE T H E AD E R

1R Y SH O U T LE T H E AD E R
N2

1R Y S U P E R H E A TE R

1R Y S U P E R H EA T E R
1R Y S H IN LE T H E A D E R

1R Y S H IN LE T H E A D E R

MM-M01.01

TO BOILER FLASH PIPE

Rev.004

TO BOILER FLASH PIPE

M P TD -3-0083

VENT

S P A C E R TU B E S

W ATER
S E P A R A TO R

FROM ECONOMIZER OUTLET HEADER

S P A C E R TU B E S

W ATER
SEPARATOR

F R O M 2R Y P A S S R E A R W A L L O U T LE T H E A D E R

FIGURE 2-4
Boiler
Mitsubishi

W ATER SEPARATOR
D R A IN T A N K

TO BCP

FLOW PATH OF SUPERHEATED STEAM

2-10

Chapter 2

TO SILENCER

General

TO SILENCER

TE

TE

TE

TE
2RY RH OUTLET HEADER

2RY REHEATER

2RY REHEATER

VENT

2RY RH INLET HEADER

TE

TE

TE

TE

RH DSH

FROM BFP INTERMEDIATE STAGE

N2

RH DSH

TE

FROM BFP INTERMEDIATE STAGE

TE

1RY RH OUTLET HEADER


TO BOILER FLASH PIPE
DSH COOLING LINE

DSH COOLING LINE

1RY REHEATER

1RY REHEATER

TO
SILENCER

TO
SILENCER

1RY RH INLET HEADER


FROM HP TURBINE EXHAUST

FROM WATER SEPARATOR


TEMP. PIPE

MPTD-3-0084

FIGURE 2-5

Boiler
Mitsubishi

FLOW PATH OF REHEATER STEAM

2-11

Chapter 2

2.4

General

Boiler Components
The boiler consists of the following major components:
Furnace pass wall, passage side wall and 2RY pass wall tubes and roof
tubes
Water separator and water separator drain tank
Superheaters
Reheaters
Desuperheaters
Economizer
Boiler supports
Casing and insulation
Safety valves

2.4.1 Furnace Pass Wall, Passage Side Wall and 2RY Pass
Wall Tubes and Roof Tubes
Refer to the Figures 2-6 to 2-17, 2-22 to 2-28, 2-31 to 2-36.
The purpose of the wall tubes and roof tubes is to absorb radiant /
convection heat produced in the furnace by the combustion of
pulverized coal and to convert water in the tubes into steam.
The furnace pass walls, passage side walls, 2RY pass walls and roof
tubes together provide the furnace area and the flue gas path.
The furnace space is formed by the furnace pass walls which are in the
form of a large vertical box. The four water wall sides of the furnace
pass, namely the front, rear, right and left, together form the furnace.
The furnace can be divided into two halves; lower furnace and upper
furnace. The burners and the additional air compartments are mounted
on the outer surface of the lower half. The upper half inside is filled with
the 2RY and 3RYsuperheater banks which absorb mostly radiant heat.
Each side water wall has an inlet header at the bottom and terminates
at an outlet header in the roof housing.
Each furnace wall side of the boiler is formed by welding together gas
tight membrane wall panels and each panel is formed by welding
several tubes together.
A nose section is formed at a height of 46.2235m for the flue gas flow
diversion. This is provided by bending the rear wall tube panels as
shown in Figure 2-6. This nose section is extended to the width of the
passage wall and connected to the rear wall outlet header and thus
provide a gas tight area for the passage wall bottom area.

Boiler
Mitsubishi

2-12

Chapter 2

General

This large vertical box has a narrow opening at the bottom side through
which the ash is removed.
Another short vertical box is formed by the 2RY pass walls which
provide a flue gas outlet path. The 2RY pass walls are generally
formed by welding together the fins of individual tubes to provide a gas
tight finned wall except for the portion of the front wall where gas flow is
to be allowed from the furnace pass to the 2RY pass. Thus the
secondary pass front wall for the length of 10.650m is provided with
screen tubes to allow gas flow from furnace pass to 2RY pass between
passage walls.
The secondary pass is divided into two paths by a division wall formed
by tubes originating from the 2RY pass division panel inlet header.
Similar to the 2RY pass front wall screen tubes are provided on the
division wall for a length of 10.210m from the division wall outlet header
to allow the gas flow through both sections. The lower portion of the
division wall is provided with finned tubes similar to other wall sections
and provides a gas tight finned wall.
Two manifolds are provided in the 2RY pass flow path between roof
outlet header and the 2RY pass wall inlet headers. These manifolds
make a homogeneous mixture of steam and make the heat transfer
uniform in the water/steam cooled walls of the 2RY pass.
The flue gas outlet is connected to a duct at the top of the air heater.
The space inside this box is filled with 1RY SH, 1RY RH and
economizer.
The short vertical box has a full width opening at the bottom through
which the hot flue gas exits.
These two vertical boxes are joined together by a small horizontal pass
formed partly by the passage side walls and partly by nose formation of
the rear furnace pass wall. These walls are extended from the furnace
rear wall outlet header. The passage walls also have the finned wall
construction. The outlet header is connected to a manifold.
This manifold is connected to different inlet headers which supplies
tubes necessary for the passage walls and the hanger pipes.
The outlet headers of hanger pipes and passage walls are suitably
supported in the roof beams. The space between the passage walls is
occupied by the 2RY RH.
Water from the hanger pipes, the furnace walls and the passage walls
enter the roof inlet header and then to the roof outlet header. The
connecting pipes of the roof headers at the front side with reference to
the hanger pipes towards the inlet header are of size 45.0mm whereas
on the rear side towards the outlet header are of size 57.1mm. The
tubes are welded with fins to form a gas tight top cover.
Boiler
Mitsubishi

2-13

Chapter 2

General

Where tubes are spaced out to allow for burner openings, manholes,
observation ports or for other tube exit through roof panel, the
additional space between the tubes is closed with split pins and sealed
with castable refractory and/or sheet casing to present a completely
sealed surface. This arrangement prevents the hot furnace gases from
leaking through these gaps.
The water walls and roof tubes are of the drainable type.
The outside surfaces of the boiler walls are insulated and covered with
a casing to reduce radiation heat loss from the system.
Some of the special features in the construction of the boiler walls are
detailed below.
Water from the economizer outlet header to the furnace inlet headers is
admitted through furnace inlet manifolds. These manifolds assist in
equalizing the flow through the furnace wall tubes.
For the final equal distribution of the flow through each tube, all the
tubes in the four furnace walls are fitted with flow equalizing orifices at
a point 270mm away from the geometric centre of the corresponding
inlet header pipes.
Due to the high flux density and unequal distribution of heat, the
enthalpy of water in the furnace wall tubes is large on the middle tubes
of walls and reduces almost parabolically along the sides of walls. The
equalization of the enthalpy in the furnace wall tubes along the breadth
and width of the upper furnace is achieved by installing distribution
manifolds and intermediate headers.
In between the inlet and outlet header of the water walls on each side
there are two intermediate headers, at a height of 42.380m and
44.310m respectively, which are placed outside of the water wall
surfaces and suitably supported to the nearby buckstays.
Alternate tubes of the water walls are extended out of the water wall
outer surfaces at two different levels (44.310m and 44.971m) and
connected to the intermediate headers without affecting the continuous
formation of the waterwall.
The water supply from the first intermediate header to the second
intermediate header is distributed through a manifold positioned in
between the two intermediate headers. There are two manifolds each
on the front and rear side and one manifold each on the left and right
side.
The furnace water walls are exposed to high temperature radiation,
and are provided with rifled tubes covering the entire furnace length
from a height of 16.500m up to the top of the intermediate outlet header
height of 45.120m. In all the other locations smooth tubes are used.
Boiler
Mitsubishi

2-14

Chapter 2

General

The rifled tubes cause the water, or steam and water mixture to spin
within the tube to provide a greater heat transfer.
Manifolds are also provided between the front wall outlet header and
the roof inlet header, rear wall outlet header and passage side wall inlet
header/rear wall intermediate inlet header. These manifolds equalize
the flow through the tubes in the roof tubes, passage wall tubes and
rear wall hanger pipes.
The entire weight of water walls is supported from the top of the roof
housing by rigid hangers provided on the water wall outlet headers.
These tubes expand downwards in the vertical direction during hot
condition with the hanger support as the zero expansion point.
The four sides of the boiler walls are surrounded by buckstay beams
which avoid the possible buckling and deformation of the tubes due to
forces applied by the furnace pressure and temperature variations. The
buckstays equalize the force around the walls through the corner plates
and corner links. The buckstays have provision to allow the walls to
expand in the traverse direction during hot condition along the boiler
stoppers provided on the buckstay beams as the zero expansion points
in the traverse direction.
Buckstay positioners installed between two adjacent elevation
buckstays guide their vertical movement during operating conditions.
Boiler stoppers are provided at different elevations as required. The
purpose of these stoppers is to arrest the horizontal movement of the
buckstay beams.

2.4.2 Water Separator and Water Separator Drain Tank


Refer to the Figures 2-29 & 2-30.
The water separator and the water separator drain tank are high
pressure vessels.
The function of the water separator is to separate the water and steam
from the wet steam. The separated steam flows upward to the 1RY
superheater. The separated water flows downward to the water
separator drain tank through a vortex breaker installed at the bottom of
each water separator.
Four outlet pipes from the 2RY pass rear wall outlet header are welded
to the upper half of each water separator with an offset as shown in
Figure 2-28. This offset provides the tangential entry of the steam. The
resultant swirling action separates any remaining water from the steam.
Each 2RY superheater bypass pipe from the two roof outlet headers
are connected to an individual MOV. The outlet of each MOV is further
divided into two pipes and each pipe joins the regular inlet pipe of each
water separator.
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Mitsubishi

2-15

Chapter 2

General

Inspection stubs are provided on the water separator to provide access


for inspection during outage. Each water separator is supported on four
lugs with spring hangers connected to the hanger beams.
The two water separators are located adjacent to the 2RY pass rear
wall near the 64.550m elevation to receive the steam from the 2RY
pass outlet header.
The drain pipe of each water separator is welded to the bottom half of
the water separator drain tank. Guide supports are provided for the
drain tank.
A nozzle at the bottom end of the water separator drain tank directs any
water to the BCP and a nozzle at the top directs the steam to the three
stage superheaters.
Provision is made in the water separator drain tank for level
transmitters which provide remote level indications in the control room
and level signals for the auto control loop.

2.4.3 Superheaters
The function of the superheater is to raise the steam temperature
above the saturation level, thus increasing the potential energy within
the steam.
The superheater consists of three basic sections.
Primary superheater(1RY SH)
Secondary superheater (2RY SH)
Tertiary superheater (3RY SH)
All the superheater assemblies are of the nondrainable type except the
1RY superheater, because of the vertical arrangement of the coils.

a)

Primary Superheater
Refer to the Figures 2-2, 2-6, 5-15 & 5-16.
The steam from the water separators enter the 1RY superheater
inlet header and then into the tube banks that make up the 1RY
superheater assembly.
The 1RY superheater tube banks are located in the 2RY pass
between the 2RY pass rear wall and the division wall and above
the economizer bank. They absorb heat from the flowing flue
gases by convection.
Constructionally the 1RY superheater is divided into two tube
banks-horizontal type and a terminal type. The banks consist of
prepared bends and straight lengths of alloy steel tubes of
45mmxt6.9mm, welded together to form large flat surfaces.

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Mitsubishi

2-16

Chapter 2

General

The horizontal type tube bank consists of bent tubes (coiled)


located above the economizer rear section of the 2RY pass and
is supported by the economizer hanger tubes. This bank consists
of 220 panels with 6 tubes in each panel.
The terminal type tube bank consists of straight tubes connecting
the horizontal type bank to the outlet header inside the roof
housing. This bank consists of 110 panels with 12 tubes in each
panel.
The 1RY SH tube banks are supported by the economizer
hanger tubes. Due to the different mediums handled by the two
sets of tubes, there is a differential expansion between the 1RY
SH terminal tubes and the economizer hanger tubes.
In order to avoid the mechanical strain due to the differential
expansion, the terminal type bank is provided with cold springs
(12mm) near the tube joints between the terminal and the
horizontal type banks (Refer to the Figure 2-6).
Fixed spacers, sliding spacers and band spacers are provided on
the1RY superheater banks at specific locations to maintain
alignment between the adjacent tubes.
At locations where the 1RY superheater tubes penetrate the roof
panel, sealing is provided to prevent the leakage of the flue gas
and fly ash into the roof.
Separate outlet pipes from the two water separators join the two
individual 1RY superheater inlet headers of 431.8mm located in
the secondary pass. The steam passes through the lower and
upper banks and enters the outlet header of 482.6mm.
The 1RY superheater banks are of the drainable type.
The entire assembly is supported at the outlet header. The outlet
header is connected to the collector beams through rigid hangers
and then the collector beams are connected to the hanger beams
with spring hangers.

b)

Secondary Superheater
Refer to the Figures 2-2, 2-6, 5-17 & 5-18.
Steam from the 1RY superheater outlet header enters the 2RY
superheater inlet header via the 1RY superheater desuperheater.
There are four sets of 2RY superheater assemblies each set
consisting of an inlet /outlet header.
The 2RY superheater is of the non drainable type.

Boiler
Mitsubishi

2-17

Chapter 2

General

Steam from the 2RYsuperheater bank tubes exits through the


2RY superheater outlet header.
The 2RY superheater assembly is located in the upper furnace
and most of the heat absorption takes place from radiant heat.
The 2RY superheater bank is a panel type and is fabricated from
48.6mm alloy steel and stainless steel tubes. The tubes
connecting the panels to the header in the roof are of size
31.8mm and have the thickness of t5.9mm, t6.4mm, t6.9mm
and t7.4mm depending on their locations in the header.
Since the panel spacing is of the order of 2403.0mm the
convection heat transfer is quite less in this superheater.
There are 12 panels arranged along the width and depth of the
furnace. Each panel consists of 160 tubes. Spool pieces have
been provided for insertion and welding between the tubes of
dissimilar materials.
To provide rigidity to the 2RY superheater bank tubes and to
prevent side movement due to turbulent gas flow inside the
furnace, girdling loop arrangements are provided around the tube
assemblies.
These girdling loops originate from each 2RY superheater inlet
header, bifurcate into two tubes forming a girdling loop around
both the 2RY and 3RY superheater assemblies at the bottom and
then terminate at each 3RY superheater outlet header after
combining as a single tube. Necessary sleeves, protectors and
supports are provided to avoid damages to the tubes.
Rod spacers and support plates are also provided on the 2RY
superheater assembly at specific locations to maintain alignment
between adjacent tubes.
Adjacent tubes of the 2RY superheater bank are interlocked with
sliding spacers which allow relative expansion between the
adjacent tubes to maintain alignment.
The locations where the 2RY superheater tubes penetrate the
furnace roof panel are provided with sealing arrangements to
prevent the leakage of flue gas.
The 2RY superheater panels and the 2RY superheater inlet and
outlet headers are supported by rigid hanger supports connected
to the hanger beams. The inlet pipes and the outlet pipes to these
headers are connected to the collector beams through rigid
hangers and then the collector beams are connected to the
hanger beams with spring hangers.

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Mitsubishi

2-18

Chapter 2

c)

General

Tertiary Superheater
Refer to Figures 2-2, 2-32, 5-19 & 5-20.
Steam from the 2RY superheater outlet header enters the 3RY
superheater inlet header via the 2RY superheater desuperheater.
They are of platen type and consist of fifty four panels.
The 3RY superheater bank is of the non drainable type.
Steam from the 3RY superheater exits through the 3RY
superheater outlet header which is connected to the main steam
pipe.
The 3RY superheater bank is located above the nose portion in
the upper furnace and is sandwiched by the 2RY superheater
and the 2RY reheater. This superheater absorbs heat, mostly, by
convection process from the hot flue gas. Some heat is also
absorbed by radiation from the furnace.
The 3RY superheater bank is fabricated from 45mm alloy steel
tubes and stainless steel tubes. The tubes connecting the inlet
header have a thickness of 5.9mm whereas the tubes connecting
the outlet header are of thickness 6.9mm.
There are 54 panels and each panel is formed by a group of 32
tubes. Spool pieces have been provided for insertion and welding
between the tubes of dissimilar materials.
Girdling loop arrangements as provided for the 2RY superheater
are extended to this superheater also to provide rigidity to the
3RY superheater banks and to prevent side movement due to
turbulent gas flow inside the furnace.
Steam cooled spacer tubes are provided for the 3RY superheater
to prevent the sidewise movement of the panel across the gas
flow path. Two steam cooled spacer tubes of 45.0mm are
tapped from each 1RY superheater inlet header at the bottom of
the 2RY pass.
The spacer tubes enter through the nose section of the furnace at
the centre line of the boiler. Each tube is drawn in between two
tubes at the front and rear end of 3RY superheater bank. The
tube runs through the entire width of the bank. Necessary
protectors are provided on the SH tubes to avoid tube damages
due to rubbing.
The spacer tubes are rigidly supported to the side wall tube with
support plates before exiting to the roof and are terminated to
each 2RY superheater outlet header on the extreme ends of both
sides respectively.

