STEAM BOILER

High potential of the Group of Companies JSC Machine-Building Plant ZiO-

Podolsk and JSC Engineering Company ZIOMAR enables them today to carry
out a wide range of activities in the field of power machine-building.

The leader of Russian industry – Machine-Building Plant ZiO-Podolsk (ZiO)

– traces its history back to the year 1919.

ZiO-PODOLSK is an industrial-engineering base for manufacturing of

high-technology, competitive heat exchange equipment. Modern methods of
production management and organization, as well as well-qualified personnel
provide high quality and reliability of the manufactured equipment.

EC ZIOMAR employees perform complex research and development

activities, equipment adjusting and examination of installations in operation
for the purpose of their reconstruction and modernization.

Our customers are the largest generating and heat-and-power companies.

We will be glad if our acquaintance grows into a constructive and fruitful

cooperation!

Main products for thermal power plants
are boilers for power units with the capacity
of 50-800 MW firing diverse fuels, designed
on the basis of advanced engineering
solutions. More than 700 boiler units with
various capacity and parameters have been
produced for 152 domestic and foreign
power plants with the total capacity of more
than 66 GW, including over 16 GW for export.
The Enterprise has more than 70 years
of experience in design and fabrication of
boilers and other thermotechnical equipment
for thermal power industry. Boilers produced
under ZiO trademark are operated at power
plants in 20 countries such as Russia, Poland,
Romania, Kazakhstan, Ukraine, Bulgaria,
Vietnam, Yugoslavia, Croatia, Macedonia,
Greece, China and others. By agreement
with the General Supplier or directly with the
Customer the complete delivery of the boiler
island, additionally to the boiler proper, can
include the following:
• sootblowing equipment;
• fuel supplying, coal grinding and
coal-pulverizing equipment;
• draft equipment and turbo air
blowers;
• air preheaters with piping and valves;
• ash-cleaning equipment including
electrostatic precipitators;
• steel structures of boiler island and
stack;
• pulverized coal, gas and air lines
complete with valves and expansion
joints;
4
SPECIALIZATION
• power plant pipelines;
• single-turn actuators and their
connections;
• other power equipment.
Boilers are supplied in modular units to
facilitate and speed up their erection. Export
boilers are fabricated in compliance with
individual Customers’ technical assignments.
The production is based on the high level
of process procedure automation and
mechanization.
At the present time a considerable part of
power generating systems do not comply with
up-to-date environmental, safety, efficiency
and cyclic load capability requirements. The
most practical way out is to modernize main
power plant equipment. In such a case the
required effect can be achieved with reduced
material expenses, which is very important
under modern economic conditions.
“ZiO-Podolsk” and EC “ZIOMAR” group
of companies is paying greater attention to
these issues, and it can propose a complex
of original engineering solutions aimed at the
modernization of the boiler equipment that
was supplied earlier to power engineers of
Russia and CIS countries.
The enterprise has developed and
implemented engineering solutions aimed
the extension of service life, producing
of extra power with minimum expenses,
improving of environmental performances
and energy saving.
We propose a complex of original
engineering solutions aimed at solving of the
below mentioned problems and required for
the modernization of the boiler equipment
that was supplied earlier:
• extension of the unit load control
range (extension of the stable
operation threshold);
• boiler switchover to non-standard
types of fuel;
• organization of nonslagging
operation due to low temperature
and stage-by-stage fuel combustion;
• improvement of fuel ignition stability
and extension of the operating range
without lighting;
• improvement of technical
and economic indexes due
to implementing of up-to-date
engineering and design solutions;
• improvement of environmental
performances and their brining to
standard values.
The armory of the Special Design
Bureau of Boiler Manufacture of EC
“ZIOMAR” includes a range of engineering
and process design solutions aimed at the
burning process optimization and NOx level
reduction to standard values without using
special catalytic reactors:
• burning process organization with
the supply of high-concentration
pulverized coal;

• new designs of low emission burner
units;
• stage-by-stage fuel combustion from
the furance top to bottom and in a
horizontal plane of each burner row;
• 3-stage fuel combustion with the use
of reburning system;
• use of downdraft nozzles;
• use of telescopic pulverized coal
dividers and special pulverized coal
concentrators;
• high air heating
• application of low temperature
tornado technology;
• NOx selective noncatalytic reduction.
Boiler thermal and hydraulic circuits
that allow sliding pressure operation are
improved in order to ensure maximum boiler
efficiency. The introduction of units with
increased efficiency in compliance with the
original engineering solutions of the plant is
also a promising direction.
The company prepared technical
proposals for ultra supercritical steam
parameter coal-fired boilers for 660 MW units
as well as proposals for the modernization
of coal-fired boilers of operating power units
with the capacity of 300 MW.
In order to satisfy the needs of industrial
power production and public utilities the
company constructed advanced tower type
gas-and-oil-fired hot water boilers with the
SPECIALIZATION
thermal output of 70 and 120 Gcal/h that
provide an opportunity for their installation in
the compartments of ПТВМ hot water boilers
that are out of date from moral and physical
standpoint.
ZiO fabricates a wide range of equipment
for thermal power units:
• low pressure and high pressure
heaters;
• tight valves of pulverized coal, gas
and air lines (round, rectangular);
• articulated and flexible non-metallic
expansion joints;
• centrifugal and telescopic pulverized
coal dividers and concentrators;
• steam and water heaters made of
spiral-finned tubes;
• heating surfaces (plain-tube,
membrane, finned);
• unified modules of tubular air
heaters;
• other boiler equipment.
Great attention is paid to the upgrading
of produced boilers by means of introducing
new engineering solutions based on trade
secrets of various areas of new equipment
development, including the following:
• improvement of thermal and
hydraulic circuits;
• optimized organization of burning
and combustion process and control
of this process with due regard to the
reduction of NOx emissions;
• prevention of abrasion and corrosion
of heating surfaces;
• wider application of designs made of
unified assemblies and components;
• introduction of heating surfaces
made of longitudinal-finned and
spiral-finned tubes;
• application of methods of exhaust
gas deep cooling;
• use of tubular air heaters with the
original staged air heating scheme.
Using the boiler equipment engineering
experience the specialists of EC “ZIOMAR”
developed and implemented the projects
of coal-fired boiler modernization with the
improvement of their technical and economic
indexes and environmental performances at
the below listed thermal power plants:
• Tom-Usinskiy GRES, 210 MW power
unit;
• Lugansk TPP, 200 MW power unit;
• Belovo GRES, 210 MW power unit;
• Nazarovo GRES, 500 MW power
unit.
The main goal of ZiO-Podolsk and EC
“ZIOMAR” boiler manufacturers is the
creation of the advanced and competitive
heat power equipment.
5
 STEAM BOILER Пп-1050-255-545КГЖ

П-50Р

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 1050
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,9 (39,6)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
Kuznetsky lean coal, natural gas
Heat value:
coal, Kcal/kg 5820
gas, Kcal/nm³ 8623
Fuel flow rate, total:
coal, t/h and gas, nm´³/h 123,7
gas, nm³/h 81
Efficiency, %:
when firing 85% of coal (as to heat) and 15% of gas (as to heat) 89,3
when firing gas 93,5
Weight of metal, t:
pressure parts 2167
total of the boiler 4211
Specific metal content, t/t/h:
pressure parts 2,06
total of the boiler 4,01

