WATER-STEAM CIRCUIT

in
SUPER CRITICAL BOILER

Prepared By: Hareesh VS

Jr.Manager
IOTEP BARH
 BOILER PARAMETERS
Once Through, Single Reheat, Coal Fired, Balanced draft,
Main Boiler Type
Side Fired, Tower type & Symmetrical to Both Axis
Furnace :- 14.9 X 23.04 M
Boiler Area Second Pass :- 6.07 X 23.04 M X 2( Both side of Furnace)
Roof :- 44.35 X 23.04 M
Guarantee Bituminous Coal
Design Fuel LCV :- 3026 kcal/kg
HCV :- 3300 kcal/kg
Material of Construction 12X1MФ and 15X1MФ

Main Steam Flow 2225 T/Hr

Main Steam Pressure 256 Kg/cm2
Main Steam Temp 540 OC
RH Steam Flow 1746 T/Hr
RH Steam Pressure 46.13 Kg/cm2
RH Steam Temp 568 OC
Feed Water Temp 290 OC
Boiler Feed pump
Collecting Header
Economizer
3320C, 299kg/cm2
Suspension Tube

Tubes to furnace
ww first run

Furnace ww 1st Run Steam to steam

heat exchanger Hot
Furnace ww 2st Run suspension

Attemperator 1st
Suspension Tubes
Furnace ww 3rd run
Economizer Upper Block
Horizontal gas duct
ww FRH & HP
Heaters
Hanger tube 1 2900C, 304kg/cm2

Roof ww
Line From Economizer Lower Block Line From BFP
Hanger tube 2 Deaerator
Tubes to furnace
Convection ww ww first run
Steam to steam Boiler Feed Pump
Intermediate Header
heat exchanger

Separator

Platen super heater Inlet Header of Furnace

Stage 1,2,3 & 4 WW First run

Final Super heater Reheat system

HP Turbine IP & LP Turbine Distribution Header of

Furnace WW First run
Recirculation pump

Economizer

Suspension Tube

Tubes to furnace
ww first run

Furnace ww 1st Run

Furnace ww 2st Run

Attemperator 1st

Furnace ww 3rd run

Horizontal gas duct

ww

Hanger tube 1 Furnace WW First Run Collecting Header Furnace

WW first run
Furnace Front & Rear Water Wall
Roof ww
Lower panels And Extreme End
Hanger tube 2 First Run WW Outlet
panels of Side water Wall Lower Headers (Intermediate
Convection ww Headers)
part
Steam to steam
heat exchanger Tubes to Furnace Side Hot Furnace Front & Rear Hot
suspension Lower part suspension Lower part
Separator
Furnace Side Hot
Platen super heater Furnace WW first run panels suspension Lower Part
Stage 1,2,3 & 4

Final Super heater Reheat system Furnace Hot suspension

Lower Part collecting
HP Turbine IP & LP Turbine Header (3770C, 301kg/cm2)
Recirculation pump Side View of Boiler
Economizer

Suspension Tube

Tubes to furnace
ww first run

Furnace ww 1st Run

Furnace ww 2st Run

Attemperator 1st

Furnace ww 3rd run

Horizontal gas duct

ww
Collecting Header Furnace
Hanger tube 1
WW first run
Roof ww

Hanger tube 2 Extreme Panels of Side WW

Convection ww

Steam to steam
heat exchanger Furnace Side Hot
suspension Lower part
Separator
Inlet Header of Furnace Furnace Front & Rear Hot
Platen super heater Second Run suspension Lower Part
Stage 1,2,3 & 4

Final Super heater Reheat system Furnace Hot suspension

Lower Part collecting
HP Turbine IP & LP Turbine Header
Recirculation pump Side View of Boiler
Economizer

Suspension Tube

Tubes to furnace
ww first run Furnace WW Second Run
Furnace ww 1st Run Furnace Side Water walls Lower Part
Furnace ww 2st Run

Attemperator 1st Collecting Headers of Middle

Furnace ww 3rd run
Horizontal gas duct
ww
Part of Hot Suspension
Furnace Hot Suspension
Middle Part
HP Spraying Attemperator-1

Hanger tube 1 Tubes to Furnace Hot

Distribution Header to suspension Middle part
Roof ww Furnace 3rd Run

Hanger tube 2
Mixing Headers of Furnace
Outlet Headers of Furnace
Convection ww Second run WW panels
Second run WW panels
Steam to steam (4010C, 296kg/cm2)
heat exchanger

Separator

Platen super heater Furnace WW second run panels

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

Recirculation pump Side View of Boiler
Economizer

Suspension Tube Furnace WW Third Run

Tubes to furnace All Upper Panels of Furnace Front,
ww first run
Rear & Side Water walls
Furnace ww 1st Run

Furnace ww 2st Run

Attemperator 1st Outlet Headers of Furnace WW

3rd run panels at Horizontal Gas
Furnace ww 3rd run duct Bottom Area (Arch Area) Tubes to Intermediate
(4330C, 291kg/cm2) Headers of 3rd Run WW
Horizontal gas duct
ww
Furnace WW 3rd run panels Distribution Header to
Hanger tube 1
Furnace 3rd Run
Roof ww
Tubes to Inlet Headers of
Inlet Headers Furnace WW 3rd
Hanger tube 2 3rd Run WW
run panels
Convection ww

Steam to steam
heat exchanger

Separator

Platen super heater

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

Recirculation pump

Economizer
Hanger Tube 1
Suspension Tube (4410C, 288kg/cm2)

