basic of boiler

COURSE BB--11

CONTENTS Basics of BoilerBasics of Boiler

MITSUBISHI HEAVY INDUSTRIES, LTD.MITSUBISHI HEAVY INDUSTRIES, LTD.

TRAINER: Yuki Yoshikawa

PAITON PAITON EXPANSION PROJECTEXPANSION PROJECT

BB--11 Basics OF BOILER PAGEBasics OF BOILER PAGE-- 22

MHI BUSINESSCONFIDENTIAL

Upon completion of the lesson, the trainee will be able to describe the features and design considerations for Paiton boiler.

Instructor Guide Material Objectives

General Objective:



Outline

nn SummarySummary

nn Design of Design of PaitonPaiton BoilerBoiler Combustion SystemsCombustion Systems Vertical Water WallVertical Water Wall Pressure PartsPressure Parts Boiler Expansion SystemsBoiler Expansion Systems Air and Gas SystemsAir and Gas Systems

nn Basics of BoilerBasics of Boilernn Feature of Feature of PaitonPaiton BoilerBoiler

Major SpecificationMajor Specification Coal PropertyCoal Property Design for SubDesign for Sub--bituminous Coalbituminous Coal

nn OperationOperation



Outline

nn SummarySummary







PurposePurpose ::

Condenser

Feed Water

High PressureHigh TemperatureSteam

Exhaust Steam

To generate high pressure and high temperature steamTo generate high pressure and high temperature steamto operate steam turbineto operate steam turbine

TURBINE

Boiler=

SteamGenerator

Make-up Water

Typical Relation

Basics of Boiler



CombustionReaction

Water

Fuel

Air

Steam

Flue Gas

Input Materials Output Materials

Fuel energy

Process of Steam Generation

Basics of Boiler

Heat transfer



Wat

er

Fuel

Air

Com

bust

ion

Flue Gas

Furn

ace

Supe

rhea

ter

Econ

omiz

er

Air

heat

er

Reh

eate

rSt

eam

Typical Scheme of Boiler System

Basics of Boiler



SuperheatedSteam

Saturated Steam

Heated by fuel combustion

Water wallSH

Superheated Steam

Basics of Boiler

Water

SteamSteamturbineturbine



Compressed WaterCompressed Water

Pres

sure

(MPa

(g))

Superheated SteamSuperheated Steam

Temperature ()

Water boils at 100Water boils at 100 in thein theatmosphere.atmosphere.

Saturation Pressure and Temperature

0 100 200 300 4000

10

20

Basics of Boiler

BoundaryBoundary= Saturation= Saturation



Pressure and Enthalpy Chart

Pressure (MPa)

Enth

alpy

(kca

l/kg)

0

200

400

600

800

1000

0 10 20 30 40

Water

600

500

400

300200

SaturationSaturation(Steam/Water)(Steam/Water)

Basics of Boiler

Critical pressure22.1 MPa

Supercritical



Pressure (MPa)

Enth

alpy

(kca

l/kg)

0

200

400

600

800

1000

0 10 20 30 40

Water

600

500

400

300

200

Basics of Boiler

Supercritical Sliding Pressure Operation

SaturationSaturation(Water/Steam)(Water/Steam)

35% 50% 75% BMCREco. Inlet

Economizer

Water Wall

Superheater

100%

SH Outlet

W.W Inlet

W.W Outlet



Comparison of Drum Type Boiler and Once-through Boiler

to Steam TurbineSH

Furnace Eco

SteamDrum

BFPBCP

SH

Furnace

Eco

WaterSeparator

BFP

to Steam Turbine

Basics of Boiler

Higher Grade(Higher steam condition)BaseTube Material

Less(Better plant heat rate)Base

Environmental Impact

Approx. 3% Better (Higher Steam Condition)Base

Plant Heat Rate(Required heat input per 1kW )

Better(Less Heat Capacity)BaseLoad Change Rate

System Schematic

SupercriticalSub-criticalOperating Press.Once-Through boilerDrum type boilerBoiler Type



Comparison of Drum Type Boiler and Once-through BoilerTube Materials of Pressure Parts

Furnace

SA-213T91 9Cr

ASME Code Case 21992.25Cr

SA-213T22 2Cr

ASME Code Case 2328-118Cr

SA-213T12 1Cr

SA-210C Carbon Steel

2ryRH

1ry RH

3ry SH

2ry SH

1ry SHEcoMaterialMaterial

Pressure Parts

Paiton (One-through Boiler)



3ry SH2ry SH

Panel

Inlet Stub

Outlet Stub

Inlet Stub

Stainless Steel

Alloy Steel ASME Code Case 2199 2.25Cr

SA-213TP347H18Cr

SA-213T91 9Cr

SA-213T22 2Cr

ASME Code Case 2328-1 (18Cr

SA-213T12 1Cr

Outlet StubPanel

MaterialMaterial

T Plant (Drum Type Boiler) Paiton (One-through Boiler)Tube Materials of Pressure Parts

