1OF5WME - Project/%Temp%/From CD Paiton3Maint2015/APS PlatformMM 1

Project Dwg. No: G101-25-1723.
09-L070
Boiler
MECHANICAL MAINTENANCE MANUAL
PT PAITON ENERGY
PAITON EXPANSION PROJECT
Boiler Maintenance
Manual No. MM-M01.01
Revision 004
Note
This mechanical maintenance manual is intended to provide the Paiton Expansion Project
mechanical maintenance personnel with the basic understanding required to perform preventive,
routine, corrective and overhaul maintenance activities on the subject equipment.
No part of this document may be reproduced for use by parties other than Mitsubishi Heavy
Industries, Ltd. and Paiton Expansion Project.
Boiler
Maintenance
Be sure to read this manual.

Contents
Safety
General
Specifications
Preventive Maintenance
Disassembly and Reassembly
Corrective Maintenance
Water Washing Method
Appendixes
Contents
Contents
Revision Record i
Important Information iii
Warranty vi
Limitation of Liability viii
Copyright x
Personnel to whom the Manual is Directed xi
Contact Address xii
Abbreviations xiii
List of Vendor Manuals xiv
Arrangement of the System Maintenance Manual xv
Chapter1
Safety ____________________________
1.1
Feature of Boiler Safety 1-1
1.2
Warnings Description 1-2

1.2.1
Definitions of Serious Injury, Minor Injury, Serious

Damage to Property, and Minor Damage to Property 1-3
1.2.2
Symbols 1-4
1.2.3
Hazards Warning Label 1-5
1.2.4
Hazard Area 1-7
1.3
Risk Assessment Standard 1-8
1.4
Safety Measures 1-10

1.4.1
Work Permit System (Lockout/Tagout) 1-10
1.4.2
General Cautions on Personnel in Working Area 1-11
1.4.2.1 Cautions against Rotating Equipment 1-11

1.4.2.2 Cautions against Electrical Equipment 1-12
1.4.2.3 Cautions against High Temperature Sections 1-13
1.4.2.4 Cautions against Steam Leak in the Plant 1-14
1.4.2.5 Cautions against Oil / Coal Leak in the Plant 1-14
1.4.2.6 Cautions against Chemicals 1-15
1.4.2.7 Cautions against Combustible Materials/Storage Areas 1-15
1.4.2.8 Cautions against Lack of Oxygen 1-16
1.4.2.9 Cautions against Lifting Heavy Object 1-16
1.4.2.10 Cautions against Sharp Objects 1-17
1.4.2.11 Cautions using Fork Lift 1-17
1.4.2.12 Cautions using Crane 1-18
Boiler
Mitsubishi
Contents
Chapter1
Safety (Continued from previous page)

1.4.2.13 Disposal 1-19
1.5
Emergency Measure 1-20

1.5.1
Evacuation on Emergency Case 1-20
1.5.1.1 Evacuation Route 1-20

1.5.1.2 Evacuation of Disabled Persons, Who Cannot Walk
by Themselves 1-20
1.5.1.3 Evacuation from Power House 1-21
1.5.2
Fire Accident 1-22
1.5.3
Earthquake 1-23
1.5.4
Explosion Accident 1-23
1.6
Qualification and Training 1-24
Chapter2
General ___________________________
2.1
Purpose 2-1
2.2
References 2-1
2.3
Overview of the Boiler and Auxiliaries 2-2
2.4
Boiler Components 2-12

2.4.1
Furnace Pass Wall, Passage Side Wall and 2RY Pass

Walls Tubes and Roof Tubes 2-12
2.4.2
Water Separator and Water Separator Drain Tank 2-15
2.4.3
Superheaters 2-16
2.4.4
Reheaters 2-20
2.4.5
Desuperheaters 2-23
2.4.6
Economizer 2-24
2.4.7
Boiler Supports 2-25
2.4.8
Casing and Insulation 2-26
2.4.9
Safety Valves 2-26
Chapter3
Specifications _____________________
Chapter4
Preventive Maintenance _____________
4.1
Prerequisites 4-1
4.2
Boiler
Mitsubishi
4.1.1
Scheduling 4-1
4.1.2
Interdepartmental Cooperation and Communication 4-2
4.1.3
Isolation of Equipment 4-2
4.1.4
Safety Precautions 4-2
Routine Maintenance 4-4
Contents
Chapter4
(Continued from previous page)
4.3
4.2.1
Preparation 4-4
4.2.2
Inspection and Maintenance 4-5
Outage Maintenance 4-14

4.3.1
Preparation 4-14
4.3.2
Inspection and Maintenance 4-15
Chapter5
Disassembly and Reassembly ________
5.1
Water Wall Tubes, Roof Tubes, Headers and Manifolds 5-1

5.1.1
5.2
Superheater Headers, Tubes and Desuperheaters 5-9

5.2.1
5.3
Recommended 10 Year Inspection 5-12
Reheater Headers, Tubes and Desuperheater 5-15

5.3.1
5.4
Economizer Headers and Tubes 5-19

5.4.1
5.5
Sample Tube Removal 5-22
Chapter6
Corrective Maintenance _____________
6.1
Prerequisites 6-1
6.2
Preparation 6-2
6.3
Boiler Tube Repair 6-2
6.4
Troubleshooting 6-2
Appendixes
Boiler
Mitsubishi
Appendix A
Torque Chart A-1
Appendix B
Recommended Spare Parts B-1
Appendix C
Special Tools C-1
Appendix D
Applicable Vendor Drawings D-1
Appendix E
Details of Refractory, Insulation, etc. E-1
Appendix F
Reference Drawings F-1
Contents
List of Figures
Boiler
Mitsubishi
Figure1-1
Types of Hazard Warning Labels 1-6
Figure 1-2
Boiler Mapping for Hazard Areas 1-9
Figure 2-1
Overview of Boiler & Auxiliaries 2-7
Figure 2-2
Cutaway View of Boiler 2-8
Figure 2-3
Flow Path up to the Water Separator 2-9
Figure 2-4
Flow Path of Superheated Steam 2-10
Figure 2-5
Flow Path of Reheat Steam 2-11
Figure 2-6
Pressure Parts Arrangement (Upper side) 2-28
Figure 2-7
Pressure Parts Arrangement (Upper side A-A of Fig. 2-6) 2-29
Figure 2-8
Pressure Parts Arrangement (Upper side B-B of Fig. 2-6)2-30
Figure 2-9
Pressure Parts Arrangement (Upper side C-C of Fig. 2-6)2-31
Figure 2-10
Pressure Parts Arrangement (Upper side D1-D1,

