Aadarsh Presentation On Boiler & Its Auxiliaries For SEL, Vedanta Draft

STERLITE ENERGY LIMITED IPP ( 4 X 600 MW), Orissa
Presentation By : Mr. P.K Mohapatra & Mr. Aadarsh
SELF INTRODUCTION
Name :
Pradip Kumar Mohapatra

Associate General Manager
Designation
Qualification
B.E. Mechanical Engg
Concerned Area :
O&M 2X 210 MW, IB Thermal , 9X135 MW, CPP & currently in IPP(4 X 600 MW), Sterlite Energy Limited, Odhisa.
SELF INTRODUCTION
Name :
Aadarsh
Associate Manager
Designation
Qualification
B.E. Mechanical Engg.( Gold Medalist), PG ( TPPE ), CWI, IPMA Level-D, Energy Manager
Concerned Area :
Project Management ,commissioning & PG Test of unit, IPP(4 X 600 MW), Sterlite Energy Limited, Odhisa.
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IBR is Indian Boiler Regulations, which was created in 15th September 1950 in exercise of the powers conferred by section 28 & 29 of the Indian Boilers Act. The Indian Boilers Act was formed in 1923, 23rd February to consolidate and amend the law relating to steam boilers. Steam Boilers that come under IBR are:Steam boiler: Steam boilers under IBR means any closed vessel exceeding 22.75 litres in capacity and which is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel which is wholly or partly under pressure when the steam is shut off. & NON IBR simply means any steam producing equipment lesser than 22.75 ltrs of water hold up capacity.
Steam pipes: IBR steam pipe means any pipe through which steam passes from a boiler to a prime mover or other user or both if pressure at which steam passes through such pipes exceeds 3.5 kg/cm2 above atmospheric pressure or such pipe exceeds 254 mm in internal diameter and includes in either case any connected fitting of a steam pipe.
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Boiler Specification Typical Boiler Specification Boiler Make & Year MCR(Maximum Continuous Rating) Rated Working Pressure Type of Boiler Fuel Fired : HBC & 2007 : 2060 TPH (F & A 100oC) :17.6 kg/cm2(g) : Water tube : Coal
BOILER TYPE: HG-2060/17.5-YM9 Model: HG-2060/17.5-YM9 ManufacturerThe China Harbin boilers Co. LTD Type: This boiler is subcritical, once reheat, assisted circulation, pulverized coal-fired boiler, with single furnace , corner tangential firing, balance ventilation, all-steel overhung construction and with dry-ash furnace.
Heating surface is any part of the boiler metal that has hot gases of combustion on one side and water on the other. Any part of the boiler metal that actually contributes to making steam is heating surface. The amount of heating surface of a boiler is expressed in square meters. The larger the heating surface a boiler has, the more efficient it becomes. For IPP : Water Wall Super heater Economizer Reheater
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: 4860 sqm : 31111 sqm : 19974 sqm : 9242 sqm
AADARSH
Maximum continuous rating is the hourly evaporation that can be maintained for 24 hours. F & A means the amount of steam generated from water at 100C to saturated steam at 100 oC
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Difference between Tube & Pipe: The primary difference between pipe and tubing is how the size is designated. Pipe is designated by a "Nominal Pipe Size" based upon the ID (inside diameter) of the most common wall thickness. Tubing is designated by the measured OD (outside diameter)
Important Terminology of Boilers Blowdown - The drain connection including the pipe and the valve at the lowest practical part of a boiler, or at the normal water level in the case of a surface blowdown. Buckstay - A structural member placed against a furnace or boiler wall to limit the motion of the wall against furnace pressure. Burner - A device which combines fuel and air in proper proportions for combustion and which enables the fuel-air mixture to burn stably to give a specified flame size and shape Burner assembly - A burner that is factory-built as a single assembly or as two or more assemblies which include all parts necessary for its normal function when installed as intended
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Damper - A device for introducing a variable resistance of regulating the volumetric flow of gas or air. Design pressure - The pressure used in the design of a boiler for the purpose of determining the minimum permissible thickness or physical characteristics of the different parts of a boiler. Downcomer - A tube or pipe in a boiler or waterwall circulating system through which fluid flows downward between headers. Drum - A cylindrical shell closed at both ends, designed to withstand internal pressure Duct - A passage for air or gas flow. Economizer - A series of tubes located in the path of flue gases. Feedwater is pumped through these tubes on its way to the boiler in order to absorb waste heat from the flue gas. Evaporation ratio - Evaporation ratio means kilogram of steam generated per kilogram of fuel consumed.
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Flue gas - The gaseous products of combustion in the flue to the stack. Forced circulation - The circulation of water in a boiler by mechanical means external to the boiler. Furnace explosion - A violent combustion of dust or gas accumulations in a furnace or combustion chamber of a boiler. Furnace volume - The cubical contents of the furnace or combustion chamber Header - A distribution pipe supplying a number of smaller lines tapped off of it. A main receiving pipe supplying one or more main pipe lines and receiving a number of supply lines tapped into it Heating surface - That surface which is exposed to the heating medium for absorption and transfer of heat to the heat medium per American Boiler Manufacturers Association (ABMA) Natural circulation - The circulation of water in a boiler caused by differences in density; also referred to as thermal or thermally induced circulation.
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Oil burner - A burner that atomizes fuel oil and blows it into the combustion chamber in the form of a fine mist or vapor. Steam or mechanical motion plus air may be used as the operating medium. Oil gun - The assembly of parts in a burner which provides atomized fuel oil mixture to the furnace for burning. Safety valve - A valve that automatically opens when pressure attains the valve setting which is adjustable; used to prevent excessive pressure from building up in a boiler. Tempering air - Air at a lower temperature added to a stream of pre-heated air to modify its temperature Water hammer - A sudden increase in pressure of water due to an instantaneous conversion or momentum to pressure
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11
Boiler Purpose To produce steam (Main Steam and Reheat Steam) at rated pressure and temperature To Convert the heat of combustion of coal/oil/gas to thermal energy of steam Steam Parameters are decided by Turbine CycleRequirements Steam Parameters adopted by NTPC 200 MW: 157 bar MS Pressure, 540 deg C 500 MW: 179 bar MS Pressure, 540 deg c 660 MW: 246 bar MS Pressure, 545 deg C/563 Advanced Supercritical Parameter 310 bar MS Pressure, 610 deg C
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12
WELDING TECHNOLOGY
Click here
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13
CONTENTS
2. Summarize of welding technology 3. Erection sequence of Boiler 4. Boiler flow schematic 5. Boiler Pressure parts 6. Drum 7. Boiler circulating water pump 8. APH 9. Pulverisers system 10. ESP 11. Bag Filters 12. Commissioning of Boilers 13. Hydro test 14. Insulation test 15. Lime kerosene test 16. Furnace pressurization test 17. Refractory dry out procedure 18. Gas distribution test 19. Chemical cleaning of boiler 20. Hanger settings of boiler 21. Safety valve settings 22. Steam blowing 23. Normalization 24. Performance Guaranteed test of boilers 25. Operational parameters of boilers AADARSH 10/30/2012 26. Boiler assessment
14
Steam Generating System
Water Circuit: water & Boiler Circulating water Fuel Circuit: Combustion Air Circuit: Flue Gas Circuit: Steam Circuit: Condensate Circuit:
Feed

