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AK MHENDSLK TAAHHT

SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : +90(212) 284 51 56 (PBX) FAX : +90(212) 325 52 86
e-mail : akmuh@superonline.com
BOILERS

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
BOILER CLASSIFICATION

Purpose
Tube Configuration
Gas Flow Conditions
Circulation
Shape
Fuel Firing Type
Production Method

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose
Heating

Process - Industrial

Power - electricity

Energy recovery

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Heating

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ;Process - Industrial
Sample

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
1. Process steam supply system
1) The gas turbine drives the alternator.
2) The secondary energies are electricity and saturated steam.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
2.Inlet air cooling system
1) The gas turbine drives the alternator.
2) The secondary energies are electricity and saturated steam. Using
secondary-energy steam as a heat source, the absorption chiller is operated.
And the generated chilled water cools the inlet air of the gas turbine, which
recovers larger gas turbine output during the summer.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
3. Steam-driven fuel gas compressor system
1) The gas turbine drives the alternator.
2) The steam expander is driven by the steam from the heat recovery
steam generator, which can drive the fuel gas compressor, air
compressor or the alternator.
3) The secondary energies are electricity and saturated steam.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
4. Mechanical-drive system
1)The gas turbine directly drives the air compressor through the clutch.
2)The secondary energy is compressed air and saturated steam

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
5. Drying system
1) The gas turbine drives the alternator.
2) The secondary energies are electricity and a heat source for drying.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
6. Supplementary burning system
1) The gas turbine drives the alternator.
2) The secondary energies are electricity and saturated steam.
3) Steam flow can be increased through supplementary burning system as
required, by installing a exhaust gas supplemental burner at the gas turbine
exhaust duct.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
7. Combined-cycle system
1) The gas turbine drives the alternator.
2) Steam from the heat recovery steam generator drives the steam
turbine, thus driving the alternator.
3) The secondary energies are electricity, from two sources, and
saturated / superheated steam.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Power - electricity
8. Cheng-cycle system
1) The turbine drives the alternator.
2) Steam from the heat recovery steam generator is injected into the combustor
of the gas turbine, which increase output and efficiency as a binary cycle.
3) The secondary energies are electricity and saturated steam.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Purpose ; Energy recovery
Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration

Fire-Smoke Tube

Water Tube

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Fire-Smoke Tube

Sample

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Package
Boilers
A boiler
supplied with all
of its
components -
burner, controls
and auxiliary
equipment,
designed as a
single
engineered
package, and
ready for on-site
installation.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Generating Tubes Generating tubes are typically the tubes extending between the mud and steam drums that convert a
large volume of water to steam. Generating tubes are manufactured in various grades of carbon steel (SA-178 Gr. A,
SA-178 Gr. C, SA-192, and SA-210 Al). Some designs require that the generating tubes be swaged to a smaller
diameter on each end. This swaging process increases the actual tube wall thickness (not ordered minimum wall
thickness) about 5% for every 1/4" increment in reduction of outside diameter. The finished actual wall after swaging
is impossible to predict because the ASME Boiler and Pressure Vessel Code permits significant variances in wall
thickness tolerance greater than the minimum wall specified.
Once the tube wall exceeds approximately .250", it can be very difficult to expand. For material SA-178 Gr. C, even
much thinner walls can provide expansion difficulties. In order to minimize these potential problems in expanding
these tube ends into the drum seats, the wall thickness can be controlled by drawing the tube over a mandrel during
the swaging process. In addition, the cold working process of swaging hardens the swaged ends.
For tubes that expanded into a drum seat, it is important that an acceptable level of hardness be maintained in the
completed swaged ends. Therefore, for generating tubes that are swaged for expansion into the drum, Ak
Mhendislik anneals those ends to maintain an acceptable level of hardness. SA-178 A, a common material used in
generating tubes, does not have a hardness requirement from the producing mill. There are ASME standards for
seamless carbon steel tubes. In lieu of any specific standard by our client, Ak Mhendislik's standard for swaged ends
(after we perform the annealing process) is to provide a hardness of less than HRB 79.
When replacing just part of a generating section, it is essential that the tube row configuration matches your existing
tubes to ensure that each row is properly aligned. This is particularly important if your generating section has baffles,
vibration restraints, or other attachments along the row. When it is time to replace a completed generating section, it
is not essential to duplicate the existing configuration exactly. All of the new tubes will be designed and fabricated as a
complete section. Ak Mhendislik typically has or can oAk Mhendislikin the information necessary to duplicate your
generating tube configuration.
For additional information on generating sections unique to your boiler, choose your style from our boiler styles and
click on the Generating section.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Waterwalls Waterwall materials, configuration, and design vary greatly depending on the style of
boiler. To see some typical waterwall sections, click on the style of boiler applicable to you.

