Construction

of
500 mw boiler

by
Vaibhav G. Paydelwar
( Project Engineer)
Sunil Hi-Tech Engineers
Limited
WHAT DO YOU MEAN BY BOILER
?
 Boiler means any closed vessel exceeding 22.75 Ltr. in capacity used
for steam generation under pressure. The first boiler was developed in
1725 and its working pressure was 10 kg/ cm2.

 Boiler can be regarded as a number of interconnected heat

exchangers arranged in such manner that heat available by burning of
fuel is transferred to convert water into steam in most efficient manner.
FUNCTION OF BOILER
 To produce the steam at the desired rate at
desired pressure and temperature with use of
resources such as oil, coal & water for generating
the power.
Types of Boilers
Natural circulation Boiler :-
Drum to down comer - to main ring header – to ww tubes
and back -to drum. Due to difference in density of water and steam this
types of circulation takes place.

 Forced circulation (Assisted circulation) Boiler :-

As per operating pressure of the boiler approaches to
the critical pressure, additional pumps are required to install in down
comers, because at this pressure there is no appreciable density
difference between water and steam to have natural circulation of
water.
 NEED FOR ASSISTED
CIRCULATION

0.7
Density of Water
0.6

0.5

0.4
Critical
0.3 Point

0.2

0.1 Density of Steam

0
80 100 120 140 160 180 200 220 240

Pressure (Kg/cm2)
According to working pressure

Sub critical pressure boiler : when working

pressure of boiler is between 130 to 180 kg/ cm2

critical boiler : when working pressure of boiler

is 225.56 kg/ cm2

Super critical boiler : when working pressure of

boiler is 240.10 kg/ cm2
Why to go for higher capacity ?

1’-2’ = Work done in turbine

from P1 – P2
2’-3 = Heat Rejection in
condenser
3-4 = Water pumped to boiler
4-1 = Heat addition in eco and
boiler.
SPECIAL FEATURES OF 500MW BOILER

 Controlled circulation of feed water in water walls with the

help of 3 Nos. of boiler circulating water pumps installed on
down comers. Rifled bore water wall tubes as against smooth
bore tubes in 210 MW boiler.
 Provision of Orifices for equal distribution of water in water
wall tubes from bottom ring header.
 All down comers are connected to front header of the
bottom ring header.
 DESIGN FACTOR
For the construction of boiler parts subjected to
pressure and their integral attachment, the designer
takes into account several factors
 Relative Cost
 Mechanical Properties
 Manufacturing Method
 Scaling Resistance
 Maintenance
Various parts of Boiler
BOILER IS DIVIDED INTO TWO PASS:-
 FIRST PASS
 SECOND PASS

First pass of the boiler consists of:-

 Furnace water wall.
 Divisional super heater pendent assembly.
 Final Super heater pendent assembly.
 Reheater front pendent assembly. (CRH)
 Reheater rear pendent assembly. (HRH)
 Rear Arch Panel.
 Water Wall screen tubes.
Second pass of the boiler consists of:-
 Steam cooled wall.
 Economizer lower bank coils.
 Economizer middle bank coils.
 Economizer upper bank coils.
 LTSH lower bank coils
 LTSH upper bank coils
 Eco. Hanger tubes.
 LTSH terminal tubes.
ECONOMISER
 Requirement why ?
 Advantages
• As the economiser recover the heat in the flue gas that leaves the boiler
and transfer to working fluid there will be saving in fuel consumption.
• As the feed water is preheated in the economiser and enter the boiler
tube at an elevated temperature( near to saturation temp.) the heat
transfer area required for the evaporation surface required will be
reduce considerably. As the size of boiler also will be reduced.
 Types of Economiser
 Steaming
 Non steaming
• Plain tube economiser
• Fin-tube economiser
Plain tubes
Direction of Gas Flow
Direction of Gas Flow

