Boiler Pressure Parts

1. Economiser
2. Bottom Ring Header
3. Water Walls
4. Upriser
5. Drum and internals
6. Super heaters
7. Reheaters

July 23, 2020 1

 Drum vents RH attemperator Steam from HPT outlet
Economiser To IPT inlet
Steam to HPT inlet
Vent
Drum BOILER – FEED WATER TOSHSTEAM
Uprisers attemperator
1 11 12 13 14 2 7 3L

3R
10
Platen RH FINAL
SH SH

LTSH
D 9
o
w 6
n W W
A A Economiser EH
C O/L
T T EH 4L
o
E E I/L
m 5
e R R 4R
Furnace 8
r
W W To SH / RH
s
A A Attemperation
L L
L L E2 E1 LLCV

Eco
RC FLCV A
Bottom Ring Header

July 23, 2020

FLCV B Feed Water
2

from BFP
 FEED LIMB

July 23, 2020 3

 FEED LIMB

 Receives Feed water from Boiler Feed Pump at about 153-

160ksc and 247C.

 Contains two Full Load Control Valves (FLCV) and one Low Load
Control Valve (LLCV).

 Both FLCV and LLCV controls Drum Level.

 Before Feed Limb, Water is taken for SH / RH attemperation.

July 23, 2020 4

 BOILER LOAD

 Boiler load is expressed in TPH.

 Boiler load expresses only Main steam flow.
 Boiler load does not mention Reheater flow, but our Boiler is
steaming Reheater steam also.
 Boiler load is 700TPH.
 Since tonnage is equal both for steam and water for the
incoming Feed water and out going Main steam, flow is
measured only in tonnage.
 30% capacity of our Boiler is around 200TPH.
 LLCV delivers Feed water uo to 30% of the Boiler demand.
 Any one of the FLCV delivers Feed water to Drum from 30% of
the Boiler load to full load.

July 23, 2020 5

 Full Load Control Valve

 In feed limb, two FLCVs are available.

 Normally, one FLCV will be in service and other serves as stand
by.
 Each FLCV has one Pneumatic Control valve and two Electrical
Isolation Valves.
 Above 50-60 MW of TG load, FLCVs are used to control the
Drum level.
 Each FLCV has drains at the both sides of Pneumatic Control
valve.

July 23, 2020 6

 Low Load Control Valve

 In feed Limb, one LLCV is available.

 A pneumatic control valve and two Electrical Isolation valves are
provided in LLCV.
 LLCV is provided with drains at both sides of Pneumatic control
valve.
 A vent is also Provided at the downstream side of Pneumatic
valve for air releasing to avoid air-lock.
 Upto 50-60MW( 200TPH), LLCV is used to control the Drum
level.
 Air vent is opened for air releasing and drains are used to warm
up the line before charging a Feed- Limb in hot condition.

July 23, 2020 7

 Economiser
Drum

LLCV
E2 E1

FLCV A

Boiler Feed
Pump
FLCV B
Before
After
Swelling
Upto
Here
In
About
case
after,
30%
the
50-60MW
light
ofeffect
Boiler
any
of
FLCV
up,
Boiler
problem
isis
Drum,
will
of
over.
lighted
Load
Unit
feed
water
Now,
inLoad,
(200TPH),
up,
the
FLCV
Regular
wall
swelling
Drum.
LLCV
which
and
LLCV
to
feeding
effect
Economiser
isFLCV
inwill
service,
occurs
change
through
feed are
the
another
inover
the
LLCV
filled
Drum.
drum.
is is
FLCV
up
done.
by
back after
Only
initiated.
should feeding
be cut
theusing
in.
completion
Low Pointof Swelling
Drains. effect, regular feeding
through Feed Limb is done.
July 23, 2020 8
 FEED LIMB CHANGE OVER

 Consider FLCV-A is in service.

 Isolation Valves of FLCV-B are in open condition.
 Consider that a problem arises in FLCV-A.
 Turbine Operator takes manual control of FLCV-A.
 FLCV-B is gradually raised and FLCV-A is lowered suitably
without disturbing Drum Level.
 FLCV-B is now feeding Drum and FLCV-A is completely closed.
FLCV-A need not be in its full open condition.

 This is the procedure of FLCV change over.

July 23, 2020 9

 Feed Water

 Its temperature is around 150C if HPHs are not in service.