Most waterwalls have a membrane panel construction. Membrane and filler wire material
typically match the tubing material. For example, if the waterwall material is SA-213 T11 (1-
1/4% chrome and 1/2% molybdenum), the membrane material would be SA-387 Gr. 11 and the
filler metal material would be E8018 (EB2).

Bends in panels are typically performed on a panel gang bender to assure proper alignment of
tubes at nose arches, ash hoppers, and wall-to-floor transitions.

Some waterwall designs are individual tubes with a tangent or near-tangent design. In these
configurations, it is extremely important to hold very tight tolerances to assure that, once
installed, overall wall width is within tolerance. Special bending dies and procedures must be
used to assure that there is no flattening of the tube. To assure that a tangent or near-tangent
waterwall loose tube will fit properly in the field, it is imperative that it be fit in the shop to a jig
that replicates the field environment.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Headers Ak Mhendislik has complete header design and fabrication capabilities. This includes
machining for facing, drilling and end preparation of large-diameter pipe, as well as
machining baffles and end plates. An automatic flux core welding process is often used for
making header-to-header joints.

Ak Mhendislik has in-house NDT capabilities, including raiography, magnetic particle


testing, dye penetrant testing, and ultrasonic testing techniques. All of these are often used in
the production of headers.

Header-to-stub joints cannot be satisfactorily radiographed. Therefore, AK MUH does a 100%


visual inspection of each root and completed weld. There are designs that put excessive
stress on tube-to-header joints, causing premature failure. The use of extruded headers
addresses this problem by completelyilluminating this joint. The "stubs" are extruded from
the header material. Ak Mhendislik has successfully used this extruded header design in a
variety of boilers.
Ak Mhendislik has experience in fabricating headers from carbon, alloy, and stainless steels.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Package Boiler - Furnace Wall The furnace wall tubes in package boilers are
tangent tubes that form the gas pass. In "D","A", and "O" style package boilers,
there are two style furnace tubes. Their configuration is identical except where
they enter the steam and mud drums on different hole rows. In some cases, the
tubes are seal-welded to form a completely gas-tight area. Refractory is used to
protect the drums and prevent gas leakage at the top and bottom.

It is essential that these tubes be fabricated to very tight bending tolerances.


These tubes are tangent and even a small amount of widening at the bend will
result in the furnace row being out of tolerance when installed. The fabricator
cannot over compensate with a flat bend, resulting in a gap in the bend area. This
will result in excessive gas leakage. Although the bend areas are often seal-
welded to form a gas-tight seal, large gaps will make it necessary to use
additional weld material and take additional time, and will increase stresses
placed on the bend area.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Outside Wall Tubes Package boiler outside wall tubes are either tangent tubes or membrane
panels. Tangent outside wall tubes must be fabricated to the same standards as tangent furnace
wall tubes. When the outside furnace wall consists of tangent tubes, the boiler has a double
casing. The inside casing lays flat against the tubes. Insulation and lagging are placed over this
inner casing. It is essential that the inner casing be cooled by the tubing. If the casing does not
remain in contact with the tube surface, it will eventually overheat, distort, and leak. In order for
this casing to fit flat against these tubes, the tangent row must be fabricated to a near-perfect fit
so there are no high or low spots along the wall.

Depending on the extent of the replacement and the experience of the installing contractor,
outside wall tubes may be installed as individual tubes or as panel sections. Supplying these
tubes as small panel sections can save significant installation time.

"D" style package boiler furnace walls are often supplied as membrane panels. These panels
need to be moderate in size (six to eight tubes wide) for easy installation. See our section on
Waterwalls for general information about panel fabrication.