6
 STEAM BOILER Пп-1050-255-545КГЖ

This boiler is designed to run with turbine K-330-240, the furnace through tertiary air nozzles (in pulverized
the design fuel is Kuznetsky lean coal and natural gas. coal its part is 22 % from air supplied to the furnace).
The boiler is double-furnace, supercritical, balanced- Horizontal gas duct walls are made of upper radiation
draft one with reheat and slag-tap removal. The both section panels that pass (without intermediate chambers)
bodies are symmetric and have the same design. into ceiling wall surface over the furnace chamber and
The boiler is arch-type and arranged indoors. The horizontal gas duct. The horizontal gas duct encloses
heating surfaces are suspended to the boiler structures two stages of a platen superheater I and II, installed
or supported by them. subsequently in the direction of gas flow. Each stage is
divided into outer and central platens.
The furnace chamber of each body has rectangular
cross-section and is enclosed by vertical panels of In the body downtaking ducts the flue gas passes
intermediate and bottom radiation sections. The furnace through the convection superheater, convection reheater
chamber bottom is made tilted and equipped with two II, convection reheater I and water economizer, which
taps for liquid slag removal. The furnace chamber top are made as horizontal packages.
is equipped with partition walls and the tubes of rear
The air supplied to the boiler unit is heated in the
furnace water-wall of the middle radiation section form
remote regenerative air heaters with diameter of 7m
an aerodynamic nose. The surface of lower radiation
(two per body). The air heaters are located outside the
section water-walls up to elevation of +15 725 is studded
boiler house.
and covered with refractory.
The boiler water-steam circuit is equipped with shut-
Pulverized coal-storage system with installation of
off, control and safety valves as well as steam and water
three ball-tube mills. The pulverized coal is fed to the
furnace by means of concentrated coal flow pneumatic samplers.
conveying system. Water washing devices are applied for furnace
The furnace of each body is equipped with 6 main cleaning. Should the platens require cleaning, long-
burners, 6 discharge nozzles, 12 gas injectors and 12 retractable steam sootblowers could be installed. For
tertiary air nozzles. this purpose special openings are provided in the side
walls of upper radiation section.
To achieve the required minimum NOX emission
when using coal, 85 % of pulverized coal (as to heat) The design provides for automation of supply,
with excess-air coefficient not less than 1 is burned in combustion and steam temperature control processes.
active combustion zone at the level of main burners. When firing pulverized coal the range of boiler automatic
15 % (as to heat) of natural gas is burned in reburning control is 70-100 % keeping rated parameters. When
zone of gas injectors. The natural gas is combusted in firing natural gas the range of boiler automatic control is
recirculation gas medium. The tertiary air is supplied to 60-100 % keeping rated parameters.

7
 STEAM BOILER Пп-660-13,7 - 540ГМ

П-56

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 660
Steam pressure, MPa (kgf/cm²)
at boiler outlet 13,7 (140)
at reheater outlet 2,5 (25,8)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
natural gas, fuel oil
Heat value:
natural gas, kcal/Nm³ 8680
fuel oil, kcal/kg 9790
Flow rate:
gas, nm³/h 52,5
fuel oil, t/h 48,5
Efficiency, %:
when firing natural gas 93,3
when firing fuel oil 92,0
Weight of metal, t:
pressure parts 1165
total of the boiler 2975
Specific metal content, t/t/h:
pressure parts 1,77
total of the boiler 4,5

8
 STEAM BOILER Пп-660-13,7 - 540ГМ
This boiler is designed to run with turbine K-200-130,
the design fuel is natural gas and fuel oil. The boiler is
double-furnace, once-through, balanced-draft, arch-
type one with reheat and is supported by his own steel
structure. It shall be installed in areas with arch-type up
to 8 points.
The furnace chamber of each body is open-type,
prismatic, with 4 opposite burners arranged on side
walls in one level (two burners on each wall).
To reduce NOx emissions at Keratzini TPP (Greece)
the furnace chamber was modernized: eight burners
were installed in two levels on side walls of each body,
tertiary air nozzles were installed over the second level
burners, recirculation of cold flue gases into the furnace
was organized via the burners and nozzles. After
modernization NOx emissions do not exceed 95 mg/
Nma at a=1,4.
The furnace chamber is completely water-walled.
The water-walls are made as horizontal-lifting panels
and form height along lower radiation section, middle
radiation sections (I and II), and upper radiation sections
(I and II).
The boiler has two similar convection passes.
Each convection pass, subsequently in the direction
of gas flow, houses the following heating surfaces: HP
convection superheater of I and II stage, LP convection
superheater, transition zone and economizer.
HP fluid flows from the boiler inlet to its outlet in two
parallel independently controlled streams (one for each
body), and LP fluid flows in four parallel streams.
HP superheat temperature is controlled with feed
water injection and LP superheat temperature is
controlled with bypass of steam-steam heat exchanger
and supply of recirculation gases into furnace bottom.
Air is preheated using regenerative air heaters with rotor
diameter 7200 mm; one of them is installed at each
boiler body outside the boiler house.
Casing is brickwork, lightweight, with liner.
Two circuits of shot-blasting are provided to clean the
heating surfaces from ash deposits. The regenerative
air heater is equipped with devices for soot-blowing and
washing.
The boiler is equipped with all necessary valves,
steam and water sampling devices, as well as
instrumentation. Boiler supply, superheat temperature
and combustion processes are controlled automatically.
Thermal protection facilities are provided for the boiler.
9
 STEAM BOILER Пп-1650-25-545/545 КТ

П-57Р

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 1650
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,9 (39,7)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
heat value, kcal/kg 3450
flow rate, t/h 327
Efficiency (guaranteed), % 91,8
Weight of metal, t:
pressure parts 2870
total of the boiler 9380
Specific metal content, t/t/h:
pressure parts 1,74
boiler total 5,68

10
 STEAM BOILER Пп-1650-25-545/545 КТ

This boiler is designed to run with 500MW turbine, The coal pulverizing system is of the direct fuel
the design fuel is Ekibastuz high-ash black coal. injection type and equipped with six ball-race mills.

The boiler is single-furnace, once-through, The technological measures are provided for to
supercritical, balanced-draft, T-shaped one with reheat reduce NOx emissions from the boiler.
and bottom-ash removal, it installed in boiler house.
The primary steam superheat temperature is
The furnace chamber is open-type, prismatic, of controlled by changing the fuel-water ratio and by
rectangular cross-section and is water-walled with
double water injection. The secondary steam superheat
vertical membrane-finned tube panels and equipped
temperature is controlled through bypassing of steam-
with 24 opposite pulverized-coal swirl burners arranged
steam heat exchanger.
on the furnace side walls in two levels.
The primary steam circuit of the boiler consists of two
The L-shaped divided water-walls are installed in the
separately controlled flows; the secondary steam circuit
furnace top to reduce gas mean and local temperature
comprises four flows.
at furnace outlet.
Taking into account high ash content of Ekibastuz
The water-walled horizontal gas ducts house platen
coal (45-55% on dry basis) and its abrasiveness,
superheaters. Further in the direction of gas flow the
the boiler design was performed using the advanced
downtake convection passes house outlet convection
superheaters of the primary and secondary steam, the technical solutions oriented to guarantee of steady

cold stage of the superheater of the secondary steam pulverized coal ignition and good burnout, prevention

and water economizer. of abrasive wear of pulverized-coal ducts, convection

heating surfaces and gas ducts.

