Water Tube boilers Boilers Basic AH.ppt
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Aug 29, 2024
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About This Presentation
Basics of boilers
Slide Content
BOILERS
PRESENTED BY ASAD HAMEED
TECHNICAL TRAINING CENTER
PRESENTED BY ASAD HAMEED
TECHNICAL TRAINING CENTER
•Boiler basics
COURSE INTENTIONS
THIS COURSE HAS BEEN PREPARED TO
INTRODUCE THE MECHANICAL
MAINTENANCE PERSONNEL, INVOLVED IN
MAINTENANCE OF BOILERS, ABOUT THE
BOILER BASICS, CONSTRUCTION AND THEIR
WORKING
SPECIAL CONSIDERATION HAS BEEN GIVEN
TO B-605 AND B-601/B-602
THIS COURSE HAS BEEN PREPARED TO
INTRODUCE THE MECHANICAL
MAINTENANCE PERSONNEL, INVOLVED IN
MAINTENANCE OF BOILERS, ABOUT THE
BOILER BASICS, CONSTRUCTION AND THEIR
WORKING
SPECIAL CONSIDERATION HAS BEEN GIVEN
TO B-605 AND B-601/B-602
COURSE OUTLINES
INTRODUCTION TO BOILERS
AUXILIARY BOILER B-605
WASTE HEAT BOILER B-601/B-602
AUXILIARY BOILER B-4601
FIRE TUBE BOILERS
TERMINOLOGIES USED
MAIN COMPONENTS
BOILER MAINTENANCE HISTORY
WATER TREATMENT TECHNIQUES
INTRODUCTION TO BOILERS
AUXILIARY BOILER B-605
WASTE HEAT BOILER B-601/B-602
AUXILIARY BOILER B-4601
FIRE TUBE BOILERS
TERMINOLOGIES USED
MAIN COMPONENTS
BOILER MAINTENANCE HISTORY
WATER TREATMENT TECHNIQUES
INTRODUCTION TO
BOILERS
BOILERS
WHAT IS A BOILER ?
THE BOILER IS A CLOSED HIGH PRESSURE
VESSEL IN WHICH HEAT CHANGES WATER INTO
STEAM.
BOILERS ARE WIDELY USED IN INDUSTRY FOR
PRODUCTION OF HOT WATER AND STEAM
THE BOILER IS A CLOSED HIGH PRESSURE
VESSEL IN WHICH HEAT CHANGES WATER INTO
STEAM.
BOILERS ARE WIDELY USED IN INDUSTRY FOR
PRODUCTION OF HOT WATER AND STEAM
WHY WE USE WATER IN A BOILER ?
THE REASON BEING:
NON-TOXIC, HAZARDOUS OR COMBUSTIBLE
WATER IS A CHEAP MEDIUM
AVAILABLE EVERYWHERE
BOILS AT RELATIVELY LOW TEMPERATURE
ON BOILING IT VOLUME INCREASES ABOUT
1600 TIMES
THE REASON BEING:
NON-TOXIC, HAZARDOUS OR COMBUSTIBLE
WATER IS A CHEAP MEDIUM
AVAILABLE EVERYWHERE
BOILS AT RELATIVELY LOW TEMPERATURE
ON BOILING IT VOLUME INCREASES ABOUT
1600 TIMES
CLASSIFICATION OF BOILERS
THERE ARE TWO MAJOR CLASSIFICATION OF
BOILERS
FIRE TUBE BOILERS
WATER TUBE BOILERS
THERE ARE TWO MAJOR CLASSIFICATION OF
BOILERS
FIRE TUBE BOILERS
WATER TUBE BOILERS
FIRE TUBE BOILERS
WHEN BOILER WATER IS ON THE SHELL SIDE
OF THE BOILER IT IS CALLED FIRE TUBE
BOILER
WHEN BOILER WATER IS ON THE SHELL SIDE
OF THE BOILER IT IS CALLED FIRE TUBE
BOILER
ADVANTAGES OF FIRE TUBE BOILER
LOW INITIAL COST
FUEL EFFICIENT
EASIER TO OPERATE
LOW PRESSURE AND TEMPERATURE
UNITS
LOW CAPACITY
LOW INITIAL COST
DISADVANTAGES
PACKAGED DESIGN
LOW INITIAL COST
FUEL EFFICIENT
EASIER TO OPERATE
LOW PRESSURE AND TEMPERATURE
UNITS
LOW CAPACITY
LOW INITIAL COST
DISADVANTAGES
PACKAGED DESIGN
LIMITATIONS
HIGH PRESSURES ARE DANGEROUS
POOR CIRCULATION
TUBE LEAKAGES AT HIGH TEMPERATURES
HIGH PRESSURES ARE DANGEROUS
POOR CIRCULATION
TUBE LEAKAGES AT HIGH TEMPERATURES
WATER TUBE BOILERS
WHEN BOILER WATER IS ON THE TUBE SIDE
OF THE BOILER IT IS CALLED WATER TUBE
BOILER
WHEN BOILER WATER IS ON THE TUBE SIDE
OF THE BOILER IT IS CALLED WATER TUBE
BOILER
TYPICAL WATER TUBE BOILER
ADVANTAGES OF WATER TUBE BOILER
HIGH CAPACITY
HIGH PRESSURES AND TEMPERATURES
GOOD EFFICIENCY
HIGH MAINTENANCE COSTS
HIGH INITIAL COST
OPERATIONAL DIFFICULTIES
DISADVANTAGES
HIGH CAPACITY
HIGH PRESSURES AND TEMPERATURES
GOOD EFFICIENCY
HIGH MAINTENANCE COSTS
HIGH INITIAL COST
OPERATIONAL DIFFICULTIES
DISADVANTAGES
OTHER CLASSIFICATION CRITERIA
FUEL USED – COAL, OIL OR GAS
PRESSURE – HIGH, MEDIUM AND
LOW PRESSURE BOILERS
FIRING METHOD – FIRED OR UNFIRED BOILERS
FURNACE TYPE – NATURAL, INDUCED OR
FORCED DRAUGHT
WATER CIRCULATION – NATURAL OR FORCED
CIRCULATION
FUEL USED – COAL, OIL OR GAS
PRESSURE – HIGH, MEDIUM AND
LOW PRESSURE BOILERS
FIRING METHOD – FIRED OR UNFIRED BOILERS
FURNACE TYPE – NATURAL, INDUCED OR
FORCED DRAUGHT
WATER CIRCULATION – NATURAL OR FORCED
CIRCULATION
BASIC TERMINOLOGIES
CONDUCTION
CONVECTION
THERMO-SIPHON
RADIATION
HEATING SURFACE
BOILER CAPACITY
BOILER BLOW DOWN
DE-AERATION
CONVECTION SECTION
CONDUCTION
CONVECTION
THERMO-SIPHON
RADIATION
HEATING SURFACE
BOILER CAPACITY
BOILER BLOW DOWN
DE-AERATION
CONVECTION SECTION
CONDUCTION
A METHOD OF HEAT TRANSFER IN WHICH
HEAT IS TRANSFERRED FROM ONE POINT TO
ANOTHER WITHOUT ACTUAL MOVEMENT OF
MOLECULES
A METHOD OF HEAT TRANSFER IN WHICH
HEAT IS TRANSFERRED FROM ONE POINT TO
ANOTHER WITHOUT ACTUAL MOVEMENT OF
MOLECULES
CONVECTION
CONVECTION IS THE MODE OF HEAT
TRANSFER IN WHICH HEAT IS TRANSFERRED
FROM ONE LOCATION TO THE OTHER
THROUGH MOVEMENT OF MOLECULES
CONVECTION IS THE MODE OF HEAT
TRANSFER IN WHICH HEAT IS TRANSFERRED
FROM ONE LOCATION TO THE OTHER
THROUGH MOVEMENT OF MOLECULES
RADIATION
A METHOD OF HEAT TRANSFER THAT DOES
NOT REQUIRE ANY MEDIUM OR MOLECULES
FOR HEAT TRANSFER
A METHOD OF HEAT TRANSFER THAT DOES
NOT REQUIRE ANY MEDIUM OR MOLECULES
FOR HEAT TRANSFER
THERMO-SIPHON
THE FLOW OF WATER (OR ANY LIQUID) FROM
A LOWER ELEVATION TO A HIGHER
ELEVATION DUE TO DIFFERENCE IN
TEMPERATURE AT TWO LOCATIONS
THE FLOW OF WATER (OR ANY LIQUID) FROM
A LOWER ELEVATION TO A HIGHER
ELEVATION DUE TO DIFFERENCE IN
TEMPERATURE AT TWO LOCATIONS
BOILER CAPACITY
IS THE QUANTITY OF STEAM PRODUCED PER
HOUR AND IT SHOWS IT SIZE. IT IS ALSO THE
QUANTITY OF WATER EVAPORATED IN ONE
HOUR. IT IS REPRESENTED IN TONNES PER
HOUR
IS THE QUANTITY OF STEAM PRODUCED PER
HOUR AND IT SHOWS IT SIZE. IT IS ALSO THE
QUANTITY OF WATER EVAPORATED IN ONE
HOUR. IT IS REPRESENTED IN TONNES PER
HOUR
HEATING SURFACE AREA
REFERS TO THE TOTAL AREA EXPOSED TO
HOT COMBUSTION GASES
REFERS TO THE TOTAL AREA EXPOSED TO
HOT COMBUSTION GASES
CONVECTION SECTION
IS THE SECTION OF THE BOILER WHERE HEAT
IS TRANSFERRED TO THE MEDIUM THRU
CONVECTION
IS THE SECTION OF THE BOILER WHERE HEAT
IS TRANSFERRED TO THE MEDIUM THRU
CONVECTION
BLOW DOWN
IS THE DRAINAGE OF WATER FROM A BOILER
TO REDUCE THE LEVEL OF IMPURITIES AND
REPLACING IT WITH BETTER QUALITY WATER
IS THE DRAINAGE OF WATER FROM A BOILER
TO REDUCE THE LEVEL OF IMPURITIES AND
REPLACING IT WITH BETTER QUALITY WATER
DE-AERATION
DE-AERATION IS THE REMOVAL OF
DISSOLVED GASES ESPECIALLY OXYGEN
FROM THE DEMIN. WATER. THESE GASES
(ESPECIALLY OXYGEN) CAUSE CORROSION
INSIDE THE BOILERS AT HIGH
TEMPERATURES
DE-AERATION IS THE REMOVAL OF
DISSOLVED GASES ESPECIALLY OXYGEN
FROM THE DEMIN. WATER. THESE GASES
(ESPECIALLY OXYGEN) CAUSE CORROSION
INSIDE THE BOILERS AT HIGH
TEMPERATURES
MAIN PARTS OF A BOILER
BOILER FURNACE
BURNERS
STEAM DRUM
BOILER BANK TUBES
SUPERHEATER
ECONOMIZER
FURNACE DRAUGHT SYSTEM
BOILER FURNACE
BURNERS
STEAM DRUM
BOILER BANK TUBES
SUPERHEATER
ECONOMIZER
FURNACE DRAUGHT SYSTEM
BOILER FURNACE
THE SECTION OF THE BOILER WHERE
FUEL IS BURNED TO GENERATE HEAT.
HEAT IS TRANSFERRED TO MEDIUM
THRU RADIATION IN THIS SECTION
THE SECTION OF THE BOILER WHERE
FUEL IS BURNED TO GENERATE HEAT.
HEAT IS TRANSFERRED TO MEDIUM
THRU RADIATION IN THIS SECTION
BURNERS
THEY ARE LOCATED IN THE VERTICAL
WALL OF THE COMBUSTION CHAMBER
AND BURN FUEL.
BURNERS ARE DESIGNED FOR EFFICIENT
BURNING OF THE FUEL AND MAINTAIN
HIGH EFFICIENCY.
THEY ARE LOCATED IN THE VERTICAL
WALL OF THE COMBUSTION CHAMBER
AND BURN FUEL.
BURNERS ARE DESIGNED FOR EFFICIENT
BURNING OF THE FUEL AND MAINTAIN
HIGH EFFICIENCY.
STEAM DRUM
STEAM DRUM IS A HIGH PRESSURE
VESSEL WHICH SERVES MANY
FUNCTIONS IN A BOILER SUCH AS A
LARGE RESERVOIR FOR BOILER FEED
WATER, CENTER FOR WATER
DISTRIBUTION AND SATURATED STEAM
COLLECTING AND SUPPLY TO
SUPERHEATER.
STEAM DRUM IS A HIGH PRESSURE
VESSEL WHICH SERVES MANY
FUNCTIONS IN A BOILER SUCH AS A
LARGE RESERVOIR FOR BOILER FEED
WATER, CENTER FOR WATER
DISTRIBUTION AND SATURATED STEAM
COLLECTING AND SUPPLY TO
SUPERHEATER.
BOILER BANK TUBES
THIS IS A BUNCH OF TUBES CONNECTED
TO STEAM DRUM (AND LOWER DRUM)
AND FALLS IN THE CONVECTION ZONE
OF THE BOILER.
THE WATER PARTIALLY EVAPORATES IN
THE BOILER BANK TUBES. IT CONTAINS
RISERS AND DOWN-COMERS.
THIS IS A BUNCH OF TUBES CONNECTED
TO STEAM DRUM (AND LOWER DRUM)
AND FALLS IN THE CONVECTION ZONE
OF THE BOILER.
THE WATER PARTIALLY EVAPORATES IN
THE BOILER BANK TUBES. IT CONTAINS
RISERS AND DOWN-COMERS.
SATURATED STEAM FROM THE STEAM
DRUM RISES THRU DEMISTER PADS AND
ENTERS INTO A SERIES OF TUBES WHICH
ARE LOCATED IN THE BOILER FURNACE
RADIANT SECTION OR IN CONVECTION
SECTION BEFORE ENTERING BOILER
SECTION.
SUPERHEATER
DRUM RISES THRU DEMISTER PADS AND
ENTERS INTO A SERIES OF TUBES WHICH
ARE LOCATED IN THE BOILER FURNACE
RADIANT SECTION OR IN CONVECTION
SECTION BEFORE ENTERING BOILER
SECTION.
SUPERHEATER
ECONOMIZER IS A STEEL TUBE BANK
PLACED AT THE OUTLET OF THE BOILER
SECTION IN THE WAY OF FLUE GASES
BEFORE THEY EXIT.
ECONOMIZER
PLACED AT THE OUTLET OF THE BOILER
SECTION IN THE WAY OF FLUE GASES
BEFORE THEY EXIT.
