Boiler Documentation

By:

Dhruv Garg
Engineer/Boiler
PS-TS, BHEL

Boiler Manufacturing Plant

High Pressure Boilers (For 500/250/210/125 MW Ratings) in
BHEL are designed And manufactured at High Pressure
Boiler Plant (HPBP), BHEL Trichy, Tamil Nadu.
Boiler Auxiliaries Like FD, ID, PA Fans, Air Pre-Heaters and
ESP are designed And manufactured At BAP Ranipet.
Coal Mills are designed and manufactured at Heavy Power
Equipment Plant, R.C Puram Hyderabad.

Boiler Documentation
Major documents associated with Erection of boiler:
Applicable PGMA list:
After basic thermal design and layout of boiler is worked out,
Trichy first finalizes the applicable PGMA list vary from project
to project.

PG stands for Product Group.

Identified by a two digits number, ranging from 00 to 99.

Boiler Documentation
Each Product Group identifies a pre-defined area of boiler.
Following are some examples:
04
Steam drum.
05
Headers in circulation system.
06
Water walls of circulation system.
07
Line, links and suspensions of
circulation system.
08
Buck stays.
35
Boiler supporting structure.
36
Boiler platforms and galleries.

Boiler Documentation
Examples (contd)
39
Structure behind main boiler.
48
Ducts.
50
Steam coil air pre-heater.
52
Regenerative air pre-heater.
55,56
Fans
78
ESP
80
Piping
95,96,97
Control and Instrumentations

Boiler Documentation
MA stands for Main Assemblies.
Identified by a three digits number and defines a sub-group
applicable to specific Product Group.
Following are some examples:
04-126
Steam drum.
04-146
Drum suspension.
05-137
Front water wall lower inlet header.
05-147
Rear water wall lower inlet header.
06-631
Front upper water wall panels.
06-634
Front inter water wall panels.
07-215
Side relief tubes.
07-223
Furnace hanger tubes.
08-101
Furnace upper buck stays.

Boiler Documentation

Examples (contd)
08-111
Rear arch buck stays.
35-010
Support structure foundation material.
35-110
Main columns left.
35-210
Ceiling structure fabricated.
39-141
Columns ID fan inlet.
48-012
Duct-FD fan to air heater.
48-022
Duct-FD fan interconnection.
52-011
Rotor post assembly for air pre-heater.
52-041
Hot end connecting plate for air preheater.

Boiler Documentation
The released applicable PGMA list for a boiler presents
following information:
Major PGs applicable to the boiler.
Main sub-assemblies applicable to that product group and
boiler.
Estimation of design weight for every PGMA.
Summed up estimated design weight of a PG.
Summed up estimated weight of complete boiler.

BOILER SHIPPING LIST

Boiler Shipping List

Basic document giving details of style of manufacture and
dispatches for complete boiler components.
Issued for each and every PGMA with title and PGMA
number.
Identified by Boiler job number (a four digits unique
number for a boiler)
Contains a three digit number called as Dispatch Priority
Number (DPN) which indicates the sequence of supply
w.r.t. erection sequence.

Nature of supply as NS-1 (main contractual supply) or NS2 (free of cost supply for some left out or modification area)
or NS-3, 4 etc.

Boiler Shipping List

In various columns in the shipping list sheet, it gives
following information:
DU (Dispatchable Unit) number as three digits number
starting from 001 for each PGMA.
Description of DU.
The drawing number to be referred for that DU. Some
times a star mark is put in this column. It indicates that a
Project drawing should be referred for the details of that
DU.

Boiler Shipping List

Item number in next column relates it to the respective
item number on the bill of material of related drawing.
Next column gives the total quantities of dispatch for that
DU.
Next column gives the weight of total numbers in Kgs.
In right hand bottom corner, the number of sheets used for
that shipping list is also indicated.
At the bottom the summed up total weight of dispatch for
complete PGMA is also indicated in Kgs.
After last DU, each shipping list is marked with -"Shipping
list completed" to ensure total DUs in that shipping list.

BOILER DRAWINGS

Boiler Drawings
Drawings, Schemes and P&ID schemes are released for
every boiler Scheme of water and steam system.
Scheme of fuel system.
Scheme of Air and Flue gas system.
Scheme of piping.
Any other applicable scheme including instrumentation.

Boiler Drawings
A set of Project drawings are released Composite foundation plan and loading data.
General arrangement of Boiler-Elevation and Plan.
Sectional drawings of General arrangement.
Pressure Parts arrangement drawing.
Sectional drawings for pressure part arrangement.
Floor Plans at various levels.
Lay out drawings for Air and Flue gas ducting.
General Assembly(GA) drawings for some equipment like
fans, mills, air pre-heaters etc.
Lay out of Fuel System

How To Read Drawing Numbers

Drawing Number
0-00-022-72045 Rev 00
Size of drawing such as 0,1,2,3 or 4
PG number for which it is applicable, such as 00, 35 or 48
etc.
MA number three digit e.g. 020, 110, 210 etc.
Individual distinctive drawing number in five digits.
Revision number such as 00 or 01 etc.
Each drawing contains all dimensional details, item
numbers and complete Bill of material(BOM) applicable to
that drawing.

