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Thursday, 7 March 2013
SPIRAL WALL-2 CONTINUE FOR BOILER
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Wednesday, 6 March 2013
PR.PARTS OF BOILER ( SPIRAL WALL -I) ABC OF THERMAL POWER PLANT
Spiral Wall
Introduction of Spiral wall in very new in India . This is now being used by foreign manufacturer
for Super critical boiler. From hopper, the water raises in the spiral wall system of furnace. In the
spiral wall, the slope can be any value from 13° to 20°. In case of Barh, this value is 20°. The
spiral walls are constructed on the concept of fin welded panels. They have stepped weld so
as to join with the other adjoining panels. The size in spiral wall chosen for Barh is 41.3mm
tubes. The material is selected as T22/ T12. The walls are provided with many openings for the
following items:-
i) Wall blowers.
ii) LRSB.
iii) Observation Doors.
iv) APM (Acoustic Pyro Meter)
v) FMS System (Flame Monitoring System).
vi) ASLD (Acoustic Steam Leak Detector).
Furnace Spiral Wall to Vertical Wall Transition Panels
The spiral walls on all four sides terminate below the screen and rear arch. The spiral wall terminates at
the designated level with forged fittings. These are small individual forged elbows with Integral Fins
and are made of Alloy Steel SA182 F12 Cl.2 or SA182 F22 Cl.3. All the spiral wall fittings are welded
on the panels at shop. Similarly, there are forged fittings for the vertical wall to intermediate header
terminal tube connections. These are combined formed fittings. i.e. one fitting takes care of 3 or more
tubes. These tubes are directed by the spiral to vertical wall tube ratio. Hence, most of the vertical wall
fittings are made up for 3 Nos. of tubes except at ends when there may be variation in number of tubes.
All the forged fittings for spiral wall as well as the vertical walls are welded at the shop floor.
From this dispatch onwards we will provide more details on Spiral wall as its is absolutely new.
Construction workers ,supervisor and engineers should have an overall idea of the system.
Both type of furnace arrangement has been shown vertical type we are using sub critical boilers
also in super critical ( with improved version of tubes) and spiral wall we are using in super critical
boiler ( the spiral wall type we worked) . As already mentioned There are two zones one is spiral
wall up to 59+ metres and ended above burner nozzle and then transition header and vertical wall.
Tube arrangements of spiral wall in comparison to vertical wall. Inclination has already been
mentioned above. Forged fittings used for connection spiral to vertical through transition header.
Pre-assembly of spiral wall is under progress with Tension. Fixing of Tension Bar is very important
for matching of the spiral wall. Please note this matching cannot be done in situ at working place like
other vertical Wall ( Tension Bar is not there in vertical wall panel)
PS: For further information on " ABC of thermal power" click on the adjacent
and are made of Alloy Steel SA182 F12 Cl.2 or SA182 F22 Cl.3. All the spiral wall fittings are welded
on the panels at shop. Similarly, there are forged fittings for the vertical wall to intermediate header
terminal tube connections. These are combined formed fittings. i.e. one fitting takes care of 3 or more
tubes. These tubes are directed by the spiral to vertical wall tube ratio. Hence, most of the vertical wall
fittings are made up for 3 Nos. of tubes except at ends when there may be variation in number of tubes.
All the forged fittings for spiral wall as well as the vertical walls are welded at the shop floor.
From this dispatch onwards we will provide more details on Spiral wall as its is absolutely new.
Construction workers ,supervisor and engineers should have an overall idea of the system.
Both type of furnace arrangement has been shown vertical type we are using sub critical boilers
also in super critical ( with improved version of tubes) and spiral wall we are using in super critical
boiler ( the spiral wall type we worked) . As already mentioned There are two zones one is spiral
wall up to 59+ metres and ended above burner nozzle and then transition header and vertical wall.
Tube arrangements of spiral wall in comparison to vertical wall. Inclination has already been
for matching of the spiral wall. Please note this matching cannot be done in situ at working place like
other vertical Wall ( Tension Bar is not there in vertical wall panel)
PS: For further information on " ABC of thermal power" click on the adjacent
advertisement
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Tuesday, 5 March 2013
FURNACE AND EVAPORATOR SYSTEM OF BOILER
In last dispatch we have discussed what are the major components constitutes the Furnace
/ Evaporator System. Today we will describe the system individually in brief.
1. The headers form a ring header pattern link in all conventional designs. The basic difference
is in the arrangements of headers. Basic points which make the header unique are that the side
wall headers donot have any stubs as they have only the economiser water connection and the
other point is headers on front and rear do not extend up to the wall as it in subcritical utility
boilers. As the spiral wall construction begins at hopper iyself , the stub arrangement is
staggered both front and rear headers.
On the front and rear sides of the furnace hopper, the tube panels are at angle of 50° to the vertical. To
match the vertical spiral wall, these transition panels have a bend in the vertical plane. These bends are
provided by the number of loose tubes in the matching panels.
