Super critical boiler manufacturing and working. Working cycle of Steam and water. Difference between sub critical and super critical boiler. Manufacturing process and definition of parts of boiler.

2. EMP CD: 30009513
MMD
Welcome APL
Topic: Super Critical Boiler
Myself: Milap Desai

3.  A boiler is a closed vessel in which water is heated and
converted into steam. The steam which gets produced in
boiler is used in various applications like heating, power
generation, process plants etc.
 Boiler consists of two principal parts: “Furnace”, which
provides heat to water for conversion to steam, usually by
burning a fuel, and “Boiler proper”, a device in which the
heat converts water into steam.

5. 3
Sub-Critical Boiler Super-Critical Boiler

7. Parameters Sub-Critical Super-Critical
Efficiency 38% 42%
Emission of CO₂
Higher than Super Critical
Boiler
Less as compare to Sub
Critical Boiler
Load Changing Capacity Lower Higher
Heat Transfer Area Lower Higher
Corrosion
More as compare to Super
Critical Boiler
Minimum as compare to
Sub Critical Boiler
Weight
Higher weight compare to
SP Boiler
Because of no drum is
present weight is reduced

8.  Has a higher efficiency due to great reduction in both fuel
input as well as emission output.
 The load change rate capability of system is not restricted
by turbine.
 Steam Temperature at inlet and outlet of the Reheater is
nearly constant over a wide load Range.
 Short Start-up times.

9.  It is also known as Bension Boiler.
 As the name suggests it works above critical pressure.
 Super Critical stage is defined as, at which the density of
liquid and vapours become equal.
 Water’s Super critical situation at 22.12 MPa pressure and
374.15˚ C temperature.
 No boiling takes place in this boiler therefore no drum is
required.
 No bubble formation takes place because the temperature
and pressure is higher than the Critical Point.

10.  There are 2 major Technologies used in Super Critical
Boiler as listed below:
I. Vertical Tube
II. Spiral Tube

12.  Can be used in Large Capacity Boilers.
 Tube are self supporting, so no supports required.
 Transition Headers at Vertical Interfaces are avoided.
 Ash Hopper tubing Geometry simplified.
 Corners are easier to form.
 Reduced Pressure Drop and Auxiliary Power.
 Faster Erections due to easier geometry

14. Advantages Disadvantages
Can be used in boilers in any
Capacity.
Furnace walls are not self
supporting because they are
inclined.
As the tubes pass through all the
furnace walls more uniform heat
absorption.
Fabrication and installation is
difficult and time consuming.
External support strap is needed.
Evaporator steam outlet
temperature is more uniform.
Above aspects tend to increase
the cost.

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Coal
Coal Bunker
Mill
Forced Draft Fan
Primary Air Duct
Secondary Air
Duct
Primary Air Fan
Cold Primary Air
Hot Primary Air
Coal Piping
Burner

18. Feed Water Economizer Inlet HDR
Eco Bank Eco Bank
Eco Bank
Eco Int. HDR
Eco Int. HDR
Eco Outlet HDR
Furnace Inlet
Manifold
Furnace Inlet HDR
Furnace Inlet
Manifold
Furnace IntermediateFurnace Intermediate
Rear Outlet HDR
Hanger &
Passage
Manifold
Passage Inlet
HDRHanger Inlet
HDR
Front Outlet HDR
Side Outlet HDR
Roof Inlet Manifold
Roof Inlet HDR Roof Outlet HDR
2nd Pass
Inlet Pipe
2nd Pass Inlet
Manifold2nd Pass Inlet Ring HDR
2nd Pass Outlet HDR
2nd Pass Rear Outlet
HDR
Water Separator
Water Separator
Drain Tank
Boiler Circulating
Pump
Pry SH Inlet HDR
Pry SH Bank
Pry SH Bank
Pry SH Bank
Pry SH Terminal
Bank
Pry SH Outlet HDR
Pry SH De-SH
Pry RH De-SH
Pry RH Outlet HDR
Pry RH Bank
Pry RH Terminal
Bank
Pry RH Bank
Pry RH Bank
Pry RH Bank
Pry RH Inlet HDR
2ry SH De-SH
2ry SH Inlet HDR
2ry SH Outlet HDR
3ry SH Outlet
HDR
3ry SH Inlet
HDR
2ry SH Tube
3ry SH Tube
Main Steam Pipe
To High Pressure
Turbine
From High Pressure Turbine
To Intermediate Pressure
Turbine
2ry RH Inlet HDR
2ry RH Outlet
HDR
2ry RH Tube