D2-D2 of Fig. 2-6) 2-32
Figure 2-11
Pressure Parts Arrangement (Upper side E-E of Fig. 2-6)2-33
Figure 2-12
Pressure Parts Arrangement (Upper side F-F of Fig. 2-6) 2-34
Figure 2-13
Pressure Parts Arrangement (Upper side G-G of Fig. 2-6))2-35
Figure 2-14
Pressure Parts Arrangement (Lower side) 2-36
Figure 2-15
Arrangement of Furnace Intermediate Headers 2-37
Figure 2-16
Sectional View of Rifle Tube 2-38
Figure 2-17
Rifle Tube Location in Furnace Wall 2-39
Figure 2-18
Arrangement of Spacer Tube & Girdling Tube 2-40
Figure 2-19
Pressure Parts Arrangement around Boiler (1/3) 2-41
Figure 2-20
Figure 2-21
Figure 2-22
Basic Plan of Water Wall Panels
Figure 2-23
Basic Plan of Water Wall Panels (2/3) 2-45
Figure 2-24
Basic Plan of Water Wall Panels (3/3)) 2-46
Figure 2-25
Typical Arrangement of Furnace Buckstay &

Boiler Stopper 2-47
Figure 2-26
General Arrangement of Buckstay-1/3 2-48
Figure 2-27
Figure 2-28
(1/3) 2-44
Contents
List of Figures (continued from previous page)
Boiler
Mitsubishi
Figure 2-29
Sectional View of Water Separator 2-51
Figure 2-30
Sectional View of Water Separator Drain Tank 2-52
Figure 2-31
Boiler Expansion Movement Diagram - 1/2 2-53
Figure 2-32
Boiler Expansion Movement Diagram 2/2 2-54
Figure 2-33
Arrangement of Boiler Header Supports 2-55
Figure 2-34
Typical Arrangement of Boiler Element Supports 2-56
Figure 2-35
Insulation of Finned Tube Walls 2-57
Figure 2-36
Insulation of Membrane Tube Walls 2-58
Figure 2-37
Insulation of Boiler Mountings 2-59
Figure 2-38
Boiler Access Door Insulation 2-60
Figure 2-39
Application of Refractory and Insulation for

Boiler and Pipes 2-61
Figure 2-40
Sectional View of a Typical Boiler Safety Valve 2-62
Figure 4-1
Criteria for Cleaning - Superheater Tube 4-19
Figure 4-2
Criteria for Cleaning - Reheater Tube 4-22
Figure 4-3
Damage to Refractory & Castable by Falling Clinker 4-25
Figure 4-4
Identification of Water Wall Tube Sample Location 4-30
Figure 5-1
Inspection Areas of Boiler 5-24
Figure 5-2
Overview of Furnace Walls 5-25
Figure 5-3
Furnace Wall Tube Panel Arrangement 1/2 5-26
Figure 5-4
Furnace Wall Tube Panel Arrangement 2/2 5-27
Figure 5-5
Overview of Passage Walls 5-28
Figure 5-6
Passage Wall Panel Arrangement 5-29
Figure 5-7
Overview of 2ry Pass Wall 5-30
Figure 5-8
2ry Pass Wall Panel Arrangement (1/3) 5-31
Figure 5-9
Figure 5-10
Figure 5-11
Overview of Economizer Assembly 5-34
Figure 5-12
Economizer Bank Arrangement 5-35
Figure 5-13
Overview of Roof Tube Walls 5-36
Figure 5-14
Arrangement of Roof Penetration Sealing 5-37
Figure 5-15
Overview of 1ry Superheater Assembly 5-38
Contents
List of Figures (continued from previous page)
Boiler
Mitsubishi
Figure 5-16
1ry Superheater Bank Arrangement 5-39
Figure 5-17
Figure 5-18
Figure 5-19
Figure 5-20
Figure 5-21
Overview of 1ry Reheater Assembly 5-44
Figure 5-22
1ry Reheater Bank Arrangement 5-45
Figure 5-23
Overview of 2ry Reheater Assembly 5-46
Figure 5-24
2ry Reheater Bank Arrangement 5-47
Figure 5-25
Sectional View of Desuperheater for Superheaters 5-48
Figure 5-26
Sectional View of Desuperheater for Reheater 5-49
Figure 5-27
Cable Opening Arrangement for Boiler Tubes 5-50
Figure 5-28
Ash Protector Arrangement for Boiler Tubes 5-51
Figure 5-29
Arrangement of Orifices in the Furnace Lower 5-52

Header Tubes
Contents
List of Tables
Boiler
Mitsubishi
Table 1-1
Risk Assessment Standard as per MIL STD822 1-8
Table 3-1
Boiler Specifications 3-1
Table 3-2
Water Wall Tube 3-2
Table 3-3
Water Separator 3-2
Table 3-4
Water Separator Drain Tank 3-3
Table 3-5
Roof Tubes 3-3
Table 3-6
Back Pass and Passage Wall Tubes 3-3
Table 3-7
Primary Superheater 3-4
Table 3-8
Secondary Superheater 3-4
Table 3-9
Tertiary Superheater 3-5
Table 3-10
Primary Reheater 3-5
Table 3-11
Secondary Reheater 3-6
Table 3-12
Desuperheater 3-6
Table 3-13
Economizer (Spiral Finned Tube) 3-6
Table 3-14
Economizer (Hanger Tube) 3-6
Table 3-15
Specification of Headers 3-7
Table 4-1
Routine Maintenance Check list 4-12
Table 4-2
Outage Maintenance Check list 4-26
Table 6-1
Troubleshooting Furnace, Superheater,

