Project name: Packaged Boiler 155,000 PPH
September 15th, 2020
Technical Specification of Boiler:
One (#1) package boiler , "A" Type watertube boiler including complete pressure part fully assembled and tested with superheater, outer casing, burner assembled, refractory and insulation, FD-FAN, Economizer package, ducts and cheminey. Constructed in accordance with the ASME Code, section I for Power Boilers.
"A" Type Design Features:
The water-tube steam generator is of the "A" type design with integral furnace and two (#2) convection boiler banks. The flue gases enter the convection zone at the rear of the furnace on both sides and circulate through the boiler bank toward the front of the unit and exit at the front top of boiler thereby taking up less floor space than a “D” style boiler arrangement.
The steam generator is designed for pressurized operation. The gas tight construction is achieved by providing continuous seal welded finned tubes for the furnace floor, sidewall, roof, boiler sidewalls, front wall and rear wall. The unit is submitted to an air pressure test at the maximum furnace pressure with all seams checked with soapy water.
The steam generator pressure parts is fabricated and hydrostatically tested in accordance with the latest edition of the A.S.M.E. Code, Section I Power Boilers.
All seams are fusion welded, X-rayed and stress relieved. The steam and mud drums are provided at each end with a 12" x 16" manhole opening and cover. All tube holes are serrated. The steam drum is supplied with suitably designed internal distribution piping for feedwater, chemical feed, continuous blowdown and steam separators as required to maintain the guaranteed steam quality and purity.
Two (#2) air cooled observation ports are provided in the rear wall. One gas tight insulated protected furnace access door (14” x 18") and one underneath observation door (12" x 10") are provided at the rear of the unit.
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September 15th, 2020
"A" Type Boiler Description:
One pressure parts module complete with front wall, rear wall, division wall, outer wall and the superheater.
This module will be shipped with insulation and outer casing along with burner assembled on. Furnace tubes will be supplied finned and formed fully assembly in package. They will not need to be installed, expanded and seal welded.
Front and rear walls will be supplied assembled with bottom and top headers assembly in package.
Riser and feeder pipes will not need to be field connected to drums.
Required seal plate material, refractory, insulation and outer casing will be supplied in packaged Boiler.
Furnace tubes, front and rear walls and all above listed are fully assembled in the Boiler package.
Technical Data:
Boiler type: ‘’A’’ Type Burner Model: Burner supplied by COEN Heat medium: Superheated steam Maximum Output: 155,000 lb/hr Design pressure: 750 psig Operating pressure: 650 psig Min. Steam Temperature: 750 oF Feedwater Temperature: 225 oF Main fuel: Natural Gas Backup fuel : Fuel Oil Location: Outdoor
Heating surfaces:
Radiant Area: 1,117 ft2 Convection: 9,314 ft2 TOTAL: 10,431 ft2 Economizer: 8,499 ft2
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September 15th, 2020
Furnace dimensions:
Volume: 2,158.96 ft3 Total length: 35.00 ft Width: 8.46 ft Height: 9.92 ft
Steam :
Separating equipment Labyinth Purity 1 ppm
Overall dimensions :
Length casing to casing: 44’-0" Width casing to casing: 12’-6.5"’ Height base to water/steam outlet: 17’-2.5"
Approximated weight (with burner) :
Shipping: 161,700 lbs
Refractory, insulation and casings:
Membrane front wall: 1" insulating board ¼ in min steel inner casing 2" insulating blanket 0.064 in. corrugated stucco finish lagging
Membrane rear wall: 1" insulating board ¼ in. min gas tight inner steel casing 3" insulating blanket 0.064 in. corrugated stucco finish lagging
Boiler sides: 3 in. insulating blanket 0.064 in. corrugated stucco finish lagging
Boiler roof: 3 in. insulating blanket 0.100 in utility finish lagging
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September 15th, 2020
Furnace floor: Castable refractory over drum 3 in. insulating blanket under tubes
Steam drum: 3 in. insulating blanket 0.100 in utility finish lagging c/w protection
Drum heads: 3 in. insulating blanket 0.064 in. stucco finish lagging
Exposed surface preparation SSPC-1 & SSPC-3
Exposed surface painting one coat primer + one coat of standard high Temperature paint
The outer casing surface temperature shall not exceed an average of 50oF above ambient temperature with a surface air velocity of 100 ft/min. when the boiler is operating at maximum continuous capacity.
"A" Type pressure parts : Dia. MWT Material Steam drum : 42" ID 2" SA-515-70 Steam drum heads : 42" ID 2" SA-515-70 Mud drum : 18" ID 1.156" SA-515-70 Mud drum heads : 18" ID 3" SA-515-70 Furnace tubes : 2" finned 0.105" SA-178 Gr.A Convection sidewall tubes : 2" finned 0.105" SA-178 Gr.A Convection free standing tubes : 2" bare 0.105" SA-178 Gr.A Superheater inlet header : 12” 1.125" SA-106 Gr.B Superheater outlet header : 12” 1.125" SA-335-P11 Superheater tubes : 2 ½” O.D. 0.165” SA-213 Gr.T22 Economizer tubes : 2” O.D. 0.150” SA-178-C Economizer header : 6” O.D. 0.280” SA-106-B
"A" Type boiler main connections: Qty. Dia. Steam outlet : 1 8" 600# RFLWN Feedwater : 1 4" 600#RFSO Blow-off : 2 1½" 600#RFSO Chemical feed : 1 1" SW
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September 15th, 2020
Burner windbox and Accessories:
A Coen Brand Low Nox burner is mounted on the boiler that will perform at 30PPM NOx with trun- down ratio 10:1 on NG and 8:1 on fuel oil.
Coen windbox and Low NOx burner assembly: FGR duct and damper PLC allen bradley based burner management system Remote combustion fan assembly on a common base The fan to windbox transition assembly
Other components:
Northern Blower FD FAN One economizer with support structure to allow for a rating of 165,000 PPH. Economizer to achieve 330°F stack temperature when firing natural gas at 155 000 PPH load Interconnecting piping from the steam drum outlet to the SH inlet header One stub stack
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September 15th, 2020
Photo 1: Boiler in fabrication shop
Photo 2: Boiler in Fabrication shop
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September 15th, 2020
Photo 5: Front wall and burner installation
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September 15th, 2020
Photo 6: Burner installtion
Photo 7: Control Panel - PLC Basis
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September 15th, 2020
Photo 8: Control Panel – PLC Basis
Photo 9: water column and Burner Damper
Page 10 of 11 Project name: Packaged Boiler 155,000 PPH
September 15th, 2020
Photo 10: Burner installation and front boiler
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