Comparison of Drum Type Boiler and Once-through Boiler

Basics of Boiler



Supercritical Sliding Pressure Operation Boilers in Japan

Soma Joint EPCO. Shinchi P/S (1995)1,000MW 24.1MPa538/566

Tohoku EPCO. Haramachi P/S (1997)1,000MW 24.5MPa566/593

Tokyo EPCO. Hirono P/S (2004)600MW 24.5MPa600/600

Chubu EPCO. Hekinan P/S (1991)700MW 24.1MPa538/566

Vertical Water Wall

Kobe steel IPP Kobe P/S (2002)700MW 24.1MPa538/566

Chugoku EPCO. Misumi P/S (1998)1,000MW 24.5MPa600/600

Kyushu EPCO. Matsuura P/S (1989)700MW 24.1MPa538/566

Kansai EPCO. Maizuru P/S (2004)900MW 24.5MPa595/595

Basics of Boiler



Global Supply Record for Vertical Water Wall BoilerNo.1 Share / 5 countries /

32,896MW / 45units

Since 1989,As of September 2010

( ): COD

SC : SupercriticalUSC : Ultra-Supercritical

Chugoku EPCO Misumi #1101000MW 24.5MPa600/600 (1998),and other 9 units for other customers

Japan 10 unitsChina 32 units (by Licensee)

Jaypee Nigrie #1, #2700MW 24.5MPa566/593 (2011),

and other 9 units for other customers

Paiton856MW 24.1MPa538/566 (2012)

Indonesia 1 unit

CFE Pacifico #1700MW 24.2MPa538/566 (2010)

Mexico 1 unitIndia 11 units

(by L&T-MHI Boiler Pvt. Ltd. as Joint Venture)

Henung Yuhuan #1 to #41001000MW 26.4MPa600/600 (2006),

and other 28 units for other customers

Basics of Boiler



Availability of Supercritical Sliding Pressure Operation Boiler (Vertical Water Wall)

Reliability (%) = (Calendar date hours(h)- forced outage hours (h)) / (Calendar date hours(h))

0%

20%

40%

60%

80%

100%A

vaila

bilit

yA

vaila

bilit

y

MisuMisumimi1,000MW1,000MW

HaramachiHaramachi1,000MW1,000MW

ShinchiShinchi1,000MW1,000MW

MatsuuraMatsuura700MW700MW

Basics of Boiler



Outline

nn SummarySummary







4.66Gcal/m2hFuel Heat Input (*1) / Plan Area

421.65m2Plan Area

29,414mmWidth55,149mmHeight

21,369m3Volume

0.089Gcal/m3hFuel Heat Input (*2) / Volume

14,335mmDepth

Furnace

25.78MPa(g)SH OutletPressure

4.85MPa(g)RH Outlet

542SH OutletTemperature

568RH Outlet

2,695t/hSteam Flow815MWNet Power Output

PaitonUnit

Major Specification

(*1)Include combustion air sensible heat and H2,H2O latent heat (HHV)

(*2)Exclude combustion air sensible heat and H2,H2O latent heat (HHV)

Feature of Paiton Boiler



Material and Design Code

MHI StandardJIS or EquivalentNon Pressure Parts

ASME Pressure Vessel Code Section

ASME Pressure Vessel Code Section ,ASME Code Case

Pressure Parts

DesignMaterial


ASME Pressure Vessel Code Section NFPA Code 85B, D E

Design for Implosion, Explosion



Outline

nn SummarySummary







ASTM* Coal Rank (*American Society for Testing and Materials)

40

60

80

100

16000Gross Calorific Value Moist Mineral Matter Free(BTU/Lb)

Dry

Min

eral

-Mat

ter F

ree

Fixe

d C

arbo

n (%

)

BituminousBituminous LigniteLigniteSubSub--BituminousBituminous

MahakamMelawan

50

70

90

3060008000100001200014000

AnthraciteAnthracite

Pasir Roto South

Loa jananEnviro

Pasir Roto North


Coals for PaitonProject are classified into Sub-Bituminous coal.

Performancecoal



40

60

80

100

37200Gross Calorific Value Moist Mineral Matter Free (kJ/kg)

Dry

Min

eral

-Mat

ter F

ree

Fixe

d C

arbo

n (%

)

BituminousBituminous LigniteLigniteSubSub--BituminousBituminous

MahakamMelawan

50

70

90

301400018600233002790032600

AnthraciteAnthracite

Pasir Roto South

Loa jananEnviro

Pasir Roto North


ASTM* Coal Rank (*American Society for Testing and Materials)

Coals for PaitonProject are classified into Sub-Bituminous coal.

Performancecoal



Sub-bituminous coal (Paiton)

Bituminous coal

5.22.51.72547

0.961.05.20.80.25.210.120

0.84120041

16.70.96

PerformanceCoal

35201018402.51.8354.03.0352.0150.5120020182.5

Range Design CoalRange

UnitItem

AS: As ReceivedAD: Air Dry Base

DB: Dry BaseDSF: Dry Ash Free

1.95.3kg/106kcalAsh Loading1.13.8kg/106kcalAl2O3SiO2 (DB)0.72.5kg/106kcalQuartz(SiO2) (DB)Erosion

Characteristic

2132%Total Moisture (AR)4353HGICoal Fineness

0.861.07Fuel Ratio (AD)0.91.8%Nitrogen N (DAF)NOx Emission

Characteristic

1.95.3kg/106kcalAsh Loading0.82.7%Na2OK2O (DB)0.21.8%Na2O (DB)Fouling

Characteristic

1.95.28kg/106kcalAsh Loading0.10.3%Total Sulfur (AD)12.520%Fe2O3 (DB)0.311.5Base/Acid Ratio(*1) (DB)

