GENERAL ARRANGEMENT OF

BOILER PRESSURE PARTS

AVTAR SINGH
 CONTENTS
 INTRODUCTION

 BOILER SPECIFICATION

 BOILER TYPE

 PRESSURE PARTS IN BOILER

 FLOW DIAGRAM OF WATER CIRCUIT

 SL. NO. OF COMPONENT DESCRIPTION ALONG WITH THEIR DIA,PITCH AND NOS

 FLOW DIAGRAM OF STEAM CIRCUIT

 SL. NO. OF COMPONENT DESCRIPTION ALONG WITH THEIR DIA,PITCH AND NOS

 NUMBERING GIVEN TO SUPERHEATERS HEADER

 BOILER AND SH DRAIN HEADERS

 CBDT AND IBDT TANK

 SAMPLE STATION

 STEAM AND WATER PARAMETERS

 BOILER VENTS
 INTRODUCTION
Definition of Boiler as per I.B.R.
“Any closed vessel exceeding 22.50 litres (5 gallons) in capacity which is used
expressly for generating steam under pressure.

Components of boiler
Boiler component” means Steam piping , Feed water piping, Economizer, water
walls, down comers, drum, Super heater, Re heaters, etc. any mounting or other
fitting and any other external or internal part of a Boiler which is subjected to
pressure exceeding 1 kg/cm² (g).

Steam Pipe
“Steam Pipe "means any pipe through which steam passes if-
Such pipe exceeds 254 mm in internal diameter and pressure of steam exceeds
1kg/cm² above the atmospheric pressure.
 BOILER SPECIFICATION

DESIGN CAPACITY 865 TPH

DESIGN PRESSURE 155 KG/CM²

DESIGN TEMPERATURE 540 ̊C

FURNACE TYPE FUSION WELDED

FURNACE HEIGHT (RING HEADER TO 43.988 M

ROOF)
FURNACE LENGTH (WIDTH) 14.326 M

FURNACE DEPTH 11.506 M

FUNACE PROJECTED AREA 2298 M²

FURNACE VOLUME 5851 M³

 BOILER TYPE
 Natural circulation
 Single drum
 Two pass
 Dry bottom type
 Tangential tilting corner fired
 Pulverised fuel
PRESSURE PARTS IN BOILERS

 Combustion chamber or Furnace

 Boiler Drum
 Superheaters
 Reheaters
 Economizer
 Desuperheater
 Combustion chamber or Furnace:

 This is a chamber in which the combustion of fuel takes place and heat

thus generated is absorbed by water walls through down comers, bottom

ring header from boiler drum.

Type of furnace
Type Balance Draft
Construction Fusion welded
Width 14326 mm
Depth 11506 mm
 Boiler Drum:
 The Boiler drum provides a reserve for the supply of feed water to the
furnace water wall tubes
 It is also forming a collecting place for steam produced.
 Connecting pipes from the top of the drum carry the saturated steam to
super heater inlet header. The boiler drum is mounted with various
internals and mountings.
Spinner blade in inner can Screen drier

Turbo Separator- 66 no's

 SUPER HEATER
 Super heaters are meant to raise the steam
temperature above the saturation temperature
by absorbing heat from the flue gases.
 Superheating also eliminates the formation of
condensate during transporting of steam in
pipelines and inside the early stages of turbine
which is harmful to the turbine blades and
pipeline
 PLATEN SUPERHEATER

The Superheater Platen Assemblies is located in the furnace between the Furnace
Front Water wall Tubes and the Reheater Vertical Spaced Assemblies Front .

OUTLET TEMP- 504˚C

OUTLET PR- 160 kg/cm2

 FINAL SUPERHEATER

The Final Superheater Assemblies is located in the Superheater Extended Pass zone
between the Waterwall Screen Tubes and Superheater Steam Cooled Front Screen Tubes.

