STEAM BOILERS

-6 0 2
& B
0 1
B-6
 General Specifications
 Major Sections & Zones
Key Points
 Operational Overview
 Steam Drum
 Combustion Chamber
 Super Heaters & Desuper Heaters
 General Specifications

► Number of Boilers 2
► Name of Manufacturer STEINMÜLLER
► Type of Boiler Natural Circulation
► Rated/Maximum Capacity 110/120 Tons/Hr
► Mean Steam Temperature 510 °C
► Super Heated Steam Pressure 103 bar
► Feed Water Temperature 110-115 °C
► Fuel Natural Gas
Synthesis Gas
Purge Gas
► Year of Manufacturing 1976
► Year of Commissioning 1980
 Boiler Parts & Sections

STEAM DRUM

BFW INLET

B-602
4 GAS BURNERS

FLUE GAS DUCT B-601

AIR INLET DUCT

SIDE VIEW FRONT VIEW

Major Sections & Zones
Steam Drum

De Super Heating Zone

Super Heating Zone

Combustion Zone
 Boiler: A 3D Tour

Click Here To View in Solid Edge

Operation: Flue Gas Circuit

FLUE GAS
Operation: BFW Circuit
Steam Drum

Economizer
 Operation: BFW to Sat. Steam

Evaporator
Header

Down Comer

Riser Tube
Bends

Riser Header
 Operation: Sat. Steam to KS

SH-III

TOWARDS SH-I
KS HEADER

SH-II
 Complete Flow Diagram
ATTEMP – II SPRAY WATER

M ATTEMP – I SPRAY WATER

ATTEMP - II ATTEMP - I
KS STEAM
SH- III SH- II SH- I

Steam Header 06-TIC-11V 06-TIC-13V

STEAM DRUM

RISERS
RISERS

RISERS
CEILING

ECONOMIZER
CURTAIN

FRONT
WALL

1 2
INTER
CIELING M
3 4
SIDE SIDE
DOWN COMER

WALL BURNERS WALL

DOWN COMER

DOWN COMER
REAR
WALL

06-FIC-7VA 06-FIC-7VB
FLOOR

BOILER FEED
WATER
 Steam Drum
► Diameter: 1.45m
► Wall Thickness: 79mm
► Length: 8.5m
► Material: A302-B (Alloy Steel)
♦ 0.25% C, 1.5% Mn, 0.4 Si, 0.6 % Mo
► Operating Temp & Pressures
♦ ~320oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~325oC & 122Kg/cm2

♦ 3D Steam Drum
 Steam Drum
► Perforated BFW Entry Pipe
► Demister Pad
► 3 Down Comer Pipes
► 82% BFW level maintained
► To convert BFW into saturated steam
► Headers & Riser Tubes

1. Combustion
► 4 Gas Burners

Chamber
 Side Wall Headers
► Header Dia: 220mm
► Header Length: 6.42m
► Tube Dia: 57mm of 4.5mm thick
► No of Tubes: 83
► Height: 11.5m
► Material: A210-A1 (MCS)
♦ Seamless medium carbon steel tubes
♦ 0.27%C, 0.93%Mn, 0.1%Si, 0.03 % S
► Operating Temp & Pressures
♦ 225-320oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~325oC & 122Kg/cm2
 Front Wall Headers
► Header Dia: 220mm
► Header Length: 5.77m
► Tube Dia: 57mm,4.5mm thick
► No of Tubes: 77
► Tube Length: 17.37m
► Material: A210-A1 (MCS)
♦ Seamless medium carbon steel tubes
♦ 0.27%C, 0.93%Mn, 0.1%Si, 0.03 % S
► Operating Temp & Pressures
♦ 225-325oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~375oC & 122Kg/cm2
 Rear Wall Headers
► Header Dia: 220mm
► Header Length: 5.77m
► Tube Dia: 57mm,4.5mm thick
► No of Tubes: 77
► Tube Length: 22.5m
► Material: A210-A1 (MCS)
♦ Seamless medium carbon steel tubes
♦ 0.27%C, 0.93%Mn, 0.1%Si, 0.03 % S
► Operating Temp & Pressures
♦ 225-325oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~325oC & 122Kg/cm2
 Fuel Flow Circuit

► Types of Fuel
♦ Natural Gas
♦ Synthesis Gas
♦ Purge Gas
► 2 Fuel inlets for Burner
♦ Mix(Natural+Syn) Gas Inlet
• Presure:1.5 Kg/Cm2
♦ Purge Gas Inlet
• Pressure:1.5 Kg/Cm2
 Mix Gas Circuit
Br# 1

Br# 2
To Pilot
Br# 3

FT-19 Br# 4
PT-13
NATURAL GAS From 15 LPS-16 Block & Bleed Valves
PCV-1 LPS-15
FT-8A FT-8B
LPS-14
MIXER

