Boiler Intro

Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Hearty Welcome to
Engineer Trainees-2004
Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Schematic Diagram of
Boiler

TYPICAL BOILER DETAILS
(Weight in Tons)
PART 67.5 MW 210 MW 500 MW
Pressure Parts 700 2100 5200
Structures 1000 2400 6000
Fuel System 200 550 900
Duct & Damper 500 1060 2600
Lining&Insulation 240 670 1500
Air Heater 430 500 1500
FANS 140 260 500
Electro Static Precipitator 1000 2000 7200
PIPING 260 860 860
Controls&Instrumentation 50 70 150
TOTAL 4600 10600 26500
Product Group Main Assy 200 350 500

(Nos.)
Despatchable Units (Nos.) 12000 20000 30000

Cust
Requirlement
Conceptual
Design
System Design Mechanical Arrgt. &

Performance Reqt. Detailed Design
Contract Future
Requirement Requirement
Heating Surfaces Heating Surfaces
Mill Airheaters
In-house Engg. Arrangement a) Number Fans Electrostatic
a) Pr. Parts a) Front Mill a) Number a) Number Precipitator
b) Bowl
b) Fuel System b) Tubular AH
b) Rear Mill c) Tube b)Type Axial c) Bisector AH
No. of
c) Non-Pr.Parts d) Ball & Race
d) C&I c) Side Mill e) Beater Mill c) Type Radial d) Trisector AH fields
Mechanical detailed design for Manufacturing

(Complying Statutory Requirement e.g IBR)
PROPOSAL ENGG. PROCESS
RECEIVE BID SPECN.(Contracts)
REVIEW BID SPECN.(BPP)
DISTRIBUTE IDENTIFY FINALISE FINALISE

TENDER BOUGHT OUT ALTERNATIVES SPL. REQMNTS
ITEMS
(BPP&PE)
ENGG. QUALITY
LIST OF OBTAIN FINALISE FINALISE FINALISE FINALISE

DEVIATIONS OFFERS BOM GUARANTEES SPARES TECH. SPEC.
DRAWINGS
COMPILE OFFER
DISCUSS WITH MANAGEMENT(Specialities & Deviations)
SUBMIT OFFER
ATTEND TENDER ADJUDN. MEETING
AWARD OF CONTRACT

CONTRACT ENGG. PROCESS
AWARD OF CONTRACT
BPP CONTRACTS
CPT BCR FINAL PROP. PACKAGE
SCHED. 00-PS SCHED.
O&M PE SECTIONS
PRODUCIBILITY PGMA SUB-DELY. MATL. FORECAST

ANALYSIS LIST LIST
MEETING
CONTRACTS PUR. M.PLG. PUR
CCSR S.D. HARMONOGRAM
PE SECTIONS
FINALISE FINALISE REL. DOC. FOR STRESS ANALYSIS

SCHEMES ARRGT. DRG BCR ACTIVITY
DETAILED DESIGN
ERECTN. PRODN. DRGS
DRGS. GMS, SHIPPING LIST
CONTRACTS CONTRACTS CIB APPL.
ARCHIVES ARCHIVES
CUSTOMER CUSTOMER OP&C / A.D. PRODN.

Boiler Code and Materials – 500 MW
Ceiling Girders
ASTM A 36
Conn. Links BSEN 10113-2 Gr. S4 20 N
SA 335 P 12 (AISC)
SH / RH Headers Steam Cooled Walls

SA 106 Gr. C / SA 210 Gr. C
SA 335 P 12 / P 22
Structures (Beams, Channels, Angles, Plates)
Drum ASTM A 36
SA 299 (AISC)
Superheaters (LTSH)
Furnace Roof SA 210 Gr. C / SA 213 T 11
SA 213 T 11 Economiser
SA 210 Gr. A1
Note:
- Pressure Parts Code: ASME Sec. I
Superheaters
- Non Pressure Parts Code: AISC
SA 213 T 11/ T22 / T 91
- Oil / Gas Piping Material : SA 106 Gr. B /
SA 213 TP 347 H
210 Gr. A1 / Gr. C
API 5L Gr. B
Reheaters
- Motors : IEC 34
SA 213 T 11/ T22 / T 91
- MCC : IEC 947
Windbox - Ele. Actuators : CEGB Std. 569701
SA 167 Type 309 - Cables. : BS-6346/IEC 502
SA 216 WCB Etc.
Dampers
ASTM A 36
SA 588 Gr.A Airheater
(AISC) ASTM A 515 Gr 65
A 588 Gr A
Downcomer A 36
SA 106 Gr.C A 48
AISI 1020, 1045, 4150
Ducts & Expansion Fan ( Radial/Axial)
Joints
ASTM A 36 Impeller: P3 55 NH
SA 588 Gr.A NAXTRA 70 / RQT 701
(AISC) Casing: ASTM A 36
Ring Header ( DIN)
SA 299