19.  Feed Pump :- It is used for the supply of water in the
Boiler.
 Economizer :- It is used for the preheating of water before
converting into the steam. It is a heat exchanger in which
heat is gained from residual heat of flue gases.
 Piping :- It is used for the transportation of water and
steam.
 Header :- It is used for the collection and distribution of
water and steam.

20.  Hangers :- To support coils and panels. Hanger-rods are
used for support as well as steam and water flow.
 Manifolds :- It is used for mixing water and making
thermal properties of liquid uniform.
 Pilot and Main Burner :- Pilot is used for the starting of
combustion and main burner is used for burning of fuel.
 Tubes :- It is used for the transportation of water and
steam as well as heat transfer.
 Fins :- Used to join tubes and form walls of boiler, also
serves the purpose of better heat transfer.

21.  Water Separator :- It is used for the separation of water
and steam.
 Drain Tank :- It is used for the collection of water from
water separator than this water again goes to the feed
pump.
 Super Heater:- Used for the conversion of saturated
steam or wet steam into the Dry Steam.
 De-Super Heater :- Used for temperature control of over
heated steam.

22.  Safety Valve :- This valves are used for the releasing the
pressure. If the pressure inside the boiler goes beyond
allowable pressure.
 Man Holes :- For cleaning and maintaining the boilers
during maintenance.
 Soot Blower :- To remove mixture of impure black carbon
with oily compound, which reduces heat transfer and
efficiency of boiler. In soot blower dry steam is used for
the removal of soot.

23.  SA-106 C
 SA-210 C
 SA-335-P12
 SA-213-T12
 SA-335-P22
 SA-213-T12
 CC-2328-1

24. Material Description Percentage ( % )
Carbon Steel SA-106 C 5-10%
Carbon Steel SA-210 C 20-25%
Alloy Steel SA-335-P12, SA-213-T12 55-60%
Alloy Steel SA-335-P22, SA-213-T22 Upto3%
Stainless Steel CC-2328-1 Upto5%

25. Chemical
Component(%)
C 0.23∼0.27
Mn 0.70∼1.0
P ≤0.030
Si ≥0.10
Cr ---
Mo ---
S ≤0.030
Mechanical
Property
Tensile
Strength(MPa
)
≥485
Yield
Strength(MPa
)
≥275
Elongation
Percent(%)
≥20
Rigidity ≤165BH

26.  Primary Reheater inlet header
 Economizer inlet header
 Economizer outlet header
 Furnace inlet header
 Furnace inlet manifold
 Furnace inlet pipe
 Drain pipe
 Economizer intermediate headers
 Boiler circulation pump outlet pipe

27. Chemical
Component(%)
C 0.18∼0.24
Mn 0.80∼1.1
P ≤0.030
Si ≥0.10
Cr ---
Mo ---
S ≤0.030
Mechanical
Property
Tensile
Strength(MPa
)
≥485
Yield
Strength(MPa
)
≥275
Elongation
Percent(%)
≥30
Rigidity ≤179BH

28.  Cable opening roof
 Sleeve for Water Separator Drain Tank O/L Pipe & strainer
Assembly
 Economizer Tubes
 Hanger Tubes
 Economizer inlet and outlet Header stubs
 Economizer intermediate header stubs
 Spare tubes

