BOILER PRESSURE

PARTS
THALNOVA POWER THAR LIMITED 1 X 330 MW
 OUTLINE

In this presentation we shall discuss major components of boiler pressure parts, their
placement in the boiler (mechanical arrangement), function and construction.
 BOILER
OVERVIEW
 BOILER PRESSURE PARTS

Parts which are subjected to higher steam and water pressure and temperature are referred to as
boiler pressure parts. Following are considered as Boiler Pressure Parts:

• Economizer
• Steam Drum
• Water walls
• Evaporator
• Superheaters
• Reheaters
• Headers
 ECONOMIZER
• First part where water from feed water line enters.
• Purpose: Preheats water before it enter the steam drum. Recovers
heat from flue gas to reduce heat input in order to increase efficiency.
• Operating Parameters:
- Water Temp 282.5 oC (BMCR)
- Water Pressure 166.7 bar or 16.67 MPa

• 3 assemblies
Elevation 19.6 to 29 m
Assembly weight = 4.4 tons weight (242 Tubes)
Tube Material: SA210C
Header Material: SA106C
Tube thickness: 4.6 mm
Tube Diameter: 38.1 mm
Field Welds: 3404
Electrode Wire to be used: ER70S-6/E7015 (Electrode)
Welding Method: GTAW/SMAW
 ECONOMIZER

• Horizontal tube

• Inline arrangement

• Plain Tube

• Convective type
 STEAM DRUM
• Water enters from the economizer and is sent via the
downcomers to waterwalls for conversion into steam.
• Purpose: Separate steam and water in order to obtain dry steam
free from water droplets. Since all the water is not converted to
steam in single pass.
• The separation of water is done by different components as
shown in Drum Internal Drawing
• Operating Parameters:
- Water Temp: 350 oC (BMCR)
- Water Pressure: 166.7 bar or 16.67 MPa
 STEAM DRUM SPECIFICATIONS

Tube Material: SA299

Drum length: 25.1 m
230 Tons weight (Approx.)
Shell Diameter: 1676 mm (I.D.)
Shell Thickness: 185 mm (approx.)
Field Welds: 100
 WATER WALLS & EVAPORATOR

• Water walls and Evaporator receives water from the steam drum.
Waterwalls are placed around the furnace to protect the casing
from melting and make use of the high furnace temperature.
• Purpose: To convert the feedwater in the drum to saturated steam
or steam.
• Operating Parameters:
- Water Temp: ~ 350 oC (BMCR)
- Water Pressure: 166.7 bar or 16.67 MPa
 WATER WALL SPECIFICATIONS
Tube Material: SA210C
Header Material: SA106C
Tube thickness: 6.1 mm
Tube Diameter: 63.5 mm
Field Welds: 6820
Electrode Wire to be used: ER70S-6/E7015 (Electrode)
Panels Weight = 2 tons to 5.5 tons
 SUPERHEATERS
• Superheating takes place in various structures throughout the
boiler. This is due to the different temperature zones of the flue
gas. Superheating Surfaces are:
• Steam Cooled Cyclone
• Backpass Enclosure
• Low Temperature Superheater (LTSH)
• Finishing Superheater

• Purpose: To heat the saturated steam coming from the steam drum
and increase its temperature. This is necessary to extract the
maximum amount of work and increase plant efficiency.
• The arrangement and materials of different panels of the
superheating section will be discussed in the upcoming slides.
• Operating Parameters:
- Water Temp: 350 oC – 538 oC(BMCR)
- Water Pressure: 166.7 bar or 16.67 MPa
 SUPERHEATER – STEAM COOLED
CYCLONE
• This is the first superheating surface after steam exits the steam drum.
Panels are placed in the barrel and inlet duct.
• Purpose: The purpose of this structure is to separate coarse particles from
ash and return them to the bed. This uses the flue gas to heat the steam
further.

Elevation 29.8 m to 52.5 m

Tube Material: SA213T12
Header Material: SA106C
Tube thickness: 6.1 mm (Duct) and 6.6 mm (Barrel)
Tube Diameter: 38.1 mm (Duct) and 50.8 mm (Barrel)
Field welds: 1642
Panels: 9 (barrel) 8 (cone)
Max panel weight = 2.8 tons Max panel height = 10 m (39 tubes)
Electrode Wire to be used: ER80S-G
Welding Method: GTAW
Pre-weld Treatment: preheated at a temperature of no less than 120 oC.
 SUPERHEATER – BACKPASS ENCLOSURE
• This is the second superheating surface and receives steam from
Cyclone. Panels are placed all around the backpass enclosure just like
waterwalls. It is divided into:
• Front Panel 11
• Rear panel 14
• Roof Panel 14
• Side wall panels 12

