3.Boiler documentation, Air & Flue Gas path, Ducts,EJ,Gates & Dampers(1.5 hrs).pdf

7/23/2019 3.Boiler documentation, Air & Flue Gas path, Ducts,EJ,Gates & Dampers(1.5 hrs).pdf

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Boiler Documentation

By:Dhruv GargEngineer/BoilerPS-TS, BHEL



Boiler Manufacturing Plant

High Pressure Boilers (For 500/250/210/125 MW Ratings) inBHEL are designed And manufactured at High PressureBoiler Plant (HPBP), BHEL Trichy, Tamil Nadu.

Boiler Auxiliaries Like FD, ID, PA Fans, Air Pre-Heaters andESP are designed And manufactured At BAP Ranipet.

Coal Mills are designed and manufactured at Heavy Power Equipment Plant, R.C Puram Hyderabad.




Major documents associated with Erection of boiler:

Applicable PGMA list:

After basic thermal design and layout of boiler is worked out,

Trichy first finalizes the applicable PGMA list vary from projectto project.

PG stands for Product Group.

Identified by a two digits number, ranging from 00 to 99.



Boiler Documentation…

Each Product Group identifies a pre-defined area of boiler.

Following are some examples:

04 Steam drum.

05 Headers in circulation system.

06 Water walls of circulation system.

07 Line, links and suspensions of

circulation system.

08 Buck stays.

35 Boiler supporting structure.

36 Boiler platforms and galleries.




Examples (cont’d…)

39 Structure behind main boiler.

48 Ducts.

50 Steam coil air pre-heater.

52 Regenerative air pre-heater.

55,56 Fans

78 ESP

80 Piping

95,96,97 Control and Instrumentations




MA stands for Main Assemblies.

Identified by a three digits number and defines a sub-group

applicable to specific Product Group.

Following are some examples:

04-126 Steam drum.

04-146 Drum suspension.

05-137 Front water wall lower inlet header.

05-147 Rear water wall lower inlet header.

06-631 Front upper water wall panels.

06-634 Front inter water wall panels.

07-215 Side relief tubes.

07-223 Furnace hanger tubes.

08-101 Furnace upper buck stays.




Examples (cont’d…)

08-111 Rear arch buck stays.

35-010 Support structure foundation material.

35-110 Main columns left.

35-210 Ceiling structure fabricated.

39-141 Columns ID fan inlet.

48-012 Duct-FD fan to air heater. 48-022 Duct-FD fan interconnection.

52-011 Rotor post assembly for air pre-heater.

52-041 Hot end connecting plate for air pre-heater.




The released applicable PGMA list for a boiler presents

following information:

• Major PGs applicable to the boiler.

• Main sub-assemblies applicable to that product group and

boiler.

• Estimation of design weight for every PGMA.

• Summed up estimated design weight of a PG.

• Summed up estimated weight of complete boiler.



BOILER SHIPPING LIST



Boiler Shipping List

Basic document giving details of style of manufacture and

dispatches for complete boiler components.

Issued for each and every PGMA with title and PGMA

number.

Identified by Boiler job number (a four digits unique

number for a boiler)

Contains a three digit number called as “Dispatch Priority

Number” (DPN) which indicates the sequence of supply

w.r.t. erection sequence.

Nature of supply as NS-1 (main contractual supply) or NS-

2 (free of cost supply for some left out or modification area)

or NS-3, 4 etc.



Boiler Shipping List…

In various columns in the shipping list sheet, it gives

following information:

• DU (Dispatchable Unit) number as three digits number

starting from 001 for each PGMA.

• Description of DU.

The drawing number to be referred for that DU. Some

times a star mark is put in this column. It indicates that a

Project drawing should be referred for the details of thatDU.



Boiler Shipping List…

• Item number in next column relates it to the respective

item number on the bill of material of related drawing.

• Next column gives the total quantities of dispatch for that

DU.