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Mitsubishi

2-19

Chapter 2

General

The locations where the spacer tubes penetrate the roof wall
panel are provided with sealing arrangements to prevent leakage
of flue gas.
A section of the spacer tube which is located outside of the boiler
and not exposed to the flue gas is insulated to reduce heat loss.
Alloy steel fasteners such as U rods and flats are used to hold
the spacer tube in position with the adjacent beams, wherever
the tube is passing through the boiler.
Rod spacers and support plates are also provided on the 3RY
superheater assembly at specific locations to maintain alignment
between adjacent tubes.
Adjacent tubes of the 3RY superheater bank are interlocked with
sliding spacers, which allow relative expansion between the
adjacent tubes and maintain alignment.
The locations where the 3RY superheater tubes penetrate the
roof wall panel are provided with sealing arrangements to prevent
leakage of flue gas.
The 3RY superheater bank and the 3RY superheater inlet and
outlet headers are supported by rigid hangers to the collector
beams which are in turn connected to the hanger beams through
spring hangers.
The outlet header is connected to the main steam pipe.

2.4.4 Reheaters
The exhaust steam from the HP turbine (having spent energy to rotate
the HP turbine) is at a pressure of 4.7 MPa(a) and a temperature of
304oC when the plant is operating at BMCR. In practice, it is not
possible to increase the pressure of this steam; but more useful work
can be obtained from the steam if its enthalpy is increased. This is
achieved within the reheater section of the boiler, where the HP turbine
exhaust steam (referred to as cold reheat steam) is reheated up to
566oC.
The reheater consists of two sections known as 1RY and 2RY reheater.
Cold reheat steam from the exhaust of the HP turbine flows to the 1RY
and then to the 2RY section of the reheater.

a)

Primary Reheater
Refer to Figures 2-2, 2-6, 5-21 & 5-22.
The 1RY reheater assembly consists of two banks known as
horizontal type and terminal type. The horizontal type bank
basically consists of three sections of bent tube assemblies
stacked one above the other with short vertical connecting pipes.

Boiler
Mitsubishi

2-20

Chapter 2

General

The terminal type consists of straight long pipes. This type of


construction makes the 1RY reheater drainable.
The 1RY RH tube banks are supported by the economizer
hanger tubes. Due to the different mediums handled by the two
sets of tubes, there is a differential expansion between the 1RY
RH terminal tubes and the economizer hanger tubes. In order to
avoid the mechanical strain due to the differential expansion, the
terminal type bank is provided with cold springs (21mm) near the
tube joints between the terminal and the horizontal type banks
(Refer to the Figure 2-6).
The 1RY reheater bank is made of 57.1mm steel tubes.
Depending on the temperature of the flue gas each section is
made of carbon steel for low temperature areas and alloy steel
for high temperature areas. The upper most section is made of
alloy steel only.
The lower horizontal bank occupies the space just above the
economizer assemblies in the front section of the 2RY pass. The
terminal type bank is located above the horizontal bank and
connects the 1RY reheater bank to the reheat inlet/outlet header.
Both banks absorb convection heat from the flue gas.
The cold reheat steam enters the horizontal 1RY reheater inlet
header located above the economizer in the 2RY pass section
and adjacent to the front wall tubes. The cold reheat steam flows
through the 1RY reheater tubes in an upward direction.
To provide rigidity to the 1RY reheater bank and to prevent side
movement due to turbulent gas flow, each element is supported
by economizer hanger tubes at two locations. There are two
hundred and twenty hanger tubes supporting the 1RY reheater
assembly.
Fixed spacers, sliding spacers and band spacers are provided on
the 1RY reheater banks at specific locations to maintain the
alignment between the adjacent tubes.
Ash erosion protectors are provided on the 1RY reheater tubes
and bends at specific erosion prone locations and also at the
front and rear water cooled walls to prevent erosion of tubes due
to ash flow.
At locations where the 1RY reheater tubes penetrate the roof,
sealing is provided to prevent the entry of flue gas and fly ash
from the flue gas.
The 1RY reheater banks are supported at the1RY reheater outlet
header by spring hangers located above the roof housing.
Boiler
Mitsubishi

2-21

Chapter 2

b)

General

Secondary Reheater
Refer to Figures 2-2, 5-23 & 5-24.
The 2RY reheater is of the non drainable type and is located in
the passage pass between the 3RY superheater and the 1RY
reheater banks. The heat transfer takes place by convection
process.
The cold reheat steam after passing through the 1RY reheater
enters the 2RY reheater section. The 2RY reheater bank is of
alloy steel and stainless steel tube material ( 57.1mm).
Steam cooled spacer tubes are provided for the 2RY reheater to
prevent the sidewise movement of the panel across the gas flow
path. Two steam cooled spacer tubes of 45.0mm are tapped
from each 1RY superheater inlet header at the bottom of the 2RY
pass.
The spacer tubes enter through the nose section of the furnace at
the centre line of the boiler. Each tube is drawn in between two
tubes at the front and rear end of 2RY reheater bank. The tube
runs through the entire width of the bank. Necessary protectors
are provided on the RH tubes to avoid tube damages due to
rubbing.
They are rigidly supported to the side wall tube with support
plates before exiting to the roof and are terminated to each 2RY
superheater outlet header on the extreme ends of both sides
respectively.
A section of the spacer tube which is located outside of the boiler
and not exposed to the flue gas is insulated to reduce heat loss.
Alloy steel fasteners such as U rods and flats are used to hold
the spacer tube in position with the adjacent beams, wherever
the tube is passing through the boiler.
Rod spacers and support plates are also provided on the 2RY
reheater assembly at specific locations to maintain the alignment
between adjacent tubes.
Adjacent tubes of the 2RY reheater bank are interlocked with
sliding spacers, which allow relative expansion between the
adjacent tubes to maintain alignment.
At locations where the 2RY reheater tubes penetrate the roof,
sealing arrangements are provided to prevent the entry of flue
gas and fly ash into the roof housing.
The secondary reheater inlet and outlet headers are located
inside the roof housing and are supported by spring hangers
located above the roof housing.

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Mitsubishi

2-22

Chapter 2

General

2.4.5 Desuperheaters
Refer to the Figures 5-25 & 5-26.
To control the final steam temperature at the 3RY superheater outlet,
spray type desuperheaters are provided between the 1RY and the 2RY
superheaters and 2RY and the 3RY superheaters.
Similarly, to control the reheat temperature under emergency
conditions desuperheaters are provided between 1RY reheater and
2RY reheater banks.
All desuperheaters have similar internal construction. As the reheater
desuperheater spray is not continuously used, it has been provided
with a steam warming / cooling pipe connection to avoid any thermal
stress to the internal parts due to sudden application of spray water.
The desuperheaters consist of a circular pipe body having the same
inner diameter as the respective outlet pipes emerging from the
superheater outlet header.
The inside surface of the body is protected with a liner pipe, which is
positioned and supported by positioning and supporting bolts that are
welded to the body. At the four locations of positioning bolts, the liner
pipe is reinforced by 9.27mm thick reinforcing pads on the inner
surface at the inlet end of steam water mixture.
The spray water pipe enters horizontally into the desuperheater body at
right angle and extends to the opposite side through the diameter of the
body. This pipe is made of cast steel and alloy steel materials as per
the temperature contour in the various sections of the pipe.
The pipe assembly consisting of positioning rod, reinforcement ring and
lugs is welded to the body. The positioning rod remains inserted into
the positioning ring in the protection nozzle welded in the opposite side
of the body. The protection nozzle is closed by the protection nozzle
end plate.
The protection nozzle side chamber (formed as above) pressure is
equalized by the two 7mm internal holes drilled at the top and bottom of
the protection nozzle as shown in the Figures 5-22&23. For the proper
functioning of the desuperheater, the fixing arrangement of the spray
pipe is very important.
The clearance between the positioning rod and the positioning ring play
an important role in this regard and need to be inspected during
maintenance.
The spray pipe is fitted with two spray nozzles. The spray nozzles are
fixed on the spray water pipe on the side opposite to the steam inlet in
a horizontal plane and supported by a spray nozzle support.

Boiler
Mitsubishi

2-23

Chapter 2

General

Thus the spray nozzles are fixed in such a way that the sprayed water
is directed along the path of the incoming superheated steam.
Inspection nozzles are provided at the steam inlet and exit end of the
desuperheater body. This facilitates the inspection of the
desuperheater during annual overhaul. The direction of steam flow is
engraved on the body.

2.4.6 Economizer
Refer to the Figures 2-2, 2-6, 5-11, & 5-12.
The function of the economizer is to raise the feed water temperature
by absorbing heat from the exiting flue gas before the feed water enters
the furnace wall inlet headers.
The feed water enters the economizer via the inlet header and then
flows upward through the economizer banks in counter flow to the
downward flue gas path. This counter flow increases the heat transfer
efficiency between the flue gas and the feed water.
The economizer is of the drainable type. The economizer consists of
tubes placed across the width of the secondary pass in four banks.
There are two horizontal tube banks with spiral fin tubes. One tube
bank consisting of only one horizontal section is placed in the front side
of the 2RY pass whereas the second bank consisting of two horizontal
assemblies is placed in the rear side. Each horizontal element has
spirally wound fins to increase the heating surface area for more
efficient heat transfer. The 19mm high, 1.4mm thick fins are mounted
with a spacing of 12.7mm on the 45.0mm OD x 4.1mm thick
economizer tubes. The tube material is carbon steel (SA-210 Gr.C).
The bends at the tube ends are not finned.
The outlets from the two horizontal banks are welded to the other two
tube banks, known as hanger type, through economizer intermediate
headers. There are two intermediate headers between each set of
horizontal and hanger type banks. The 57.1/50.8 mm or 63.5/50.8mm
OD hanger pipes support the economizer tube banks, 1RY superheater
tube bank and the 1RY reheater tube bank.
The hanger pipes passing through the 1RY superheater and 1RY
reheater tube bank support them using fixed and sliding supports. The
hanger pipes are fitted with anti vibration bands at fixed locations.
Support lugs, support plates, stoppers and lugs are used at appropriate
locations to support the economizer tube bank. These support plates
are secured to the intermediate headers by welding, thus providing
support to the economizer assemblies.
Anti-vibration plates are provided over the top tubes of the element to
prevent damage to tubes and fins due to vibration.
Boiler
Mitsubishi

2-24

Chapter 2

General

The pitch of the economizer bank is maintained by the economizer


supports. These supports are welded to the respective economizer
intermediate headers located above the economizer assemblies.
Ash erosion protectors are provided on the economizer tubes and
bends at specific locations and also at the front and rear walls to
prevent erosion of tubes due to ash flow.
At locations where the economizer hanger tubes penetrate the roof,
sealing arrangements are provided to prevent the entry of flue gas into
the roof housing.
The economizer outlet header is supported by rigid hangers from the
top of the roof housing.

2.4.7 Boiler Supports


Refer to the Figures 2-2, 2-33 & 2-34.
The boiler pressure parts are supported and hung from the boiler
structure in the roof housing.
The outlet tubes from each side of the furnace water walls, 2RY pass
walls, passage walls; 1RYsuperheater, 1RY reheater, economizer, etc.
are welded to their respective outlet headers located inside the roof
housing. The outlet headers are supported on the boiler structural
beams using rigid and spring hangers.
The inlet headers of the 1RYsuperheater, 1RY reheater and the
economizer inlet and intermediate headers are supported from the 2RY
pass walls inside the 2RY pass.
The 2RY superheater, 3RY superheater and the 2RY reheater inlet and
outlet headers are located in the roof housing and supported on the
boiler structure.
Feed water and steam pipes connected to the boiler and feed water are
routed outside of the furnace and are supported on the boiler structure.
Water separator, water separator drain tank, boiler circulation pump etc.
are the equipment located external to the boiler. Such equipment is
supported on prepared structures.
For Details of the type and the location of the various supports, please
refer to Appendix G.

Boiler
Mitsubishi

2-25

Chapter 2

General

2.4.8 Casing and Insulation


Refer to the Figures 2-2, 2-35 to 2-37, 2-39 and Appendix E.
Thermal insulation is provided in the boiler for the following reasons.
To prevent burns to personnel.
To improve efficiency by reducing heat loss from steam and hot
water systems.
To protect the boiler internal components from damage.
The thermal insulation used in the boiler is mainly in the form of
refractory, mineral fiber materials, calcium silicate blocks and insulating
plastics.
Refractory materials are provided in the form of bricks, mortar and
castable refractory mainly in access doors, roof tube penetrations,
finned tubes and burner panels. Mineral fiber materials are used in the
form of mattress, board or blanket in boiler furnace, steam cooled walls,
air and flue gas ducts and expansion joints. Calcium silicate and
insulating plastics are also used in certain locations in the boiler.
For more details refer to the vendor manual OM-01.08.

2.4.9 Safety Valves


Refer to the Figures 2-4, 2-5 & 2-40.
To relieve the excess pressure and to protect the boiler pressure parts
in the event of over pressurization, safety valves are provided.
There are six spring loaded safety valves at the common steam outlet
header of the water separator and the water separator drain tank.
There is also a spring loaded safety valve in the main steam pipe 3B
connected to the outlet from the 3RY superheater outlet header.
The reheat steam system is provided with eight spring loaded safety
valves, six on the cold reheat lines and two on the hot reheat header, to
relieve the excessive pressure and protect boiler pressure parts in the
reheat steam flow path during accidental over pressurization.
Each spring loaded safety valve opens at a fixed set pressure and
closes at a lower reset pressure automatically after relieving the excess
steam to atmosphere. The valve has provisions to adjust the lifting and
reseating pressures.
The boiler is also provided with three solenoid operated pressure relief
valve at the outlet from the 3RY superheater header.

Boiler
Mitsubishi

2-26

Chapter 2

General

The solenoid operated safety valve opens at a fixed set pressure and
closes at lower reset pressure automatically after relieving the
excessive steam to the atmosphere.
The solenoid valve has provisions to adjust the lifting and reseating
pressures, in addition to automatic operation.
The solenoid operated relief valve can be manually opened and closed
at any operating pressure. For further details of the boiler safety valves
refer to the respective vendor operation and maintenance manual
(OM-15.01).

Boiler
Mitsubishi

2-27

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-6
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE)

2-28

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-7
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE A-A OF FIGURE 2-6)

2-29

Chapter 2

General

B O IL E R F R O N T

O P E N IN G F O R
L IF T IN G P L A T F O R M

FRONT W ALL
OUTLET HDR.

+ 6 47 5 0

+ 6 46 00

SECONDARY PASS REAR WALL TUBE (219-O38.1)

ROOF TUBE (REAR) (220-O57.1)

1RY SH TUBE (110-O45.0)

ECO. HANGER TUBE (110-O50.8)

SECONDARY PASS DIVISION WALL (147-O45.0)

1RY RH TUBE (110-O57.1)

2 R Y P A S S D IV IS IO N
W ALL OUTLET HDR.

2RY PASS FRONT


W ALL OUTLET HDR.

REAR W ALL HANG ER


O U T LE T H D R .

+ 6 45 0 0

ECO. HANGER TUBE (110-O50.8)

SECONDARY PASS FRONT WALL


(110-O45.0)

2RY RH TUBE (108-O57.1)

REAR WALL HANGER TUBE


(109-O48.6)

2RY SH TUBE
(12-O45.0)

ROOF TUBE (FRONT)


(440-O45.0)
+ 6 42 00

3RY SH TUBE (54-O45.0)

SPACER TUBE
O 4 5.0

FRONT WALL TUBE (660-O28.6)


R O O F IN LE T H D R .