Inline Arrangement
Staggered
Arrangement
Fin-tube Eonomiser
Tube size and spacing
 The tubes can be made any length and diameter with 38mm to 52mm
OD. The side spacing and back spacing can be arranged for good
cleaning, absorption of heat and less draught loss. Spacing about 90mm
to 140mm.
 It is composed of three banks of 130 parallel tube elements arranged in
horizontal rows in such a manner that each row is in line with the row
above and below.
Drum & Drum Internals
 Requirement
 Separation of saturated steam from the steam-water mixture produced by
the evaporating tubes
 Mixing feed water from economiser and water separated from steam – water
mixture, and re-circulate through the evaporating tubes.
 Carrying out blow down for reduction of boiler water salt concentration.
 Treatment of Boiler water by chemicals

construction of drum

11 111
1
BOILER DRUM:
Construction: Fusion welded
Material specification: SA299
Design pressure: 204.9 kg/cm2
Maximum operating press: 193 kg/cm2
Thickness for straight portion: 195/165 mm
Overall length of drum : 22070 mm
Outside dia. Of Drum : 2138 mm
Internal dia. Of Drum :1778 mm
Elevation of drum centre above ground level: 71.583 meter
No. of distribution headers : 6
No. of cyclonic separator :92
No. of secondary dryers : 92
No. of final dryers : 124
Maximum permissible DT between any two parts of Drum : 50 0C
Connection to Boiler Drum
 Main connection
• Feed lines
• Down comers
• Up risers
• Super heater supply tubes

 Auxiliary connection
• Blow down line
• Chemical dosing line
• Instrumentation tapping
• Air vents
• Safety valves
• Nitrogen filling line
• High and low level trips
Drum Internals
Feed header
Anti vortex spider
Steam separator
Steam dryers or scrubbers
C.B.D. line
 E.B.D. line
 chemical dosing line
Water Walled Furnace
 Requirement
 Advantages
 In furnace not only combustion but also heat transfer is taking place
simultaneously.
 The maintenance work involved in repairing the firebricks (which is
otherwise necessary) is completely eliminated.
 Due to heat transfer in the furnace, temperature of the flue gas leaving
the furnace is reduced to the acceptable level of the superheating
surfaces.
 Higher heat loading in the furnace is possible, as heat is being
simultaneously removed by heat transfer, and hence economy in
surfacing.
 Providing a Gas tight seal to the combustion chamber to prevent air
infiltration.
Water Wall Furnace Constuction
 Expansion and Sealing

53mm

29mm

58mm

174mm

36mm

330 mm
Buckstay and Furnace Guides
Superheaters
 Requirement?

 By increasing the temperature of the steam, the useful energy that can be
recovered economically increases thus the efficiency of the cycle also as can
be seen in Fig.3.40.
 Superheating of steam eliminates the condensation of steam during
transporting of steam in pipelines and inside the early stages of turbines
which is harmful to the turbine blades and pipe lines.
 Limits the work done by turbine stages to avoid excessive erosion of blades
Types of superheater
 radiant superheater
 convective superheater
Relationship in SH Design
 The steam temperature desired
 The super heater surface area required
 The rate of steam flow through the tubes (mass flow)
 The material best suited for the super heater tubes
 The gas temperature zones where the surfaces are to
be located
 The arrangement of surfaces to meet the characteristics
of the fuel to be used with specific reference to the
spacing of tubes
Material for SH
ASME CODE NOMINAL TEMP.LIMIT 0C
COMPOSITION
SA 213 CARBON STEEL 450
SA 213 T1 C-1/2 Mo. 470
SA 213 T11 11/4 Cr. –1/2 Mo. 550
SA 213 T22 21/4 Cr.-1 Mo. 580
SA 213 T9 9 Cr.-1 Mo. 635
SA 213 TP 304 H 18 Cr.-8 Ni. 705
SA 213 TP 347 H 18 Cr.-10 Ni. 705
SA 213 TP 316 H 16 Cr.-12 Ni.-2 Mo. 705