 Its temperature raises to 247C if HPHs are cut in.
 Normally, HPHs are cut in at about 160-180 MW.
 Feed Limb air releasing is done immediate after priming of first
BFP by Using air vent in LLCV and opening BFP discharge valve.
Ensure adequate water in the Deaerator.
 Warm up of FLCV in cold condition is not needed, as already the
Feed Limb is filled up and air released.
 But, warm up of FLCV in hot condition is essential as it may lead
to slight hammering or fast heating in the valve.
 Ensure opening of isolation valves before charging a line.
 Ensure closure of isolation valves of a Feed Limb and isolation of
modules before giving LC in it.

July 23, 2020 10

 FEED LIMB NRV healthy?

 Can be ascertained even before LLCV feeding.

 To be ascertained as said above.
 Because…..
 Any passing in E1, will not hold water in the Economiser.
Starvation of Economiser may occur during every cold starts.
 How to ascertain?
 Drum level is filled up. Economiser recirculation valves: open.
Open LLCV isolation valve. Keep/ ensure E2 open. If the LLCV
air vent is opened, no water should come through.
 Thus confirm healthiness of Feed limb NRV in every cold starts.
 Thus, you are saving and improving the life of your Economiser.

July 23, 2020 11

 Certain Whys?

Why isolation valves to Feed Limb Control Valves?

 To isolate in case of issuing Line Clear (LC).
 To isolate in case of any emergencies like leakages.

Why Electrical isolation valves?

 For quicker response (opening for bringing in service and closing in
case of emergency / LC).
 For opening and closing Feed limbs right from UCB itself.

Why Remote operation for isolation valves?

 Saving time.
 Avoiding accidents to Local operator in case of leakage.

Why Feed Limb control?

 To meet out the Feed Water Demand changes.

July 23, 2020 12

 ECONOMISER RECIRCULATION

 Avoids Economiser starvation during every Cold- start ups.

 In Hot starts, regular feeding though Economiser is available
from Boiler Feed Pumps.
 Eco. RC connects Bottom Ring Header and Economiser.
 Whenever there is water in the Drum, Economiser will also have
water level.
 There are two numbers Economiser RC lines.
 Any one Economiser RC is enough.
 Economiser has one NRV and a isolation valve. This NRV avoids
water reversal from Economiser. The isolation valve can be used
to isolate Economiser in case of need.
 If regular feeding is started, the water in Economiser to BRH is
avoided by Economiser RC NRV.

July 23, 2020 13

 Drum Level Control

 Boiler Feed Pump Scoop and Feed Limb jointly controls the
Drum Level.
 The method used in Drum Level Control in a Thermal power
Station is Three Element Control.

Three Elements for Drum Level Control:

 Feed Water Flow - Measured before Feed Limb.
 Main Steam Flow - Measured after PRDS tapping.
 Drum Level - Hydra steps and Level Indicator.

July 23, 2020 14

 P2
P1 52m

BFP
DRUM

4.5m Feed Limb

P1 = Pressure at discharge of Boiler Feed Pump.

P2 = Pressure at Drum.
X = Pressure Loss in pipe line.

If P1 ≤ P2 + x, no water goes to drum from pump. (1)

If P1 > P2 + x, water goes to Drum. (2)

(2) Can be rewritten as P1 = P2 + ∆P, where ∆P= Extra pressure+ pressure loss.

∆P = Extra pressure needed due to Height difference in ksc + x

(52m – 4.5m)
∆P = + x = 5.5 ksc
10
So, We have to maintain ∆P between P1 and P2 above 5.5ksc to get better Drum
July 23, 2020
feeding. It is maintained by Boiler Feed Pump Scoop. 15
 Super Heaters PRDS
(15TPH)

Economiser Main Steam Flow

Sensor
Drum
Feed
Limb
HPT
Upriser

Feed Water Flow Water Wall

Sensor

Bottom Ring Header

High Pressure
Heaters

BFP

July 23, 2020 16

 FEED WATER

 Pressurized and delivered by two BFPs.

 Some quantity of feed water is availed for HP Bypass
attemperation if needed (during Warm and Hot starts only.)
 Some quantity of Feed water is availed to PRDS attemperation if
required. ( Normally, CEP water is only used for this PRDS
attemperation.)
 All quantity of Feed water is going into the HP Heaters (nearly at
about 80-90% of the Unit load) for its temperature improvement
from 150C-247C.
 Some quantity of Feed water is sent to SH/RH attemperation
from Feed water line just before Feed limb.