OTHER DOCUMENTS
REQUIRED FOR
ERECTION & COMMISSIONING
ACTIVITIES

Other Documents
IBR approved drawings for pressure parts.
IBR provisional certificate to invite Boiler inspector for
ground inspection of pressure part components.
IBR data book along with form IIIC of valves, before
Hydraulic test of boiler.
Thickness calculation sheets for pressure part
components.
Erection Welding Schedule (EWS)
Welding Procedure Specifications (WPS) for various types
of welding joints.
Welding, NDT and Heat treatment manuals.
Field Quality Plans(FQP) for Products / Systems e.g Boiler
structure and Pressure Parts

Other Documents
Electrical and Control Panel arrangement drawings.
Cable Schedules and Termination details.
Hydraulic test procedure.
Commissioning Procedures for specific equipments.
Acid Cleaning procedure.
Steam blowing procedure and scheme.
Safety valve settings procedure.
Operation & Maintenance Manual for specific Equipment
Start up and Unit loading curves.
PG Test Procedure.

BOILER COLUMNS LAYOUT

Boiler Columns Layout

Boiler center line is generally at right angle to the center line
of Steam turbine-generator-Exciter line.
The vertical cavity formed by first four main columns of boiler
support structure (usually named S7L&R, S8L&R, S9L&R and
S10L&R) accommodates the main furnace of boiler. This
cavity referred as First Pass.

The vertical cavity formed by rear columns (S10L&R, S11L&R

and S12L&R) Referred as Second Pass.

REGULAR

ARRANGEMENT OF BOILER COLUMNS FOR RAMAGUNDAM 500 MW

UNIT 7 (53 NO OF COLUMNS)

BOILER
STRUCTURE

DIMEMSIONAL DETAILS OF BOILER COLUMNS FOR

KAHALGOAN 500 MW

BOILER LAYOUTS

LAYOUT CATEGORY
A) LAYOUT FOR GREEN FIELD PROJECTS.
B) LAYOUT FOR EXTENSION OF EXISTING UNITS.

C) LAYOUT FOR ANY RENOVATION & MODERNIZATION

OF EXISTING UNITS

TYPES OF LAYOUT
BASIC BOILER LAYOUT IS DESIGNATED BASED ON THE
LOCATION OF MILLS .
FOLLOWING FOUR TYPES OF LAYOUTS ARE IN USE

FRONT MILL LAYOUT

REAR MILL LAYOUT
SIDE MILL LAYOUT
VIJAYAWADA (SPECIAL) LAYOUT

FRONT MILL LAYOUT

FRONT MILL LAYOUT

REAR MILL LAYOUT (PANIPAT)

REAR MILL LAYOUT

SIDE MILL LAYOUT

VIJAYAWADA MILL LAYOUT

VIJAYAWADA MILL LAYOUT

AIR & FLUE GAS PATH OF

BOILER

SCHEME OF FLUE GAS PATH

FURNACE 1ST
PASS

CHIMNEY

BACK PASS
OR 2ND
PASS

AIR PREHEATER

ID FAN

ESP

SCHEME OF SECONDARY AIR PATH

FORCED
DRAFT
(FD) FAN

TO FURNACE
THROUGH
WINDBOX

SECONDARY
AIR PREHEATER

HOT
SECONDARY
AIR

SCHEME OF PRIMARY AIR PATH

PRIMARY
AIR(PA)
FAN

PRIMARY AIR
PRE-HEATER

TEMPERING (COLD)AIR

HOT PRIMARY AIR

MIXED PRIMARY AIR

RAW
COAL

FEEDER

MILLS
PULVERISED COAL
WITH AIR
FURNACE

FLOW DIAGRAM OF AIR & FLUE GAS

PATH
FLUE GAS FROM ECONOMISER

HOT SEC. AIR TO WIND BOX

HOT PA TO MILLS

AIR HEATER

FD FAN

PA FAN
FLUE GAS TO ESP

DUCTS

DUCTS & DAMPERS

DUCTS

Duct is a closed path for the flow of cold air , hot air
and gases from one point to another point in a
system . This can be of any shape like Circular ,Elbow
, Straight , Square, Rectangular or some other shape.
There are eleven duct systems in Boiler :
1 . Cold air duct - FD fan to air heater.
- PA fan to air heater.
2 . Tempering Air system .