Reheater, Economizer 6-3
Table A-1
Torque Chart A-1
Table B-1
Recommended Spare Parts B-1
Table F-1
Boiler Pressure Parts Reference Drawings List F-1
Revision Record
Page Number
Page B-5
Description of Revision
Revision Issue
Date
Additional spare parts
Date Revised
Pages
Inserted
2011/06/13
2011/06/13
199
included.
Page E-1
Appendix E - Attached
~E-199
Assembly and Details of

Refractory & Insulations
Page 2-2
Chapter 2 Section 2-3 SH
2012/03/19
2012/03/01
2012/03/19
2012/03/01
2012/03/19
2012/03/01
2012/03/19
2012/03/02
steam & RH steam pressures

and temperatures values
corrected.
Page 4-15,
Chapter 4 Sub-Section 4.3.2
4-17, 4-20,
clause a), c), d) & e) para 1,
4-22,
added information related to

thickness survey.
Page 4-18,
Chapter 4 Sub-section 4.3.2
4-20
clause c) para 9 added

clearances between liner
DeSH body (1ry & 2ry DeSH),
clause d) para 8 RH clearance
DeSH between liner added.
Page 4-18,
Chapter 4 Sub-section 4.3.2
4-20
clause c) para 9, d) para 8

added inspection of
counterbore of positioning
/support bolt and fillet welding
part by ultrasonic test.
Boiler
Mitsubishi
Continued from previous page.

Page Number
Description of Revision
Revision Issue
Date Revised
Date
Page 4-18,
Chapter 4 Sub-section 4.3.2.
4-21
clause c) & d) Inspection &
Pages
Inserted
2012/03/19
2012/03/02
2012/03/19
2012/03/05
2012/03/19
2012/03/05
2012/03/19
2012/03/06
2012/03/19
2012/03/06
2012/03/19
2012/03/07
186
2012/03/19
2012/03/07
2012/03/19
2012/03/08
180
2012/09/19
2012/09/19
2012/09/19
Maintenance procedure for the

removal of exfoliated scale
inside SH & RH tubes added.
Page 4-24
Chapter 4 Table 4-2 Outage
~4-27
Maintenance Check list

updated.
Page 5-29,
Chapter 5 Figures 5-6, 5-8,
5-31, 5-32,
5-9, 5-10, 5-12, 5-16, 5-18,
5-33, 5-35,
5-20, 5-22 and 5-24 (corrected
5-39, 5-41,
tsr to ts and t-tsr to tsr)
5-43, 5-45,
5-47
E-6 ~ E-135
Figure 5-28 revised and added

table of materials.
Detail of Refractory and
Insulation replaced with latest
Revision 2
E-136 ~201
Insulation Procedure Detail

replaced with latest Revision 1
F-1 to F-186
Appendix F Reference
Drawings added
F-1 ~ F-6
Table F-1 Boiler Pressure

Parts Reference Drawings List
added
F-7 ~ F-186
Boiler Pressure Parts

Drawings added in Appendix F
4-23 ~ 4-24
Chapter 4, Sub-Section 4.3.2,

clause (g) revised
4-25
Added Figure 4-3 Damage to

Refractory & Castable by
Falling Clinker.
4-30
Figure number 4-3 changed to

Figure 4-4
Boiler
Mitsubishi
ii
Important Information
Purpose of the Plant Usage
This boiler is designed to generate steam at supercritical pressure and high steam
for producing net electric power of 815MW by the steam turbine generator.
The boiler is used only for electric power generation purpose that supports stable
and reliable electric power supply to the power grid and supplying steam for
auxiliary equipment in the power station.
General
1.
To satisfy the purpose mentioned above the following points must be strictly
observed,
a)
The operation, maintenance and inspection of the Boiler must be

performed by the persons who have basic technical knowledge and
have been trained concerning the hazard of the Boiler and the
avoidance of the hazard.
b)
The operators and maintainers must read and understand these

manuals before starting the operation, maintenance or inspection.
It is often experienced that serious damages to the equipment or
personnel have occurred by the unexpected action of operators or
maintainers who do not understand well about the equipment.
c)
The modification or change of operational specification must be

performed under MHI supervision or as per the written acceptances of
MHI.
The modification or change of specification causes not only a decline in
performance but also a decline in safety for operation of the equipment.
The customer is requested to discuss with MHI about any modification
or changes before the work actually starts.
The address for MHI to be contacted is shown in this chapter.
Boiler
Mitsubishi
2.
The operation and maintenance must be performed according to the

applicable laws and regulations at the location of the power station.
3.
Disposal from the power station must be treated to satisfy the local
regulations.
4.
The copyright of software, drawings and other documents provided by MHI

at all times, is still reserved by MHI.
iii
5.
Use or copying of the whole or part of any information provided by MHI for
any purpose other than operation and maintenance of this plant without
written consent is strictly prohibited.
Important General Notice for Safety