S E C O N D A R Y P A S S S ID E W A LL T U B E
(2 -105 -O 38 .1 )

P A S S A G E S ID E W A L L T U B E
(2 -67-O 3 8 .1)

S ID E W A L L T U B E ( 2-32 2 -O 28 .6)
C A B L E O P E N IN G

2RY PASS REAR


W ALL OUTLET HDR.
+ 6 4 50 0

+ 6 4 75 0
ROO F OUTLET HDR.

+ 6 32 00
R O O F TU B E

CL O F F R O N T W A LL T U B E

2R Y SH TU BE

3R Y SH TU BE

2RY RH TUBE
C
L OF REAR W ALL
HANGER TUBE

1RY RH TUBE
C
L O F 2R Y P A S S F R O N T
W ALL TU B E

1R Y SH TU B E
C
L O F 2 R Y P A S S D IV IS IO N
W A LL T U B E

C
L O F 2R Y P A S S R E A R
W ALL TUBE

SPACER TUBE
O 4 5.0

MM-M01.01

Rev.004

O P E N IN G F O R
L IF T IN G P L A T F O R M
C A B L E O P E N IN G

+ 6 47 50

M P T D -3 -00 87

FIGURE 2-8
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE B-B OF FIGURE 2-6)

2-30

Chapter 2

General

REAR WALL HANGER


OUTLET PIPES
HANGER ROD
+67100
CL OF BOILER

2RY PASS FRONT


WALL OUTLET HDR.
1-O219.1

C
L OF BOILER
HANGER ROD

+64200

+63200
ROOF TUBE

+64200

REAR WALL HANGER


OUTLET PIPES
ROOF TUBE (REAR)
.
(220-O57.1)

1RY SH TUBE
. (110-O45.0)

1RY RH TUBE (110-O63.5)


.

g-g

2RY PASS REAR. WALL TUBE (219-O38.1)

SECONDARY PASS SIDE WALL


TUBE (2x105-O38.1)
.

ECO. HANGER TUBE


.
(110-O50.8)

2RY PASS FRONT


WALL
.
(110-O45.0)

.
REAR WALL HANGER
TUBE
(109-O48.6)

2RY SH. TUBE


(12-O45.0)

HANGER ROD

PASSAGE SIDE
WALL TUBE
.
(2x67-O38.1)

3RY SH TUBE .(54-O45.0)

FRONT WALL TUBE


.
(660-O28.6)

SIDE WALL TUBE


(2x322-O28.6)
.

2RY PASS DIVISION


. WALL (147-O45.0)
ECO. HANGER TUBE
(110-O50.8)
.

2RY RH TUBE. (108-O57.1)

+62690

F
+64200

FRONT WALL
OUTLET HDR.
1-O323.8

B-B

BOILER FRONT

+65900

HANGER ROD

A-A

HANGER ROD

+63200
ROOF TUBE

2RY PASS REAR


WALL OUTLET HDR.
1-O323.8
+64750

+63200
ROOF TUBE

2RY PASS REAR WALL . TUBE (2219-O38.1)

+64200

BOILER FRONT
+64750

+64750

+64200

REAR W ALL
HANGER OUTLET HDR.
1-O219.1
+64600

+65900

REAR WALL HANGER


OUTLET HDR.

FRONT WALL OUTLET HDR.


ROOF INLET HDR.
+64200

+64600

+64500

2RY PASS FRONT


WALL OUTLET HDR.
+64750

2RY PASS REAR


WALL OUTLET HDR.
+64750

2RY PASS DIVISION


WALL OUTLET HDR.
+64500

MM-M01.01

Rev.004

COLD SIDE

b-b

COLD SIDE

c-c

COLD SIDE

d-d

COLD SIDE

COLD SIDE

e-e

+64500

+62630

ROOF OUTLET HDR.

f-f

FIGURE 2-9
Boiler
Mitsubishi

C-C

+64200

+63200
ROOF TUBE

M PTD-3-0088

D-D

j
C
L OF BOILER
2RY PASS
DIVISION WALL OUTLET HDR.
1-O219.1
BOILER FRONT

F-F

+63200
ROOF
TUBE

BOILER FRONT

+63200

+64500

BOILER FRONT

C
L OF BOILER

C
L OF BOILER

PRESSURE PARTS ARRANGEMENT (UPPER SIDE C-C OF FIGURE 2-6 )

2-31

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-10
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE D1-D1, D2-D2 OF FIGURE 2-6)

2-32

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-11
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE E-E OF FIGURE 2-6)

2-33

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-12
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE F-F OF FIGURE 2-6)

2-34

Partitioning
plate

Drain Nozzle
Eoc. Inlet HDR.
1-O610.0

DETAIL OF "A"
2ry Pass Front
Wall Inlet HDR.
1-O219.1

Eco. Inlet HDR.


1-O610.0

+38865

Partitioning
plate

Eco. Inlet HDR.


1-O610.0

Sleeve

2ry Pass Division


Wall Inlet HDR.
1-O219.1

2ry Pass Division


Wall Inlet HDR.
1-O219.1

Eco. Inlet HDR.


1-O610.0

DETAIL OF "B"

+37565

a
CL OF BOILER

2ry Pass
Supply Pipe
O114.3

DETAIL OF "D"

Partitioning
plate

2ry Pass Division


Wall Inlet HDR.
1-O219.1

2ry Pass
Supply Pipe
O168.3

a-a

b-b

2ry Pass
Supply Pipe
O168.3
+37565

+38015

2ry Pass Rear


Wall Inlet HDR.
1-O219.1

General

+38015

+38865

Chapter 2

DETAIL OF "E"

2ry Pass
Supply Pipe
O168.3

+38865

Drain Nozzle

2ry Pass Front


Wall Inlet HDR.
1-O219.1

2ry Pass Rear Wall


Tube (219-O38.1)
.

2ry Pass Inlet Pipe


2-O660.0

DETAIL OF "C"

2ry Pass Rear


Wall Inlet HDR
1-O219.1

DRAIN NOZZLE
"A"

2ry Pass Inlet


Manifold Air Vent Pipe
(25A)

"D"
Eco. Inlet Pipe
O610.0

MM-M01.01

"E"

"B"
2ry Pass Division
Wall Tube (294-O38.1)
.

BOILER FRONT

Rev.004

2ry Pass Side Wall .Tube (105-O38.1)

2ry Pass Inlet Manifold


2-O1230.0

"C"

Eco. Inlet HDR.


1-O610.0

2ry Pass Division


Wall Inlet HDR
1-O219.1

2ry Pass Side


Wall Inlet HDR
2-O219.1

Economizer
(194-O45.0)
.

CL OF BOILER

2ry Pass
Supply Pipe
38-O168.3

DRAIN NOZZLE

2ry Pass Front


Wall Inlet HDR
1-O219.1

2ry Pass
Supply Pipe
76-O114.3

2ry Pass Front Wall


Tube (220-O38.1)
.

MPTD-3-0092

FIGURE 2-13
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT (UPPER SIDE G-G OF FIGURE 2-6)

2-35

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-14
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT LOWER SIDE

2-36

Chapter 2
BS FL+45500

A
E

E
D
C
L BOILER

"d"
Front Wall Intermediate
Manifold Outlet Pipe
2x34-O114.3

FL+45120
FL+44971.8

Rear Wall
2nd Intermediate HDR
1-O323.8
F

F
D

FL+44310

BS FL+44000

BOILER FRONT

Front Wall
Intermediate Manifold
2-O762.0

S1

FL+43750

D-D

Rear Wall
Intermediate Manifold
2-O762.0
CL BOILER

Rear Wall Intermediate


Manifold Outlet Pipe
34-O114.3
FL+44971.8

H
CL FURNACE

H
BS FL+42650
FL+42380

a-a

Rear Wall Tube


660-O28.6
Furnace Intermediate
HDR (Rear Wall)
1-O323.8

BS FL+41750
Front Wall
Intermediate Manifold
2-O762.0

BOILER FRONT

BS FL+45500

DETAIL "C"

C
L BOILER

7FL +46300
Side Wall
2nd Intermediate HDR
2-O323.8
Side Wall
Intermediate Manifold
2-O762.0
Side Wall Intermediate
Manifold Outlet Pipe
17-O114.3

Front Wall
2nd Intermediate HDR
1-O323.8

General

KEY PLAN

DETAIL "d"

FL+44310

a
CL BOILER
BS FL+42650

FL+42380

FL+42380

BS FL+41750
Furnace Intermediate
HDR (Side Wall)
2-O323.8

Furnace Intermediate
HDR (Front Wall)
1-O323.8
Front Wall Tube 660-O28.6
.

Side Wall Tube


2x322-O28.6

Rear Wall
2nd Intermediate HDR
1-O323.8

Front Wall Intermediate


Manifold Outlet Pipe
2x34-O114.3

A-A

S5

S5
S5
S5
S5
S5

S3
S3
S3
S3
S3
S3
S3

S5
S5
S5
S5
S5
S5
S5
S5
S5

S3
S3
S3

e
S2
S2
S2
S2
S2
S2
S2

Rear Wall
Intermediate Manifold
2-O762.0

Rear Wall
Rear Wall
Manifold
2-O762.0

Side Wall Intermediate


Manifold Outlet Pipe
2x16-O114.3

Rear Wall Intermediate


Manifold Outlet Pipe
34-O114.3
Furnace Intermediate
HDR (Rear Wall)
2-O323.8

BOILER FRONT

b-b

7FL +46300
Front Wall
2nd Intermediate HDR
1-O323.8
Front Wall
Intermediate Manifold
2-O762.0
Front Wall Intermediate
Manifold Outlet Pipe
34-O114.3
FL+42380

Side Wall
Intermediate Manifold
2-O762.0

E-E

"C"
FL+46223.5

BS FL+45500
FL+44310

b
BS FL+42650

FL+42380
C
L FURNACE

Rev.004
MM-M01.01

Furnace Intermediate
HDR (Side Wall)
2-O323.8

G-G

H-H

S4

S4

S5

S5

S2
S3
S4
S5

S2
S3
S4
S5

FL+42380

BS FL+41750
Furnace Intermediate
HDR (Front Wall)
1-O323.8
Front Wall Tube
660-O28.6

F-F

Rear Wall
2nd Intermediate HDR
1-O323.8
Rear Wall
Intermediate Manifold
2-O762.0
Rear Wall Intermediate
Manifold Outlet Pipe
34-O114.3

Furnace Intermediate
HDR (Rear Wall)
1-O323.8
Side Wall Intermediate
Manifold Outlet Pipe
2x16-O114.3

Side Wall Tube. 2x322-O28.6

B-B

Rear Wall Tube


660-O28.6

FL+42380

FL+42380

Furnace Intermediate
HDR (Rear Wall)
2-O323.8

Furnace Intermediate
HDR (Rear Wall)
2-O323.8

e-e

f-f

MPTD-3-0094

FIGURE 2-15
Boiler
Mitsubishi

S4
S4
S4
S4
S4
S4
S4
S4
S4

S1
Rear Wall Intermediate
Manifold Outlet Pipe
34-O114.3

Side Wall
2nd Intermediate HDR
2-O323.8

S4
S4
S4
S4
S4

S1

Air Vent
Nozzle

CL FURNACE

Side Wall
Intermediate Manifold
2-O762.0

Rear Wall
2nd Intermediate HDR
1-O323.8

Rear Wall
2nd Intermediate HDR
1-O323.8

S2
S2
S2
S4

ARRANGEMENT OF INTERMEDIATE HEADERS

2-37

Chapter 2

General

Rifled Tube
MPTD-4-0095
MSD-4-0041

FIGURE 2-16
Boiler
Mitsubishi

SECTIONAL VIEW OF RIFLE TUBE

2-38

Chapter 2

General

BO ILE R FR ON T
FR ON T W ALL
O UTLET H DR .
1-O 323.8

R O OF IN LET H D R .
1-O 219.1

+64500

S1

S2

+63200
R OO F TU BE

S6

BS+61700

BS+60200

BS+60200

BS+58700

Left Side O nly

+61100

R O OF O U TLET HD R .
1-O 610.0

D D D D

+58900

BS+58700
+58100

BS+57200

BS+57200
BS+55700
+55100
BS+54200

S7

+53700

BS+52700

BS+51200

BS+51200

BS+49700

BS+49700

+54700

+55100
+54500
+53600
+53223.4
+52250

BS+48200

BS+48200

BS+46700

BS+46700
BS+45500
+45120

+47600

BS+45500

+45120

BS+40350

BS+35850

BS+3585

BS+34350

BS+29744

E
C
L OF C O AL BU RN ER S
C
L O F OIL BUR N ERS
C
L OF C O AL BU RN ER S

E
C
L OF C O AL BU RN ER S
C
L O F OIL BUR N ERS
C
L OF C O AL BU RN ER S

+30729

BS+40100
+39465
+38865

S3

S4

S5
SECO ND AR Y PASS SID E
W ALL IN LET H DR .
2-O2 19.1

SEC O N D AR Y PASS SID E W ALL

U
B

BS+28260

BS+26776

BS+26776

BS+24806

BS+24806

BS+23322

BS+23322

BS+21838

BS+21838

BS+19868

BS+19868

BS+18384

BS+18384

BS+16800

BS+16800
+16500

A
R
E
A

+15686

R igh t Side Only


an

BS+10400

+12200

+12000

br

Left Side Only

FUR NAC E INLET PIPE


2-O 457.0

+13507.7

em

BS+13000
+12200

+13507.7

SIDE W ALL IN LET H D R .


1-O 219.1

BS+10400

BS+14600

C
L OF FURNACE

Membrane

C
L OF BO ILER

BS+13000

Membrane

BS+41400

BS+29744

BS+28260

BS+14600

Smooth Tube

Rev.004

+39315

S10

+7833.3

MM-M01.01

+42300

+42420

+20828

+16500
B.L+15686

+7133.3

+7133.3

S1-S1
FR O N T W ALL

FRO N T W ALL INLET H DR .


1-O 219.1

S1

S2

SID E W ALL

FIGURE 2-17
Boiler
Mitsubishi

BS+44800

+25791

M PTD -3-0096

BS+46350

BS+43200

BS+31714
RifleTube

C
L OF C O AL BU RN ER S
C
L O F OIL BUR N ERS
C
L OF C O AL BU RN ER S

S10

BS+31714

+21515
+20828

+34950
BS+34350
+33600
BS+33385

Smooth Tube

RifleTube

BS+33385

+47050

I
F

+33600

+26453
+25791
+25129

BS+48200

+38150
BS+37350

BS+50000

+47300

BS+37350

+50450

+42580

+42400

S9

S8
BS+53600
PR IM AR Y SH
IN LET H D R.
2-O 457.0
BS+51800

+50050

+42840

BS+38850

BS+38850

CL OF A.A

S9

CL OF A.A

T.V

BS+41750
+41150
BS+40350

BS+41750
+41150

S11
S11

PASSAG E SID E
+50650
W ALL IN TLET H D R .
2-O 219.1
C ABLE O PEN IN G
+47300
+47000
PR IM AR Y R H
IN LET H D R.
2-O 559.0

BS+42650

BS+42650

47100

+54400

+50800

+50500
O PEN IN G FOR
LIFTIN G PLATFO RM
+47600

+54700

S7

Membrane

S8

Smooth Tube

+56300

BS+52700

+31391
+30729
+30067

+64750

S6

Both Side

BS+54200

+34950

S5

+64500

+62630
+60850

+54900

+37733

S4
+64750

+63200
R OO F TU BE

BS+61700

BS+55700

+39061

SECO N D ARY PASS


SID E W ALL O UTLET H D R .
2-O2 19.1

S3

+64600

+64200

Hanger Tube
(Except For Bend Tube)
Smooth Tube

PASSAG E SID E
W ALL O U TLET H D R.
2-O 219.1

SID E W ALL
O U TLET H D R.
2-O 323.8

RIFLE TUBE LOCATION IN FURNACE WALLS

2-39

Chapter 2

General

SPACER SPECIFICATION
Material

Thickness
(t)

3ry Superheater (Front)

65

SA240-310S

3ry Superheater (Rear)

65

SA240-310S

2ry Reheater (Front)

65

SA240-310S

2ry Reheater (Rear)

65

SA240-310S

Pipe Position

1
2
"E"
"E"

Height (H)

Tube No.