July 23, 2020 17

 DRUM LEVEL CONTROL D
Drum Level Differential Differential
R
Pressure ∆P: flow U
6ksc ∆F:15TPH
Normal M
∆F<15TPH Raise Pulse goes to L
Low Scoop and BFP
loaded slightly.
E
High V
E
∆F Feed Limb Discharge Pressure L
increases Opens increases
C
O
∆P normalises ∆P increases N
slightly
∆F>15TPH T
Lower Pulse to BFP unloaded DP
R
Scoop slightly decreases O
July 23, 2020
Drum level No flow to L
18

Normalises Drum
 ECONOMISER

July 23, 2020 19

 ECONOMISER

 It is one of the Regenerative system in the Boiler.

 It preheats the incoming Feed water to about 32C by absorbing the
heat from the flue gas that is coming from the LTSH.
 Steaming in the Economiser is to be avoided as water is badly needed
in the Drum.
 The flue gas temperature at the inlet of the Economiser is around
420C.
 The flue gas temperature at the outlet of the Economiser is around
363C.
 There are three sets of coils in the Economiser.
 These tubes are of Finned type.
 Economiser has a curved gas duct at its down stream side along with 4
numbers fly-ash collecting hoppers.
 Coarser fly-ash, which attains higher velocity energy in the curved
trajectory, will hit the Economiser hopper and falls down after losing its
energy.

July 23, 2020 20

 FURTHER DETAILS

 Economiser is provided at the bottom of the Rear gas path in the

Boiler.
 One NRV (E1) and one electrical isolation valve are available in
the inlet side of the Economiser.
 Two numbers Economiser recirculation valves are also connected
with the inlet of the Economiser.
 One number Economiser drain is connected with this Economiser
inlet which goes and connects the Water Wall Drain Header.
 Feed water sampling line is also provided in its inlet.
 Two numbers outlet pipes are emerging from the Economiser
outlet and delivers water to Drum. One number Eco. Vent is
provided in this line at Drum level.
 Economiser man-Holes are available at its both ends.
July 23, 2020 21
 ECONOMISER COLD END CORROSION

 COLD END CORROSION IS CAUSED BY THE ACIDIC FUMES

THAT ARE FORMED DURING THE COLD LIGHT UP OF THE
BOILER.
 SULPHUR REACTS WITH OXYGEN TO PRODUCE SULPHUR DI-
OXIDE.
 IT GOES ALONG WITH FLUE-GAS.
 WHENEVER IT IS COMING ACROSS MOISTURE, IT REACTS
WITH WATER TO FORM SULPHUROUS OR SULPHURIC ACID.
 THIS ACID FORMATION IS POSSIBLE ONLY IF ACID DEW
POINT IS ARRIVED AT THAT CONCERNED LOCATION.
 SUCH A CONDITION MAY OCCUR AT THE BOTTOM OF THE AIR
PRE- HEATER AND ECONOMISER BOTTOM.

July 23, 2020 22

 ECONOMISER COLD END CORROSION……

 Sub-cooling is possible in the lower part of the Economiser tube

outlet, only if cold Feed Water is pumped to the Drum.
 But, First Feed Water Pump is started only after 150 minutes of
a Boiler Light up.
 Because, fresh water is not needed to a Drum till 165 minutes of
a Boiler cold start up( swelling effect in the Pressure parts will
not require fresh water to the Drum).
 While first BFP is started, the flue gas temperature at
Economiser outlet will reach above 72C
 This sequence should be adopted for every Cold start ups.
 Economiser cold end corrosion will never occur.

July 23, 2020 23

 ECONOMISER RE CIRCULATION VALVES

 These valves are kept open always.

 These valves are not to be closed during initial filling.
 These valves are not to be closed during Swelling periods.
 These valves are not to be closed till regular feeding is started
by the Boiler Feed Pump and such feeding should be continuous
too.
 In case of emergency, any one Economiser Re-Circulation line
may be isolated if badly needed.
 There is no harm in keeping open these lines while the Boiler is
steaming as there is NRV in each lines.