Tubes to furnace Collecting Header of

ww first run Furnace 3rd Run

Furnace ww 1st Run Horizontal Gas Duct WW

Furnace ww 2st Run Inlet Headers of Horizontal

Attemperator 1st Gas Duct WW

`
Furnace ww 3rd run Intermediate Headers of 3rd
Outlet headers of
Run WW
3rd run panels
Horizontal gas duct
(4430C, 291kg/cm2)
ww
Furnace WW 3rd run panels Inlet Header of Hanger
Hanger tube 1
Tube 1
Roof ww
Tubes to Inlet Headers of
Inlet Headers Furnace WW 3rd
Hanger tube 2 3rd Run WW
run panels
Convection ww

Steam to steam
heat exchanger

Separator

Platen super heater

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

Recirculation pump
Roof WW Inlet Header
Economizer
Roof Water Wall
Suspension Tube

Tubes to furnace Roof Water Wall Collecting

ww first run Header (4480C, 284kg/cm2)

Furnace ww 1st Run Distribution Header of

Hanger Tube 2
Furnace ww 2st Run

Attemperator 1st Hanger Tube 2

`
Furnace ww 3rd run

Horizontal gas duct

ww
Inlet Header of
Hanger tube 1 Hanger tube 2
Roof ww

Hanger tube 2

Convection ww

Steam to steam
heat exchanger

Separator

Platen super heater

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

Recirculation pump Distribution Header Of
Upper Hot suspension
Economizer Convection Shaft &
Furnace Area
Suspension Tube

Tubes to furnace Collecting Header Of

ww first run Hanger Tube-2
(4520C, 281kg/cm2)
Furnace ww 1st Run Tubes to Furnace
Hot Suspension
Furnace ww 2st Run

Attemperator 1st

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Hanger Tube-3

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Furnace ww 3rd run Convection Shaft
Convection Shaft Hot Suspension
Horizontal gas duct
ww Water Walls

Hanger tube 1 Tubes to Convection Hot

Suspension
Distribution Header of
Roof ww
Convection Shaft WW
Tubes to Hot Suspension
Hanger tube 2
Collecting Header
Convection ww

Steam to steam
heat exchanger

Separator

Platen super heater

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

 High Pressure Spray
Recirculation pump Attemperator – 2
(4390C, 273kg/cm2)
Economizer
Wet Steam
Suspension Tube
Separator
Tubes to furnace
ww first run High Pressure Tubes to
Collecting Header of SSHE
Furnace ww 1st Run (4570C, 274kg/cm2)
Furnace ww 2st Run
Drain Header
Attemperator 1st

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Furnace ww 3rd run Moisture Content in
Steam After Separation
Tubes to Steam To Steam Heat
Horizontal gas duct
Exchanger
ww
Collecting Header of
Hanger tube 1 Convection Shaft WWs &
Steam To Steam Heat Hanger Tube – 3
Roof ww Exchanger (4650C, 278kg/cm2)
Hanger tube 2

Convection ww

Steam to steam
heat exchanger

Separator

Platen super heater

Stage 1,2,3 & 4

Final Super heater Reheat system

HP Turbine IP & LP Turbine

Recirculation pump Tubes to Platen Super
Heater
Economizer (4390C, 273kg/cm2)

Suspension Tube Spray Type

Attemperator -3
Tubes to furnace (5110C, 259kg/cm2)
ww first run Tubes to Final
Super Heater
Furnace ww 1st Run (5000C, 258kg/cm2)

Furnace ww 2st Run

Convection Super Heater
Attemperator 1st (Final Super Heater)

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Furnace ww 3rd run Main Steam
Out Let Header
Horizontal gas duct (5400C, 256kg/cm2)
ww
Platen Super Heaters
Hanger tube 1 Stage 1, 2, 3 & 4.

Roof ww
Steam Flow in 4 Stages of
Hanger tube 2 Platen Super Heater

Convection ww Rear

Steam to steam I/L

heat exchanger

Separator

O/L

O/L
Platen super heater
Stage 1,2,3 & 4

Left

Right
Final Super heater Reheat system
I/L
HP Turbine IP & LP Turbine
Front
Recirculation pump

Economizer LP Spray

HRH Line
Atemperator
Suspension Tube
LPR Stage – 2
Tubes to furnace (Final) Collecting Header
ww first run of LPR
Steam to Steam
(4840C, 47kg/cm2)
Heat Exchanger
Furnace ww 1st Run

Main Steam Line to TG(5400C, 256kg/cm2)

CRH Line from
Furnace ww 2st Run HP Turbine

Hot Re Heat Line (5680C, 46kg/cm2)

Attemperator 1st

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Cooled Re Heat Line (2970C, 48kg/cm2)

Furnace ww 3rd run LPR Upper Suspension Tubes

of LPR
Horizontal gas duct LPR Middle
ww
LPR Lower
Hanger tube 1
Tube to Low Pressure
Roof ww Reheater
(4490C, 28kg/cm2)
Hanger tube 2

Convection ww

Steam to steam Generator

IP Turbine
Coupling
HP Turbine
heat exchanger LP Turbine Generator
Cooling Water
Separator Condenser

Platen super heater Hot Water to Cooling Tower

Deaerator
Stage 1,2,3 & 4 LPR Stage - I

Final Super heater LPR Stage - II

Water Line To Boiler Feed Pump
HP Turbine IP & LP Turbine Make Up Water Line From
DM Plant