Air is preheated by means of a large-block tubular air
heater mounted in a separate building with air flow as a These boilers have shown good service in long-time

unique Z two-way crossing circuit. operation at a number of power plants.

11
 STEAM BOILER Пп-990-25-545 ЛТ

П-64

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 990
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,9 (39,7)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
heat value, kcal/kg 2940
flow rate, t/h 235
Efficiency (guaranteed), % 87 ± 0,5
Weight of metal, t:
pressure parts 2450
total of the boiler 9500
Specific metal content, t/t/h:
pressure parts 2,45
boiler total 9,5

12
 STEAM BOILER Пп-990-25-545 ЛТ

This boiler is designed to run with turbine 300 MW, controlled streams, and in the reheater it flows in four
the design fuel is Yugoslavian low-grade lignite with parallel streams.
a wide range of moisture content (W=33-44%), ash
The primary steam superheat temperature
content (Aw=8-32%) and sulphur content (Scorn) up to
is controlled by injection, while reheated steam
5,6%.
temperature is controlled through bypass of steam-
After modernization the boilers of this type were steam heat exchanger.
delivered to Novo-Angrenskaya TPP to fire Angren
The coal pulverizing system is of the direct fuel
lignite (caloric content QPH =2940 kcal/kg, moisture
injection type and equipped with eight fan-mills, type
content 39,0%, ash content Aw = 13,4%.
EVT-KSG with let-down beater section and inertial
The boilers of the second stage of Novo-Angrenskaya
separators.
TPP were modernized to fire natural gas.
The boiler is delivered in large size modules.
The boiler is a once-through, single-furnace, closed,
T-shaped, supercritical one with reheat. The reliable, stable and slag-free operation of the
boiler furnace is ensured by a rather large sectional area
The furnace chamber is open-type, of rectangular
and volume of the furnace, three level arrangement of
cross-section and is equipped with 24 opposite slot
slot burners along the long sides of the furnace, and fuel
burners and is completely water-walled with tubes
gas drying.
forming gas-intake ports above burners on side walls.

The boiler has two similar convection passes. To Horizontal-inclined arrangement of water-wall tubes

preheat air ZIO-Podolsk cascade tubular air heater reduces temperature unbalance, greatly improves

is installed in a separate pass outside the boiler. This temperature conditions and raises reliability of the

prevents corrosion and choking of the air heater tubes furnace tubes.

when the boiler fires high-sulphur fuel. Properly selected gas velocities in the convective
The fluid in the primary superheat path flows from the passes ensure slag-free operation of the convection
boiler inlet to its outlet in two separating independently heating surfaces without abrasive wear.

13
 STEAM BOILER Пп-2650-25-545/545 БТ

П-67

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 2650
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,7 (37,8)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
heat value, kcal/kg 3740
flow rate, t/h 480
Efficiency (guaranteed), % 91
Weight of metal, t:
pressure parts 7500
total of the boiler 19400
Specific metal content, t/t/h:
pressure parts 2,83
boiler total 7,32

14
 STEAM BOILER Пп-2650-25-545/545 БТ

This boiler is designed to run with turbine 800 MW,
the design fuel is Beresovo lignites of the Kansk-Achinsk
deposits.
The boiler is a single-furnace, once-through, gas
tight, balanced-draft, T-shaped, supercritical one with
reheat and bottom-ash removal.
A tubular air heater is provided for air preheating.
An excess air generating system is provided to reduce
the exit gas temperature and raise the electrostatic
precipitator efficiency.
The boiler is suspended from a building structures.
Heat insulation is placed on the gas-tight boiler walls.

The furnace chamber is open-type, prismatic, of The boiler is delivered in large-size modules.
square cross-section and is completely water-walled The temperature of gases in the flame core and
with vertical membrane-finned tube panels and equipped at the furnace outlet is reduced due to the sufficient
with 24 tangential slot burners arranged in four levels on height of the furnace and supply of recirculation gases
four walls, thereby creating a single rotating flame. through the burners and to its top. Unburned carbon
All the walls of the furnace chamber and gas ducts loss is reduced by feeding of hot air to the bottom ash
are all-welded of finned tubes, convection pass walls are hopper through a number of nozzles. There is combined
made with a greater tube pitch. cleaning system of the boiler heating surfaces from
external ash deposits.
Platen-type heating surfaces are arranged above
the furnace and in the horizontal gas duct; the platens The coal pulverizing system is of the direct fuel
arranged first in the direction of gas flow are all-welded injection type and equipped with fan-mills and fuel gas
of finned tubes. The convection heating surfaces drying. Gas for drying is extracted at the area of the

are located in downtaking passes within the medium boiler turning chamber.

temperature zone. All the convection heating surfaces The boiler design provides for conditions required for
are suspended from support tubes. The economizer is repair of some boiler assembly units.
membrane type.
The main advanced design features of the boiler:
The primary steam superheat temperature is gas-tight suspension structure, arrangement and design
controlled by injection, while the secondary steam of heating surfaces, steam conditions and high unit
superheat temperature is controlled through bypass of power, meet the current trends and standards in the field
steam-steam heat exchanger. of boiler manufacture.

15
 STEAM BOILER Пп-1650-25-545/545 КТ

П-76

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 1650
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,9 (40)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
heat value, kcal/kg 5360
flow rate, t/h 207
Efficiency (guaranteed), % 91,5 ± 0,5
Weight of metal, t:
pressure parts 4731
total of the boiler 12100
Specific metal content, t/t/h:
pressure parts 2,86
boiler total 7,33

16
 STEAM BOILER Пп-1650-25-545/545 КТ

This boiler is designed to run with 500 MW power unit The HP primary steam circuit consists of two
of «Tzisuan» TPP (China), the design fuel is Chinese separately controlled flows; the secondary steam circuit
black coal. The boiler is installed in high-seismicity (up comprises four controlled flows.
to 7 points) region.
The primary steam superheat temperature is
The boiler is single-furnace,
once-through, controlled by feed water injection, while the secondary
supercritical, balanced-draft, T-shaped one with reheat
steam temperature is controlled through bypass of
and bottom-ash removal. The boiler is of gas-tight
steam-steam heat exchanger.
design, the furnace and convection passes are water-
Air is preheated by means of four rotating regenerative
walled with membrane panels.
air heaters with diameter of 10 m with vertical shaft.
The coal pulverizing system is of the direct fuel
injection type and equipped with eight ball-race mills. Steam and water sootblowing devices are applied for

cleaning the boiler heating surfaces.