29. Chemical
Component(%)
C 0.05∼0.15
Mn 0.30∼0.60
P ≤0.030
Si ≤0.50
Cr 0.80∼1.25
Mo 0.44∼0.65
S ≤0.030
Mechanical
Property
Tensile
Strength(MPa
)
≥415
Yield
Strength(MPa
)
≥220
Elongation
Percent(%)
≥22
Rigidity ≤163HB

30.  Rear Wall outlet Hanger
 Passage side outlet Header
 2RY pass Front , Rear & Division wall Inlet Header
 2RY Pass Division wall Outlet Header
 Rear wall hanger Outlet pipe nozzle
 Passage side wall O/L pipe nozzle
 Roof Inlet Supply Pipe
 Side wall outlet header
 Roof outlet Header
 2ry pass inlet pipe nozzle
 Water Separator Steam vent
 Intermediate Manifold Outlet Pipe (Front, Rear & Side)
 Auxiliary Steam Pipe

31. Chemical
Component(%)
C 0.05∼0.15
Mn 0.30∼0.61
P ≤0.025
Si ≤0.50
Cr 0.8∼1.25
Mo 0.44∼0.65
S ≤0.025
Mechanical
Property
Tensile
Strength(MPa
)
≥415
Yield
Strength(MPa
)
≥220
Elongation
Percent(%)
≥30
Rigidity ≤163HB

32.  Passage Panel
 Roof Panel
 Secondary pass Upper and lower panel
 Back pass inlet stub
 Primary Super Heater Tube
 Secondary Super Heater Tube
 Secondary Super Heater Inlet header tube Nozzle
 Primary Reheater Tube
 Rear wall hanger tube
 Furnace Intermediate Panel

33. Chemical
Component(%)
C 0.05∼0.15
Mn ---
P ≤0.030
Si ≤0.50
Cr 1.90∼2.6
Mo 0.87∼1.13
S ≤0.030
Mechanical Property
Tensile
Strength(MPa
)
≥415
Yield
Strength(MPa
)
≥205
Elongation
Percent(%)
≥22
Rigidity ≤163HB

34.  Liner pipe
 Drain pipe
 Air Vent Pipe

35. Chemical
Component(%)
C 0.05∼0.15
Mn 0.30∼0.60
P ≤0.030
Si ≥0.50
Cr 1.9∼2.6
Mo 0.87∼1.13
S ≤0.010
Mechanical
Property
Tensile
Strength(MPa
)
≥415
Yield
Strength(MPa
)
≥205
Elongation
Percent(%)
≥30
Rigidity ≤163BH

36.  Primary Reheater Tubes
 Rear wall Hanger ( Connecting) Sleeve ,Rear wall hanger
seal Attachment
 Secondary Pass Front (Division ) wall Screen panel Sleeve
 Secondary super heater Tubes
 Primary Re Heater Outlet header tube nozzle

37. Chemical
Component(%)
C 0.07∼0.13
Mn ≤1.0
P ≤0.04
Si ≤0.3
Cr 17∼19
Mo ---
S ≤0.01
Mechanical
Property
Tensile
Strength(MP
a)
≥850
Yield
Strength(MP
a)
≥590
Elongation
Percent(%)
≥35
Rigidity

38.  Secondary Super Heater Tube
 Primary Reheater Tubes

39. Water
Separator
Fabrication FlowchartComponent
Circumferential end preparation Face lathe
Drilling and Boring Horizontal boring mill
Heat treatment Heat treatment furnace
(bogie hearth)
Circum.
end prep.
Plate
Long. welding
Circum.
welding
Drilling &
Boring
Nozzle &
Attach.
welding
Painting &
Shipping
Heat
treatment
Blasting
Bending
(Outsourced)
Longitudinal
Edge Prep.
(Outsourced)
List of Fabrication Facility
5m
(WSDT L15m)
1 2
3
1
2
3

