BOILER PRESSURE PARTS

KUNAL KANT
DY-MANAGER-BMD
 Boiler Pressure Parts
In a steam generator the parts through which the feed water and steam flows
where the pressure of system is much higher than atmospheric pressure are
generally known as Boiler Pressure Parts

The following parts of the boilers are generally known as Boiler Pressure Parts
• Water wall system
• Boiler Drum
• Super heater
• Re heater
• Economiser

Except boiler drum, others form the heat absorbing/ heat recovery surface of
boiler.
 Boiler Pressure Parts
Water wall system
With the need of increase in steam capacity of boilers
and to minimize the furnace heat losses by radiation,
in modern boiler the evaporative surface is made of
water wall, which form the major enclosure of furnace.

Advantages of Water Wall Furnace

• Combustion and heat transfer is taking place
simultaneously
• Due to heat transfer in furnace, temperature of
flue gas leaving the furnace is reduced
• High heat loading in the furnace is possible.

The water wall tubes are welded together by means of flats

(metal strip) called membrane wall. With membrane wall
construction the furnace wall are air tight.
 Boiler Pressure Parts
Boiler drum
In a sub critical recirculation boiler,
The function of drum are
• Separation of saturated steam from
steam water mixture
• Mixing feed water from economiser
with water separated from steam
and recalculate through water tubes
• Carrying out blow down for
reduction of boiler salt concentration
• Treatment of boiler water by
chemical

Design Pressure 164 kg/cm2(g)

Design metal temp. 348˚C
Actual thickness 110/140 mm
 Boiler Pressure Parts
Feed lines
The feed water from the economizer outlet header is brought through the feed
lines, which are connected to the feed nozzle mounted on one side of drum.

Down comer
The down comer pipes are connected to the bottom of the drum.. The water from
the drum is circulated to water wall tubes through down comers, which are kept
external to the heating zone of boiler.

Bottom Ring Header

There are four down comers in which carry water from boiler drum
to the ring header. They are installed from outside the furnace to keep density
difference for natural circulation of water & steam.

Riser tubes
Water steam mixture from inside the water wall tubes is collected in top of headers
From top of headers, the water steam mixture brought back to the boiler drum
through riser tubes
 Boiler Pressure Parts
Super heaters
Super heaters are provided in the boiler to raise the steam temperature above the
saturation temperature by absorbing heat from flue gases. Use of super heated
steam in turbine brings following advantage

• Increase cycle efficiency

• Eliminate the condensation of steam in turbine
• Increase work done in turbine

The maximum temperature of super heater is limited by boiler metallurgy.

 Boiler Pressure Parts
Classification of Super heaters according to shape

• Platen or pendent type

These type of super heaters are hanging from and supported by headers, also
known as Vertical super heater and normally located in first pass of boiler.

• Horizontal type
super heater may be horizontal type with tubes arranged across the boiler and
normally located in second pass of boiler

• Drainable and non drainable type

if condensate collected in super heater can be drained by gravity, known as
drainable type super heaters other wise non drainable type superheater.
 Boiler Pressure Parts

Arrangement of Superheaters

Platen or pendent type Horizontal type

Super heaters
 Boiler Pressure Parts
Re heaters
Re heaters are provided in the boiler to raise the temperature of steam coming out
from high pressure turbine by absorbing heat from flue gases. Use of Re heated
steam in turbine brings following advantage

• Increase cycle efficiency

• Eliminate the condensation of steam in low pressure turbine
• Increase work output

The maximum temperature of Re heater is limited by boiler metallurgy.

 Boiler Pressure Parts
Economiser
Economisers are used in boiler to improve the efficiency of boiler by extracting the
heat from flue gases and add it as either sensible heat alone or sensible heat and
latent heat to the feed water before water enters the evaporating surface of boiler.

Advantages of Economisers
• Fuel saving
• Reduce boiler size

Location and arrangement

it is usual to locate the economiser ahead of air heaters and following the primary
super heater in the convective pass of the gas stream. These are arranged for
downward flow of gas and upward flow of water and are designed for horizontal
Placement, which facilitate the draining of coils.
 Boiler Pressure Parts

Finned Economiser
Plain tube Economiser
 Boiler specification
Furnace specification
Manufacturer M/s. BHEL.
Boiler Type Wet-Bottom, Radiant Reheat, Single Drum, Top
Supported, Balanced Draft Furnace.
Type of Firing Tilting Tangential.
Furnace Type Balanced Draft Furnace with Fusion
Welded W/W. Wall Water steam cooled
Tube arrangement Membrane
Residence time for fuel particles 3 Secs.
Furnace Volume 3468 M3
Drum elevation 48.62 M
Fuel Heat input 382.3 MKCal/hr.
Total heating surface area of W/W 1947 M2
Design Pr. of tubes 166.8 kg/cm2
Design temp. 376˚C
 Boiler specification
Superheater Specification
LTSH Platen F.S.H

Materials SA 213 T11/ SA 213 TP347H/ SA213 T22

SA210GR-c T91/T22
Type Convective Radiant Convective
Drainable / Non-drainable Drainable Non-drainable Non-drainable
Effective Heating Surface area 3975 M2 586 M2 400 M2
OD 44.5 mm 47.63 mm 44.5 mm
Total no. of assembly 90 24 74
Design Temperature 0C 474/500 574/588 565/575

Re heater specification
Materials SA 213 T11/T22/T91
Type Radiant Front Radiant, Convective Rear Pendant.
Total heating surface area 1646 M2
Design Pressure 42.5 kg/cm2(g)
No. of assembly 49
Tube OD 54.0 mm
 Thermal Structure of A SG

drum screen

Platen SHTR
R
H tubes

DPNL SH T
R

LTSH

Economiser stack
BCW
pump
Furnace

APH ESP ID Fan

Bottom ash
 H.
R.
M.S C.R.H H

FROM F.R.S
BOTTOM RNG HDR& Z-PANEL 1ST PASS W.W
1ST PASS W.W O/L HDRS ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
S.H. HEADER R.H.HEADER
2ND PASS ROOF O/L HDR(REAR ECONOMISER
Thank You !