OUTLET TEMP- 540 ˚C

OUTLET PR - 155 kg/cm2

LOW TEMPERATURE SUPERHEATER (LTSH)
The Superheater Rear Horizontal Spaced Coils Upper and Lower Banks and
Superheater Rear Vertical Spaced Assemblies are located in the second pass above the
Economiser Assemblies.
OUTLET TEMP- 403 ˚C
OUTLET PR - 165 kg/cm2
 REHEATER
 Purpose: RE-HEAT THE STEAM FROM HP TURBINE TO 540 ˚C.
The steam comes from HP turbine through CRH (cold reheat pipe) in reheater inlet header at
pressure of 39.4 kg/cm2 and temperature of 344.6 ˚C where it gets heated .Steam comes out from
reheater outlet header in HRH (hot reheat pipe) at temperature of 540 ˚C and goes to intermediate
turbine after meeting their temperature specifications in reheater.

 The Reheater is composed of two sections

 Front platen section

The Reheater Vertical Spaced Assemblies Front is located in-between Superheater Pendant Platen
Assemblies and Furnace Rear Waterwall Hanger Tubes.
INLET TEMP- 345˚C
INLET PR- 39.4 kg/cm2

 Finishing section
The Reheater Vertical Spaced Assemblies Rear is located above the Furnace Rear Arch Tubes
between the Furnace Rear Waterwall Hanger Tubes and Waterwall Screen Tubes.
OUTLET TEMP- 540˚C
OUTLET PR- 37.35 kg/cm2
 ECONOMIZER
 When the combustion gases leave the boiler after giving most of their heat to Water wall

tubes, superheated tubes and reheater tubes, they still posses lot of heat, such heat used

by this device to increases the temperature of feed water.

 It also conveys feed water to steam drum.

INLET TEMP- 287 ˚C
INLET PR- 176.1 kg/cm2
 DESUPERHEATER
Desuperheater is provided in the Superheater connecting link and the Reheater inlet leads to permit reduction

of steam temperature when necessary and to maintain the temperatures at design values within the limits of

the nozzle capacity. Temperature reduction is accomplished by spraying water into the path of the steam

through a nozzle at the entry of the Desuperheater. The spray water comes from the Boiler feed water system

which is at 22 mtr in front side of boiler. It is essential that the spray water is chemically pure and free of

suspended and dissolved solids, containing only approved volatile organic treatment material, in order to

prevent chemical deposition in the Desuperheater and Reheater avoiding carryover of solids to the turbine.

STAGE 1- LTSH TO PLATEN SUPERHEATER (2 NOS)

STAGE2 – PLATEN TO FINAL SUPERHEATER (2 NOS)

REHEATER – CRH (1 NOS)

FLOW DIAGRAM OF WATER CIRCUIT
 SL. NO. COMPONENT DESCRIPTION ALONG WITH THEIR
DIAMETERS AND NO'S
 01. Economiser Inlet Lead - Ø 368 mm
 02. Economiser Inlet Header - Ø 323.9 mm