1ry SH Outlet HDR


2-O431.8

7
ROUND TO EDGE

PROTECTOR

2ry SH Outlet HDR


2-O355.6

ROUND TO EDGE
END TUBE OF SH/RH BANK

SPACER TUBE

+66200
+65900

+65300
+64750

+54038.8

+65700

+54900

"B" O45.0 7 "B"

BS+54200

"B"

2ry Pass
Rear Wall Tube
219-O38.1

(T)

"B"

3ry SH Tube
ST=2136
STN=54
+56485
O45.0
O45.0
+56050
1

+55220
+54220

+54100

+56300 +56485
4 O45.0
3 O45.0
+55485
+55485
"B" +55100
+55100
2 O45.0
Support from
Buckstay (+55700)
+53600
+53400
+52400

+50863.3
+50400

Protector
t4

Protector
t4
a

+54900
b

DETAIL "G"

DETAIL "F"

Plate(t5)

Protector
t6

Protector
t6

Support(t5)

Protector
t4

Protector
t6

+61700

1ry RH Tube
ST=133.5
STN=220
O57.1

+50800

clearance
(O54.88)

+56000

+62630
2ry Pass Wall. Tube (Side)
2x105-O38.1

+58100

Girdling
Tube Support

O45.0

DETAIL "D"
DETAIL "E"

COLD
SIDE

Passage Side
Wall Tube
.
2x67-O38.1
+61700
+61100
7 O45.02ry RH Tube
ST=267
STN=108
+59800
O57.1
+59500
+59500
+59800
+58900

2ry SH Tube
ST=2136
STN=12
O45.0
BS+55700 "A"

O28.6

+56485
+56050
+55220

Girdling Tube
24-O45.0

DETAIL "B"

Side Wall. Tube


2x322-O28.6
"C"

Sleeve
O42.0xt5.0

SPACER TUBE
(O45.0)

+54161.2

+64500

Roof Tube (Rear)


220-O57.1

clearance
(O54.88)

2ry Pass Rear


Wall Outlet HDR
1-O457.0
Roof Outlet HDR
2-O610.0

1ry SH Outlet HDR


2-O482.6

Economizer
Outlet HDR
1-O457.0

2ry Pass Division


Wall Outlet HDR
1-O219.1

2nd SH Tube O45.0


(3rd SH Tube O45.0)

+63600

Roof Tube (Front)


440-O45.0
O45.0 7

Rev.004

1ry SH
Inlet Pipe
2-O482.6

COLD
SIDE

+66600
+65800

+64750

+63200

MM-M01.01

1ry RH Outlet HDR


2-O711.0

2ry RH
Outlet HDR
2-O864.0

+66300

2ry Pass Front


Wall Outlet HDR
1-O219.1

2ry SH Inlet HDR


4-O323.8
+65800

2ry RH Inlet HDR


2-O660.0

Front Wall Outlet HDR


2-O323.8

Rear Wall Hanger


Outlet HDR
1-O219.1

3ry SH Inlet HDR


2-O431.8

Roof Inlet HDR


1-O219.1

BOILER FRONT

3ry SH Outlet HDR


2-O482.6

DETAIL "I"

1ry SH Tube
ST=133.5
Support from
Buckstay (51800) STN=220
O45.0
+51500
+50650

+49700

+54100

+54100
O45.0

BS+51800

DETAIL "C"
+50450
+50050

Sleeve
O42.0xt5.0

Girdling Tube
(Y-Piece)
O54.0

O45.0

Girdling Tube
O54.0

O45.0

+53900
+54100

a-a

b-b
DETAIL "A"

Support from Rear Wall


Upper Support Beam

MPTD-3-0097

Boiler
Mitsubishi

1st SH Inlet HDR


2-O431.8

FIGURE 2-18

ARRANGEMENT OF SPACER TUBE & GIRDLING TUBE

2-40

Chapter 2

General

Silencer

RFL +73632

Air Vent Nozzle


Water Separator Equalizer Pipe
1-O323.8

Pressure Gauge Nozzle


BOILER FRONT

Water Separator
Inlet Pipe
4-O406.4

FL+69400

FL+69850

FL+67750
FL+66600

1st SH Inlet Pipe


2-O482.6

FL+63200

Roof Outlet HDR


2-O610.0

FL+61100

FL+66700

FL+64750 FL+64900
FL+64050
FL+64650
FL+62630

2ry Pass
Rear Wall FL+64100
Outlet HDR
1-O355.0
FL+62800

FL+65300
FL+64550
FL+63750
PIT

Water Separator
2-O760id
Water Separator Drain Tank
Steam Vent Pipe
1-O219.1
Level Transmitter Pipe Nozzle

FL+61450
FL+60800

Air Vent Nozzle

9FL +60400

Secondary Pass Bypass Pipe


2-O457.0

FL+58900

FL+58100

Water Separator
Outlet Pipe
2-O610.0
2ry Pass Bypass Pipe
4-O323.8

FL+69450
FL+68800
FL+68000

FL+68750

10FL +68600

(T)

FL+56700

FL+56300

PIT

TE

FL+55100
FL+54600

FL+55100

Support from 9FL

FL+54700

8FL +53600

Water Separator Drain Tank


1-O760id

FL+54200
FL+27800
FL+53000

FL+52900

RH Safety Valve
Test Nozzle
(Left Side Only)

FL+50800
FL+50050

FL+49700

Water Separator Drain Tank


Inlet Pipe
2-O559.0

FL+50450

FL+26346

1st SH Inlet HDR


2-O431.8
FL+47300

FL+47300

FL+47300

Level Transmtter Pipe Nozzle

7FL +46300

FL+45350
FL+45350
FL+43600
FL+42420
FL+42300

2ry Pass Inlet Pipe


2-O660.0

2ry Pass Inlet Manifold


2-O1174

6FL +40300

3FL +24200

Boiler Circulation Pump


Inlet Pipe
1-O508.0

FL+39465

FL+39315

FL+38865

TE
FL+38000
FL+37700
FL+37400

FL+37565
5FL +36500

DETAIL "A"

FL+35865
FL+34800
WDS

Drain Pipe Nozzle


Furnace Inlet Pipe
2-O457.0

FWP

FL+29848
4FL +29000

"A"
FL+28500
FL+27800

FL+27700

BCP. Warming Pipe Nozzle


(Left Side Only)
FL+25200

FL+25700

FL+26800
FL+26346
FL+25296

FL+24840

3FL +24200

Boiler Circulation
Pump Outlet Pipe
1-O406.4

ORIFICE
Flow Transmitter
Nozzle

FL+19600

Strainer
Insp.Hole

Chemical Cleaning
Nozzle

Insp.Hole

FL+18500

FL+17800

FL+17500
FL+16800
FL+16100
FL+14950
FL+13650
FL+12750

FL+12250

FL+12200

2FL +11000

Support from Furnace


Bottom Buckstay

Drain Pipe Nozzle

Rev.004

FL+7833.3

Outlet
Boiler Circulation Pump
Valve
Outlet Flow Control Valve
Drain Pipe Nozzle
Minmum Flow Pipe Nozzle

PIT

Boiler Circulation Pump

BCP. Warming Pipe Nozzle

Furnace Inlet Manifold


2-O813.0

MM-M01.01

CL FORCED DRAFT FANS

MPTD-3-0098

FL+- 0

FIGURE 2-19
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT AROUND BOILER (1/3)


2-41

Chapter 2

General

BOILER FRONT

Boiler Circulation Pump


Outlet Flow Control Valve

3FL +24200

+11000
BCP.Floor
Outlet Valve

Drain Pipe Nozzle


HPFW

Boiler Circulation Pump


Outlet Pipe
1-O406.4

Flow Transmitter
Nozzle

Minmum Flow Pipe Nozzle


Insp.Hole
PIT

Boiler Circulation Pump


Inlet Pipe
1-O508.0

Boiler Circulation Pump

ORIFICE
Drain Pipe Nozzle

FL+16800

2FL +11000

PIT

BCP Warming Pipe Nozzle

RH Safety Valve
Test Nozzle
(Left Side Only)
5FL

Chemical Cleaning
Nozzle

Air Vent Nozzle

BCP. Warming Pipe Nozzle


(Left Side Only)

Furnace Inlet Pipe


2-O457.0

9FL +60400

2RY PASS BYPASS VALVE

7FL +46300

Support from Furnace


Bottom Buckstay
+60800
W S.Floor

Support from 6FL

Drain Pipe
Nozzle

Air Vent Nozzle


Water Separator
Equalizer Pipe
1-O323.8
Pressure Gauge
Nozzle

Furnace Inlet Manifold


2-O813.0

PIT

Water Separator Drain Tank


1-O760id
+60400
W SDT.Floor

CL FURNACE

Support from Furnace


Bottom Buckstay

Chemical Cleaning
Nozzle

TE

Level Transmitter Pipe Nozzle


Insp.Nipple

C
L BOILER

Support from Furnace


Bottom Buckstay

+46300
W SDT.Floor

Silencer

WSD

2ry Pass Inlet Pipe


2-O660.0
2ry Pass
Bypass Pipe
4-O323.8
Water Separator
Inlet Pipe
4-O406.4
2ry Pass Rear Wall
Outlet HDR
1-O355.6
Economizer Inlet HDR
2-O457.0
Roof Outlet HDR
Furnace Inlet Pipe
2-O610.0
2-O457.0
Air Vent Nozzle

Level Transmtter
Pipe Nozzle

Water Separator Drain Tank


Steam Vent Pipe
1-O219.1
Water Separator Drain Tank Inlet Pipe
2-O559.0
Air Vent Nozzle
2ry Pass Inlet Manifold
+60800
2-O1174
W S.Floor

Water Separator
2-O760id
Water Separator Outlet Pipe
2-O610.0

Insp.Nipple

CL BOILER

2ry Pass Inlet Pipe


2-O660.0

Boiler Circulation Pump


Inlet Pipe
1-O508.0
TE

Drain Pipe
Nozzle

Water Separator Drain


Tank Inlet Pipe
2-O559.0

1st SH Inlet HDR


2-O431.8

Secondary Pass Bypass Pipe


2-O457.0
1st SH Inlet Pipe
2-O482.6
1st SH Inlet Pipe
2-O482.6

MM-M01.01

Rev.004

TE PIT

+46300

MPTD-3-0099

FIGURE 2-20
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT AROUND BOILER (2/3)

2-42

Chapter 2

General

S ile ncer
W ater S eparator
E qu alizer P ipe
1 -O 32 3.8 A ir V ent N ozzle

P ressure G auge N oz zle


RFL+73632

W ater S epara tor D rain Tank


S team V en t Pipe
1-O 219.1
A ir V ent N ozzle

W ater S epara tor


O utle t P ipe
2-O 61 0.0
W ater S eparator
2-O 7 60id

FL+69 450

W ater S eparator
Inlet P ipe
4-O 40 6.4

FL+68800

10F L +68600

FL+68000

FL+67750

2R Y P A S S B Y P A S S V A LV E

2ry P as s B ypass P ipe


4-O 32 3.8
A ir V ent N ozzle
2ry P as s B ypass P ipe
2-O 45 7.0

FL+66 600

A ir V ent N ozzle
FL+64750
FL+64050

FL+64550

FL+65300

FL+64650

FL+64100
FL+63750

P IT

FL+62 800

FL+62630

FL+6 1450
W ater Lev el
G auge N oz zle

2ry P ass R ear W all


O utlet H D R
1-O 355.6

9FL+60400

R oo f O utlet H D R
2-O 610.0

FL +60800

FL+56700

P IT

S up port from 6FL

FL+55100
FL+54600

FL+54 200

TE

8FL +53600

FL+53000

FL+52900

R H S afety V alve Tes t No zzle


(Left S ide O nly)

P IT

W ater S eparator
D rain Tank
1-O 7 60id
TE

TE

TE
W ater S eparator D rain Tank
Inlet P ipe
2-O 55 9.0

1st S H Inlet H D R
2-O 43 1.8

FL+50050

1st S H Inlet P ipe


2-O 482.6

FL+47 300

7FL+46300
FL+45350

2ry P ass Inlet Pipe


FL+43500
2 -O 66 0.0
B o iler C irculation P um p
Inlet P ipe
1-O 50 8.0

Level Tra nsm tter


P ipe N o zz le
6FL +40300

Furnac e Inlet P ipe


2 -O 45 7.0

FL+38865
FL+38000
FL+37700
FL+37400

5FL+36500

TE

2 ry P ass In let M anifold


2-O 11 74

FL+35865

D rain P ip e N oz zle

FL+34800
W DS

D rain P ip e N ozzle

FW P

FL+29848
4FL +29000

FL+28750

FL+28500

FL+25700

FL+25296
FL+24840
3FL+24200

FL+26800
FL+26 346

FL+25200

B C P . W arm ing P ipe N oz zle


(Le ft S ide O nly)

Insp.H ole
S trainer
Insp.H ole

FL+27800

FL+27700

B oiler C irculation P um p
O utle t P ipe
1-O 406.4

Flow Transm itter


N oz zle
FL+18500
FL+17 800

FL+17500

FL+19 600

FL+19600

C hem ica l Cleaning


N oz zle

C h em ical C leaning
N ozzle

FL+16800
FL+16100

M in m u m Flo w Pipe N ozzle


FL+12250
2FL+11000

S up port fro m Furnace


B ottom B uc ks tay

FL+15850

P IT

FL+14950

B oile r C irculation P um p
O utlet P ipe
1-O 406.4
B C P W arm ing
P ipe N o zz le

S up port from Furnace


B ottom B uckstay

FL+13650

FL+12750

FL+12200

D rain P ip e N ozzle
B oile r C irculation P um p

Fu rnac e In let M anifold


2-O 81 3.0

MM-M01.01

Rev.004

FL+7833.3

FL +- 0
M PT D -3-0100

FIGURE 2-21
Boiler
Mitsubishi

PRESSURE PARTS ARRANGEMENT AROUND BOILER (3/3)

2-43

Chapter 2

General

BO ILE R FR ON T
FR O NT W ALL
O UT LET HD R .
1-O 323.8

R OO F IN LET H DR .
1-O 219.1

+64500

S1

S2

Hanger Tube
(Except For Bend Tube)

S6

BS+61700

BS+60200

BS+60200

BS+58700

Left Side O nly

+61100

R O OF O U TLET H DR .
1-O 610.0

D D D D

+58900

BS+58700
+58100

BS+57200

BS+57200
BS+55700
+55100
BS+54200

S7

+53700

BS+52700

BS+51200

BS+51200

BS+49700

BS+49700

+54700

+55100
+54500
+53600
+53223.4
+52250

BS+48200

BS+48200

+47600
BS+46700

BS+46700
BS+45500
+45120

BS+45500

+45120

BS+42650

BS+40350

BS+37350

BS+37350

BS+35850

BS+3585

BS+50000
BS+48200

+47300
+47050

BS+46350
BS+44800
BS+43200

+42580
+42300

+39315

BS+33385

S 10

BS+31714

+42420
BS+41400
BS+40100
+39465
+38865

BS+29744

C
L OF C OAL BU RN ER S
C
L O F OIL BU R N ERS
C
L OF C OAL BU RN ER S

S4

S5
SEC O N DAR Y PAS S SID E
W ALL IN LET HD R.
2-O 219.1

S 10

SE C O N DA RY PA SS SIDE W ALL

BS+31714
RifleTube

C
L OF C OAL BU RN ER S
C
L O F OIL BU R N ERS
C
L OF C OAL BU RN ER S

S3

+34950
BS+34350
+33600
BS+33385

BS+34350

+30729
BS+29744

BS+28260

BS+28260

BS+26776

BS+26776

BS+24806

BS+24806

BS+23322

BS+23322

BS+21838

BS+21838

BS+19868

BS+19868

BS+18384

BS+18384

BS+16800

BS+16800
+16500

+25791

C
L OF C OAL BU RN ER S
C
L O F OIL BU R N ERS
C
L OF C OAL BU RN ER S

+20828

+16500
B.L+15686

BS+10400

BS+14600
BS+13000
+12200

+13507.7

Left Side Only


BS+10400

FU R N ACE IN LET PIPE


2-O 457.0

+13507.7
C
L OF FURNACE

C
L OF BOILER

Membrane

BS+13000

Smooth Tube

+15686
BS+14600

Membrane

+50450

+38150

+33600

+21515
+20828

S8
BS+53600
PR IM ARY SH
IN LET H DR .
2-O 457.0 BS+51800

+50050

+42840
+42400

BS+38850

+34950

+26453
+25791
+25129

T.V

S9

BS+38850

CL O F A.A

+31391
+30729
+30067

S9

CL O F A.A
+38150

BS+41750
+41150
BS+40350

+41150

S 11
S 11

PASSAG E SID E
+50650
W ALL IN TLET H DR .
2-O 219.1
C ABLE O PEN IN G
+47300
+47000
PR IM ARY R H
IN LET H DR .
2-O 559.0

BS+42650

BS+41750

+39061

47100

+54400

+50800

+50500
O PENIN G FO R
LIFTIN G PLATFOR M
+47600

+54700

S7

Membrane

S8

Smooth Tube

+56300

BS+52700

+64750

S6

Both Side

BS+54200

RifleTube

S5

+64500

+62630
+60850

+54900

Smooth Tube

S4
+64750

+63200
R OO F TUBE

BS+61700

BS+55700

+37733

SEC ON D AR Y PASS
SID E W A LL O U TLET H D R.
2-O 219.1

S3

+64600

+64200
+63200
R OO F TUBE

Smooth Tube

PASSAG E SID E
W ALL O U TLET HD R .
2-O 219.1

SID E W ALL
O UT LE T H D R .
2-O 323.8

+12000

+12200
R ight Side O nly
SIDE W ALL INLET HD R.
1-O 219.1

+7833.3

MM-M01.01

Rev.004

+7133.3

+7133.3

S1-S1
M P TD -3-01 01

FR O NT W A LL

FR O NT W ALL IN LET H DR .
1-O 219.1

S1

S2

SID E W ALL

FIGURE 2-22
Boiler
Mitsubishi

BASIC PLAN OF WATER WALL PANELS (1/3)

2-44

Chapter 2

General

B OILER FRONT

ROOF TUBE
.
(FRONT)

ROOF TUBE
.
(REAR)

ROOF TUBE (FRONT)

REAR W ALL OUTLET HDR.