40. Header
Pipe End prep. Drilling Circum. welding
Stub welding
Stub end prep. Blasting
Fabrication FlowchartComponent
Drilling Header drilling machine
Correction of distortion 500ton Press
List of Fabrication Facility
Attachment
welding
Heat
treatment
Correction of
distortion
Painting & Shipping
5~30m
1
2
1
2

41. Body
Material Checking
Drilling
T-Piece
Material Checking
Grinding
End plate
Material Checking
Drilling
Circumferential Welding
Drilling
Welding of Nozzles
Attachment
Material Checking
Marking
Cutting
Welding of Attachments
Nozzle and Stub
Material Checking
Bending
Welding of Stubs
Cutting Hot swaging
Edge preparation
Edge preparation

43. Furnace Intermediate Header Primary Super Heater Inlet Header

44. Body
Material Checking
Edge preparation
Drilling
Welding of inner nozzle
End plate
Material Checking
Edge preparation
Drilling
Welding of end plate
Butt welding
Nozzle
Material Checking
Cutting
Edge preparation
Welding of nozzle

46. Circumferential welding MAG welding machine
End preparation End prep. Machine
Bending Manual pipe bender
Induction heating pipe bender
Drilling
Pipe and Elbow
Circum. welding Bending Edge prep.
Circum. welding Nozzle &
Attachment welding
Heat treatment Painting & Shipping
Fabrication FlowchartComponent
Pipe
List of Fabrication Facility
Blasting
5~12m
1 23
1
2
3

47. Body
Material Checking
Bending
Preparation of pipe end
Welding
Bending
Marking
Hot swaging
Grinding
Nozzle pipe
Material Checking
Preparation of pipe end
Drilling
Welding
Welding
Assembling of fitting
Welding

51. Shot Blasting End prep. Butt Welding Panel Welding
Butt Welding of
Bend Tube
Welding of
Attachment Heat Treatment
List of Fabrication Facility
Component Fabrication Flowchart
Water Wall
Panel Welding Panel Welding machine (MPM)
Butt Welding Butt Welding line
Panel Bending Panel Bending machine
Panel Bending
Painting & Shipping
5~20m
~3.8m
12
3
1
2
3

52. Fin
Material Checking
Panel
Material Checking
Butt welding
Tube-fin welding
Bend tube
Material Checking
Marking/Cutting
Tube bending
Welding bend tube - fin
Butt welding
Cutting/Edgepreparation
Welding of seal plate
Welding of attachment
Welding of fin edge
Preparation of panel end

53. 14 Tube Panel 20 Tube Panel

55. Fabrication FlowchartComponent
Assembly Butt welding
Auto-TIG butt welding Auto-TIG welding machine
Tube bending Manual tube bender
NC tube bending system
Heat treatment Heat treatment furnace
(roller hearth)
Tube bending
Auto-TIG
butt welding
Attachment
welding
Heat
treatment
Painting &
Shipping
List of Fabrication Facility
Superheater / Reheater
/ Economizer tubes
End Prep.Tube
5~8m
1
2
3
1
2
3

56. Material Checking
Transition Piece
Marking & Cutting
Automatic Butt Welding
Material Checking
Cr-Mo Tube
Marking & Cutting
Automatic Butt Welding
Bending
Butt Welding
Assembly Welding
Stainless Steel
Material Checking
Marking & Cutting
Automatic Butt Welding
Bending
Butt Welding
Assembly Welding
Stainless Steel
Material Checking
Marking & Cutting
Automatic Butt Welding
Bending
Butt Welding
Assembly Welding
Butt Welding
Attachment Welding

59.  L&T-MHI, India
 BHEL, India
 B&W, USA
 ABB-CE
 MHI, Japan
 PODOLSK, Russia
 Foster Wheeler, USA
 ANSALDO, Italy
 TAGANROG, Russia
 BABCOCK HITACHI, Japan
 STEIN MULLER, Germany
 STEIN INDUSRIE,FRANCE
 EVT, GERMANY
 DEUTCHE BABCOCK, GERMANY
 MBEL, U.K.