July 23, 2020 24

 ECONOMISER DRAIN

 Normally, this drain is used for draining the Economiser during a

Shut-down.
 Also used for draining Economiser during a Hydraulic test, if
needed.
 Also used for filling up the Economiser and Drum during Initial
Feeding of Drum.
 Normally kept in closed condition.
 These drains are available only at Low Point Drains Header.
 Boiler draining is to be done through IBD Flash tank.
 Cold Boiler can be drained through atmospheric drain of Low
Point Drain Header too.
 Never drain hot Boiler through atmospheric drain.

July 23, 2020 25

 ECO. TO DRUM

 Two pipe lines are emerging from Economiser outlet to Drum.

 One from Left.
 Another from Right.
 Each pipe line is divided into two.
 These lines are called “Drum feed lines from Eco.”
 All these four lines are connected to the top of the Drum.
 One vent is taken from Economiser outlet line.
 Two vents are taken in Drum feed lines near Drum.
 These vents are provided at 52m level with a trough at its
bottom.

July 23, 2020 26

 VENTS OPERATION

 Meant for air releasing.

 To be closed only after ensuring no air in the Drum & Eco.
 Closed only if Drum steam pressure reaches 2ksc.
 If Drum is having steam of 2ksc, naturally, the already
entrapped air would have replaced out by the produced steam.
 This procedure is adopted only during Light-up.
 During Shut-down, the Drum pressure starts lowering due to
condensing effect of steam inside the Boiler.
 If steam pressure drops to 2ksc, then the vents in the Drum and
Eco. are to be opened.
 This is to be done to facilitate the Hot draining of the Boiler
through Low Point and SHH Drains.

July 23, 2020 27

 HOT DRAINING

 Atmospheric air contains moisture and certain unwanted gas.

 Presence of moisture and such gas inside cold tubes will lead to
the formation of acids and hence the corrosion.
 This corrosion will be serious if tubes are of wet nature.
 Hence, the Boiler is to be drained in the hot condition.
 If it is so, the wet condition of the tubes would be avoided.
 This is to be done in each Shut-down.
 This is not to be done to the Boilers which are to be relighted up
well within the Drum pressure killing.
 Ensure no steam pressure in the Drum. Open SHH drains and
Low Point Drains valves and divert it to IBD Flash Tank.

July 23, 2020 28

 WATER ENTRY TO DRUM

 Pre-heated water enters Drum.

 Fills and goes to Bottom Ring Header through Down-Comers.
 Raises up in the Water walls.
 Fills Economiser through Economiser Recirculation valves.
 There is a drain in the Bottom Ring Header.
 It is normally kept closed.
 It is used only by BM crew, that too, during Shut down periods
to clean the Bottom Ring Header.
 This drain is not to be used by Operators at any condition.

July 23, 2020 29

 NATURAL CIRCULATION

 Water in the BRH, Eco., Down comer and water walls.

 Heat in the furnace.
 Absorbed by the water walls.
 Wet saturated steam is produced.
 Density is lowered.
 Steam goes up by its own accord..
 Level lowers in water walls.
 Replaced by the water from the Drum through Down comers.

 It is called as “ NATURAL CIRCULATION”.

July 23, 2020 30

 DRUM SWELLING

 INITIAL HEATING IS LITTLE BIT DIFFERENT.

 Water up to the Drum middle.
 Flame is introduced in the furnace.
 Water walls are getting heated first.
 Water level in the Drum slightly lowers.
 Further heating continues.
 Water is getting heated.
 Water swelling starts.
 Water level increases in the Drum.
 Use EBD and control the Drum level within limit.
 Steam is produced and swelling ceases.
 Water level decreases in Drum and regular feeding is given.
July 23, 2020 31
 EBD AND SWELLING

 EBD valves are to be used to drain water from Drum in case of

Swelling.
 Thus, Drum level is maintained well within the top portion of the
Hydrastep.
 Opening of the EBD should be avoided in case Drum pressure
reaches above 5ksc.
 Such an operation will pressurize the EBD Flash tank.
 Reversal of water to CRH or HRH Header may occur in Turbine
side.
 Later, hammering may occur.

 SO, NEVER USE EBD VALVES IN PRESSURIZED BOILER.

July 23, 2020 32

 DRUM INTERNALS

 Primary separator.

 Secondary separator.

 Wire-mesh separator.

 EBD

 CBD

 Phosphate Dozing.