The panels would be gang bent, and a half-wide membrane is used on the outside tubes to permit
fin-to-fin field welding when joining two panel sections together. This method of construction
minimizes the onsite time associated with seal-welding each individual tube.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Package Boiler Superheaters Package boiler superheaters typically are located in the rear of the
boiler. For "A" and "O" style package boilers, the headers are arranged vertically outside the
boiler and the superheaters are stacked horizontally. For boilers that do not have a gas-tight
welded rear wall, the overall project cost (including downtime and installation cost) may be
significantly lower if a replacement superheater is shop-assembled as a completed module.

For "D" style package boilers, the superheater is typically nested in the rear of the boiler just
prior to the generating pass. The headers are parallel and adjacent to the mud and/or steam
drum. These units often have alignment or support mechanisms tied to the steam drum and
adjacent generating tubes. Support systems on older package boilers with headers at the mud
drum often fail prematurely. Excess stress develops, which causes failures at support systems
and at the superheater header-to-tube joints. These problems can be addressed by a variety of
design solutions, including the use of extruded headers and flexible supports of high alloy
content. Typically, the only practicable way to replace these superheaters is as a complete shop-
assembled module.

SUPERHEATED STEAM - Steam with its temperature raised above that of saturation. The
temperature in excess of its saturation temperature is referred to as superheat.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Fabricatio
n Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Fabricatio
n Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Fabricatio
n Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Fabricatio
n Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Fabricatio
n Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers
Sample1

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers
Sample2

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers
Sample3

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers
Sample4

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Industrial
Boilers
Sample5

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Industrial Field-Erected Boiler Superheaters Field-erected industrial boiler superheaters are designed
from an extensive variety of materials that typically include carbon steel (SA-178A, SA-178C, SA-
192, and SA-210 A1) and alloy (SA-213 T11 and SA-213 T22). The larger furnaces, lower pressures,
and temperatures common to these style boilers assist in typically long life, unless there are unique
fuels or operating problems. When they do fail, it is often with little advanced warning.
Ak Mhendislik can design, material, fabricate, and deliver a complete superheater section within a few
weeks, as opposed to many months from the Original Equipment Manufacturer. Repair loops can
often be supplied within a few days from stock material.
Areas exposed to erosion can be protected with the use of spiral clad tubing.
All fabrication will be in accordance with the latest edition of the ASME Boiler and Pressure Vessel Code
Section I (Power Boilers) and industry standards. Inspection will be performed by our Independent
Authorized Inspection Agency. Partial Data Reports will be issued and signed by our Independent
Authorized Inspection Agency.
All pressure retaining tube-to-tube welds will be done using the GTAW welding process for both root
and cover pass.
Ak Mhendislik will check 10% of all bent tubes using an ultrasonic wall thickness measuring device to
ensure that thinning below Ak Mhendislik's fabrication standards has not occurred in the critical
bend area.
A sponge is blown through each circuit of each assembly to ensure no foreign substances are within the
tubing. Ends prepared for field welding are protected with a coat of deoxaluminate, and then capped
and sealed with tape to provide an essentially watertight seal.
The units is protected with one clear rust inhibitor coat of Conlux or equal on the outside surface
exposed to the atmosphere.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Spiral Clad Tubing Tube failure is among the leading causes of boiler outages, particularly if the failure is associated with
erosion and/or corrosion. This often occurs because tubes are directly in the combustion path. There, they are
subjected to extremely aggressive conditions, which can accelerate wall loss. Many operators have tried to prevent
boiler tube failure by upgrading their tubing from carbon to low-alloy T11 or T22, but without much success. Others
have tried shields, but have experienced an even greater acceleration of wall loss when the shield attachment fails.
Over the past three to five years, a more reliable and highly cost-effective solution has been developed: a pre-overlaid
tube with an alloy composition, which is designed to lessen the effects of the operating environment. Known as spiral
clad tubing, these tubes are generally fabricated from the same base metal design as the original tubing. However,
they have a pre-selected alloy weld metal that is applied to the outside diameter of the tubing. It is applied using a
pulse-spray, gas-metal arc welding process. The tubes may also be subjected to a post-welded, gas-tungsten, arc
wash process, which smoothes the surface and, in some cases, imparts additional ductility to the tubing. In addition,
the use of the same base metal eliminates the need for field-installed, dissimilar metal welds. Spiral clad tubing has
been used successfully in a variety of industries.
Waste to energy ,Utility ,Waste heat recovery ,Recovery ,Industrial ,Petrochemical
Applications
Screens
Waterwalls
Division walls
Roofs
Burner nests
Smelt openings
Floors
Arches
BOF hoods
Reheater and superheater tubing
Open hearth furnaces (steel making)