The furnace chamber is of rectangular cross-section
and is equipped with 32 opposite burners arranged in Boiler lining is made as overtube insulation, fastened

four levels. on membrane panels. It is covered with metal sheets. The

The platen superheater is arranged at the furnace boiler has no own framework and is suspended from the
outlet, further the horizontal gas duct house the platen building frame using intermediate steel structures. Boiler
superheaters: final stages of the primary and secondary supply, stem temperature and combustion processes

superheaters. are controlled automatically. The boiler is equipped

The boiler has two similar convection passes, that with all necessary valves, steam and water sampling

house, in the direction of the gas flow, the following devices, as well as instrumentation. The boiler design

heating surfaces: inlet stages of the secondary provides for conditions required for repair of some boiler

superheater, economizer. assembly units.

17
 STEAM BOILER Пп-1650-25-545/545 БТ

П-78

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 1650
Steam pressure, MPa (kgf/cm²)
at boiler outlet 25,0 (255)
at reheater outlet 3,9 (40)
Steam temperature, °C:
primary 545
reheated 545
Design fuel:
heat value, kcal/kg 2580
flow rate, t/h 445
Efficiency (guaranteed), % 89,5 ± 0,5
Weight of metal, t:
pressure parts 5912
total of the boiler 14000
Specific metal content, t/t/h:
pressure parts 3,58
boiler total 8,48

18
 STEAM BOILER Пп-1650-25-545/545 БТ

This boiler is designed to run with 500 MW turbine, HP fluid flows from the boiler inlet to its outlet
the design fuel is Chinese lignite. in two separatw streams, and LP fluid flows in four
independently controlled streams. Four streams go into
The boiler is single-furnace, once-through,
two streams at the boiler outlet.
supercritical, balanced-draft, closed T-shaped one with
reheat and bottom-ash removal. The boiler is of gas- The HP steam superheat temperature is controlled

tight design, the furnace and downtaking gas duct are by changing of fuel-water ratio and feed water injections,
water-walled with membrane panels. while the LP steam superheat temperature is controlled
through bypass of steam-steam heat exchanger.
The furnace chamber is open-type, prismatic, of
The boiler is equipped with water sootblowing
square cross-section and is equipped with 32 pulverized-
system for furnace water-walls and steam sootblowing
coal direct-fired burners arranged in four levels.
system for heating surfaces in horizontal gas duct and
The coal pulverizing system is of the direct fuel
convection passes.
injection type and equipped with eight fan-mills. The
Air is preheated by means of four rotating regenerative
furnace chamber heating surfaces are divided into lower
air heaters with diameter of 9.8 m with vertical shaft.
and upper radiation sections.
Boiler lining is made as overtube insulation, fastened
The platen multistage superheater is arranged at the
on membrane panels. It is covered with metal sheets.
furnace outlet, further the horizontal gas duct house the
The boiler has no own framework and is suspended from
final convection stages of the primary and secondary
the building frame using intermediate steel structures.
superheaters.
The boiler is equipped with all necessary valves, steam
The boiler has two similar convection passes, that and water sampling devices, as well as instrumentation.
house the following heating surfaces: inlet stage of the Boiler supply, stem superheat temperature and
secondary superheater, convection primary superheater combustion processes are controlled automatically.
and economizer. Thermal protection facilities are provided as required.

19
 STEAM BOILER Е-160-3,9-440 ГМ

П-95

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 160
Steam pressure, MPa (kgf/cm²) 3,9 (39,8)
Steam temperature, °C 440
Design fuel:
heat value, kcal/kg 7905
flow rate, t/h 14,7х10³
Efficiency (guaranteed), % 94,0

20
 STEAM BOILER Е-160-3,9-440 ГМ
This boiler is designed both to run with turbine and
at cross-connection plants, the design fuel is natural
gas (main fuel) and fuel oil (emergency fuel).
The boiler is gas-tight, single-furnace, drum,
balanced-draft, natural circulation, top-supported one.
The heating surfaces are arranged as horizontal arch.
The boiler is suspended from its own framework, which
may be supported by foundation or by natural base
through its own support platform.
The boiler is appropriate for installation in limited
spaces of existing buildings.
The boiler furnace and gas duct are water-walled
with membrane panels:
• furnace is made of tubes 60 x 5 with spacers;
• gas ducts are made of tubes 32 x 4 with spacers.
“Penthouses” containing chambers and crossover
pipes of heating surfaces are located above the boiler
and under it. The boiler water-steam circuit consists of
the following three systems with one common drum:
• economizer and air-to-water heat exchanger;
• circulation evaporating system;
• superheater zone.
Boiler evaporator includes water-wall section
(furnace water-walls) and convection section
(evaporator-l and evaporator-2).
Boiler superheater includes gas duct water-walls
and two-stage convection superheater (convection
superheater-l and convection superheater-2).
Spray attemperator is installed between the first
and second stage of convection superheater to control
the superheated steam temperature downstream the
boiler.
Economizer and evaporator-2 are made of spiral-
finned tubes 32x4.
Convection superheater-l, convection superheater-2
and evaporator-l are membrane-type, made of tubes
42 x 4 with spacers.
Membrane water-wall box has two levels of stiffening
beams.
The drum with internals is installed on central beams
of the boiler framework.
Combustion equipment is made as follows:
• front wall of the horizontal furnace chamber is
equipped with two levels of four dual-channel for
air and dual-channel for gas oil/gas burners;
• the furnace side walls are equipped with four
nozzles for tertiary air supply at burner elevations.
The cold gas recirculation is provided to reduce
NOx formation, is fed to windbox upstream the burners.
The boiler is equipped with shut-off, control and
safety valves as well as steam and water sampling
devices.
Boiler design provides for steam blowing, chemical
and water washing.
The boiler is insulated by plates mounted over the
tubes. The boiler front, rear and side walls are covered
with decorative metal sheets.
The boiler can be delivered both separately and
together with the following auxiliaries:
• main induced-draft fan;
• forced-draft fan;
• induced-draft fan for gas recirculation;
• gas-air ducts and gas-tight valves.
21
 STEAM BOILER Е-50-0,7-250Г

П-102

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 50
team parameters downstream the boiler:
Temperature, ºC 210-260
Pressure, MPa (kgf/cm²) 0,7 (7,1)
Steam temperature, °C 104
Design fuel: heat value, Kcal/Nm³ 8540
Fuel flow rate under the independent mode, Nm³/h 3870
Efficiency (gross) at rated load and under independent mode of op-
eration with district water heater in service, %:
Design 95,1
Guaranteed 94,0

22
 STEAM BOILER Е-50-0,7-250Г

Steam boiler П-102 fires natural gas. It is designed exhaust gas mixture is the location of the convective
for independent and combined operation with GTPP superheater, and the convective pass comprises the
Ural-6000. convective evaporator, economizer and district water
Drum-type boiler is of single-furnace design, with heater.
natural circulation and balanced draft. Superheated steam temperature is regulated by
Arc-arranged boiler is top supported. spraying the feed water downstream the superheater.

The furnace and convective pass are enclosed with The boiler is equipped with required steam and
gas tight screens which consist of tubes and bars and water valves, gas&air circuit is provided with control and
thus form the all-welded construction. Insulation is shutoff valves, water and steam sampling devices are
provided on tubes. Decorative casing is made of metal. installed.
The area along the gas flow downstream of the Main characteristics of the boiler are listed in the
furnace and downstream of the point of GTPP Ural-6000 table.