1.
The operator and maintainer must have knowledge about the equipment to
maintain good operating condition and to avoid danger when using the
equipment and systems.
2.
The protection measures must satisfy all of the operational functions.
3.
The safety activity must be planned systematically as Safety and Health

management system and operate continuously.
Safety and Health management system must include the following points,
a) Instruction for the use and the maintenance of the personal protective
equipment issued to operators and maintainers
b) The establishment of a work management organization to make clear
the operation directives and work procedures
c) Implementation of training for operator and maintainer
4.
The customer must train the operators and maintainers to act positively and
to prevent the occurrence of an accident by using their knowledge of the
power plant.
5.
The customer must make the operators and maintainers understand that the
most important purpose of safety control is to protect all personnel from
accidents and also to maintain operation of the plant without troubles.
6.
To prevent accidents involving personnel and equipment, it is necessary to

observe the notices of this manual and to keep the correct operation
according to the description provided in this manual.
If the notices are not observed, the following dangers could occur to the
operators and the maintainers:
7.
a)
Risk of a fatal accident
b)
Danger to lose their health and fitness
c)
Danger of damage to the equipment
MHI can not forecast all possible dangers existing in the plant such as
danger due to human error and/or dangers caused by the operating
environment.
As this manual and the alert label cannot cover all of the dangers, the
operators and maintainers have to pay their full attention to all general safety
notices.
Boiler
Mitsubishi
iv
8.
MHI can not be responsible for damages and injury caused by neglecting the
notices in this manual, and other necessary general notices.
Instruction of this Manual
Boiler
Mitsubishi
1.
This manual is provided for people familiar with the use of English. If some
person not familiar with English is going to operate the plant, the Customer
must train him specially.
2.
The warning labels are to be expressed in the English language.
3.
This manual contains optional matters.
4.
Some figures in this manual include internal parts of the equipment which
may not be obvious, when looking at the completed equipment drawing.
5.
MHI may change the content of this manual without notice.
6.
This manual is intended for the use by the operators and maintainers and it
must be accessible to them at all times.
7.
If the Customer needs more detailed information, please contact MHI local
office or MHIs official agent.
Warranty
The provisions set forth in this section are in addition to all liability and
warranty disclaimers and limitations set forth in the Contract, whether arising
under law or from course of performance, course of dealing, or usage of trade.
Nothing in these provisions shall constitute or be deemed to constitute any
additional liability undertaking or warranty, express or implied, with respect to
the Plant. All capitalized terms used, but not defined in this Warranty
Limitations section shall have the respective meanings ascribed to them in the
Contract.
The Contract Warranties are subject to the construction, installation and
commissioning works having been performed in full compliance with the
requirements stated in (a) the Contract, (b) all manuals provided by MHI,
including this manual, (c) all applicable rules, regulations and laws prevailing
in the location where the Plant has been installed and will operate, and (d) any
other instructions, if any, provided by MHI (collectively, Rules and
Requirements). The Contract Warranties will NOT cover any accidents,
partial or total failure of the Plant, losses or damages to personnel or property
(including, without limitation, the Plants components, parts, systems and
other equipment), or any other liability (collectively, Accidents and Damages)
in the case of any breach of the stated Rules and Requirements.
For the detailed terms and conditions of the warranty concerning the Works
and Project, refer to the Contract.
In addition to the foregoing, the Contract Warranties will NOT cover any of the
following Accidents and Damages:
Accidents and Damages caused by any deviation from the Rules and
Requirements;
Boiler
Mitsubishi
vi
Accidents and Damages caused by the modification or re-installation of the

Plant after the original installation, or caused by operation of the Plant for a
purpose other than that for which it is designed;
Accidents and Damages caused by natural disasters or accidents during
transfer or related handling;
Accidents and Damages occurring after the term of the warranty has expired;
Accidents and Damages due to faulty operation or operation not in
accordance with the Rules and Requirements;
Accidents and Damages due to inappropriate maintenance or servicing
performed by the Customer, its personnel or any other party.
Accidents and Damages caused by any components, parts, systems or other
equipment other than those delivered by MHI;
Accidents and Damages caused by unidentifiable reasons including loss of
the damaged parts which is necessary to pinpoint a cause of the failure;
Accidents and Damages caused by referring to inadequate, or incorrect
references, data or information provided by the Customer;
Accidents and Damages or rust/corrosion due to inadequate handling and/or
storage by the Customer; or
Accidents and Damages due to handling, storage and/ or use of the Plant
under severe conditions or in an environment that does not meet the design
specification conditions.
Boiler
Mitsubishi
vii
Limitation of Liability
Use and Disposal
Nothing in this Limitation of Liability section or manual shall constitute or be
deemed to constitute any additional liability undertaking or warranty, express
or implied, with respect to the Plant. All capitalized terms used, but not defined
in this Limitation of Liability section shall have the respective meanings
ascribed to them in the Contract.
The contents of this manual are subject to change without prior notice and
without any obligation or liability to MHI.
For Documents and Safety Training

Use of the Plant must be limited to the use specified by MHI, including without
limitation, use of the Plant in accordance with the Contract, this manual, all
Safety Manuals, all applicable laws and regulations, and any other instructions,
if any, provided by MHI. The Plant components, parts, systems and other
equipment (collectively, Equipment) must be appropriately disposed of in
accordance with the Contract, this manual, all Safety Manuals, all applicable
laws and regulations, and any other instructions, if any, provided by MHI.
For Damage to the Plant

The Customers personnel must read, understand and abide by all documents
provided by MHI, including without limitation, the operation and maintenance
manuals, safety manuals, and instruction manuals (collectively, Safety
Manuals) and must have received all required and/or necessary safety
training prior to the start of their work. Persons who have not received such
safety training are not permitted to work on the installed Plant. This initial
training, however, is merely the minimum requirements prior to allowing any
personnel to work on the installed Plant. The Customer must, on a continual
and regular schedule, give up-to-date training to its personnel on safety
requirements, provide testing or other methods to confirm their understanding
of the safety training, and confirm that they have the physical and mental
capability to perform their respective roles. The Customers obligation for
safety training and personnel supervision is an ongoing obligation and must
be continuously performed and kept current throughout the operation of the
Plant. Accidents, partial or total failure of the Plant, damage to personnel or
property, loss, injuries, and other liability (collectively, Liability) caused by
inadequate safety training or the Customers personnels failure to abide by
the documents provided by MHI are expressly excluded from the coverage of
any warranty provided by MHI and are the sole and exclusive responsibility of
the Customer.
Boiler
Mitsubishi
viii
MHI will NOT be liable for any Liability caused by modification or changes
made in Plant-related documents (including any Safety Manual) by anyone
other than MHI.
For Damage to the Plant

