CONSTRUCTION OF 500 MW

BOILER (PRESSURE PARTS)

BY ABHAY D. KHOBRAGADE
A. E. (CHANDRAPUR PROJECT)
CONTENTS
 WHY TO GO FOR HIGHER CAPACITY
BOILER

1’ 1’-2’ = Work done in turbine

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

3-4 = Water pumped to

4 boiler
P2
4-1 = Heat addition in eco
3 2 2’ and boiler.
S
 Theoretically rankine 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 Rankine 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
 SPECIFICATION OF BOILER
500 MW
 FURNACE
 TYPE: Balanced Draft
 Wall: Fusion welded
 Bottom: Dry
 Tube arrangement: Membrane
 Explosion / Implosion withstand Capacity at 67% yield
point : +/- 660mmhg
 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

 SPECIFICATION OF BOILER
500 MW
 Width : 18.034 meter
 Furnace Volume : 14580 m3
 Design Code: IBR
 Type of Firing: Tilting Tangential

 SPECIAL FEATURES OF 500 MW
BOILER
 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.

NEED FOR ASSISTED
CIRCULATION
Densit y of Wat er

Crit ical
Point

Densit y of
St eam

Pressure (Kg/cm 2)
 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.
 DESIGN FACTOR
For the construction of boiler parts subjected to


pressure and their integral attachment, the designer

takes into account several factors
CONSTRUCTION OF
PRESSURE PARTS
 ECONOMIZER TUBES
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
 WATER WALL TUBES
 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
W. W.wall tube
Hanger Ø63.5 X 11 SA – 210 Gr-C
tubes
W. W. Screen Ø63.5 X 7.1 SA – 210 Gr-A1
tubesArch Tubes Ø51 X 5.6
Rear 
SA – 210 Gr-C
Ø63.5 X 7.1
SA – 210 Gr-C


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 FUR UPPER
BOILER DRUM Ø273 REAR WW HDR
Ø1778 Ø273

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

 SUPER HEATER TUBES

Description Tube Size Material

Radiant Roof Tubes  Ø 63.5 X 6.3 SA 213, T11

 Ø 57 X 5.6 SA 213, T11
Steam Cooled Side wall tubes Ø 63.5 X 6.3 SA 210, Gr C
Ø 51 X 5 SA 210, Gr C
Steam Cooled front wall tubes Ø 51 X 5
76.1 X 10 SA 210, Gr C
Ø 63.5 X 6.3 SA 210, Gr C
Front Wall Hanger Tubes Ø
Ø 51 XX
44.5 5.07.1 SA 210, Gr C

Rear Roof Tubes Ø 51 X 5

 SA 210, Gr C
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
 SUPER HEATER TUBES
Description Tube Size Material
Steam Cooled Side Wall tubes Ø 51 X 5 SA 210, Gr C

Bifurcate Tubes (Bottom Header) Ø 51 X 5 SA 210, Gr C

LTSH Horizontal Tubes  Ø 51 X 5 SA 210, Gr C

 Ø 51 X 5.6 SA 210, Gr C
Pendent Coil Tubes  Ø 51 X 5 SA 213, T11
 Ø 51 X 5.6 SA 213, T11
Divisional Panel inlet loose tubes Ø 51 X 6 SA 210, Gr C
Ø 44.5 X 4.5 SA 210, Gr C
Divisional Panel Outlet loose tubes  Ø 51 X 6 SA 213, T11

Steam Cooled Spacer Ø 63.5 X 8 SA 213, T11

Ø 51 X 5.6 SA 213, TP347H
Ø 63.5 X 6.5 SA 213, TP347H
Ø63.5 X 7.1 SA 213, T11
Ø 63.5 X 7.1 SA 210, Gr C
Ø 51 X 5.0 SA 213, T11
Ø 51 X 5.0 SA 210, Gr C
 SUPER HEATER TUBES
 Superheater tubes is composed of
three basic stages of 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 Ø 508, 2 NOS. MAIN 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

ASSY, Ø 51, 6 ASSY

SH & ECO SUPP
TUBES, Ø 51

SH VERT PLATEN
LTSH UPPE BANK
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 BP LWR SIDE REAR BP LWR REAR

HDR, Ø 406.4 HDR, Ø 406.4 HDR, Ø 323.9
BP LWR SIDE REAR
HDR, Ø 323.9
 REHEATER
 TUBE DETAILS

Description Tube Size Material
Reheater Wall Ø 60.3 X 4 SA 313, T11
tubes
Cross over Ø 54 X 3.6 SA 213, T11
tubes
 REHEATER
 There heater section is composed of
three stages or section.
 REHEATER
 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
457.2

SH ROOF O/L RH VERT PLATEN

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

RH VERT PLATEN
O/L HDR, Ø
558.8

COMPLETE CYCLE 500 MW

 BOILER DRUM
 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.
 BOILER DRUM
 Separationis generally performed in
three stages.
 Boiler Drum Internals
Boiler Int ernals Mainly Consist s of: -
Separating Chamber
 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.
 Turboseparator
 From the lower end
of the separating
chamber the
steam and water
mixture is forced
upward in the
Spinner turboseparator.
Blades
 Turbo separator is
Cans a main
separating
device.
 Primary stage
 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.
Secondary st age
 The secondary st age consist s of t wo opposed banks
of closely spaced t hin corrugat ed sheet s.
 It direct s t he st eam t hrough a curved pat h and
separat es t he rem aining ent rained wat er.
 Since t he velocit y is relat ively low t his wat er is not
picked up again but runs down t he plat e and flows
down t o t he drum wat er.
 This st age of separat ion is called secondary
separat ion or st eam scrubbing.
Third stage
 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.
 Chemical Composition of
tubes used in 500 MW boiler
Sr. No. Materila C Mn P S Si Ni Cr Mo V Cb Used in
spec.
1 SA 210, Gr- 0.27 0.93 0.048 0.058 0.10 Extended side WW tube, WW screen tube arch tube
A1
2. SA 210, Gr 0.35 0.29 to 0.048 0.058 0.10 WW Panel & corner transition tube, hanger tubes,
C 1.06 rear arch tube, Eco tube, steam cooled wall, rear
roof, SH hanger tube, LTSH divisional Panel loose
3. SA 213, 0.15 0.30 to 0.03 0.03 0.5 to 1.0 to 0.44 to Radiant roof pendent coil divisional panel, S, C,
tube.
T11 0.60 1.0 1.5 0.65 spacer, SH Platen coil, re heater wall , re heater coil.
4. SA 213, 0.15 0.3 to 0.60.03 0.03 0.5 1.9 to 0.87 to Divisional Panel, SH Platen coil, RH Platen Coil,
T91 2.6 1.13 RH rear coil.
5. SA 213, 0.08 to 0.3 to 0.60.02 0.01 0.2 to 0.4 8.0 to 0.85 to 0.18 0.06 to Platen SH coil, platen RH Coil.
T91 0.12 0.5 9.5 1.05 to 0.10
0.25
6. SA 213 TP 0.04 to 2.0 0.04 0.03 0.75 8.0 to 18.0 to - - - Divisional Panel, RH platen coil.
304-H 0.10 11.0 20.0
7 SA 213, TP 0.04 2.0 0.04 0.03 0.75 9.0 to 17.0 to Divisional panel, SH platen coil, steam cooled
304-H 13.0 20.0 spacer.
THANK YOU