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SALIENT FEATURES OF 500 MW BOILER

• TYPE OF BOILER: • FIRST PASS:


• Single Drum Top supported, • Boiler Furnace Depth -15.7972mtr
• Fusion welded WW Panel, • Furnace Width -19.177mtr
• Controlled circulation system, • Height of Furnace (upto Radient roof)-
64.168mtr.
• Tangential fired, Radiant
• Dry Bottom
• SECOND PASS:
• Depth -13.716mtr
• Pulverized coal fired outdoor
• Width -19.177mtr
• Balanced Draught • Total Height of Boiler- 90mtr.
• Cut corner
• 51mm OD WW Tubes at 63.5 mm pitch
• Rap around Buck stay system
BOILER EXPANSION DETAILS

FIRST PASS:
• Vertically Downward Expansion at Ring Header (10.250mtr
elev.) : 330mm
• Horizontal Expansion at Ring Header
(10.250mtr elev.) : 36mm
SECOND PASS :
• Vertically Downward Expansion at Ring Header
(44.060mtr elev.) : 174mm
• Horizontal Expansion at Ring Header
(44.060mtr elev.) : 58mm
• BOILER DRUM EXPANSION :
• Vertical Downward Expansion at 75.333mtr elev.=29mm
• Horizontal Expansion at 75.333mtr elev.= 53mm
BOILER PARAMETERS (BMCR)
• STEAM FLOW AT SH OUTLET - 1625 t/h
• PRESSURE OF SUPERHEATED STEAM - 178 kg/sq.cm
• TEMP.OF SUPERHEATED STEAM - 540 0C

• STEAM FLOW AT REHEATER OUTLET - 1392.4 t/h


• ENTRY PRESSURE OF REHEATED STEAM - 45.04 kg/sq.cm
• ENTRY TEMP. OF REHEATED STEAM - 337 0C
• EXIT PRESSURE OF REHEATED STEAM - 42.39kg/sq.cm
• ENTRY TEMP. OF REHEATED STEAM - 540 0C

• FEED WATER INLET TEMP. - 254.5 0C


FEED WATER TEMP BEFORE ECO. - 283 0C
FEED WATER TEMP AFTER ECO. - 357 0C
• TEMP.AT LTSH OUTLET - 436 0C
• TEMP.AT S/H DIVISIONAL OUTLET - 488 0C
• TEMP.AT FINAL S/H OUTLET - 540 0C
DESIGN PARAMETERS OF BOILER

• BOILER DRUM PRESSURE- 209 kg/sq cm


• SH OUTLET PRESSURE - 191 kg/sq cm
• FINAL SH TEMP. - 540 0C
• REHEATER OUTLET PRESSURE - 52.4 kg/sq cm
• BOILER HYD. TEST PRESSURE - 313.5 kg/sq cm
• REHEATER HYD. TEST PRESSURE - 78.6 kg/sq cm
HEATING SURFACE OF BOILER

• ECONOMISER - 20000 sq mtr


• WATER WALL - 7000 sq mtr
• STEAM COOLED WALL - 2010 sq mtr
• LTSH - 8500 sq mtr
• SH DIVISIONAL PANELS - 2025 sq mtr
• PLATEN SH (FINAL SH) - 2200 sq mtr
• SH ROOF - 830 sq mtr
• RH FRONT COILS - 4128 sq mtr
• RH REAR COILS - 3500 sq mtr

• TOTAL HEATING SURFACE AREA = 50193 sq mtr


WATER HOLDING CAPACITY OF BOILER

• BOILER DRUM (FULL) : 60 cubic mtr


• CIRCULATION SYSTEM : 170 cubic mtr
• ECONOMISER : 150 cubic mtr
• SUPERHEATER(LTSH,SH Div. Panel, Final SH): 130 cubic mtr
• REHEATER : 105 cubic mtr
• TOTAL VOLUME : 615 cubic mtr

• DM WATER REQUIRED FOR HYD. TEST


(DRAINABLE) : 420 cubic mtr
SOOT BLOWER DETAILS

• WALL SOOT BLOWERS : 88 Nos. (FUTURE - 16 Nos.)