Accidents may occur by use of Equipment that is acquired from anyone other
than MHI or anyone not appointed by MHI to modify or repair this Plant. The
Customer shall not be permitted to modify or repair the Plant or change
Equipment of the Plant without MHIs prior written approval, under any
circumstance.
MHI will NOT be liable for any Liability resulting from any abuse, misuse,
misapplication of the Equipment supplied by MHI.
MHI will NOT be liable for any Liability caused by an act by the Customer in
violation of the Contract, this manual, any applicable law or regulation, or any
Safety Manual or any other instruction provided by MHI, including without
limitation, a change of the installation environment or the removal and
installation of any Equipment in a location different to that originally selected
by MHI.
MHI will NOT be liable for any Liability caused by a defect, imperfection, or
fault, in material or Equipment that was used during a repair, even when such
repair was performed by or under an instruction given by MHI.
Boiler
Mitsubishi
ix
Copyright
COPYRIGHT 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED.
ANY REPRODUCTION IS EXPRESSLY PROHIBITED.
All of the content contained in this manual is protected by Japanese, International
and/or United States copyright laws.
All copyright, trade secrets, and other proprietary and intellectual property rights in
the documents provided by Mitsubishi Heavy Industries, Ltd.(MHI) (including
safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject
to your compliance with the restrictions set forth below, MHI grants to you a limited,
non-exclusive license in the copyright for the sole purpose of allowing you to use,
operate, maintain and inspect the Plant.
Use, copying, other reproduction of the whole or part of the documents provided by
MHI (including safety-and-instruction manuals) for any purpose other than the
purpose described above without MHIs prior written consent is strictly prohibited.
The act of rewriting, translating, modifying, revising, creating electronic copies,
uploading, selling, sublicensing, or otherwise disclosing the whole or part of the
manuals is strictly prohibited.
Except as specifically set forth above, no right, title or license to the documents
provided by MHI, whether arising from contract, implication, estoppel or otherwise, is
being granted or otherwise transferred.
Boiler
Mitsubishi
Personnel to whom the

Manual is directed
This Manual was prepared for all personnel who will participate in the operation
and maintenance of the plant, and other related mechanical plant and equipment
installed.
In this Manual, MHI classifies personnel into the following two classes based on
their ability, experience and their attitude to the safety of personnel, and the plant
installed.
Only the personnel recognized by the Customer as trained personnel are allowed
to perform the operation and maintenance specified in the manuals.
Maintainers and Operators are required to have read and understood the contents
of the safety, operation, and maintenance manuals and sufficiently understand the
work procedures before actually starting their tasks.
Operator
Operators following the instructions of their supervisor or the Shift Charge

Engineer are permitted to handle materials to be used in the operation of the plant.
Operators are allowed to turn on the power supply, startup equipment, open up or
remove covers or panels on receipt of an instruction or authorization from their
superior.
Operators are permitted access to emergency stop devices following instructions
given by their superior when dangerous or hazardous situations are recognized.
Maintainer
Maintainers are permitted to perform maintenance on the plant. They will also
perform troubleshooting routine and periodical inspections of the installed
equipment. The maintainer will also work under the supervision of MHIs
supervisors during on-the-job training and annual maintenance and overhaul work
if MHIs supervisors are requested to witness periodical inspections, etc.
Maintainers MUST have attended the training programme initially provided by MHI
and subsequently by the Customer, and they must have obtained the necessary
knowledge and maintenance skills to understand the characteristics of their tasks
before actually starting their work.
Boiler
Mitsubishi
xi
Contact Address
For any question or any clarification required, please do not hesitate to contact MHI
through the following address (es).
For Support before Operation:

MITSUBISHI HEAVY INDUSTRIES, Ltd.
Nagasaki Shipyard & Machinery Works
1-1, Akunoura Machi, Nagasaki 850-063
For Support after Commissioning and in an Emergency

(later)
Boiler
Mitsubishi
xii
Abbreviations
Abb.
Expanded Form
Abb.
Expanded Form
1RY
Primary
IP
Intermediate Pressure
2RY
Secondary
ID
Induced Draft
3RY
Tertiary
IDF
Induced Draft Fan
AC
Alternating Current
LP
Low Pressure
AA
Additional Air
SP
Secondary Pass
AVT
All Volatile Treatment
MSDS
Material Safety Data Sheet
BCP
Boiler Circulating Pump
MW
Mega Watt
BMCR
Boiler Maximum Continuous

Rating
NDT
Non Destructive Test
DCS
Distributed Control System
OD
Outside Diameter
DeSH/DSH
Desuperheater
OJT
On Job Training
Eco.
Economizer
PAF
Primary Air Fan
ESP
Electrostatic Precipitator
P&ID
Piping and Instrumentation

Diagram
FD
Forced Draft
PPE
Personal Protective Equipment
FDF
Forced Draft Fan
PTW
Permit to Work
FGD
Flue Gas Desulphurization
PVC
Polyvinyl Chloride
GRF
Gas Recirculation Fan
RH
Reheater
HDR
Header
SH
Superheater
HP
High Pressure
WB
Wind Box
I&C
Instrument and Control
WW
Water Wall
CWT
Combined Water Treatment
WS
Water Separator
MOV
Motor Operated Valve
WSDT
Water Separator Drain Tank
DC
Direct Current
TV
Television
OD
Outer Diameter
Boiler
Mitsubishi
xiii
List of Vendor Manuals