Feed water circuit: Deaerator:

Boiler circulation water : Natural Circulation:

Boiler circulation water : Forced Circulation:
Once Through Force Flow:

Nucleate Boiling :

Fuel Circuit: Coal: Pulverizing PA Temperature Oil: Viscosity Heating Atomizing Cleaning

Combustion Air Circuit: Draught Primary Air Secondary Air Excess Air

Flue Gas Circuit:

Superheater: Radiation has a rising temperature characteristic
curve over the boiler load
Convection has a rising temperature characteristic

curve over the boiler load
Platen type combination of both

Convection Heat Transfer: Approach Point & Pinch Point:
Approach Point of Economizer - 10 to 15oC

Steam Circuit:

Steam Separator:
Tangential Firing System Corner Windbox Arrangement
Tangential Firing System Arrangement

(Joseph. G. Singer, 1981 )
Flame In Tangential Firing (Joseph. G.

Singer, 1981 )
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37
Trajectory Plot of Gas From Each Burner of 500 MW Coal Fired Boiler
( Hiroya Shida, 1984 )
Gas flow pattern in a 500 MW Boiler - Burners in Horizontal position

( Hiroya Shida, 1984 )
The Pattern of Recirculation In Tangentially Fired Boiler.

(Joseph. G. Singer, 1981 )
EXPLOSION
Ignition of an accumulated combustible mixture with in the combustion space of the Furnace or associated Boiler Passes, Ducts and Fans that convey the flue gases to the Stack. The intensity and magnitude of the explosion depends on both the relative quantity of combustible accumulated and the proportion of air mixer.
FIRE TRIANGLE
To start and sustain fire, Three items are required.
FUEL (Object) HEAT (Ignition temperature)
OXYGEN (air)
For combustion
FUEL (object i.e solid or liquid or gas etc. OXYGEN ( to assist combustion)
Oxygen for starting & self sustaining combustion Air contain approx 20.9% oxygen.
HEAT (Ignition temperature for starting.

It varies from material to material.
FIRE EXTINGUISHING TRIANGLE Removal of one or more of the factors of the triangle of fire is the basic principle of fire presentation
Starvation
Blanketing
Cooling
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45
Introduction
SH Capacity:-2060t/hr. SHO/L Pressure:-17.5 Mpa. S/H O/L Temp:-5400C. RH Capacity:-1741.6 t/hr. RH Inlet Pressure:-4.012 Mpa. RH Inlet Temp:-3340C. RH O/L Pressure:-3.81Mpa. RH O/L Temp:-5400C. Boiler Design Pressure:-19.95 Mpa. Operating Pressure:-19.0 Mpa. Hydro test pressure:-29.925 Mpa.
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Presented by Aadarsh
46
Boiler Erection Sequence 1
1.Steam Drum
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Boiler Erection Sequence

1
1.Steam Drum 2.Downcomer
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Water wall with hdr. (Front)
1.Steam Drum 2.Downcomer 3.Front w. wall along with hdr upto 17 mtr &LTR.
2 3
17 Mtr
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Boiler Erection Sequence 1.Steam Drum 2.Downcomer 3.Front w. wall along with hdr upto 17 mtr. 4.(RHS) Side water wall along with hdr upto ring hdr.
4
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Boiler Erection Sequence 1.Steam Drum 2.Downcomer 3.Front w. wall along with hdr upto 17 mtr. 4.(RHS) Side water wall along with hdr upto ring hdr.
5
3 2
5.(LHS) Water wall up to 30 mtr. (For future approach for panel assembly)
5 (LHS) Water wall up to 30 Mtr.
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1. Steam Drum 2. Down comer
3. Front w. wall along with hdr upto 17 mtr. 4. (RHS) Side water wall along with hdr upto ring hdr.
3 2 5
5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side wall.
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7 Hdr along with screen tube.

