SPIRAL WALL SYSTEM OF 2 X 660 MW

REPORT
ON

SPIRAL WALL SYSTEM OF 2 X 660 MW

(BARH STPP STAGE-II)
AT

BHEL :PSER:BARH SITE

Prepared By:
RohitManjhi
Engineer
BHEL PSER Barh site

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Guided By:
Mr. S Chatterjee
SDGM
BHEL PSER Barh site

By Rohit

SPIRAL WALL SYSTEM OF 2 X 660 MW

Acknowledgement
First and foremost, I would like to thank my guide for this report, Mr. Sumanta Chatterjee,
Senior. Deputy General Manager, BHEL:PSER:BARH Site for his valuable guidance and
wholehearted support in completing my report as well as enriching my knowledge. His advice
from time to time has been very helpful; without which this report would not have been
possible.
Besides, I would like to thank my esteemed organization , BHEL for providing me with a good
environment and facilities to complete this report. It was am opportunity to study and learn
about various welding & NDE work , which are inevitable while erecting spiral wall system.
Finally, I am grateful for the support which I have received from Mr. D Guha GM
/Projects(Barh), Mr. M Prasad AGM, Our Technical associate ASTOM India Barh site &
colleagues during this total exercise.

Rohit Manjhi

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By Rohit

SPIRAL WALL SYSTEM OF 2 X 660 MW

Contents
SL NO

DESCRIPTION

1.

Introduction

1-3

2.

Why do we use Spiral wall system

4- 4

3.

Detail of spiral-wall system

4-10

4.

Critical checks on spiral wall system

11-18

5.

References

19-19

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PAGE NO.

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SPIRAL WALL SYSTEM OF 2 X 660 MW

1. Introduction
Supercritical Boiler technology is gaining acceptance worldwide as Clean Coal Technology
due to its significant advantages like higher overall plant efficiency, reduced coal
consumption, reduced gaseous emissions like SO2, NO2 and CO2 and particulate
emission. Large capacity units of size 600 to 1000 MW are now built up with supercritical
parameters. In India, the trend is clearly towards large capacity Mega / Ultra Mega Power
Projects based on supercritical technology. Evaporators of once through supercritical
boilers are designed with either high mass flux spiral/vertical wall or low mass flux vertical
wall.
The major difference between a drum type boiler and once through supercritical boiler is the
furnace wall design. An once through furnace wall design needs to take care of the
temperature difference between tube-to-tube at furnace wall outlet due to the variation in
furnace
heat absorption. Also the occurrence of boiling crisis, associated metal
temperatures need to be critically analyzed and taken care in the furnace wall design. There
are basically two types of furnace wall designs used namely helically wound spiral wall and
vertical wall. The design aspects of these two types of furnace wall are discussed in this
paper.

TEMPERATURE ENTROPY DIAGRAM OF SUPERCRITICAL RANKINE CYCLE

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Key parameters of Super Critical Boiler at Barh

Main steam flow

2120 T/hr

SH steam pressure

255 kg/cm2

SH steam temp.

568 deg centigrade

Feedwater temp.

294 deg centigrade

RH steam flow

1708 T/hr

RH steam pressure

54.7 kg/cm2

RH steam temp.

596 deg centigrade

What are the key differences between the subcritical units

and the Supercritical units?
Efficiency
The main advantage and the reason for a higher pressure operation is the increase in the
thermodynamic efficiency of the Rankine cycle.
Large Subcritical thermal power plants with 170 bar and 540 / 540 C (SH / RH) operate at
an efficiency of 38 %. Supercritical units operating at approx 250 bar and 600/610 C can
have efficiencies in the range of 42 %.
Ultra supercritical units at 300 bar and 615 / 630 C will still increase the efficiency up to 44
%.
Increase in efficiency directly lead to reductions in unit cost of power and CO2 emissions.

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Operational Flexibility
Most of the Supercritical units use the once-through technology. This is ideal for sliding
pressure operation which has much more flexibility in load changes and controlling the
power grid.
However this also requires more sensitive and quick responding control systems.

Evaporation End Point

In subcritical units the drum acts as a fixed evaporation end point. The furnace water walls
act as the evaporator. Not so, in the case of a supercritical unit. The evaporation end point
can occur in various levels of the furnace depending on the boiler load. The percentage of
Superheat in supercritical units is higher than subcritical units. Because of this the furnace
tubes act more as superheaters than waterwalls. This necessitates the use of higher grade
of materials like alloy steels in the furnace.

Heat transfer Area

Higher steam temperatures in supercritical units results in a lesser differential temperature
for heat transfer. Because of this, heat transfer areas required are higher than subcritical
units.
Higher Superheat steam temperatures entering the HP turbine also mean higher reheater
inlet temperatures which again results in a higher heat transfer areas.

