WHY TO GO HIGHER CAPACITY BOILER SPECIFICATION OF 500 MW BOILER

SPECIAL FEATURE OF 500 MW BOILER NEED FOR ASSISTED CIRCULATION / FORCED CIRCULATION

DESIGN FACTORS
CONSTRUCTION OF WATER WALL TUBE, SUPER HEATER, REAHEATER

CONSTRUCTION OF BOILER DRUM

1 T 1
P1

1-2 = Work done in turbine from P1 P2 2-3 = Heat Rejection in condenser 3-4 = Water pumped to boiler

4
P2

2 S

4-1 = Heat addition in eco and boiler.

Theoretically Carnot Cycle is the ldeal cycle. But it is having practical difficulties. For steam power plant, practically thermal cycle used is modified rankine cycle. The maximum efficiency between two limits of the working fluid as given by the carnot cycle is Efficiency = (T1 T2)/T1 where T1 and T2 are max. and min absolute temp. Now as T2 is limited by ambient conditions so T1 must be as high as possible. Thus from the efficiency point of view, the largest gain can be obtained by the use of higher temperature. i.e to increase T1

FURNACE

TYPE: Balanced Draft Wall: Fusion welded Bottom: Dry Tube arrangement: Membrane Explosion / Implosion withstand Capacity at 67% yield point : +/- 660mmwg Residence time for fuel particles in the furnace : 3 sec. Effective volume used to calculate residence time: 14580 m3 Furnace height(from center of ring header to centre of roof inlet header) : 61.168 meter. Depth : 15.289 meter

Width : 18.034 meter Furnace Volume : 14580 m3 Design Code: IBR Type of Firing: Tilting Tangential

Controlled circulation of feed water in water walls with the help of 3

Nos. of boiler circulating water pumps installed on down comers.

Rifled bore water wall tubes as against smooth bore tubes in 210 MW boiler. Provision of Orifices for equal distribution of water in water wall tubes from bottom ring header. All down comers are connected to front header of the bottom ring header.

4 Nos. of bisector air pre heater, two for primary air and two for
secondary air. 8 Nos. of XRP 1043 bowl mills.

0.7 0.6

Density of Water

0.5
0.4 0.3 0.2 0.1 Density of Steam 80 100 120 140 160 180 200 220 240

Critical Point

0
Pressure (Kg/cm2)

Density difference is the driving force for the steam and water mixture. Circulation takes place at such a rate that the driving force and the frictional resistance are balance. But as the pressure increases, the difference in density between the water and steam reduces. Hydrostatic head available may not be able to overcome the frictional resistance for the flow corresponding to the minimum requirement of cooling of water wall tubes. Therefore, natural circulation is limited to Boiler with the drum operating pressure around 175 kg/cm2 Above 175 kg/cm2 of pressure, circulation is to be assisted with mechanical pumps, to overcome the frictional losses. To regulate the flow through various tubes orifice plates are used.

For the construction of boiler parts subjected to pressure and their integral attachment, the designer takes into account several factors

TUBE DETAILS All economizer tube are of 51mm X 5mm. Located in the boiler back pass. It is composed of three banks of 130 parallel tube elements arranged in horizontal rows. Each row is in line with the row above and below. All tube circuit originate from the inlet header and terminate at the outlet header.

ECO OUTLET HDR 406.4

ECO UPPER BANK

ECO MIDDLE BANK

ECO LOWER BANK ECO INLET HDR 508

EC0 FEED PIPE

TUBEE DETAILS
Description Riser Tube Water wall panel tubes Extended side water wall tube W. W. Screen tubes Rear Arch Tubes Tube Size 159 X 15 51 X 5.6 63.5 X 7.1 Material SA 106 Gr-C SA 210 Gr-C SA 210 Gr-A1