1. Steam Drum 2. Down comer
3. Front w. wall along with hdr upto 17 mtr. 4. (RHS) Side water wall along with hdr upto ring hdr.
3 2 5
5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side wall. 7. Screen tube hdr along with screen tube.
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1. Steam drum 2. Down comer 3. Front w. wall along with hdr upto 17 mtr.
6 7 3
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr.
2 5 Back pass ext. wall along with ext. lower hdr.

6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr.
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9 1
7

6 8
3 2 5
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR.
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9 1
7

6 8
3 2 5
10FSH Coils
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil.
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9 1
7

1. Steam Drum 2. Down Comer
11
10 6 8
3. Front w. wall along with hdr upto 17 mtr. 4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr.
3 2 5
6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil.
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11.Roof I/L Hdr.
57
9 1
1. Steam drum
11 10 6 8
2. Down comer 3. Front w. wall along with hdr upto 17 mtr. 4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube.
3 2 5
8. Back pass ext. wall along with ext. lower hdr.
12
9. I/L & O/L FSH HDR. 10.FSH Coil. 11.Roof I/L Hdr. 12.Roof O/L Hdr along with BP Front wall.
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9 1
7

11
10 6 8 12
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall.
3 2 5
7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil. 11.Roof I/L Hdr.
13 BP Rear Wall
12.Roof O/L Hdr along with BP Front wall. 13.BP Rear wall.
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9 1
7

11 10 6 8 12 13
3 2 5
7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR.
14 ECO Inter.Hdr.
10.FSH Coil.
14 LTSH I/L Hdr.
11.Roof I/L Hdr. 12.Roof O/L Hdr along with BP Front wall. 13.BP Rear wall. 14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr.
60
14 Bottom ring hdr.

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9 1
7

1 5
11
10 6 8 12 13
3 2 5
7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR.
14. 14
10.FSH Coil. 11.Roof I/L Hdr. 12.Roof O/L Hdr along with BP Front wall. 13.BP Rear wall. 14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr.
14 .
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15.BP Roof.
61

1
7
16
11 10
15
6 8 12 13
6. LHS BP Side water wall. 7. Hdr along with screen tube.
3 2 5
8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil. 11.Roof I/L Hdr.
14 14
14
14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15.BP Roof. 16.LTSH O/L Hdr.
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1 9 16
7
15 11 10 17 6 8 12 13
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube.
3 2 5
14 14
14
14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15.BP Roof. 16.LTSH O/L Hdr. 17.Ver.LTSH Panel, parallel crown plate.
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18

1 9 16
7
11 10 15
17
6 8 12 13
6. LHS BP Side water wall. 7. Hdr along with screen tube.
3 2 5
14 14
14
14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15.BP Roof. 16.LTSH O/L Hdr. 17.Ver.LTSH Panel.
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18.ECO O/L Hdr.
64

1
7
9
16
18
11 10
15 17 6 8 12 13
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil.
3 2 5
11.Roof I/L Hdr. 12.Roof O/L Hdr along with BP Front wall.
14 19 14 14
13.BP Rear wall. 14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15.BP Roof. 16.LTSH O/L Hdr. 17.Ver.LTSH Panel. 18.ECO O/L Hdr. 19.Eco.Hanger Tube along with Horz.LTSH Coil.
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1
7
9
16
18
11 10
15 17 6 19 7 14 5 14 14 20 4 8 12 13
4. (RHS) Side water wall along with hdr upto ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10.FSH Coil. 11.Roof I/L Hdr. 12.Roof O/L Hdr along with BP Front wall. 13.BP Rear wall. 14.ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15.BP Roof. 16.LTSH O/L Hdr. 17.Ver.LTSH Panel. 18.ECO O/L Hdr. 19.Eco.Hanger Tube along with Horz.LTSH Coil.
3 2
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20.ECO coil. & balance hanger tube erection.
66

1
7
9
16
1. Steam drum 18 2. Down comer 3. Front w. wall along with hdr upto 17 mtr. 4. (RHS) Side water wall along with hdr upto ring hdr.
15 11 10
11
5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr.
12
6 17
6 19 3 2 5 14 14 8
20
9. I/L & O/L FSH HDR. 10. FSH Coil. 11. Roof I/L Hdr. 12. Roof O/L Hdr along with BP Front wall. 13. BP Rear wall. 14. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15. BP Roof. 16. LTSH O/L Hdr. 17. Ver.LTSH Panel. 18. ECO O/L Hdr.
21
19. Eco.Hanger Tube along with Horz.LTSH Coil. 20. ECO coil. & balance hanger tube erection. 21. ECO I/L Hdr after hopper comp & RHS BP Wall comp.
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7
1. Steam drum 2. Down comer 3. Front w. wall along with hdr up to 17 mtr. 4. (RHS) Side water wall along with hdr up to ring hdr. 5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side water wall. 7. Hdr along with screen tube. 8. Back pass ext. wall along with ext. lower hdr. 9. I/L & O/L FSH HDR. 10. FSH Coil. 11. Roof I/L Hdr. 12. Roof O/L Hdr along with BP Front wall. 13. BP Rear wall. 14. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. 15. BP Roof. 16. LTSH O/L Hdr. 17. Ver.LTSH Panel. 18. ECO O/L Hdr. 19. Eco.Hanger Tube along with Horz.LTSH Coil. 20. ECO coil. & balance hanger tube erection. 21. ECO I/L Hdr.
9
15
17
14
11 10
12 17
2 3
8
19
13
4&5
13 13
20
21
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Boiler Erection Sequence 22 FRH Hdr 1

