• WHY TO GO HIGHER CAPACITY BOILER

• SPECIFICATION OF 500 MW BOILER

• SPECIAL FEATURE OF 500 MW BOILER

• NEED FOR ASSISTED CIRCULATION / FORCED CIRCULATION

• DESIGN FACTORS

• CONSTRUCTION OF
• WATER WALL TUBE, SUPER HEATER, REAHEATER

• CONSTRUCTION OF BOILER DRUM

 1’ 1’-2’ = Work done in
1 turbine from P1 – P2
T
P1
2’-3 = Heat Rejection in
condenser

3-4 = Water pumped to

4 boiler
P2
3 2 2’ 4-1 = Heat addition in eco
and boiler.
S
 Theoretically Carnot Cycle is the ldeal cycle. But it
is having practical difficulties.
 For steam power plant, practically thermal cycle
used is modified rankine cycle.
 The maximum efficiency between two limits of the
working fluid as given by the carnot cycle is
 Efficiency = (T1 – T2)/T1
where T1 and T2 are max. and min absolute temp.
 Now as T2 is limited by ambient conditions so T1
must be as high as possible.
 Thus from the efficiency point of view, the largest
gain can be obtained by the use of higher
temperature. i.e to increase T1
FURNACE
 TYPE: Balanced Draft
 Wall: Fusion welded
 Bottom: Dry
 Tube arrangement: Membrane
 Explosion / Implosion withstand Capacity at 67% yield point :
+/- 660mmwg
 Residence time for fuel particles in the furnace : 3 sec.
 Effective volume used to calculate residence time: 14580 m3
 Furnace height(from center of ring header to centre of roof
inlet header) : 61.168 meter.
 Depth : 15.289 meter
 Width : 18.034 meter
 Furnace Volume : 14580 m3
 Design Code: IBR
 Type of Firing: Tilting Tangential
 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.
 4 Nos. of bisector air pre heater, two for primary air and two for
secondary air.
 8 Nos. of XRP 1043 bowl mills.
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)
 Density difference is the driving force for the steam and water
mixture.
 Circulation takes place at such a rate that the driving force
and the frictional resistance are balance.
 But as the pressure increases, the difference in density
between the water and steam reduces.
 Hydrostatic head available may not be able to overcome
the frictional resistance for the flow corresponding to the
minimum requirement of cooling of water wall tubes.
 Therefore, natural circulation is limited to Boiler with the drum
operating pressure around 175 kg/cm2
 Above 175 kg/cm2 of pressure, circulation is to be assisted
with mechanical pumps, to overcome the frictional losses.
 To regulate the flow through various tubes orifice plates are
used.
For the construction of boiler parts subjected to
pressure and their integral attachment, the designer
takes into account several factors
TUBE DETAILS
 All economizer tube are of Ø 51mm X 5mm.
 Located in the boiler back pass.
 It is composed of three banks of 130 parallel
tube elements arranged in horizontal rows.
 Each row is in line with the row above and
below.
 All tube circuit originate from the inlet
header and terminate at the outlet header.
 ECO OUTLET HDR
Ø406.4

ECO UPPER BANK

ECO MIDDLE
BANK

ECO LOWER
BANK

ECO INLET HDR

EC0 FEED PIPE Ø508
TUBEE DETAILS
Description Tube Size Material
Riser Tube Ø 159 X 15 SA – 106 Gr-C
Water wall panel Ø51 X 5.6 SA – 210 Gr-C
tubes
Extended side Ø 63.5 X 7.1 SA – 210 Gr-A1
water wall tube
W. W. Hanger tubes Ø63.5 X 11 SA – 210 Gr-C
W. W. Screen tubes Ø63.5 X 7.1 SA – 210 Gr-A1
Rear Arch Tubes i. Ø51 X 5.6 SA – 210 Gr-C
ii. Ø63.5 X 7.1 SA – 210 Gr-C
iii. Ø63.5 X 7.1 SA – 210 Gr-A1
 FUR REAR HGR
RISER TUBES, Ø TUBE O/L HDR
159 Ø273

FUR UPPER SIDE

WW HDR Ø273 FUR UPPER REAR
BOILER DRUM WW HDR Ø273
Ø1778

REAR WALL
HGR TUBES SCREN TUBES
Ø63.5 Ø63.5

FURN FRONT
SUCTION WALL TUBES
MANIFOLD , Ø508 Ø51

FURN REAR
FURN SIDE WALL TUBES
WALL TUBES Ø51
Ø51

BCW PUMP

FURN SIDE FURN REAR

HDR , Ø914.4 HDR , Ø914.4

WATER WALL DETAILS AND CYCLE

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 tubes Ø 47.63 X 8.6 SA 210, Gr C
Description Tube Size Material
Steam Cooled Side Wall Ø 51 X 5 SA 210, Gr C
tubes
Bifurcate Tubes (Bottom Ø 51 X 5 SA 210, Gr C
Header)
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 i. Ø 51 X 6 SA 210, Gr C
tubes ii. Ø 44.5 X 4.5 SA 210, Gr C
Divisional Panel Outlet loose i. Ø 51 X 6 SA 213, T11
tubes
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
 Super heater tubes is composed of three
basic stages of section.
Finishing
pendent
platen super
heater

Divisional A Low
Panel Temperature
Section Section
 The finishing section is located on the
horizontal gas path above the furnace rear
arch tubes.
 The divisional panel section are located in
the furnace between the front wall and the
pendent platen section.
 It consist of 6 front and 6 rear assemblies.
 The low temperature section are located in
the furnace rear back pass above the
economizer section.
 They are composed of 116 assemblies
spaced on across the furnace width.
 The back pass wall and roof section forms
the side, front, rear wall and roof of the
vertical gas pass.
 DIV PANEL O/L LINK MAIN
Ø 508, 2 NOS. STEAM

SH DESH Ø 508, 2
NOS.

