Professional Documents
Culture Documents
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.
0.7
Density of Water
0.6
0.5
0.4
Critical
0.3 Point
0.2
Density of Steam
0.1
0
80 100 120 140 160 180 200 220 240
Pressure (Kg/cm2)
According to working pressure
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
Requirement?
758-726 ºC 720 ºC
1020-793 ºC
1135-1020 ºC LTSH
461 ºC
1300-1400
ECO
1100-1250
355 ºC
SA-318 ºC APH
A B PA-313 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 & 1 PASS
ST
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
2 ND
PASS ROOF O/L HDR(REAR ECONOMISER
Thank You