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Typical
Typical 500MW
500MW Boiler
Boiler
 BOILER
“BOILER” MEANS ANY CLOSED VESSEL
EXCEEDING 22.75 Litres IN CAPACITY
WHICH IS USED FOR GENERATING STEAM
UNDER PRESSURE.

-
IBR
 TYPES OF
BOILERS
(A) BASED ON APPLICATION:

1. UTILITY Boilers are large capacity steam generators

used purely for electrical power generation.

2. INDUSTRIAL Boilers are small capacity boilers intended

for use in the process industries.
TYPES OF
BOILERS
(B) BASED ON CONSTRUCTION:
1.Vertical Package- VP
2.Vertical Recovery-V2R
3.Vertical Unit 40-VU40
4.Vertical Unit 60-VU60
5.Modular Unit-MU
6. 2 Pass Single Arch
7. 2 Pass Double Arch
8. Close couple
9. Box Type
10.Tower Type
 TYPES OF BOILERS…contd
(C) BASED ON FUEL FIRING:
1.OIL FIRED
2.OIL AND COAL FIRED
3.BLACK LIQUOR (For Paper Mills)
4.BAGGASE
(D) BASED ON TYPE OF FIRING:
1.WALL FIRING
2.CORNER TANGENTIAL FIRING
3.STOKER

(E) BASED ON NO OF DRUM:

1.SINGLE DRUM 2. BI- DRUM
3.NO DRUM (Vertical Separator)
 TYPES OF BOILERS…contd

(F) BASED ON CIRCULATION:

1. NATURAL
2. CC+ (Pump + Orifice + Rifled Tubing)
3. Once Through
 BOILER PARAMETER:
(A) UTILITY BOILERS:
1. Main Steam Flow – T/Hr.
2. Main Steam Pressure – Kg/Sq.Cm.(g)
3. Main Steam Temperature - ºc
4. Reheater Flow – T/Hr.
5. Reheater Pressure – Kg/Sq.Cm.(g)
6. Reheater Temperature - ºc
(B) INDUSTRIAL BOILERS:
Steam Flow – T/Hr.
(C) HEAT RECOVERY UNITS:
Fuel Used – T/Day.
 BOILER COMPONENTS
(General)

1. STRUCTURAL COMPONENTS
2. PRESSURE PART COMPONENTS
3. FUEL SYSTEM COMPONENTS
4. AIR & FLUE GAS SYSTEM COMPONENTS
5. CONNECTING DUCTS & DAMPER COMPONENTS
6. LINING AND INSULATION COMPONENTS
7. CONTROLS AND INSTRUMENTATION COMPONENTS
8. MISCELLANIOUS COMPONENTS
 PRESSURE PARTS

(A) BASED ON CONFIGURATION

1. HEADERS
2. PANELS
3. COILS
4. CONNECTING LINKS
5. SUPPORTS & SUSPENSIONS

(B) BASED ON SYSTEM

1. ECONOMISER SYSTEM
2. CIRCULATION SYSTEM
3. SUPERHEATER SYSTEM
5. REHEATER SYSTEM
 PRESSURE PARTS …contd
(C) BASED ON FLOW
1. FEED PUMP
2. ECONOMISER
2.1 Eco inlet Link
2.2 Eco inlet Header
2.3 Eco Coils
2.4 Eco Intermediate Headers
2.5 Eco Hanger Tubes
2.6 Eco Outlet Header
2.7 Eco Connecting Links to Drum
3. DRUM With Internals
4. DOWN COMERS
4.1 Suction Manifold (500 MW)
4.2 Circulating Pumps (500MW)
4.3 Discharge Lines (500MW)
 PRESSURE PARTS …contd
(C) BASED ON FLOW …contd
5. WATER WALL INLET HEADERS
6. WATER WALL PANELS
6.1 Front ,Rear, Side & Extd.Side
7.WATER WALL Loose tubes
(Arch,Extd.side,Hanger and screen)
8.Water wall outlet headers.
9.Risers
10.Drum
11.Saturated connecting links to Radiant Roof inlet Header
12.Radiant roof inlet header
13.Radiant roof Tubes
14.Radiant roof outlet header
15.Back pass side wall inlet headers.
16.Back pass SH side wall panels
 PRESSURE PARTS …contd
(C) BASED ON FLOW …contd
17. Back pass SH side wall outlet headers
18. Back pass SH Front wall inlet header
19. Back pass SH Front wall panels
20. Back pass Extd. side supply tubes (210 & 250MW)
21. Back pass Extd. side inlet header (210 & 250MW)
22. Back pass Extd. side panels (210 & 250MW)
23. Back pass Extd side outlet header (210 & 250MW)
24. Back pass Roof junction header
25. Conn. tubes from Sl.no23 to Sl.no.24 (210 & 250MW)
26. Back pass roof
27. Economiser support tubes (500MW)
28. Eco support tubes inter headers (500MW)
29. LTSH support tubes (500MW)
30. Connecting tubes to Sl.no 24. (500MW)
 PRESSURE PARTS …contd
(C) BASED ON FLOW …contd
31. Back pass SH rear upper panels
32. Back pass side wall outlet header (rear)
33. Back pass rear wall lower inlet header
34. Back pass rear wall lower
35. Low temperature Super heater inlet header.
36. LTSH banks
37. LTSH terminal tubes
38 .LTSH links to DESH
39. DESH
39.1. DESH to Div.panel (connecting links)(500MW)
39.2. DESH to Platen (connecting links)(210,250MW)
40. Divisional panel inlet headers (500MW)
41. Divisional panels (500MW)
 PRESSURE PARTS …contd

