PRESENTED BY

MAHAVIR RATHORE
 INTRODUCTION
BOILER DRUM IS DEVICE WHICH
SEPARATE THE WATER FROM
THE STEAM & WATER MIXTURE
GENERATED IN FURNACE WALL
AND REDUCE THE DISSOLVED
SOLID CONTENTS OF THE STEAM
TO BELOW THE PRESCRIBED
LIMIT OF 1 PPM.
 MODIFIED RENKINE CYCLE

1-2 WORK DONE BY BFP

5 6
2-3 HEAT ADDITION IN ECONOMISER
T5
3-4 HEAT ADDITION IN FURNACE WW
3 4 4-5 HEAT ADDITION IN SUPERHEATER
5’ 5-5’ WORK DONE BY HP TURBINE
T
2 5’-6 HEAT ADDITION IN REHEATER
6-7 WORK DONE BY IP&LP TURBINE
T1 1 7-1 HEAT REJECTION IN CONDENSER
7

S
 300 MW

M.S. LINE
HRH LINE
CRH
FROM CRHLINE
LINE

FROM F.R.S
 ERECTION OF DRUM
• The drum is placed at the upper part of boiler 164 tons of
whole weight.The weight of drum’s hanger is13 tons.
• Sort, count and number the equipments after opening the
package.
• Remove the drum’s inside devices that will be installed
after chemical cleaning and store them in storehouse.
• Review the vertical and horizontal center line. Line the
horizontal center line as per a quarter of the perimeter of
drum while take the center of the connecting surface
between down comer and base as norm. The horizontal
center line shall be compared with the mark of the center
line of equipments and signed with punch. Line out the
center line of drum’s hanger according to drawing and
take it as the norm of hanger’s erection.
• Check the drum, inside device and alloy parts of hanger by
spectrum before erection.

• Temporarily hang the hanger on the drum by chain block

before lifting drum.

• Aligning norm of drum: setting dimension will take the

boiler’s center line as norm; take 1m elevation of the steel
structure as the norm for the elevation; measure the
horizontality and elevation by horizontal tubes and do
record.
• Alignment method: take the center line of column E-G3
and E-G5 as norm to ensure the longitudinal and
latitudinal deviation of drum; take the elevation that is
marked on the column E-G3 or E-G6 as norm(as per the
accuracy of the 1 meter elevation to choose the column)
to ensure the elevation and horizontality deviation of the
drum.

• The hydraulic lifting device can be removed after the

alignment and reinforcement of drum being finished. The
alignment of drum shall be assisted by the hydraulic
lifting device.
• The drum shall be reinforced on boiler structure by relative
big sized steel after the alignment of drum. The reinforcing
measures shall be removed after the erection of pressure
parts and before boiler water pressure test.
• The quality control of drum’s erection:
• The deviation of elevation shall be not more than ±5mm(for
the final one when all the connecting pipes’ installation is
completed) ;
• The deviation of horizontality shall be not more than
±2mm;
• The distance deviation between drum’s center line and
boiler’s center line shall be not more than ±5mm.
WHY WE REQUIRE BOILER
DRUM
 Function of drum
1.To store water and steam sufficiently to meet
varying load requirement
2. To aid in circulation
3. To separate vapor and steam from water steam
mixture, discharge by riser.
4. To provide enough surface area for liquid steam
disengagement.
5. To maintain certain desired PPM in the drum
water by tri sodium phosphate inject and blow
down.
CONTINUE………..
 DRUM AND INTERNALS
 THE DRUM IS EQUIPED WITH-