 03. Economiser Assemblies- Ø 38.1 mm ,177 nos,122.8 mm pitch

 04. Economiser Intermediate Header - Ø 219.1mm

 05. Economiser Hanger Tubes - Ø 44.5 mm

 06. Economiser Outlet Header - Ø 323.9 mm

 07. Economiser Links to Steam Drum - Ø 273mm,20 nos

 08. Steam Drum

 09. Downcomers - Ø 457.2 mm,6 nos

 10. Furnace Front Waterwall Lower Inlet Header- Ø 406.4 mm

 11. Furnace Rear Waterwall Lower Inlet Header- Ø 406.4 mm

 12. Furnace Side Waterwall Lower Inlet Headers - Ø 406.4 mm

 13. Furnace Front Waterwall Tubes- Ø 63.5 mm ,187 nos

 14. Furnace Front Waterwall Outlet Header - Ø 219.1 mm
 15. Furnace Side Waterwall Tubes- Ø 63.5mm ,142 nos

 16. Furnace Side Waterwall Outlet Headers - Ø 219.1 mm

 17. Furnace Rear Waterwall Tubes -Ø 63.5 mm ,187 nos

 18. Furnace Rear Waterwall Hanger Tubes - Ø 76.1 mm,39 nos

 19. Furnace Rear Waterwall Hanger Outlet Header - Ø 219.1 mm

 20. Furnace Rear Arch Tubes -Ø 76.1 mm

 21. Waterwall Screen Tubes – Ø 76.1 mm,128 nos

 22. Waterwall Screen Outlet Header- Ø 273 mm

 23. Furnace Extended Side Waterwall Inlet Header Supply Tubes- Ø

63.5,10nos /side

 24. Furnace Extended Side Waterwall Inlet Header- Ø 219.1 (L&R)

 25. Furnace Extended Side Waterwall Tubes- Ø 63.5,25 nos

 26. Riser Tubes from Furnace Front Waterwall Outlet Header,

Furnace Side Waterwall Outlet Headers, Furnace Rear Waterwall
Hanger Outlet Header and Waterwall Screen Outlet Header to Steam
Drum- Ø 127,140 nos
FLOW DIAGRAM OF STEAM CIRCUIT
 SL. NO. COMPONENT DESCRIPTION ALONG WITH THEIR
DIAMETERS AND NO'S
 01. Saturation Connecting Links -Ø 127 mm ,22 nos
 02. Radiant Roof Inlet Header -Ø 219 mm

 03. Radiant Roof Tubes Front- Ø 51 mm,124 nos,114.3 mm pitch

 04. Radiant Roof Tubes Rear- Ø 51 mm,124 nos,114.3 mm pitch

 05. Superheater Radiant Roof Outlet Header -Ø 323.9 mm

 06. Superheater Steam Cooled Side Wall Inlet Headers Left/Right- Ø

323.9 mm

 07. Superheater Steam Cooled Side Wall Front Tubes- Ø 44.5 mm,52
nos/side

 08. Superheater Steam Cooled Side Wall Outlet Headers Left/Right

(Front)-Ø 273mm
 09. Superheater Steam Cooled Front Wall Inlet Header -Ø 273 mm

 10. Superheater Steam Cooled Front Wall Tubes -Ø 44.5mm,124 nos,143.3 pitch

 11. Superheater Steam Cooled Front Screen Tubes -Ø 44.5 mm

 12. Superheater Rear Roof Junction Header- Ø 219.1 mm

 13. Superheater Steam Cooled Rear Roof Tubes- Ø 44.5mm,124 nos,143.3 pitch
 14. Superheater Steam Cooled Rear Wall Tubes Upper - Ø 44.5mm,124 nos,143.3 pitch
 15. Superheater Rear Horizontal Spaced Inlet Header- Ø 368mm

 16. Superheater Extended Side Steam Cooled Wall Supply Tubes - Ø 127 mm,4 nos

 17. Superheater Extended Side Steam Cooled Wall Inlet Header - Ø 219.1 mm

 18. Superheater Extended Side Wall Tubes- Ø 44.5 mm,20nos

 19. Superheater Extended Side Steam Cooled Wall Outlet Header- Ø 219.1
mm ,20nos
 20. Superheater Extended Side Wall Outlet Pipes
 21. Superheater Steam Cooled Side Wall Rear Tubes- Ø 44.5 mm,26 nos/side

 22. Superheater Steam Cooled Side Wall Outlet Headers Left/Right (Rear) - Ø
273mm
 23. Superheater Steam Cooled Rear Wall Inlet Header - Ø 273 mm
 24. Superheater Steam Cooled Rear Wall Tubes Lower- Ø44.3 mm ,102 nos,139.7 pitch

 25. Superheater Rear Horizontal Spaced Coils Upper and Lower Banks- Ø
47.63,124 nos,133.35 pitch
 26. Superheater Rear Vertical Spaced Assemblies
 27. Superheater Rear Horizontal Spaced Outlet Header - Ø 368mm

 28. Superheater Links to Desuperheater- Ø 368 mm,2 nos

 29. Superheater Desuperheater

 30. Superheater Links from Desuperheater

 31. Superheater Pendant Platen Inlet Header- Ø 323.9 mm
 32. Superheater Pendant Platen Assemblies –Ø47.63 mm,30 nos,533.4 pitch