Materials
Supercritical power plants use special high grade materials for the boiler tubes. The turbine
blades are also of improved design and materials. In fact, the very increase in higher
pressure and temperature designs are dependent on the development of newer and newer
alloys and tube materials.
The aim of the industry is to achieve power plant efficiencies in the range of 50 %.

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SPIRAL WALL SYSTEM OF 2 X 660 MW

2. Why do we use spiral wall system:i)

Smaller OD tubes.

ii)

Helically wound spiral wall construction in which the tubes are inclined (15 to
25 deg.) and furnace tubes pass through the circumference of the furnace
more than one time and connected to a transition header above the burner
zone. Above the transition header the furnace enclosure is made up of
vertical water wall tubes. The spiral wall concept reduces the number of
parallel tubes and hence increases the mass flux through the tubes. As all
tubes pass through all the furnace walls, any variation in heat absorption is
applicable to all these tubes and hence the temperature difference between
these tubes is minimized.

iii)

To achieve reliable cooling, the mass flux generally adopted is around 2000
kg/(m2s) at full load. It may be chosen higher for other reasons, e.g. to lower
the minimum load for once through operation.

iv)

Smooth tubes are adequate, as the mass flux is high.

v)

By using spiral wall system total height of the boiler get reduced.

3. Details of spiral wall system in 660 MW

Barh stage II project:Joints detail of spiral wall system as per FWS:SL
NO.

MATERIAL
SPEC.

DIM(mm)

SA213 T22
+ SA 213
T22
SA213
T22+
SA182 F12
CL2

Dia 41.3
+ 41.3

NO. OF
JOINTS

TIG & ARC

9498

TIG & ARC

TIG & ARC

ELECTRODE

WPS
NO.

TIG
ER90S
B3

ARC
E 9018B3

1032

ER80S
B2

E 8018B2

1011/01

ER70S
A1

E 7018A1

1005/05

Dia 38.1
+ 38.1

SA106
Dia
GR.C+SA23 406.4+
4 WPC
406.4

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PROCESS
OF WELD

By Rohit

1031/01

SPIRAL WALL SYSTEM OF 2 X 660 MW

Sequence wise snapshot of spiral wall system at 2X660 MW Barh

stage-II project.

Term-Tube
Transition
Header

Assembly of transition header with terminal tubes at pre-assembly area

Pre-assembly/Fit-up of spiral wall panel for matching confirmation

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Tube welding of transition header term tube with vertical water wall panel

Pre-assembly of tension bar with spiral wall panel

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Scallop
Bar,

Tension Bar,
Material-

MaterialSA387 Gr
22 Cl 2

SA387 Gr 22
Cl 2

Thickness12 mm

Thickness30mm

Pre-assembled spiral wall panel ready for lifting after DP & sponge test

Lifting of assembled right side spiral wall panel

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Buck stay
fitted with
stir-up
system &
spiral panel
Tension bar

Corner tube joints

Assembly of sofa panel

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Burner panel fit-up at boiler-IV corner-1

A view of bottom side Spiral wall system

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SPIRAL WALL SYSTEM OF 2 X 660 MW

Assembled bottom ring header with term tube

Assembled bottom ring header with term tube

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SPIRAL WALL SYSTEM OF 2 X 660 MW

4. Critical checking of spiral wall panel

SL
NO.

CHECKING DESCRIPTION

Physical verification of header, panels,

Tension bar, scallop bar etc.
Measurement of materials as per
FQP/drawing

As per FQP/Drawing

Header(1mm/M),
Panel(+2mm or -5mm)

Fit-up checking of tube joints, panel fin to

fin joints, tension bar, Scallop bar.
Root gap checking of tube joints, panel fin
to fin joints, TB & SB .

Mismatch(2.5 mm)

Tube(2 to 5mm),fin(3 mm),

TB(3 to 4 mm)

Visual inspection of weld joints

As per ASME code & FQP,

Reinforcement(0.5 to 4 mm)
, weave(3X dia of electrode)

Vi

Nomenclature of weld joints.

As per FQP/drawing

Vii

DP test of weld joints as per FWS &FQP

As per FWS/FQP, 10% for

TB,SB & fin (T-22 & T-12 )

Viii

Radiography test of weld joints as per

FWS &FQP
If found some discrepancy in the weld
segment in RT/DP Test, required to do
repair for the same & take RT/DP (as per
requirement) for confirmation
PWHT/SR of applicable weld joints as per
FWS

Asper FQP/FWS, 20% RT

As per ASME code & NDE

MANUAL

As per WPS (+ or 15 deg

centigrade)

Ii

Iii
Iv

Ix

CLASS OF TOLERENCE
CHECK

Material Test Report of Tension Bar, Scallop Bar & Fins,

Nomenclature of weld joints and Protocols of
Radiography Test, Dye Penetration Test & Post Weld
Heat Treatment are attached below:-

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Nomenclature of weld joints

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5. References:

FWS of 2X660 MW Barh stage-II

Approved drawing of Barh stage-II , Boiler unit-IV

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