12001320Ash Softening Temperature

Slagging Characteristic

40.543.5%Volatile Matter (AD)13.417.6C/H Ratio (DAF)0.861.07Fuel Ratio (AD)

Combustion Characteristic

() The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)

Coal Property




Sub-bituminous coal (Paiton)

Bituminous coal

5.22.51.72547

0.961.05.20.80.25.210.120

0.84120041

16.70.96

PerformanceCoal

35201018402.51.8354.03.0352.0150.5120020182.5

Range Design CoalRange

UnitItem

1.95.3kg/106kcalAsh Loading1.13.8kg/106kcalAl2O3SiO20.72.5kg/106kcalQuartz(SiO2)Erosion

Characteristic

2132%Total Moisture (As Received)4353HGICoal Fineness

0.861.07Fuel Ratio0.91.8%Nitrogen N (Dry Ash Free)NOx Emission

Characteristic

1.95.3kg/106kcalAsh Loading0.82.7%Na2OK2O (in Ash)0.21.8%Na2O (in Ash)Fouling

Characteristic

1.95.28kg/106kcalAsh Loading0.10.3%Total Sulfur12.520%Fe2O3(in Ash)0.311.5Base/Acid Ratio(*1)

12001320Ash Softening Temperature

Slagging Characteristic

40.543.5%Volatile Matter (Air Dry Base)13.417.6C/H Ratio0.861.07Fuel Ratio

Combustion Characteristic

() The ratio of basic substances (Fe2O3, CaO,MgO,Na2O,K2O) to acid substances (SiO2, Al2O3, TiO2)

Coal Property




Outline

nn SummarySummary







SlaggingSlaggingcharacteristiccharacteristic

Design Considerations for Sub-bituminous Coal


Low calorific valueLow calorific value

High spontaneous High spontaneous combustibilitycombustibility

High moisture contentHigh moisture contentCoal FinenessCoal Fineness

Coal Property of Coal Property of subsub--bituminous bituminous coalcoal



SlaggingSlaggingcharacteristiccharacteristic


Low calorific valueLow calorific value

High spontaneous High spontaneous combustibilitycombustibility

High moisture contentHigh moisture contentCoal FinenessCoal Fineness

Coal Property of Coal Property of subsub--bituminous bituminous coalcoal





lHigh spontaneous combustibilityDecrease Pulverizer Outlet Air Temperature

60

Sub-Bituminous Coal (Paiton)

77

Bituminous Coal

Pulv

eriz

erO

utle

t Air

Tem

p.(

)

50

100

0





lHigh moisture contentIncrease Pulverizer Inlet Air Temperature


255

Bituminous Coal

Pulv

eriz

erIn

let A

ir Te

mp.

(

)

100

200

300241

0





lLow calorific value (More coal flow)Larger capacity pulverizer is selected.


108 t/h

Bituminous Coal

Pulv

eriz

erC

apac

ity

(t/h)

50

100

150

95 t/h

0




Proper arrangement of Wall Deslagger

Wall Deslagger : 68

Half Retractable Sootblower : 10

Long Retractable Sootblower : 26

Features of Paiton Boiler

lSlagging characteristicDesign Considerations for Sub-bituminous Coal



Outline

nn SummarySummary







Boiler Front

Fixed SeparatorPulverizer

In-Furnace DeNOx System MACT* (*Mitubishi Advanced Combustion Technology)

Circular Corner Firing CCF

Low NOxA-PM* Burner(*Advanced Pollution minimum)

Combustion Systems

Combustion Systems



Plan View

2. High Combustion StabilityMutual supporting combustion byadjacent burner

1. High Efficient CombustionBetter mixing of fuel and airLong flame path by effective use of furnace

Circular Corner Firing (CCF)

Combustion Systems

Side View

3. Low NOx Emission4. Less Furnace slaggingUniform combustion without peak heat flux.

l Twin furnacel Eight(8) burnersl No division walll Two concentric circles are

formed by circular firing.

- Main Structure -



Coal Fired Supercritical Pressure Operation Boiler-CCF Units (Twin Furnace)-

CoalMar.2003600MWChina FPC USA CP #413

CoalSep.2000600MWChina FPC USA CP #28

Coal.2000600MWTaiwan Mailiao FPCC #69

CoalMar.2000600MWChina FPC USA CP #17

CoalAug.2004900MWKansai EPC Maizuru #114

Coal.2002600MWTaiwan Mailiao FPCC #712

Coal.2002600MWTaiwan Mailiao FP #411

CoalJan.2000600MWChina FPC USA CP #310

CoalSep.1999600MWTaiwan Mailiao FP #26

CoalJun.1999600MWTaiwan Mailiao FP #15

CoalJul.19981000MWChugoku EPC Misumi #14

CoalJul.19971000MWTohoku EPC Haranomachi #13

CoalJul.19951000MWSoma Kyodo PC Shinchi #22

CoalOct.1991700MWChubu EPC Hekinan #11

FuelCommercialOperationCapacityPlant NameNo.