23
 STEAM BOILER Е-210-9,6-540 КТ

ОР-210М

PERFORMANCE CHARACTERISTICS
Steam capacity, t/h 210
Steam pressure, MPa (kgf/cm²) 9,6 (98)
Primary steam temperature, ºC 540
Design fuel:
heat value, kcal/kg 4987
flow rate, t/h 27,0
Efficiency (guaranteed), % 92,0

24
 STEAM BOILER Е-210-9,6-540 КТ

Steam Boiler is designed to produce high pressure NOx emissions in the boiler are decreased by the
superheated steam for common station manifold, firing 3-stage fuel combustion circuit that provides for NOx
black Silesian coal of three types and mixture of the reduction pulverized-coal stage. For this purpose the
combustion chamber is fitted with eight straight-flow
coals.
slot burners and four tertiary air-type burners, installed
The rehabilitated boiler is of one-drum type with tangentially. The main burners are installed in two levels
natural circulation, indoors installation. and the tertiary air-type burners are installed in one
The boiler has arch-type configuration with level over the main burners. Also the installation of 8
secondary air nozzles as well as 6 blocks of tertiary air
suspension of the heating surfaces (excluding tubular
nozzles is provided for this purpose.
air heater) to roof covering disc plate and consists of
Ash extraction is of dry and mechanical type, and it
prismatic open-type furnace chamber (riser gas duct)
provides for the use of a scraper slag removal device.
with 7920x7360 dimensions and a convection pass
(downtaking backpass) connected with each other by a Flue gas cleaning from ash takes places in the
electrostatic precipitators.
rotating gas duct with a platen superheater and 3 stages
of a convection superheater. The backpass comprises 3 Furnace chamber water walls are cleaned from
bundles (2 stages) of a water economiser and 3 passes possible ash and slag deposits by means of long-throw
water soot-blowers, and platens are cleaned with long-
of a tubular air heater along the gas flow. The furnace
retracting steam devices.
chamber, roof radiant tubes, the rotating gas duct and
major part of the convection pass up to the economizer The boiler has balanced draft and it is intended to
be operated under base-load conditions. The boiler is
lower bank inlet are made of membrane water walls
fitted with the required scope of automatic regulation,
with strip spacer plate tubes, and they form a gas tight
protection and interlocks facilities, remote control
chamber.
of valves and dampers, and also safety devices,
The pulverized-coal system provides for a pulverized- instrumentation.
coal intermediate hopper and for the installation of two The boiler design provides for water and chemical
ball pulverizers per boiler. Pulverized coal is supplied to cleaning, steam purges and mechanical repair.
the boiler furnace by means of the concentrated coal The setting of gas tight chamber walls is made
flow pneumatic conveying system with the use of high of insulation plates with outer sheathing formed by
pressure turbo blowers. galvanized steel sheets.

25
 STEAM BOILER Еп-690-15,4-540 ЛТ

NEYVELI

PERFORMANCE CHARACTERISTICS
Steam capacity, max., t/h 690
Steam capacity, rated, t/h
(corresponds to 210 MW) 592
Steam pressure, MPa (kgf/cm²):
at boiler outlet 15,4 (157,1)
at reheater outlet 3,5 (35,7)
Steam temperature, ºC:
primary 540
downstream reheater 540
Design fuel:
calorific value, kcal/kg 2350
consumption, t/h 215
Efficiency (guaranteed), % 89,9

26
 STEAM BOILER Еп-690-15,4-540 ЛТ

The boiler is designed for operation within 210 MW mill fanning. The mills are equipped with the devices of
unit with firing low-calorie Indian lignite with calorific electrody-namic deceleration.
value of Q,r=2190-2730 kcal/kg, moisture of Wr=51- The pulverised coal and the drying agent are
55%, ash content of Аг=2,1-6% and sulphur content of distributed throughout the burners through the centrifugal
Sr=0,54-1,46%. pulverized coal distributor intended for the division of the
The boiler is of drum, single-furnace, reheat fuel-air mixture among four combustion stages.
subcritical pressure type with natural circulation, The two-stage combustion circuit with horizontal and
bottom-ash removal and tower-type arrangement. The vertical fuel combustion is arranged in order to reduce
boiler has a gas tight design the furnace and convection NOx emissions. The lower part of the dry bottom hopper
pass enclosure made of membrane panels. The boiler provides for the installation of an after-burning grate.
provides for the installation of 2 regenerative air heaters. The processes of boiler feeding, superheated steam
Water and steam purging devices are installed for temperature control, combustion and level-wise fuel
heating surface cleaning. distribution are automated.
The square open furnace chamber is provided with The boiler is designed together with ANSALDO
12 double straight-flow multi-channel burners installed company. EC “ZIOMAR” performed the works on basic
tangentially on all the furnace walls in two levels. and detailed engineering of the fuel preparation and
The direct injection firing system has six fan-mills combustion system and fuel cleaning system as well as
of MV 3400/900/490 type and supports fuel drying by on the detailed design and supply of a part of the heating
gas. The design of the fan-mills provides for a range of surfaces and the sets of coal-pulverizing and furnace
engineering solutions that make it possible to regulate and burner equipment.

27
 HOT WATER BOILER КВ-Г-81,4-150Н

П-130

BOILER PERFORMANCE CHARACTERISTICS

VALUE
DESCRIPTION
Basic conditions Forced conditions
Heating efficiency, MW (Gcal/h); 81,4 (70) 87,23 (75)
District water flow through the boiler, t/h; 867 929
Absolute water pressure at the boiler outlet, MPa (kgf/cm2) 1,2 (12) 1,2 (12)
Maximum water circuit flow resistance, MPa (kgf/cm2) 0,25 (2,5) 0,33 (3,3)
Water temperature at the boiler inlet, ºС 70 70
Water temperature at the boiler outlet, ºС 150 150
Furnace overpressure, Pa (kgf/m²) 197 (19,7) 236 (23,6)
Excess air coefficient at the furnace outlet 1,1 1,1
Exhaust gas temperature, ºС 115 120
Fuel flow, nm3/h (t/h) 8598,7 (6,31) 9221,5 (6,76)
Design boiler efficiency (gross), % 95 94,8
NOX emissions downstream of the boiler (at α =1,4), mg/nm3 125 at most 125 at most
CO emissions, mg/nm3 50 at most 50 at most

Boiler overall dimensions, m:

Width along the column axes – 6,24
Depth along the column axes – 6,24
Height by the structure top elevation – 17,500