This is typical status of erection site at the beginning of pressure part erection. Any body can observe
that roof sheeting work is over. It will benefit the erection work during monsoon season, As you
know structural work starts from bottom but Pressure parts work starts from Top. Therefore
suspension work , lifting of link pipes , roof panel , top headers etc can be lifted. Suspended
suspension and a few headers can be seen. It also observed that lot of horizontal buck stay has
been lifted and kept in position . There are two schools of thought regarding lifting of buck stay
one is buck stay to be lifted along with the wall panel because bigger length and avoid bending
during lifting and other school is buck stay to be lifted separately and attached after lifting of
panel. Both the theories have their advantage and disadvantage therefore it will be the decision
of erectors and material position that will guide. We have followed mixed rout of both the system.
It can be observed that all silencers are erected on the roof .
As described earlier transition header with spiral panel and vertical panel pre-assembled and
getting lifted.
Furnace wall vertical is taking it shape . Buck stays were attached now and helping in formation of
furnace.
/ Evaporator System. Today we will describe the system individually in brief.
Furnace wall inlet Headers.
is in the arrangements of headers. Basic points which make the header unique are that the side
wall headers donot have any stubs as they have only the economiser water connection and the
other point is headers on front and rear do not extend up to the wall as it in subcritical utility
boilers. As the spiral wall construction begins at hopper iyself , the stub arrangement is
staggered both front and rear headers.
Spiral wall inlet tubes
The spiral hopper formation starts at the hopper inlet tubes. The pitching and arrangement
is such that the required angle of spiral hopper and pitching of tubes is achieved at the
loose tubes.
Furnace Hopper Spiral Walls
The water from the bottom inlet header enters the spiral hopper walls. The hopper walls are slanted to
the hopper angle on front and rear and are vertical on sides. The hopper walls on front and rear have
two inclination angles to accommodate the tubes and to facilitate the formation of helix. All the end
connections are with loose tubes only and there is no spiral panel gang bending requirement. These
loose tubes at all the four corners are welded at site. Furnace hopper side walls have the large access
door opening (610 mm x 762 mm), which is given for taking equipments like scaffold door, etc. inside
the furnace. The tubes are to be bent in multi plane to arrive at all openings.
Furnace Hopper to Vertical Transition
match the vertical spiral wall, these transition panels have a bend in the vertical plane. These bends are
provided by the number of loose tubes in the matching panels.
This is typical status of erection site at the beginning of pressure part erection. Any body can observe
that roof sheeting work is over. It will benefit the erection work during monsoon season, As you
know structural work starts from bottom but Pressure parts work starts from Top. Therefore
suspension work , lifting of link pipes , roof panel , top headers etc can be lifted. Suspended
suspension and a few headers can be seen. It also observed that lot of horizontal buck stay has
been lifted and kept in position . There are two schools of thought regarding lifting of buck stay
one is buck stay to be lifted along with the wall panel because bigger length and avoid bending
during lifting and other school is buck stay to be lifted separately and attached after lifting of
panel. Both the theories have their advantage and disadvantage therefore it will be the decision
of erectors and material position that will guide. We have followed mixed rout of both the system.
It can be observed that all silencers are erected on the roof .
As described earlier transition header with spiral panel and vertical panel pre-assembled and
getting lifted.
Furnace wall vertical is taking it shape . Buck stays were attached now and helping in formation of
furnace.
Monday, 4 March 2013
PRESSURE PARTS ( FURNACE AREA) FOR BOILER.
The Economiser outlet connection are made with the furnace inlet headers. The total furnace
system consits of the following system.
a. Furnace wall inlet headers ------------- Front , Rear and sides.
b. Furnace inlet loose tubes -------------- Front and Rear.
c. Furnace Hopper Spiral wall ------------- Front ,Rear and sides.
d. Furnace Hopper to Spiral wall Transition ------------- Front , Rear and sides.
e. Furnace wall Spiral ------------------------ Front , Rear and side attachments.
f. Furnace wall Transition panels ---------- Front , Rear and sides including spiral & vertical
fittings and forged fitting used for transition.
g. Furnace wall intermediate headers ----------------- Front and Rear.
h. Furnace vertical wall ----------------------------------Front and sides.
i. Furnace wall rear arch tube panels and Furnace rear hanger tubes.
j. Furnace vertical wall outlet headers ---------------- Front , rear and sides.
k. Burner Tubes bundles at four corners.
l. Sofa panel on the side walls.
m. Furnace outlet riser pipes to seperator.------------------- Front , rear and sides.
n. Rear Arch Supports ( Special for once through Boiler)
A picture of pressure erection is added to explain some basic points. This is Sprial panel with
transition header pre-assembled and lifted . You can see the vertical Panel on the top . Vertical
panel got assembled with loose tubes and header . Also notice the Y shape alloy steel plate for
supports. This plates are fitted during pre -assembly of panel and keep the continuty of the plate
during susequent panel fitting. Header is 60 + elevation.
Same panels are getting positioned at respective elevation and giving a birds eye view for furnace
formation.