ECONOMIZER
FURNACE DRAUGHT SYSTEM
IT REGULATES THE FLOW OF AIR TO AND
FROM THE BURNER AND PROVIDES ENOUGH
AMOUNT OF OXYGEN REQUIRED FOR
COMBUSTION IT ALSO FORCES OUT
COMBUSTION GASES OUT OF THE FURNACE
TO THE EXHAUST DUCT.
A FORCED DRAFT SYSTEM USES A FAN TO
FORCE (OR PUSH) AIR THROUGH THE FURNACE
AN INDUCED DRAFT SYSTEM USES A FAN TO
DRAW (OR PULL) AIR THROUGH THE
FURNACE.
BALANCED DRAFT SYSTEM IS SOMETIMES
USED WHICH UTILIZES BOTH FORCED AND
INDUCED DRAFT FANS.
IT REGULATES THE FLOW OF AIR TO AND
FROM THE BURNER AND PROVIDES ENOUGH
AMOUNT OF OXYGEN REQUIRED FOR
COMBUSTION IT ALSO FORCES OUT
COMBUSTION GASES OUT OF THE FURNACE
TO THE EXHAUST DUCT.
A FORCED DRAFT SYSTEM USES A FAN TO
FORCE (OR PUSH) AIR THROUGH THE FURNACE
AN INDUCED DRAFT SYSTEM USES A FAN TO
DRAW (OR PULL) AIR THROUGH THE
FURNACE.
BALANCED DRAFT SYSTEM IS SOMETIMES
USED WHICH UTILIZES BOTH FORCED AND
INDUCED DRAFT FANS.
WATER PROPERTIES
•CHEMICAL PROPERTIES OF WATER
•CHEMICAL DESCRIPTION:
•A UNIVERSAL SOLVENT
•pH
•PHYSICAL PROPERTIES OF WATER
•Uniqueness in existence as the only natural substance on the Earth that is found in all three states of
matter i-e
–Liquid
–Solid (ice)
–Gas (steam)
•Water freezes at 0°C and boils at 100°C. Both of these points are considered as the base lines with
which temperature is measured.
•It has a high specific heat index which indicates that water can absorb a lot of heat before it starts to
get hot. This property keeps water in liquid state in most areas of the Earth at high or low
temperature. This also makes water a valuable substance to be used in industries and in car’s
radiator.
•It has a high latent heat of vaporization which gives resistance to dehydration and considerable
evaporative cooling of the human body.
•Other physical properties include:
•CHEMICAL DESCRIPTION:
•A UNIVERSAL SOLVENT
•pH
•PHYSICAL PROPERTIES OF WATER
•Uniqueness in existence as the only natural substance on the Earth that is found in all three states of
matter i-e
–Liquid
–Solid (ice)
–Gas (steam)
•Water freezes at 0°C and boils at 100°C. Both of these points are considered as the base lines with
which temperature is measured.
•It has a high specific heat index which indicates that water can absorb a lot of heat before it starts to
get hot. This property keeps water in liquid state in most areas of the Earth at high or low
temperature. This also makes water a valuable substance to be used in industries and in car’s
radiator.
•It has a high latent heat of vaporization which gives resistance to dehydration and considerable
evaporative cooling of the human body.
•Other physical properties include:
•COHESION
•ADHESION
•SURFACE TENSION
•CAPILLARY ACTION
•MELTING
•EVAPORATION
•CONDENSATION
•SUBLIMATION
•FROST FORMATION
•ADHESION
•SURFACE TENSION
•CAPILLARY ACTION
•MELTING
•EVAPORATION
•CONDENSATION
•SUBLIMATION
•FROST FORMATION
STEAM THERMODYNAMIC
PROPERTIES
•ENTHALPY:
•ENTROPY:
•DENSITY:
•SPECIFIC VOLUME:
•SPECIFIC WEIGHT:
•WORKING FLUID:
•STATE OF WORKING FLUID:
PROPERTIES
•ENTHALPY:
•ENTROPY:
•DENSITY:
•SPECIFIC VOLUME:
•SPECIFIC WEIGHT:
•WORKING FLUID:
•STATE OF WORKING FLUID:
THERMODYNAMIC
PROCESSES
•REVERSIBLE PROCESS:
•IRREVERSIBLE PROCESS:
•ADIABATIC PROCESS:
•ISOTHERMAL PROCESS
•ISOBARIC PROCESS
PROCESSES
•REVERSIBLE PROCESS:
•IRREVERSIBLE PROCESS:
•ADIABATIC PROCESS:
•ISOTHERMAL PROCESS
•ISOBARIC PROCESS
THERMODYNAMIC CYCLE
•1. A working fluid
•2. Engine
•3. A heat source
•4. A heat receiver
•5. A pump.
•CLOSED CYCLE:
•OPEN CYCLE:
•1. A working fluid
•2. Engine
•3. A heat source
•4. A heat receiver
•5. A pump.
•CLOSED CYCLE:
•OPEN CYCLE:
HEAT ADDITION AND
TEMPERATURE
•SENSIBLE HEAT:
•LATENT HEAT:
•LATENT HEAT OF FUSION:
•HEAT CAPACITY:
•SUBCOOLED LIQUID:
•SATURATED LIQUID:
•LIQUID / VAPOR MIXTURE:
•SATURATED VAPOR:
•SUPERHEATED VAPOR:
•SATURATION TEMPERATURE:
•DEW POINT:
•BUBBLE POINT:
•DEGREE OF SUPERHEAT:
•WET VAPOR:
•QUALITY OF WET VAPOR:
•VAPOR AND GAS:
TEMPERATURE
•SENSIBLE HEAT:
•LATENT HEAT:
•LATENT HEAT OF FUSION:
•HEAT CAPACITY:
•SUBCOOLED LIQUID:
•SATURATED LIQUID:
•LIQUID / VAPOR MIXTURE:
•SATURATED VAPOR:
•SUPERHEATED VAPOR:
•SATURATION TEMPERATURE:
•DEW POINT:
•BUBBLE POINT:
•DEGREE OF SUPERHEAT:
•WET VAPOR:
•QUALITY OF WET VAPOR:
•VAPOR AND GAS:
•CRITICAL POINT OF WATER-
STEAM
•It is a point where vapor and liquid
become indistinguishable.
•STEAM TABLES
•MOLLIER DIAGRAM:
STEAM
•It is a point where vapor and liquid
become indistinguishable.
•STEAM TABLES
•MOLLIER DIAGRAM:
PRINCIPLE OF
COMBUSTION
COMBUSTION
TO BE LEARNED
•On completion of this tutorial you should be able to
do the following.
– Write down combustion equations.
– Solve the oxygen and air requirements for the combustion
– Determine the products of combustion.
– Determine the air/fuel ratio from the products of
combustion
– Solve problems involving energy released by combustion
and fuel required for steam production.
•On completion of this tutorial you should be able to
do the following.
– Write down combustion equations.
– Solve the oxygen and air requirements for the combustion
– Determine the products of combustion.
– Determine the air/fuel ratio from the products of
combustion
– Solve problems involving energy released by combustion
and fuel required for steam production.
WHAT IS COMBUSTION
•Combustion is the process of chemical
reaction between fuel and oxygen (reactants).
The process releases heat and produces
products of combustion. The main elements
which burn are :
CARBON
HYDROGEN
SULPHUR
•Combustion is the process of chemical
reaction between fuel and oxygen (reactants).
The process releases heat and produces
products of combustion. The main elements
which burn are :
CARBON
HYDROGEN
SULPHUR
COMBUSTION DIAGRAM
CH4 + 2O2 => CO2 + 2H2O
Reactants => Products + Heat
CH4 + 2O2 => CO2 + 2H2O
Reactants => Products + Heat
BURNER IS SUPPOSED TO DO ...
•Provide heat to a boiler
• Control the outlet temperature or pressure of a
boiler
•Provide a high turndown so that it does not
shut off over the full range of boiler load
demands
•Burn the fuel in the most efficient way
possible to keep fuel consumption low
•Provide heat to a boiler
• Control the outlet temperature or pressure of a
boiler
•Provide a high turndown so that it does not
shut off over the full range of boiler load
demands
•Burn the fuel in the most efficient way
possible to keep fuel consumption low
COMBUSTION EQUATION
GENERALIZED COMBUSTION
EQUATION (GASEOUS FUELS)
FOR CALCULATION PURPOSE
AIR COMPOSTION BY VOLUME (FOR GASEOUS FUELS):
O2: 21% N2: 79%
AIR COMPOSITION BY MASS (FOR LIQUID/SOLID FUELS):
O2: 23% N2: 77%
EQUATION (GASEOUS FUELS)
FOR CALCULATION PURPOSE
AIR COMPOSTION BY VOLUME (FOR GASEOUS FUELS):
O2: 21% N2: 79%
AIR COMPOSITION BY MASS (FOR LIQUID/SOLID FUELS):
O2: 23% N2: 77%
INCOMPLETE COMBUSTION
•CO FORMATION
•GENERATES 28% LESS HEAT THAN CO2
•SNUFFING MAY CAUSE FLAME
EXTINGUISH AND ULTIMATELY
EXPLOSION
•CO FORMATION
•GENERATES 28% LESS HEAT THAN CO2
•SNUFFING MAY CAUSE FLAME
EXTINGUISH AND ULTIMATELY
EXPLOSION
TERMINOLOGIES
•THEORETICAL AIR: Stoichometric amount of
air required for complete combustion
•Excess Air: The extra amount of air added to the
burner above that which is required to completely
burn the fuel
% EXCESS AIR= ACTUAL AIR – THEORETICAL AIR
THEORETICAL AIR
= O2 measured in flue gas
20.9-O2 measured
•THEORETICAL AIR: Stoichometric amount of
air required for complete combustion
•Excess Air: The extra amount of air added to the
burner above that which is required to completely
burn the fuel
% EXCESS AIR= ACTUAL AIR – THEORETICAL AIR
THEORETICAL AIR
= O2 measured in flue gas
20.9-O2 measured
•Turndown: The ratio of the burner’s
maximum BTUH firing capability to the
burner’s minimum BTUH firing capability
maximum BTUH firing capability to the
burner’s minimum BTUH firing capability
GAS CONC. % OF
THEORETICAL AIR
THEORETICAL AIR
CALORIFIC HEATING
VALUE
Heat generated during combustion per NMC of
gas. In case of liquid/ solid fuel, per kg is
considered.
•NET HEATING VALUE – LOWER
Water vapors in product and with air are not
condensed.
•GROSS HEATING VALUE – HIGHER
Water vapors are condensed.
VALUE
Heat generated during combustion per NMC of
gas. In case of liquid/ solid fuel, per kg is
considered.
•NET HEATING VALUE – LOWER
Water vapors in product and with air are not
condensed.
•GROSS HEATING VALUE – HIGHER
Water vapors are condensed.
BURNING EFFICIENCY
•Combustion Efficiency equals the total
heat released in combustion, minus the heat
lost in the stack gases, divided by the total
heat released. For example, if 1000 BTU/Hr
are released in combustion and 180 BTU/Hr
are lost in the stack, then the combustion
efficiency is 82%: (1000 – 180)/1000 =
0.82 or 82%.
•Combustion Efficiency equals the total
heat released in combustion, minus the heat
lost in the stack gases, divided by the total
heat released. For example, if 1000 BTU/Hr
are released in combustion and 180 BTU/Hr
are lost in the stack, then the combustion
efficiency is 82%: (1000 – 180)/1000 =
0.82 or 82%.
BOILER HEAT LOSSES
•Fuel-to-Steam efficiency is the most important because it
is a measure of the energy that is converted to steam and
that is, after all, the reason a user installs a steam boiler –
to produce steam. Fuel-to-Steam efficiency is equal to
combustion efficiency less the percent of heat losses
through radiation and convection. For example, as in the
example above, 20 BTU/Hr are lost to convection and
radiation then the convection and radiation losses are 2%:
20/1000 = .02 or 2%. If the combustion efficiency for this
same case is 82% then the Fuel-to-Steam efficiency is
80%: 82% - 2% = 80%.
is a measure of the energy that is converted to steam and
that is, after all, the reason a user installs a steam boiler –
to produce steam. Fuel-to-Steam efficiency is equal to
combustion efficiency less the percent of heat losses
through radiation and convection. For example, as in the
example above, 20 BTU/Hr are lost to convection and
radiation then the convection and radiation losses are 2%:
20/1000 = .02 or 2%. If the combustion efficiency for this
same case is 82% then the Fuel-to-Steam efficiency is
80%: 82% - 2% = 80%.
•In a boiler, as the excess air is increased, the
stack temperature rises and the boiler's
efficiency drops. It takes fewer BTU's of
input to the burner to get the same number
of BTU's out of the boiler if lower excess air
can be used. Therefore one of the most
important functions of a burner is to burn the
fuel at the lowest possible excess air to
achieve the greatest overall boiler efficiency.
EFFECT OF EXCESS AIR IN BOILER EFFICIENCY
stack temperature rises and the boiler's
efficiency drops. It takes fewer BTU's of
input to the burner to get the same number
of BTU's out of the boiler if lower excess air
can be used. Therefore one of the most
important functions of a burner is to burn the
fuel at the lowest possible excess air to
achieve the greatest overall boiler efficiency.
EFFECT OF EXCESS AIR IN BOILER EFFICIENCY
ASSIGNMENT
2.
2.
4. A boiler burns coal with the following analysis by mass :
75% C 15% H2 7%S remainder ash. Calculate the % Carbon
Dioxide present in the dry products if 20% excess air is
supplied. (16.5% CO2)
3. Calculate the Natural gas (FFC composition) required for the
production of I ton of KS, considering boiler efficiency of 80%.
75% C 15% H2 7%S remainder ash. Calculate the % Carbon
Dioxide present in the dry products if 20% excess air is
supplied. (16.5% CO2)
3. Calculate the Natural gas (FFC composition) required for the
production of I ton of KS, considering boiler efficiency of 80%.
TEST
INSTRUCTOR: FAISAL GHAFOOR (AMM-1)
NAME: P.NO. UNIT:
1.Gross heating value incorporates --------- of water.
2.Increasing excess air ------- the burning efficiency.
3.High turndown ratio means burner is --------- efficient. (more/less)
4.Soot formation occurs in liquid & solid fuels and indicates ---------------. And
Gaseous fuels need ----------- excess air than liquids.
5.Generalized combustion equation for fuels is:
6.Calorific value of natural gas containing 80 methane, 15% nitrogen and 5%
CO2 is ------------. (Calorific value of methane is 8550 kcal/nmc)
7.CO formation reaction produces ---------- heat than CO2.
8.Combustion of diesel requires --------- excess air than gasoline. (LESS/ MORE)
9.Fuel preheating ----------- the fuel consumption for the same steam production
rates. (increases / reduces)
10.Flue gas is analyzed by Orsat analysis on --------basis (dry / wet).