Combustion Systems



A-PM Burner (1/2)

Conc. flame surface is extended

Stable Ignition

Conc.

Weak

Conc.

CoalCoal

A-PM Burner : Advanced - Pollution Minimum Burner

Aux.2

AA

Aux.1

Oil / AirCoal

Coal

Aux.1

Aux.1

Oil / AirCoal

Coal

Aux.1

Aux.1

Oil / AirCoal

Coal

AA

AA

AA

Oil / Air

Coal

Coal

AA : Additional Air

Aux.1(U)

Combustion Systems



ConcFlame

A-PM Burner (2/2)N

Ox

(ppm

)

Primary Air / Coal Ratio0

A-PM Burner

7834

Single Flame Burner

A

C1 C2

WeakFlame

C0

Combustion Systems



Main Burner

AdditionalAir

Furnaceoutlet

CombustionCompletionZone

ReductiveDeNOxZone

Main BurnerCombustionZone

Stable and Low NOxCombustionwith A-PM Burner

Combustion Air

40%

60%

- In-Furnace DeNOx System- MACT (Mitsubishi Advance Combustion Technology)

Combustion Systems



Fixed Separator and Pulverizer (1/2)

Combustion Systems

Hot AirHot Air

Raw Raw CoalCoal

Pulverized Pulverized CoalCoal

Coarse CoalCoarse Coal

Fine CoalFine Coal

RollerRoller

Grinding Grinding TableTable

Hydraulic Hydraulic Loading Loading DeviceDevice

FixedFixedSeparatorSeparator



Pulverizer and Coal Pipe ArrangementFixed Separator and Pulverizer (2/2)

Pulverize

r : 6 units

Coal Pipe

BoilerFront

Combustion Systems



Boiler Front

Fixed SeparatorPulverizer

In-Furnace DeNOx System MACT* (*Mitubishi Advanced Combustion Technology)

Circular Corner Firing CCF

Low NOxA-PM* Burner(*Advanced Pollution minimum)

Combustion Systems

Combustion Systems



Outline

nn SummarySummary







Smooth Tube

Film Boiling

Nucleate Boiling

Nucleate Boiling

(Spiral Wall)Rifled Tube

(Vertical Wall)

Vertical Water Wall

Boiling Phenomenon



Spiral Water WallVertical Water Wall (Paiton)

Vertical Water Wall

Smooth TubeRifled Tube

Boiler Type

(1)(1) Simple StructureSimple Structure

(2)(2) Low Low P at Water WallP at Water Wall

(3)(3) Easy Removal of SlagEasy Removal of Slag

Merits of Vertical Water WallMerits of Vertical Water Wall



Smooth TubeMass Velocity 1,500 kg/m2s Mass Velocity 3,100 kg/m2s

Film Boiling

Nucleate Boiling

Nucleate Boiling

PwwPww --5 kg/cm5 kg/cm22

(Spiral Wall)Rifled Tube

(Vertical Wall)

Vertical Water Wall

Boiling Phenomenon



700

600

500

400

0.0 0.2 0.4 0.6 0.8 1.0Steam Quality

2,000kg/m2s

3,000

3,500

Tube

Met

al T

empe

ratu

re (

)

Maximum Allowable Temp.

Steam Quality = ( Steam Flow ) / ( Steam Flow + Liquid Flow )

Smooth Tube

Design3,100 kg/m2s

2,000 2,500Rifled Tube

Design1,500 kg/m2s

WaterWater

Furnace Hopper Burner Zone Upper Furnace

SteamSteam

Vertical Water Wall

Steam Quality and Tube Metal Temperature



8P

Vertical Water Wall

Spiral Water Wall

n 30 deg. Incline

n Half pcs. of tubes

4P

30

Vertical Water Wall

Spiral Water Wall

For smooth tube, For smooth tube, Sufficient mass Sufficient mass velocity is required.velocity is required.



Horizontal Buckstay

Support Structure of Spiral Water Wall

Holder

Vertical Tie

Holder

Lug

Vertical Water Wall



Keeper Lug

Horizontal Buckstay

Support Structure of Vertical Water Wall

HolderHolder

Vertical Water Wall

Horizontal tie



Fall easilyAdhere on the shelf of tube fin

Vertical Water Wall Spiral Water WallEasy Removal of Slag

Vertical Water Wall



Spiral Water WallVertical Water Wall (Paiton)

Vertical Water Wall

Smooth TubeRifled Tube

(1)(1) Simple StructureSimple Structure

(2)(2) Low Low P at Water WallP at Water Wall

(3)(3) Easy Removal of SlagEasy Removal of Slag

Merits of Vertical Water WallMerits of Vertical Water Wall

Spiral Spiral water wall has been awater wall has been adopteddopted previously.previously.Now, MHI has deNow, MHI has deveveloplopeded and adopted vertical and adopted vertical water wall with rifled tube over 20 years, water wall with rifled tube over 20 years, considering above merits.considering above merits.