7 18
16 15
1. 2. 3. 4.
5.
11
10
12 17
6. 7. 8.
2 3
8 19
13
9. 10. 11. 12. 13. 14.
4&5
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22.
Steam drum Down comer Front w. wall along with hdr upto 17 mtr. (RHS) Side water wall along with hdr upto ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr.
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22 18 7
15 14
1. 2. 3. 4.
5.
11
23
17
10
12
6. 7. 8.
2 3
8
19
13
9. 10. 11. 12. 13. 14.
4&5
13 13
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate.
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22 7
18
16 15
1. 2. 3. 4.
5.
11
23
10 24 FRH COIL
12
6. 7. 8.
2 3
8 19
13
9. 10. 11. 12. 13. 14.
4&5
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24.
Steam drum Down comer Front w. wall along with hdr upto 17 mtr. (RHS) Side water wall along with hdr upto ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr.. FRH Hdr. FRH crown plate. FRH coil.
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Boiler Erection Sequence 1 25 Hanger tube with hdr
22 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
8 19
13
9. 10. 11. 12. 13. 14.
4&5
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr.
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25
22 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
8 19
13
9. 10. 11. 12. 13. 14.
4&5 26 Rear Arch.
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25. 26.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch.
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25
22 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
26
1 7
8 19
13
9. 10. 11. 12. 13. 14.
4&5
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25. 26. 27.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Dr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall.
27 Rear w.wall
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Boiler Erection Sequence 1 28 MRH Hdr

25
22 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
26
8 19
13
9. 10. 11. 12. 13. 14.
4&5
27
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25. 26. 27. 28.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr.
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29 MRH CROWN & HANGER
22 28 25 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
26
8 19
13
9. 10. 11. 12. 13. 14.
4&5
27
14 14
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown
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22 29 28 25 7
18
16 15
1. 2. 3. 4.
5.
11
23
10
24
12
6. 7. 8.
2 3
30 MRH Coil
8 19
26
13
9. 10. 11. 12. 13. 14.
4&5
27
13 13
15. 16. 17. 18. 19.
20
21
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown MRH Coil.
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31
22 29 28 25 7 18
1. 2. 3. 4. Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along wiyh screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown MRH Coil. Link Pipe for platen,FSH & ECO Link to Drum.
16
5.
15 6.
7.
11
23
10
24 30
12
8.
9. 10. 11. 12.
2 3
26
8 19
13 13.
14.
15. 16. 17. 18. 19.
4&5
27
20.
14 14
20
21
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
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31

1. 2. 3. Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown MRH Coil. Link Pipe for platen,FSH & ECO Link to Drum.
32 R.O/L Hdr 32 Di.Hdr
32 plate n hdr
22 28 29 25 7
18
4.
16
5.
15 6.
23
7.
11
24 30
10
12
8.
9. 10. 11. 12.
2 3
26
8 19
13 13.
14.
15. 16. 17. 18. 19.
4&5
27
20.
14 14 32. Div.Hdr,Platen Hdrs Rad.RH O/L Hdr
20
21
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
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31

1. 2. 3. Steam Drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown MRH Coil. Link Pipe for platen,FSH & ECO Link to Drum.
1
32 32 32 28 29 25
22 7
18
4.
16
5.
15 6.
23
7.
11
33 roof up to platen sup.htr 24 30
10
12
8.
9. 10. 11. 12.
2 3
8 19
26
13 13.
14.
15. 16. 17. 18. 19.
4&5
27
20.
14 14 32. Div.Hdr,Platen Hdrs Rad.RH O/L Hdr 33. Roof up to platen Sup.Htr.
20
21
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
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31

1. 2. 3. Steam drum Down comer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS) Water wall up to 30 mtr. LHS BP Side water wall. Hdralong with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil. Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall. ECO.Intermediate hdr,LTSH I/L Hdr & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver.LTSH Panel. ECO O/L Hdr. Eco.Hanger Tube along with Horz.LTSH Coil. ECO coil. & balance hanger tube erection. ECO I/L Hdr. FRH Hdr. FRH crown plate. FRH coil. Hanger tube with hdr. Rear arch. Rear water wall. MRH Hdr. MRH Crown MRH Coil. Link Pipe for platen,FSH & ECO Link to Drum.
1
32 32 32 28 29 33 25
22 7
18
4.
16
5.
15 6.
23
7.
11
24 30
10
12
8.
9. 10. 11. 12.
2 3
34 Div.Coil 34 platen Coil 26
8 19
13 13.
14.
15. 16. 17. 18. 19.
4&5
27
20.
14 14 32. Div.Hdr,Platen Hdrs Rad.RH O/L Hdr 33. Roof up to platen Sup.Htr. 34. Platen Coil,Div.coil
20
21
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
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31

1
32 32 32 28 29 33 25
22 7
18
4.
16
5.
14 6.
23
34 24 30
7.
11
34
10
12
8.
9. 10. 11. 12.
2 3
26
8 19
13 13.
14.
15. 16. 17. 18. 19.
4&5
27
14 14
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
35 LHS Balance w.wall & support.
32. Div.Hdr,Platen Hdrs Rad.RH O/L Hdr 33. Roof up to platen Sup.Htr. 34. Platen Coil,Div.coil 35. LHS W.wall Comp & Suppt.for Spanel.
20
21
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31

