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REPORT
ON
Prepared By:
RohitManjhi
Engineer
BHEL PSER Barh site
1|Page
Guided By:
Mr. S Chatterjee
SDGM
BHEL PSER Barh site
By Rohit
Acknowledgement
First and foremost, I would like to thank my guide for this report, Mr. Sumanta Chatterjee,
Senior. Deputy General Manager, BHEL:PSER:BARH Site for his valuable guidance and
wholehearted support in completing my report as well as enriching my knowledge. His advice
from time to time has been very helpful; without which this report would not have been
possible.
Besides, I would like to thank my esteemed organization , BHEL for providing me with a good
environment and facilities to complete this report. It was am opportunity to study and learn
about various welding & NDE work , which are inevitable while erecting spiral wall system.
Finally, I am grateful for the support which I have received from Mr. D Guha GM
/Projects(Barh), Mr. M Prasad AGM, Our Technical associate ASTOM India Barh site &
colleagues during this total exercise.
Rohit Manjhi
2|Page
By Rohit
Contents
SL NO
DESCRIPTION
1.
Introduction
1-3
2.
4- 4
3.
4-10
4.
11-18
5.
References
19-19
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PAGE NO.
By Rohit
1. Introduction
Supercritical Boiler technology is gaining acceptance worldwide as Clean Coal Technology
due to its significant advantages like higher overall plant efficiency, reduced coal
consumption, reduced gaseous emissions like SO2, NO2 and CO2 and particulate
emission. Large capacity units of size 600 to 1000 MW are now built up with supercritical
parameters. In India, the trend is clearly towards large capacity Mega / Ultra Mega Power
Projects based on supercritical technology. Evaporators of once through supercritical
boilers are designed with either high mass flux spiral/vertical wall or low mass flux vertical
wall.
The major difference between a drum type boiler and once through supercritical boiler is the
furnace wall design. An once through furnace wall design needs to take care of the
temperature difference between tube-to-tube at furnace wall outlet due to the variation in
furnace
heat absorption. Also the occurrence of boiling crisis, associated metal
temperatures need to be critically analyzed and taken care in the furnace wall design. There
are basically two types of furnace wall designs used namely helically wound spiral wall and
vertical wall. The design aspects of these two types of furnace wall are discussed in this
paper.
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By Rohit
2120 T/hr
SH steam pressure
255 kg/cm2
SH steam temp.
Feedwater temp.
RH steam flow
1708 T/hr
RH steam pressure
54.7 kg/cm2
RH steam temp.
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By Rohit
Operational Flexibility
Most of the Supercritical units use the once-through technology. This is ideal for sliding
pressure operation which has much more flexibility in load changes and controlling the
power grid.
However this also requires more sensitive and quick responding control systems.
Materials
Supercritical power plants use special high grade materials for the boiler tubes. The turbine
blades are also of improved design and materials. In fact, the very increase in higher
pressure and temperature designs are dependent on the development of newer and newer
alloys and tube materials.
The aim of the industry is to achieve power plant efficiencies in the range of 50 %.
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By Rohit
Smaller OD tubes.
ii)
Helically wound spiral wall construction in which the tubes are inclined (15 to
25 deg.) and furnace tubes pass through the circumference of the furnace
more than one time and connected to a transition header above the burner
zone. Above the transition header the furnace enclosure is made up of
vertical water wall tubes. The spiral wall concept reduces the number of
parallel tubes and hence increases the mass flux through the tubes. As all
tubes pass through all the furnace walls, any variation in heat absorption is
applicable to all these tubes and hence the temperature difference between
these tubes is minimized.
iii)
To achieve reliable cooling, the mass flux generally adopted is around 2000
kg/(m2s) at full load. It may be chosen higher for other reasons, e.g. to lower
the minimum load for once through operation.
iv)
v)
By using spiral wall system total height of the boiler get reduced.
MATERIAL
SPEC.
DIM(mm)
SA213 T22
+ SA 213
T22
SA213
T22+
SA182 F12
CL2
Dia 41.3
+ 41.3
NO. OF
JOINTS
9498
ELECTRODE
WPS
NO.
TIG
ER90S
B3
ARC
E 9018B3
1032
ER80S
B2
E 8018B2
1011/01
ER70S
A1
E 7018A1
1005/05
Dia 38.1
+ 38.1
SA106
Dia
GR.C+SA23 406.4+
4 WPC
406.4
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PROCESS
OF WELD
By Rohit
1031/01
Term-Tube
Transition
Header
By Rohit
Tube welding of transition header term tube with vertical water wall panel
6|Page
By Rohit
Scallop
Bar,
Tension Bar,
Material-
MaterialSA387 Gr
22 Cl 2
SA387 Gr 22
Cl 2
Thickness12 mm
Thickness30mm
Pre-assembled spiral wall panel ready for lifting after DP & sponge test
By Rohit
Buck stay
fitted with
stir-up
system &
spiral panel
Tension bar
By Rohit
9|Page
By Rohit
By Rohit
CHECKING DESCRIPTION
As per FQP/Drawing
Header(1mm/M),
Panel(+2mm or -5mm)
Mismatch(2.5 mm)
Vi
As per FQP/drawing
Vii
Viii
Ii
Iii
Iv
Ix
CLASS OF TOLERENCE
CHECK
11 | P a g e
By Rohit
12 | P a g e
By Rohit
13 | P a g e
By Rohit
By Rohit
15 | P a g e
By Rohit
16 | P a g e
By Rohit
17 | P a g e
By Rohit
18 | P a g e
By Rohit
5. References:
19 | P a g e
By Rohit