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
ECONOMIZER - Utilizes waste heat by transferring heat from flue gases to warm incoming feedwater.
Ak Mhendislik has complete economizer design capabilities. We begin with the optimum surface for the
application. We consult with you on your type of fuel, heat source, flue gas characteristics, operating
hours, load variation, available draft, fouling, pluggage, sootblower requirements, gas velocity, and
temperatures to assure you the best solution.
The heating surface options offered will combine your boiler's operating history with modern technology
to provide high efficiency, long life, and competitive solutions to your economizer problems.
The steel "H" and cast-iron designs provide in-linetube and fin surfaces for dirty gas applications and
have added features such as compact sizing, lower draft losses, and isolated bends.
Bare tube, continuous fin, and spiral fin surfaces complete our range of products.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Sootblower
Blueprints of all fabricated parts are archived for future reference.
Performance assessments and evaluations are performed for complete system
overhauls.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Waste to Energy Boilers


Sample

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Waste to Energy Boiler Waterwalls The configuration and base materials used in
waterwalls (for boilers designed for the waste-to-energy market) are no different
than other similar-size industrial boilers. However, the severe furnace environment
of these units has led most users to apply a weld overlay to their waterwalls with
an alloy material that is most effective in reducing corrosion and erosion for their
particular fuel. The typical application is with a high-nickel base alloy.

Often, having new panels shop-fabricated with a shop-applied weld overlay can
result in significant savings. Because the outage duration for the installation of
new panels is usually shorter than the outage duration for the field weld overlay of
existing panels, savings can be realized from the cost associated with the shorter
outage period.

New panels with a shop-applied weld overlay provide the additional benefits of
new, full-thickness tubing and a weld overlay applied under ideal conditions,
resulting in a product superior to the field overlay of existing waterwalls.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Waste to Energy Superheaters The configuration and base materials used in


superheaters for boilers designed for the waste-to-energy market is similar to
superheaters of similar-size industrial boilers. However, the severe furnace
environment of these boilers often results in the upgrade of tubing materials to
higher-grade alloys or stainless steels, increasing wall thickness and adding tube
shields, or using a weld overlay in high-erosion and corrosion areas.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Utility Boiler
Sample

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Utility Boiler Superheaters Superheaters in utility boilers are available in a variety of configurations and utilize
the full range of boiler tube materials. These include high ferritic alloys such as SA-213 T7, SA-213 T5, SA-
213 T9, and SA-213 T91, as well as various stainless steel materials. Ak Mhendislik has ASME Code-qualified
welding procedures for fabricating all of these materials.
The large size of some of these elements may lead to premature failure at supports, ties, alignment
attachments, and roof seals. Some examples of this are the use of SA-351 CK20 Box and "Tee"-style slip
spacers, which are welded to carbon and alloy steel tubing with the use of Inconel filler wire. We can use
these spacers in areas as small as 3/8", replacing original flex ties which are prone to premature failure.
Pendant unit alignment problems may be addressed by using "split ring" style alignment devices. The
differences in the materials and the design used make a significant difference in their performance and cost.
For example: a 2" wide x 1/2" thick "split ring" alignment device of SA-351 CK40 will operate at significantly
higher temperatures and offer much greater strength at a higher cost than 3/8" thick x 1-1/2" brackets of HK20.
"Split ring" castings are limited in the length to which they can be manufactured. Therefore, it may take
several alignment brackets overlapping one or more tubes to supply support to the entire width of an element.
For some designs, alignment brackets can be jointed by special clamp devices.
Platen unit solid ties can be replaced with pin spacers. Although they add significantly to the cost (because of
the high cost of materialsSA-351 CK20 for the spacers themselves and Inconel filler wireand
the additional labor), they can solve serious and costly problems associated with tube leaks, which can
develop at solid tie locations in platen assemblies.
Horizontal units are often supported from vertical hanger tubes. This support system is attached by welding
directly to the bend from the vertical to horizontal section. This often fails because of the high stresses
concentrated at the bend and the large distance between the tubes, which allows a large amount of heat to
concentrate at this critical position.
Superheaters as well as reheaters often require welds between austenitic and ferritic materials (dissimilar
welds). Studies have shown welds between these dissimilar metals in utility boilers (particularly cycling units)
to be susceptible to premature failure under certain operating conditions. This more costly
procedure includes a 60 bevel on the alloy material, 37-1/2 bevel on the stainless material, welded with fully
automatic GTAW process, use of ERNICR (Inconel) filler metal, and 100% radiography of each weld.
Often these elements contain very tight radius bends that must be hot formed.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Recovery Boiler