 TWO DUAL COLOR WATER LEVEL GAUGES

 ONE ELECTRICAL WATER LEVEL GAUGE FOR PURCH WATER
FILLED
 FOUR SINGLE ROOM BALANCE VESSLES
 PRESSURE MEASURING POINT
 METAL TEMP. MEASURING POINT
 SAFETY VALVES
 VENT LINE
 NITROGEN FILLING LINE
 CHEMICAL FEEDING LINE
 MAIN HOLE
 DRUM INTERNAL
Drum internals is single sect vaporize system, the first stage
distributor is turbo separator (vertical) of Φ315,. The second
stage distributor is corrugate plates, total 104, they are arranged
at two lines along C.L of drum shell, which is symmetrical;
corrugate plates are located at lean 5, little separated water flow
into water space through drain tube located on bottom of drum,
on top of drum are equipped with equalizing hole plates. On
bottom of drum a baffle is equipped to avoid directly contact
between saturated water and feed water. In order to avoid water
over cooling and stagnating, the design values of production rate
of steam between front part and rear part is 0.35 to 0.65, which to
produce the pressure to in force mixture to flow from front to
behind, so the temperature of up and down of drum can be the
same.
The normal water level of drum is 100mm below the drum
centerline, the allowable fluctuate is ±50mm.
 DRUM INTERNALS
1. Cyclone separator
2. Drain pipe
3. Perforated plates
4. Corrugated plate
5. Feeding pipe
6. Blow down tube
7. Emergency drain tube
8. Baffle plate
9. Mixture of vapor and water
10. Saturation steam
11. Feed water
12. Return water
13. Chemical dosing tube
 DRUM SPECIFICATION
1. CONSTRUCTION - SINGLE
2. MATERIAL SPECIFICATION - DIN 13MnNiMo54
3. MANUFACTURER OF PLATE MATERIAL - GERMANY
4. ULTIMATE TENSILE STRENGTH OF PLATE - 575 MPA
5. DESIGN PRESSUER - 19.66MPA
6. DESIGN METAL TEMP. - 363 C
7. DESIGN STRESS AT WORKING METAL TEMP. - 205 Kg/CM2
8. DESIGN STANDARD - DIN
9. DESIGN THICHNESS FOR STRAIGHT PORTION - 97 MM
10. DESIGN THICHNESS FOR DISHED END - 127.8 MM
11. ACTUAL THICKNESS USED FOR STRAIGHT PORTION - 145 MM
12. ACTUAL THICKNESS USED FOR DISHED END - 145
13.OVERALL LENGTH OF DRUM - 22250 MM
14. INSIDE DIA. OF DRUM - 1800 MM
15. CORROSION ALLOWANCE - 4 MM
16. ELEVATION OF DRUM CENTER LINE FROM GROUND - 66800 MM
17. NO. OF CYCLONIC SEPARATOR - 108
19. NO. OF RISER STUB - 94
20. NO. OF DOWN COMER - 04
21. NO. OF SECONDARY DRIER - 2 ROWS
22. NO. OF FINAL DRIER - 2 ROWS
 CONTINUE…….

MAXIMUM PERMISSIBLE TEMP. DEFFRENCE BETWEEN ANY TWO PART OF THE DRUM

a. DURING NORMAL - 40 C
b. DURING ACCELERATED STARTING - 50 C
c. DURING SLIDING PRESS. OPERATION FROM 100% - 40 C
TMCR TO 40% TMCR

WATER CAPACITY AT MCR CONDITION B/W NORMAL - 23 M3

AND LOWET WATER LEVEL PERMITED
WATER VOLUME - 54 M3
 WORKING PROCEDURE OF DRUM
STEP–1 WATER ENTERS INTO THE DRUM THROUGH ECO FEED LINES
FORMING A COMMON HEADER AND FALL DOWN THROUGH
HOLES OF HDR AND COLLECTED ON THE LOWER SURFACE OF
DRUM.

STEP–2 WATER FALL DOWN THROUGH DOWN COMER AND ENTER INTO
WATER WALL LOWER HEADERS.

STEP–3 WATER GOES UP THROUGH WATER WALL AND THE MIXTURE OF

WATER AND STAEM ENTERS INTO THE WATER WALL UPPER
HEADER.

STEP-4 STEAM AND WATER MIXTURE FROM UPPER RING HEADER OF

WATER WALL ENTER INTO THE DRUM THROUGH RISER TUBES.

STEP-5 MIXTURE ENTER INTO THE DEFLECTING SEPARETOR AND

ROTATE DUE TO CENTRIFUGAL FORCE.
 CONTINUE…..

STEP 6 - DUE TO THE WEIGHT WATER PARTICAL FALLS DOWN ON THE

SALVER AND MIX WITH THE FEED WATER AND STEAM DUE TO
THE LIGHT DENSITY GOES UP.

STEP-7 STEAM ENTERS INTO THE SECONDRY OR CORRUGATED

SEPARATOR AND PASS THROUGH CORRUGATED FINS.
WATER PARTICAL FALLS DOWN AND MIX WITH FEED WATER.

STEP– 8 NOW STEAM ENTERS INTO THE FINAL CORRUGATED

SEPARATOR WHERE THE REST WATER PARTICAL FALLS
DOWN AND MIX WITH FEED WATER FLOWING THROUGH
CONNECTING PIPE AND STEAM FINALY GOES UP INTO THE
SATURATED STAEM LEAD LINE PASSING THROUGH
PEFORATED PLATES.
 CHEMICAL DOSING IN DRUM

IT IS USED TO REMOVE THE SILICA PARTICAL FROM

THE WATER COMING FROM THE ECO FEED LINE TO
AVOID CORROSION ON THE TURBINE BLADES. WE
USE TRI SODIUM PHOSPHATE WHICH REACT WITH
WATER AND SEPARATE THE SILICA PARTICAL
WHICH COMES DOWN THROUGH CONTINUOUS
BLOW DOWN LINE
 NITROGEN FILLING IN DRUM

FIRST DRUM INTERNALS ARE CEANED BY THE

CHEMICAL TO REMOVE THE FOREIGN
PARTICALS AND OTHER INGRADIENTS WHICH
ARE PRESENT OR STICKED DURING
MANUFACTURING THEN
NITROGEN IS FILLED INSIDE THE DRUM TO AVOID
THE REACTION OF THE INTERNALS WITH THE
OTHER FOREIGN MATERIALS AND ELEMENTS
AFTER CHEMICAL CLEANING
 PRIMING AND FOAMING

PRIMING –
IF THERE IS TOO MUCH MOISTURE CARRY OVER
BECAUSE OF HIGH WATER LEVEL OR A HIGH
STEAMING RATE.