1
32 32 32 28 29 33
22 25 7
18
4.
HP CRH
MSP
11 2 3 IP LP
16
5.
15 6.
23
34 24 30
7.
10
12
8.
34
9. 10. 11. 12.
8 19
26
13 13.
14.
15. 16. 17. 18. 19.
HR H
4&5
32. Div.Hdr,Platen Hdrs Rad.RH 27 O/L Hdr 33. Roof up to platen Sup.Htr. 35
14 14
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
20
21
36 SPanel & Ring Hdr 10/30/2012
34. Platen Coil,Div.coil 35. LHS W.wall Comp & Suppt.for S-panel. 36. S-panel & Ring hdr work. Presented byerection Aadarsh
83
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Steam Drum Downcomer Front w. wall along with hdr up to 17 mtr. (RHS) Side water wall along with hdr up to ring hdr. (LHS )Side water wall along with hdr up to 30 MTR. LHS BP Wall. Hdr along with screen tube. Back pass ext. wall along with ext. lower hdr. I/L & O/L FSH HDR. FSH Coil . Roof I/L Hdr. Roof O/L Hdr along with BP Front wall. BP Rear wall . ECO. Intermediate Hdr 4 no, LTSH I/L HDR & BP Ring Hdr. BP Roof. LTSH O/L Hdr. Ver. LTSH panel.
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
Eco. O/l hdr. Eco Coil with balance hanger tube. Eco I/L Hdr. FRH crown plate. FRH COIL. Hanger tube with Hdr. Rear arch. Rear water wall. MRH Hdr. MRH CROWN. MRH coil. LINK PIPE for platen , FSH & ECO LINK to drum. Div. HDR, PLATEN HDRS & Rad. RH O/L HDR. ROOF up to platen super heater. Platen coil & Div.coil. LHS W. wall completion & Bottom support. S-Panel & Ring Hdr Erection work.
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BOILER DRUM
Click here for Drum Lifting
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CALCULATION FOR THE BOILER PRESSURE PARTS

4x600 MW was one of the first of its kind in India. SEL have erected Indias First Sub crtical Boiler Drum in unit # 2. In order to ensure the safety of boiler , calculation of the boiler pressure parts was mandatory and we have done the calculation for pressure parts as per IBR.
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WORKING PRESSURE CALCULATION OF DRUM AS PER IBR: D1:- ID = 1749mm OD = 2103mm Th = 188mm / 177.4mm (Plate used)/(Actual) D2:- ID = 1778mm OD = 2074mm Th = 153mm / 148mm (Plate used)/(Actual) Design temperature: 360 C Design Pressure: 19.95Mpa Working Pressure: 19Mpa (As per Form III) Ligament efficiency e = 0.862 YS at 370 C at P/36 of IBR folder is 290 Mpa Working metal temp. : 370 C Hence, f = 290/ 1.5 = 193.33 Mpa
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Working Pressure =
= 25.49 Mpa and Hence Safe
Click here for boiler pressure parts calculation
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ECONOMISER
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STEEL H ECONOMISERS ADVANTAGES WHAT IS STEEL H HOW STEEL H IS PRODUCED SUPPLY OPTIONS FUELS/BOILERS CASE STUDIES
STEEL H EXTENDED SURFACE TUBE Named Steel H because the original fin resembled The capital letter
STEEL H is an extended fin tube on Machines designed and built in house to our own specification.
STEEL H ADVANTAGES
STEEL H PLATE FIN In Line Tube Arrangement with Straight Gas Passages Ensure Low Fouling and Sustained High Efficiency with Dirty Fuels More Effective Sootblowing Compact Size Low Pressure Loss Less Tubes and Weight Lower Boiler Costs Proven Heat Transfer Rates Double H Inherent Stiffness
Heating Surface Area M2 in 1 Cubic Metre of Space.
Heating Surface [ m2 ]
100 50 15.46 0
PS CFS HF
87.54 96.78 42.13
32.4
Steel H
Double Stl H
Single steel H
Helical Fin
STEEL H DESIGN
GAS FLOW
Fins placed in areas of highest heat transfer.

35
20 35
15 20
20 30 30 35
30
15
15
30 35 30
20 30
Fin weld on sides of tube where maximum heat transfer takes place. Fin material not placed where dust can accumulate above and below the tube. Fin sizes optimised for efficient use of material.
20
20
35
35
30 20 15 10
30 20 5 10 15
STEEL H PRODUCTION
STEEL H PRODUCTION Fins are held in the correct position by Jaws. Current and forge pressure is applied to weld fins to tube. Tube is precisely indexed forward for next fin weld.
Weld Current
Weld Current
Forge Pressure
Forge Pressure
PRECISE INDEXING
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M.S
RE HEATER CIRCUIT NON DRAINABLE PORTION DRAINABLE PORTION
Water and Steam flow Circuit
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540C, 255 Ksc 568C, 47 Ksc

FUR ROOF I/L HDR
492C, 260 Ksc 457C, 49 Ksc

ECO HGR O/L HDR
HRH LINE MS LINE 411C, 277Ksc 411C, 275 Ksc
SEPARATOR
S T O R A G E T A N K HPT
FINAL SH FINAL RH DIV PANELS SH PLATEN SH LTRH
VERTICAL WW
305C, 49 Ksc
ECO JUNCTION HDR
G
LPT
C O N D E N S E R
LPT
IPT
ECONOMISER
ECO I/L
BWRP
FEED WATER
290C, 302 KSC
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FUR LOWER HDR
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101
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Click Here
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Click Here
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Click Here
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Why use an ESP ?

To control atmospheric pollution caused by fly ash .
To meet statutory requirement of pollution control (< 50mg/Nm3 as per Gazette notification by MoEF dated 150mg/Nm3 at 19.05.93).
The byproduct- Fly ash can be utilized for applications like cement works, brick manufacturing etc.
Principle of operation
The ash particles move along the stream of flue gas
Our interest is to change their direction of travel so that they get separated from the stream of flue gas
How ?
Principle of operation (continued)

We impart electrical charge to the particles.
We have a surface with opposite electrical polarity nearby.
The particles are electrically attracted to the surface.