28
 HOT WATER BOILER КВ-Г-81,4-150Н

The boiler is designed to burn natural gas. Gas is boards. The sheathing made of galvanized or aluminum
considered to be main and standby fuel. The boiler corrugated plates is installed above the insulation.
is intended for generating hot water used for district
Platforms, ladders, inspection doors and manholes
heating (the heat supply system is of closed type). It is a
are used for boiler operation, as well as for the
vertical water tube, tower-type, once-through, gas-tight,
performance of maintenance and adjustment works.
pressurized boiler suspended from its own structure.
There is provision for the system of potential leakage
The furnace and the convection pass formed by their sealing with the blower head air in order to eliminate the
front, rear and common side waterwalls are located possibility of flue gas entering the boiler house from the
in the boiler along the combustion product flow. The boiler operating under pressurized conditions. There is
furnace and the pass are basically an integrated all- also provision for the air supply required for the sealing
welded gas-tight structure. of furnace inspection doors, ignition control system
The top headers of the furnace waterwalls and the ignitors, flame monitoring sensors and gas burner
convection pass give support to the metal sheet pass inspection doors. Manholes are sealed with the use of
downstream of the boiler. The pass is under vacuum elastic gaskets.
conditions created by the stack. The stack is located The boiler water circuit is equipped with necessary
above the pass, and it is resting on its own structure.
valves, drains, vents and a water sampling device. The
The stack structure is resting on the boiler structure.
boiler design makes it possible to carry out water and
The pass and the stack are interconnected through a
chemical washes.
non-metallic expansion joint. The pass downstream of
the boiler is the place where the silencer and the valve The boiler is equipped with process protections,
aimed at vacuum control downstream of the last stage interlocks, automatic regulators, I&C, remote control
along the gas flow are located. means. The boiler is designed to operate under basic
(nominal) conditions and under forced conditions (with
The boiler furnace chamber is equipped with four
the increased heating efficiency) for a short period.
swirl gas low-emissivity burners located in the opposite
way in one row on its side walls. The combustion fuel is The boiler stable operation under basic conditions
supplied via natural gas pipelines. using main and standby fuel is maintained within the
load range of 30÷107%. The same load range is the
The required NOX emission level is achieved by using
automatic control range.
the flue gas recirculation from the convection pass to
the forced draft fan suction. The boiler has water-cooled Main design parameters of the boiler at the load of
thermal insulation made of thermal insulating power 100% are specified in the table

29
 HOT WATER BOILER КВ-ГМ-140-150Н

П-112

BOILER PERFORMANCE CHARACTERISTICS

VALUE
DESCRIPTION
Basic conditions Forced conditions
Heating efficiency, MW (Gcal/h); 140 (120) 110 (95)
District water flow through the boiler, t/h; 1483 2056
Consumer district water flow, t/h 1483 1483
Absolute water pressure at the boiler inlet, MPa (kgf/cm²) 1,42 (14,5) 1,6 (16,3)
Absolute water pressure at the boiler outlet, MPa (kgf/cm²) 1,18 (12,0) 1,18 (12,0)
Water temperature at the boiler inlet, ºС 70 115*
Water temperature at the boiler outlet, ºС 150 160
Temperature of water supplied to the system, ºС 150 133**
Furnace overpressure, Pa (kgf/m²) 197 (19,7) 236 (23,6)
Furnace pressurization, Pa (kgf/m²) 500 (50) at most 400 (40) at most
Excess air coefficient at the furnace outlet 1,05 1,1
Exhaust gas temperature, ºС 108 210
Design boiler efficiency (gross), % 95,5 90,8
NOX emissions downstream of the boiler (at α=1,4), mg/nm³ 230 at most 300 at most
CO emissions, mg/nm³ 300 at most 300 at most
* To be ensured due to hot water recirculation from the boiler
** To be ensured due to cold district water bypassing
Boiler overall dimensions, m:
width along the column axes – 6,9
depth along the column axes – 6,9
height by the structure top elevation – 15,65

30
 HOT WATER BOILER КВ-ГМ-140-150Н
The boiler is designed to burn natural gas and oil. Gas
is considered to be main fuel, and oil is considered to be
emergency fuel. The boiler is intended for generating hot
water used for district heating (the heat supply system is of
open type).
It is a vertical water tube, tower-type, once-through, gas-
tight, pressurized boiler suspended from its own structure.
The pass downstream of the boiler is under vacuum
conditions created by the stack.
The furnace and the convection pass formed by their
front, rear and common side waterwalls are located in the
boiler along the combustion product flow. The furnace and
the pass are basically an integrated all-welded gas-tight
structure.
There are two possible alternatives of the gas exhaust
duct layout:
1. The top headers of the furnace waterwalls and the
convection pass give support to the pass downstream of the
boiler. The pass is under vacuum conditions created by the
stack. The stack is located above the pass, and it is resting on
its own structure. The stack structure is resting on the boiler
structure. The pass and the stack are interconnected through
a non-metallic expansion joint. The pass downstream of the
boiler is the place where the silencer and the valve aimed at
vacuum control downstream of the last stage along the gas
flow are located.
2. Exhaust gases are led to the stack available at the
enterprise by means of installing a confuser with a pass
being adjacent to it that rest upon the top headers of the
furnace waterwalls and the convection pass.
The top part of the furnace along the gas flow is the location
of the membrane convection heating surface (MCHS1) after
which the convection heating surfaces (central CS2 and top
CS3 bundles) made of tubes with spiral fins are located.
The boiler has a two-pass circulation circuit with water
up flow through all the furnace waterwalls and MCHS1 and
water down flow in CS2 and CS3.
There is provision for the use of two shock-wave
generators installed on the boiler side walls between CS2
and CS3 aimed at the convection surface cleaning from
external scaling in case of oil operation.
The decrease in NOX emissions requires the specification
of the two-stage fuel combustion diagram in compliance with
which the furnace chamber is equipped with four swirl oil and
gas low-emissivity burners and tertiary blast nozzles located
at two levels on the side walls (burners are located at the
bottom level, nozzles are located at the top level, each wall
has two burners and two nozzles). The burners are located
in the opposite way, and the nozzles are located tangentially
to the conceptual circuit.
Each oil and gas burner of the boiler consists of a gas
burner with a steam-mechanical oil atomizer installed in
it. Combustion fuel is supplied through natural gas and oil
pipelines. The burner has a two-port design as far as natural
gas and air are concerned. Its air ports (a central and a
peripherical port) are equipped with axial blade swirlers and
valves at the port inlet that make it possible to adjust and
control air flow through the ports for all operation conditions.
Outer surfaces of the boiler, gas pipelines and pipelines
are thermally insulated. The design temperature on the
outside of the insulation does not exceed 45ºC at the
ambient air temperature of 25ºC. The boiler has water-cooled
thermal insulation made of boards or basalt extra fine fiber.
The sheathing made of galvanized or aluminum corrugated
plates is installed above the insulation.
There is provision for the system of potential leakage
sealing with the forced draft fan head air in order to eliminate
the possibility of flue gas entering the boiler house from the
boiler operating under pressurized conditions. There is also
provision for the air supply required for the sealing of boiler
valves (except for manholes), oil atomizers, ignition control
system ignitors, burner flame monitoring sensors, inspection
doors of the impact and wave cleaning device. Manholes are
sealed with the use of elastic gaskets.
The boiler water circuit is equipped with necessary
valves, drains, vents and a water sampling device. The boiler
design provides for carrying out water and chemical washes.
Platforms, ladders, inspection doors, access doors and
manholes are used for boiler operation, as well as for the
performance of maintenance and adjustment works.
The boiler is equipped with the process parameter
automatic control system, burner firing automated control,
process protections and interlocks, remote control, auxiliary
mechanisms as well as with the system of process parameter
thermotechnical control.
The range of the boiler load automatic control in case
of natural gas operation is 100-30%, and the range of the
boiler load automatic control in case of oil operation (with Sp
content that does not exceed 1.1%) is 78-30%.
Main design parameters of the boiler at the load of 100%
are specified in the table.
31
 STEAM BOILER Е-90-3,9-440Д