Outline

nn SummarySummary







Economizer

Water Wall

2ry Superheater

2ry Reheater3ry Superheater

1ry Reheater

Pressure Parts

Pressure Parts Arrangement

1ry Superheater



Arrangement and Flow Diagram (1/12)

EcoEcoInlet PipeInlet Pipe

Eco InletEco InletHeaderHeader

Furnace Furnace Inlet PipeInlet Pipe

Furnace Furnace Inlet PipeInlet Pipe

EcoEcoInlet PipeInlet Pipe

Eco Inlet HeaderEco Inlet Header

Eco Outlet Eco Outlet HeaderHeader

Eco Outlet Eco Outlet HeaderHeader

Pressure Parts

IntermediateIntermediateHeaderHeader

Intermediate Intermediate HeaderHeader

Economizer



Economizer

Pressure Parts

IntermediateHeader

Outlet Header

Roof Tube

Inlet Header

IntermediateHeader

Design considerations

u Counter flow for more efficient heat transfer

u Intermediate HDR for temp. equalization

u Heating surface area is designed considering Eco. outlet temp.

u Sufficient Eco. outlet subcool is ensured.

Horizontal Horizontal PartPart

Hanger Hanger PartPart



A

A

Eco Tube

Eco Tube

Spiral Fin

Eco Intermediate HDR

Eco Hanger Tube

Eco Hanger TubeEco Intermediate HDR

A-A

Support Assembly

Clevis

Economizer horizontal part

Pressure Parts



Water Wall(Furnace)

Furnace InletFurnace InletManifoldManifold

Furnace Outlet Furnace Outlet HeaderHeader

Furnace InletFurnace InletManifoldManifold

Furnace Furnace Outlet Outlet HeaderHeader

Pressure Parts


Furnace Furnace Intermediate Intermediate ManifoldManifold

Furnace Furnace Intermediate Intermediate manifoldmanifold



Water Wall(Roof)

Roof Inlet Roof Inlet ManifoldManifold

Roof Inlet Roof Inlet HeaderHeader

Roof Inlet Roof Inlet ManifoldManifold

Roof Outlet Roof Outlet HeaderHeader

Roof Outlet Roof Outlet HeaderHeader

Roof Inlet Roof Inlet HeaderHeader

Pressure Parts




Water Wall(Passage Side Wall)(Rear Wall Hanger)

Outlet HeaderOutlet Header


Inlet HeaderInlet Header

Passage Side WallPassage Side WallInlet ManifoldInlet Manifold

RearRear Wall HangerWall HangerInlet ManifoldInlet Manifold

Rear Wall HangerRear Wall Hanger Inlet ManifoldInlet ManifoldPassage Side Wall Inlet ManifoldPassage Side Wall Inlet Manifold



Pressure Parts



Water Wall(Back Pass)


Back PassBack PassInlet PipeInlet Pipe


Inlet ManifoldInlet Manifold

Water SeparatorWater SeparatorInlet PipeInlet Pipe

Water SeparatorWater SeparatorInlet PipeInlet PipeInlet HeaderInlet Header

Back PassBack PassInlet PipeInlet Pipe

InletInletManifoldManifold



Pressure Parts



Water Wall2RY PASS FRONTWALL OUTLET HDR.

RIGHT SIDE ONLY

SM

OO

TH T

UB

E

LEFT SIDE ONLY

RIF

LE T

UB

ESM

OO

TH

TUB

E

MEM

BRANE

MEM

BRANE

FURNACE INLET PIPE

+16500

+45120

ROOF INLET HDR.

+64200

SIDE WALL OUTLET HDR.

PASSAGE SIDE WALLOUTLET HDR.

SECONDARY PASS SIDEWALLOUTLET HDR.

FIN FIN

FIN ROOF OUTLET HDR.

SIDE WALLSIDE WALL INLET HDR.

1st TUBE OF PASSAGE SIDE WALLFROM BOILER FRONT TO BEINCLUDED WITH FURNACESIDE WALL TUBE PANEL.

C L O

F F

UR

NA

CE

SECONDARY PASS SIDE WALL

PRIMARY SH INLETHDR.

SECONDARY PASS SIDE WALLINLET HDR.

MEM

BRAN

E

PRIMARY RH INLETHDR.

1st TUBE OF PASSAGE SIDE WALLFROM BOILER REAR TO BE INCLUDEDWITH FURNACE SIDE WALL TUBE PANEL.

FURNACE INTER MEDIATEHDR. (SIDE)

PASSAGE SIDE WALLINLET HDR.REAR WALL HANGER

TUBE

REAR WALL HANGERINLET HDR

OUTSIDE WELDINGGROOVE

FRONT WALL OUTLET HDR. REAR WALL HANGEROUTLET HDR.

2RY PASS REARWALL OUTLET HDR.

2RY PASS DIVISION WALLOUTLET HDR

2RY PASS DIVISION WALLINLET HDR

Rifled TubeRifled Tube

Pressure Parts


u Plan area is designed considering the coal slagging characteristic

u Furnace size is designed so that 2ry SH outlet gas temp is below the ash softening temp.

u Rifled tube is used at furnace lower wall



Water Wall

Adjustment of heat absorptionAdjustment of heat absorptionpp InIn--tube orifice tube orifice

Variation of orifice diameterVariation of orifice diameter

pp Intermediate HDR and manifoldIntermediate HDR and manifold

Elimination of temp. differenceElimination of temp. differencein upper wall tubesin upper wall tubes

Pressure Parts

Heat absorption in each tube is not equal.