Emitting electrode is charged at high voltage DC (negative). + Collecting Electrode (plate) is at ground potential (positive).

-
Emitting electrodes sprays negative ions towards positive plate (corona discharge).
-
- They collide with ash
particles and transfer the charge to them.
Ash particles get negatively charged.

-
The positive collecting plate attracts negative ash particles.
On reaching the collecting plate, the particles get electrically neutralized and remain there.

After a layer of ash is collected on the collecting plate,it is mechanically rapped so that the ash falls into the hopper for disposal through ash handling system.
Construction
To achieve laminar flow at lower velocity the gas path is split in several Passes.
Perforated GD screen at the entry of each pass ensure uniform velocity distribution.
To achieve better collection efficiency several fields are provided in series in each pass.
Many combinations are possible depending on boiler size.
Construction (major parts)

Collecting plates Emitting electrodes Rapping mechanism (collecting,emitting) Insulators High Voltage Rectiformers Heaters Ash Level Indicators
ESP typical construction
Construction (collecting rapping)

Type: Side driven flexible arm rapper Rapper control typeMicrocomputer Hammers for each row of collecting plates are mounted at different angles on the rapper shaft. When the shaft rotates all rows get hammered one by one. Max no. of electrodes rapped by a rapper at a time- 2
Construction(hopper heaters)
A portion of the hopper is double walled. Heaters (4.5 kW) are placed between the walls to keep the ash warm so that it does not stick to the sides of the hopper. Total No of Hoppers for one boiler- 50
Construction (insulator heaters)

Shaft insulators and support insulators do not fall in regular gas flow path.
They get colder and help ash accumulation on them. This reduces the field voltage.
Heaters for individual insulators are used to keep them warm.
Construction
(ash level indicators )
Ash Level indicators are provided in each hopper for sensing hopper overfilled condition.
High level trips the particular field.
Control philosophy
To have a voltage just below the spark-over voltage for as long as possible. The controller measures current and calculates dI/dt . When this value crosses a limit a spark is sensed. Voltage is made zero for few milliseconds of pause time to allow ionized air to flow away. Voltage again rises at a fast rate to very near the spark over value (say 90%). Rate of rise then slows down. If a spark is sensed, the process repeats itself. If no spark is sensed, the voltage continues to rise till voltage/current limit is reached.
Controller (graph)
Controller(back corona)
All controllers use the above method of dynamic control of voltage.
However use of only this method is unable to tackle the BACK CORONA problem.
Modern controllers have micro-processor based computing facilities to take care of the back corona problem.
Controller(potential difference )
The neutralization of charged ash particles constitute a current.
+ V=IxR
Current has to pass through the layer of ash already collected.
Potential difference is created across the layer. (V=IR)
Controller(ionization of trapped air)

Due to the high resistivity of ash the potential difference in a few mm thick layer can be several kV.
+ + +
This ionizes the air trapped between the ash layers.
Controller(back corona)
The positive ions are repelled by the positive plate & they come out in a stream.
+
+ + + + +
This phenomenon is BACK CORONA.
Controller(effects of back corona)

BACK CORONA Neutralize charged ash particles, so they are not collected.
+ + +
Dislodges already collected particles & allows them fly away.
Draws extra power & reduces collection efficiency.
Controller(controlling back corona)

To reduce Back Corona IR drop has to be reduced. R is a property of ash which cannot be controlled.
To reduce I, V has to be reduced which will reduce the main corona. Hence collection itself will be reduced.
Controller (intermittent charging)

Similar to a fluorescent tube, higher voltage is required to start a corona. Once started, the corona can be maintained by a much lesser voltage.
The field behaves like a RC circuit. Once charged, the voltage decays only gradually through the collection current.
It can be charged again before corona stops.
Controller (less average voltage)

In conventional method of charging every half cycle, difference between the peak & average voltages is very small.
In intermittent charging, firing of the thyristors is skipped for several half cycles & voltage is allowed to decay. While the peak voltage remains same, the average voltage comes down drastically.
Controller (intermittent charging)

2 1 3 4 5 6 7 8 9 10 11 12 13 14 15
1:1
1:5 0
Controller (less average current)

Reduction of average voltage reduces average current which in turn reduces the IR drop across the ash layer. Thus back corona is controlled. The number of half cycles skipped is denoted by charge ratio. A charge ratio of 1:5 means firing takes place at every 5th half cycle. If we use charge ratio more than 1:5, the voltage becomes too low to sustain the main corona after the 5th half cycle. To avoid this thyristors are fired just before 180 deg from 6th half cycle onwards. This is called BASE CHARGE.
Controller (base charge graph)
Base Charge
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CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The purpose of boiler life assessment Life Evaluation by Inspection Preparations for Inspection Data requirement Inspection of high pressure parts. Sample tube inspection. Visual inspection for other parts of boiler . Water quality survey. Visual Inspection for aux Equipment high pressure parts Inspection details
THE PURPOSE OF BOILER LIFE ASSESSMENT

Evaluate the present state and the condition of the boiler components in order To continue stable and reliable boiler operation Evaluate the remaining life for Superheater and Reheater by metallurgical inspection Evaluation of creep life and future inspection scheme by metallurgical inspection for water wall, economizer, Superheater and Reheater tubes Evaluation degree of creep damage for Superheater and Reheater by hardness test Evaluate the remaining life based on thickness Measurement for water wall, Evaluate the remaining life based on thickness thinning for economizer due to low Temperature Corrosion, Evaluate the remaining life based on thickness thinning for Superheater and Reheater tubes due to high Temperature Corrosion Confirm the cause of the inner scale generation Evaluate the remaining life based on check of metal structure ,inner scale ,etc for sample tube
LIFE EVALUATION BY INSPECTION