DATE:
INSTRUCTOR: FAISAL GHAFOOR (AMM-1)
NAME: P.NO. UNIT:
1.Gross heating value incorporates --------- of water.
2.Increasing excess air ------- the burning efficiency.
3.High turndown ratio means burner is --------- efficient. (more/less)
4.Soot formation occurs in liquid & solid fuels and indicates ---------------. And
Gaseous fuels need ----------- excess air than liquids.
5.Generalized combustion equation for fuels is:
6.Calorific value of natural gas containing 80 methane, 15% nitrogen and 5%
CO2 is ------------. (Calorific value of methane is 8550 kcal/nmc)
7.CO formation reaction produces ---------- heat than CO2.
8.Combustion of diesel requires --------- excess air than gasoline. (LESS/ MORE)
9.Fuel preheating ----------- the fuel consumption for the same steam production
rates. (increases / reduces)
10.Flue gas is analyzed by Orsat analysis on --------basis (dry / wet).
DATE:
BOOKS to be consulted
•DuPont --- Sr#53 “Principles of combustion”
•“Steam Generation” ---URDU version (Total
3 editions)
•Alberta Series ---- First/ 2
nd
class “Steam
Generation”
•Presentation Handouts ----- (Principles of
combustion --- FG)
•DuPont --- Sr#53 “Principles of combustion”
•“Steam Generation” ---URDU version (Total
3 editions)
•Alberta Series ---- First/ 2
nd
class “Steam
Generation”
•Presentation Handouts ----- (Principles of
combustion --- FG)
Fire tube boilers
TOWNSHIP BOILERS
TWO YORK SHIPLEY STEAM-PAK PACKAGED
TYPE AUTOMATIC BOILERS ARE INSTALLED IN
TOWNSHIP AIR-CONDITIONING UNIT
FIRE TUBE BOILERS
THESE BOILERS SUPPLY LOW PRESSURE
SATURATED STEAM AT 3-4 PSI AND 110
o
C. THIS
STEAM IS UTILIZED FOR AIR-CONDITIONING
THIS IS A THREE PASS, HORIZONTAL, FIRED
WITH NATURAL GAS, FIRE TUBE BOILER. THE
MAXIMUM CAPACITY IS 220 HP WITH A
MAXIMUM PRESSURE OF 15 PSI.
TWO YORK SHIPLEY STEAM-PAK PACKAGED
TYPE AUTOMATIC BOILERS ARE INSTALLED IN
TOWNSHIP AIR-CONDITIONING UNIT
FIRE TUBE BOILERS
THESE BOILERS SUPPLY LOW PRESSURE
SATURATED STEAM AT 3-4 PSI AND 110
o
C. THIS
STEAM IS UTILIZED FOR AIR-CONDITIONING
THIS IS A THREE PASS, HORIZONTAL, FIRED
WITH NATURAL GAS, FIRE TUBE BOILER. THE
MAXIMUM CAPACITY IS 220 HP WITH A
MAXIMUM PRESSURE OF 15 PSI.
TUBE ROLLING FAILURE
THERE ARE A TOTAL OF 158 TUBES.
94 TUBES IN LOWER SECTION, 64 IN UPPER
TWO SECTIONS
TUBE DIAMETER IS 46 MM.
TUBES ARE ARRANGED IN A ROTATED
TRIANGLE ARRANGEMENT.
THE TUBES ARE FLARED AND ROLLED INTO
TUBE SHEET
CONSTRUCTIONAL DETAILS
94 TUBES IN LOWER SECTION, 64 IN UPPER
TWO SECTIONS
TUBE DIAMETER IS 46 MM.
TUBES ARE ARRANGED IN A ROTATED
TRIANGLE ARRANGEMENT.
THE TUBES ARE FLARED AND ROLLED INTO
TUBE SHEET
CONSTRUCTIONAL DETAILS
BOILER FRONT VIEW BOILER REAR VIEW
TUBE PITCH ARRANGEMENT
TUBE PITCH ARRANGEMENT
HIGH HEAT INPUT REQUIRED FOR REFORMING
PROCESS IS LATER RECOVERED IN A WASTE
HEAT BOILER WHICH COMPRISES THE LARGEST
STEAM GENERATION SOURCE AT FFC PLANT
PROCESS GAS WASTE HEAT BOILER
THIS BOILER IS VIRTUALLY A HEAT
EXCHANGER DIVIDED INTO TWO SECTIONS.
BFW IS PROVIDED ON SHELL SIDE, COMING
FROM A STEAM DRUM THRU DOWNCOMER
TUBES AND RISING BACK THRU RISERS. STEAM
IS SUPERHEATED SOMEWHERE ELSE.
THE PROCESS GAS AT 30 KG/CM
2
AND AT 900
o
C
ENTERS INTO HIGH TEMP. SECTION & LOW
TEMP. SECTIONS GIVING THEIR HEAT TO BFW
PROCESS IS LATER RECOVERED IN A WASTE
HEAT BOILER WHICH COMPRISES THE LARGEST
STEAM GENERATION SOURCE AT FFC PLANT
PROCESS GAS WASTE HEAT BOILER
THIS BOILER IS VIRTUALLY A HEAT
EXCHANGER DIVIDED INTO TWO SECTIONS.
BFW IS PROVIDED ON SHELL SIDE, COMING
FROM A STEAM DRUM THRU DOWNCOMER
TUBES AND RISING BACK THRU RISERS. STEAM
IS SUPERHEATED SOMEWHERE ELSE.
THE PROCESS GAS AT 30 KG/CM
2
AND AT 900
o
C
ENTERS INTO HIGH TEMP. SECTION & LOW
TEMP. SECTIONS GIVING THEIR HEAT TO BFW
WASTE HEAT BOILER – BASE. UNIT
INLET
CHAMBER
E-208 /A E-208 /B E-208/B
BYPASS
VALVE
GAS INLET TRANSITION
CHAMBER
GAS OUTLET
INLET
CHAMBER
E-208 /A E-208 /B E-208/B
BYPASS
VALVE
GAS INLET TRANSITION
CHAMBER
GAS OUTLET
WASTE HEAT BOILER – EXP. UNIT
E-4207
E-4208
GAS INLET
CONE
GAS OUTLET
E-4209
KS INLETKS OUTLET
U-TUBE
EXCH.
E-4207
E-4208
GAS INLET
CONE
GAS OUTLET
E-4209
KS INLETKS OUTLET
U-TUBE
EXCH.
WASTE HEAT BOILER
B-601/B-602
B-601/B-602
DUCT DAMPERS
BOILER BY-
PASS DUCT
BOILER
BY-PASS
DAMPERS
AUXILIARY BURNERS
ECONOMIZER
STEAM DRUM
EVAPORATOR
FORCED
CIRCULATION
PUMPS
SUPERHEATER
GAS TURBINE BOILER SECTION
BOILER BY-
PASS DUCT
BOILER
BY-PASS
DAMPERS
AUXILIARY BURNERS
ECONOMIZER
STEAM DRUM
EVAPORATOR
FORCED
CIRCULATION
PUMPS
SUPERHEATER
GAS TURBINE BOILER SECTION
TWO WATER TUBE, WASTE HEAT BOILERS
(B-601/B-602) ARE INSTALLED AT THE
UTILITIES PLANT FOR RECOVERING WASTE
HEAT OF TWO GAS TURBINES (TG-701)
INTRODUCTION
THIS IS A SIMPLE CONVECTION DUCT
BOILER PRODUCING HS STEAM.
(B-601/B-602) ARE INSTALLED AT THE
UTILITIES PLANT FOR RECOVERING WASTE
HEAT OF TWO GAS TURBINES (TG-701)
INTRODUCTION
THIS IS A SIMPLE CONVECTION DUCT
BOILER PRODUCING HS STEAM.
MAIN FEATURES
CAPACITY 55 TONS PER HOUR
TYPE FORCED CIRCULATION
WATER TUBE
MANUFACTURER FOSTER WHEELER USA
STEAM PRESSURE 39 KG/CM
2
STEAM TEMPERATURE 385
o
C
FUEL GAS TURBINE EXHAUST
GASES PLUS
AUXILIARY FIRING
CAPACITY 55 TONS PER HOUR
TYPE FORCED CIRCULATION
WATER TUBE
MANUFACTURER FOSTER WHEELER USA
STEAM PRESSURE 39 KG/CM
2
STEAM TEMPERATURE 385
o
C
FUEL GAS TURBINE EXHAUST
GASES PLUS
AUXILIARY FIRING
DUCT DAMPERS
BOILER BY-
PASS DUCT
BOILER
BY-PASS
DAMPERS
AUXILIARY BURNERS
ECONOMIZER
STEAM DRUM
EVAPORATOR
FORCED
CIRCULATION
PUMPS
SUPERHEATER
GAS TURBINE BOILER SECTION
EXHAUST GASES
BOILER BY-
PASS DUCT
BOILER
BY-PASS
DAMPERS
AUXILIARY BURNERS
ECONOMIZER
STEAM DRUM
EVAPORATOR
FORCED
CIRCULATION
PUMPS
SUPERHEATER
GAS TURBINE BOILER SECTION
EXHAUST GASES
MAIN PARTS OF THE BOILER
FOLLOWING ARE THE MAIN PARTS OF BOILER:
GAS DUCT AND BOILER ENCLOSURE
DUCT BURNERS AND FIRING SYSTEM
ECONOMIZER COILS
EVAPORATOR COILS
SUPERHEATER COILS
STEAM DRUM
DE-SUPERHEATER
CIRCULATION PUMPS
FOLLOWING ARE THE MAIN PARTS OF BOILER:
GAS DUCT AND BOILER ENCLOSURE
DUCT BURNERS AND FIRING SYSTEM
ECONOMIZER COILS
EVAPORATOR COILS
SUPERHEATER COILS
STEAM DRUM
DE-SUPERHEATER
CIRCULATION PUMPS
BOILER GAS DUCT CONSISTS AN OUTER
CARBON STEEL SHELL (1/4” Thk.), AN
INSULATION LAYER (5” Thk.)COVERED BY SS-
304 COVER PLATE (1/8” Thk.)
GAS DUCT & BOILER ENCLOSURE
THE COVER PLATE IS INSTALLED USING SS-304
ANCHORS(ø1/2”) WHICH ARE WELDED TO THE
OUTER SHELL. EXPANSION LAP HAS BEEN
PROVIDED BETWEEN EACH PLATE
AN EXPANSION JOINT HAS BEEN PROVIDED AT
THE JUNCTION OF GAS TURBINE AND DUCT
CARBON STEEL SHELL (1/4” Thk.), AN
INSULATION LAYER (5” Thk.)COVERED BY SS-
304 COVER PLATE (1/8” Thk.)
GAS DUCT & BOILER ENCLOSURE
THE COVER PLATE IS INSTALLED USING SS-304
ANCHORS(ø1/2”) WHICH ARE WELDED TO THE
OUTER SHELL. EXPANSION LAP HAS BEEN
PROVIDED BETWEEN EACH PLATE
AN EXPANSION JOINT HAS BEEN PROVIDED AT
THE JUNCTION OF GAS TURBINE AND DUCT
GAS TRANSFER DUCT
EXHAUST
GAS
INLET
BLANKING
PLATE
BOILER DUCT
STARTS FROM
HERE
DUCT
MANHOLES
EXHAUST
GAS
INLET
EXPANSION
JOINT
SIDE
VIEW
TOP
VIEW
EXHAUST
GAS
INLET
BLANKING
PLATE
BOILER DUCT
STARTS FROM
HERE
DUCT
MANHOLES
EXHAUST
GAS
INLET
EXPANSION
JOINT
SIDE
VIEW
TOP
VIEW
EXPANSION JOINT WITH THE DUCT
DUCT X-SECTION SHROUD PLATE OVERLAP ANCHORS LAYOUT
DUCT OBSERVATION PORT
CONSTRUCTIONAL DETAILS
DUCT X-SECTION SHROUD PLATE OVERLAP ANCHORS LAYOUT
DUCT OBSERVATION PORT
CONSTRUCTIONAL DETAILS
(CONTINUED)
BURNERS, DUCT DAMPERS ARE INSTALLED IN
THE DUCT BEFORE THE BOILER SECTION
STARTS
THE BOILER DUCT ALSO HOUSES THE BOILER
SECTION THAT INCLUDES SUPERHEATER,
EVAPORATOR AND ECONOMIZER COILS
A STACK IS PROVIDED AT THE END OF THE
DUCT TO VENT HOT EXHAUST GASES.
A VERY HEAVY STRUCTURE HAS BEEN
ERECTED TO SUPPORT THE ENCLOSURE.
BURNERS, DUCT DAMPERS ARE INSTALLED IN
THE DUCT BEFORE THE BOILER SECTION
STARTS
THE BOILER DUCT ALSO HOUSES THE BOILER
SECTION THAT INCLUDES SUPERHEATER,
EVAPORATOR AND ECONOMIZER COILS
A STACK IS PROVIDED AT THE END OF THE
DUCT TO VENT HOT EXHAUST GASES.
A VERY HEAVY STRUCTURE HAS BEEN
ERECTED TO SUPPORT THE ENCLOSURE.
BOILER DUCT DAMPERS
A DAMPER WITH THREE BLADES IS MOUNTED
IN THE DUCT BEFORE THE AUXILIARY
BURNERS. THESE DAMPER BLADES REGULATE
THE FLOW OF THE EXHAUST GASES TO
BOILER.
THREE DAMPERS ARE CONNECTED TO EACH
OTHER BY A MECHANICAL LINK.
THE DAMPER MAY BE CLOSED IN CASE THE
BOILER IS NEED TO BE ISOLATED WHILE GAS
TURBINE IS RUNNING.
A DAMPER WITH THREE BLADES IS MOUNTED
IN THE DUCT BEFORE THE AUXILIARY
BURNERS. THESE DAMPER BLADES REGULATE
THE FLOW OF THE EXHAUST GASES TO
BOILER.
THREE DAMPERS ARE CONNECTED TO EACH
OTHER BY A MECHANICAL LINK.
THE DAMPER MAY BE CLOSED IN CASE THE
BOILER IS NEED TO BE ISOLATED WHILE GAS
TURBINE IS RUNNING.
DAMPERS CONSTRUCTION
THE DAMPER BLADES AND SHAFT IS MADE OF
SS-304 WHILE DAMPER FINS ARE MADE OF SS-
316.
THE DAMPER SHAFT IS SUPPORTED AT THE
ENDS BY PLUMMER BLOCK BEARINGS.
THE SHAFT IS HOLLOW ONE WITH SOLID
STUBS AT THE BOTH ENDS.
