SALIENT FEATURES OF 500 MW BOILER TYPE OF BOILER: Single Drum Top supported, Fusion welded WW Panel, Controlled circulation system, Tangential fired, Radiant Dry Bottom Pulverized coal fired outdoor Balanced Draught Cut corner 51mm OD WW Tubes at 63.5 mm pitch Rap around Buck stay system FIRST PASS: Boiler Furnace Depth -15.7972mtr Furnace Width -19.177mtr Height of Furnace (upto Radient roof)-64.168mtr. SECOND PASS: Depth -13.716mtr Width -19.177mtr Total Height of Boiler- 90mtr.

BOILER EXPANSION DETAILS FIRST PASS: Vertically Downward Expansion at Ring Header (10.250mtr elev.) : 330mm Horizontal Expansion at Ring Header (10.250mtr elev.) : 36mm SECOND PASS : Vertically Downward Expansion at Ring Header (44.060mtr elev.) : 174mm (44.060mtr elev.) : 58mm

BOILER DRUM EXPANSION : Vertical Downward Expansion at 75.333mtr elev.=29mm Horizontal Expansion at 75.333mtr elev.= 53mm

BOILER PARAMETERS (BMCR) STEAM FLOW AT SH OUTLET - 1625 t/h PRESSURE OF SUPERHEATED STEAM - 178 kg/sq.cm TEMP.OF SUPERHEATED STEAM - 540 0C STEAM FLOW AT REHEATER OUTLET - 1392.4 t/h ENTRY PRESSURE OF REHEATED STEAM - 45.04 kg/sq.cm ENTRY TEMP. OF REHEATED STEAM - 337 0C EXIT PRESSURE OF REHEATED STEAM - 42.39kg/sq.cm EXIT TEMP. OF REHEATED STEAM - 240 0C FEED WATER INLET TEMP. - 254.5 0C FEED WATER TEMP BEFORE ECO. - 283 0C FEED WATER TEMP AFTER ECO. - 357 0C

TEMP.AT LTSH OUTLET - 436 0C TEMP.AT S/H DIVISIONAL OUTLET - 488 0C TEMP.AT FINAL S/H OUTLET - 540 0C

DESIGN PARAMETERS OF BOILER BOILER DRUM PRESSURE- 209 kg/sq cm SH OUTLET PRESSURE - 191 kg/sq cm FINAL SH TEMP. - 540 0C REHEATER OUTLET PRESSURE - 52.4 kg/sq cm BOILER HYD. TEST PRESSURE - 313.5 kg/sq cm REHEATER HYD. TEST PRESSURE - 78.6 kg/sq cm

HEATING SURFACE OF BOILER ECONOMISER - 20000 sq mtr WATER WALL - 7000 sq mtr STEAM COOLED WALL - 2010 sq mtr LTSH - 8500 sq mtr SH DIVISIONAL PANELS - 2025 sq mtr PLATEN SH (FINAL SH) - 2200 sq mtr SH ROOF - 830 sq mtr RH FRONT COILS - 4128 sq mtr RH REAR COILS - 3500 sq mtr TOTAL HEATING SURFACE AREA = 50193 sq mtr

WATER HOLDING CAPACITY OF BOILER BOILER DRUM (FULL) : 60 cubic mtr CIRCULATION SYSTEM : 170 cubic mtr ECONOMISER : 150 cubic mtr SUPERHEATER(LTSH,SH Div. Panel, Final SH): 130 cubic mtr REHEATER : 105 cubic mtr TOTAL VOLUME : 615 cubic mtr DM WATER REQUIRED FOR HYD. TEST (DRAINABLE) : 420 cubic mtr

SOOT BLOWER DETAILS WALL SOOT BLOWERS : 88 Nos. (FUTURE - 16 Nos.) (FRONT & REAR AT EACH ELEVATION - 6 Nos. EACH, RHS &LHS -5 Nos. EACH, TOTAL 4 ELEVATIONS) LRSB : 40 Nos. (FUTURE - 4 Nos.) APH SOOT BLOWERS :2 Nos.

COMPARISON BETWEEN NATURAL & ASSISTED CIRCULATION BOILERS S/H S/H DRUM DRUM BOILER WALLS BOILER WALLS ECO ECO CC PUMP FEED LINE FEED LINE RING HEADER RING HEADER NATURAL CIRCULATION BOILER (SUB CRITICAL BOILER 30MW-250MW) DRUM CG. 26 MTR – 58 MTR ASSISTED CIRCULATION BOILER (500MW) DRUM CG – 75.33 MTRS FORCE CAUSING FLOW OF WATER THROUGH TUBES F = WCOLD X H1 - W HOT X H2

CRITICAL BOILERS OR ONCE TROUGH OR MONOTYPE BOILER S/H STEAM BOILER WALLS SEPERATOR WATER ECO DRAIN FEED PUMP

IMPORTANT FEATURES OF 500 MW BOILER C.C. PUMPS ORIFICE PLATES IN BOTTOM RING HEADER RIFLED TUBES IN WATER WALLS DIVISIONAL SUPERHEATERS ECO LINK CONNECTIONS FROM BOTTOM OF BOILER DRUM DOWN COMMERS CONNECTION TO ONLY BOTTOM RING HEADER. ECO RECIRCULATION CONNECTION TO BOTTOM RING HEADER REAR. 2 NOS. TRISECTOR TYPE AIR PREHEATERS. 8 NOS. BOWL MILLS ( XRP 1043 TYPE) & GRAVEMETRIC 36” SIVE FEEDER ( FEEDER LOCATION 21 ML ) 4 NOS OIL ELEVATION & 8 NOS. COAL ELEVATION. 2 NOS. I.D FANS, 2 NOS. F.D.FANS, 2 NOS. SEAL AIR FAN, 11 SILENCERS , 20 SAFETY VALVES HEA INNITERS. COAL CONSUMPTION – 8400 T/HR.

NUMBER OF TUBES & DIAMETERS DESCRIPTION NO. OF TUBES / PANELS DIAMETER OF TUBE IN MM RISER TUBES( W/W O/L HDR. TO DRUM) 68 NOS. 159 WATER WALL ( FUSION WELDED ) FRONT-269 NOS., REAR-269 NOS, LHS-212 NOS, RHS-212 NOS. 51 HANGER TUBES 44 NOS. 63.5 SCREEN TUBES 177 NOS. REAR ARCH EXTENDED SIDE W/W PANEL LHS-37 NOS.& RHS-37 NOS. ECONOMISER 92 X 3 BANKS 38.1 LTSH 62 X 2 BANKS 47.63 DIVISIONAL PANELLETE 6 ASSY. & 8 PANELS i.e. 48 NOS. 44.5 FINAL SUPERHEATER 25 COILS REAHEATER FRONT-74 NOS. & REAR 74 NOS. 54 RADIENT ROOF 1ST PASS 150 NOS. SUPER HEATER CONNECTION TUBES(DRUM TO RADIENT ROOF ) 21 NOS. B.P. SIDE WALL ( FRONT ) 60 NOS. B.P. SIDE WALL ( REAR ) 31 NOS. B.P. ROOF TUBES 126 NOS. B.P.FRONT SCW TUBE B.P.REAR WALL TUBE 137 NOS.

SAFETY VALVES LOCATION M.S.LINE HRH LINE CRH LINE DRUM SAFETY VALVE 2 4 6 ERV (ELECTROMATIC RELIEF VALVE)