ERECTION SCHEDULE FOR 210/250 MW BOILER
Zero Supply Drum Matls for Matls for Supply

date start Desp Hyd test Light upt Compln.
ZD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Events at site Ern. Drum Hyd Light Syn HO

Start Lifting Test up

CONTRACT PHASE TRANSMITTALS

FURNACE DIMENSIONS
DRUM SELECTION DATA
SH, RH & ECO. ARRANGEMENT SKETCH
HEADER / PIPING LIST
TUBING LIST
DUCT DESIGN DATA SHEET
FAN SELECTION DATA
AIR HEATER SELECTION DATA
E.P. SELECTION DATA
LOCATION OF WALL/SOOT BLOWERS
SAFETY VALVE SELECTION DATA

DELIVERABLES
ARRANGEMENT DRAWINGS:-
- Supporting Structures
- Ducting Arrangement
- Pressure Part Arrangement
- Fuel Piping Arrangement
- Wind Box Arrangement
DETAILED MANUFACTURING DRAWINGS:-
- Pressure Parts
- Fuel Systems
- Ducts & Dampers
- Lining & Insulation
- Feeders, Coal Valves
-ENGINEERING DOCUMENTS:-
- Material Forecast & R-Indents
- Group Manufacturing Specification (GMS)
- Shipping List
- Welding Schedules
-ERECTION DRAWINGS
-OPERATION & MAINTENANCE MANUALS
COMMONLY REFERRED STANDARDS
Std. No. Title For
ASME Sec.I Power Boilers Pressure Parts
ASME Sec.II Matl. Specification Pressure Parts

(Part-D)
IBR 1950 Indian Boiler Regulation Pressure Parts
ASME B31.1 Power Piping Pressure Parts
IS 800 Code of Practice for General Structures

Construction in Steel Duct & Dampers
IS 875 Code of Practice for Design loads for Structures &

building & structures Duct & Dampers
Criteria for Earth Quake resistant Structures
IS 1893 design of structures Duct & Dampers
NFPA 85 Standard for pulverised Fuel System Fuel Systems

Computer Aided Engineering and Analysis
In-house
Bought-out: • IBP – Integrated boiler program
▪ ANSYS – Stress • NAPH – New Airheater program
Analysis • MTP – Metal Temperature program
▪ Caepipe – Piping • BSAS- Boiler efficiency calculation
Analysis
▪ StaadPro – Structural
Analysis • SCAD – Structural Detailing
& Detailing
▪ Phoenix – CFD
• OPTIPLUS-Column optimisation
▪ AutoCAD for Drafting • CEILPRO- Ceiling Girder
• BUCKSTAY

RAW MATERIALS VENDOR ITEMS

SPRAY CONTROL VALVE
TRIP VALVES
DRUM PLATE FLAMES SCANNERS
IMPORTED
PLATE > 63mm CIRCULATING PUMPS
HANDLING EQUIPMENTS
HEADER PLATE INDG. &
CABLES
TUBES & PIPES IMPORTED CONTROL PANELS
DUCT PLATE - INDG. PRESS./TEMPERATURE

TRANSMITTERS
CCTV
ELEVATOR
Weldability
Service Condition:
550 Deg C: 250 bars
Pipe ID: 300 mm
Martensitic Ferritic
P 22 X 20 P 91
55 % wt 11 % wt
Reduction Reduction

Producibility

INSPECTABILITY
700
HEADER
MAGNETIC PRODS
CLOSE
PITCH
SPACE NOT
SUFFICIENT FOR
KEEPING MAGNETIC
PRODS FOR MPI OF
WELDING

TRANSPORTABILITY
(Prior Clearance from Railways reqd.)

ERECTABILITY
(>100T)
Hybrid Ceiling girder within the lifting capacity of Cranes

PRODUCT ENGINEERING / FOSSIL BOILER
LAYOUT & GENL. ARRANGEMENT

PRESSURE PART ARRANGEMENT
DRUM AND WATER WALLS
SUPERHEATER, REHEATER & ECO.
BOILER MOUNTINGS
FUEL SYSTEMS (Coal, Oil & Gas)
DUCTS AND DAMPERS
SUPPORTING STRUCTURES
LINING & INSULATION
SUPPORT SERVICES
-Product Engineering Services
-CAD Centre
-Archives, Standards & Library
-O&M Manual
-Engineering Quality Coordination
-Value Engineering & Trg. Coordination
LAYOUTS

FRONT MILL ARRGT.