p Heat distribution in furnace

p Burner shaded part



Water Separator& Drain Tank

1ry SH1ry SHInlet PipeInlet Pipe WSWS

DrainDrainTankTank

WaterWaterSeparatorSeparator

Drain TankDrain Tank

1ry SH1ry SHInlet PipeInlet Pipe


Pressure Parts



Water Separator

3310mm (Shell)Height

1000mmOutside diameter

SA-387-11-2 (Shell)

Material

120mm (Shell)Thickness

Pressure Parts



Water Separator Drain Tank

16.4m (Shell)Height

1000mmOutside diameter

SA-387-11-2(Shell)

Material

120mm (Shell)Thickness

Pressure Parts



1ry SH1ry SH--DeSHDeSH

1ry Superheater


1ry SH1ry SHInlet HeaderInlet Header


1ry 1ry SHSH--DeSHDeSH

1ry SH1ry SHOutlet HeaderOutlet Header

1ry SH 1ry SH InletInletHeaderHeader

1ry SH 1ry SH OutletOutletHeaderHeader


Pressure Parts



Outlet Header

Roof Tube

Inlet Header

Pressure Parts

1ry Superheater

Design considerationsu Counter flow for more

efficient heat transfer.

u Heating surface area is decided so that necessary total heat absorption of SH is obtained.

u The height is within the effective area of soot blowing.Horizontal Horizontal

PartPart

Terminal Terminal PartPart



2ry Superheater









Pressure Parts




Outlet HeaderInlet Header

2ry Superheater

Roof Tube

Girdling Tube

Pressure Parts

u Panel type, which absorbs the radiant heat from furnace effectively.

u Heating surface area is designed based on the furnace size.

u 2ry SH outlet gas temp. is designed below the ash softening temp.

u Girdling tube and wrapper tube are provided for anti-vibration.




Girdling tube / 2ry SH Wrapper tube

Pressure Parts



3ry Superheater



MainSteam

MainSteam3ry SH3ry SH



Pressure Parts




Girdling Tube

Outlet HeaderInlet Header

3ry Superheater

Roof Tube

Pressure Parts

u Platen type, which absorbsthe radiant heat from furnace and convectionheat from flue gas.

u Heating surface area isdesigned based on the furnace size.

u Girdling tube and spacer tube are provided for anti-vibration.




1ry SH Inlet HDR

Spacer tube

Pressure Parts



1ry Reheater

2ry RH2ry RHInlet PipeInlet Pipe

1ry RH1ry RHOutlet HeaderOutlet HeaderRHRH--DeSHDeSH

LTRLTR 1ry RH1ry RHInlet HeaderInlet Header

1ry RH Outlet Header1ry RH Outlet Header


RHRH--DeSHDeSHLTRLTR

1ry RH1ry RHInletInlet

HeaderHeader


Pressure Parts



Outlet Header

Inlet Header

1ry Reheater

Pressure Parts

u Counter flow for moreefficient heat transfer

u Heating surface area isdecided so that necessarytotal heat absorption of RHis obtained.

u The height is within theeffective area of soot blowing.


Horizontal Horizontal PartPart

Terminal Terminal PartPart



2ry Reheater

2ry RH2ry RHOutlet HeaderOutlet Header

2ry RH2ry RHInlet HeaderInlet Header

2ry RH2ry RHInlet HeaderInlet Header

2ry RH2ry RHOutlet HeaderOutlet Header


Pressure Parts



Inlet Header Outlet Header

2ry Reheater

Roof Tube

Pressure Parts

u Pendant type, which absorbsthe convection heat from fluegas.

u Heating surface area is designedbased on the furnace size.

u Spacer tube are provided foranti-vibration.




2ry SH2ry SH2ry2ryRHRH

3ry3rySHSH

EcoEco

WSWS

ECOECO 1ry RH1ry RH 2ry RH2ry RHWSWSBack PassBack PassFurnaceFurnace RoofRoofPassage Side WallPassage Side WallRear Wall HangerRear Wall Hanger


Pressure Parts

1ry1ryRHRH

1ry 1ry SHSH

3ry SH3ry SH2ry SH

1ry SH1ry SH



Eco - Furnace31.49

28.00

Roof, PSW30.11 Back Pass

28.77WS 1ry SH

28.61 2ry SH29.80

27.563ry SH

SH out27.05

5.84RH

654

Design Pressure Diagram

26

24

25

27

28

29

30

31

32

33

Pres

sure

(MPa

)

654

Operating Pressure

Predicted Performance + MSV Inlet OperatingPress.5%Predicted Performance

IncludedNot Included

Pressure Parts



250

600

550

500

450

400

350

300

250

600

550

500

450

400

350

300

Design Temperature DiagramTe

mpe

ratu

re

Operating Temperature 350

582

513550

3ry SH

454450WS 1ry SH

467

2ry SH

391

450Back Pass450

Eco - Furnace350

FurnaceInterm.

HDR 450ECOInterm.HDR

362

Roof, PSW

1ry SH InletHDR 533

496RH

IncludedNot Included

Pressure Parts



SH Outlet DesignPress.27.05

Spring Loaded

3.97

%29.52

30.74

PCV

2.99

%

26.24

27.05

Safety Valve DesignPr

essu

re (M

Pa)

33

32

31

30

29

28

27

26

26

24

34

SH outletWS outlet

SH Outlet Press.25.80

Operating PressureWS Outlet Press.