FOAMING –
IT IS CONDITION RESULTING FROM THE FORMATION
OF BUBBLES ON THE WATER SURFACE.
 Boiler performance data (design coal)
Description Unit B-MCR T-MCR
SH flow t/h 1025 913.2
SH out pressure(gauge) MPa 17.5 17.3
SH outlet temp. Deg.C 540 540
RH flow t/h 841.9 755.3
RH inlet/outlet pres.(gauge) MPa 3.83/3.64 3.43/3.27
RH inlet/outlet temp. Deg.C 329.6/540 318/540
Feed water temp Deg.C 280 272
Drum pres.(gauge) MPa 18.7 18.28
SH 1st spray water flow t/h 6.23 19.08
SH 2rd spray water flow t/h 1.56 4.77
RH spray water flow t/h 6.36 2.91
CONTINUE………..
Furnace outlet gas temp. Deg.C 972 942
Final RH outlet gas temp. Deg.C 781 766
Final SH outlet gas temp. Deg.C 685 674
Primary SH outlet gas temp. Deg.C 426 423
Econ. Outlet gas temp. Deg.C 372 366
Exit gas temp.(modified) Deg.C 127 127
AH inlet air temp. Deg.C 25 25
AH outlet air temp. (PA/SA) Deg.C 225/343 251/341
Coal consumption t/h 173.74 155.88
Boiler design efficiency % 92.66 92.65
Overmuch air coefficient of outlet of eco. / 1.22 1.22
=
The SET Pressure and Capacity of Safety Valves and PCVS
Service Description Qty Set pressure Blow Capacity
(Mpa.g) down(%) (Kg/H)

SH outlet 1730WD 1 18.30 4 114000

SH outlet 1730WD 1 18.34 4 115000

Drum 1749WB 1 19.64 4 273000

Drum 1749WB 1 20.03 4 281000

Drum 1749WB 1 20.23 4 286000

PCV 3537W 1 18.12 2 119000

outlet
 Water Level Alarm and Protection of the Drum
Content Water value Operation measure

Normal water level (under the centre100mm

line of the drum)

Warning value of the high water level +100mm Check the water gauge, reduce the feedwater
1

Warning value of the high water level +150mm Open the emergency control valve promptly until the water
2 level is normal

Tripping value of high water level (The+250mm Emergency shutdown, an automatic control device delays time
emergency shutdown ) for 2 seconds

Warning value of the low water Level 1-100mm Increase the feed water, check the water gauge , stop blowdown

Warning value of the ow water level 2 -150mm Check the feedwater system, economize and water wall if they
runed normally

Tripping value of low water level (The-250mm Emergency shutdown, an automatic control device delays time
emergency shutdown ) for 2 seconds

Note: Warning value, tripping value are as to normal water level.

 THREE ELEMENT CONTROL SYSTEM
Steam

Drum Level
sensor

Normal

Controller
Feed Water Water
Flow sensor Level
Control
Valve Steam Drum

Feed Water
Steam Flow
Sensor

Trimming Signal
 Three-Element Drum Level Control
To address the issues of phasing still present in the two-element control strategy, a third
element, feed water flow is added to the drum level control strategy. In this system the
math summer output of the two-element controller is cascaded down to a second

Feed water Flow Controller to act as a Remote Set point.

The feed water controller is a fast acting flow controller, which uses feed water flow as
its process variable and steam flow as its set point. Thus for every pound of steam flow
leaving the boiler a pound of feed water is added. This loop has final control on the feed
water valve. As the remote set point from the two element level control changes with
steam flow and drum level variations due to blow down or other minor losses, the feed
water controller modulates its output to regulate the necessary feed water flow to keep
the drum level in a mass/heat balanced and level state.
Independent tuning of each controller allows for very precise control of the drum level
regardless of steam demand and feed water influences. However it is very important to
take the thermal dynamics of the boiler’s recovery rate into account when tuning the feed
water controller. If you fail to do this and set the controller reset too fast on the feed
water controller you may inadvertently sub-cool the drum and start a cyclic phasing
action much like that found in a two-element system. Do the math it will save you a lot
of heartache.
The three-element control strategy can easily handle large and rapid
load changes because it is matching the mass balance between the
steam flow from the boiler and the feed water flow to it. This strategy
is a must on multiple boilers sharing the same feed water header and
supply system, due to the variations in the available feed water flow to
any one boiler, while two or more boilers are on line. This is
irrespective to boiler size. Additionally if the boilers are subjected to
sudden or unpredictable demand changes such as in a batching
process, this strategy is capable of matching these demands without
operator trim corrections or supervision.