THE SHAFT AND STUBS ARE FASTENED
TOGETHER WITH 03 COTTER PINS MADE OF SS-
316 OR INCOLOY 600
THE DAMPER BLADES AND SHAFT IS MADE OF
SS-304 WHILE DAMPER FINS ARE MADE OF SS-
316.
THE DAMPER SHAFT IS SUPPORTED AT THE
ENDS BY PLUMMER BLOCK BEARINGS.
THE SHAFT IS HOLLOW ONE WITH SOLID
STUBS AT THE BOTH ENDS.
THE SHAFT AND STUBS ARE FASTENED
TOGETHER WITH 03 COTTER PINS MADE OF SS-
316 OR INCOLOY 600
BOILER DAMPER X-SECTION AND SIDE VIEW
DAMPER BLADE X-SECTION
DAMPER CLOSED VIEW DAMPER SEALING SYSTEM
DAMPER CLOSED VIEW DAMPER SEALING SYSTEM
DAMPERS WORKING
THE DAMPERS SEAL AGAINST EACH OTHER
AND AGAINST DUCT AFTER THEY ARE CLOSED
BOTTOM DAMPER IS POWERED BY A
LIMITORQUE OPERATOR MOTOR
UPPER TWO BLADES CONNECTED WITH LINK
OPERATE WITH LOWER DAMPER.
DAMPERS OPERATE WITH PRE-ADJUSTED
BLADE TRAVEL CONTROLLED BY LIMIT
SWITCHES.
A BLANKING PLATE IS PROVIDED AFTER THE
DAMPERS IF THE BOILER IS TO BE ISOLATED
FOR LONG DURATION WHILE TURBINE IS
NEEDED TO KEEP RUNNING
THE DAMPERS SEAL AGAINST EACH OTHER
AND AGAINST DUCT AFTER THEY ARE CLOSED
BOTTOM DAMPER IS POWERED BY A
LIMITORQUE OPERATOR MOTOR
UPPER TWO BLADES CONNECTED WITH LINK
OPERATE WITH LOWER DAMPER.
DAMPERS OPERATE WITH PRE-ADJUSTED
BLADE TRAVEL CONTROLLED BY LIMIT
SWITCHES.
A BLANKING PLATE IS PROVIDED AFTER THE
DAMPERS IF THE BOILER IS TO BE ISOLATED
FOR LONG DURATION WHILE TURBINE IS
NEEDED TO KEEP RUNNING
DUCT BURNERS & FIRING SYSTEM
BOILER IS CAPABLE OF OPERATING AT FULL
LOAD EVEN AT THE LOWEST GAS TURBINE
LOAD WITH ITS AUXILIARY FIRING
THE BURNERS UTILIZE NATURAL GAS FOR
COMBUSTION.
THE BOILER DOES NOT HAVE ITS OWN AIR
SUPPLY SO THEY CANNOT BE OPERATED
WITHOUT GAS TURBINE EXHAUST WHICH
CONTAINS ENOUGH OXYGEN
THERE ARE FOUR VERTICAL BURNERS WHILE
ONE HORIZONTAL PILOT BURNER
BOILER IS CAPABLE OF OPERATING AT FULL
LOAD EVEN AT THE LOWEST GAS TURBINE
LOAD WITH ITS AUXILIARY FIRING
THE BURNERS UTILIZE NATURAL GAS FOR
COMBUSTION.
THE BOILER DOES NOT HAVE ITS OWN AIR
SUPPLY SO THEY CANNOT BE OPERATED
WITHOUT GAS TURBINE EXHAUST WHICH
CONTAINS ENOUGH OXYGEN
THERE ARE FOUR VERTICAL BURNERS WHILE
ONE HORIZONTAL PILOT BURNER
CONSTRUCTION DETAILS
VERTICAL AND HORIZONTAL BURNERS ARE
MADE OF SS-304 PIPE WITH HOLES OF ø_ FOR
NATURAL GAS OUTLET
VERTICAL BURNERS ENTER THE DUCT FROM
TOP THRU ø2” GAS INLET PIPE.
AN IGNITOR AND A SCANNER FOR FLAME
DETECTION ARE ALSO INSTALLED.
THE BURNERS ARE SEALED WITH THE DUCT
BY THE AIR SEALS WITH SLIGHTLY HIGHER
PRESSURE THEN PRESENT IN THE DUCT AS
SHOWN.
VERTICAL AND HORIZONTAL BURNERS ARE
MADE OF SS-304 PIPE WITH HOLES OF ø_ FOR
NATURAL GAS OUTLET
VERTICAL BURNERS ENTER THE DUCT FROM
TOP THRU ø2” GAS INLET PIPE.
AN IGNITOR AND A SCANNER FOR FLAME
DETECTION ARE ALSO INSTALLED.
THE BURNERS ARE SEALED WITH THE DUCT
BY THE AIR SEALS WITH SLIGHTLY HIGHER
PRESSURE THEN PRESENT IN THE DUCT AS
SHOWN.
AUXILIARY FIRING ARRANGEMENT
RUNNER PIPE
END
SUPPORT
PILOT BURNER &
SEALING SYSTEM
RUNNER PIPE
END
SUPPORT
PILOT BURNER &
SEALING SYSTEM
BOILER SECTION
BOILER SECTION IS ALSO HOUSED IN THE
BOILER DUCT AND IT INCLUDES:
EVAPORATOR COILS
ECONOMIZER COILS
SUPERHEATER COILS
BOILER SECTION IS ALSO HOUSED IN THE
BOILER DUCT AND IT INCLUDES:
EVAPORATOR COILS
ECONOMIZER COILS
SUPERHEATER COILS
EXHAUST
BOILER SECTION DETAILS
SUPERHEATER
72 TUBES, Ø2”
BOTTOM
24 TUBES OF P-1
EVAPORATOR
432 TUBES, Ø2”
CARBON STEEL
ECONOMIZER
384 TUBES, Ø2”
CARBON STEEL
FINNED
Ø6” CS Sch. 80
INLET PIPE
Ø6” CS Sch. 80
OUTLET PIPE
Ø
8
”
C
S
S
c
h
.
8
0
I
N
L
E
T
A
N
D
O
U
T
L
E
T
P
I
P
E
Ø10” CS Sch. 80
INLET PIPE
Ø10” P-1 Sch. 80
INLET PIPE
HOT GASES
INTERMEDIATE
TUBE SUPPORTS
BOILER SECTION DETAILS
SUPERHEATER
72 TUBES, Ø2”
BOTTOM
24 TUBES OF P-1
EVAPORATOR
432 TUBES, Ø2”
CARBON STEEL
ECONOMIZER
384 TUBES, Ø2”
CARBON STEEL
FINNED
Ø6” CS Sch. 80
INLET PIPE
Ø6” CS Sch. 80
OUTLET PIPE
Ø
8
”
C
S
S
c
h
.
8
0
I
N
L
E
T
A
N
D
O
U
T
L
E
T
P
I
P
E
Ø10” CS Sch. 80
INLET PIPE
Ø10” P-1 Sch. 80
INLET PIPE
HOT GASES
INTERMEDIATE
TUBE SUPPORTS
BOILER SECTION DETAILS – SIDE VIEW
E
C
O
N
O
M
I
Z
E
R
E
V
A
P
O
R
A
T
O
R
SUPERHEATER
STEAM DRUM
E
C
O
N
O
M
I
Z
E
R
E
V
A
P
O
R
A
T
O
R
SUPERHEATER
STEAM DRUM
INTERMEDIATE TUBE SHEET SUPPORT
TUBE SHEET STRUCTURE
BRACKET
SUPPORT
HOLE FOR
TUBE
SIDE VIEW FRONT VIEW
TUBE SHEET STRUCTURE
BRACKET
SUPPORT
HOLE FOR
TUBE
SIDE VIEW FRONT VIEW
TYPICAL BOILER COIL TUBE AND ENDS
24’-5” TUBE LENGTH
FINNED LENGTH
180
o
U-BEND AT TUBE END 90
o
BENDS AT TUBE END TUBE TO HEADER JOINT
24’-5” TUBE LENGTH
FINNED LENGTH
180
o
U-BEND AT TUBE END 90
o
BENDS AT TUBE END TUBE TO HEADER JOINT
DUCT TO INLET PIPES SEALING AND EXPANSION
PIPE TO DUCT SEALING PIPE TO DUCT
EXPANSION JOINT
½” STUD
CERAMIC
FIBER ROPE
(04 RINGS)
BOILER DUCT
BOILER
DUCT
PIPE
SS-321 EXP.
JOINT
WELDED HERE
PIPE TO DUCT SEALING PIPE TO DUCT
EXPANSION JOINT
½” STUD
CERAMIC
FIBER ROPE
(04 RINGS)
BOILER DUCT
BOILER
DUCT
PIPE
SS-321 EXP.
JOINT
WELDED HERE
ECONOMIZER COILS
ECONOMIZER IS A FINNED TUBE COILS
SITUATED IN THE UPPER PORTION OF THE DUCT
FOR RECOVERING WASTE HEAT FROM THE
FLUE GASES BEFORE THEY LEAVE THE BOILER
ECONOMIZER CONSISTS OF ø2” FINNED CARBON
STEEL TUBES CONNECTED AT THEIR ENDS TO A
ø6” INLET AND OUTLET HEADERS
THERE ARE 16 ROWS OF 24 TUBES MAKING A
TOTAL OF 384 TUBES.
TOTAL HEATING AREA IS 6061 M
2
ECONOMIZER RAISES BFW TEMP. FROM 110
o
C TO
130
o
C
ECONOMIZER IS A FINNED TUBE COILS
SITUATED IN THE UPPER PORTION OF THE DUCT
FOR RECOVERING WASTE HEAT FROM THE
FLUE GASES BEFORE THEY LEAVE THE BOILER
ECONOMIZER CONSISTS OF ø2” FINNED CARBON
STEEL TUBES CONNECTED AT THEIR ENDS TO A
ø6” INLET AND OUTLET HEADERS
THERE ARE 16 ROWS OF 24 TUBES MAKING A
TOTAL OF 384 TUBES.
TOTAL HEATING AREA IS 6061 M
2
ECONOMIZER RAISES BFW TEMP. FROM 110
o
C TO
130
o
C
EVAPORATOR COILS
EVAPORATOR CONSIST OF THREE SECTIONS
TOP, MIDDLE AND LOWER.
THERE ARE TWO INDEPENDENT INLETS AND
TWO OUTLETS FOR EACH SECTION i.e. (TOTAL
SIX INLETS AND SIX OUTLETS)
THERE ARE 16 ROWS OF 24 TUBES MAKING A
TOTAL OF 384 TUBES.
TOTAL HEATING AREA IS 6061 M
2
EVAPORATOR OUTLET ENTER STEAM DRUM
IN EVAPORATOR COILS MAX. HEAT TRANSFER
TAKES PLACE AND PARTIAL EVAPORATION OF
WATER TAKES PLACE
EVAPORATOR CONSIST OF THREE SECTIONS
TOP, MIDDLE AND LOWER.
THERE ARE TWO INDEPENDENT INLETS AND
TWO OUTLETS FOR EACH SECTION i.e. (TOTAL
SIX INLETS AND SIX OUTLETS)
THERE ARE 16 ROWS OF 24 TUBES MAKING A
TOTAL OF 384 TUBES.
TOTAL HEATING AREA IS 6061 M
2
EVAPORATOR OUTLET ENTER STEAM DRUM
IN EVAPORATOR COILS MAX. HEAT TRANSFER
TAKES PLACE AND PARTIAL EVAPORATION OF
WATER TAKES PLACE
EVAPORATOR CONSTRUCTION
LOWER AND BOTTOM SECTIONS COMPRISE OF 4
ROWS OF 24 TUBES EACH (TOTAL TUBES = 96
EA)
EVAPORATOR CONSISTS OF ø 2” FINNED
CARBON STEEL TUBES ARE CONNECTED AT
THEIR ENDS TO ø8”SCH. 80 CARBON STEEL PIPE
HEADERS
THE TUBES ARE SUPPORTED AT THREE
LOCATION WITH THE DUCT AS SHOWN IN THE
FIGURE WITH A TUBE SHEET OF ---” THK.
TOP SECTION COMPRISE OF 10 ROWS OF 24
TUBES EACH (TOTAL TUBES = 240 EA)
THE TUBES ARE JOINED TOGETHER AT THE
ENDS WITH EACH OTHER USING 180
o
BENDS
LOWER AND BOTTOM SECTIONS COMPRISE OF 4
ROWS OF 24 TUBES EACH (TOTAL TUBES = 96
EA)
EVAPORATOR CONSISTS OF ø 2” FINNED
CARBON STEEL TUBES ARE CONNECTED AT
THEIR ENDS TO ø8”SCH. 80 CARBON STEEL PIPE
HEADERS
THE TUBES ARE SUPPORTED AT THREE
LOCATION WITH THE DUCT AS SHOWN IN THE
FIGURE WITH A TUBE SHEET OF ---” THK.
TOP SECTION COMPRISE OF 10 ROWS OF 24
TUBES EACH (TOTAL TUBES = 240 EA)
THE TUBES ARE JOINED TOGETHER AT THE
ENDS WITH EACH OTHER USING 180
o
BENDS
SUPERHEATER COILS
SUPERHEATER CONSISTS OF 3 ROWS OF 24 TUBES
EACH (TOTAL TUBES = 72 EA). LOWEST ROW IS
MADE OF P-1 MATERIAL WHILE UPPER TWO ROWS
ARE OF CARBON STEEL
ø2” FINNED TUBES ARE CONNECTED AT INLET END
TO ø10” SCH. 80 CS PIPE HEADER WHILE THE OUTLET
HEADER IS OF ø10” SCH. 80 P-1 PIPE AS SHOWN IN
FIGURE
HOT COMBUSTION PRODUCTS FIRST OF ALL COME
IN CONTACT WITH THE SUPERHEATER COILS.
THE SATURATED STEAM AT 250
o
C FROM THE STEAM
DRUM ENTERS THE SUPERHEATER, WHERE IT GETS
MAXIMUM OF THE HEAT AND IS SUPER-HEATED TO
HS AT 400
o
C
SUPERHEATER CONSISTS OF 3 ROWS OF 24 TUBES
EACH (TOTAL TUBES = 72 EA). LOWEST ROW IS
MADE OF P-1 MATERIAL WHILE UPPER TWO ROWS
ARE OF CARBON STEEL
ø2” FINNED TUBES ARE CONNECTED AT INLET END
TO ø10” SCH. 80 CS PIPE HEADER WHILE THE OUTLET
HEADER IS OF ø10” SCH. 80 P-1 PIPE AS SHOWN IN
FIGURE
HOT COMBUSTION PRODUCTS FIRST OF ALL COME
IN CONTACT WITH THE SUPERHEATER COILS.