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Recovery Boiler
Sample1

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Recovery Boiler
Sample2

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Recovery Boiler - Economizer During the development of the recovery boiler-from
the pre-low-odor units to the modern-low-odor, high-throughput boilers-the
Original Equipment Manufacturers have used a variety of economizer
configurations. Many of these designs utilize long vertical sections of
unsupported tubes, which has resulted in premature tube failure at the header-to-
stub joint. The large amount of gas-side solids flowing through these economizers
often results in blockage, erosion, and significant distortion. Using extruded
headers, which eliminate the header-to-tube weld and the addition of restraints,
can minimize these problems.

Older units are extremely difficult to repair because of limited access. Often a
replacement economizer is shop-modularized for field erection. Some modern
designs use individual platen assemblies with small-diameter headers at each
end. These individual platens can be replaced more easily.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Superheaters Superheater materials, configuration, and design vary significantly.
We have extensive experience with all of the common alloys such as SA-213 T11
and SA-213 T22, as well as less common alloys such as SA-213 T91 and the many
various grades of stainless. Some of these materials may require heat treatment to
assure prolonged life.

Superheaters often have tight radius bends which may require hot forming. Ak
Mhendislik has specific hot-forming procedures to assure an acceptable bend
geometry and material mechanical characteristics for use in your unit.

All pressure retaining tube-to-tube welds will be done using the GTAW welding
process for both root and cover pass.

A sponge will be blown through each circuit of each assembly to ensure no


foreign substances are within the tubing. Ends prepared for field welding will be
protected with a coat of deoxaluminate, and then capped and sealed with tape to
provide an essentially watertight seal.

The carbon and alloy tubing portions of each unit are protected with one clear
coat of Conlux or equal on the outside surface exposed to the atmosphere.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Recovery Boiler - Waterwalls Waterwalls in recovery boilers are subject to a severe
erosion/corrosion environment. To extend the life of these tubes and provide an additional
margin of safety, waterwalls typically utilize external protection, including the following:
Studding-For lower pressure units, the application of studs has shown to be an effective and
economical way to extend waterwall life. Originally, these studs were often 3/8" in diameter and
made of carbon steel material on a relatively wide-spaced pattern. The use of 1/2" diameter
studs on a four/four pattern provides a much longer life. Using alloy studs or metal studs can
extend life even further.
Co-Extruded (Composite) Tubing-Almost all recovery boilers built in the United States in the
last 10 years have used co-extruded tubes (SA-210 A1/304) for the waterwalls. In addition, a
number of recovery boilers have replaced their original carbon steel or studded waterwalls with
those of co-extruded tubes.
Chrome, Chrome Silicon, or Aluminum Alloys Diffused into the Base Metal by Special
Processes. These processes are not metal spray and, if done properly, form a true metal-
lurgical bond. The protective layer is quite thin and, unfortunately, there has been a history of
problems associated with inadequate controls used during the application process. These
problems have now largely been resolved.
Spiral Clad Tubing-Weld overlay has been used successfully in furnace floors. Although similar
in metallurgical composition to co-extruded tubing, weld overlay has some distinct advantages:
A heavier layer of protection can be applied.
A wider range of alloy materials is available.
The protective layer can be applied to only part of the tube, if so desired.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Laminar Flow Air Register The shape of the opposing foils enables the register to deliver the
combustion air farther into the boiler and with less inlet pressure.
The design of the register virtually eliminates turbulent flow. Turbulent air flow severely reduces
the ability of an air system to maximize mixing, penetration and pressure.
In Recovery Boilers, this delivery system provides the ability to control bed height which
effectively lowers the combustion envelope. This control results in increased furnace
stabilization and optimal heat absorption by moving the char bed to a precise location within
the furnace.
Over-fire air (OFA) levels can be added or upgraded to Power Boilers with the Laminar Flow
Register resulting in improved grate heat release, more uniform furnace exit temperatures,
thicker fuel bed and better mixing of air and volatiles.
Benefits
Increased penetration of combustion air
Increased reduction efficiency
Reduced Carryover
Reduced Boiler Plugging
Reduced pressure drop across damper
Reduced manual cleaning requirements
Reduction of excess O2
Reduction in fan horsepower requirements
Reduction of SO2 and TRS
Reduction in auxiliary fuel costs
Reduction in hog fuel flow