1-O273.0

L CABLE OPENING

+53600

OPENING FOR
LIFTING PLATFORM

+52250

M em brane

M em brane

OPE NING FOR


LIFTING PLATFORM

C O F SIDE W ALL

CL OF 2RY P ASS SIDE W ALL

CL O F PA SSAG E SIDE W ALL

S11-S11
REA R W ALL
HANGER OUTLET HDR.
1-O219.1
+64600

+64200
+63200
RO OF TUBE

ROOF INLET HDR.


1-O219.1
REAR W ALL HANGER
.
TUBE

CL OF BOILER
ROOF OUTLET HDR.

+53700

REA R W ALL
HANGER OUTLET HDR.
1-O219.1

Smooth. Tube

+50500

OPENING FOR
LIFTING PLATFORM

S6-S6

CABLE OPENING
+45120

B OILER FRONT

BS+45500
+44971.8
+44310

FIN t9

FIN t9

BS+42650
BS+41750
+41150
BS+40350
C
L O F A.A
+38150

+39061

REAR W ALL
HANGER INLE T HDR.
2-O219.1

BS+38850

C
L O F A.A

BS+37350
BS+35850

REAR W ALL OUTLET HDR.


1-O273.0

+34950
BS+34350
+33600

B S+33385

Rifle Tube
.

CL O F BOILER
+31391
+30729
+30067

BS+31714

CL O F CO A L BURNERS
CL O F O IL BURNERS
CL O F CO A L BURNERS

+30729

BS+29744
BS+28260

+26453
+25791
+25129

+25791

CL O F CO A L BURNERS
CL O F O IL BURNERS
CL O F CO A L BURNERS

BS+26776

CL O F CO A L BURNERS
CL O F O IL BURNERS
CL O F CO A L BURNERS

B S+21838

BS+24806
BS+23322

+21515
+20828
+20191

+20828

S7-S7
B S+19868

REAR W ALL
HANGER TUBE

B S+18385

FRO NT W ALL TUBE


BS+16800

+16500
B.L+15686

PASSAGE SIDE
W ALL TUBE

2RY PASS
FRO NT W ALL TUBE

SIDE W ALL TUBE


CL O F SIDE W ALL

CL O F PASSAG E SIDE W ALL

2RY PASS
SIDE W ALL TUBE

2RY PASS
REAR W ALL TUBE

CL O F 2RY PASS S IDE W ALL

Smooth Tube
.

BS+14600

2RY PASS
DIVISION W ALL TUBE

Membrane

Membrane

BS+13000

CL O F BOILER

BS+10400

+7833.3

Rev.004

+7133.3

S2-S2

REAR W A LL INLET HDR.


1-O219.1
BO ILER FRONT

MM-M01.01

REAR W ALL
M PT D-3-0102

CL OF BOILER

S8-S8
FIGURE 2-23

Boiler
Mitsubishi

BASIC PLAN OF WATER WALL PANELS (2/3)

2-45

Chapter 2
SECON DARY PASS
FRO NT W ALL OUTLET HD R.
1-O219.1
+64750

SEC OND ARY PASS


D IV ISION WALL OUTLET HDR .
1-O219.1
+64500

+64200

General

+64200

+63200
RO OF TU BE

+63200
R OOF TU BE

CL OF BOILER

SEC ON DAR Y PASS FR ON T WALL TUBE


.

+54590
+54290

+54300

+54100

+54825

BS+51800
BS+50000
BS+48200
BS+46350
BS+44800
BS+43200
BS+41400
BS+40100
+38865

+38865

CL OF BO ILER

SEC OND ARY PASS


FRO NT W ALL IN LET H DR.
1-O 219.1

S3-S3

S4-S4

SECO NDARY PASS FRONT W ALL

SEC OND AR Y PASS


D IVISION W ALL IN LET HD R.
1-O 219.1

SECONDARY PASS DIVISIO N W ALL


SEC ON DARY PASS
REAR W ALL O UTLET HD R.
1-O 355.6

+64750
+64200
+63200
RO OF TU BE
BS+61700
BS+60200

BOILER FRON T

BOILER FR ONT

C
L OF BO ILER
BS+58700
BS+57200
BS+55700

BS+53600
BS+51800

CL OF BOILER

CL OF BO ILER

BS+50000
BS+48200
BS+46350
BS+44800
BS+43200
BS+41400
BS+40100
+38865

Rev.004

SECON D ARY PASS


REAR W ALL INLET HD R.
1-O 219.1

S5-S5

MM-M01.01

M PTD-3 -0103

SECONDARY PASS REAR W ALL

S9-S9

S10-S10

FIGURE 2-24
Boiler
Mitsubishi

BASIC PLAN OF WATER WALL PANELS (3/3)

2-46

General

Chapter 2

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14

DESCRIPTION
WATER WALL TUBES
BLOCK INSULATION (MINERAL FIBER BOARD)
INSULATION PINS
PIN CLIPS
OUTER CASING
LOOSE MINERAL FIBER
BUCKSTAY
TIE PLATE
HOLDER
CORNER LINK
CORNER LINK BRACKET
STOPPER BEAM
BOILER STRUCTURE COLUMN
STIFFENER

1
3
2

14
12

13

6
7

11

10

9
MPTD-4-0106

FIGURE 2-25

TYPICAL ARRANGEMENT OF FURNACE BUCKSTAY & BOILER


STOPPER

Boiler
Mitsubishi

2-47

Chapter 2

11267

14335

RFL +73400

BOILER FRONT

6022

7167.5

11570

8106.2

LONGITUDINAL
BUCKSTAY SIZE

7167.5

General

1 2VFR/L-1

CL OF FURNACE

1872

H294x200x8/12

2 2VFR/L-2
H294x200x8/12

EXP.=0

FL+68600
833

4000

8200

3 7VCR/L-1
2000

1302

3785

3785

H294x200x8/12

2000

4 7VCR/L-2
4585

6200

2717

H294x200x8/12
51

5 8VFR/L-1

H294x200x8/12

2545

2500

2500

1006.5
2545
13FR/L

5607
2545
1040.5

FL+24806
EXP. 259.22

1500

20VFR/L-2
H400x200x9/12

1500

C11

3000

H500x200x9/12

3000

H400x200x9/12

FL+26776
EXP. 247.60

3000
22FR/L

3000

3000

23FR/L

H800x250x14/22

24FR/L

H500x200x9/12

H500x200x9/12

26FR/L

H800x250x14/22
26VFR/L-2
H400x200x9/12

H400x200x9/12

C03
FL+18384
EXP. 297.11

10

13CR/L

H800x250x14/22

14CR/L

H800x250x14/22

FL+39315

1500
1500
1500
1500
1500
2100

FL+44800
EXP. 139.42

B06

A13

12CR/L-B
H500x200x9/19
FL+42420
FL+42580

FL+42300

FL+46350
EXP. 130.43

A09

FL+43200
EXP. 148.70
A12
FL+41400
EXP. 159.14

A04

FL+40100
EXP. 166.68

FL+39465

EXP.
45.8

EXP.
112.9
EXP.
173.8

D02
FL+35490

D07

750

C02

27FR/L

H500x200x9/12
C11

28FR/L

H500x200x9/12

29FR/L

H800x250x14/22

BOILER
FRONT

C02

5607

5607

1560.5

FL+14600
EXP. 319.44

4167.5

C12

D06 250
32FR/L

FL+13000
EXP. 328.88

H800x250x14/22
3000
3000

FL+12200

31FR/L
2750
C09

EXP.
313.03

H800x250x14/22
250
2750
D06

H800x250x14/22
D08

FL+12000

2600

EXP.
11.0

1220.8

FL+15686
EXP.
313.03

1302.3

EXP.
73.50

96.1
1302

FL+16800
EXP. 306.46

1964.7

1134.5 1865.5
33FR/L

FL+10400
EXP. 344.22

CL OF FURNACE FRONT WALL

C
L OF FURNACE REAR WALL

FL+15686

C08
30FR/L
4167.5

817.5
7167.5

CL OF FURNACE
EXP.0

C03

1560.5

14335
7167.5

C03

393

FL+19868
EXP. 288.36

A19

FL+47050
H800x250x14/22

817.5

307
FL+23322
EXP. 267.98

FL+48200
EXP. 119.70

FL+47300

7365.6
H800x250x14/22

FL+42400

B07

1560.5

2607

C11
25FR/L
2300

FL+50000
EXP. 109.26

H500x200x9/16

158.1
1455.5 1072.4

1167.5

FL+28260
EXP. 238.85

FL+21838
EXP. 276.74

2107.5
3110
S2-R/L
C05
18FR/L
H800x350x16/32
3865.5
3302
7167.5
FL+34950
C04
19FR/L
H800x350x16/36
3167.5
4000
4000
3167.5
H800x250x14/22
20FR/L
3317.5
3100
3100
3317.5
1917.5
C10
1917.5
21FR/L
H500x200x9/12

750

C03

H600x200x9/12
1950
1950

23VFR/L-2
H400x200x9/12

C01
D07

FL+38150
17FR/L
3110

H400x200x9/12
20VFR/L-1

FL+35850
EXP. 194.07

3467.5

H500x200x9/12

16FR/L

23VFR/L-1

2107.5

D02

18VFR/L-1 H400x200x9/12

D03

H600x200x9/12
3700

10CR/L

2350
11CR/L

12CR/L-A
H500x250x9/19

H800x250x14/22

FL+41150
15FR/L
3700

1854.4
B05

1560.5
5607
2545
1071
H800x250x14/22

14FR/L

3467.5

FL+47000

FL+46223.5

FL+42380
E02

9CR/L
H800x250x14/22

FL+47300

H800x250x14/22
2500
2500

8CR/L-B

A16

H800x250x14/22

FL+14613.6
31FF

FL+13000
33FF

FL+14613.6
31FB

FL+13158.1
32FF

FL+13158.1
32FB
33FB

FL+11779.2
34FF
FL+10400
36FF

2686

1560.5
1037

A02

FL+51800
EXP. 98.82

A17
FL+50450

H500x200x9/16

H294x200x8/12
FL+47600

FL+53600
EXP. 88.38

A17

1246.9

H800x300x16/28
FL+50650

8CR/L-A

B08
10FR/L-B

3000

7CR/L

H294x200x8/12
3807.75

FL+49700

FL+55700
EXP. 76.20

250

H294x200x8/12

FL+11779.2
34FB

FL+10476.9
35FF

FL+10476.9
35FB

FL+9098
37FF
37FB
FL+7833.3

2600

1283

12FR/L
2500

7323.1

FL+50800

FL+50863.3

9FR/L-C

H294x200x8/12

B02

FL+40350
EXP. 167.52

B09

6467.5

H800x250x14/22 7
FL+47100
T.V

11FR/L
250

SEE DWG.NO.

FL+29744
EXP. 230.09

9FR/L-B

6CR/L

1400

PH FL+47600 10FR/L-A

C 16300-0421

FL+34350
EXP. 202.92
FL+33385
EXP. 208.61

1400

H294x200x8/12

FL+45500
EXP. 137.13

FL+37350
EXP. 185.22

1800
1800
S1-R/L-5

H800x250x14/22
250
FL+54700
FL+54400
H800x350x16/36

FL+54700

10 11VCR/L-2

36FB
3266.7

9FR/L-A
H294x200x8/12

FL+46700
EXP. 130.05

FL+38850
EXP. 176.37

1800

A07

FL+48200
EXP. 121.20

FL+42650
EXP. 153.95
FL+41750
EXP. 159.26

1800

3450.5
H800x250x14/22

1400

1617
8FR/L

FL+51200
EXP. 103.50

1800

H800x350x16/36

18VFR/L-2 H400x200x9/12

B04

1800

7FR/L

5FR/L-C

FL+57200
EXP. 67.50

A06
250

FL+55100
FL+54500

FL+58700
EXP. 58.80

H294x200x8/12

50??

1200

383

H800x250x14/22

A21

552

A07

FL+49700
EXP. 112.35

H294x200x8/12
FL+56300
H294x200x8/12

S1-R/L-4

H800x350x16/36

H800x250x14/22

4FR/L-C

H400x200x12/22
9 11VCR/L-1

1800

6FR/L

FL+52700
EXP. 94.65

5FR/L-B

3FR/L-D
B04

FL+55100

A07
FL+54200
EXP. 85.80

4FR/L-B

FL+60200
EXP. 50.10

H800x250x14/22

H400x200x12/22
8 8VFR/L-4

1800

S1-R/L-3

H800x350x16/36

iT j 1

1VFR/L-2

A07
5FR/L-A

2FR/L-C

H294x200x8/12
FL+58900
3FR/L-C
3FR/L-B
H294x200x8/12
H294x200x8/12
FL+58100

FL+55700
EXP. 76.95

A06

1800

S1-R/L-2

FL+61700
EXP. 41.40

H800x250x14/22

1850

H800x350x16/36

2FR/L-B

1FR/L-C

1550

4FR/L-A

H400x200x9/12
1400
2370.5

1600

S1-R/L-1

1FR/L-B
2251.5

H294x200x8/12
7 8VFR/L-3

1800

1VFR/L-1

FL+57200
EXP. 68.10

1970
1484
1484

6100
H800x350x16/36

1970
1484
1484

H800x250x14/22

2933
3FR/L-A

1970
1484

2FR/L-A

A07

2200

1584

FL+61100

FL+63200
EXP. 32.70

1300

FL+58700
EXP. 59.25

FL+31714
EXP. 218.47

1600

H800x250x14/22
FL+60850

A06
FL+60200
EXP. 50.40

2717

H1000 3
~50 1
~9/36

1FR/L-A

FL+61700
EXP. 41.55

4585

6200

BH1200x300x25/50

833

26VFR/L-1

1671

965 1500

1500

1500

1500

1400 900

2850

1200

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

1500

6 8VFR/L-2
FL+63200
EXP. 32.70

FL+7133.3
2000

4000

4000

FL+7833.3

FURNACE BOTTOM TRUSS BUCKSTAY

FL+7133.3
FL +0
4000

7900

6534.5

11900

10400

G17300-0002
D-9

B
G17300-0003
D-9

10400

C
G17300-0004
F-3

8200

G17300-0004
F-7

RIGHT SIDE WALL


MPTD-3-0105-1

MM-M01.01

Rev.004

G A

3865.5
10400

FIGURE 2-26

Boiler
Mitsubishi

GENERAL ARRANGEMENT OF BUCKSTAY 1/3

2-48

Chapter 2
29414
RFL+73400

LONGITUDINAL
BUCKSTAY SIZE

29414

14707

RFL+73400

14707

14707

FL+69400

14707

FL+69400

11 18VFF-3

FL+68600
5700

5700

5700

H500x250x12/25

FL+68600

EXP.=0
457

5700

12 18VFF-4

EXP.=0

457

5700

H500x250x12/25

1000

13 20VFF-1

CL BOILER

H300x300x10/15
H800x250x14/25
15 20VFF-3

1500
A05

1850

4FF-B

F1-2

2667

3700
9FF-B

3700

3700

FL+47600

SEE DWG. NO.