THE SATURATED STEAM AT 250
o
C FROM THE STEAM
DRUM ENTERS THE SUPERHEATER, WHERE IT GETS
MAXIMUM OF THE HEAT AND IS SUPER-HEATED TO
HS AT 400
o
C
STEAM DRUM
THE WATER FROM THE ECONOMIZER ENTERS THE
STEAM DRUM THRU A DIA. 6” PERFORATED PIPE,
WHICH SUPPLIES WATER ALONG THE LENGTH OF
THE BOILER.
CHEMICAL FEED LINE AND BLOW DOWN LINES
ALSO ENTER THE DRUM ON THE SAME SIDE
PREHEATED BFW LEAVES THE DRUM AT IT BOTTOM
THRU TWO OUTLETS AND ENTERS IN EVAPORATOR
IN RETURN WATER ENTERS STEAM DRUM FROM ITS
SIDES AS SHOWN THRU A SERIES OF CYCLONE
SEPARATORS WHICH SEPARATE WATER AND STEAM
THE SEPARATED STEAM LEAVES THE DRUM
TOWARDS SUPERHEATER FROM DRUM TOP AFTER
SCREENING THRU DEMISTER PADS
THE WATER FROM THE ECONOMIZER ENTERS THE
STEAM DRUM THRU A DIA. 6” PERFORATED PIPE,
WHICH SUPPLIES WATER ALONG THE LENGTH OF
THE BOILER.
CHEMICAL FEED LINE AND BLOW DOWN LINES
ALSO ENTER THE DRUM ON THE SAME SIDE
PREHEATED BFW LEAVES THE DRUM AT IT BOTTOM
THRU TWO OUTLETS AND ENTERS IN EVAPORATOR
IN RETURN WATER ENTERS STEAM DRUM FROM ITS
SIDES AS SHOWN THRU A SERIES OF CYCLONE
SEPARATORS WHICH SEPARATE WATER AND STEAM
THE SEPARATED STEAM LEAVES THE DRUM
TOWARDS SUPERHEATER FROM DRUM TOP AFTER
SCREENING THRU DEMISTER PADS
THIS BOILER HAS ONLY ONE STEAM DRUM OF
10 FEET CYLINDRICAL LENGTH AND 5 FEET
DIAMETER AND IS MADE OF ASTM A 516 GR. 70
(CARBON STEEL)
STEAM DRUM CONSTRUCTION
THERE ARE NINE CYCLONE SEPARATORS IN
TWO ROWS FOR SEPARATING WATER & STEAM
THERE ARE MANHOLES OF ø16” ON BOTH ENDS
TWO PSV’S AND A GLG FOR LEVEL MONITORING
ARE ALSO MOUNTED ON THE STEAM DRUM
BFW INLET LINE IS OF ø6”, BOTTOM OUTLETS OF
ø16” EACH WHILE SATURATED STEAM OUTLET
PIPE IS OF ø10”, ALL OF CARBON STEEL & SCH. 80
10 FEET CYLINDRICAL LENGTH AND 5 FEET
DIAMETER AND IS MADE OF ASTM A 516 GR. 70
(CARBON STEEL)
STEAM DRUM CONSTRUCTION
THERE ARE NINE CYCLONE SEPARATORS IN
TWO ROWS FOR SEPARATING WATER & STEAM
THERE ARE MANHOLES OF ø16” ON BOTH ENDS
TWO PSV’S AND A GLG FOR LEVEL MONITORING
ARE ALSO MOUNTED ON THE STEAM DRUM
BFW INLET LINE IS OF ø6”, BOTTOM OUTLETS OF
ø16” EACH WHILE SATURATED STEAM OUTLET
PIPE IS OF ø10”, ALL OF CARBON STEEL & SCH. 80
STEAM DRUM GENERAL ARRANGEMENT
STEAM DRUM
DOUBLE
SET GLG
SINGLE
SET GLG
PSV’S
FOOT
SUPPORT
VENTS
WATER
COLUMN
STEAM DRUM
DOUBLE
SET GLG
SINGLE
SET GLG
PSV’S
FOOT
SUPPORT
VENTS
WATER
COLUMN
STEAM DRUM CONSTRUCTION- TOP CUT VIEW
FEED PIPE Ø6” CARBON
STEEL 9’-10” LG WITH 29
HOLES OF Ø1/8” @4”C-C
AT 45o FROM TOP
BLOW DOWN PIPE Ø1” CS
WITH 16 HOLES Ø1/4” @1-
1/4” AT TOP
CHEMICAL
FEED LINE
Ø3/4” SS-304
WITH
WATER INLET FROM
EVAPORATOR (BOTH SIDES)
FEED PIPE Ø6” CARBON
STEEL 9’-10” LG WITH 29
HOLES OF Ø1/8” @4”C-C
AT 45o FROM TOP
BLOW DOWN PIPE Ø1” CS
WITH 16 HOLES Ø1/4” @1-
1/4” AT TOP
CHEMICAL
FEED LINE
Ø3/4” SS-304
WITH
WATER INLET FROM
EVAPORATOR (BOTH SIDES)
STEAM DRUM CONSTRUCTION X-SECTION
RISERS
BFW FEED PIPE
BLOW DOWN
LINE
VERTEX BREAKER
DOWN-COMERS (02EA)
DEMISTER
PADS
SATURATED
STEAM OUTLET
WATER
COLLECTION
CHAMBERS
CYCLONE
SEPARATORS
RISERS
BFW FEED PIPE
BLOW DOWN
LINE
VERTEX BREAKER
DOWN-COMERS (02EA)
DEMISTER
PADS
SATURATED
STEAM OUTLET
WATER
COLLECTION
CHAMBERS
CYCLONE
SEPARATORS
STEAM DISCHARGE FROM THE SUPERHEATER IS AT
A HIGHER TEMPERATURE THEN REQUIRED, SO
BOILER FEED WATER IS SPRAYED INTO IT TO
LOWER ITS TEMPERATURE TO BRING IT TO
REQUIRED TEMPERATURE.
DE-SUPERHEATER
DE-SUPERHEATER CONSIST OF A SPRAY NOZZLE
WHICH SPRAY BFW IN STEAM IN MIST FORM.
WATER QUANTITY SPRAYED DEPENDS ON THE
TEMPERATURE READING AT THE INLET TO
SUPERHEATER, WHICH IS GOVERNED BY A
CONTROL VALVE TIC-153
A HIGHER TEMPERATURE THEN REQUIRED, SO
BOILER FEED WATER IS SPRAYED INTO IT TO
LOWER ITS TEMPERATURE TO BRING IT TO
REQUIRED TEMPERATURE.
DE-SUPERHEATER
DE-SUPERHEATER CONSIST OF A SPRAY NOZZLE
WHICH SPRAY BFW IN STEAM IN MIST FORM.
WATER QUANTITY SPRAYED DEPENDS ON THE
TEMPERATURE READING AT THE INLET TO
SUPERHEATER, WHICH IS GOVERNED BY A
CONTROL VALVE TIC-153
DE-SUPERHEATER
REPLACEABLE
LINER
BFW INLET
SPRAY HEAD
SPRAY PLUG
INCONEL
SPRING
BODY
BFW
ADJUSTMENT
NUT
REPLACEABLE
LINER
BFW INLET
SPRAY HEAD
SPRAY PLUG
INCONEL
SPRING
BODY
BFW
ADJUSTMENT
NUT
GAS FLOW CIRCUIT OF B-601/B-602
GAS FLOW CIRCUIT OF B-601/B-602
GAS FLOW CIRCUIT OF B-601/B-602
WATER FLOW CIRCUIT OF B-601/B-602
WATER FLOW CIRCUIT OF B-601/B-602
B-605
AUXILIARY BOILER B-605
INTRODUCTION
B-605 IS IS INSTALLED AT UTILITIES UNIT AND
PRODUCES KS STEAM WHICH IS SUPPLIED TO
BATTERY LIMIT FOR VARIOUS PURPOSES
IT IS A COMBUSTION ENGINEERING VU-60
DESIGN, WATER TUBE, NATURAL WATER
DRAUGHT, FORCED AIR DRAUGHT, HIGH
PRESSURE BOILER THAT UTILIZES NATURAL
GAS, PURGE GAS AND SYNTHESIS GAS AS
FUEL
B-605 IS IS INSTALLED AT UTILITIES UNIT AND
PRODUCES KS STEAM WHICH IS SUPPLIED TO
BATTERY LIMIT FOR VARIOUS PURPOSES
IT IS A COMBUSTION ENGINEERING VU-60
DESIGN, WATER TUBE, NATURAL WATER
DRAUGHT, FORCED AIR DRAUGHT, HIGH
PRESSURE BOILER THAT UTILIZES NATURAL
GAS, PURGE GAS AND SYNTHESIS GAS AS
FUEL
MAIN FEATURES
CAPACITY 70 TONS/HOUR
FUEL FIRED NATURAL GAS,
PURGE GAS
& SYN. GAS
TEMPERATURE 510
o
C
PRESSURE 105 KG/CM
2
MAX. PRESSURE 122 KG/CM
2
MANUFACTURER ABB-COMBUSTION
ENGINEERING USA
MAX. CAPACITY 77 TONS/HOUR
CAPACITY 70 TONS/HOUR
FUEL FIRED NATURAL GAS,
PURGE GAS
& SYN. GAS
TEMPERATURE 510
o
C
PRESSURE 105 KG/CM
2
MAX. PRESSURE 122 KG/CM
2
MANUFACTURER ABB-COMBUSTION
ENGINEERING USA
MAX. CAPACITY 77 TONS/HOUR
MAIN PARTS OF THE BOILER
FOLLOWING ARE THE MAIN PARTS OF BOILER:
BOILER ENCLOSURE
WINDBOX ASSEMBLY
ECONOMIZER COILS
BOILER BANK
SUPERHEATER
STEAM DRUM
DE-SUPERHEATER
GAS FIRING EQUIPMENT
OBSERVATION PORT
LOWER DRUM
FD FAN, AIR DUCT AND VENT STACK
FOLLOWING ARE THE MAIN PARTS OF BOILER:
BOILER ENCLOSURE
WINDBOX ASSEMBLY
ECONOMIZER COILS
BOILER BANK
SUPERHEATER
STEAM DRUM
DE-SUPERHEATER
GAS FIRING EQUIPMENT
OBSERVATION PORT
LOWER DRUM
FD FAN, AIR DUCT AND VENT STACK
B-605 PARTS LIST
STEAM DRUM
LOWER DRUM
BOILER
BANK TUBES
FLOOR TUBES
FRONT WATER WALL
BOILER SIDE WALL
UPPER SIDE WALL
DISTRIBUTION HEADERS
BOILER REAR
WALL TUBES
SIDE WALL HEADERS
SATURATED
STEAM OUTLET
SUPERHEATER
ROOF RISER
TUBES
STEAM OUTLET
HEADER
ACCESS DOOR
AIR INLET
PLENUM
BURNERS AIR SUPPLY DUCT
BURNERS ASSEBMLY
WINDBOX ASSEMBLY
FURNACE FLOOR TILES
CROSS FLOW
BAFFLES
BOILER BUCKSTAY
MINERAL FIBER
BLANKET
FURNACE ROOF TUBES
RIBBED CASING
RISER TUBES
STEAM DRUM
LOWER DRUM
BOILER
BANK TUBES
FLOOR TUBES
FRONT WATER WALL
BOILER SIDE WALL
UPPER SIDE WALL
DISTRIBUTION HEADERS
BOILER REAR
WALL TUBES
SIDE WALL HEADERS
SATURATED
STEAM OUTLET
SUPERHEATER
ROOF RISER
TUBES
STEAM OUTLET
HEADER
ACCESS DOOR
AIR INLET
PLENUM
BURNERS AIR SUPPLY DUCT
BURNERS ASSEBMLY
WINDBOX ASSEMBLY
FURNACE FLOOR TILES
CROSS FLOW
BAFFLES
BOILER BUCKSTAY
MINERAL FIBER
BLANKET
FURNACE ROOF TUBES
RIBBED CASING
RISER TUBES
B-605 PARTS LIST
STEAM DRUM
LOWER DRUM
BOILER
BANK TUBES
FLOOR TUBES
FRONT WATER WALL
BOILER SIDE WALL
UPPER SIDE WALL
DISTRIBUTION HEADERS
BOILER REAR
WALL TUBES
SIDE WALL HEADERS
SAT. STEAM OUTLET
SUPERHEATER
ROOF RISER
TUBES
STEAM OUTLET HEADER
ACCESS DOOR
AIR INLET
PLENUM
BURNERS AIR
SUPPLY DUCT
BURNERS
ASSEBMLY
WINDBOX ASSEMBLY
FURNACE FLOOR TILES
CROSS FLOW
BAFFLES
BOILER BUCKSTAY
MINERAL FIBER BLANKET
FURNACE ROOF TUBES
RIBBED CASING
RISER TUBES
STEAM DRUM
LOWER DRUM
BOILER
BANK TUBES
FLOOR TUBES
FRONT WATER WALL
BOILER SIDE WALL
UPPER SIDE WALL
DISTRIBUTION HEADERS
BOILER REAR
WALL TUBES
SIDE WALL HEADERS
SAT. STEAM OUTLET
SUPERHEATER
ROOF RISER
TUBES
STEAM OUTLET HEADER
ACCESS DOOR
AIR INLET
PLENUM
BURNERS AIR
SUPPLY DUCT
BURNERS
ASSEBMLY
WINDBOX ASSEMBLY
FURNACE FLOOR TILES
CROSS FLOW
BAFFLES
BOILER BUCKSTAY
MINERAL FIBER BLANKET
FURNACE ROOF TUBES
RIBBED CASING
RISER TUBES
BOILER ENCLOSURE
BOILER ENCLOSURE IS THE THE STRUCTURE
WHOSE FLOOR, WALLS AND ROOF ENCLOSE
THE BOILER WATER TUBES AND DRUMS AND
FORM THE FURNACE.
IN B-605 THE BOILER ENCLOSURE IS MADE OF
THE TUBES WHICH IS A FEATURE CALLED
WATER WALL CONSTRUCTION
BOILER ENCLOSURE IS THE THE STRUCTURE
WHOSE FLOOR, WALLS AND ROOF ENCLOSE
THE BOILER WATER TUBES AND DRUMS AND
FORM THE FURNACE.
IN B-605 THE BOILER ENCLOSURE IS MADE OF
THE TUBES WHICH IS A FEATURE CALLED
WATER WALL CONSTRUCTION
WATER WALL CONSTRUCTION
A BOILER CONSTRUCTION DESIGN IN WHICH
WATER TUBES ARE MADE A PART OF FLOOR,
ROOF AND WALLS OF THE FURNACE.