KEY PLAN OF FRONT MILL ARRGT

REAR MILL LAYOUT-PANIPAT

KEY PLAN OF REAR MILL LAYOUT

KEY PLAN OF SIDE MILL LAYOUT

Bench Marking - Boiler Layout
NEI / UK MHI/ Japan BHEL

BHEL modified
Rihand Anpara practice
No.of Columns 42 42 53 42
Use of Long From Talcher

Yes No No
span floor grills onwards
Optimised From Rihand

Yes Yes No
Boiler Roof onwards

Boiler Structures

2D Structure vs 3D Structure
2D PLANE FRAMES 3D SPACE FRAME

BEFORE AFTER
Optimization of boiler structures

Through 3D analysis
Capacity of Weight Direct
boiler reduction of Saving in
Columns per Rs.Lakhs
boiler in (Material
tonnes cost)
500 MW 671 119
Boiler ( 27% )
250 MW 361 64
Boiler ( 26% )
Implementation:
500 MW boilers: Talcher 4 Units,Rihand 2 Units, Ramagundam 1 Unit
250 MW boilers: Panipat 2 Units
All current & future Boilers of all capacities

Engg. Automation
An expert system for optimised Design

of welded Plus-I column for boiler
supporting structure after >1000
iterations. Implemented in Rihand /
Ramagundam 500 MW. Savings Rs.109
Lakhs (200Tons)per 500 MW Boiler

Location of flap
damper

Engg. Automation
Automation of Gates/Dampers
detailing thro’ 3D Solid modelling
Reduction in Engineering Cycle time
From 250 To 60 man days.
Error free Engineering Drawings.
Enhanced product visualisation.

Existing:-
Pneumatic
operated Hot Air
Gate at mill inlet
Improvement
proposed:-
Pneumatic
operated FLAP
TYPE DAMPER
Benefits:-
Location of flap
damper
• Pressure assisted seal hence better leak tightness in high pressure applications
• Space for super structure is not needed resulting in compact and aesthetic layout
around Mill Bay.
• Quick closing due to rotational movement (90 deg.) of flap from open to close.
FEED BACK IMPLEMENTATION OF NON METALLIC

EXPANSION JOINTS FAILURE ANALYSIS
PTFE SEALING ELASTOMER COATED GLASS FABRIC
LAYER OUTER LAYER SUPPORT LAYER
CAVITY
PILLOW
GLASS FABRIC
BOLSTER
DUCT S.S WIREMESH
FABRIC DETAILS FOR N.M.E.J
Location of flap
ORIGINAL
damper SUPPLIED MATERIAL (AT SIMHATRI): – SILICON COATED GLASS
FABRIC OUTER LAYER
BETTER MATERIAL IMPLEMENTED FLOURO PLASTIC/ FLOURO
( FROM TALCHER ONWARDS):- ELASTOMER COATED
GLASS FABRIC

Pressure Parts

Pr.Part arrgt of
Typical 210/250
MW boiler

CODES / REGULATIONS
BOILERS PRESSURE IBR-1950
PARTS DESIGN
MATERIAL ASTM STANDARDS

MANUFACTURE / ERECTION IBR - 1950
DRUM SA 299
HEADER SA 106 Gr.C
WATER WALL PANEL SA 210 Gr.C
ECONOMISER COIL SA 210 Gr.A1
SUPERHEATER COIL SA 213 T11; SA 213 T22;
SA TP 347H
DUCT CARBON STEEL
STRUCTURES IS 2062, A36

SKID ASSY FOR SH\RH SPRAY CONTROL STATION
ADVANTAGES
❖ ERECTION EASINESS
Outlet ❖ CYCLE TIME EDUCTION
Inlet

FUEL SYSTEMS

FUELS Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Fuels
SOLIDS LIQUIDS GAS
COAL HSD LCV
Anthracite LSD Producer gas
Bituminous LSHS Blast Furnace Gas
Lignite Vacuum Residue Pyrolysis Gas
Refinery Process wastes Corex Gas
BIO-MASS Black liqour Refinery Lean Gas
Bagasse Natural Gas