W. W. Hanger tubes 63.5 X 11

63.5 X 7.1 i. 51 X 5.6 ii. 63.5 X 7.1 iii. 63.5 X 7.1

SA 210 Gr-C
SA 210 Gr-A1 SA 210 Gr-C SA 210 Gr-C SA 210 Gr-A1

RISER TUBES, 159

FUR REAR HGR TUBE O/L HDR 273

FUR UPPER SIDE WW HDR 273 BOILER DRUM 1778

FUR UPPER REAR WW HDR 273

REAR WALL HGR TUBES 63.5

SCREN TUBES 63.5

SUCTION MANIFOLD , 508

FURN FRONT WALL TUBES 51 FURN REAR WALL TUBES 51

FURN SIDE WALL TUBES 51 BCW PUMP

FURN SIDE HDR , 914.4

FURN REAR HDR , 914.4

WATER WALL DETAILS AND CYCLE

Description

Tube Size

Material

Radiant Roof Tubes

Steam Cooled Side wall tubes Steam Cooled front wall tubes Front Wall Hanger Tubes Rear Roof Tubes Eco and LTSH Support tubes

i. ii.
i. ii. iii. i. ii. iii.

63.5 X 6.3 57 X 5.6

63.5 X 6.3 51 X 5 76.1 X 10 51 X 5 63.5 X 6.3 44.5 X 7.1

SA 213, T11 SA 213, T11

SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C

51 X 5.0 i. ii. 51 X 5 44.5 X 7.1

47.63 X 8.6

Description Steam Cooled Side Wall tubes Bifurcate Tubes (Bottom Header) LTSH Horizontal Tubes Pendent Coil Tubes

Tube Size 51 X 5 51 X 5 i. ii. i. ii. 51 X 5 51 X 5.6 51 X 5 51 X 5.6

Material SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 210, Gr C SA 213, T11 SA 213, T11

Divisional Panel inlet loose tubes

Divisional Panel Outlet loose tubes Steam Cooled Spacer

i. ii.
i. i. ii. iii. iv. v. vi. vii.

51 X 6 44.5 X 4.5
51 X 6 63.5 X 8 51 X 5.6 63.5 X 6.5 63.5 X 7.1 63.5 X 7.1 51 X 5.0 51 X 5.0

SA 210, Gr C SA 210, Gr C
SA 213, T11 SA 213, T11 SA 213, TP347H SA 213, TP347H SA 213, T11 SA 210, Gr C SA 213, T11 SA 210, Gr C

Super heater tubes is composed of three basic stages of section.

Finishing pendent platen super heater

Divisional Panel Section

A Low Temperature Section

The finishing section is located on the horizontal gas path above the furnace rear arch tubes. The divisional panel section are located in the furnace between the front wall and the pendent platen section. It consist of 6 front and 6 rear assemblies. The low temperature section are located in the furnace rear back pass above the economizer section. They are composed of 116 assemblies spaced on across the furnace width. The back pass wall and roof section forms the side, front, rear wall and roof of the vertical gas pass.

DIV PANEL O/L LINK 508, 2 NOS.

MAIN STEAM

SH DESH 508, 2 NOS.

SH ROOF O/L HDR, 406.4

SH CONN TUBES, 59

SH VERT PLATEN ASSY, 51, 6 ASSY

LTSH UPPE BANK 47.63

SH & ECO SUPP TUBES, 51 LTSH I/L HDR, 323.9 BP LWR REAR HDR, 323.9 BP LWR SIDE REAR HDR, 323.9

SH DIV. PANELETTE, 44.5, 6 ASSY

LTSH LWR BANK 47.63

BP LWR FRONT HDR, 406.4

BP LWR SIDE REAR HDR, 406.4

BP UPPER REAR HDR, 273

TUBE DETAILS
Description Reheater Wall tubes Tube Size 60.3 X 4 Material SA 313, T11 SA 213, T11

Cross over tubes 54 X 3.6

The re heater section is composed of three stages or section.