ADVANTAGES
WATER IN W.W. TUBES TUBES ABSORBS
MAXIMUM OF THE RADIANT HEAT IN THE
FURNACE.
THE OTHER ADVANTAGE IS SAVING OF
REFRACTORY SYSTEM WHICH NEEDS
FREQUENT MAINTENANCE
A BOILER CONSTRUCTION DESIGN IN WHICH
WATER TUBES ARE MADE A PART OF FLOOR,
ROOF AND WALLS OF THE FURNACE.
ADVANTAGES
WATER IN W.W. TUBES TUBES ABSORBS
MAXIMUM OF THE RADIANT HEAT IN THE
FURNACE.
THE OTHER ADVANTAGE IS SAVING OF
REFRACTORY SYSTEM WHICH NEEDS
FREQUENT MAINTENANCE
WATER WALL X-SECTION
WATER WALL
TUBES
MINERAL
FIBER
INSULATION
TUBE FIN
OUTER
ALUMINUM
CASING
BOILER BUCKSTAY
WELD LINE
WATER WALL
TUBES
MINERAL
FIBER
INSULATION
TUBE FIN
OUTER
ALUMINUM
CASING
BOILER BUCKSTAY
WELD LINE
BOILER FURNACE
W
I
N
D
B
O
X
A
S
S
E
M
B
L
Y
MANHOLE
FLOOR TILES
F
R
O
N
T
W
A
T
E
R
W
A
L
L
T
U
B
E
S
SIDE WATER WALL TUBES
W
I
N
D
B
O
X
A
S
S
E
M
B
L
Y
MANHOLE
FLOOR TILES
F
R
O
N
T
W
A
T
E
R
W
A
L
L
T
U
B
E
S
SIDE WATER WALL TUBES
BOILER ENCLOSURE
BOILER ENCLOSURE – TOP VIEW
CONSTRUCTION PARAMETERS
W.W. TUBES IN THE FURNACE ARE MADE OF
Ø3” CS TUBES LOCATED AT 4” CC DISTANCE
AND THE SPACE BETWEEN IS FILLED BY A 1”
WIDE CS STRIP, WELDED TO BOTH TUBES.
THE FRONT AND REAR FURNACE WALLS
EMERGE FROM LOWER DRUM, WHILE SIDE
WALLS MAKE THEIR WAY FROM TWO Ø8-5/8”
HEADERS WHICH GET SUPPLY FROM 12 NO.
Ø4” DIA TUBES. A Ø5” SCH. 160 PIPE
CONNECTS TWO HEADERS
ALL TUBES AND HEADERS ARE MADE OF CS
W.W. TUBES IN THE FURNACE ARE MADE OF
Ø3” CS TUBES LOCATED AT 4” CC DISTANCE
AND THE SPACE BETWEEN IS FILLED BY A 1”
WIDE CS STRIP, WELDED TO BOTH TUBES.
THE FRONT AND REAR FURNACE WALLS
EMERGE FROM LOWER DRUM, WHILE SIDE
WALLS MAKE THEIR WAY FROM TWO Ø8-5/8”
HEADERS WHICH GET SUPPLY FROM 12 NO.
Ø4” DIA TUBES. A Ø5” SCH. 160 PIPE
CONNECTS TWO HEADERS
ALL TUBES AND HEADERS ARE MADE OF CS
OTHER ENCLOSURE
PARAMETERS
THE OUTER SURFACE OF THE BOILER IS
COVERED WITH A 3” THK. MINERAL FIBER
BLANKET REINFORCED BY WIRE MESH, THE
BLANKET IS INSTALLED WITH IMPALLING
PINS AND CLIPS.
THE INSULATION BLANKET IS PROTECTED BY
RIBBED ALUMINUM SHEET
BAFFLES ARE INSTALLED IN THE GAS FLOW PATH TO
RE-ROUTE HOT GASES FOR MAXIMUM HEAT
RECOVERY
PARAMETERS
THE OUTER SURFACE OF THE BOILER IS
COVERED WITH A 3” THK. MINERAL FIBER
BLANKET REINFORCED BY WIRE MESH, THE
BLANKET IS INSTALLED WITH IMPALLING
PINS AND CLIPS.
THE INSULATION BLANKET IS PROTECTED BY
RIBBED ALUMINUM SHEET
BAFFLES ARE INSTALLED IN THE GAS FLOW PATH TO
RE-ROUTE HOT GASES FOR MAXIMUM HEAT
RECOVERY
FURNACE DESCRIPTION
THE FURNACE FLOOR TUBES ARE COVERED WITH
LOOSELY PLACED FIRE BRICK TILES OF SIZE 1’X1’X2”
THK. MANHOLE OPENINGS ARE FILLED WITH LOOSE
LAY OF INSULATING FIRE BRICK.
THERE ARE 05 MANHOLE IN THE BOILER
ENCLOSURE, 04 OBSERVATION PORTS IN THE
FURNACE ENCLOSURE. TUBES ARE BENT AT THESE
LOCATIONS
THE FURNACE IS OF 12’X 14’X30 FEET HIGH IN
SIZE.THE FURNACE DESIGN IS MADE SUCH THAT
COMBUSTION PROCESS COMPLETE WITHIN THE
FURNACE SECTION.
THE FURNACE FLOOR TUBES ARE COVERED WITH
LOOSELY PLACED FIRE BRICK TILES OF SIZE 1’X1’X2”
THK. MANHOLE OPENINGS ARE FILLED WITH LOOSE
LAY OF INSULATING FIRE BRICK.
THERE ARE 05 MANHOLE IN THE BOILER
ENCLOSURE, 04 OBSERVATION PORTS IN THE
FURNACE ENCLOSURE. TUBES ARE BENT AT THESE
LOCATIONS
THE FURNACE IS OF 12’X 14’X30 FEET HIGH IN
SIZE.THE FURNACE DESIGN IS MADE SUCH THAT
COMBUSTION PROCESS COMPLETE WITHIN THE
FURNACE SECTION.
WINDBOX ASSEMBLY
FURNACE FLOOR TUBES ARE COVERED WITH
LOOSELY PLACED FIRE BRICK OF SIZE 1’x1’x2”.
MANHOLE OPENINGS ARE FILLED WITH LOOSE
LAY OF INSULATING FIRE BRICK.
EACH WINDBOX ASSEMBLY IS DIVIDED INTO
FIVE HORIZONTAL SECTION,TWO SECTIONS FOR
AIR INLET, TWO FOR NATURAL GAS (PLUS SYN.
GAS) AND ONE FOR PURGE GAS AS SHOWN IN
FIGURE.
THERE ARE FOUR WINDBOX ASSEMBLIES
LOCATED IN THE COMBUSTION CHAMBER FOR
FOR FUEL FIRING
FURNACE FLOOR TUBES ARE COVERED WITH
LOOSELY PLACED FIRE BRICK OF SIZE 1’x1’x2”.
MANHOLE OPENINGS ARE FILLED WITH LOOSE
LAY OF INSULATING FIRE BRICK.
EACH WINDBOX ASSEMBLY IS DIVIDED INTO
FIVE HORIZONTAL SECTION,TWO SECTIONS FOR
AIR INLET, TWO FOR NATURAL GAS (PLUS SYN.
GAS) AND ONE FOR PURGE GAS AS SHOWN IN
FIGURE.
THERE ARE FOUR WINDBOX ASSEMBLIES
LOCATED IN THE COMBUSTION CHAMBER FOR
FOR FUEL FIRING
PURGE GAS
NATURAL
GAS
AIR INLET
NATURAL
GAS
AIR INLET
FLAME SCANNER
IGNITOR
WINDBOX ASSEMBLY
NATURAL
GAS
AIR INLET
NATURAL
GAS
AIR INLET
FLAME SCANNER
IGNITOR
WINDBOX ASSEMBLY
GAS FIRING EQUIPMENT
MAIN GAS TORCHES
FUEL FIRING EQUIPMENT CONSIST OF :
PURGE GAS TORCH
IGNITORS
FLAME SCANNER
MAIN GAS TORCHES
FUEL FIRING EQUIPMENT CONSIST OF :
PURGE GAS TORCH
IGNITORS
FLAME SCANNER
IGNITORS
IGNITORS AR ELECTRICALLY IGNITED AND
CAN BE OPERATED REMOTELY, THEY IGNITE
THE MAIN GAS TORCHES
IT CONSISTS OF IGNITOR NOZZLE, SPARK
PLUG, FLAME ROD, AND EDDY PLATE.
AIR IS SUPPLIED THROUGH 2.38” OD INLET
CONNECTION. BOOSTER AIR IS SUPPLIED TO
IGNITOR THRU THIS FLEXIBLE PIPE WHICH IS
DRAWN FROM A BOOSTER BLOWER.
IGNITORS AR ELECTRICALLY IGNITED AND
CAN BE OPERATED REMOTELY, THEY IGNITE
THE MAIN GAS TORCHES
IT CONSISTS OF IGNITOR NOZZLE, SPARK
PLUG, FLAME ROD, AND EDDY PLATE.
AIR IS SUPPLIED THROUGH 2.38” OD INLET
CONNECTION. BOOSTER AIR IS SUPPLIED TO
IGNITOR THRU THIS FLEXIBLE PIPE WHICH IS
DRAWN FROM A BOOSTER BLOWER.
PURGE GAS
NATURAL
GAS
NOZZLES
NATURAL
GAS
SCANNER
WINDBOX
ASSEMBLY
DAMPER
POWER
POSITIONER
IGNITOR
GAS FIRING EQUIPMENT
AIR INLET
NATURAL
GAS
NOZZLES
NATURAL
GAS
SCANNER
WINDBOX
ASSEMBLY
DAMPER
POWER
POSITIONER
IGNITOR
GAS FIRING EQUIPMENT
AIR INLET
TANGENTIAL FIRING SYSTEM
ALL THE BURNERS ARE LOCATED IN
CORNERS OF THE COMBUSTION CHAMBER
SUCH THAT THE FUEL AND AIR STREAMS
STRIKE AT TANGENT TO AN IMAGINARY
CIRCLE. THUS A SWIRLING FLAME,
ROTATING CLOCKWISE IS PRODUCED.
THIS SPECIAL COMBUSTION TECHNIQUE
FULLY CONSUMES THE FUEL WITH LESSER
NOx GASES AT THE BOILER DISCHARGE
ALL THE BURNERS ARE LOCATED IN
CORNERS OF THE COMBUSTION CHAMBER
SUCH THAT THE FUEL AND AIR STREAMS
STRIKE AT TANGENT TO AN IMAGINARY
CIRCLE. THUS A SWIRLING FLAME,
ROTATING CLOCKWISE IS PRODUCED.
THIS SPECIAL COMBUSTION TECHNIQUE
FULLY CONSUMES THE FUEL WITH LESSER
NOx GASES AT THE BOILER DISCHARGE
TANGENTIAL FIRING
BURNER
ASSEMBLY
BURNER
ASSEMBLY
IMAGINARY
CIRCLE
BURNER
ASSEMBLY
BURNER
ASSEMBLY
IMAGINARY
CIRCLE
TANGENTIAL FIRING
OBSERVATION PORT
IF PORT NEEDS TO OPENED DURING OPERATION,
UTILITY AIR IS USED AGAINST FURNACE
PRESSURE
OBSERVATION PORTS ARE PROVIDED TO PERMIT
THE OBSERVATION OF THE PRESSURIZED
FURNACE IN OPERATION.
SEAL AIR TAKEN FROM THE FD FAN DUCT AT
SLIGHTLY HIGH PRESSURE IS USED TO SEAL AIR
CHAMBER IN THE OBSERVATION PORT.
A CONTINUOUS STREAM OF AIR IS ALSO
SUPPLIED TO KEEP THE OBSERVATION GLASS
COOL AND CLEAN.
IF PORT NEEDS TO OPENED DURING OPERATION,
UTILITY AIR IS USED AGAINST FURNACE
PRESSURE
OBSERVATION PORTS ARE PROVIDED TO PERMIT
THE OBSERVATION OF THE PRESSURIZED
FURNACE IN OPERATION.
SEAL AIR TAKEN FROM THE FD FAN DUCT AT
SLIGHTLY HIGH PRESSURE IS USED TO SEAL AIR
CHAMBER IN THE OBSERVATION PORT.
A CONTINUOUS STREAM OF AIR IS ALSO
SUPPLIED TO KEEP THE OBSERVATION GLASS
COOL AND CLEAN.
OBSERVATION PORT
SEAL AIR
CHAMBER
PORT GLASSASPIRATING
AIR CHAMBER
GASKET
BODY
SEAL AIR
CHAMBER
PORT GLASSASPIRATING
AIR CHAMBER
GASKET
BODY
BOILER BANK TUBES
BOILER BANK CONSISTS OF 490 CARBON STEEL
TUBES OF 2-1/4” DIAMETER, MADE OF SA-192
CARBON STEEL.
ALL TUBES ARE ROLLED INTO STEAM DRUM
AND LOWER DRUM.
BOILER BANK ALSO PERFORMS THE FUNCTION
OF SUPPORTING THE STEAM DRUM UP ABOVE.
IN BOILER BANK MAXIMUM HEAT RECOVERY IS
CARRIED OUT. BAFFLES ARE INSTALLED TO
DIVERT THE GAS FLOW AND MAKE IT MULTI-
PASS.
BOILER BANK CONSISTS OF 490 CARBON STEEL
TUBES OF 2-1/4” DIAMETER, MADE OF SA-192
CARBON STEEL.
ALL TUBES ARE ROLLED INTO STEAM DRUM
AND LOWER DRUM.
BOILER BANK ALSO PERFORMS THE FUNCTION
OF SUPPORTING THE STEAM DRUM UP ABOVE.
IN BOILER BANK MAXIMUM HEAT RECOVERY IS
CARRIED OUT. BAFFLES ARE INSTALLED TO
DIVERT THE GAS FLOW AND MAKE IT MULTI-
PASS.
BOILER BANK
UPPER DRUM
BOILER
BANK
LOWER
DRUM
UPPER DRUM
BOILER
BANK
LOWER
DRUM
STEAM DRUM
THE BOILER IS EQUIPPED WITH A LARGE STEAM DRUM
OF 54” DIA. WHICH IS DESIGNED TO SUPPLY HIGH
QUALITY STEAM TO SUPERHEATER. .
