PRODUCT ENGINEERING (FOSSIL BOILERS)

IMPROVEMENTS DONE IN BOILER LAYOUTS

1. REDUCTION OF BOILER COLUMNS IN 500 MW CONTRACTS. 53 COLUMNS PROVIDED

IN RAMAGUNDAM UNIT 7, REDUCED TO 43 Nos IN KAHALGOAN & TO 39 Nos IN
BELLARY.

2. INTEGRATION OF LIFT STRUCTURE WITH BOILER STRUCTURE AS AGAINST STAND-

ALONE STRUCTURE EARLIER.

3. WIDER SPACING OF BOILER MAIN COLUMNS (From Boiler centre line ) FOR BETTER
ACCESS SPACE.

4. FIRST 250 MW DESIGNED WITH 7 BOWL MILLS WITH REAR MILL ARRANGEMENT &
WITH UNSYMMETRIC ARRANGEMENT OF MILLS { 4 NOS ON LEFT SIDE & 3 NOS ON
RIGHT SIDE WITH A CENTRE GAP} FOR KORBA 2x 250 MW

03/27/2021 Boiler Design 1

 PRODUCT ENGINEERING (FOSSIL BOILERS)
IMPROVEMENTS DONE IN BOILER LAYOUTS

5) RETROFIT OF ECONOMISER COIL HANDLING

6) IMPROVEMENT OF BRACING PATTERN ON THE REAR SIDE OF THE BOILER FOR

ECONOMISER COIL HANDLING.

7) RELOCATION OF GATES IN THE ECONOMISER BYPASS DUCTS FOR

ECONOMISER COIL HANDLING .
8) OPTIMIZATION OF DAMPERS IN THE AIR DUCTS TO AIR PREHEATERS.

9) LAYOUT FOR THE TWIN REHEATER HEADERS FOR 500 MW NEW CONTRACTS.

03/27/2021 Boiler Design 2

REGULAR ARRANGEMENT OF BOILER COLUMNS FOR RAMAGUNDAM 500
MW UNIT 7 (53 NO OF COLUMNS)

03/27/2021 Boiler Design 3

 OPTIMIZED BOILER COLUMN LOCATION FOR KAHALGAON 500 MW
(43 NOS OF COLUMNS)

03/27/2021 Boiler Design 4

OPTIMIZED ARRANGEMENT OF BOILER COLUMNS FOR BELLARY
500 MW UNIT (39 NO OF COLUMNS)

03/27/2021 Boiler Design 5

 DESIGN IMPROVEMENT IN THE BOILER LIFT
STRUCTURE

03/27/2021 Boiler Design 6

 DIMEMSIONAL DETAILS OF BOILER COLUMNS FOR
KAHALGOAN 500 MW

03/27/2021 Boiler Design 7

SUMMARY OF BOILER COLUMN SPACING IN CURRENT 500 MW
UNITS

CONTRACT NAME NO OF SPACING OF BOILER MAIN COLUMNS

COLUMNS FROM BOILER CENTRE LINE

RAMAGUNDAM 500 MW 53 NOS 13 M

UNIT 7

KAHALGOAN 500 MW 43 NOS 15.5 M

BELLARY 500 MW 39 NOS 14.5 M

03/27/2021 Boiler Design 8

 BELLARY TPS 1 x 500 MW BOILER
SALIENT FEATURES OF BOILER LAYOUT

• SIDE MILL LAYOUT.

• 7 nos OF XRP 1003 BOWL MILLS

• WIDER MAIN BOILER COLUMN PITCHING AT

29 Mtrs.

• TRISECTOR REGEN AIRHEATER 31.5 VIM(T)

2000 - USED IN THIS CONTRACT

03/27/2021 Boiler Design 9

 BELLARY TPS 1 x 500 MW BOILER
SALIENT FEATURES OF BOILER LAYOUT

• LARGE MAN HOLE DOOR(1.8 x 0.9 Mt) ENVISAGED IN

PENT HOUSE FOR MAINTANECE.

• CL ELEVATION OF RING HEADER = 10.25 Mtrs.

• CL ELEVATION OF DRUM = 70.608 Mtrs.

• BOTTOM OF THE CEILING GIRDER = 78.550 Mts.