16300-0401

6759
2545 2047
13FF-A

2074
833.5

2545

FL+42650
EXP. 153.95 FL+42380
FL+41750
EXP. 159.26

5000

2417

2417

5000

5000

BH1500x200x25/25

12FF-A

1600

690

5429
2545
2545
BH800x350x25/50

445
1646.5

1646.5

5429
2545

6759
2047 2545
13FF-B

2545

1807

H294x200x8/12

17FF-A

H294x200x8/12

18FF-A

BH1500x300x25/25

1800

1800

1600

1400

15FF-B
H294x200x8/12
16FF-B
H294x200x8/12
FL+37700

1800

17FF-B
H294x200x8/12

4050

F2
2000

900

1200

14FF-B

FL+41150
H294x200x8/12

15FF-C

H294x200x8/12

16FF-C

FL+38150
H294x200x8/12

17FF-C

18FF-B
5100

2350

1800

1807

FL+34950

13
21FF-A
H294x200x8/12

FL+29744
EXP. 230.09

22FF-A
H294x200x8/12
23FF-A

FL+24806
EXP. 259.22

25FF-A
H294x200x8/12

3600

3600

3850

16

2350

17

18

2057
C01

4157
20
21FF-E
H294x200x8/12

21FF-D
H294x200x8/12

21FF-C
H294x200x8/12

15

19FF-B
3100
20FF-B
3100

4500

D01

19

22FF-B
H294x200x8/12
H294x200x8/12

22FF-C
H294x200x8/12

24FF-B
H294x200x8/12

24FF-C
H294x200x8/12

24FF-D
H294x200x8/12

25FF-B
H294x200x8/12
H294x200x8/12

25FF-C
H294x200x8/12

25FF-D
H294x200x8/12

27FF-B
H294x200x8/12

27FF-C
H294x200x8/12

27FF-D
H294x200x8/12

28FF-B
H294x200x8/12

28FF-C
H294x200x8/12

28FF-D
H294x200x8/12

PH

FL+47600

22FF-E
H294x200x8/12

22FF-D
H294x200x8/12

23FF-B

23FF-C

24FF-E
H294x200x8/12

27 20VFB-4
H700x200x12/22
BH1800x300x25/50

12FB-B

H800x250x14/25
29 20VFB-2
833.5

2545

2047
2545
2545
BH800x350x25/50

2545
13FB-B

1646.5 1646.5

2545
13FB-A

2047
2545

2545

H800x250x14/25

833.5

2545

30 20VFB-1
H300x300x10/15

FL+42380

1878

14FB-B
15FB-C

16FB-C

H294x200x8/12

17FB-C

H294x200x8/12
6955

307

FL+35850
EXP. 194.07

1500

1800

557

FL+34350
EXP. 202.92
FL+33385
EXP. 208.61

C01

H294x200x8/12

1500
607
3750
21FB-E
H294x200x8/12

FL+29744
EXP. 230.09

22FB-E
H294x200x8/12

FL+28260
EXP. 238.85
FL+26776
EXP. 247.60

24FB-E
H294x200x8/12

FL+24806
EXP. 259.22

25FB-E
H294x200x8/12

16FB-B
H294x200x8/12

5429

17FB-B
H294x200x8/12

R2
1800

H1000x250x16/28
5200
BH1500x450x25/50
6750

19FB-B
5000
20FB-B

5429

900 900

3600

1800

1800

1800
5100

4000

15FB-A

H294x200x8/12

16FB-A

H294x200x8/12

17FB-A

H294x200x8/12

FL+38150

6955

26

1500
1800
FL+34950
19FB-A
5100
20FB-A
6350

27

28

E01

1878
307

18FB-A
1500
1800

1500
D02 C04
1500

557

4357

30

21FB-B
H294x200x8/12

21FB-C
H294x200x8/12

25

FL+41150

445

4900

21FB-D
H294x200x8/12

23FB-C

14FB-A

22

15FB-B

18FB-B

24

21

H294x200x8/12

BH1500x300x25/25
8400

23
FL+31714
EXP. 218.47

BH1300x250x25/50

D01

21FB-A
H294x200x8/12

29

22FB-D
H294x200x8/12
H294x200x8/12

22FB-C
H294x200x8/12

24FB-D
H294x200x8/12

24FB-C
H294x200x8/12

24FB-B
H294x200x8/12

25FB-D
H294x200x8/12
H294x200x8/12

25FB-C
H294x200x8/12

25FB-B
H294x200x8/12

27FB-D
H294x200x8/12

27FB-C
H294x200x8/12

27FB-B
H294x200x8/12

28FB-D
H294x200x8/12
29FB-B

28FB-C
H294x200x8/12

28FB-B
H294x200x8/12
29FB-A

22FB-A
H294x200x8/12

22FB-B
H294x200x8/12

23FB-B

23FB-A

24FB-A
H294x200x8/12

1484
1484

4583.5

3382

250

890 890

4984

28FB-A
H294x200x8/12
250

3382

4583.5

867.5

D05

C07
FL+16800
EXP. 306.46

30FB-B

3700

30FB-A
7400

3700

FL+16800
EXP. 306.46

3607

FL+13158.1
EXP. 327.95
FL+11779.2
EXP. 336.08
FL+10476.9
EXP. 343.76
FL+9098
EXP. 351.89

H200x200x8/12
H200x200x8/12
H200x200x8/12
BH200x200x12/25

31FB-B

31FB-A

32FB-B
34FB-B
35FB-B
37FB-B

R3

32FB-A
34FB-A
35FB-A
37FB-A

FL+14600
EXP. 319.44
FL+13000
EXP. 328.88

2600

H200x200x8/12

FL+14613.6
EXP. 319.36

1600

2200

3607

BH1000x300x25/36
7400

31VFB-1 BH400x300x12/25

FL+10400
EXP. 344.22

27FB-A
H294x200x8/12

31VFB-2 BH400x300x12/25

2200
FL+13000
EXP. 328.88

867.5

BH1500x450x25/50
250
4984

31VFB-3 BH400x300x12/25

37FF-B

26FB-A

31VFB-4 BH400x300x12/25

35FF-B

FL+14600
EXP. 319.44

250

FL+18384
EXP. 297.11

BH400x300x12/25

F3

34FF-B

28FB-E
H294x200x8/12

31VFB-5

BH200x200x12/25

867.5

31VFF-8 BH400x300x12/25

37FF-A

H200x200x8/12

3607
4583.5

31VFF-7 BH400x300x12/25

FL+9098
EXP. 351.89

35FF-A

32FF-B

31VFF-6 BH400x300x12/25

FL+12000

FL+10476.9
EXP. 343.76

H200x200x8/12

31VFF-5 BH400x300x12/25

34FF-A

H200x200x8/12

7400
3382

4984

FL+16800
EXP. 306.46

31FF-B
BH400x300x12/25

FL+11779.2
EXP. 336.08

3700
890 890

H200x200x8/12

31FF-A

32FF-A

3700
4984

31VFF-4

FL+13158.1
EXP. 327.95

30FF-B

31VFF-3 BH400x300x12/25

FL+14613.6
EXP. 319.36

31VFF-2 BH400x300x12/25

BH400x300x12/25

867.5

31VFF-1

1302.28
1455.48 2186.46
1378.88
1378.88

D04
BH1500x300x25/36
7400
3382

30FF-A
3607
4583.5

FL+19868
EXP. 288.36

31VFB-6 BH400x300x12/25

250

C06
FL+16800
EXP. 306.46

27FB-E
H294x200x8/12

25FB-A
H294x200x8/12

26FB-B

FL+20350

1584

250

29FF-B
250

1600

1584

BH1500x450x25/50
250

29FF-A

28FF-E
H294x200x8/12

2600

1484

FL+20350

FL+18384
EXP. 297.11

FL+21838
EXP. 276.74

31VFB-7 BH400x300x12/25

28FF-A
H294x200x8/12

27FF-E
H294x200x8/12

26FB-C

31VFB-8 BH400x300x12/25

FL+19868
EXP. 288.36

FL+23322
EXP. 267.98

1484

27FF-A
H294x200x8/12

26FF-C

1970

FL+21838
EXP. 276.74

25FF-E
H294x200x8/12

26FF-B

1302.28
1455.48 2186.46
1378.88
1378.88

1484

26FF-A

1970

1484

FL+23322
EXP. 267.98

FL+10400
EXP. 344.22

FL+7833.3
FL+7133.3

FL+7133.3

Rev.004

28 20VFB-3

12FB-A

FL+7833.3

FL +0
-

FL +0
18800

3B
MM-M01.01

H700x200x12/22

PH

1970

24FF-A
H294x200x8/12

3850

2700

1970

FL+26776
EXP. 247.60

H1000x250x16/28
3850

21FF-B
H294x200x8/12
14

FL+28260
EXP. 238.85

3600

H800x250x14/25

1970

FL+31714
EXP. 218.47

5100
BH1500x450x25/50
3100

26 20VFB-5

FL+37350
EXP. 185.22

1484

20FF-A
4157

FL+48200
EXP. 121.20

H800x250x14/25

FL+38850
EXP. 176.37

1484

19FF-A

2157

1970

1671

FL+34350
EXP. 202.92
FL+33385
EXP. 208.61

D02 C04

25 20VFB-6

FL+40350
EXP. 167.52

1500

16FF-A

12

FL+49700
EXP. 112.35

FL+42650
EXP. 153.95
FL+41750
EXP. 159.26

1500

H294x200x8/12

11

24 20VFB-7

SEE DWG.NO.