(FRONT & REAR AT EACH ELEVATION - 6 Nos. EACH, RHS &LHS -5 Nos. EACH, TOTAL 4 ELEVATIONS)

• LRSB : 40 Nos. (FUTURE - 4 Nos.)


• APH SOOT BLOWERS :2 Nos.
COMPARISON BETWEEN NATURAL & ASSISTED CIRCULATION BOILERS

S/H
S/H

DRUM
DRUM

BOILER
BOILER
WALLS
WALLS

ECO
ECO

CC PUMP

FEED LINE
FEED LINE

RING HEADER RING HEADER

NATURAL CIRCULATION BOILER


(SUB CRITICAL BOILER 30MW-250MW) ASSISTED CIRCULATION BOILER
(500MW) DRUM CG – 75.33
DRUM CG. 26 MTR – 58 MTR MTRS

FORCE CAUSING FLOW OF


F = WCOLD X H1 - W HOT X H2
WATER THROUGH TUBES
CRITICAL BOILERS OR ONCE TROUGH OR MONOTYPE BOILER

S/H

STEAM

BOILER WALLS
SEPERATOR

WATER

ECO

DRAIN

FEED PUMP
IMPORTANT FEATURES OF 500 MW BOILER

• C.C. PUMPS
• ORIFICE PLATES IN BOTTOM RING HEADER
• RIFLED TUBES IN WATER WALLS
• DIVISIONAL SUPERHEATERS
• ECO LINK CONNECTIONS FROM BOTTOM OF BOILER DRUM
• DOWN COMMERS CONNECTION TO ONLY BOTTOM RING HEADER.
• ECO RECIRCULATION CONNECTION TO BOTTOM RING HEADER REAR.
• 2 NOS. TRISECTOR TYPE AIR PREHEATERS.
• 8 NOS. BOWL MILLS ( XRP 1043 TYPE) & GRAVEMETRIC 36” SIVE
FEEDER ( FEEDER LOCATION 21 ML )
• 4 NOS OIL ELEVATION & 8 NOS. COAL ELEVATION.
• 2 NOS. I.D FANS, 2 NOS. F.D.FANS, 2 NOS. SEAL AIR FAN, 11
SILENCERS , 20 SAFETY VALVES
• HEA INNITERS.
• COAL CONSUMPTION – 8400 T/HR.
NUMBER OF TUBES & DIAMETERS

DESCRIPTION NO. OF TUBES / PANELS DIAMETER OF TUBE


IN MM
RISER TUBES( W/W O/L HDR. TO 68 NOS. 159
DRUM)
WATER WALL ( FUSION WELDED ) FRONT-269 NOS., REAR-269 NOS, 51
LHS-212 NOS, RHS-212 NOS.
HANGER TUBES 44 NOS. 63.5
SCREEN TUBES 177 NOS. 63.5
REAR ARCH 177 NOS. 63.5
EXTENDED SIDE W/W PANEL LHS-37 NOS.& RHS-37 NOS. 63.5

ECONOMISER 92 X 3 BANKS 38.1


LTSH 62 X 2 BANKS 47.63
DIVISIONAL PANELLETE 6 ASSY. & 8 PANELS i.e. 48 NOS. 44.5
FINAL SUPERHEATER 25 COILS 51
REAHEATER FRONT-74 NOS. & REAR 74 NOS. 54
RADIENT ROOF 1ST PASS 150 NOS. 63.5
SUPER HEATER CONNECTION 21 NOS. 159
TUBES(DRUM TO RADIENT ROOF )
B.P. SIDE WALL ( FRONT ) 60 NOS. 63.5
B.P. SIDE WALL ( REAR ) 31 NOS. 51

B.P. ROOF TUBES 126 NOS. 51


B.P.FRONT SCW TUBE 126 NOS. 51
B.P.REAR WALL TUBE 137 NOS. 51
SAFETY VALVES LOCATION

M.S.LINE HRH LINE CRH LINE DRUM

SAFETY
2 4 4 6
VALVE

ERV
(ELECTROMATIC 2 2
RELIEF VALVE)