Е-90

BOILER PERFORMANCE CHARACTERISTICS

gas oil
Type of fuel atmospheric residue
hydrocracking
Boiler steam capacity, t/h 90
Superheated steam pressure, MPa 3,9
Superheated steam temperature, ˚С 440
Feed water temperature, ˚С 130
Boiler dimensions, m:
• width along the column axes 9,2
• depth along the column axes 9,85
• height (main beam elevation) 21,7
Boiler efficiency, % 93,7
Boiler weight removal value, t 475,5

ADVANCED DEVELOPMENTS
32
 STEAM BOILER Е-90-3,9-440Д

The boiler is designed to generate superheated two opposed burners on each side wall located in one
steam when firing gas oil and atmospheric residue row in the area where the furnace side walls are merging
hydrocracking. This is a single-furnace, one-drum into the bottom waterwall).
steam boiler with natural circulation and close-coupled
Steam superheat temperature is regulated with the
arch arrangement of heating surfaces for balanced
injection of the “internal” condensate in the attemperator.
draft operation that is equipped with gas oil firing
There is provision for feed water injection as a stand-by
installations. The boiler consists of a furnace chamber
and a downtaking duct, protected by gas tight membrane injection and an injection for the start-up period.
walls, a drum, burner devices, a condensing unit, water The tubular air heater on its own structure consists of
and steam circulating tubes with an attemperator, water
six tubes installed horizontally in one row throughout the
supply and steam discharge pipes and a tubular air
height. The air heater is equipped with blowing and fire
heater.
extinguishing devices.
The open-type furnace chamber is rectangular in
The specified lifetime between overhauls is at
section, and its plan dimensions are 4480х6800 mm.
The lower part of the side waterwalls form a double-pitch least 4 years. The designed life of the boiler pressure

bottom sloping towards the furnace center at an angle of elements with the design temperature corresponding to
30º. The furnace chamber walls are made of plain tubes, the creeping area is at least 100 thousand hours for the
and a bar is welded between them. The waterwalls have tubes of the heating surfaces and superheater chambers
corresponding interconnections for burners, access and at least 200 thousand hours for other components.
doors, inspection doors and manholes. The gas tight
The boiler load control range is from 30% to 100%.
boiler enclosures are equipped with stiffening rings in
order to resist the pressure inside the furnace in case The allowable rate of load changing within the control
of possible puffs and to ensure that external loads are range of 30% - 70% is at least 1.5% per minute, and
carried. it is at least 4% per minute within the control range of

This boiler provides for the installation of semi- 70% - 100%. The boiler is operating under base load
bottom burners in the amount of four pieces (two and conditions.

ADVANCED DEVELOPMENTS
33
 STEAM BOILER Е-120-9,8-515 ГМ

Е-120

BOILER PERFORMANCE CHARACTERISTICS

natural gas
Type of fuel
oil
Boiler steam capacity, t/h 120
Superheated steam pressure, MPa 9,8
Superheated steam temperature, ˚С 515
Feed water temperature, ˚С 132
Boiler dimensions, m:
• width along the column axes 9,3
• depth along the column axes 17,3
• height (main beam elevation) 20,9
Boiler efficiency, % 94,5
Boiler weight removal value, t 515

ADVANCED DEVELOPMENTS
34
 STEAM BOILER Е-120-9,8-515 ГМ
Steam boiler Е-120-9,8-515 ГМ is designed to
generate superheated steam when firing natural gas
and oil.
This is a single-furnace, one-drum steam boiler
with natural circulation and close-coupled arch
arrangement of heating surfaces for balanced draft
operation that is equipped with burner devices for
natural gas and oil firing. The boiler consists of a
furnace chamber and a downtaking duct the walls of
which are designed as gas tight panels made of tubes
with a bar welded between them. The first stage
convection superheater is located at the furnace
outlet. The downtaking duct is the place when the
second and the third stage convection superheater
and a water economizer are located.
The open-type furnace chamber is of the prismatic
form, and its plan dimensions are 7000х6240 mm.
The front and rear waterwall panels in the furnace
chamber bottom part are bent towards the furnace
interior at an angle of 15° towards the horizontal
plane, and they form the furnace bottom. The gas
tight boiler enclosures are equipped with stiffening
rings in order to resist the pressure inside the furnace
in case of possible puffs and to ensure that external
ADVANCED DEVELOPMENTS
loads are carried. The furnace chamber is equipped
with eight swirl burners located in two rows on the
furnace side walls.
The superheated steam temperature is regulated
with the injection of feed water in the attemperators
located between the stages of convection superheater
1 and between convection superheater 2 and
convection superheater 3.
The tubular air heater is located downstream of
the convection pass, and it consists of six pots.
The specified lifetime between overhauls is at
least 4 years. The designed life of the boiler pressure
elements with the design temperature corresponding
to the creeping area is at least 100 thousand hours
for the tubes of the heating surfaces and superheater
chambers and at least 200 thousand hours for other
components.
The boiler load control range is from 30% to
100%. The allowable rate of load changing within
the control range of 30% - 70% is at least 1.5% per
minute, and it is at least 4% per minute within the
control range of 70% - 100%. The boiler is operating
under intermediate load conditions.
35
 STEAM BOILER Е-220-3,7-420Г

Е-220

BOILER PERFORMANCE CHARACTERISTICS

natural gas
Type of fuel
diesel oil
Boiler steam capacity, t/h 220
Superheated steam pressure, MPa 3,7
Superheated steam temperature, ˚С 420
Feed water temperature, ˚С 150
Boiler dimensions, m:
• width along the column axes 11,6
• depth along the column axes 16,0
• height (main beam elevation) 29,95
Boiler efficiency, %:
• in case of natural gas firing 93,4
• in case of diesel oil firing 91,06
Boiler weight removal value, t 760,2

ADVANCED DEVELOPMENTS
36
 STEAM BOILER Е-220-3,7-420Г

Steam boiler Е-220-3,7-420Г is designed to generate made of tubes with a bar welded between them.
superheated steam when firing natural gas as main fuel
The boiler side walls is the place where eight low-
and diesel oil as emergency fuel.
emissivity burners are located opposedly in two rows.
This one-drum steam boiler with natural circulation is
Steam superheat temperature is regulated with the
designed with the use of the close-coupled arrangement
injection of the “internal” condensate. There is provision
of the boiler heating surfaces (Figures 1, 2). The boiler
for feed water injection as a stand-by injection.
consists of a furnace chamber, and it is equipped with
burner devices for natural gas and diesel oil firing. The The tubular air heater consists of two parts designed
uptaking duct is the location area of the second stage to have four air flows.
convection superheater, and the downtaking duct is the
The specified lifetime between overhauls is at
location area of the first stage convection superheater.
least 4 years. The designed life of the boiler pressure
The economizer and the tubular air heater are located in
elements with the design temperature corresponding to
the free standing gas duct along the gas flow.
the creeping area is at least 100 thousand hours for the
The furnace chamber is of the prismatic form, and
tubes of the heating surfaces and superheater chambers
it is rectangular in section with the dimensions along
and at least 200 thousand hours for other components.
the tube axes of 7200х9600 mm. The top part of the
rear waterwall evaporating tubes form a curtain wall The boiler load control range is from 30% to 100%.

between the uptaking duct (above the furnace) and The allowable rate of load changing within the control

the downtaking duct. The uptaking and the downtaking range of 30% - 70% is at least 1.5% per minute, and

ducts are enclosed by the furnace side waterwalls. The it is at least 4% per minute within the control range of

walls of the furnace chamber, the boiler uptaking and 70% - 100%. The boiler is operating under intermediate
downtaking ducts are designed as gas tight panels load conditions.