03/27/2021 Boiler Design 10

 GA OF BOILER
SECTIONAL ELEVATI

03/27/2021 Boiler Design 11

 GA OF BOILER
SECTIONAL PLA

03/27/2021 Boiler Design 12

03/27/2021 BOILER COLUMN
Boiler Design LOCATION 13
WITH MAIN AUXILIRIES
 BELLARY TPS 1 x 500 MW BOILER
SALIENT FEATURES OF BOILER LAYOUT
KEY PLAN OF BOILER AND ID SYSTEM

03/27/2021 Boiler Design 14

 BELLARY TPS 1 x 500 MW BOILER
SALIENT FEATURES OF BOILER LAYOUT
LAYOUT OF ID SYSTEM - ELEVATION

03/27/2021 Boiler Design 15

 BELLARY TPS 1 x 500 MW BOILER
SALIENT FEATURES OF BOILER LAYOUT
LAYOUT OF ID SYSTEM - PLAN

03/27/2021 Boiler Design 16

 SALIENT FEATURES OF KORBA 2 x 250
MW UNITS

1. FIRST 250 MW UNIT WITH SEVEN BOWL MILLS WITH REAR

MILL LAYOUT.

2. MILLS LOCATED UNSYMMETRICALLY ABOUT THE BOILER

AXIS : 4 NOS ON THE LEFT SIDE & 3 NOS ON THE RIGHT
SIDE WITH AN EMPTY BAY AT THE CENTRE

03/27/2021 Boiler Design 17

 GENERAL ARRANGEMENT DRAWING SIDE ELEVATION:
KORBA 2 x 250 MW

03/27/2021 Boiler Design 18

 KORBA 2 X 250 MW SECTIONAL PLAN

03/27/2021 Boiler Design 19

 KORBA 2 x 250 MW : I.D SYSTEM SECTIONAL ELEVATION

03/27/2021 Boiler Design 20

 KORBA 2 x 250 MW : I.D SYSTEM
PLAN

03/27/2021 Boiler Design 21

Structure for handling of Eco. Coils from
Zero mtr. to 43.5 mtrs.

03/27/2021 Boiler Design 22

Replacement work of Eco. Bank in
Unit#4

03/27/2021 Boiler Design 23

03/27/2021 Boiler Design 24
Eco. Coil shifting to the position

03/27/2021 Boiler Design 25

03/27/2021 Boiler Design 26
 Manual handling arrangement for insertion and
removal of Eco. Coils from platform to inside the
boiler

03/27/2021 Boiler Design 27

 VINDYACHAL
UNIT Nos. 7 & 8
(NO HANDLING
ENVISAGED)

WITH PERMANENT
BRACING

03/27/2021 Boiler Design 28

 SIMHADRI

WITH REMOVABLE
BRACING

03/27/2021 Boiler Design 29

 TALCHER 4X500MW

WITH POST

03/27/2021 Boiler Design 30

 KAHALGAON 2X500MW
OPEN
WITHOUT POST AND
BRACINGS

03/27/2021 Boiler Design 31

 EARLIER ARRANGEMENT WITH
GATES HINDERING THE
ECONOMISER COIL
WITHDRAWAL

03/27/2021 Boiler Design 32

 MODIFIED ARRANGEMENT
OF GATES TO FACILITATE
THE EASY WITHDRAWAL OF
ECONOMISER COILS

03/27/2021 Boiler Design 33

 EARLIER ARRANGEMENT
OF DAMPERS { 3
LOUVERS & 1 BIPLANE }

B – BIPLANE DAMPER
L – LOUVER DAMPER
03/27/2021 Boiler Design 34
03/27/2021 Boiler Design 35
 MODIFIED ARRANGEMENT
OF DAMPERS WITH 2
BIPLANE & 1 LOUVER

B – BIPLANE DAMPER
L – LOUVER DAMPER
03/27/2021 Boiler Design 36
 LAYOUT OF SINGLE HRH HEADER

03/27/2021 Boiler Design 37

 NEW LAYOUT WITH TWIN HRH HEADER

03/27/2021 Boiler Design 38

 MODIFIED ROUTING OF HRH PIPING

OLD ARRANGEMENT MODIFIED ARRANGEMENT

03/27/2021 Boiler Design 39