• Next column gives the weight of total numbers in Kgs.

• In right hand bottom corner, the number of sheets used for that shipping list is also indicated.

• At the bottom the summed up total weight of dispatch for

complete PGMA is also indicated in Kgs.

• After last DU, each shipping list is marked with -"Shippinglist completed" to ensure total DUs in that shipping list.



BOILER DRAWINGS



Boiler Drawings

Drawings, Schemes and P&ID schemes are released for

every boiler-

• Scheme of water and steam system.

• Scheme of fuel system.

• Scheme of Air and Flue gas system.

• Scheme of piping.

• Any other applicable scheme including instrumentation.



Boiler Drawings…

A set of Project drawings are released-

• Composite foundation plan and loading data.

• General arrangement of Boiler-Elevation and Plan.

• Sectional drawings of General arrangement.

• Pressure Parts arrangement drawing.• Sectional drawings for pressure part arrangement.

• Floor Plans at various levels.

• Lay out drawings for Air and Flue gas ducting.

• General Assembly(GA) drawings for some equipment likefans, mills, air pre-heaters etc.

• Lay out of Fuel System



How To Read Drawing Numbers

Drawing Number

0-00-022-72045 Rev 00

• Size of drawing such as 0,1,2,3 or 4

• PG number for which it is applicable, such as 00, 35 or 48

etc.

• MA number three digit e.g. 020, 110, 210 etc.

• Individual distinctive drawing number in five digits.

• Revision number such as 00 or 01 etc.

Each drawing contains all dimensional details, item

numbers and complete Bill of material(BOM) applicable tothat drawing.



OTHER DOCUMENTSREQUIRED FOR

ERECTION & COMMISSIONINGACTIVITIES



Other Documents

• IBR approved drawings for pressure parts.

• IBR provisional certificate to invite Boiler inspector for

ground inspection of pressure part components.

• IBR data book along with form IIIC of valves, before

Hydraulic test of boiler.

• Thickness calculation sheets for pressure part

components.• Erection Welding Schedule (EWS)

• Welding Procedure Specifications (WPS) for various types

of welding joints.

• Welding, NDT and Heat treatment manuals.• Field Quality Plans(FQP) for Products / Systems e.g Boiler

structure and Pressure Parts



Other Documents…

• Electrical and Control Panel arrangement drawings.

• Cable Schedules and Termination details.

• Hydraulic test procedure.

• Commissioning Procedures for specific equipments.

• Acid Cleaning procedure.

• Steam blowing procedure and scheme.

• Safety valve settings procedure.

• Operation & Maintenance Manual for specific Equipment

• Start up and Unit loading curves.

• PG Test Procedure.



BOILER COLUMNS LAYOUT



• Boiler center line is generally at right angle to the center line

of Steam turbine-generator-Exciter line.

• The vertical cavity formed by first four main columns of boiler

support structure (usually named S7L&R, S8L&R, S9L&R and

S10L&R) accommodates the main furnace of boiler. This

cavity referred as First Pass.

• The vertical cavity formed by rear columns (S10L&R, S11L&R

and S12L&R) Referred as Second Pass.

Boiler Columns Layout



REGULAR ARRANGEMENT OF BOILER COLUMNS FOR RAMAGUNDAM 500 MW

UNIT 7 (53 NO OF COLUMNS)



BOILERSTRUCTURE

DIMEMSIONAL DETAILS OF BOILER COLUMNS FOR



DIMEMSIONAL DETAILS OF BOILER COLUMNS FOR

KAHALGOAN 500 MW



BOILER LAYOUTS



LAYOUT CATEGORY

A) LAYOUT FOR GREEN FIELD PROJECTS.

B) LAYOUT FOR EXTENSION OF EXISTING UNITS.

C) LAYOUT FOR ANY RENOVATION & MODERNIZATION

OF EXISTING UNITS



TYPES OF LAYOUT

BASIC BOILER LAYOUT IS DESIGNATED BASED ON THELOCATION OF MILLS .

