Different steps involved in formation of drums

1. DRUM MANUFACTURING
PRESNTEDBY :ANURAG HARSH

2. Functions of a Boiler Drum..
To provide necessary space for steam-water
separation
To house the equipment's, needed for steam
purification
Acts as a storage vessel and always maintains a
water level and supplies the same according to
variation of load

3. Standard Drums Manufactured
Capacity Plate thickness (in
mm)
Length of drum (in
Meters)
WT (in Tons)
150 MW 145,115 13.6 87.3
250 MW 140,175 16.2 133.2
500 MW 160,190 22 214.3
600 MW 160,190 28 247.5
FR9FA 140 18 157.5

4. RAW MATERIAL PLATE

5. DRUM PLATE SUPPLIERS
 SA 299 (C-0.28, Mn- 0.9, Si-0.15, P-0.02, S-0.01, Cr- 0.25,Ni+Mo+Cu+V+Nb-
0.8)
 Dillinger – Germany
 Salzgitter - Germany
 Reiner Brach- Germany
 Indu Steel – France
 SA 515 Gr 70(C-0.35, Mn- 1.2, P-0.03, S-0.03, Si-0.15)
 SAIL, INDIA

6. 600MW: FOURSHELLCONFIG
SHELL:
1 ) 160 X 3960 X 8295 - 41,257.339 Kg - 2 NO
2) 160 X 3960 X 6400 - 31,832.064 Kg – 2 NO
3) 190 X 2840 X 8295 - 35,136.459 Kg – 2 NO
4) 190 X 2840 X 6400 - 27,109.504 Kg – 2 NO
DISHED END : 185 X 3000 X 3000 - 13,069.800 Kg

7. 500MW:TWOSHELLCONFIG:
Shell :
1) 160 X 3960 X 11350 - 56,452 Kg - 2 NO
2) 190 X 2840 X 11350 - 48,077.1 Kg – 2 NO
Dished End: 185 X 3000 X 3000 - 13,069.800 Kg

8. 500MW- THREESHELLCONFIG:
SHELL-
1) 160 X 3960 X 8295 - 41,257.339 Kg – 2 NO
2) 160 X 3960 X 6400 - 31,832.064 Kg – 1 NO
3) 190 X 2840 X 8295 - 35,136.459 Kg – 2 NO
4) 190 X 2840 X 6400 - 27,109.504 Kg – 1 NO
DISHED END – 185 X 3000 X 3000 - 13,069.800 Kg – 2 NO

9. 250 MW – TWOSHELL CONFIG:
SHELL –
1) 140 X 3300 X 7990 - 28,977.333Kg - 2 NO
2) 175 X 3365 X 7990 - 36,922.803 Kg – 2 NO
DISHED END – 165 X 2850 X 2850 - 10,520.262 Kg

10. HOT FORMING

11. STEPSREQUIRESDFOR PRESSINGTHE PLATES
 Plates are loaded into furnace and heated to temperature
ranging
 from 870-900 deg C in case of SA299 and 870-900 deg C in
 case of SA515 Gr70
 Soaking time=1.25mins/mm
 ROH for hot working/normalizing:
 For t <= 100mm, 200deg C/hr.
 For t > 100mm, 150deg C/hr.
 QC checks the soaking time and temperature of heat
treatment cycle.

12. PRESS WORK

13. DRUMDISHEDENDHOT FORMING

14. PRESSEDDISHED-ENDS

15. PRESSEDSHELLS

16. LONG SEAMEDGE PREPARATION

17. EDGE PREPARAEDHALF SHELL

18. LONG SEAMFIT UP OF TWOHALF SHELLS

19. INSIDE LONG SEAMFCAW

20. OUTSIDE LONG SEAM SAW

21. OUTSIDE LONG SEAMSAW

22. OUTSIDE LONG SEAMSAW

23. LONG SEAMRADIOGRAPHY

24. NDE Techniques Employed
 Radiography – LS & CS joints
 Ultra Sonic Testing – Raw material plate, All full throat nozzles (DC, FN &
SV nozzles) and Lifting lug
 MPI – LS & CS Joints and all stubs of shells and dished ends
 LPI – Dished end stub weldment

25. CIRSEAMEDGE PRPARATION

26. DISHEDENDMAN HOLE MACHINING

27. DISHEDENDEDGE PREPARATION

28. STUBHOLES DRILLING

29. SAFETY VALVE NOZZLE WELDING

30. LIFTINGFOR INTERSTAGE SR

31. INSIDE ATTACHMENTS

32. CIRCSEAMSAW

33. RESISTANCE SEAM WELDING
Resistance seam welding is a process that produces a weld at the faying
surfaces of two similar metals. The seam may be a butt joint or an overlap joint
and is usually an automated process. ... Like spot welding, seam welding relies
on two electrodes, usually made from copper, to apply pressure and current.

34. CIRSEAMMACHINE GRINDING

35. CIRSEAMMACHINE GRINDING

36. STRESS RELIEVING

37. AFTER SRMPI

38. Heat Treatment processes involved
 Normalizing – U shells, Door plates, SV nozzles, Lifting lugs
 Inter-Stage Stress Relieving- After DC & FN welding
 Stress Relieving

39. AFTER SRUT

40. HYDRO TEST

41. Hydro test pressure
Capacity Working pressure(Kg/Cm2) Test Pressure (Kg/ Cm2)
150 MW 164 246
250 MW 182 273.25
500 MW 210 315
600 MW 210 315

42. FINISHEDDRUM– READY FOR DESPATCH

43. FINISHEDDRUM – DESPATCH

44. DRUM LIFTING AT SITE

45. THANK YOU