(C) BASED ON FLOW …contd

42. Divisional panel outlet headers (500MW)

43.Div. panel outlet link to platen inlet header(500MW)
42. Super heater platen inlet header
43. Super heater platen coils
44. Super heater platen outlet header
45. Links from platen to final (210 &250MW)
46. Final SH inlet header(210 & 250MW)
46. Final SH coils(210 & 250MW)
47. Final SH outlet header(210 & 250MW)
48. Main steam line.
 PRESSURE PARTS …contd
(C) BASED ON FLOW …contd

Reheater circuit

1. Reheater inlet header

2. Reheater coils Front

3. Reheater coils rear

4. Reheater outlet header.

5. Reheater outlet line

 PRESSURE PARTS
(WITH RESPECT TO ARRANGEMENT)

PERFORMANCE PARAMETERS:
1. SIZE (Diameter)
2. SIZE (Thickness)
3. MATERIAL (Specification)
4. TRANSVERSE SPACING (ST)
5. LONGITUDINAL SPACING (SL)
6. HEATING SURFACE AREA
7. No. OF ELEMENTS
8. No. OF ASSEMBLIES
9. INLET / OUTLET CONNECTION REQUIREMENTS
PRESSURE PARTS …contd
(WITH RESPECT TO ARRANGEMENT)

PERFORMANCE PARAMETERS …contd

10. FURNACE WIDTH
11. FURNACE DEPTH
12. EXTENDED PASS DEPTH
13. BACKPASS DEPTH
14. HOPPER ANGLE
15. ARCH CONFIGURATION
16. COIL / BANK DEPTH
 PRESSURE PARTS …contd
(WITH RESPECT TO ARRANGEMENT)

DETAIL DESIGN REQUIREMENTS:

• IBR REQUIREMENT
(Strength Calculations)
• BENDING REQUIREMENTS
• HEAT TREATMENT REQUIREMENTS
• TRANSPORT LIMITATIONS (ODC)
PRESSURE PARTS …contd
(WITH RESPECT TO ARRANGEMENT)

STRESS ANALYSIS REQUIREMENTS:

• GUIDES ,SUPPORTS & SUSPENSIONS
• THERMAL EXPANSION
• FLEXIBILITY OF COMPONENTS
• DISTANCE BETWEEN HEADER
CENTRELINE ABOVE ROOF
• BUCKSTAY SPACING
 PRESSURE PARTS …contd
(WITH RESPECT TO ARRANGEMENT)

ARRANGEMENT REQUIREMENTS:
• INTERFERANCE FREE ARRGT./ ROUTING
OF RISERS / PIPES / LINKS
• WELD ACCESSIBILITY
• TAKING CARE OF LAYOUT
REQUIREMENTS (Ex. Matching Components
• TAKING CARE OF PERFORMANCE, DETAIL
DESIGN & STRESS ANALYSIS ASPECTS
SPECIAL FEATURES OF 500MW

1. ORIFICE PLATES IN WaterWall LOWER RING HEADERS

2. CIRCULATING PUMPS
3. STEAM COOLED ECO. / LTSH HANGERS
4. RIFLED TUBINGS IN WaterWalls
5. DIVISIONAL PANEL / PANALETTE ARRGT.
6. WALL REHEATER ( PRESENTLY NOT FOLLOWED)
RECENT CHANGES IN 500MW

TO MEET THE REQUIREMENT OF PERFORMANCE

THE FOLLOWING MODIFICATIONS ARE
CARRIEDOUT IN SOME OF OUR BOILERS:

1. TWIN REHEATER OUTLET HEADERS

2. DESUPER HEATER CRISS-CROSS LOCATION
CHANGED FROM LTSH OUTLET TO DIVISIONAL
PANEL OUTLET
3. WALL SUPER HEATER ADDITION IN
VINDHYACHAL
4. WALL REHEATER REMOVAL
THANK YOU
 DRUM AND DRUM INTERNALS:
CIRCULATION SYSTEM:

The circulation system of water through the

furnace water wall is due to either natural circulation
or controlled circulation. Natural circulation boilers
employ the effect of density differences between water
and steam to produce circulation.

This density differences together with the height

of the boiler constitutes a head which overcomes the
losses occurring in the circuit and makes circulation
possible. In controlled circulation boilers this density
difference is augmented by a pump output energy to
ensure positive circulation through the water wall
tubes.
The circulation system for a natural circulation boiler
comprises of the Drum, Downcomers, Furnace walls
and connecting pipes at the top of the boiler furnace.

DRUM:

The boiler drum serves three main functions:

 To provide the necessary space for separation of

steam from mixture of steam and water.

 To provide the required space for the separated

steam till it leaves the drum as purified steam.
 To house the equipment needed for purification of
steam after separation from the mixture of steam
and water.

 To provide a water storage for preventing the

starvation of tubes during operation.

 The Drum size is determined to meet all the above

requirements. Drum diameter and length should
be sufficient to provide accessibility for installation
and inspection. The drum is checked for stresses
induced due to self weight and external loads.
 DRUM INTERNALS:

The following are the functions of Drum Internals.

 Separation of water from steam water mixture.

 Removal of water bubbles from water volume of

boiler from entering downcomer.

 Mixing and distributing the feed water.

 Adding chemicals.

 Facilitating blow down.

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     
Pressure parts
Arrangement

BHEL / TIRUCHY