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system consits of the following system.
a. Furnace wall inlet headers ------------- Front , Rear and sides.
b. Furnace inlet loose tubes -------------- Front and Rear.
c. Furnace Hopper Spiral wall ------------- Front ,Rear and sides.
d. Furnace Hopper to Spiral wall Transition ------------- Front , Rear and sides.
e. Furnace wall Spiral ------------------------ Front , Rear and side attachments.
f. Furnace wall Transition panels ---------- Front , Rear and sides including spiral & vertical
fittings and forged fitting used for transition.
g. Furnace wall intermediate headers ----------------- Front and Rear.
h. Furnace vertical wall ----------------------------------Front and sides.
i. Furnace wall rear arch tube panels and Furnace rear hanger tubes.
j. Furnace vertical wall outlet headers ---------------- Front , rear and sides.
k. Burner Tubes bundles at four corners.
l. Sofa panel on the side walls.
m. Furnace outlet riser pipes to seperator.------------------- Front , rear and sides.
n. Rear Arch Supports ( Special for once through Boiler)
A picture of pressure erection is added to explain some basic points. This is Sprial panel with
transition header pre-assembled and lifted . You can see the vertical Panel on the top . Vertical
panel got assembled with loose tubes and header . Also notice the Y shape alloy steel plate for
supports. This plates are fitted during pre -assembly of panel and keep the continuty of the plate
during susequent panel fitting. Header is 60 + elevation.
Same panels are getting positioned at respective elevation and giving a birds eye view for furnace
formation.
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Friday, 1 March 2013
BOILER ERECTION (ECONOMISER) CONTINUED WITH PICTURES
after erection look. We will not discuss about erection of the coils header etc as the same will be
during erection sequence. etc. There are two theory of lifting economiser coil 1. by doing pre-
-assembly of two coils . 2. lifting it by one by one. There is advantage and disadvantage of both
the system which we will discuss later.
We conclude the discussion about economiser loose tube with header pre-assembly at site.
PS: For further information on " ABC of thermal power" click on the adjacent
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Thursday, 28 February 2013
PR.PARTS (ECONOMISER) OF BOILER
The economiser outlet links are taken form the ends of header and they join to form a single lead.
Just before these join the Furnace Inlet headers on left and right side, they are again bifurcated.
As there is no Drum in once through design the feed water after economiser directly enters the
Furnace wall system / evaporators.
Details of Economiser System
Description No off Size thickness Matl. Spec Design Pr. Design/temp
kg/cm.sq deg. C
Eco inlet link 1 457.2 55.5 SA 106 C 306 293.7
Eco. inlet header 1 457.2 79.4 SA106 C 301 321.7
Eco Coils 812 44.5 8 SA210 C 301 358.6
Eco Outlet header 1 508 101.6 SA 335 P22 297.9 375.6
Eco outlet link 2 508 71.6 SA106 C 297.9 348.8
Total Pressure drop calculated in economiser system is around 5.5 kg/cm. sq.
Total Pressure drop calculated in evaporator system is around 14.4 kg/cm.sq.
Total design Pressure calculated is = 1.05 x working pressure.
Pressure Parts design should be in line with IBR ( Indians Boiler Regulation )
There should be provision of Erosion and thinning allowance of 1.00 mm and 10% respectively.
- Above drawing shows the position of ECO coils , headers etc in the system. Economiser
erection will be done after RH coil , 2nd Pass roof erection . The same will be explained
at a later stage.
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Wednesday, 27 February 2013
PRESSURE PART ERECTION OF BOILER IN A THEMAL POWER PLANT.
We have completed the discussion about structural erection of Boiler in brief. Please note
erection strategy to finalised before starting of erection. This will give control over cost
and time. Interface with civil work will be there but it should minimum . The whole planning
should be discussed amongst the team for setting priority. Structural member where ever
possible should be pre-assembled on ground . This will help us to reduce number of lift to
performed. It is sign of Good erection if we complete all the platform work including
hand railing. Once we complete the structural erection of roof and aligned the girder , WB
and rolled beam etc .then we are ready for Pressure Part erection. Before we discuss about
the erection sequence a brief description of Pressure Parts for a 660 MW boiler with MNC
design ( as Indian manufacturer does not have the technology) is given below. It has been
seen that for Pressure Parts the weight of component of Indo-American company and the
Chinese company is more or less same . However one can compare the same system wise
a conclusion can be drawn.
Before we start explaining let us add some photos to understand how pressure parts look like.
The above picture shows that pressure parts components are hanged by suspension rod from
rolled beam of roof structure.
The above picture shows the erection of separator and collector vessel and their interconnection
piping. In super critical boiler there is no drum instead we have separator vessel.
DETAILED DESCRIPTION OF PRESSURE PARTS
PPA ( Pressure Parts arrangements)
The pressure part system of once through units consist of the following.
a. Economiser System
b. Furnace System.
c. Start up system ( new and different from sub critical unit)
d. Super heater System.
e. Re heater System.
A. Economiser System
The economiser is plain tube inland type and made of carbon steel tubing. The numbers of
elements are 04 nos in the project we have worked for. There are two banks of economiser.
The coils are supported by hanger tubes The economiser inlet headers and outlet headers
are positioned inside the flue gas path.
(to be continued)
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