27.36

3.98

%

3.97

%

3.99

%

3.98

%

3.99

%

3.98

%

Spring Loaded

30.38

31.64

30.24

31.49

30.09

31.34

29.95

31.19

29.80

31.04

29.66

30.89

Pres

sure

(MPa

)

6.0

5.5

5.0

4.5

6.5

RH Outlet Press.4.86

RH Outlet

Operating PressureRH Inlet Press. 5.03

RH inlet

RH Design Press.5.90

Spring Loaded

3.87

%

5.46

5.68

6.07Spring Loaded

3.90

%

5.67

5.903.95

%

5.83

3.99

%

5.77

6.01

3.86

%

5.73

5.96

Reheat Steam LineReheat Steam LineMain Steam LineMain Steam LineAs per ASME Boiler & Pressure Vessel Code, Section, PG-67

Pressure Parts

WS Design Press.28.77 MFT 28.67

ANN 26.83



1ry Reheater


1ry RH1ry RHOutlet HeaderOutlet HeaderRHRH--DeSHDeSH

LTRLTR 1ry RH1ry RHInlet HeaderInlet Header

1ry RH Outlet Header1ry RH Outlet Header


RHRH--DeSHDeSHLTRLTR

1ry RH1ry RHInletInlet

HeaderHeader


Pressure Parts



2ry SH2ry SH2ry2ryRHRH

3ry3rySHSH

EcoEco

WSWS

ECOECO 1ry RH1ry RH 2ry RH2ry RHWSWSBack PassBack PassFurnaceFurnace RoofRoofPassage Side WallPassage Side WallRear Wall HangerRear Wall Hanger


Pressure Parts

1ry1ryRHRH

1ry 1ry SHSH

3ry SH3ry SH2ry SH

1ry SH1ry SH



Outline

nn SummarySummary







CE

NTE

R O

F FU

RN

AC

EC L

BOILER FRONT

Furnace Bottom

Boiler Expansion Systems

Furnace Furnace HopperHopper

Drag Drag Chain Chain ConveyorConveyor

Seal Seal PlatePlate

Free

Free

FreeFree



CORNER PLATE11

STOPPER BEAM12

BOILER STRUCTURE COLUMN13

STIFFENER14

CORNER LINK10

HOLDER9

TIE PLATE8

BUCKSTAY7

LOOSE MINERAL FIBER6

OUTER CASING5

PIN CLIPS4

INSULATION PINS3

BLOCK INSULATION(MINERAL FIBER BOARD)

2

WATER WALL TUBES1

DESCRIPTIONITEM

Buckstay Arrangement

Free

Free

Free

FreeFix

Fix

Boiler Expansion Systems



Outline

nn SummarySummary







Air & Gas Systems

PAF

2ry Air

2ry Air

1ry Cold Air

PAF

1ry Cold Air

FDF

FDF

1ry Hot Air

1ry Hot Air

Pulverizer Outlet Temp. control

Pulverizer Outlet Temp. Control

Furnace(Boiler)

Air

heat

erA

ir H

eate

r

Furnace Eco.

Pulverizer

Gas

Gas

Air & Gas Systems

IDF

IDFEP

EP

FGD

Stack



Gas side,Cold end

Soot blower Arrangement

Gas side,Hot end

369 / 145

1,683 t/h(BMCR, Design coal)

2 sets

Regenerative, RotaryVertical Trisector

Gas Temp. (Inlet / Outlet (Uncorrected))

Inlet Gas Flow

Stationary Water Washing device

Number

Type

Air Heater (1/3)

Air & Gas Systems



Air Heater (2/3)

Gas Inlet

2ry AirOutlet

1ry AirOutlet

Air & Gas Systems

Soot Soot blowerblower



Over View

B-side

A side

2ry Duct

1ry Duct

Gas Duct

1ry Duct

lRotating Direction

Air Heater (3/3)

Air & Gas Systems

Flue Gas Path

2ry Air Path

1ry Air Path

lRotation Speed

Approx. 1 rpm



Fans

211Impeller StageImpeller Stage

8,580kW3,400kW2,500kWMotor CapacityMotor Capacity

Variable Blade Pitch Control

Inlet Vane Control

Variable Blade Pitch ControlControl SystemControl System

14025.525.5Inlet AirInlet Air//Gas Gas TemperatureTemperature

-540mmAq-50mmAq-50mmAqInlet PressureInlet Pressure430mmAq1,570mmAq480mmAqDischarge PressureDischarge Pressure

45,400m3/min9,900m3/min21,000m3/minCapacityCapacity222NumberNumber

Axial FlowHorizontal

CentrifugalHorizontal

Axial FlowHorizontalType

Type

IDFIDFPAFPAFFDFFDFFanFan

Air & Gas Systems



Drive UnitDrive Unit

Seal PlateSeal Plate

Link ChainLink Chain

Lower TroughLower Trough

DewateringDewateringFurnace

FlightFlight

Dewatering sectionDewatering section

Falling of the Clinker

Chain RollerChain Roller

TransportTransport

Air & Gas Systems

Upper TroughUpper Trough

Cooling To Bottom ash storage pitTo Bottom ash storage pitCoolingCooling

Bottom Ash Handling SystemDrag Chain Conveyor

CrushCrush

GrinderGrinder



Outline

nn SummarySummary







Operation

nn Operation ModeOperation Mode

nn Main Steam Temp. ControlMain Steam Temp. Control

nn Reheat Outlet Steam Temp. ControlReheat Outlet Steam Temp. Control

nn PulverizerPulverizer OperationOperation

nn NOxNOx TuningTuning



Feed Water FlowWater Fuel Ratio (WFR)

30% 100%

Dry Mode (Once-Through Mode)

0% - 20%Load

Fuel flowPress. ControlSprayTemp. Control

System Schematics

Wet Mode (Circulation Mode)

Same system as drum type boiler.BCP is operated to re-circulate the water for the heat recovery.