DUCTS :
HOT HOT
AIRAIR
DUCTS
*

Hot air To Wind box

Hot air To Bus duct

Hot air to Mills

GAS DUCTS :
GAS DUCTS

Gas To Economizer

Gas To Boiler Outlet

Gas To Electro statics precipitator

Gas To ID Fan

Gas To Chimney

COLD AIR DUCT FROM

FD FAN TO SECONDARY
AIR HEATER

HOT SECONDARY AIR

DUCT FROM SAPH TO
FURNACE WINDBOX

TEMPERING AIR DUCTING (COLD PA)

Hot Primary Air duct from

PAPH to Mills &
Tempering Air Duct to Mills

FLUE GAS DUCT FROM

ECONOMISER TO AIR PREHEATER

AIR PRE- HEATERS TO

BOILER OUTLET FLANGE (BOF)

BOF TO AIR HEATERS

FLUE GAS DUCT FROM BOF
TO ESP PASS

FLUE GAS
DUCT FROM
ESP to ID FAN

FLUE GAS DUCT

FROM ID FAN TO
CHIMNEY

Raichur -7, 210 MW Top View

Duct Modules
Straight duct

Elbow duct

Circular to
Rectangular duct

Transition duct

Bend duct

T duct

Y duct

FLUE
GAS
OUT

3D VIEW OF TUBULAR
AIRPREHEATERS WITH
DUCTS
COLD
AIR IN

AH-I

FLUE
GAS IN
AH-II

ELBOW DUCT

AH-III
HOT AIR
OUT

TRANSITION
DUCT

SUPPORTS & RESTRAINTS OF

DUCTS

Anatomy of a simple straight duct

STIFFENER

DUCT
PLATE

CORNER
ANGLE

FLANGE

DUCT WITH
INTERNAL
TRUSS

Anatomy of a simple straight duct

SUPPORT

CORNER
ANGLE

GUSSET
PLATE

STRUT TUBE WELD

RESTRAINT

BASE PLATE
WITH (BEARING)

SUPPORT

FLOW METER

EXPANSION JT

HOT SECONDARY AIR DUCT

TOP SUPPORT WITH

HANGER AND LUG PLATE

RESTRAINT SUPPORT

DUCT WITH BOTTOM SUPPORT

FLANGE WITH
FITUP HOLES

SUPPORT

I-BEAM
SUPPORT

TOP PLATE

BEARING PLATE

BASE PLATE

BOTTOM SUPPORT WITH BASE PLATE

AND BEARING PLATE

BOTTOM SUPPORT WITH STOPPERS

TOP PLATE

BEARING PLATE
BASE PLATE
WITH STOPPER

EXPANSION JOINTS

EXPANSION JOINTS
Takes care of Axial & Lateral Expansion in Ducts.
Also Takes care of slight misalignment between two
duct pieces.
Used in Hot Air Ducts, Flue Gas Ducts, Ducts
connecting with wind box, furnace and Boiler
Auxiliaries.
Expansion Joints always work in compression mode
rather than in tension mode

EXPANSION JOINT
ASSEMBLED IN DUCT

Expansion Movement in Duct

CL of support

C L of support

Lateral movement to Toggle

Movement
of duct

Axial movement

Movement
of A.H.

Axial movement

AIR PREHEATER

TYPES OF EXPANSION JOINTS

Metallic Expansion Joints (MEJ)

Non- Metallic Expansion Joints (NMEJ)

METALLIC EXPANSION JOINT

NON-METALLIC EXPANSION JOINT

(Circular Shape)

PTFE SEALING
LAYER

ELASTOMER COATED
OUTER LAYER (silitex)

GLASS FABRIC
SUPPORT LAYER

CAVITY
PILLOW
BOLSTER

DUCT

GLASS FABRIC

S.S WIREMESH

FABRIC DETAILS FOR N.M.E.J

GATES

GUILLOTINE GATES
Guillotine gates are used in
boilers for isolation of any
duct, system or equipment by
restricting the flow of air or
flue gas during running of
boiler.

Gates are 100 % leak tight in

full close condition.

100% Leak tightness for Gates

The seal air is admitted inside the
seal air chamber with a pressure of
125 mm WC more than the system
pressure.

P2>P1&P3

PLENUM DUCT

BLOWER

TESTING TUBE
FLOW

P1

P2

P3

DAMPERS

DAMPERS
Dampers are used in the ducts to control flow of air or
flue gas in the Boiler system.
Types of Dampers used in the Power Plants:
1. Louver Damper
2. Bi-plane Damper
3. Flap Damper

LOUVER DAMPER
This damper is used in two way ducts and provides only
single plane sealing in the system.
This damper is only 95 % leak tight in full close
condition.

BI-PLANE DAMPER
This damper is also used in two way ducts and provides
double plane sealing in the system.
This is considered as 99 % leak tight in full close
condition.
Used in Secondary Air Damper etc.

BIPLANE DAMPERS

FLAP DAMPER
This damper is used in three way ducts.
This damper is 100 % leak tight in full close condition
and can replace Gates due to easy operation.
Used in Economizer Bypass ducts, mill hot air ducts etc.

FLAP DAMPER
ACTUATOR

GEAR BOX

SEAL AIR FAN

CASING
BLADE

FLAP DAMPER WORKING

ACTUATOR

FLOW-IN

DUCT
FLAP WITH
TOGGLELEVER