An animated presentation over Complete water steam circulation in a super critical boiler with flow chart. The water-steam path through various Systems (High pressure & Low pressure systems) in boiler for a 660MW thermal power plat, and also indicates the temperature and pressure variations after flowing through individual systems. Watch Live Presentation on YouTube: http://youtu.be/snIVrTmI4bM

1. WATER-STEAM CIRCUIT
in
SUPER CRITICAL BOILER
Prepared By: Hareesh VS
Jr.Manager
IOTEP BARH

2. BOILER PARAMETERS
Once Through, Single Reheat, Coal Fired, Balanced draft,
Main Boiler Type
Side Fired, Tower type & Symmetrical to Both Axis
Furnace :- 14.9 X 23.04 M
Boiler Area Second Pass :- 6.07 X 23.04 M X 2( Both side of Furnace)
Roof :- 44.35 X 23.04 M
Guarantee Bituminous Coal
Design Fuel LCV :- 3026 kcal/kg
HCV :- 3300 kcal/kg
Material of Construction 12X1MФ and 15X1MФ
Main Steam Flow 2225 T/Hr
Main Steam Pressure 256 Kg/cm2
Main Steam Temp 540 OC
RH Steam Flow 1746 T/Hr
RH Steam Pressure 46.13 Kg/cm2
RH Steam Temp 568 OC
Feed Water Temp 290 OC

3. Boiler Feed pump
Collecting Header
Economizer
3320C, 299kg/cm2
Suspension Tube
Tubes to furnace
ww first run
Furnace ww 1st Run Steam to steam
heat exchanger Hot
Furnace ww 2st Run suspension
Attemperator 1st
Suspension Tubes
Furnace ww 3rd run
Economizer Upper Block
Horizontal gas duct
ww FRH & HP
Heaters
Hanger tube 1 2900C, 304kg/cm2
Roof ww
Line From Economizer Lower Block Line From BFP
Hanger tube 2 Deaerator
Tubes to furnace
Convection ww ww first run
Steam to steam Boiler Feed Pump
Intermediate Header
heat exchanger
Separator
Platen super heater Inlet Header of Furnace
Stage 1,2,3 & 4 WW First run
Final Super heater Reheat system
HP Turbine IP & LP Turbine Distribution Header of
Furnace WW First run

4. Recirculation pump
Economizer
Suspension Tube
Tubes to furnace
ww first run
Furnace ww 1st Run
Furnace ww 2st Run
Attemperator 1st
Furnace ww 3rd run
Horizontal gas duct
ww
Hanger tube 1 Furnace WW First Run Collecting Header Furnace
WW first run
Furnace Front & Rear Water Wall
Roof ww
Lower panels And Extreme End
Hanger tube 2 First Run WW Outlet
panels of Side water Wall Lower Headers (Intermediate
Convection ww Headers)
part
Steam to steam
heat exchanger Tubes to Furnace Side Hot Furnace Front & Rear Hot
suspension Lower part suspension Lower part
Separator
Furnace Side Hot
Platen super heater Furnace WW first run panels suspension Lower Part
Stage 1,2,3 & 4
Final Super heater Reheat system Furnace Hot suspension
Lower Part collecting
HP Turbine IP & LP Turbine Header (3770C, 301kg/cm2)

5. Recirculation pump Side View of Boiler
Economizer
Suspension Tube
Tubes to furnace
ww first run
Furnace ww 1st Run
Furnace ww 2st Run
Attemperator 1st
Furnace ww 3rd run
Horizontal gas duct
ww
Collecting Header Furnace
Hanger tube 1
WW first run
Roof ww
Hanger tube 2 Extreme Panels of Side WW
Convection ww
Steam to steam
heat exchanger Furnace Side Hot
suspension Lower part
Separator
Inlet Header of Furnace Furnace Front & Rear Hot
Platen super heater Second Run suspension Lower Part
Stage 1,2,3 & 4
Final Super heater Reheat system Furnace Hot suspension
Lower Part collecting
HP Turbine IP & LP Turbine Header

6. Recirculation pump Side View of Boiler
Economizer
Suspension Tube
Tubes to furnace
ww first run Furnace WW Second Run
Furnace ww 1st Run Furnace Side Water walls Lower Part
Furnace ww 2st Run
Attemperator 1st Collecting Headers of Middle
Part of Hot Suspension
Furnace ww 3rd run
Furnace Hot Suspension
Horizontal gas duct Middle Part
ww HP Spraying Attemperator-1
Hanger tube 1 Tubes to Furnace Hot
Distribution Header to suspension Middle part
Roof ww Furnace 3rd Run
Hanger tube 2
Mixing Headers of Furnace
Outlet Headers of Furnace
Convection ww Second run WW panels
Second run WW panels
Steam to steam (4010C, 296kg/cm2)
heat exchanger
Separator
Platen super heater Furnace WW second run panels
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

7. Recirculation pump Side View of Boiler
Economizer
Suspension Tube Furnace WW Third Run
Tubes to furnace All Upper Panels of Furnace Front,
ww first run
Rear & Side Water walls
Furnace ww 1st Run
Furnace ww 2st Run
Attemperator 1st Outlet Headers of Furnace WW
3rd run panels at Horizontal Gas
Furnace ww 3rd run duct Bottom Area (Arch Area) Tubes to Intermediate
(4330C, 291kg/cm2) Headers of 3rd Run WW
Horizontal gas duct
ww
Furnace WW 3rd run panels Distribution Header to
Hanger tube 1
Furnace 3rd Run
Roof ww
Tubes to Inlet Headers of
Inlet Headers Furnace WW 3rd
Hanger tube 2 3rd Run WW
run panels
Convection ww
Steam to steam
heat exchanger
Separator
Platen super heater
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