1500

FL+35850
EXP. 194.07

15FF-A

BH1300x250x25/50

H300x300x10/15

FL+51200
EXP. 103.50

C 16300-0411

965 1500

FL+37350
EXP. 185.22

14FF-A

H500x250x12/25
23 20VFB-8

FL+45500
EXP. 137.13

1671

18VFF-1 H500x250x12/25

FL+38850
EXP. 176.37

1484

1500

2074
833.5
2545

EXP.
86.8

FL+46700
EXP. 130.05

12FF-B

E01

FL+40350
EXP. 167.52

1484

B01

2850

5000

1600

FL+45500
EXP. 137.13

A01

11FF-B

1400 900

690

22 18VFB-3
EXP.
86.8

FL+52700
EXP. 94.65

1200 1500

A05

H300x300x10/15
21 18VFB-4
H500x250x12/25

1500

10FF-B

BH1500x200x25/25

11FF-A

FL+46700
EXP. 130.05

A05

BH1500x200x25/25

10FF-A
FL+47100
T.V

H800x250x14/25
20 20VFF-8

FL+54200
EXP. 85.80

1500

A05

940

H800x250x14/25
19 20VFF-7

FL+55700
EXP. 76.95

1500

2667

FL+57200
EXP. 68.10

1500

3700

18VFF-6 H500x250x12/25

1500

3700

18VFF-5 H500x250x12/25

1500
1500
1500

3700
9FF-A

8FF-B

BH1500x200x25/25

FL+48200
EXP. 121.20

1400 900

7FF-B

BH1500x200x25/25

8FF-A
940

1500

EXP.
86.8
A05

FL+49700
EXP. 112.35

1500

6FF-B

F1-5

BH1500x200x25/25

7FF-A

FL+51200
EXP. 103.50

1500

F1-4

BH1500x200x25/25

6FF-A
EXP.
86.8

FL+52700
EXP. 94.65

965 1500

5FF-B
A05

FL+54200
EXP. 85.80

F1-3

BH1500x200x25/25

5FF-A

18VFF-2 H500x250x12/25

1500

FL+55700
EXP. 76.95

H700x200x12/22
18 20VFF-6

FL+58700
EXP. 59.25

1500

3850

BH1500x200x25/25

3FF-B

H700x200x12/22
17 20VFF-5

FL+60200
EXP. 50.40

18VFB-1 H500x250x12/25

4FF-A

F1-1

BH1500x200x25/25

FL+61700
EXP. 41.55

18VFB-2 H500x250x12/25

FL+57200
EXP. 68.10

A05

C
L BOILER

3FF-A

2FF-B

18VFB-5 H500x250x12/25

FL+58700
EXP. 59.25

1FF-B

H800x250x14/25
16 20VFF-4

18VFB-6 H500x250x12/25

BH1500x200x25/25

1500

2FF-A

1500

1FF-A

FL+60200
EXP. 50.40

FL+63200
EXP. 32.70

1500

1500
1500
1500
1500
1500

FL+61700
EXP. 41.55

A05

1200 1500
2850

14 20VFF-2

FL+63200
EXP. 32.70
BH1500x200x25/25

General

MPTD-3-0105-2

18800

18800

5A

7A

7A

18800

5A

SECTION A-A

SECTION B-B

FURNACE FRONT WALL


G17300-0001
F-9

FURNACE REAR WALL


G17300-0001
D-9

FIGURE 2-27
Boiler
Mitsubishi

3B

GENERAL ARRANGEMENT OF BUCKSTAY 2/3


2-49

Chapter 2

General

29404.5
14702.25

14702.25

14702.25

FL+69400

14702.25

FL+69400

FL+68600

FL+68600
EXP.=0

EXP.=0
1897.25

2805

5000

5000

2500

2500

5000

FL+63200
EXP. 32.70

FL+63200
EXP. 32.70

FL+61700
EXP. 41.40

FL+61700
EXP. 41.40

FL+60200
EXP. 50.10

FL+60200
EXP. 50.10

FL+58700
EXP. 58.80

FL+58700
EXP. 58.80

BH1500x200x25/25

3CB-B

R1-1

3CB-A

FL+57200
EXP. 67.50

FL+57200
EXP. 67.50

BH1500x200x25/25

4CB-B

R1-2

4CB-A

FL+55700
EXP. 76.20

FL+55700
EXP. 76.20

BH1500x200x25/25

5CB-B

R1-3

5CB-A

FL+53600
EXP. 88.38

FL+53600
EXP. 88.38

BH1500200x25/25

6CB-B

R1-4

6CB-A

FL+51800
EXP. 98.82

BH1500x200x25/25

7CB-B

R1-5

7CB-A

FL+50000
EXP. 109.26

BH1500x200x25/25

8CB-B

8CB-A

FL+48200
EXP. 119.70

BH1500x200x25/25

9CB-B

9CB-A

FL+46350
EXP. 130.43

BH1500x200x25/25

10CB-B

10CB-A

FL+44800
EXP. 139.42

BH1500x200x25/25

11CB-B

11CB-A

FL+43200
EXP. 148.70

BH1500x200x25/25

12CB-B

12CB-A

FL+41400
EXP. 159.14

BH1500x200x25/25
5000

13CB-B
5000

1897.25

3430

BH1500x250x25/25
6250

1CB-B
3125

BH1500x200x25/25

2CB-B

1897.25

2805

1CB-A
3125

6250

1897.25

3430

A05

2CB-A

A05

A05

A20

EXP.
86.8

EXP.
86.8

FL+51800
EXP. 98.82

EXP.
86.8

EXP.
86.8

A15
FL+50000
EXP. 109.26

5000

5000

1102.2

3600

A15
FL+48200
EXP. 119.70

9CF-A

BH1400x200x25/25

9CF-B
3300

FL+46350
EXP. 130.43

10CF-A

FL+44800
EXP. 139.42

11CF-A

H1000x250x16/28

3300

3300

3300

750 752.2

10CF-B

A18

A18

A10

A08
11CF-B
H1000x250x16/28

3900

3900

3900

2100

902.2

A11
FL+43200
EXP. 148.70

12CF-A BH1000x350x25/50

FL+41400
EXP. 159.14

13CF-A

FL+40100
EXP. 166.68

14CF-A

12CF-B

A14
7600

13CF-B

BH250x300x9/25

13CF-E
A15

14CF-B

BH250x300x9/25

14CF-D

14CF-C

2147.25

FL+38865

2680

7252

3491

3491

Rev.004
MM-M01.01

18800

7252

3959.25

3959.25

7252

1647.25

A03

B03

3491

3491

18800

5A

7252

3959.25

FL+35240

18800

7A

7A

18800

5A

SECTION C-C

SECTION D-D

BACK PASS FRONT WALL


G17300-0001
C-9

BACK PASS REAR WALL


G17300-0001
B-9

FIGURE 2-28
Boiler
Mitsubishi

2930

14CB-A

FL+35240

MPTD-3-0105-3

13CB-A
5000

FL+38865

3959.25

3B

A15
5000

14CB-B
BH1500x200x25/25

FL+40100
EXP. 166.68

14CF-E

125

125

6200
13CF-D

13CF-C

3B

GENERAL ARRANGEMENT OF BUCKSTAY 3/3


2-50

Chapter 2

General

SUPPORT PLATE

LIFTING LUG

SHELL

STEAM
OUTLET

WATER
OUTLET

INSPECTION NOZZLE

BOILER FRONT

BOILER FRONT

SHELL
INSPECTION
NOZZLE

INSPECTION
NOZZLE
SHELL

SHELL

INSPECTION
NOZZLE

INSPECTION
NOZZLE

C-C

A-A

B-B

MPTD-4-0107

FIGURE 2-29
Boiler
Mitsubishi

SECTIONAL VIEW OF WATER SEPARATOR

2-51

Chapter 2

WATER INLET

Boiler
Mitsubishi

WATER INLET

FIGURE 2-30

General

SECTIONAL VIEW OF WATER SEPARATOR DRAIN TANK

2-52

Chapter 2
B
1880

2145

1872

EXP.=0

S17

FL+68600

2553.625

FL+67750

4.5

94.0

15.4

74.8

112.9

25.4

23.9

45.8

24.8

27.3

FL+68800

R8

S21
57.4

FL+58100
14335 FD

E9
E10

28.7

FL+58900
52.7

S14

14.6

S7

R3

8106

(T)
6022

11570

FL+56700
EXP.=0

68.0

FL+56300
42.3
58.8 FL+54700
FL+54400

S6

CL ADDITIONAL AIR
3382

4561

1691

5073

4FL +36500

102.5

11.3

FL+39315

FURNACE

FL+42420

FL+38015
88.6

FL+39465
99.0

FL+38865

180.2

51.2
31.2 FL+38150
CL ADDITIONAL AIR FL+37733

FL+38150

179.0

39.9

168.2

59.9

E5
45.8

175.1

CL ADDITIONAL AIR FL+39419

177.6

CL ADDITIONAL AIR

167.6

734

FL+48650

173.8

109.0

FL+42300

6.8

149.9

1.3

167.3

FL+41250

149.0

21.3

127.3

19.0
41.2

153.9

69.3 61.2

150.6

10.0

151.1

29.9 FL+41250

49.9

155.1

FL+42480
81.5
69.8

50.6

FL+42840
70.1 FL+42220
60.3
FL+42580
67.1

FL+35865

E4
FL+34950

194.0

1691

CL COAL BURNERS FL+26453


CL O IL BURNERS FL+25791
CL COAL BURNERS FL+25129

CL CO AL BURNERS
CL OIL BURNERS
CL CO AL BURNERS
3FL +24200

W9

W7

215.0

715

W1

244.1

CL COAL BURNERS FL+31391


CL O IL BURNERS FL+30729
CL COAL BURNERS FL+30067
715

CL CO AL BURNERS
OIL BURNERS
CL
CL CO AL BURNERS

11.0

218.9

73.5

248.0

3382

W8

W9

CL FURNACE

281.1

CL COAL BURNERS FL+21515


CL O IL BURNERS FL+20853
CL COAL BURNERS FL+20191

CL CO AL BURNERS
OIL BURNERS
CL
CL CO AL BURNERS

273.2

3382

277.1

3382

222.8

2870

FL+34950

251.9

86.8

135.7

E8

104.4

R1

E7

82.6

95.4

FL+50450
FL+50050

E6

D
94.2

FL+47300
121.1

FL+47300
FL+47050
FL+47000

83.5

94.0

106.1

101.3

R2
FL+47600

122.6

5FL +46300

103.1

S5

122.9

2403

107.6

107.0

BOILER
C
L

4539

FL+47400
T.V

119.3

4539

FL+47600

120.5

3226

14.2

119.3

40.7

18.1

27.9 FL+49700

59.8

1500

FL+50650
60.0 FL+50800

FL+50500

FL+50400

3138

87.7

1200
39.4
97.3

FL+52250

79.8

89.3

FL+53600

77.5

FL+54300

92.4

75.1

FL+55100

FL+47600

FL+64200

118.4

37.0

39.7

1.3 FL+61100

66.1

1500

S1

6FL +60400

29414 FW

ITEM
1750

79.5

11.3

15.4

13.2

15.0

20.5
26.5

S15

S13

22.3

1750

S4

60.3
11.0

2106

32.7

FL+63200

73.5
25.4

27.3

78.9

6.8

1000

S9

S10

34.4

7.5

9.8

28.7

41.2

3281.875

C
R4

R6

S19 S11

2681.875

400

59.5

FL+67400

2452.625 600

S2

24.2

S16 S12

1997

S3

W79
W78
W77
W76
W75
W74
W73
W72
W71
W70
W69
W68
W67
W66
W65
W64
W63
W62
W61
W60
W59
W58
W57
W56
W55
W54
W53
W52
W51
W50
W49
W48
W47
W46
W45
W44
W43
W42
W41
W40
W39
W38
W37
W36
W35
W34
W33
W32
W31
W30
W29
W28
W27
W26
W25
W24
W23
W22
W21
W20
W19
W18
W17
W16
W15
W14
W13
W12
W11
W10
W9
W8
W7
W6
W5
W4
W3
W3
W3
W2
W1

NAME
Secondary Pass Bypass Pipe
W ater Separator Drain Tank Outlet Pipe
W ater Separator Drain Tank
W ater Separator Drain Tank Inlet Pipe
W ater Separator
W ater Separator Inlet Pipe
Secondary Pass Rear Wall Outlet Header
Secondary Pass Division W all Outlet Pipe
Secondary Pass Side Wall Outlet Pipe
Secondary Pass Front Wall Outlet Pipe
Secondary Pass Division W all Outlet Header
Secondary Pass Side W all Outlet Header
Secondary Pass Front Wall Outlet Header
Secondary Pass Division W all (Screen)
Secondary Pass Division Wall
Secondary Pass Side W all
Secondary Pass Rear Wall
Secondary Pass Front Wall (Screen)
Secondary Pass Front Wall
Secondary Pass Division W all Inlet Header
Secondary Pass Side W all Inlet Header
Secondary Pass Rear Wall Inlet Header
Secondary Pass Front Wall Inlet Header
Secondary Pass Division W all Supply Pipe
Secondary Pass Side Wall Supply Pipe
Secondary Pass Rear Wall Supply Pipe
Secondary Pass Front Wall Supply Pipe
Secondary Pass Inlet Manifold
Secondary Pass Inlet Pipe
Roof Outlet Header
Passage Side Wall Outlet Pipe
Rear Wall Hanger Outlet Pipe
Roof (Rear)
Roof (Front)
Roof Inlet Header
Roof Inlet Supply Pipe
Roof Inlet Manifold
Roof Inlet Pipe
Roof Inlet Pipe (Side)
Roof Inlet Pipe (Front)
Passage Side Wall Outlet Header
Passage Side Wall
Side Wall Outlet Header
Rear Wall Hanger Outlet Header
Rear Wall Hanger
Front W all Outlet Header
Rear Wall Hanger Inlet Header
Rear Wall Hanger Supply Pipe
Rear Wall Hanger Inlet Manifold
Rear Wall Hanger Inlet Pipe
Passage Side Wall Inlet Header
Passage Side Wall Supply Pipe
Passage Side Wall Inlet Manifold
Passage Side Wall Inlet Pipe
Rear Wall Outlet Header
Furnace Side Wall (Upper)
Furnace Rear Wall (Upper)
Furnace Front W all (Upper)
Side Wall Intermediate Outlet Header
Rear Wall Intermediate Outlet Header
Front Wall Intermediate Outlet Header
Side Wall Intermediate Manifold Outlet Pipe
Rear Wall Intermediate Manifold Outlet Pipe
Front W all Intermediate Manifold Outlet Pipe
Side Wall Intermediate Manifold
Rear Wall Intermediate Manifold
Front W all Intermediate Manifold
Furnace Intermediate Header (Side Wall)
Furnace Intermediate Header (Rear Wall)
Furnace Intermediate Header (Front Wall)
Furnace Side Wall (Lower)
Furnace Rear Wall (Lower)
Furnace Front W all (Lower)
Side Wall Inlet Header
Rear Wall Inlet Header
Front W all Inlet Header
Furnace Supply Pipe (Side Wall)
Furnace Supply Pipe (Rear Wall)
Furnace Supply Pipe (Front Wall)
Furnace Inlet Manifold
Furnace Inlet Pipe

ITEM

REHEATER

1170

S8

SUPERHEATER

1903.5

E11

41.3

4297

R3

66.6

1650

R9

17.9

2714.5

R7

17.7

2600

S22

MS

1000

S20

HTRH

S18

ECONOMIZER

FL+47600

General

NAME

R10
R9
R8
R7
R6
R5
R4
R3
R2
R1

Reheater Desuperheater W arming Pipe


Secondary Reheater Outlet Header
Secondary Reheater
Secondary Reheater Intlet Header
Reheater Desuperheater Outlet Pipe
Reheater Desuperheater
Reheater Desuperheater Inlet Pipe
Primary Reheater Outlet Header
Primary Reheater
Primary Reheater Inlet Header

S22
S21
S20
S19
S18
S17
S16
S15
S14
S13
S12
S11
S10
S9
S8
S7
S6
S5
S4
S3
S2
S1

Tertiary Superheater Outlet Header


Tertiary Superheater
Tertiary Superheater Intlet Header
Superheater Secondary Desuperheater Outlet Pipe
Superheater Secondary Desuperheater
Superheater Secondary Desuperheater Intlet Pipe
Superheater Secondary Desuperheater Intlet Pipe
Secondary Superheater Outlet Header
Secondary Superheater
Secondary Superheater Intlet Header
Superheater Primary Desuperheater Outlet Pipe
Superheater Primary Desuperheater Outlet Pipe
Superheater Primary Desuperheater
Superheater Primary Desuperheater Intlet Pipe
Primary Superheater Outlet Header
Primary Superheater (pendant)
Primary Superheater
Primary Superheater Intlet Header
Primary Superheater Inlet Pipe
W ater Separator Outlet Pipe
W ater Separator Outlet Equalizer Pipe
W ater Separator Drain Tank Steam Vent

E11
E10
E9
E8
E7
E6
E5
E4
E3
E2
E1

Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer

Outlet Header
Hanger (SH pass)
Hanger (RH pass)
Intermediate Header (SH pass)
Intermediate Header (RH pass)
(SH pass)
(RH pass)
Inlet Header
Inlet Pipe
Inlet Pipe
Inlet Pipe

329.4

FL+12000
2FL +11000

Rev.004

W2
94.5

MM-M01.01

W6

3865.5
10400

W2

W5

6534.5

Boiler
Mitsubishi

FL+7833.3
5.7

40.9

W4

SECTION A-A

4.0

W3

W3

10400

10400

8200

FIGURE 2-31

BOILER EXPANSION MOVEMENT DIAGRAM 1/2

2-53

Chapter 2

BOILER
C
L

S4

S18

S2

1000

2600

2714.5

S20

1650

4297

S22

1903.5 1170

R7
1880

R9
2145

14335 FD

R3
1997

2553.625

E11

S8

2452.625 600 2681.875

S3
3281.875

1000

2106

General

S2
1750

1750

1500

11570

6022

EXP.=0

86.8

99.6

78.9

4.3

22.3

77.9

60.3

57.6

FL+64200

100.4

102.9

97.9

3B

3B

97.9

44.9

74.8

118.4
34.4

112.9

FL+63200

11570

67.7
55.1

45.8

11.0

74.8

FL+56700

37.6

34.5

44.1

44.1
73.5
EXP.=0

59.5

86.8

18800

6.8

28.7

8106

18800

S1

44.9

37.6

14.2

26.8

135.7

1872
29414 FW

EXP.=0
BOILER
C
L

S2

26.8

S12 S15

S1

R1

S16

18800

44.9

44.1
55.1

E4

S10

S11

34.5

S17

18800

14.2

S13

S18

67.7

FL+38865

5A

5A

EXP.=0

44.6

FL+48650

37.6

FL+50050

FL+35865

100.4

77.9

S9
102.9

SECTION B-B

99.6

86.8

S19

10400

R5

R4

10400

W1

S4

97.9

R6

10400

10400

8200

SECTION C-C

8200

SECTION D-D

Rev.004
MM-M01.01

7A

7A

MPTD-3-0109-2

FIGURE 2-32
Boiler
Mitsubishi

BOILER EXPANSION MOVEMENT DIAGRAM 2/2

2-54

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-33
Boiler
Mitsubishi

ARRANGEMENT OF BOILER HEADER SUPPORTS

2-55

General

MM-M01.01

Rev.004

Chapter 2

FIGURE 2-34
Boiler
Mitsubishi

TYPICAL ARRANGEMENT OF BOILER ELEMENT SUPPORTS

2-56

Chapter 2

General

INSPECTION ITEMS
* SCALES (THICKNESS, AMOUNT, COMPOSITION)
* O.D., THICKNESS OF TUBE
* MECHANICAL PROPERTIES, COMPOSITION OF
TUBE.

ITEM
1
2
3
4
5

DESCRIPTION
FINNED TUBE WALL PANEL
BLOCK INSULATION (MINERAL FIBER BOARD)
OUTER CASING
PIN CLIPS
INSULATION PINS

MPTD-3-0112

FIGURE 2-35
Boiler
Mitsubishi

INSULATION OF FINNED TUBE WALLS

2-57

Chapter 2

PLAN VIEW OF
STEAM GENERATOR
CORNER

TUBES

MINERAL FIBER

General

WELD
PIN

SPEED WASHER

JOINTS

SIDE WALLS

RIBBED LAGGING

SPEED WASHER

MPTD-4-0113

FIGURE 2-36
Boiler
Mitsubishi

INSULATION OF MEMBRANE TUBE WALLS

2-58

General

MM-M01.01

Rev.004

Chapter 2

MPTD-3-0114

FIGURE 2-37
Boiler
Mitsubishi

INSULATION OF BOILER MOUNTINGS

2-59

Chapter 2

OUTER CASING

General

STEAM GENERATOR TUBES

CLASS 4 CASTABLE
ACCESS DOOR OPENING

CLASS 4 CASTABLE
REFRACTORY ACCESS DOOR
(IN 3 PARTS)

EXTERNAL STEEL DOOR

BLANKET TYPE INSULATION

CASTABLE BLOCK SUPPORT

PLAN VIEW OF
ACCESS DOOR

MINERAL FIBER BOARD


CASTABLE CLASS 4 REFRACTORY
CERAMIC FIBER BLANKET

MPTD-4-0115

FIGURE 2-38
Boiler
Mitsubishi

BOILER ACCESS DOOR INSULATION

2-60

Chapter 2

General

INSULATION SUPPORT

SUS WIRE

OD
PIPE

BOLT NUT

JOINTS

BOILER-FRONT

FRONT WALL TUBE

SIDE WALL TUBE

REAR WALL TUBE

INSULATION SUPPORT

INSULATING PIPE
COVER

FOR ALL SINGLE PIPES WITH AN O.D. LARGER THAN 89.1 MM


AND A SLOPE OF 60 OR MORE, THE INSULATION SHALL BE
FASTENED WITH SUPPORTING BANDS AS SHOWN ABOVE.

HORIZONTAL PIPE

+7833.3

INSULATION
t100

INSULATION
t100

SEAL PLATE

REFRACTORY
t130

REFRACTORY
t130
GLASS TAPE

BUCKSTAY
OD

GLASS TAPE
"A"

50

SCREW
AND WASHER

0.9

100

INSULATION SUPPORT
CL FURNACE
ANCHOR ROD

ANCHOR ROD
POSITIONER

METAL LAGGING

DETAIL "A"

INSULATION SHALL BE
CAREFULLY AND TIGHTLY
APPLIED IN THIS AREA.