FOLLOWING FOUR TYPES OF LAYOUTS ARE IN USE

FRONT MILL LAYOUT

REAR MILL LAYOUT

SIDE MILL LAYOUT

VIJAYAWADA (SPECIAL) LAYOUT

FRONT MILL LAYOUT



FRONT MILL LAYOUT



FRONT MILL LAYOUT

REAR MILL LAYOUT (PANIPAT)



REAR MILL LAYOUT (PANIPAT)

REAR MILL LAYOUT



REAR MILL LAYOUT

SIDE MILL LAYOUT



SIDE MILL LAYOUT

VIJAYAWADA MILL LAYOUT










AIR & FLUE GAS PATH OF

BOILER



SCHEME OF FLUE GAS PATH

FURNACE 1ST

PASS

AIR PRE-

HEATER

ESPID FANCHIMNEY

BACK PASS

OR 2 ND

PASS



SCHEME OF SECONDARY AIR PATH

FORCED

DRAFT

(FD) FAN

SECONDARY

AIR PRE-

HEATER

TO FURNACE

THROUGH

WINDBOX

HOT

SECONDARY

AIR



SCHEME OF PRIMARY AIR PATH

PRIMARYAIR(PA)

FAN

PRIMARY AIR

PRE-HEATER

MILLS

FURNACE

TEMPERING (COLD)AIR HOT PRIMARY AIR

MIXED PRIMARY AIR

FEEDER

PULVERISED COALWITH AIR

RAW

COAL



FLOW DIAGRAM OF AIR & FLUE GASPATH

FLUE GAS TO ESP

FD FAN PA FAN

AIR HEATER

HOT SEC. AIR TO WIND BOX HOT PA TO MILLS

FLUE GAS FROM ECONOMISER



DUCTS

DUCTS & DAMPERS

DUCTS



Duct is a closed path for the flow of cold air , hot airand gases from one point to another point in asystem . This can be of any shape like Circular ,Elbow, Straight , Square, Rectangular or some other shape.

There are eleven duct systems in Boiler :

1 . Cold air duct - FD fan to air heater.

- PA fan to air heater.

2 . Tempering Air system .

DUCTS

HOT AIR DUCTS :

HOT AIR DUCTS



* Hot air To Wind box

* Hot air To Bus duct

* Hot air to Mills

GAS DUCTS :

* Gas To Economizer

* Gas To Boiler Outlet

* Gas To Electro statics precipitator

* Gas To ID Fan

* Gas To Chimney

HOT AIR DUCTS

GAS DUCTS



COLD AIR DUCT FROM

FD FAN TO SECONDARY

AIR HEATER



HOT SECONDARY AIR

DUCT FROM SAPH TO

FURNACE WINDBOX



TEMPERING AIR DUCTING (COLD PA)



Hot Primary Air duct from

PAPH to Mills &

Tempering Air Duct to Mills

FLUE GAS DUCT FROM



FLUE GAS DUCT FROM

ECONOMISER TO AIR PRE-

HEATER



AIR PRE- HEATERS TO

BOILER OUTLET FLANGE (BOF)



BOF TO AIR HEATERS

FLUE GAS DUCT FROM BOF

TO ESP PASS



FLUE GAS

DUCT FROM

ESP to ID FAN



FLUE GAS DUCTFROM ID FAN TO

CHIMNEY

Raichur -7, 210 MW – Top View



Duct Modules



Straight ductCircular to

Rectangular ductTransition duct Y duct

T ductBend ductElbow duct

3D VIEW OF TUBULARFLUE

GAS



3D VIEW OF TUBULAR AIRPREHEATERS WITH

DUCTS

FLUE

GAS IN

COLD

AIR IN

HOT AIR

OUT

GAS

OUT

AH-I

AH-II

AH-III

ELBOW DUCT

TRANSITION

DUCT



SUPPORTS & RESTRAINTS OFDUCTS

Anatomy of a simple straight duct



STIFFENER

DUCT

PLATE

FLANGE

CORNER

ANGLE

DUCT WITH

INTERNAL

TRUSS

Anatomy of a simple straight duct



RESTRAINT

STRUT TUBE WELD

GUSSET

BASE PLATE

WITH (BEARING)