8. Recirculation pump
Economizer
Hanger Tube 1
Suspension Tube (4410C, 288kg/cm2)
Tubes to furnace Collecting Header of
ww first run Furnace 3rd Run
Furnace ww 1st Run Horizontal Gas Duct WW
Furnace ww 2st Run Inlet Headers of Horizontal
Attemperator 1st Gas Duct WW
`
Furnace ww 3rd run Intermediate Headers of 3rd
Outlet headers of
Run WW
3rd run panels
Horizontal gas duct
(4430C, 291kg/cm2)
ww
Furnace WW 3rd run panels Inlet Header of Hanger
Hanger tube 1
Tube 1
Roof ww
Tubes to Inlet Headers of
Inlet Headers Furnace WW 3rd
Hanger tube 2 3rd Run WW
run panels
Convection ww
Steam to steam
heat exchanger
Separator
Platen super heater
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

9. Recirculation pump
Roof WW Inlet Header
Economizer
Roof Water Wall
Suspension Tube
Tubes to furnace Roof Water Wall Collecting
ww first run Header (4480C, 284kg/cm2)
Furnace ww 1st Run Distribution Header of
Hanger Tube 2
Furnace ww 2st Run
Attemperator 1st Hanger Tube 2
`
Furnace ww 3rd run
Horizontal gas duct
ww
Inlet Header of
Hanger tube 1 Hanger tube 2
Roof ww
Hanger tube 2
Convection ww
Steam to steam
heat exchanger
Separator
Platen super heater
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

10. Recirculation pump Distribution Header Of
Upper Hot suspension
Economizer Convection Shaft &
Furnace Area
Suspension Tube
Tubes to furnace Collecting Header Of
ww first run Hanger Tube-2
(4520C, 281kg/cm2)
Furnace ww 1st Run Tubes to Furnace
Hot Suspension
Furnace ww 2st Run
Attemperator 1st
`
`
`
`
`
`
Hanger Tube-3
`
Furnace ww 3rd run Convection Shaft
Convection Shaft Hot Suspension
Horizontal gas duct
ww Water Walls
Hanger tube 1 Tubes to Convection Hot
Suspension
Distribution Header of
Roof ww
Convection Shaft WW
Tubes to Hot Suspension
Hanger tube 2
Collecting Header
Convection ww
Steam to steam
heat exchanger
Separator
Platen super heater
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

11. High Pressure Spray
Recirculation pump Attemperator – 2
(4390C, 273kg/cm2)
Economizer
Wet Steam
Suspension Tube
Separator
Tubes to furnace
ww first run High Pressure Tubes to
Collecting Header of SSHE
Furnace ww 1st Run (4570C, 274kg/cm2)
Furnace ww 2st Run
Drain Header
Attemperator 1st
`
`
`
`
`
`
`
Furnace ww 3rd run Moisture Content in
Steam After Separation
Tubes to Steam To Steam Heat
Horizontal gas duct
Exchanger
ww
Collecting Header of
Hanger tube 1 Convection Shaft WWs &
Steam To Steam Heat Hanger Tube – 3
Roof ww Exchanger (4650C, 278kg/cm2)
Hanger tube 2
Convection ww
Steam to steam
heat exchanger
Separator
Platen super heater
Stage 1,2,3 & 4
Final Super heater Reheat system
HP Turbine IP & LP Turbine

12. Recirculation pump Tubes to Platen Super
Heater
Economizer (4390C, 273kg/cm2)
Suspension Tube Spray Type
Attemperator -3
Tubes to furnace (5110C, 259kg/cm2)
ww first run Tubes to Final
Super Heater
Furnace ww 1st Run (5000C, 258kg/cm2)
Furnace ww 2st Run
Convection Super Heater
Attemperator 1st (Final Super Heater)
`
`
`
`
`
`
`
Furnace ww 3rd run Main Steam
Out Let Header
Horizontal gas duct (5400C, 256kg/cm2)
ww
Platen Super Heaters
Hanger tube 1 Stage 1, 2, 3 & 4.
Roof ww
Steam Flow in 4 Stages of
Hanger tube 2 Platen Super Heater
Convection ww Rear
Steam to steam I/L
heat exchanger
Separator
O/L
O/L
Platen super heater
Stage 1,2,3 & 4
Left
Right
Final Super heater Reheat system
I/L
HP Turbine IP & LP Turbine
Front

13. Recirculation pump
Economizer LP Spray
HRH Line
Atemperator
Suspension Tube
LPR Stage – 2
Tubes to furnace (Final) Collecting Header
ww first run of LPR
Steam to Steam
(4840C, 47kg/cm2)
Heat Exchanger
Furnace ww 1st Run
Main Steam Line to TG(5400C, 256kg/cm2)
CRH Line from
Furnace ww 2st Run HP Turbine
Hot Re Heat Line (5680C, 46kg/cm2)
Attemperator 1st
`
`
`
`
`
`
`
Cooled Re Heat Line (2970C, 48kg/cm2)
Furnace ww 3rd run LPR Upper Suspension Tubes
of LPR
Horizontal gas duct LPR Middle
ww
LPR Lower
Hanger tube 1
Tube to Low Pressure
Roof ww Reheater
(4490C, 28kg/cm2)
Hanger tube 2
Convection ww
Steam to steam Generator
IP Turbine
Coupling
HP Turbine
heat exchanger LP Turbine Generator
Cooling Water
Separator Condenser
Platen super heater Hot Water to Cooling Tower
Deaerator
Stage 1,2,3 & 4 LPR Stage - I
Final Super heater LPR Stage - II
Water Line To Boiler Feed Pump
HP Turbine IP & LP Turbine Make Up Water Line From
DM Plant