Peanut Shell LPG
Paddy Husks Coal gas
Coffee Bean
Wood Chips
Barks
Wood
Petcoke
Municipal Refuse
Used Tyres
BURNERS:
Burners undertake the task of delivering coal and

air in a proper proportion, facilitate ignition energy
to the coal air stream, sustain the ignition and
provide a stable flame during the operation,
complete the task of combustion and delivering
heat to the intended purpose.
Burners are broadly classified as follows:
(1) Tangential Burners
(2) Wall Burners
(3) Down shot or fan tail burners



Engg. Automation
Computer aided engineering of
coal piping (CAE-COPS)-
implemented.
Detailed Drgs. Generation time
reduced from 320 to just 2hrs
For the First time ,using PDS-P&ID, the Scheme and Valve Schedule
of Steam & Water Circuit and Fuel System have been completed.
Implemented in Kahalgaon, Bellary, Unchahar and in Sipat
Contracts.


Skid mounted Oil Control Station
HFO + LFO OIL BURNER FITTINGS

SKID MOUNTED OIL CONTROL STATION
OLD - 2150 components sent as 43 Dus.

NEW - 20 assemblies sent as 2 Dus.

Retrofitting of Gravimetric Feeder
• To overcome the chocking problems

Experienced in Rotary Feeder
• Accurate measure of coal fed to boiler.
• Better boiler controllability
upon load variation.

Larger Access Door in Pent House

Before After
8 Doors of Size 610x610 7 Doors of Size 610x610

Plus
one Door of Size 900x1800

OBSERVATION DOOR
Existing New (Under dev.)

Technology Initiatives
➢ FEM analysis of thick walled components
➢ Computational Fluid Dynamics of

- Flow distribution in Elbow ducts, Duct before ESP
- Flow distribution in coal nozzles
- Steam & water distribution in various circuits
- Air & Gas & Fuel piping systems
- Air distribution in wind box and air compartments
- Lower furnace / upper furnace & Back pass
➢ Electronic submission of Engg.Drgs & obtaining appl.
➢ 3D Plant Modelling
➢ e-Vault introduction
Electronic Submission of Drgs. For Approval
Submission
Appl.
Documents
Attributes
BHEL Customers
3D Plant Model of a Boiler
Situation earlier
Boiler visualized
With 2D Drawings
Situation Now
Comprehensive 3D
model of Boiler with
Better Visualization
Knowledge Management Architecture

Database System to generate
System to Store, Retrieve, and store contractual engg
View and Print drawings information,
prepared in paper and Built-in business rules like
digital media with workflow Drawing Revision control,
automation. Engineering
Management Provision to re-use previously
INSTANT ACCESS TO ALL Data
generated information
DRAWINGS Management
Design
Web-enabled Guidelines & Provision to store and
Mechanical Standards, Technical Project retrieve information
Web-enabled
Design work-outs, Standards Information (Old O&M manuals,
Intelligent templates KBE Design data, IBR
docs) of completed
contracts prepared in
e-Vault hardcopy & digital
(Doc Mgmt) formats
3D Plant modeling Engineering
Design
3D Solid modeling Automation Document System to Index,
Processes Store, Search & Retrieve
2D drawing generation engineering information
instantly
Engineering Design &
Analysis
Other Units, Sites, Customers

IT Initiatives
Installed PDMS, STRUCAD
Design guidelines for Pr.Parts,

Fuel Systems & Ducts
e-Vault
In-house developed comprehensive
DWG
Electronic filing system The system is
DOC
.XLS
capable of handling digital documents
.PPT and hardcopy content. outcome of the
.PDF
system is the release of more working
.HTM
… space in disks for network users.

Integration of Systems & Resources
❑ On-line viewing of Drg. images (in PDF)

facilitated through creation of Drg.Vault.
❑ Network Enhancement (Server, 150 PCs,

Printers, UPS, Other Hardware & Software)
installed in a record time.
❑ Extending our Systems to other Product

Groups (IPP,Nuclear,FES,C&I)
❑ O&M in Compact Discs
❑ Migration to Oracle – GMS System

CONVENTIONAL O&M MANUAL IN

O&M MANUALS COMPACT DISC
First digital
O&M manual given
For
Shamanur sugars

PATENTS
Dual Belt Gravimetric feeder
Flexible Fuel Pipe Joint
Multi-fuel firing bed

( BHEL-Stoker)
Fibre fuel distributor

(Bagasse distributor)
Fossil fuel injector

(Coal spreader)
Multi-fuel burner

Customer’s Appreciation

TECHNICAL PAPERS
➢ On Control valves for the International Conference.
➢ Reliability Exercise on 250 MW Boiler completed and vetted by Centre