SUPPORT

CORNER ANGLE PLATE



HOT SECONDARY AIR DUCT

FLOW METER

EXPANSION JT

SUPPORT

TOP SUPPORT WITH

HANGER AND LUG PLATE



HANGER AND LUG PLATE

RESTRAINT SUPPORT



DUCT WITH BOTTOM SUPPORT



SUPPORT

FLANGE WITH

FITUP HOLES



I-BEAM

SUPPORT

TOP PLATE

BEARING PLATE

BASE PLATE

BOTTOM SUPPORT WITH BASE PLATE

AND BEARING PLATE

BOTTOM SUPPORT WITH STOPPERS



TOP PLATE

BEARING PLATE

BASE PLATE

WITH STOPPER



EXPANSION JOINTS

EXPANSION JOINTS



• Takes care of Axial & Lateral Expansion in Ducts.• Also Takes care of slight misalignment between two

duct pieces.

• Used in Hot Air Ducts, Flue Gas Ducts, Ductsconnecting with wind box, furnace and BoilerAuxiliaries.

• Expansion Joints always work in compression mode

rather than in tension mode



EXPANSION JOINT

ASSEMBLED IN DUCT

CL of support C L of support

Expansion Movement in Duct



AIR PRE-

HEATER

Lateral movement to Toggle

Axial movement

Axial movement

Movement

of duct

Movement

of A.H.

pp pp

TYPES OF EXPANSION JOINTS



1 Metallic Expansion Joints (MEJ)

2 Non- Metallic Expansion Joints (NMEJ)

METALLIC EXPANSION JOINT



NON-METALLIC EXPANSION JOINT(Circular Shape)



ELASTOMER COATEDOUTER LAYER (silitex)PTFE SEALINGLAYER

GLASS FABRICSUPPORT LAYER



DUCT S.S WIREMESH

FABRIC DETAILS FOR N.M.E.J

GLASS FABRIC

CAVITY

PILLOW

BOLSTER



GATES

GUILLOTINE GATES



Guillotine gates are used in

boilers for isolation of anyduct, system or equipment byrestricting the flow of air orflue gas during running ofboiler.

Gates are 100 % leak tight infull close condition.

100% Leak tightness for Gates

The seal air is admitted inside the



The seal air is admitted inside theseal air chamber with a pressure of

125 mm WC more than the systempressure.

BLOWER TESTING TUBE

PLENUM DUCT

FLOW

P1 P2P3

P2>P1&P3



DAMPERS

DAMPERS



Dampers are used in the ducts to control flow of air or

flue gas in the Boiler system.

Types of Dampers used in the Power Plants:

1. Louver Damper2. Bi-plane Damper

3. Flap Damper

LOUVER DAMPER



This damper is used in two way ducts and provides onlysingle plane sealing in the system.

This damper is only 95 % leak tight in full close

condition.

BI-PLANE DAMPER



This damper is also used in two way ducts and providesdouble plane sealing in the system.

This is considered as 99 % leak tight in full close

condition.

Used in Secondary Air Damper etc.

BIPLANE DAMPERS



FLAP DAMPER



This damper is used in three way ducts.

This damper is 100 % leak tight in full close conditionand can replace Gates due to easy operation.

Used in Economizer Bypass ducts, mill hot air ducts etc.

FLAP DAMPER



CASING

BLADE

SEAL AIR FAN

ACTUATOR

GEAR BOX



FLAP DAMPER WORKING











DUCT

FLAP WITH

TOGGLE

LEVER

FLOW IN

ACTUATOR







Date post:	12-Feb-2018
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