BCP is stopped.

Boiler Operation Mode

SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

BCPBCP

Operation



Pressure (MPa)

Enth

alpy

(kca

l/kg)

0

200

400

600

800

1000

0 10 20 30 40

Water

600

500

400

300200

SaturationSaturation(Water/Steam)(Water/Steam)

Supercritical Sliding Pressure Operation

35% 50% 80% BMCREco. Inlet

Economizer

Water Wall

Superheater

SH Outlet

W.W Inlet

W.W Outlet

Operation

W.W outlet Enthalpy in W.W outlet Enthalpy in Wet Mode (0Wet Mode (020%Load)20%Load)

W.W outlet Enthalpy in W.W outlet Enthalpy in Transition (20Transition (2030%Load)30%Load)



SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

Wet Mode

1ry SH Inlet Pipe1ry SH Inlet Pipe

Water SeparatorWater Separator

Furnace Inlet PipeFurnace Inlet Pipe

SH

EcoBFP

to Steam Turbine

Eco Inlet PipeEco Inlet Pipe

Furnace

WaterSeparator

BCPBCP

BCP Outlet PipeBCP Outlet Pipe

Drain TankDrain Tank

BCP Inlet PipeBCP Inlet Pipe

BCPBCP

EcoEco

Operation



SH

EcoBFP

to Steam Turbine

Furnace

WaterSeparator

Dry Mode

1ry SH Inlet Pipe1ry SH Inlet Pipe

Water SeparatorWater Separator

EcoEco

Furnace Inlet PipeFurnace Inlet Pipe

SH

EcoBFP

to Steam Turbine

Eco Inlet PipeEco Inlet Pipe

Furnace

WaterSeparator

Operation



Dry ModeDry ModeWet ModeWet Mode BCP is inBCP is in--service.service.

Boiler Operation Mode

Load (%)

Wat

er F

low

thro

ugh

Furn

ace

wal

l (%

)

25

25%

Boiler minimum flow for furnace wall tubes protection

0

100

25

50

75

0 50 75 100

50%

No.4

70%

No.5 Mill

35%

No.3

20%

No.1,2

Operation

BCP is stopped.BCP is stopped.

Transition Transition

3020



Main Steam Temperature Control SystemsOperation modeOperation mode

Separate controlSeparate controlOver injectionOver injectionprotection functionprotection function

-- Supplementary Supplementary --Load changeLoad changeQuick responseQuick responseSeparate controlSeparate control

SH spraySH spray(2 Stages)(2 Stages)

N/AN/A

-- Main Main --Control avg. value ofControl avg. value offinal SH outlet steamfinal SH outlet steamtemp.temp.

Water / Fuel RatioWater / Fuel Ratio

Wet ModeWet ModeDry ModeDry ModeControlControlMatterMatter

Operation



Stea

m T

emp.

1SH 1ry DeSH 2SH 2ry DeSH 3SH

SpraySpray

SH Desuperheater

Operation



RH Outlet Steam Temperature Control Systems

Gas DistributionDamper (Main)

Adjustable Burner Nozzle angle(Auxiliary)

RH spray (For load changeand emergency)

RHRHPassPass

SHSHPassPass

Division WallDivision Wall

Operation



Pulverizer Operation

Upper Limit 90%

Lower Limit 30%

PasirPasirRotoRoto

NorthNorth

Perform

ance

Perform

ance

coalcoal

Boiler Load (%)

Pulv

eriz

er L

oad

(%)

100

75

50

25

020 40 60 80 100

25%

30%

50%

100%

75%

BM

CR

3 Pulv

erizer

s

4 Pulve

rizers

5 Pulver

izers

6 Pulveri

zers

2 Pulv

erize

rs

Operation



Operating Parameter for NOx Tuning

Low NOx High NOx

Additional AirDamper CloseOpen

Excess Air IncreaseDecrease

Coal Damper OpenClose

Auxiliary AirDamper OpenClose

Operation

Burner Nozzle Angle UpwardDownward



SummarynBoiler design for Paiton project is

based on a lot of MHIs experiences.

nnBoiler design for Boiler design for PaPaitoniton project is project is based on design coal properties.based on design coal properties.

nnWe are looking forward to We are looking forward to demonstrating high performance demonstrating high performance and high reliability of and high reliability of PaPaitoniton Boiler.Boiler.

basic of boiler

Documents

design considerations

saturation pressure

boilernn feature of

gas systemsair

high temperature steamto

steam turbineturbineboiler

steam turbineto

course bb