FAILURE
CREEP
DAMAG CAUSA
Clogging with
PHENOMENON
Swelling Metal structure
LIFE EVALUATION
Outside diameter and
INSPECTION ITEM
Metallurgical inspection for SH, RH
foreign material Deposition and growth of scale on Inner surface Long-term stress
FATIGUE Cycle thermal
change
thickness measurement Metallurgical inspection
header, Metallurgical inspection and NDT (UT) for main steam pipe line and high temperature RH pipe
Growth of crack
Stress analysis Surface crack
NDE (PT, MT) of spacer welded for SH
stress
and RH Tube
inspection (PT,MT)
CORROSION Cyclic thermal Interaction of Ultrasonic test Sample tube inspection Sample tube inspection for SH, RH
FATIGUE
stress under corrosive environment

High temp
corrosion and fatigue
and water wall Check of Burner Nozzle and Wind Box Damper
measurement of tube thickness for SH
CORROSION EROSION
Thickness
Annual thickness
corrosion Low temp corrosion Ash erosion
thinning
measurement
,RH, Water Wall and Eco by UT Steam drum Boiler aux Eco Hanger tube by endoscope, etc
PREPARATIONS FOR INSPECTION

Before inspection
Superheater, reheater, economizer and water wall cleaning Air heater washing Scaffolding Removal of insulation Open man holes, inspection holes, flanges etc Surface preparation of inspection parts Surface finishing (grinding) of inspection parts Instrument of apparatus of inspection Cutting tubes Welding tubes
During inspection

Material requirement
New tubes Man hole packing insulation
Period of inspection
Two weeks
DATA REQUIREMENT
Boiler reference data
Steam temperature Maximum Steam flow Boiler design pressure Feed water temp Reheated inlet steam temperature Reheated outlet steam temperature Reheater design pressure Kind of fuel
0c
Ton/hr Kgm/cm2 0c 0c 0c Kgm/cm2 Gas, Oil
Functional inspection with boiler in operation

Collection of drawings and main technical data Recording of actual operating and functional data at different loads and conditions at MCR and Verification of the operation of the boiler Collection of data relevant to the thermal history and interventions ,if any made on the boiler during his operation life
INSPECTION OF HIGH PRESSURE PARTS

NON Destructive test for the following item
1. 2. 3. 4. 5. 6. 7. 8. Economizer headers, coils, Piping from economizer to steam drum,. Steam drum. Furnace water walls, screen, roof wall, feeders, riser ,Water walls headers. Saturation steam pipe. Primary, secondary super heater. Connecting pipe between primary superheater and secondary superheater. Reheater. Main SH steam pipes
**Inspection item 1. 2. 3. 4. 5. 6. 7. 8. External visual inspection Internal visual inspection with endoscope UT for thickness measurements by UT MT and UT on circumferential welds MT on piping attachments Metallographic inspection by plastic replicas MT on nozzles welds of the coil tubes MT on nozzles welds to the shell of the inlet/outlet pipe
the minimum required thickness
t = minimum required thickness. D = outside diameter of cylinder. e = thickness factor for expanded tube ends. P = maximum allowable working pressure. S = maximum allowable stress value at the design temperature of the metal.
DESIGN / OPERATING INFORMATION FOR CALCULATION OF REMAINING TIME BASED ON THICKNESS Design information
material type or grade Nominal outside diameter Designing pressure Design life Deign temperature Original nominal thickness Thickness measurements of water wall tubes furnace
Operating information
Maximum tube metal temperature Normal operating pressure Original measured minimum thickness Metal thinning rate
SAMPLE TUBE
Destructive test for the Sample tube For Water Wall ,SR and RH tubes Life diagnoses based on check of metal structure, thickness, inner scale, etc
Sample tube takes according to the result of hardness measurement
Investigation Items
Visual inspection Non destructive test Chemical analysis Measurement of the tube dimension Cross sectional microstructure observation Steam oxidation observation Creep rupture test Measurement of the inner scale thickness
Hardness measurement
Information
Material of Sample tube tube dimension
sample tubes
Thinning of bulged zone
Internal surface scale
External surface scale
Optical micrograph
Optical micrograph of non-bluged zones tube wall side showing ferrite pearlite structure with no internal defects
Normal and deteriorated microstructure
normal microstructure ( good condition tube) Which shows a typical ferritic pearlitic structure
deteriorated microstructure which shows the decomposition of the pearlitic colonies
7-Visual inspection for other parts of boiler

Burner Wind Box Hanger for riser pipe Outer casing Skin casing Buckstay
WATER QUALITY SURVEY

This inspection to confirm the cause of the scale generation
Inspection items
Check of laboratory analysis method for quality items Confirmation of water quality results at previous load operation Check of instrument condition on sampling rack used for water quality control Confirmation of PH value and iron/copper balance in the cycle
VISUAL INSPECTION FOR AUX EQUIPMENT

This inspection to confirm the cause of the scale generation
Condenser hot well. Condenser tube side Deaerator. LP-feed water heater. Feed water tank. HP-feed water heater.
HIGH PRESSURE PARTS INSPECTION DETAILS

1. 2. 3. 4. 5. 6. 7. 8. Economizer headers ,coils, Piping from economizer to steam drum, Steam drum Furnace water walls, screen, roof wall, feeders, riser ,Water walls headers Saturation steam pipe Primary, secondary superheater Connecting pipe between primary super heater and secondary superheater Reheater Main SH steam pipes
ECONOMIZER
NDE For headers
External visual inspection Internal visual inspection with endoscope Measurement of thickness by UT MT on nozzles welds of the coil tubes and headers attachments MT and UT on circumferential welds between header and conical pieces
NDE For tube