ADVANCED DEVELOPMENTS
37
 STEAM BOILER Е-310-9,8-540Г

Е-310

BOILER PERFORMANCE CHARACTERISTICS

natural gas
Type of fuel
diesel oil
Boiler steam capacity, t/h 310
Superheated steam pressure, MPa 9,8
Superheated steam temperature, ˚С 540
Feed water temperature, ˚С 150
Boiler dimensions, m:
• width along the column axes 11,6
• depth along the column axes 17,28
• height (main beam elevation) 31,3
Boiler efficiency, %:
• in case of natural gas firing 93,76
• in case of diesel oil firing 89,61
Boiler weight removal value, t 905,1

ADVANCED DEVELOPMENTS
38
 STEAM BOILER Е-310-9,8-540Г
Steam boiler Е-310-9,8-540Г is designed to generate
superheated steam when firing natural gas as main fuel
and diesel oil as emergency fuel.
This one-drum steam boiler with natural circulation is
designed with the use of the close-coupled arrangement
of the boiler heating surfaces (Figures 1, 2). The boiler
consists of a furnace chamber, and it is equipped with
burner devices for natural gas and diesel oil firing. The
uptaking duct is the location area of the first and second
stage convection superheaters, and the downtaking
duct is the location area of the third and fourth stage
convection superheaters. The economizer and the
tubular air heater are located in the free standing gas
duct along the gas flow.
The furnace chamber is of the prismatic form, and elements with the design temperature corresponding to
it is rectangular in section with the dimensions along the creeping area is at least 100 thousand hours for the
the tube axes of 7200х9600 mm. The top part of the
rear waterwall evaporating tubes form a curtain wall
between the uptaking duct (above the furnace) and
the downtaking duct. The uptaking and the downtaking
ducts are enclosed by the furnace side waterwalls. The
walls of the furnace chamber, the boiler uptaking and
downtaking ducts are designed as gas tight panels
made of tubes with a bar welded between them.
ADVANCED DEVELOPMENTS
The boiler side walls is the place where eight low-
emissivity burners are located opposedly in two rows.
Steam superheat temperature is regulated with the
injection of the “internal” condensate. First injection
spray attemperators are installed between the first
and the second stage convection superheaters, and
the second injection spray attemperators are installed
between the second and the third stage convection
superheaters. There is provision for feed water injection
as a stand-by injection.
The economizer with spiral finning consists of
two parts. The tubular air heater consists of two parts
designed to have four air flows.
The specified lifetime between overhauls is at
least 6 years. The designed life of the boiler pressure
tubes of the heating surfaces and superheater chambers
and at least 200 thousand hours for other components.
The boiler load control range is from 30% to 100%.
The allowable rate of load changing within the control
range of 30% - 70% is at least 1.5% per minute, and
it is at least 4% per minute within the control range of
70% - 100%. The boiler is operating under intermediate
load conditions.
39
 STEAM BOILER Е-500-13,8-560Д

Е-500

BOILER PERFORMANCE CHARACTERISTICS

natural gas
Type of fuel
diesel oil
Boiler steam capacity, t/h 500
Superheated steam pressure, MPa 13,8
Superheated steam temperature, ˚С 560
Feed water temperature, ˚С 230
Boiler dimensions, m:
• width along the column axes 14,5
• depth along the column axes 20,2
• height (main beam elevation) 35,3
Boiler efficiency, % 93,8
Boiler weight removal value, t 2511,17

ADVANCED DEVELOPMENTS
40
 STEAM BOILER Е-500-13,8-560Д

Steam boiler Е-500-13,8-560Д is designed to of possible puffs and to ensure that external loads are
generate superheated steam when firing gas oil. This carried.
is a single-furnace, one-drum steam boiler with natural
This boiler provides for the installation of semi-
circulation and close-coupled arch arrangement of
bottom burners in the amount of six pieces (three and
heating surfaces for balanced draft operation that is
three opposed pieces on each side wall located in the
equipped with gas oil firing installations. The boiler
area where the furnace side walls are merging into the
consists of a furnace chamber and a downtaking
bottom waterwall).
duct, protected by gas tight membrane walls, a drum,
burner devices, a condensing unit, water and steam Steam superheat temperature is regulated with the
circulating tubes with an attemperator, water supply injection of the “internal” condensate. There is provision
and steam discharge pipes, outside-mounted cyclones for feed water injection as a stand-by injection.
and regenerative air heaters. The furnace chamber top
The regenerative air heaters with the rotor diameter
part is the location area of the three stages of the platen
of 6800 mm are installed in the amount of two pieces
superheater, and the downtaking duct is the location
per boiler. The pattern of flue gas and air interdependent
area of the three stages of the convection superheater
flow is counter flow.
and the economizer. The regenerative air heaters in the
amount of two pieces are located outside of the boiler The specified lifetime between overhauls is at
house. least 5 years. The designed life of the boiler pressure
elements with the design temperature corresponding to
The open-type furnace chamber is rectangular in
the creeping area is at least 100 thousand hours for the
section, and its plan dimensions are 10560х11280 mm.
tubes of the heating surfaces and superheater chambers
The lower part of the side waterwalls form the bottom
and at least 200 thousand hours for other components.
sloping towards the furnace center at an angle of 30º.
The furnace chamber walls are made of tubes, and a The boiler load control range is from 30% to 100%.
bar is welded between them. The waterwalls have The allowable rate of load changing within the control
corresponding interconnections for burners, access range of 30% - 70% is at least 1.5% per minute, and
doors, inspection doors and manholes. The gas tight it is at least 4% per minute within the control range of
boiler enclosures are equipped with stiffening rings in 70% - 100%. The boiler is operating under base load
order to resist the pressure inside the furnace in case conditions.

ADVANCED DEVELOPMENTS
41
 NOTES:

42
 ATOMENERGOMASH
ROSATOM GROUP OF COMPANIES

ZIO-PODOLSK
THE MACHINE-BUILDING PLANT

ZIOMAR
ENGINEERING COMPANY

www.aozio.ru

2, Zheleznodorozhnaya, Podolsk, Moscow Region, Russia, 142103

Tel.: + 7 (495) 747 10 17 (commercial directorate),
+7 (495) 747 10 25 (multi-channel)

E-mail: kd@eatom.ru; ziomar@eatom.ru