Finishing section

Front Platen Section

Radiant wall section

The finishing section is located above he furnace arch between the furnace screen tubes and the super heater tubes. It consists of 46 tubes assemblies. The reheater front and side radiant wall is composed of tangent tubes on 63.5 centres across the furnace width.

SH CONN TUBES, 59

RH VERT PLATE I/L HDR, 457.

SH ROOF O/L HDR, 406.4

RH VERT PLATEN O/L HDR, 558.8

RH VERT PLATEN I/L HDR, 457.2

MAIN STEAM

RH VERT PLATEN O/L HDR, 558.8

COMPLETE CYCLE 500 MW

The function of the boiler drum internals is to separate the water from the steam generated in the furnace walls. To reduce the dissolved solid contents of the steam to below the prescribed level.

Separation is generally performed in three stages.

IInd Stage
Ist stage Spinner Blades Corrugated sheets
IIIrd Stage Screen Dryers

Dry Saturated Steam

Boiler Internals Mainly Consists of: -

From the riser tube steam and water mixture flows into the Drum through a narrow annulus formed by a shroud extending along the length of the Drum Shell called the Separating Chamber. This is a welded construction formed by Baffles. These surfaces direct the flow of substances either to prevent or o improve its flow. It directs the steam and water mixture entering the drum to the turbo separator.

Spinner Blades Cans

From the lower end of the separating chamber the steam and water mixture is forced upward in the turboseparator. Turbo separator is a main separating device.

The primary stage is formed by two concentric cans and a spinner blade located inside the inner can. The fixed spinner blade of turbo separator which is located inside the inner can imparts a centrifugal motion to the mixture of steam and water flowing upward through the inner can.

The secondary stage consists of two opposed banks of closely spaced thin corrugated sheets. It directs the steam through a curved path and separates the remaining entrained water. Since the velocity is relatively low this water is not picked up again but runs down the plate and flows down to the drum water. This stage of separation is called secondary separation or steam scrubbing.

The third and final stage of steam/water separation takes place in the screen dryer. It removes residual moisture from the steam leaving turbo separator. The screen dryer box consists of wire mesh of different gauges. Exterior meshes are of thicker wire rod, which have better mechanical rigidity to the screen box. The steam passing between the strips making one or more sharp changes of direction and throwing the heavier water particle coming in contact with the strips.

Sr. No. 1 2.

Materil a spec. SA 210, Gr- A1 SA 210, Gr C

Mn

Si

Ni

Cr

Mo

Cb

Used in

0.27 0.35

0.93 0.29 to 1.06 0.30 to 0.60 0.3 to 0.6 0.3 to 0.6

0.048 0.048

0.058 0.058

0.1 0 0.1 0

Extended side WW tube, WW screen tube arch tube WW Panel & corner transition tube, hanger tubes, rear arch tube, Eco tube, steam cooled wall, rear roof, SH hanger tube, LTSH divisional Panel loose tube. 1.0 to 1.5 1.9 to 2.6 0.4 8.0 to 9.5 0.44 to 0.65 0.87 to 1.13 0.85 to 1.05 0. 18 to 0. 25 0.06 to 0.10 Radiant roof pendent coil divisional panel, S, C, spacer, SH Platen coil, re heater wall , re heater coil. Divisional Panel, SH Platen coil, RH Platen Coil, RH rear coil. Platen SH coil, platen RH Coil.

3.

SA 213, T11 SA 213, T91 SA 213, T91

0.15

0.03

0.03

0.5 to 1.0 0.5

4.

0.15

0.03

0.03

5.

0.08 to 0.12

0.02

0.01

0.2 to 0.5

6.

SA 213 TP 304H SA 213, TP 304H

0.04 to 0.10 0.04

2.0

0.04

0.03

0.7 5 0.7 5

8.0 to 11.0 9.0 to 13.0

18.0 to 20.0 17.0 to 20.0

Divisional Panel, RH platen coil.

2.0

0.04

0.03

Divisional panel, SH platen coil, steam cooled spacer.