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 (cont’d…)
 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 (cont’d…)
 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 pre-
heater.
 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 NS-
2 (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 BACK PASS AIR PRE-

PASS OR 2ND HEATER
PASS

CHIMNEY ID FAN ESP

SCHEME OF SECONDARY AIR PATH

FORCED SECONDARY
DRAFT AIR PRE-
(FD) FAN HEATER

TO FURNACE HOT
THROUGH SECONDARY
WINDBOX AIR
 SCHEME OF PRIMARY AIR PATH

PRIMARY PRIMARY AIR

AIR(PA) PRE-HEATER
FAN

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 .
HOT HOT
AIRAIR
DUCTS
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 PRE-
HEATER
 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
Circular to
Transition duct Y duct
Straight duct Rectangular duct

Elbow duct Bend duct

T duct
 FLUE
3D VIEW OF TUBULAR GAS
OUT
AIRPREHEATERS WITH
DUCTS

COLD
AH-I
AIR IN

FLUE
GAS IN

AH-II ELBOW DUCT

AH-III
HOT AIR TRANSITION
OUT DUCT
SUPPORTS & RESTRAINTS OF
DUCTS
 Anatomy of a simple straight duct

STIFFENER

DUCT WITH
INTERNAL
TRUSS
DUCT
PLATE

CORNER
ANGLE

FLANGE
Anatomy of a simple straight duct

SUPPORT
CORNER GUSSET
ANGLE 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
Movement
Lateral movement to Toggle of duct

Axial movement

Movement
of A.H.

AIR PRE-
Axial movement HEATER
 TYPES OF EXPANSION JOINTS

1 Metallic Expansion Joints (MEJ)

2 Non- Metallic Expansion Joints (NMEJ)

METALLIC EXPANSION JOINT
NON-METALLIC EXPANSION JOINT
(Circular Shape)
PTFE SEALING ELASTOMER COATED GLASS FABRIC
LAYER OUTER LAYER (silitex) SUPPORT LAYER

CAVITY
PILLOW
GLASS FABRIC
BOLSTER

DUCT 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

P3
P1 P2
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
TOGGLE-
LEVER