For Reliability.
➢ 'Automated conversion of AutoCAD DWG Files to PDF Format'

presented in the BHEL-Autodesk Conference held at BHEL, Bhopal.
➢ Under the auspices 4th CAE meet held at Bhopal on 19th & 20th
Nov.2003 Papers presented on "Overview of Engg. automation &
Cycle time reduction" Following Technical papers were presented
by our Engineers.
- Software for automated generation of Ceiling girders“

- OPTIPLUS software for optimised selection of boiler columns“
- 3d dynamic analysis of boiler structure using advanced softwares"
- Automation of bottom supported Duct Sections" and
- Automation of Elbow duct detailing
and got the appreciation of the audience.

Future Technology Strategies

❖ Once through Super Critical Boilers
❖ Dev. of 275 MW boiler design on cost per MW basis
❖ Dev. of 300 MW/350 MW, 170 ata pressure boiler for
studying the economics
❖ Dev. of 1300 TPD, Single drum, Chemical recovery
Boiler meet market requirements.
❖ Low Nox Burners-Wall Firing System
❖ Crude Oil Firing System
❖ Gas Pressurisation & filteration System
❖ Gas Flaring System
❖ Higher Size gates & Dampers
❖ Truss type ceiling girders
❖ Rotary Gravimetric feeder
Technology Area
Boiler for Super Critical Parameters-660MW
❖ Medium Term Plan

JOINT WORKING with Suitable Technology cum
Business partners on Project to Project Basis
❖ Long Term Plan

Technical Collaboration (TCA) as a parallel action
from X Plan (2002-2007) Period
❖ Current year approach

Joint working with Alstom USA for the Initial
Super critical projects of NTPC
Action for TCA with Alstom USA started by Corp.Office
Technology Area
Higher Capacity Boilers [800-1000MW] with
Super Critical Parameters as per CEA .
❖ Medium Term Plan
In house R&D-Tie up with External Consultant for vetting
stagewise development
❖ Long Term Plan
- Cover under the likely TCA to be signed
or
Joint research and funding with Technology (TCA)
partner for putting up Model Power Station
❖ Current year approach
MOU with IITM Chennai likely to be used for
Joint working on Stage wise development
800 MW Design Dev. Schedule is drawn to start with.
Possible to extend to 1000MW

Boiler Intro

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Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

TOTAL 4600 10600 26500

Product Group Main Assy 200 350 500

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

System Design Mechanical Arrgt. &

Mechanical detailed design for Manufacturing

DISTRIBUTE IDENTIFY FINALISE FINALISE

LIST OF OBTAIN FINALISE FINALISE FINALISE FINALISE

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

PRODUCIBILITY PGMA SUB-DELY. MATL. FORECAST

FINALISE FINALISE REL. DOC. FOR STRESS ANALYSIS

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

SH / RH Headers Steam Cooled Walls

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

ERECTION SCHEDULE FOR 210/250 MW BOILER

Zero Supply Drum Matls for Matls for Supply

Events at site Ern. Drum Hyd Light Syn HO

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

CONTRACT PHASE TRANSMITTALS

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

ASME Sec.I Power Boilers Pressure Parts

ASME Sec.II Matl. Specification Pressure Parts

IBR 1950 Indian Boiler Regulation Pressure Parts

ASME B31.1 Power Piping Pressure Parts

IS 800 Code of Practice for General Structures

IS 875 Code of Practice for Design loads for Structures &

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Computer Aided Engineering and Analysis

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

RAW MATERIALS VENDOR ITEMS

DUCT PLATE - INDG. PRESS./TEMPERATURE

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Hybrid Ceiling girder within the lifting capacity of Cranes

PRODUCT ENGINEERING / FOSSIL BOILER

LAYOUT & GENL. ARRANGEMENT

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

FRONT MILL ARRGT.

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

KEY PLAN OF FRONT MILL ARRGT

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

REAR MILL LAYOUT-PANIPAT

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

KEY PLAN OF REAR MILL LAYOUT

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

KEY PLAN OF SIDE MILL LAYOUT

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Bench Marking - Boiler Layout

NEI / UK MHI/ Japan BHEL

Use of Long From Talcher

Optimised From Rihand

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

2D PLANE FRAMES 3D SPACE FRAME

Optimization of boiler structures

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

An expert system for optimised Design

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation

Committed to making a better world CII – EXIM Award –Sep.,2004 Presentation