FOLLOWING ARE MAIN FEATURES OF THE STEAM
DRUM :
MADE OF CARBON STEEL ASTM A 516 GR.70
TUBE SECTION IS THICKNESS FOR ROLLING
FEED NOZZLE DIA. IS 4” SCH.80
(DISTRIBUTION OF WATER THRU 24 HOLES
OF Ø1” LOCATED ALONG THE
LONGITUDINAL LENGTH OF HEADER)
TWO DEMISTERS PADS AND BAFFLES ARE
INSTALLED FOR SCREENING STEAM
THE BOILER IS EQUIPPED WITH A LARGE STEAM DRUM
OF 54” DIA. WHICH IS DESIGNED TO SUPPLY HIGH
QUALITY STEAM TO SUPERHEATER. .
FOLLOWING ARE MAIN FEATURES OF THE STEAM
DRUM :
MADE OF CARBON STEEL ASTM A 516 GR.70
TUBE SECTION IS THICKNESS FOR ROLLING
FEED NOZZLE DIA. IS 4” SCH.80
(DISTRIBUTION OF WATER THRU 24 HOLES
OF Ø1” LOCATED ALONG THE
LONGITUDINAL LENGTH OF HEADER)
TWO DEMISTERS PADS AND BAFFLES ARE
INSTALLED FOR SCREENING STEAM
5”
STEAM DRUM
SATURATED
STEAM OUTLET
SECONDARY
SCREEN
RISER TUBES Ø5”
Ø4” FEED PIPE
WATER LEVEL
PRIMARY
SCREEN
BAFFLE PANELS
FRONT WALL TUBES
DRAIN PIPE
Ø16” MANHOLE
BOILER BANK TUBES
REAR WALL TUBES
REAR WALL TUBES
STEAM DRUM
SATURATED
STEAM OUTLET
SECONDARY
SCREEN
RISER TUBES Ø5”
Ø4” FEED PIPE
WATER LEVEL
PRIMARY
SCREEN
BAFFLE PANELS
FRONT WALL TUBES
DRAIN PIPE
Ø16” MANHOLE
BOILER BANK TUBES
REAR WALL TUBES
REAR WALL TUBES
TUBE AREA IS THICKER
THAN OTHER PORTION
STEAM DRUM CUT-AWAY VIEW
THAN OTHER PORTION
STEAM DRUM CUT-AWAY VIEW
TUBE ROLLING IN STEAM DRUM
SUPERHEATER
THE SUPERHEATER IN B-605 CONSIST OF TWO STAGES
OR SECTIONS,THEY ARE: AND
THE SUPERHEATER TUBES ARE SEPARATED FROM
EACH OTHER THROUGH FLEXIBLE SPACERS, TIES AND
SUPPORT PLATES.
THE HIGH TEMPERATURE SPACED PENDANT
SUPERHEATER
THE LOW TEMPERATURE PLATEN
SUPERHEATER
WHICH DAMP VIBRATION, SUPPORT SUSPENDED TUBES
AND MAINTAIN A CERTAIN DISTANCE BETWEEN THE
TUBES. THEY ARE MADE OF T-22 MATERIAL.
THE SUPERHEATER IN B-605 CONSIST OF TWO STAGES
OR SECTIONS,THEY ARE: AND
THE SUPERHEATER TUBES ARE SEPARATED FROM
EACH OTHER THROUGH FLEXIBLE SPACERS, TIES AND
SUPPORT PLATES.
THE HIGH TEMPERATURE SPACED PENDANT
SUPERHEATER
THE LOW TEMPERATURE PLATEN
SUPERHEATER
WHICH DAMP VIBRATION, SUPPORT SUSPENDED TUBES
AND MAINTAIN A CERTAIN DISTANCE BETWEEN THE
TUBES. THEY ARE MADE OF T-22 MATERIAL.
SUPERHEATER
PRIMARY
SUPERHEATER
SECONDARY
SUPERHEATER
STEAM DRUM
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SUPERHEATER
INLET HEADER
PRIMARY
SUPERHEATER
OUTLET HEADER
PRIMARY
SUPERHEATER
OUTLET HEADER
FINAL STEAM
OUTLET PIPE
STEAM OUTLET
HEADER
SATURATED
STEAM
OUTLET PIPES
SECONDARY
SUPERHEATER
INLET
SECONDARY
SUPERHEATER
INLET
DE-SUPERHEATER
DE-SUPERHEATER
PRIMARY
SUPERHEATER
SECONDARY
SUPERHEATER
STEAM DRUM
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SUPERHEATER
INLET HEADER
PRIMARY
SUPERHEATER
OUTLET HEADER
PRIMARY
SUPERHEATER
OUTLET HEADER
FINAL STEAM
OUTLET PIPE
STEAM OUTLET
HEADER
SATURATED
STEAM
OUTLET PIPES
SECONDARY
SUPERHEATER
INLET
SECONDARY
SUPERHEATER
INLET
DE-SUPERHEATER
DE-SUPERHEATER
SUPERHEATER
PLATEN SUPERHEATER ASSEMBLY (08 TOTAL) SPACED ASSEMBLY (31 TOTAL)
PLATEN SUPERHEATER ASSEMBLY (08 TOTAL) SPACED ASSEMBLY (31 TOTAL)
SUPERHEATER
SUPERHEATER
0.180MWT SA-213 T-11
SUPPORT PLATES
STEAM DRUM
SOLID TIES
Ø8-5/8” PLATEN
INLET HEADER
0.180MWT SA-213 T-1
0.180MWT SA-213 T-1
8 – Ø2” PLATEN
ASSEMBLIES
FLEXIBLE CONNECTORS
0.180MWT SA-213 T-11
0.180MWT SA-213 T-1
0.180MWT SA-213 T-1
31 – Ø1-3/4” PLATEN
ASSEMBLIES
SPACERS
Ø10-3/4” PLATEN
OUTLET HEADER
Ø10-3/4” DE-
SUPERHEATER
Ø10-3/4” SPACED INLET HEADER
Ø10-3/4” SPACED
OUTLET
Ø10-3/4” SPACED
OUTLET
0.180MWT SA-213 T-11
SUPPORT PLATES
STEAM DRUM
SOLID TIES
Ø8-5/8” PLATEN
INLET HEADER
0.180MWT SA-213 T-1
0.180MWT SA-213 T-1
8 – Ø2” PLATEN
ASSEMBLIES
FLEXIBLE CONNECTORS
0.180MWT SA-213 T-11
0.180MWT SA-213 T-1
0.180MWT SA-213 T-1
31 – Ø1-3/4” PLATEN
ASSEMBLIES
SPACERS
Ø10-3/4” PLATEN
OUTLET HEADER
Ø10-3/4” DE-
SUPERHEATER
Ø10-3/4” SPACED INLET HEADER
Ø10-3/4” SPACED
OUTLET
Ø10-3/4” SPACED
OUTLET
PRIMARY SUPERHEATER IS LOCATED IN RADIANT
SECTION OF THE BOILER AND RAISES STEAM
TEMPERATURE BY 70
o
C BEFORE DISCHARGING INTO AN
INTER-CONNECTING HEADER (10-3/4ӯ) WHICH
CONSTITUTES DE-SUPERHEATER
SATURATED STEAM FROM STEAM DRUM FLOW THRU
09 Ø 4” PIPES TO PRIMARY SUPERHEATER INLET
HEADER OF Ø 8-5/8”.
PRIMARY SUPERHEATER CONSIST OF 8 ASSEMBLIES
OF Ø 2” . TUBES, MADE OF T-1 AND T-11 MATERIAL
(SEE FIGURE)
PRIMARY SUPERHEATER
PIPES AND HEADERS ARE MADE UP OF CARBON
STEEL.
SECTION OF THE BOILER AND RAISES STEAM
TEMPERATURE BY 70
o
C BEFORE DISCHARGING INTO AN
INTER-CONNECTING HEADER (10-3/4ӯ) WHICH
CONSTITUTES DE-SUPERHEATER
SATURATED STEAM FROM STEAM DRUM FLOW THRU
09 Ø 4” PIPES TO PRIMARY SUPERHEATER INLET
HEADER OF Ø 8-5/8”.
PRIMARY SUPERHEATER CONSIST OF 8 ASSEMBLIES
OF Ø 2” . TUBES, MADE OF T-1 AND T-11 MATERIAL
(SEE FIGURE)
PRIMARY SUPERHEATER
PIPES AND HEADERS ARE MADE UP OF CARBON
STEEL.
SECONDARY SUPERHEATER IS LOCATED IN
CONVECTION SECTION OF THE BOILER AND PRODUCES
OUR FINAL PRODUCT AT TEMPERATURE OF 510
O
C
STEAM FROM DE-SUPERHEATER ENTERS INTO
SECONDARY SUPERHEATER INLET HEADER OF Ø10-3/4”,
BEFORE ENTERING IN SUPERHEATER COILS.
THESE TUBES DISCHARGE INTO A Ø10-3/4”
SUPERHEATER OUTLET HEADER.
SECONDARY SUPERHEATER
IT CONSISTS OF 31 ASSEMBLIES OF Ø1-3/4” TUBES,
MADE OF T-11 AND T-22 AND SS-304 MATERIAL (SEE
FIGURE)
CONVECTION SECTION OF THE BOILER AND PRODUCES
OUR FINAL PRODUCT AT TEMPERATURE OF 510
O
C
STEAM FROM DE-SUPERHEATER ENTERS INTO
SECONDARY SUPERHEATER INLET HEADER OF Ø10-3/4”,
BEFORE ENTERING IN SUPERHEATER COILS.
THESE TUBES DISCHARGE INTO A Ø10-3/4”
SUPERHEATER OUTLET HEADER.
SECONDARY SUPERHEATER
IT CONSISTS OF 31 ASSEMBLIES OF Ø1-3/4” TUBES,
MADE OF T-11 AND T-22 AND SS-304 MATERIAL (SEE
FIGURE)
DE-SUPERHEATER
DE-SUPERHEATER IS INSTALLED IN THE INTERLINK
BETWEEN HIGH TEMPERATURE PLATEN AND LOW
TEMPERATURE PENDANT SPACED SUPERHEATER
THE SPRAY TUBE HAS 20 HOLES (ø4.8 MM) IN FIVE
VERTICAL ROWS,
FOLLOWING ARE ITS MAIN FEATURES:
A ø10-3/4” HEADER OF SA-106 GR- B
A DIA. 4.5” OUTER DIA. CARBON STEEL (A-106-B)
WATER SPRAY NOZZLE IS FITTED AT THE INLET OF
THE DE-SUPERHEATER
HEADER CONTAINS A REPLACEABLE LINER,
CENTERED IN THE HEADER
THE SPRAY NOZZLE CONSISTS OF A REPLACEABLE
SPRAY TUBE
DE-SUPERHEATER IS INSTALLED IN THE INTERLINK
BETWEEN HIGH TEMPERATURE PLATEN AND LOW
TEMPERATURE PENDANT SPACED SUPERHEATER
THE SPRAY TUBE HAS 20 HOLES (ø4.8 MM) IN FIVE
VERTICAL ROWS,
FOLLOWING ARE ITS MAIN FEATURES:
A ø10-3/4” HEADER OF SA-106 GR- B
A DIA. 4.5” OUTER DIA. CARBON STEEL (A-106-B)
WATER SPRAY NOZZLE IS FITTED AT THE INLET OF
THE DE-SUPERHEATER
HEADER CONTAINS A REPLACEABLE LINER,
CENTERED IN THE HEADER
THE SPRAY NOZZLE CONSISTS OF A REPLACEABLE
SPRAY TUBE
DE-SUPERHEATER
DE-SUPERHEATER
LINK PIPE 10-3/4”
BFW ENTERS
HERE
REPLACEABLE
LINER Ø2” SS-304 REPLACEABLE
LINER
END SEALING &
SUPPORT NUT
SUPPORTING
SCREWS
SUPPORTING
PADS
PIPE ENDS
WELD HERE
SPRAY
NOZZLE
ADJUSTMENT
SCREW
DE-SUPERHEATER
LINK PIPE 10-3/4”
BFW ENTERS
HERE
REPLACEABLE
LINER Ø2” SS-304 REPLACEABLE
LINER
END SEALING &
SUPPORT NUT
SUPPORTING
SCREWS
SUPPORTING
PADS
PIPE ENDS
WELD HERE
SPRAY
NOZZLE
ADJUSTMENT
SCREW
ECONOMIZER
Ø4” OUTLET PIPE
Ø6” INLET HEADER
Ø4” OUTLET PIPE
Ø6” OUTLET
HEADER
Ø2” FINNED
TUBES U-BENDS
Ø4” OUTLET PIPE
Ø6” INLET HEADER
Ø4” OUTLET PIPE
Ø6” OUTLET
HEADER
Ø2” FINNED
TUBES U-BENDS
ECONOMIZER
AIR PLENUM DUCT–“T-TYPE”
MOTOR
STEAM
TURBINE
AIR
BLOWER
GUIDE
VANES
EXPANSION
JOINT
AIR
FILTER
WINDBOX
ASSEMBLY
AIR
BLOWER
ACCESS
DOOR
MOTOR
STEAM
TURBINE
AIR
BLOWER
GUIDE
VANES
EXPANSION
JOINT
AIR
FILTER
WINDBOX
ASSEMBLY
AIR
BLOWER
ACCESS
DOOR
Created with Visio
Created with Visio
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Created with Visio
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Created with Visio
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Created with Visio
Maintenace history
B-605
TUBE TO TUBE-SHEET ROLLED JOINT
LEAKAGE
THE PROBLEM OF TUBE ROLLING JOINT
LEAKAGE IS PRESENT SINCE COMMISSIONING
OF THE BOILER IN 1982. THE PROBLEM
SOLVED BY SEAL WELDING OF THE ROLLED
JOINT.
FAILURE OF SPIRAL FIN ECONOMIZER
THE FAILURE OF THE ECONOMIZER WAS DUE
TO OVERHEATING ESPECIALLY FINS. THE
ECONOMIZER WAS REPLACED
MAINTENANCE HISTORY
TUBE TO TUBE-SHEET ROLLED JOINT
LEAKAGE
THE PROBLEM OF TUBE ROLLING JOINT
LEAKAGE IS PRESENT SINCE COMMISSIONING
OF THE BOILER IN 1982. THE PROBLEM
SOLVED BY SEAL WELDING OF THE ROLLED
JOINT.