Description Tube Size Material

Radiant Roof Tubes i. Ø 63.5 X 6.3 SA 213, T11

ii. Ø 57 X 5.6 SA 213, T11

Steam Cooled Side wall i. Ø 63.5 X 6.3 SA 210, Gr C

tubes ii. Ø 51 X 5 SA 210, Gr C
iii. Ø 76.1 X 10 SA 210, Gr C

Steam Cooled front wall i. Ø 51 X 5 SA 210, Gr C

tubes ii. Ø 63.5 X 6.3 SA 210, Gr C
iii. Ø 44.5 X 7.1 SA 210, Gr C

Front Wall Hanger Tubes Ø 51 X 5.0 SA 210, Gr C

Rear Roof Tubes i. Ø 51 X 5 SA 210, Gr C

ii. Ø 44.5 X 7.1 SA 210, Gr C

Eco and LTSH Support Ø 47.63 X 8.6 SA 210, Gr C

tubes
Description Tube Size Material

Steam Cooled Side Wall tubes Ø 51 X 5 SA 210, Gr C

Bifurcate Tubes (Bottom Header) Ø 51 X 5 SA 210, Gr C

LTSH Horizontal Tubes i. Ø 51 X 5 SA 210, Gr C

ii. Ø 51 X 5.6 SA 210, Gr C

Pendent Coil Tubes i. Ø 51 X 5 SA 213, T11

ii. Ø 51 X 5.6 SA 213, T11

Divisional Panel inlet loose tubes i. Ø 51 X 6 SA 210, Gr C

ii. Ø 44.5 X 4.5 SA 210, Gr C

Divisional Panel Outlet loose tubes i. Ø 51 X 6 SA 213, T11

Steam Cooled Spacer i. Ø 63.5 X 8 SA 213, T11

ii. Ø 51 X 5.6 SA 213, TP347H
iii. Ø 63.5 X 6.5 SA 213, TP347H
iv. Ø63.5 X 7.1 SA 213, T11
v. Ø 63.5 X 7.1 SA 210, Gr C
vi. Ø 51 X 5.0 SA 213, T11
vii. Ø 51 X 5.0 SA 210, Gr C
Reheater
 Requirement?

Description Tube Size Material

Reheater Wall tubes Ø 60.3 X 4 SA 313, T11

Cross over tubes Ø 54 X 3.6 SA 213, T11

Sr Heating Surface
. Type Area in m2
N
o.
1 Radiant roof, steam cooled wall LTSH 9620
Horizontal and pendent.
2 Super Heater Divisional Panel 1361
3 Final Super heater Platen 1458
4 Reheater radiant wall front and side, 5075
front platen, rear platen.
Total Heating Surface 17514 M2
Sr. Parameters Rating
No.
1
Super heater system flow 1681 TPH
2
Reheater System Flow 1430.64 TPH
3
Pressure at super heater outlet 179 Kg/cm2
4
Temperature at super heater outlet 540 oC
5
Pressure at reheater inlet 44.88 Kg/cm2 (g)
6
Temperature at reheater inlet 342.7 oC
7
Pressure at reheater outlet 42.68 Kg/cm2 (g)
8
Temperature of reheater outlet 540 oC
9
Feed Water temperature 255 oC
10
Ambient air temperature 28 oC
11
Combustion air temperature secondary 335 oC
12
Fuel Quantity 330 TPH
13
Air Quantity (Total Combustion air) 2030 TPH
14
Temperature of Gas at boiler exit 142 oC
15
Total Heat output of the system 1076 Kcal/Hr
 BOILER AIR & FLUE GAS TEMPERATURES MAX-134 ºC
PLSH RH FSH
DRUM

758-726 ºC 720 ºC
1020-793 ºC
1135-1020 ºC LTSH
461 ºC

ECO
1100-
355 ºC
1250
SA-318 ºC APH
A B PA-313 ºC

147 ºC 143 ºC 137 ºC

ESP
 BOILER WATER & STEAM TEMPERATURE
PLSH RH FSH
DRUM
286-349 ºC
520-540 ºC
344-540
426-520 ºC 349-426 ºC
LTSH

243-286 ºC ECO
1300-1400

APH
A B

ESP
 H.
500MW BOILER
R.
M.S C.R.H H

BCW
Pump
FROM F.R.S
BOTTOM RNG HDR WW PANELS & 1ST PASS
W.W.
1ST PASS W.W O/L HDRS ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH & O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
FINAL S.H. R.H.HEADER
2ND PASS ROOF O/L HDR(REAR ECONOMISER