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube
Smelt Spout Openings We recommend periodic inspection and replacement of
recovery boiler smelt spout openings.
There are critical environments for which smelt spout openings must be fabricated
to the highest quality standards. Each smelt spout opening is fully heat-treated and
inspected by magnetic particle testing. For openings fabricated from weld overlay
tubing, the entire bend area isradiographed.

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Marine Boilers

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Marine Boilers
V Type

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Tube Configuration ; Water Tube

Marine Boilers
H Type

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Gas Flow Conditions

Single Pass
Two Pass
Three Pass
Multi Pass

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Gas Flow Conditions

Single Pass

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Gas Flow Conditions

Two Pass

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Gas Flow Conditions
Three Pass

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Gas Flow Conditions
Multi Pass

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Circulation

Natural Circulation

Forced Circulation

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Shape

Cylindrical ( Scotch )

Rectangular

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Shape ; Cylindrical ( Scotch )
Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Shape ; Rectangular
Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type

Gas Fired
Oil Fired
Solid-Waste Fired
Unfired ( Waste Heat )

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Gas Fired

Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Solid-Waste Fired
Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Unfired
STEAM GENERATING UNIT - A unit to which water, fuel, and air are supplied and in
which steam is generated. It consists of a boiler furnace, and fuel burning equipment,
and may include as component parts water walls, superheater, reheater, economizer,
air heater, or any combination thereof.
Waste Heat: Heat energy produced in an energy conversion or transfer process that is
lost during conversion or transfer and is not available for useful purposes.
Cogeneration: The simultaneous production of electrical energy and another form of
useful thermal energy (such as heat or steam) from the same fuel source, often used for
industrial, commercial, heating, or cooling purposes
Gas Turbine: Rotating machinery where liquid or gaseous fuel is burned to produce
electric power and heat. Hot combustion gases are passed to the turbine and where
they expand to drive the generator and are then used to run the compressor. Gas
turbines typically consist of an axial-flow air compressor; one or more combustion
chambers and a turbine drive section connected to a generator.
Combined Cycle: A multi-stage electric generating technology in which electricity is
produced first from one or more conventional gas (combustion) turbines and then from
steam turbines, although typically about two-thirds of the total power is generated in
the gas turbine portion of the plant. A variety of fuels can supply the gas turbine stages,
after which waste heat exiting the gas turbines is routed to a conventional boiler or a
heat recovery steam generator for use by a steam turbine to produce additional
electricity

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Unfired
Sample1

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Unfired
Sample2

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Unfired
Sample3

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Fuel Firing Type ; Unfired
Sample4

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Production Method

Package

Industrial Field Erected

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Production Method ; Package

Samples

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com
Production Method ; Field Erected

Industrial
Field Erected
Boilers

AK MHENDSLK TAAHHT SAN. VE TC. LTD. T.


elik Sok. No : 65 Seyrantepe / STANBUL
TEL : (212) 284 51 56 (PBX) FAX : (212) 325 52 86 e-mail : akmuh@superonline.com

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