FAILURE OF SPIRAL FIN ECONOMIZER
THE FAILURE OF THE ECONOMIZER WAS DUE
TO OVERHEATING ESPECIALLY FINS. THE
ECONOMIZER WAS REPLACED
MAINTENANCE HISTORY
TUBE ROLLING FAILURE
LEAKING
TUBE
SCALING
AROUND
TUBE
LEAKING
TUBE
SCALING
AROUND
TUBE
B-601 / B-602
BOILER DAMPER SHAFT AND LOCKING
ARRANGEMENT FAILURE
BURNING OF SUPERHEATER COIL FINS
MAINTENANCE HISTORY
SHROUD PLATE ANCHORS FAILURE
HOT SPOTS ON DUCT
BULGING OF TUBES IN B-601
LOWERING OF U-BENDS THICKNESS
BOILER DAMPER SHAFT AND LOCKING
ARRANGEMENT FAILURE
BURNING OF SUPERHEATER COIL FINS
MAINTENANCE HISTORY
SHROUD PLATE ANCHORS FAILURE
HOT SPOTS ON DUCT
BULGING OF TUBES IN B-601
LOWERING OF U-BENDS THICKNESS
BROKEN COTTER PINS
DAMPER BLADE
FAILURE OF BLADE LOCKING PINS
WELD FAILURE DUE TO HEAVY TORQUE
DAMPER BLADE
FAILURE OF BLADE LOCKING PINS
WELD FAILURE DUE TO HEAVY TORQUE
SHAFT FAILED DUE TO HEAVY TORQUE
STUB SHAFT
HOLLOW
SHAFT STARTS
HERE
DAMPER BLADE
PINS SHEARED
BLADE
STUB SHAFT
HOLLOW
SHAFT STARTS
HERE
DAMPER BLADE
PINS SHEARED
BLADE
SHROUD PLATE CRACKING & ANCHORS FAILURE
SHROUD PLATE
ANCHOR
PLATE
ANCHOR
BOLT
CRACKED
SHROUD
PLATE
NO
INSULATION
HERE
SHROUD PLATE
ANCHOR
PLATE
ANCHOR
BOLT
CRACKED
SHROUD
PLATE
NO
INSULATION
HERE
THICKNESS REDUCTION OF U-BENDS
U-BEND SUPPORT
PADS
TUBE SHEET
TUBE FINS
U-BEND SUPPORT
PADS
TUBE SHEET
TUBE FINS
THE STUB SHAFT AND LOCKING COTTER PINS OF THE
LOWEST DAMPER BLADE HAVE BEEN CAUSING
PROBLEM SINCE LONG DUE TO HIGH TORQUE AND
VIBRATION WHICH THE SHAFT SUSTAINS.
ACTIONS TAKEN
THE SHAFTS AND THE COTTER ARE REPLACE IF
DAMAGED WITH INCOLOY MATERIAL
THE BROKEN ANCHORS ARE RE-WELDED TO THEIR
ORIGINAL POSITION
INSULATION IS INSERTED WHERE MISSING AND
WHERE HOT SPOTS ARE OBSERVED
CRACKED AND BULGED PLATE IS RECTIFIED
BURNED FINS HAVE BEEN PROTECTED BY A PLATE
U-BEND MAY BE REPLACED OR PROTECTED BY PADS
LOWEST DAMPER BLADE HAVE BEEN CAUSING
PROBLEM SINCE LONG DUE TO HIGH TORQUE AND
VIBRATION WHICH THE SHAFT SUSTAINS.
ACTIONS TAKEN
THE SHAFTS AND THE COTTER ARE REPLACE IF
DAMAGED WITH INCOLOY MATERIAL
THE BROKEN ANCHORS ARE RE-WELDED TO THEIR
ORIGINAL POSITION
INSULATION IS INSERTED WHERE MISSING AND
WHERE HOT SPOTS ARE OBSERVED
CRACKED AND BULGED PLATE IS RECTIFIED
BURNED FINS HAVE BEEN PROTECTED BY A PLATE
U-BEND MAY BE REPLACED OR PROTECTED BY PADS
B-4601
ONLY ONE MAJOR PROBLEM HAS BEEN
OBSERVED WHICH IS FAILURE OF TUBE
SUPPORTS OF PRIMARY SUPERHEATER
DUE TO HIGH TEMPERATURE
THE PROBLEM WAS RESOLVED IN 1998
WITH REPLACEMENT OF P-22 SUPPORTS
WITH SS-310 SUPPORTS
MAINTENANCE HISTORY
ONLY ONE MAJOR PROBLEM HAS BEEN
OBSERVED WHICH IS FAILURE OF TUBE
SUPPORTS OF PRIMARY SUPERHEATER
DUE TO HIGH TEMPERATURE
THE PROBLEM WAS RESOLVED IN 1998
WITH REPLACEMENT OF P-22 SUPPORTS
WITH SS-310 SUPPORTS
MAINTENANCE HISTORY
NEW TUBE SUPPORTS INSTALLED
SUPERHEATER TUBES
NEW SUPPORT
SUPERHEATER TUBES
NEW SUPPORT
NEW TUBE SUPPORTS INSTALLED
WATER WALL TUBES
SUPERHEATER TUBES
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SUPERHEATER TUBES
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B-4601
AUXILIARY BOILER
B-4601
B-4601
B-4601 IS AUXILIARY BOILER INSTALLED AT
EXPANSION UNIT TO MEET THE STEAM DEMANDS
OF THE PLANT. MAIN FEATURES ARE:
INTRODUCTION
CAPACITY 120 TONS PER HOUR
TYPE NATURAL CIRCULATION
WATER TUBE,
FORCED DRAUGHT
MANUFACTURER MACHHI, ITALY
STEAM PRESSURE 115 KG/CM
2
STEAM TEMPERATURE 510
o
C
FUEL NATURAL GAS +
OFF GAS + PURGE GAS
EXPANSION UNIT TO MEET THE STEAM DEMANDS
OF THE PLANT. MAIN FEATURES ARE:
INTRODUCTION
CAPACITY 120 TONS PER HOUR
TYPE NATURAL CIRCULATION
WATER TUBE,
FORCED DRAUGHT
MANUFACTURER MACHHI, ITALY
STEAM PRESSURE 115 KG/CM
2
STEAM TEMPERATURE 510
o
C
FUEL NATURAL GAS +
OFF GAS + PURGE GAS
MAIN PARTS
FOLLOWING ARE THE MAIN PARTS OF BOILER:
BOILER ENCLOSURE
COMBUSTION CHAMBER
STEAM DRUM
ECONOMIZER
EVAPORATOR
SUPERHEATER TUBES
DE-SUPERHEATERS
CIRCULATION PUMPS
FOLLOWING ARE THE MAIN PARTS OF BOILER:
BOILER ENCLOSURE
COMBUSTION CHAMBER
STEAM DRUM
ECONOMIZER
EVAPORATOR
SUPERHEATER TUBES
DE-SUPERHEATERS
CIRCULATION PUMPS
STEAM DRUM
PRIMARY SUPERHEATER INLET
SEC. SUPERHEATER OUTLET
WATER WALL FURNACE
ECONOMIZER OUTLET
BOILER EXHAUST
LOWER DISTRIBUTION
HEADERS
WATER COLLECTION
HEADER
SATURATED DSTEAM OUTLETBOILER
STRUCTURE
UPPER DISTRIBUTION HEADER
DE-SUPERHEATER
PRIMARY SUPERHEATER OUTLET
BURNERS (04 EA)
GAS DEFLECTOR
SEC. SUPERHEATER INLET
DOWNCOMERS
RISERS
PRIMARY SUPERHEATER INLET
SEC. SUPERHEATER OUTLET
WATER WALL FURNACE
ECONOMIZER OUTLET
BOILER EXHAUST
LOWER DISTRIBUTION
HEADERS
WATER COLLECTION
HEADER
SATURATED DSTEAM OUTLETBOILER
STRUCTURE
UPPER DISTRIBUTION HEADER
DE-SUPERHEATER
PRIMARY SUPERHEATER OUTLET
BURNERS (04 EA)
GAS DEFLECTOR
SEC. SUPERHEATER INLET
DOWNCOMERS
RISERS
BOILER ENCLOSURE
THE BOILER ENCLOSURE IS MADE OF WATER
WALL TUBES, MAKING A GAS TIGHT
ENCLOSURE.
THE BOILER IS HANGED TYPED I.E. IT IS
STRUCTURALLY SUPPORTED FROM THE TOP
AND EXPANSION OCCURS DOWNWARD WHEN
THE BOILER IS PUT IN SERVICE AS COMPARED
TO B-605
THE BOILER ENCLOSURE IS MADE OF WATER
WALL TUBES, MAKING A GAS TIGHT
ENCLOSURE.
THE BOILER IS HANGED TYPED I.E. IT IS
STRUCTURALLY SUPPORTED FROM THE TOP
AND EXPANSION OCCURS DOWNWARD WHEN
THE BOILER IS PUT IN SERVICE AS COMPARED
TO B-605
COMBUSTION CHAMBER
FOUR BURNERS ARE INSTALLED ON THE
FRONT WALL FOR FUEL COMBUSTION
THE FLOOR OF THE COMBUSTION CHAMBER
IS TAPERED WHICH REDUCES ASH DEPOSIT
ON THE FLOOR TUBES
BAFFLES ARE INSTALLED AT THE OUTLET
OF THE FURNACE TO DEFLECT GASES TO
ENSURE UNIFORM MIXING OF GASES.
FOUR BURNERS ARE INSTALLED ON THE
FRONT WALL FOR FUEL COMBUSTION
THE FLOOR OF THE COMBUSTION CHAMBER
IS TAPERED WHICH REDUCES ASH DEPOSIT
ON THE FLOOR TUBES
BAFFLES ARE INSTALLED AT THE OUTLET
OF THE FURNACE TO DEFLECT GASES TO
ENSURE UNIFORM MIXING OF GASES.
STEAM DRUM
A LARGE STEAM DRUM OF DIA. 1.37m, 5m
LG, 105mm THK. AT TOP & 85mm AT
BOTTOM, MADE OF CARBON STEEL HAS
BEEN PROVIDED
BOILER DOWNCOMERS ARE WELDED TO
NIPPLES OF STEAM DRUM.
THERE ARE 22 CYCLONE SEPARATORS IN
TWO ROWS FOR SEPARATING STEAM &
WATER. FINAL SEPARATION IS CARRIED
OUT IN DEMISTER PADS
A LARGE STEAM DRUM OF DIA. 1.37m, 5m
LG, 105mm THK. AT TOP & 85mm AT
BOTTOM, MADE OF CARBON STEEL HAS
BEEN PROVIDED
BOILER DOWNCOMERS ARE WELDED TO
NIPPLES OF STEAM DRUM.
THERE ARE 22 CYCLONE SEPARATORS IN
TWO ROWS FOR SEPARATING STEAM &
WATER. FINAL SEPARATION IS CARRIED
OUT IN DEMISTER PADS
ECONOMIZER
ECONOMIZER IS A FINNED TUBE
EXCHANGER
THE TUBE ENDS ARE JOINED TOGETHER
WITH 180
o
U-BENDS
TUBE DIAMETER IS 1-½” AND MATERIAL IS
CARBON STEEL.
THERE ARE 14 TUBES PER ROW AND THERE
ARE 14 ROWS SO A TOTAL OF 196 TUBES.
ECONOMIZER IS A FINNED TUBE
EXCHANGER
THE TUBE ENDS ARE JOINED TOGETHER
WITH 180
o
U-BENDS
TUBE DIAMETER IS 1-½” AND MATERIAL IS
CARBON STEEL.
THERE ARE 14 TUBES PER ROW AND THERE
ARE 14 ROWS SO A TOTAL OF 196 TUBES.
THE IS NO SEPARATE SECTION AS
EVAPORATOR OR BOILER BANK TUBES IN
THIS BOILER. THE WATER WALLS PERFORM
THIS FUNCTION.
THE WATER FROM THE STEAM DRUM
FLOWS THROUGH THESE WALLS AND
AFTER GETTING HEATED RETURNS TO
STEAM DRUM THRU THERMO-SIPHON
EVAPORATOR
EVAPORATOR OR BOILER BANK TUBES IN
THIS BOILER. THE WATER WALLS PERFORM
THIS FUNCTION.
THE WATER FROM THE STEAM DRUM
FLOWS THROUGH THESE WALLS AND
AFTER GETTING HEATED RETURNS TO
STEAM DRUM THRU THERMO-SIPHON
EVAPORATOR
THERE ARE TWO SUPERHEATERS IN THIS
BOILER, PRIMARY AND SECONDARY INTER-
LINKED TOGETHER BY A DE-SUPERHEATER
PRIMARY SUPERHEATER IS SUBJECTED TO
RADIANT AS WELL AS CONVECTION ZONE
SUPERHEATER
SECONDARY SUPERHEATER IS SUBJECTED
CONVECTION HEAT ONLY
BOILER, PRIMARY AND SECONDARY INTER-
LINKED TOGETHER BY A DE-SUPERHEATER
PRIMARY SUPERHEATER IS SUBJECTED TO
RADIANT AS WELL AS CONVECTION ZONE
SUPERHEATER
SECONDARY SUPERHEATER IS SUBJECTED
CONVECTION HEAT ONLY
DE-SUPERHEATER IS INSTALLED TO CONTROL
TEMPERATURE OF STEAM COMING FROM
PRIMARY AND MOVING TO SECONDARY FOR A
FINAL OUTPUT STEAM AS REQUIRED
DE-SUPERHEATER
BOILER USES FD FAN TO SUPPLY AIR FOR FUEL
COMBUSTION AND FOR MAINTAINING A
POSITIVE DRAUGHT IN THE FURNACE.
FORCED DRAUGHT FAN
A SMALL AIR BLOWER SUPPLIES SEALING AIR
FOR BURNERS, OBSERVATION PORTS, FLAME
DETECTORS
TEMPERATURE OF STEAM COMING FROM
PRIMARY AND MOVING TO SECONDARY FOR A
FINAL OUTPUT STEAM AS REQUIRED
DE-SUPERHEATER
BOILER USES FD FAN TO SUPPLY AIR FOR FUEL
COMBUSTION AND FOR MAINTAINING A
POSITIVE DRAUGHT IN THE FURNACE.
FORCED DRAUGHT FAN
A SMALL AIR BLOWER SUPPLIES SEALING AIR
FOR BURNERS, OBSERVATION PORTS, FLAME
DETECTORS
BOILER GAS FLOW DIAGRAM
Water treatment
S-901
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e
r
S-901
Clarifier
R
A
W
W
a
t
e
r
Clarifier
R
A
W
W
a
t
e
r
S-901
Clarifier
R
A
W
W
a
t
e
r
Clarifier
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
S-901
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
P-601/
P-602
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
Clarifier
S-902
Clarified Water
P-904
V-901
Sand Filter
T-902
Filtered Water
P-907
CATION
EXCHANGER
V-905
ANION
EXCHANGER
V-907/908
MIXED BED
EXCHANGER
V-915
T-901
Demin Water Storage
P-901
De-aerator
P-601/
P-602
Degasifier
T-903
Deionized water
storage tank
To Cooling
Towers
Steam
Air
R
A
W
W
a
t
e
r
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