NIL
Boiler
Mitsubishi
xiv
A r r a n g e me n t o f t h e S y s t e m
Maintenance Manual
This manual is arranged as follows.
Chapter 1
Describes health and safety issues during maintenance, disassembly and reassembly
of the Boiler.
Chapter 2
Describes the construction, purpose, and function of the Boiler and the associated
parts.
Chapter 3
Describes the Boiler parts, using the relevant Data Sheets.
Chapter 4
Describes the Preventive, Routine, and Outage Maintenance.
Chapter 5
Describes the disassembly and reassembly procedures, necessary to obtain access
to internal parts for inspection and repair during Boiler overhaul.
Chapter 6
Describes the corrective maintenance procedures to be followed to investigate,
identify and remedy defects occurring during operation.
Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/Documents
Boiler
Mitsubishi
xv
Chapter 1
Safety
C h a p t er
1 Safety
1.1
Feature of Boiler Safety

The boiler produces high pressure and high temperature steam during the
combustion of pulverized coal in the furnace. The boiler while in service is
subjected to furnace pressure fluctuations including extreme conditions of
explosion or implosion.
To maintain the boiler operating conditions under control, all equipment
provided in the fuel firing system must operate correctly. That means, the fuel
burners and associated equipment are maintained in good condition.
As the boiler is operated at super critical pressure and high superheated steam
temperature, the pressure parts of the boiler and steam pipes are subjected to
high stress during operation. The boiler being a large structure, the several parts
of the boiler are subjected to unequal temperature distribution. Thus the boiler
encounters severe stress conditions and there is a risk of failure of pressure
parts causing steam / water leak. Leaking water and/or steam from the failed
parts of the boiler can cause injury to person working near the failed area.
The high temperature steam leaking from cracks is not visible, but produces
noise. Hence, all persons working in the boiler area must move cautiously
around the boiler in case any abnormal noise is heard.
Coal burned in the boiler produces a huge amount of ash. The abrasive ash
causes wear on the boiler tubes located in the gas path leading to another type
of tube failure under high stress condition.
Some ash with traces of combustibles embedded form clinkers and stick on the
furnace walls forming big lumps known as clinkers. When the clinker becomes
large enough, they tend to fall to the furnace bottom. Be aware of these clinkers
while doing maintenance jobs in the furnace bottom.
As the boiler is a very tall structure, there is the danger due to falling or tripping
over boiler parts or materials being transported for both operation and
maintenance works. Hence utmost care is to be taken while handling materials
at the various levels around the boiler.
All operators and maintainers must realize these dangers and keep themselves
alert without jeopardizing safety, following the instructions written in this chapter.
The operator and maintainer are requested to strictly observe the warning signs
and the instructions provided to avoid endangering their own or their colleagues
lives.
Boiler
Mitsubishi
1-1
Chapter 1
1.2
Safety
Warnings Description
Safety of personnel working in the power plant is the most important matter. MHI
have taken all steps to avoid the risks of danger in the design of the power plant.
However, certain risks are unavoidable due to the nature of the plant.
This manual classifies the severity and hazard level of such risks by two
categories, DANGER and CAUTION. Read and understand the indications
thoroughly before operation or maintenance of the plant.
The contents of wordings, DANGER and CAUTION are described as follows;
Kinds
Meaning of Warnings
DANGER indicates an imminently hazardous situation
during use of the Boiler, which, if not avoided, could
result in death or serious injury, or serious damage to
the property or environment.
CAUTION indicates a potentially hazardous situation
CAUTION
during use of the Boiler, which, if not avoided, may result

in minor injury or minor damage to the property or
environment.
This manual also uses the following indicators in addition to the hazard level
indications described so far.
Kinds
Meaning of Warnings
IMPORTANT describes the particular information or
IMPORTANT
items that personnel must know during operation and

maintenance of the Boiler, and that, if not heeded, may
result in an accident of an in-assessable hazard level.
Notice
Boiler
Mitsubishi
NOTICE describes useful information and tips for

operation and maintenance of the Boiler.
1-2
Chapter 1
Safety
1.2.1 Definitions of Serious Injury, Minor Injury,

Serious Damage to Property, and Minor Damage to
Property
Serious Injury
This term describes injuries, which leave after effects such as loss of
eye sight, permanent disability, bone fracture or breakage, gas
inhalation, asphyxiation, electric shock, hospitalization or prolonged
hospital visits for treatment.
Minor Injury
This term describes injuries, which do not require hospitalization or
prolonged attention at a hospital (injuries other than the serious
injuries described above).
Serious Damage to Property

This term describes damages, which require a suspension of
productive activity for one day or more due to restoration of the
damaged property.
Minor Damage to Property

This term describes damage, which does not require any suspension
of productive activity due to restoration of the damaged property.
Boiler
Mitsubishi
1-3
Chapter 1
Safety
1.2.2 Symbols
In this manual, the following symbols are added for easy understanding
of the contents of warnings and are found next to DANGER,
CAUTION and other indications.
These symbols are in compliance with ISO 3684.
Symbol
Description
This symbol indicates the possible presence of high voltage, and
warns of a hazard which may result in system shock, burn or
death by electric shock if safety precautions are neglected or the
system is handled incorrectly.
This symbol indicates a movable section that is inside a safety
cover or is exposed.
Movable parts may inflict laceration or bone fracture to body parts
such as a hand by pinching the hand and/or clothing.
This symbol indicates the presence of parts the surface of which
could be hot, and may cause a burn if handled incorrectly.
This symbol indicates that care should be taken where you place
your feet when moving around the area.
Risk of injury by tripping is present near this symbol due to
factors such as a location with an unstable surface, or
obstructions such as scaffolding, temporary pipe lines, or other
protrusions.
This symbol indicates the possible presence of gas(es) harmful or
asphyxiant to personnel.
Be sure to ventilate fully before work commences.
This symbol indicates caution against the handling of a heavy
object or working in an abnormal position.
Do not work in an abnormal posture which may damage your back
or waist.
This symbol indicates prohibited items or actions during the

operation and maintenance of the Boiler.
This symbol indicates a movable section that is inside a safety

cover or exposed.
Do NOT touch any equipment where this symbol is displayed.
Boiler
Mitsubishi
1-4
Chapter 1
1.2.2
Safety
Symbols (Continued from previous page)
Symbol
Description
This symbol indicates that personnel must not touch since the
surface is hot.
Do NOT enter any area where this symbol is displayed.
This symbol indicates that the entry of personnel is prohibited.