HDR, Ø 406.4
SH ROOF O/L

BP UPPER REAR
HDR, Ø 273
SH CONN TUBES,
Ø 59

SH & ECO SUPP

ASSY, Ø 51, 6 ASSY

LTSH UPPE BANK TUBES, Ø 51

SH VERT PLATEN
Ø 47.63

LTSH I/L HDR, Ø

323.9
SH DIV. PANELETTE, LTSH LWR BANK
Ø 44.5, 6 ASSY Ø 47.63

BP LWR FRONT HDR, BP LWR SIDE REAR BP LWR REAR

Ø 406.4 HDR, Ø 406.4 HDR, Ø 323.9
BP LWR SIDE REAR
HDR, Ø 323.9
TUBE DETAILS
Description Tube Size Material
Reheater Wall Ø 60.3 X 4 SA 313, T11
tubes
Cross over tubes Ø 54 X 3.6 SA 213, T11
 The re heater section is composed of
three stages or section.

Finishing
section

Front Platen Radiant wall

Section section
 The finishing section is located above he
furnace arch between the furnace
screen tubes and the super heater tubes.
 It consists of 46 tubes assemblies.
 The reheater front and side radiant wall is
composed of tangent tubes on 63.5
centres across the furnace width.
SH CONN TUBES,
Ø 59

RH VERT PLATE
I/L HDR, Ø 457.

SH ROOF O/L RH VERT PLATEN

HDR, Ø 406.4 O/L HDR, Ø 558.8
 RH VERT PLATEN
I/L HDR, Ø 457.2
MAIN
STEAM

RH VERT PLATEN
O/L HDR, Ø 558.8

COMPLETE CYCLE 500 MW

 The function of the boiler drum internals is
to separate the water from the steam
generated in the furnace walls.
 To reduce the dissolved solid contents of
the steam to below the prescribed level.
 Separation is generally performed in
three stages.
IInd Stage
Ist stage Corrugated
Spinner sheets
Blades
IIIrd Stage
Screen
Dryers

Dry Saturated Steam

Boiler Internals Mainly Consists of: -
 From the riser tube steam and
water mixture flows into the
Drum through a narrow
annulus formed by a shroud
extending along the length of
the Drum Shell called the
Separating Chamber.
 This is a welded construction
formed by Baffles.
 These surfaces direct the flow
of substances either to
prevent or o improve it’s flow.
 It directs the steam and water
mixture entering the drum to
the turbo separator.
  From the lower
end of the
separating
chamber the
steam and water
mixture is forced
Spinner
Blades
upward in the
turboseparator.
Cans
 Turbo separator is
a main separating
device.
 The primary stage is formed by two concentric cans
and a spinner blade located inside the inner can.
 The fixed spinner blade of turbo separator which is
located inside the inner can imparts a centrifugal
motion to the mixture of steam and water flowing
upward through the inner can.

 The secondary stage consists of two opposed banks

of closely spaced thin corrugated sheets.
 It directs the steam through a curved path and
separates the remaining entrained water.
 Since the velocity is relatively low this water is not
picked up again but runs down the plate and flows
down to the drum water.
 This stage of separation is called secondary
separation or steam scrubbing.
 The third and final stage of
steam/water separation takes
place in the screen dryer.
 It removes residual moisture
from the steam leaving turbo
separator.
 The screen dryer box consists
of wire mesh of different
gauges.
 Exterior meshes are of thicker
wire rod, which have better
mechanical rigidity to the
screen box.
 The steam passing between
the strips making one or more
sharp changes of direction
and throwing the heavier
water particle coming in
contact with the strips.
Sr. Materil C Mn P S Si Ni Cr Mo V Cb Used in
No. a
spec.
1 SA 210, 0.27 0.93 0.048 0.058 0.1 Extended side WW tube, WW screen
Gr- A1 0 tube arch tube
2. SA 210, 0.35 0.29 0.048 0.058 0.1 WW Panel & corner transition tube,
Gr C to 0 hanger tubes, rear arch tube, Eco tube,
1.06 steam cooled wall, rear roof, SH hanger
tube, LTSH divisional Panel loose tube.
3. SA 213, 0.15 0.30 0.03 0.03 0.5 1.0 0.44 Radiant roof pendent coil divisional
T11 to to to to panel, S, C, spacer, SH Platen coil, re
0.60 1.0 1.5 0.65 heater wall , re heater coil.
4. SA 213, 0.15 0.3 0.03 0.03 0.5 1.9 0.87 Divisional Panel, SH Platen coil, RH Platen
T91 to to to Coil, RH rear coil.
0.6 2.6 1.13
5. SA 213, 0.08 0.3 0.02 0.01 0.2 0.4 8.0 0.85 0. 0.06 Platen SH coil, platen RH Coil.
T91 to to to to to 18 to
0.12 0.6 0.5 9.5 1.05 to 0.10
0.
25
6. SA 213 0.04 2.0 0.04 0.03 0.7 8.0 18.0 - - - Divisional Panel, RH platen coil.
TP 304- to 5 to to
H 0.10 11.0 20.0
7 SA 213, 0.04 2.0 0.04 0.03 0.7 9.0 17.0 Divisional panel, SH platen coil, steam
TP 304- 5 to to cooled spacer.
H 13.0 20.0