• Purpose: The purpose of this structure is to increase the temperature of

the steam further and help reach towards the final temperature of 538
o
C.
Elevation: 31.8 m to 61.8 m
Maximum panel length = 18.2 m – Max. weight = 2.86 tons (24 tubes)
Tube Material: SA210C
Header Material: SA106C
Tube thickness: 7.62 mm (Front/Rear/Roof) and 5.1 mm (Side wall)
Tube Diameter: 50.8 mm (Front/Rear/Roof) and 57.2 mm (Side Wall)
Field Welds: 2080
Electrode Wire to be used: ER70S-6/E7015 (Electrode)
Welding Method: GTAW/SMAW
Pre-weld Treatment (where applicable): to be preheated at a temperature
of no less than 80 oC.
Post Weld Heat Treatment (where applicable): Heated to 595-650 oC and
held at this temperature for 1.5-2 hours.
 SUPERHEATER – LTSH
• This is the third stage of superheating surface and receives steam from
the backpass enclosure.
• Purpose: The purpose of this structure is to increase the temperature of
the steam further and help reach towards the final temperature of 538
o
C.
• Transported as a complete assembly consisting of modules
6.9 tons assembly weight (163 Tubes)
Width 8 m – Length – 21.25 m – Elevation – 41.9 m to 44.6 m
Tube Material: SA213T12
Header Material: SA335P12
Tube thickness: 4.57 mm
Tube Diameter: 50.8 mm
Field Welds: 1296
Electrode Wire to be used: ER80S-G/E8015-B2 (Electrode)
Welding Method: GTAW/SMAW
Pre-weld Treatment (where applicable): to be preheated at a temperature
of no less than 150 oC.
 SUPERHEATER – FINISHING
SUPERHEATER
• This is the final stage of superheating surface and receives steam from the LTSH.
The steam leaving from this surface will enter the turbine. It consists of 2 panels:
• Panel 1 – 13 panels – 27.8 m length – 27.1 m base elevation
• Panel 2 – 16 panels - 27.8 m length – 27.1 m base elevation

• The steam enters the first panel and then the second.
• Purpose: The purpose of this structure is to increase the temperature of the steam
further and help reach towards the final temperature of 538 oC.
Panel 1 weight = 7 tons Panel 2 weight = 6.7 tons
Tube Material: SA213T22 (Panel 1) and SA213TP304H (Panel 2)
Header Material: SA335P12 (Panel 1) and SA335P91 (Panel 2)
Tube thickness: 8.13 mm (Panel 1) and 7.62 (Panel 2)
Tube Diameter: 44.5 mm
Number of joints: 4031
Electrode Wire to be used:
ER90S-G/ER308/ER80S-G/E8015-B2/ER90S-B9/ER9015-B9
Welding Method: GTAW/SMAW
Pre-weld Treatment (where applicable): 150 oC (SA335P12), 120 oC (SA213T12),
200 oC (SA335P91)
Post Weld Heat Treatment (where applicable): 650-705 oC for 1.5 hrs (SA335P12)
and 730-785 oC for 1.5 hrs (SA335P91)
 REHEATER
• Reheating takes place in two zones in the boiler backpass. This is
due to the different temperature zones of the flue gas. The
construction of Reheating panels is the same as the economizer
and is explained the economizer section. Reheating Surfaces are:
• Low Temperature Reheater (LTRH)
• Finishing Reheater

• Purpose: To heat the exhaust steam coming from the HP Turbine

and increase its temperature. This is necessary to extract the
maximum amount of work and increase plant efficiency.
• These surfaces are divided into subparts lower, intermediate and
upper panels. Further arrangement and materials of different
panels of the reheating section will be discussed in the upcoming
slides.
• Operating Parameters:
- Water Temp: ~ 320 oC – 538 oC(BMCR)
- Water Pressure: ~ 40 bar or 4 MPa
 REHEATER – LTRH
• This is the first stage of reheating and receives exhaust steam from
HP Turbine. As it can be seen this reheater is further divided into 3
parts to ensure effective heat transfer and ease of construction
• Purpose: The purpose of this structure is to increase the
temperature of the steam further and help reach towards the final
temperature of 538 oC.
• 3 assemblies
Elevation 33.4 to 41 m – Width 8 m – Length 21.25 m - Height 2 m
Assembly weight = 8 tons weight (162 Tubes)
Tube Material: SA210C (Lower), SA213T12 (Intermediate),
SA213T22 (Upper)
Tube thickness: 4.19 mm
Tube Diameter: 63.5 mm
Field Welds: 2931
Electrode Wire to be used: ER70S-6 (Lower), ER80S-G
(Intermediate), ER90S-G (Upper)
Welding Method: GTAW
 REHEATER – FINISHING REHEATER
• This is the last stage of reheating and receives steam from LTRH
• Purpose: The purpose of this structure is to increase the temperature of
the steam further and help reach towards the final temperature of 538 oC.
• 3 assemblies
Elevation 44.6 to 52 m – Width 8 m – Length 21.25 m - Height 1.3 m
Assembly weight = 4 tons weight (81 Tubes)
Tube Material: SA213T12 (Lower), SA213T22 (Intermediate), SA213T91
(Upper)
Tube thickness: 4.19 mm
Tube Diameter: 63.5 mm
Field Welds: 2931
Electrode Wire to be used: ER80S-G (Lower), ER90S-G (Intermediate),
ER90S-B9 (Upper)
Welding Method: GTAW
Pre-weld Treatment (where applicable): 150 oC (SA213T22), 120 oC
(SA213T12), 200 oC (SA213T91)
Post Weld Heat Treatment (where applicable): 730-785 oC for 1.5 hrs
(SA213T91)
THANK YOU