Do NOT enter any area where this symbol is displayed.
This symbol indicates that physical contact is prohibited.

Do NOT touch or enter a location or enclosure where this symbol
is displayed.
This symbol indicates that the stated items or actions in the
warning notices relative to operation and maintenance of the
Boiler are mandatory.
1.2.3 Hazards Warning Label

Hazard warning labels are applied where potential hazards are present
during operation and maintenance activities.
Hazard warning labels will be in appropriate sizes and colors that will
catch the eye and the attention of personnel. They also have symbols
that show the hazard types, in addition to the descriptions of warning
contents.
IMPORTANT
Personnel are requested to confirm the location of, and to read, and
thoroughly understand the contents of all hazard warning labels
applied to this Boiler. If any of the hazard warning labels peel off/wear
out or become unreadable, install a new label in the original location
without delay.
Boiler
Mitsubishi
1-5
Chapter 1
WARNING
Safety
DO NOT COME
NEAR TO SHAFT
EXPOSED ZONE
WHEN IN
OPERATION
PINCH POINT
STEEP
DROP
DO NOT
ENTER
DO NOT
TOUCH
DO NOT
TOUCH
TB0001_A
FIGURE 1-1
Boiler
Mitsubishi
TYPES OF HAZARD WARNING LABELS
1-6
Chapter 1
1.2.4
Safety
Hazard Area
IMPORTANT
Only trained maintainers or operators are allowed to enter the
maintenance work area. Entry to the area by personnel untrained
could cause not only injury but also serious damage to the Boiler.
Boiler
Mitsubishi
1-7
Chapter 1
1.3
Safety
Risk Assessment Standard

As prepared by the Design Section as per MIL STD822D.
TABLE 1-1
RISK ASSESSMENT STANDARD

Detailed Description of Impact on each Object
Category
Safety
Catastrophic
II
Critical
III
Marginal
VI
Negligible
Health
- Unit shutdown (unit cannot be

operated)
- More than 4 days for repairing
- Unit shutdown (can not be
operated)
- Within 3 days for repairing
- Unit shutdown (can not be
operated)
- Can be repaired by Customer
TABLE 1-1
Environment
- Death
- Harmful gas, coal or oil leakage

- High pressure and temperature
material leakage such as steam,
water, air and gas, oil, coal etc.
- Low oxygen
- Serious Injury
- Same as the above
- Minor Injury
(with
hospitalization)
- Minor Injury
(without
hospitalization)
- Same as the above

- High temperature surface
- High elevation or unstable
- Not harmful and high pressure
& temperature leakage
-Mechanical protected
RISK ASSESSMENT STANDARD (CONTINUED)
Definition
Description
Category
Detailed
(A)
Frequent
Repeating occurrence
1 time / 1 or 2 months
(B)
Probable
Known to occur, or, it has happened
1 time / 1 year
(C)
Occasional
Could occur
1 time / 5 years
(D)
Remote
Not likely to occur
1 time / 10 years
(E)
Improbable
Practically Impossible
1 or 2 times / total life
TABLE 1-1
Hazard
Categories
Frequency
of Occurrence
RISK ASSESSMENT STANDARD (CONTINUED)

I
II
III
VI
Catastrophic
Critical
Marginal
Negligible
(A)
Frequent
13
(B)
Probable
16
(C)
Occasional
11
18
(D)
Remote
10
14
19
(E)
Improbable
12
15
17
20
Boiler
Mitsubishi
1-8
Chapter 1
Safety
DANGER ZONE
(Contains the high temperature
& high pressure medium such
as steam, water, air and gas,
coal, oil etc)
MM-M01.01
Rev.004
WORKING FLOOR
MPTD-3-0536
Boiler
Mitsubishi
FIGURE 1-2
BOILER MAPPING FOR HAZARDOUS AREAS

1-9
Chapter 1
1.4
Safety
Safety Measures
1.4.1 Work Permit System (Lockout / Tagout)
Work permit system is applied when equipment is shutdown for
maintenance work, to complete the maintenance work under a safe
condition. The outline of the work permit system is as follows:
(1)
The Maintenance Engineer applies for the work permit clearly

indicating the content of the maintenance work that he wants to
do, and submits it to the Shift Charge Engineer.
(2)
The Shift Charge Engineer passes the work permit form to the
operator to study and decide the isolation method from the line in
operation on the mechanical and electrical view point and then
report to the Shift Charge Engineer with his comments on the
hazard conditions for the work.
(3)
The Shift Charge Engineer gives work permit number and

prepares necessary tags to show the work permit number and
the situation of isolation by valves and power supply. He will then
instruct the operators to set the isolation condition following the
work permit form.
(4)
The operators will open the breaker and set the valves to the
specified condition, they will drain and vent the equipment to be
worked on, and the breaker and the valves are then locked. The
operators return the work permit to the Shift Charge Engineer.
(5)
The Shift Charge Engineer checks the isolation and will issue the
signed work permit to the Maintenance Engineer, or his
representative.
(6)
The Maintenance Engineer orders the start of the maintenance

work to the personnel nominated.
(7)
The Maintenance Engineer or his representative will then return

the signed work permit to the Shift Charge Engineer after making
sure the maintenance work is completed.
(8)
The Shift Charge Engineer will then send operators to release the
locks and return to the original situation.
(9)
The operators check the situation and report that the system is
now back to the normal condition when signing off the work
permit.
(10) The Shift Charge Engineer makes sure that the work under the
permit is completed and files details in the log book.
The work permit system is to clarify responsibility for the works on each
step and to ensure that the work is performed safely.
Boiler
Mitsubishi
1-10
Chapter 1
Safety
1.4.2 General Cautions on Personnel in Working Area