July 23, 2020 33

 WET TO DRY SATURATED STEAM

DRUM SEPARATORS

PRIMARY WIRE-MESH

SEPARATOR SEPARATOR.
SECONDARY
SEPARATOR

July 23, 2020 34

 PRIMARY SEPARATOR

 Wet Saturated steam comes to Primary separator bottom.

 Steam goes up with swirling trend in the Primary separator.
 High mass moisture in the steam is thrown away at the top of
the Primary separator.
 The above moisture/ water is thrown down to the water in the
Drum.
 Steam finds a way to the entry of the Secondary separator.

 PRIMARY SEPARATOR SEPARATES WATER FROM THE WET

SATURATED STEAM BY MEANS OF CYCLONIC EFFECT.

July 23, 2020 35

 SECONDARY SEPARATOR

 Plates are staggered in this Separator.

 Acute bends of steam flow path is made here.
 Wet saturated steam from Primary separator enters here.
 While flow reversals are made in these separators, steam is
easily makes twists. But, the water in the steam can not make
so.
 Hence, water particles stayed at the bottom or the ends are
collected to a level and drops below to Drum water.

 THUS, FURTHER WATER PARTICLE SEPARATION IS DONE AT

THE SECONDARY SEPARATOR.

July 23, 2020 36

 WIRE-MESH SEPARATOR.

 Provided at the top of the Drum.

 Provided above the Secondary Separator.
 Steam from the Secondary Separator is going through the Wire-
Mesh Separator.
 As the holes are very minute in the wire-mesh, the steam
passes very easily through the holes.
 Due to surface tension effect, the water will stick to the wire
surface.
 After collecting considerably, the water drops down to Drum
water.

 ONLY NOW, THE STEAM ATTAINS DRY STATE.

July 23, 2020 37

 NUMBERS

 PRIMARY SEPARATORS 2X96.

 SECONDARY SEPARATORS 2X96.

 WIRE-MESH SEPARATOR 1

July 23, 2020 38

 PRIMARY,
WET
SECONDARYAND DRY
SATURATED
WIRE MESH SATURATED
STEAM
SEPARATORS STEAM

UPRISER SUPER HEATER

MOISTURE TO
TUBES. TUBES.
WATER INSIDE
DRUM.

July 23, 2020 39

 Moisture separation principle

 Primary separator Cyclonic method.

 Secondary separator Flow reversal.

 Wire-mesh separator Surface tension.

July 23, 2020 40

 EBD

 Emergency blow-down.
 Starts draining Drum if level raises to +150mm.
 Stops draining the Drum if Drum level lowers down to -50mm.
 Take-off point inside Drum.
 No valve at Drum side.
 Two electric valves are at 18m level.
 Very first valve is of isolation type.
 The next valve is of regulation type.
 Delivers water to IBD Flash Tank.
 EBD delivery is connected to Boiler Drain Header and then goes
to IBD FT.
 Normally used only during Drum Swelling periods.
July 23, 2020 41
 EBD
VENT
DRUM

EBD LINE

ELECTRIC ISOLATION VALVE

ELECTRIC REGULATION VALVE

IBD FT

July 23, 2020

DRAIN 42
 CONTINUOUS BLOW DOWN

 Done at Drum.
 Done continuously to remove Silica.
 Silica by itself will be removed where temperature is more than
300C and pressure is within 60 to 160ksc.
 These conditions are fairly available in the Drum.
 Silica is removed maximum by Temperature and upto some
extent by Tri Sodium Phosphate (TSP) Dozing.
 TSP converts silica in water into Silicates (precipitates).
 These precipitates are easily disposed off through CBD.
 If silica is less (<0.2ppm), then Steam at CBD FT can be
reutilised in FWST.
 At Lower Pressure and Temperature, Silica will be more affinitive
to Water and hence water from CBD opening is drained off.