SD-9 FRC-8
PT-36 PT-10

SYN GAS From 03 Area

FT-9A FT-9B

SD-10 FRC-9
 Purge Gas Circuit

Br# 1

Br# 2
PT-37 PT-47
PURGE GAS From 05 Area
Br# 3

FT-10A FT-10B Br# 4

To Burner
PT-12
LPS-25 Block & Bleed Valves
LPS-26
LPS-27

SD-11 FRC-10
 Burners
Cylinder for Air Slide

Pilot Air Inlet

Ignition Burner

Flame Detector 1 Flame Detector 2

Purge Gas Inlet Natural Gas Inlet

Pilot Gas Inlet

 Burners

► 4 main burners
► Type:
♦ Pre-Mix Pilot
♦ Post-Mix Main
► No of Nozzles: 6+6
► Air Vanes
 Combustion Air Circuit
► Combustion Air Pressure: ~40mBar
Burner Housing Combustion Chamber

Flue Gas to Stack

TK

Heated Combustion Air Combustion Air MK

Regenerative Air Air Flow Damper AIR BLOWER

Pre-Heater
 Air Slide Drum

Air for Opening Air for Closing

CYLINDER FOR AIR SLIDE DRUM

COMBUSTION AIR

AIR SLIDE DRUM

DRUM SLIDE
Air Flow in Burner
 ► Economizer
► 1st Super Heater
► 2nd Super Heater
► 3rd Super Heater
2. Super Heating Chamber
2. Super Heating Chamber

1st and 2nd Super Heater

 Economizer
► For Pre Heating Boiler Feed Water
► Inlet Header
♦ BFW at 110oc from TP-601
► Outlet Header
♦ BFW at 225oc to Steam Drum
 Economizer

► Header Dia: 152mm

► Header Height: 3.88m
► Tube Dia: 38mm,3.6mm thick
► No of Coils: 61
► Single Tube Length: 82.5m
► Material: A201-A1
♦ Seamless Medium Carbon Steel Tubes
► Operating Temp & Pressures
♦ 120-225oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~325oC & 122Kg/cm2
 1 st Super Heater

► For Super Heating the saturated steam

► Inlet Header
♦ Steam at 320oc from Steam Drum
► Outlet Header
♦ Steam at 420oc to Attemp-I
► 2 different materials
♦ A210-A1: Medium Carbon Steel
♦ A209-T1: Carbon-Moly Alloy Steel
 1 st Super Heater

► Header Dia: 244mm

► Header Height: 3.65m
► Tube Dia: 38mm,3.6mm thick
► No of Coils: 61
► Single Tube Length: 46.7m
► Operating Temp & Pressures
♦ 325-420oC & 110Kg/cm2
► Max Allowable Temp & Pressures
♦ ~426oC & 122Kg/cm2
 2 nd Super Heater

► Inlet Header
♦ Steam at 356oc from Attemp-I
► Outlet Header
♦ Steam at 456oc to Attemp-II
► 3 different materials
♦ A209-T1: Carbon-Moly Alloy Steel
♦ A213-T12: Austenitic Alloy Steel
♦ A213-T22: Austenitic Alloy Steel
 2 nd Super Heater

► Header Dia: 244mm

► Header Height: 3.65m
► Tube Dia: 38mm,max 5.6mm thick
► No of Coils: 61
► Single Tube Length: 25m
► Operating Temp & Pressures
♦ 350-460oC & 109Kg/cm2
► Max Allowable Temp & Pressures
♦ 426-528oC & 122Kg/cm2
 3 rd Super Heater

► Inlet Header
♦ Steam at 435oc from Attemp-II
► Outlet Header
♦ Steam at 505oc to KS Header
► 2 different materials
♦ A213-T12: Austenitic Alloy Steel
♦ A213-T22: Austenitic Alloy Steel
 3 rd Super Heater

► Header Dia: 244mm

► Header Height: 3.65m
► Tube Dia: 38mm,max 5.6mm thick
► No of Coils: 61
► Single Tube Length: 13.6m
► Operating Temp & Pressures
♦ 435-505oC & 105Kg/cm2
► Max Allowable Temp & Pressures
♦ 490-528oC & 122Kg/cm2
► 1st De-Super Heater (Attermperator-I)
► 2nd De-Super Heater (Attemperator-II)

3.De-Super Heating
Chamber
Spray Header
BFW Entry
Inlet
 Attemperator I
► De-Super Heats steam from 420 to 355oc
► BFW spray controlled through 06-TIC-11V
► Diameter: 219mm
► Wall Thickness: 18mm
► Length: 13.7m
► Material: A335-P12
♦ Seamless Ferritic Alloy Steel Pipe
► Operating Temp & Pressures
♦ 420-355oC & 108Kg/cm2
► Max Allowable Temp & Pressures
♦ 426-456oC & 122Kg/cm2
 Attemperator II
► De-Super Heats steam from 455 to 435oc
► BFW spray controlled through 06-TIC-13V
► Diameter: 219mm
► Wall Thickness: 18mm
► Length: 13.7m
► Material: A335-P12
♦ Seamless Ferritic Alloy Steel Pipe
► Operating Temp & Pressures
♦ 455-435oC & 107Kg/cm2
► Max Allowable Temp & Pressures
♦ 490-510oC & 122Kg/cm2
 Conclusion

 General Specifications
 Major Sections & Zones
 Operational Overview
 Steam Drum
 Combustion Chamber
 Super Heaters
 Desuper Heaters
 Q & A Session

THANK YOU