INCLINED PIPE
BUCKSTAY

OUTER METAL LAGGING


SCREW
DRIP PLATE SUPPORT

DRIP PLATE
DRIP PLATE

CIRCUMFERENTIAL JOINT
METAL LAGGING

LONGITUDINAL JOINT
METAL LAGGING

FRONT & REAR WALL

FURNACE BOTTOM ARRANGEMENT

DETAIL OF METAL LAGGING JOINT

MPTD-3-0116

MM-M01.01

Rev.004

SIDE WALL

FIGURE 2-39
Boiler
Mitsubishi

APPLICATION OF REFRACTORY AND INSULATION FOR BOILER & PIPES

2-61

Chapter 2

MARK

DESCRIPTION

BASE

COVER PLATE ASSEMBLY

2A

COVER PLATE

2B

WASHER RETAINER

2C

FLOATING WASHER

2D

PIN

General

TOP PLATE ASSEMBLY

3A

TOP PLATE

3B

WASHER RETAINER

3C

FLOATING WASHER

3D

SCREW

3E

PIN

SPINDLE

SEAT BUSHING

COMPRESSION SCREW

UPPER ADJUSTMENT RING

UPPER ADJUSTMENT RING PIN

LOWER ADJUSTMENT RING

10

LOWER ADJUSTMENT RING PIN

12

YOKE

14

DISC

15

GUIDE

16

SPRING

17

LIFTING GEAR

18

DISC HOLDER

19

DISC COLLAR

20

LIFT STOP

21

OVERLAP COLLAR

23

LOCK NUT

`A'

VENT

STEAM
EXHAUST
DRAIN

DETAIL `A'

STEAM INLET

MPTD-4-0048

FIGURE 2-40
Boiler
Mitsubishi

SECTIONAL VIEW OF A TYPICAL BOILER SAFETY VALVE

2-62

Chapter 3

Specifications

C ha pte r

3 Specifications
Applicable Standard

ASME Boiler Pressure Vessel Code Section I without stamp

TABLE 3-1

BOILER SPECIFICATIONS

Subject

Specifications

Boiler Type

Supercritical, sliding pressure operation, once


through boiler, single reheat cycle

Evaporation (BMCR)

2,695t/hr

Main steam pressure at BMCR

25.78MPag (3ry SH outlet)

Main steam temperature at BMCR

542C (3ry SH outlet)

Feed water temperature at Economizer inlet

290.0C

Steam pressure at Reheater outlet

4.84MPag

Reheat steam temperature at BMCR

568C (2ry RH outlet)

Excess air at BMCR

15%
Superheater

27.05MPag

Reheater

5.90MPag

Superheater

550C

Reheater

582C

Design pressure

Design temperature

Drafting system

Balance draft
Average

25.5C

Summer

33C

Ambient temperature

Changing point between Wet and Dry Operation

Approx.25% load

Fuel

Coal (diesel oil startup and support)

Grade of automatic operation

Fully automated on boiler operation

Boiler
Mitsubishi

3-1

Chapter 3

Specifications

TABLE 3-2 WATERWALL TUBES


Subject

Specifications

Manufacturer

MHI

Type

Membrane wall

Furnace width

29.414m

Furnace depth

14.335m

Furnace height (Furnace lower header


to roof)

56.067m

Furnace volume

21369m3

Effective Projected Radiation Surface


(EPRS)

5405m2

Operating pressure (WS outlet)

27.36MPag (BMCR)

Tube outside diameter

28.6mm

Tube material

SA-213T12

Pitch

44.5mm

Fluid

Steam/water

TABLE 3-3 WATER SEPARATOR


Subject

Specifications

Manufacturer

MHI

Outside diameter

1000mm

Thickness

120mm

Height (Shell end to end)

3.31m

Design pressure

28.77MPa

Design temperature

450C

Operating medium

Steam/water

Shell material

SA387-11-2

Boiler
Mitsubishi

3-2

Chapter 3

Specifications

TABLE 3-4 WATER SEPARATOR DRAIN TANK


Subject

Specifications

Manufacturer

MHI

Outside Diameter

1000mm

Thickness

120mm

Height

16.4m

Design Pressure

28.77MPa

Design Temperature

450C

Operating medium

Water

Shell material

SA387-11-2

TABLE 3-5 ROOF TUBES


Type:

Fin welded panel

Design pressure:

30.11MPag

Heating surface:

1170m2
Tube Size (mm)

No. of
Tubes

Material

Roof front

440

Roof rear

220

Tube

Outside Diameter

Thickness

Tube Pitch
(mm)

SA213-T12

45.0

9.4

66.75

SA213-T12

57.1

8.9

133.5

TABLE 3-6 BACK PASS AND PASSAGE WALL TUBES


Type:

Fin welded panels

Design pressure:

29.8MPag

Heating surface:

3680m

Tube Size (mm)


No. of
Tubes

Material

Outside
Diameter

Thickness

Tube Pitch
(mm)

Back pass front wall


-Lower
-Screen

220
110

SA213-T12
SA213-T12

38.1
45.0

8.9
7.4

133.5
267.0

Back pass rear wall

219

SA213-T12

38.1

8.9

133.5

Back pass side wall

2 105

SA213-T12

38.1

8.9

111.25

Screen

146

SA213-T12

45.0

7.4

200.25

Lower

292

SA213-T12

38.1

8.9

100.125

2 67

SA213-T12

38.1

8.9

89

Tube

Back pass division


wall

Passage side wall

Boiler
Mitsubishi

3-3

Chapter 3

Specifications

TABLE 3-7 PRIMARY SUPERHEATER


Type:

Horizontal, drainable

Design pressure:

28.61MPag

Heating surface:

7830m

Tube Size (mm)


Panel Pitch (mm)

Number
of Panels

Material

Outside
Diameter

Thickness

Tube Pitch
(mm)

133.5

220

SA213-T12

45.0

6.9

80.0

267

110

SA213-T12

45.0

6.9

80.0

TABLE 3-8 SECONDARY SUPERHEATER


Type :

Panel, non-drainable

Design pressure:

28.0MPag

Heating surface:

3470 m

Tube Size (mm)


Panel Pitch (mm)

2403

Girdling Tube

Boiler
Mitsubishi

Number
of Panels
12

Outside
Diameter

Thickness

Tube Pitch
(mm)

SA213-T12

45.0

9.4

54.5

ASME Code Case 2199-3

45.0

5.9

54.5

ASME Code Case 2328-1

45.0

5.4

54.5

ASME Code Case 2328-1

45.0

6.9

54.5

SA213-T12

38.1

6.4

54.5

SA213-T12

31.8

5.9

54.5

SA213-T12

31.8

6.4

54.5

SA213-T12

31.8

7.4

54.5

SA213-T91

45.0

6.9

54.5

ASME Code Case 2328-1

45.0

5.4

SA213T12

45.0

6.9

SA213-T91

45.0

6.9

Material

3-4

Chapter 3

Specifications

TABLE 3-9 TERTIARY SUPERHEATER


Type:

Platen, non-drainable

Design pressure:

27.56MPag

Heating surface:

2800m

Tube Size (mm)


Panel Pitch (mm)

534

Number
of Panels
54

Cooling Spacer Tube

Outside
Diameter

Thickness

Tube Pitch
(mm)

ASME Code Case 2328-1

45.0

4.9

54.5

ASME Code Case 2328-1

45.0

5.4

54.5

SA213-T91

45.0

5.9

54.5

SA213-T91

45.0

6.9

54.5

ASME Code Case 2328-1

45.0

5.4

SA213-T12

45.0

6.9

SA213-T12

31.8

5.9

SA213-T91

45.0

6.9

Material

TABLE 3-10 PRIMARY REHEATER


Type:

Horizontal, Drainable

Design pressure:

5.90MPag

Heating surface:

15540m

Tube Size (mm)


Number
of Panels

Material

Outside
Diameter

Thickness

Tube Pitch
(mm)

133.5

220

SA213-T12

57.1

3.5

115,140,160

267

110

SA213-T22

57.1

4.0

115

267

110

Code Case 2328-1

57.1

3.5

115

267

110

SA213-T12

63.5

7.2

115

Panel Pitch (mm)

Boiler
Mitsubishi

3-5

Chapter 3

Specifications

TABLE 3-11 SECONDARY REHEATER


Type:

Pendant, non-drainable

Design pressure:

5.90 MPag

Heating surface:

4180 m

Tube Size (mm)


Panel Pitch (mm)

Number
of Panels

267

108

Outside
Diameter

Thickness

Tube Pitch
(mm)

ASME Code Case 2328-1

57.1

3.5

115

SA213-T22

57.1

4.5

115

SA213-T12

57.1

3.5

115

SA213-T12

38.1

3.5

115

SA213-T91

57.1

4.5

115

Material

TABLE 3-12 DESUPERHEATERS


Material

OD
(mm)

ID
(mm)

Thickness
(mm)

Design P
MPa(g)

Design T
(C)

Spray
Cap.t/h

Qty
(Nos.)

Primary SH
De-superheater

SA335-P12

482.6

332.6

75

28.0

467

269.5

Secondary SH
De-superheater

SA335-P91

482.6

352.6

65

27.56

533

269.5

Reheat
De-superheater

SA335-P12

711.0

653.0

29

5.90

496

89.0

Description

TABLE 3-13 ECONOMIZER (SPIRAL FINNED TUBE)


Design pressure:

31.49MPag

Heating surface:

44120m

Tube Size (mm)


Panel Pitch
(mm)

Number of
Panels

Material

Reheater pass (Front


section)

150.0

194

Superheater pass
(Rear section)

150.0

194

Location

Tube Pitch

Outside
Diameter

Thickness

(mm)

SA210-C

45.0

6.9

115

SA210-C

45.0

6.9

115

TABLE 3-14 ECONOMIZER (HANGER TUBE)


Design pressure:

31.49MPag
Tube Size (mm)

Panel Pitch
(mm)

Number of
Panels

Material

Reheater pass (Front


section)

267

110
110

Superheater pass
(Rear section)

267

110
110

Location

Boiler
Mitsubishi

Tube Pitch
(mm)

Outside
Diameter

Thickness

SA210-C
SA210-C

50.8
57.1

7.4
8.4

SA210-C
SA210-C

63.5
50.8

9.4
7.4

3-6

Chapter 3

Specifications

TABLE 3-15 SPECIFICATION OF HEADERS


No.

Description

Material

OD &
Thickness
(mm)

Design
Pressure
(MPa)

Design
Temp. C

Furnace Inlet Header (Front)

SA-106C

219.4 40

31.49

362

Furnace Inlet Header (Rear)

SA-106C

219.4 40

31.49

362

Furnace Inlet Header (Side)

SA-106C

219.4 40

31.49

362

Furnace Intermediate Header (Front)

SA-335P12

323.8 63

31.49

450

Furnace Intermediate Header (Rear)

SA-335P12

323.8 63

31.49

450

Furnace Intermediate Header (Side)

SA-335P12

323.8 63

31.49

450

Furnace 2nd Intermediate Header (Front)

SA-335P12

323.8 63

31.49

450

Furnace 2nd Intermediate Header (Rear)

SA-335P12

323.8 63

31.49

450

Furnace 2nd Intermediate Header (Side)

SA-335P12

323.8 63

31.49

450

10

Furnace Outlet Header (Front)

SA-335P12

323.8 60

30.11

450

11

Furnace Outlet Header (Rear)

SA-335P12

323.8 65

30.11

450

12

Furnace Outlet Header (Side)

SA-335P12

323.8 65

30.11

450

13

Rear Wall Hanger Inlet Header

SA-335P12

219.1 44

30.11

450

14

Rear Wall Hanger Outlet Header

SA-335P12

219.1 44

30.11

450

15

Passage Side Wall Inlet Header

SA-335P12

219.1 44

30.11

450

16

Passage Side Wall Outlet Header

SA-335P12

219.1 44

30.11

450

17

Roof Inlet Header

SA-335P12

219.1 44

30.11

450

18

Roof Outlet Header

SA-335P12

610 123

29.8

450

19

Back Pass Inlet Header (Front)

SA-335P12

219.1 44

29.8

450

20

Back Pass Inlet Header (Rear)

SA-335P12

219.1 44

29.8

450

21

Back Pass Inlet Header (Side)

SA-335P12

219.1 44

29.8

450

22

Back Pass Outlet Header (Front)

SA-335P12

219.1 44

28.77

450

23

Back Pass Outlet Header (Rear)

SA-335P12

355.6 61

28.77

450

24

Back Pass Outlet Header (Side)

SA-335P12

219.1 44

28.77

450

25

Back Pass Inlet Header (Division wall)

SA-335P12

219.1 44

29.8

450

26

Back Pass Outlet Header (Division wall)

SA-335P12

219.1 44

28.77

450

27

Primary SH Inlet Header

SA-335P12

431.8 84

28.61

461

28

Primary SH Outlet Header

SA-335P12

482.6 80

28.0

467

29

Secondary SH Inlet Header

SA-335P12

323.8 60

28.0

454

30

Secondary SH Outlet Header

SA-335P91

355.6 56

27.56

533

31

Tertiary SH Inlet Header

SA-335P91

406.4 52

27.56

513

Boiler
Mitsubishi

3-7

Chapter 3

Specifications

Continued from previous page

No.

Description

Material

OD &
Thickness
(mm)

Design
Pressure
(MPa)

Design
Temp. C

32

Tertiary SH Outlet Header

SA-335P91

482.6 70

27.05

550

33

Primary RH Inlet Header

SA-106C

559.0 28

5.9

350

34

Primary RH Outlet Header

SA-335P12

711.0 39

5.9

496

35

Secondary RH Inlet Header

SA-335P12

660.0 39

5.9

496

36

Secondary RH Outlet Header

SA-335P91

762.0 50

5.9

582

37

Economizer Inlet Header

SA-106C

610.0 98

31.49

350

38

Economizer Intermediate Header


(Reheater pass)

SA-106C

219.1 44

31.49

391

39

Economizer Intermediate Header


(Superheater pass)

SA-106C

219.1 44

31.49

391

40

Economizer Outlet Header

SA-106C

457.0 67

31.49

362

Boiler
Mitsubishi

3-8

Chapter 4

Preventive Maintenance

C ha pte r

4 Preventive Maintenance
Preventive maintenance is carried out to avoid or reduce the possibility of failure or
deterioration of boiler performance. This requires a constant effort from operators and
maintainers to make sure that the Unit is available on demand.
There are two categories of preventive maintenance; Routine Maintenance and Outage
Maintenance.
Routine maintenance helps to reduce the possibility of outage and hence the downtime
of machinery.
Outage maintenance is required to maintain the internal components of the installed
equipment.
The vendor/manufacturers recommendations provide a good basis for the provision of a
preventive maintenance schedule. However, the frequency and other details must be
updated from time to time. It must be based on practical experience and actual feedback
gathered during inspection and normal operation of the boiler.
Consideration of these site related specific issues will make the preventive maintenance
more effective.

4.1

Prerequisites
The necessary prerequisites for the preventive maintenance of the boiler and
associated tube banks are as follows:

4.1.1 Scheduling
Scheduling is the first activity in the preparation of a preventive
maintenance program. The schedule must include planning to perform
inspections on all operating equipment on a fixed regular basis.
Initially, schedules will be prepared based on vendor/manufacturers
generic instructions. The schedules, however, must be updated
(frequency, nature of inspection, etc.) so that the latest site data can
always be available.
Preventive maintenance must be coordinated with other concerned
departments.
In case of a major scheduled outage, maintainer and other concerned
departments must jointly prepare a plan of activities, well in advance.

Boiler
Mitsubishi

4-1

Chapter 4

Preventive Maintenance

The plan must include the inspection activities and other logistics (such
as the availability and supply of required equipment, spare parts, and
tools, etc.).
The schedule must clearly identify the critical path. Priority must be given
to specific tasks that also involve parallel activities to reduce the
equipment downtime and to complete the work within the scheduled
time.

4.1.2 Interdepartmental Cooperation and Communication


Interdepartmental cooperation and communication is essential to reduce
a risk of failure in routine or annual outage maintenance.
Prior to starting preventive maintenance, all concerned persons (shift
supervisors, operators, etc.) must be made aware of the schedule and
the nature of the activities.
If there is any problem or discrepancy found in the schedule, it must be
solved mutually and agreed upon by the parties concerned.

4.1.3 Isolation of Equipment


It is important that isolations are agreed and valid clearances and work
permits are obtained before any maintenance work is performed.
The isolation boundaries of the particular equipment to be taken under
maintenance must be clearly identified.
In the case of an electrical isolation, the power supply must be
disconnected and/or the fuses removed.
In the case of a mechanical isolation, close the valves or other
mechanical means of isolation at the isolation boundaries, and if possible
they must be locked closed and a Do not operate tag should be
attached.
The boiler system within the isolation boundaries must be depressurized.

4.1.4 Safety Precautions


Before the start of any maintenance work, the person in charge of the
work site must perform a risk assessment and method statement for the
safe execution of the job, as per the work permit.
Risk assessment includes identifying, recognizing and understanding the
potential hazards associated with the work.
The method statement must illustrate the safe working practices in
accordance with the safety manual and the manufacturers instruction
manual to prevent personal injury and/or equipment damage.

Boiler
Mitsubishi

4-2