July 23, 2020 43

 DRUM (inclined 1 to Horizontal)

To FWST

CBD Control Valve CBD FT

TSP Dozing
CBD FT LCV

Boiler Drain Header IBD FT

July 23, 2020
 Feed water limits

DRUM Pr. 61 to 102 and DRUM PR. 61 TO 100 101 and

(ksc) 100 above. (KSC) above.
pH for Copper 8.8 8.8 to pH for 9.0 to 9.4 9.0 to9.4.
alloy to 9.2. Copper
free alloy
9.2.
Oxygen 0.007 0.007 Iron 0.01 0.01
Max. ppm Max. ppm.
Copper 0.01 0.01 Silica 0.02 0.02
Max. ppm. Max.ppm.
Conductivity 0.5 0.5 Hydrazine 0.01 to 0.01 to
Micro.siem/cm Residual 0.02 0.02
ppm.
July 23, 2020 45
 BOILER WATER LIMITS

DRUM 61 TO 125 126 TO 165 166 TO 180 181 TO 205

PRESSURE
(ksc)
Total
dissolved 100 50 25 15
solids ppm.
Conductivity
Micro 200 100 50 30
siemens
per cm.
Phosphate in
steam ppb 5 to 20 5 to 10 5 to 10 2 to 6
pH 9.1 to 10.1 9.1 to 9.8 9.1 to 9.8 9.1 to 9.8
Silica in
steam ppm
July 23, 2020
0.2 0.2 0.2 0.2 46
 DRUM PRESSURE AND SILICA LIMIT

Drum Pr. Ksc Silica ppm

60 70
75 4.0
90 2.3
105 1.5
120 0.96
135 0.636
150 0.386
165 0.25
180 0.13
July 23, 2020 47
 WHEN TO START PHOSPHATE DOZING

 Already dozed water is fed with Drum before Light up.

 That dozing is only for dissolved Oxygen and pH.
 Phosphate dozing is ineffective in cold state.
 Hence, Phosphate dozing is to be given at hot condition of water
in the Drum.
 This dozing is given when continuous feeding is started through
BFP.

 This dozing is stopped if Boiler is tripped.

July 23, 2020 48

 Intermittent Phosphate dozing.

WHY?

TRACES OF PHOSPHATE IN DRUM FEED

WATER WILL REACT WITH SILICA AND
REMOVAL OF SILICATES IS POSSIBLE.
SO, REGULAR DOZING IS NOT NEEDED.

July 23, 2020 49

 DRUM
 2 Man-holes one at each side.
 Drum Gauge glasses ( one at each side).
 Hydrasteps (one at each side).
 Pressure transmitters.
 Temperature transmitters.
 Wet saturated steam sampling points( 5numbers)
 CBD routine sampling line and stand by sampling line.
 3 numbers Drum safety valves( one at one side and two at other
side.
 Four numbers feed water incoming lines from Economiser.
 Dry saturated steam outlet from Drum to SHH-1
 Drum casing thickness is more at upriser end and lower at
other end

July 23, 2020 50

 Phosphate dozing line

 Always kept open.

 Closed only during Hydraulic test.
 Pump is started and stopped accordingly to maintain the
Phosphate value within 5 to 10 ppb.
 NRV is provided near Drum side to avoid reverse flow from
Drum.
 Flushing of the Dozing line is a ‘must’ before and after this
dozing.
 If not, clogging and subsequently choking of the line may arise.
 Phosphate limit may be raised to 10 to 20 ppb, only if condenser
tube leakage is suspected and is minimum.
 Hand tripping of the Boiler is to be done in case the main steam
pH lowers below 8, eventhough Phosphate limit is 10-20 ppb.

July 23, 2020 51

 SUPER HEATERS

 There are 14 numbers Super heater Headers.

 Those are of Roof type, side wall type, Low temperature type,
Platen type and Final type.
 Having vents in all the top level Super heaters.
 These vents are opened before Light up and closed after
reaching 2ksc pressure in the Drum.
 Having drains in the bottom level Super heaters along with that
at SHH-1 and SHH-14.
 These drains are opened before Light up and closed only after
reaching 7ksc in the Drum.
 Having one ERV and one Super heater Safety valve.
 Having two numbers SH start up air vents.
 Having attemperation facility between 10 th and 11th header.

July 23, 2020 52

 WHAT FOR?

 AIR VENTS AIR RELEASING

 SHH DRAINS MOISTURE RELEASING.