External visual inspection Measurement of economizer tube and hanger tube thickness with endoscope UT for thickness measurements
NDE For Piping from economizer to steam drum

External visual inspection for piping, hangers and supports UT for thickness measurements MT and UT on circumferential welds MT on piping attachments MT on the elbows extrados
STEAM DRUM
Before the NDT inspections, the internal parts of the drum shall be dismantled
NDE For steam drum
External visual inspection Internal visual inspection UT for shell thickness measurements UT for head thickness measurements MT and UT on circumferential and longitudinal welds MT on steam drum attachments (saddles and accessories) MT on nozzles welds
NDE For downcomers

External visual inspection for piping, hangers and supports UT for thickness measurements MT and UT on circumferential welds MT on piping attachments
FURNACE WATER WALLS, SCREEN, ROOF WALL, FEEDERS AND RISER

NDE for furnace water walls, screen, roof wall
External visual inspection UT for thickness measurements Metallographic examination by plastic replicas Samples for destructive test
NDE for feeders and riser

External visual inspection UT for thickness measurements
NDE for headers

External visual inspection Internal visual inspection with endoscope UT for thickness measurements MT on nozzles welds of the coil tubes MT on branches welds and headers attachments, including drains tubes
SATURATION STEAM PIPE

NDE for each pipe
External visual inspection UT for thickness measurements MT and UT on circumferential welds MT on piping attachments MT on the elbows extrados
DIVISIONAL & PLATEN SUPER HEATER

NDE for the headers External visual inspection Internal visual inspection with endoscope UT for thickness measurements UT for head thickness measurements MT on nozzles welds of the coil tubes MT on nozzles welds to the shell of the inlet/outlet pipe MT and UT on circumferential welds between header and heads/ piping MT on headers attachments Metallographic examination by plastic replicas NDE for Coils External visual inspection UT for thickness measurements Internal visual inspection with endoscope Hardness measurements Samples for destructive examinations
CONNECTING PIPE BETWEEN DIVISIONAL & PLATEN SUPERHEATER, DESUPERHEATER

NDE for connecting pipe External visual inspection UT for thickness measurements MT and UT on circumferential welds MT on piping attachments MT on the elbows extrados Metallographic examination by plastic replicas NDE for desuperheater ATPS External visual inspection Internal visual inspection with endoscope UT for thickness measurements MT on circumferential welds Metallographic examination by plastic replicas
REHEATER
NDE For each one of the headers
External visual inspection Internal visual inspection with endoscope UT for thickness measurements UT for head thickness measurements MT on nozzles welds of the coil tubes MT on nozzles welds to the shell of the inlet/outlet pipe MT and UT on circumferential welds between header and heads/ piping MT on headers attachments Metallographic examination by plastic replicas
NDE For Coils
External visual inspection UT for thickness measurements Internal visual inspection with endoscope Hardness measurements Samples for destructive examinations
MAIN SH STEAM PIPES

NDE for each pipe
External visual inspection UT for thickness measurements MT and UT on circumferential welds MT on piping attachments MT on the elbows extrados MT on nozzles welds to the pipe Metallographic examination by plastic replicas
10/30/2012
AADARSH
167

Aadarsh Presentation On Boiler & Its Auxiliaries For SEL, Vedanta Draft

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Aadarsh Presentation On Boiler & Its Auxiliaries For SEL, Vedanta Draft

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STERLITE ENERGY LIMITED IPP ( 4 X 600 MW), Orissa

Presentation By : Mr. P.K Mohapatra & Mr. Aadarsh

Pradip Kumar Mohapatra

B.E. Mechanical Engg

: 4860 sqm : 31111 sqm : 19974 sqm : 9242 sqm

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Once Through Force Flow:

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Steam Generating System

Convection has a rising temperature characteristic

Platen type combination of both

Steam Generating System

Approach Point of Economizer - 10 to 15oC

Steam Generating System

Steam Generating System

Tangential Firing System Corner Windbox Arrangement

Tangential Firing System Arrangement

Flame In Tangential Firing (Joseph. G.

Gas flow pattern in a 500 MW Boiler - Burners in Horizontal position

The Pattern of Recirculation In Tangentially Fired Boiler.

To start and sustain fire, Three items are required.

FUEL (Object) HEAT (Ignition temperature)

HEAT (Ignition temperature for starting.

Boiler Erection Sequence 1

Boiler Erection Sequence

1.Steam Drum 2.Downcomer

Water wall with hdr. (Front)

Boiler Erection Sequence

5 (LHS) Water wall up to 30 Mtr.

Boiler Erection Sequence

5. (LHS) Water wall up to 30 mtr. 6. LHS BP Side wall.

7 Hdr along with screen tube.

Boiler Erection Sequence

Boiler Erection Sequence

2 5 Back pass ext. wall along with ext. lower hdr.

Boiler Erection Sequence

Boiler Erection Sequence

Boiler Erection Sequence

11.Roof I/L Hdr.

Boiler Erection Sequence

8. Back pass ext. wall along with ext. lower hdr.

Boiler Erection Sequence

Boiler Erection Sequence

14 LTSH I/L Hdr.

14 Bottom ring hdr.

Boiler Erection Sequence

Boiler Erection Sequence

6. LHS BP Side water wall. 7. Hdr along with screen tube.

Boiler Erection Sequence

Boiler Erection Sequence

6. LHS BP Side water wall. 7. Hdr along with screen tube.

18.ECO O/L Hdr.

Boiler Erection Sequence