 33. Superheater Pendant Platen Outlet Header –Ø 323.9mm

 34. Superheater Spaced Inlet Links -Ø 368 mm,2 nos

 35. Final Superheater Inlet Header -Ø 406.4 mm

 36. Final Superheater Assemblies -Ø 47.63 mm,123 nos,190.5 pitch

 37. Final Superheater Outlet Header -Ø 564 mm

 38. Superheater Outlet Leads

 39. Reheater Inlet Leads

 40. Reheater Inlet Header -Ø 508 mm

 41. Reheater Vertical Spaced Assemblies Front -Ø 54/63.5 mm,61 nos,304.8

pitch
 42. Reheater Vertical Spaced Assemblies Rear- Ø 54/57 mm,61 nos,304.8
pitch
 43. Reheater Outlet Header- Ø 812.8 mm
 44. Reheater Outlet Leads
SUPERHEATER HEADERS CAN ALSO BE DENOTED AS FOLLOWS
 SHH1 -Radiant roof inlet header
 SHH2 -Radiant roof outlet header
 SHH3 (L&R) -SH B.P side wall inlet header
 SHH3A -SH B.P extended side wall outlet header
 SHH4 -SH B.P side wall outlet header (front)
 SHH4A -SH B.P side wall outlet header(rear)
 SHH5 -SH B.P front wall inlet header
 SHH6 -SH B.P extended side inlet header
 SHH7 -SH rear roof junction header
 SHH8 -SH B.P rear wall inlet header
 SHH9 -LTSH inlet header
 SHH10 -LTSH outlet header
 SHH11 -Platen inlet header
 SHH12 -Platen outlet header
 SHH13 -Final SH inlet header
 SHH14 -Final SH outlet header
 BOILER AND SH DRAINS HEADER
SHH1 SHH14
SHH4 (L&R) SHH4A (L&R)

SH drain header

Ring
header
HP manifold Ring header Ring
Ring
header Eco inlet link drain
header

Boiler drain header

HP manifold
 CBDT AND IBDT TANK
CBDT TANK
DRUM
SH drain hdr
Working PR-7.16
kg/cm2
Main steam
Working temp- IBDT TANK
165°C
Downcomer
Spare 4 Working PR-1.1
no's kg/cm2
Boiler
drain hdr
Working temp-102°C

HP MANIFOLD

LP MANIFOLD

Wall APH soot blower Scaph Flash pipe

blower EBD drain
Service water
Spare 3 no's spray
LRSB drain
 SAMPLE STATION

Samples of feed water and steam should be taken from sample station at 16 mtr (RHS) at boiler front to check

the parameters of feed water and steam.Sample coolers (5) are used to cool the cool down the hot water and

steam so that samples should be taken easily.

DMCW HRH
inlet
FEED WATER SATURATED SUPERHEATED
DMCW CBD
STEAM STEAM
outlet

Sample Sample Sample

Sample cooler Sample cooler
cooler cooler cooler

TRAY
 WATER AND STEAM PARAMETERS
FEED WATER PARAMETERS AT ECONOMISER
PH - 8.8-9.2
Conductivity - <5.0 µs/cm
Silica - <10 ppb
Hydrazine - <20 ppb
DRUM WATER PARAMETERS
PH – 9.0-9.6
Conductivity - <30 µs/cm
Silica - <100 ppb
Chloride - <1 ppm
Phosphate - <2 to 4 ppm
SUPERHEATED AND SATURATED STEAM PARAMETERS
PH - 8.8-9.2
Conductivity - <5.0 µs/cm
Silica - <10 ppb
Sodium - <20 ppb
 BOILER VENTS
SHH12 to SHH2
SHH13 SHH3A to SHH7 RHH2

EH3 to Drum
LHS
drum

SHH3A to
SHH7
RHH1 SHH14 SHH10 to Drum
SHH11

RHS
 HT AND LT HEADER
SCAPH

Interconnection to unit#2
Mill inerting

Atomizing steam FOPH

FOPH

LT HEADER (12.5,240°C)
Spray
HT HEADER (12.5,320°C) water
PRDS CRH

Spray
water
Gland sealing

PRDS MS
APH soot blower Dearator pegging

Interconnection to unit#2
THANK YOU