 SHH START UP VENTS TO VENT OUT STEAM FOR

CREATING STEAM FLOW.
 ERV OPENED IF REQUIRED AT
ANY TIME TO VENT OUT
STEAM. ALSO, ACTS LIKE
A SAFETY VALVE.
• SAFETY VALVE TO RELEASE STEAM TO
AVOID PRESSURIZATION.
July 23, 2020 53
 ATTEMPERATION

 Temperature reduction to a slight level to the requirement

within the same status of steam temperature.
 Done at 10th header of the Super heaters.
 Also done at the inlet header of the Reheater.
 Normally, the steam temperature is maintained at 540 C.
 Avoid attemperation in Super heater and Reheaters as it would
reduce Efficiency and scale formation in heating surface.
 Part of Feed water at 250C is sprayed against the Main steam
or Reheat steam to be lowered. The sprayed water becomes
steam and thus lowers the steam temperature.
 Main steam attemperation is normally done at 70 MW and
Reheater attemperation is done at 120 MW.

July 23, 2020 54

 DRUM SAFETY VALVES

 B1 Releases at 158.2ksc.( 1% BD)

 B2 Releases at 161.4ksc ( 1% BD)

 B3 Releases at 162.95ksc.( 1% BD)

July 23, 2020 55

 FEED WATER TUBE

 OUTER DIAMETER 323.9mm.

 THICKNESS 36.4mm.

 Material SA 106 Gr.C

July 23, 2020 56

 MAIN STEAM OUTLET PIPES

 TWO NUMBERS.

 INNER DIAMETER 255.6mm.

 Thickness 49.2mm.

 Material SA 335 P 22.

July 23, 2020 57

 SUPER HEATER SAFETY VALVE

 There is only one Safety valve called S14.

 Acts at 142ksc. (1% BD)

 ERV is also provided at Super heater outlet; but, in the other

limb.
 Acts at 140.6ksc.( 1% BD)
 ERV can be operated at any pressure.

July 23, 2020 58

 Re heater safety valves

 There are 4 numbers Safety valves in the Cold Re heater side.

 First one releases at 33ksc.
 Second one releases at 33.33ksc.
 Third one releases at 33.7ksc.
 Fourth one releases at 34ksc.

 There is only one Safety valve at Hot Re heater side.

 Acts at 30.1ksc.

July 23, 2020 59

 Furnace details

 Fusion welded furnace.

 Effective projected radiant surface 2118m2
 Width 13868mm.
 Depth 10592mm.
 Volume 5202m3.
 Fuel heat input 534.6X 106.

July 23, 2020 60

 Calorific value & full load coal flow.

COAL FLOW (TPH FOR FULL LOAD) APPROXIMATE CALORIFIC VALUE

K Cal/Kg.
118 4530
125 4277
130 4112
135 3960
140 3819
145 3687
150 3564
155 3449
160 3341
165 3240
170 3145
July 23, 2020 61
 HOT REHEAT PIPE

 TWO NUMBERS

 OUTER DIAMETER 558.8mm

 Thickness 32.2mm

 Material SA 335 P 22.

July 23, 2020 62

 COLD RE HEATER PIPE

 TWO NUMBERS

 OUTER DIAMETER 508mm

 Thickness 12.7mm.

 Material SA 106 Gr. B

July 23, 2020 63

 DRUM DETAILS

 INNER DIAMETER 1676mm

 OUTER DIAMETER 1972mm

 WEIGHT 130 T

 INNER SIDE WALL THICKNESS MORE

 EXPOSED WALL THICKNESS LESS.

 DRUM LENGTH 20m (approx)

July 23, 2020 64
 HEATING AREAS

 Front water wall tubes 181 nos. of (OD) 63.5mm.

 Side water wall tubes 130 nos. of (OD) 63.5mm.
 Super heater outlet tube 137ksc (nor) 158.2ksc (design)
 LTSH 5180m2.
 Platen Super heater 1007m2.
 Final Super heater 1039m2.
 Total Super heater 7226m2.
 Radiant Re heater 2654m2.
 Economiser 4745m2.
 Air pre heater 2 X 19000m2.

July 23, 2020 65

 MAIN STEAM

 135Ksc, 540C and 650 tph.

 Having MSSVs at both the ends.

 Each MSSV has one bypass valve.

 Main steam goes to Turbine and PRDS.

 Bypass for warming up. MSSVs for regular use & box-up
July 23, 2020 66
 RE HEATERS

 HPT exhaust steam comes to Re heater through Cold Reheat

pipes.

 Cold Re heat steam 24.8 ksc, 330C

 Hot Re heat steam 24.4 ksc, 540C

 Hot Reheat steam goes to IPT for expansion there at IPT and
LPT.
July 23, 2020 67