1.4.2.1
Cautions against Rotating Equipment

All couplings on rotating machines are covered by the
coupling cover but whole parts of the shaft are not fully
covered. It is recommended that the following warning is
observed strictly.
Do not approach or operate the equipment where protective

covers have been removed. Get additional supervisor
assistance.
Make sure that the breaker for the motor is opened when you
are required to remove the cover.
Care must be taken of the exposed rotating parts especially in
the area between the casing and the coupling.
All shafting, coupling and other rotating parts must be guarded
in order to prevent accidental contact.
Boiler
Mitsubishi
1-11
Chapter 1
1.4.2.2
Safety
Cautions against Electrical Equipment

The electrical equipment covered under this section
includes all the concerned plant equipment and the
maintenance tools like grinders, lamps, welding equipment
etc. though live parts of the plant equipment or
maintenance tools are insulated, be sure to observe the
following cautions. Failure to observe them may cause
fatal accidents, personal injuries and damage to the
electrical equipment.
Always, confirm that power supply is disconnected at the

up-stream side of power supply system and it is locked
according to the Work Permit.
Do not remove or open panels or doors labeled with high
voltage live part warning label not included in the Work Permit.
Ensure the proper earthing is provided for all electrically
operated tools and equipment used for maintenance works.
When using lamps for internal inspection, ensure that a low
voltage system (24volts) is available.
Make sure that no materials or Parts remain in the Panel or
terminal box before closing them finally.
Boiler
Mitsubishi
1-12
Chapter 1
1.4.2.3
Safety
Cautions against High Temperature Sections

Various equipment and pipelines contain high temperature
fluid in the plant and they are insulated on their surface.
Even though several hot spots exist in the wide area of
insulated surface, some specified equipment and pipe
lines are not insulated for cooling purpose. Since the
temperature is very high and you could get burned,
observe the following caution to avoid burn injury.
CAUTION
Suitable working wear is always available and should be worn,
including gloves, to avoid direct contact to hot spots in the
plant.
Level gauges of pressure vessels including connecting pipes
are not insulated to cool down the steam to drain.
Sampling piping is not insulated to cool down the steam to a
suitable temperature for the analyzer except on the places
located close to the working areas.
All exhaust pipes of the safety valves and the exhaust pipe of
the boiler flush pipe are not insulated.
Always wear gloves.
Boiler
Mitsubishi
1-13
Chapter 1
1.4.2.4
Safety
Cautions against Steam Leak in the Plant

The steam leak especially from high temperature steam
may cause serious injury to the personnel and it must be
repaired at an early stage of the leakage. The following
pre-cautions must be followed to find leakage at an early
stage.
Water drips may occur at the insulated parts such as the

connected part of the lagging. The leaking point can be found
by removing insulation partially using great care.
As you approach the leakage, the water will change to visible
steam. It is now too dangerous to remove the insulation.
Leakage of the superheated steam only makes whistling
noise without generating white steam. It is very dangerous to
approach the noise area.
Contact the Charge Engineer to obtain a Permit to Work
before repairing the damage.
Be well aware of the steam. The steam could leak from the
water system containing water at 100C or higher even if it is
a low pressure type water system.
High temperature drain or steam could leak from the flush
pipe during start-up.
If not avoided, the steam or vapor can enter the inside of your
working wear through the small gap between the body and
the clothing.
1.4.2.5 Cautions against Oil / Coal Leak in the Plant
CAUTION
Oil / Coal leakage is very dangerous. It is a potential fire
hazard.
Any oil spillage must be reported to the Shift Charge
Engineer.
Oil leaks make the area slippery and people are advised to
move around these areas carefully.
Boiler
Mitsubishi
1-14
Chapter 1
1.4.2.6
Safety
Cautions against Chemicals

Pay attention to the items listed below to prevent any
accident related to the chemicals in the plant.
IMPORTANT
Precaution against chemicals:
Operate chemical injection systems by strictly following the
instruction of the chemist. The operator must use suitable
protective tools.
Disposal:
Observe the rules and regulation of the installation site.
Material safety data sheet (hereafter MSDS):
Always understand the content of applicable MSDS in
advance, and observe the notified instructions when
handling.
Emergency response:
Solution against emergency must be thoroughly instructed
to all personnel involved so that the fullest measures can be
taken against any situation.
1.4.2.7
Cautions against Combustible Materials/

Storage Areas
IMPORTANT
Storage containers must be clearly marked to indicate the
content.
Bunding must be provided for bulk tanks.
Suitable fire protection must be provided for each area.
Do not store bulk combustible materials on the site.
Small quantities of combustible materials must be stored in
fire resistant cupboards.
Combustible materials must be segregated from other
equipment.
Boiler
Mitsubishi
1-15
Chapter 1
1.4.2.7
Safety
Cautions against Combustible Materials /

Storage Areas (Continued)
IMPORTANT
Leakage of gasoline has the risk of fire. Maximum storage
quantity of gasoline outside of the dispensing pump is five
liters.
Emergency response:
Personnel directly involved in combustible materials MUST
be properly trained and thoroughly instructed. Other
personnel in the vicinity must be aware of the dangers and
take precautions in all situations.
1.4.2.8
Cautions against Lack of Oxygen
Check that the oxygen content in the equipment vessel or in

the confined space is between 18~22% before entering, and
ensure sufficient ventilation.
Continue monitoring oxygen and ventilation during
inspection.
It is recommended that you do not enter the equipment,
vessel or confined space alone but if the situation demands
that you must enter, take the necessary preventive safety
measure provided, breathing system etc, and find a partner
who will wait for your return at the point of entry, keeping in
verbal contact throughout.
Make complete arrangements for rescue.
1.4.2.9
Cautions against Lifting Heavy Object

Be careful during the removal/installation of any
equipment during maintenance.
CAUTION
Do NOT attempt to move or lift equipment in an abnormal
posture. ALWAYS install/remove equipment, using a forklift
or a crane. A normal lift without mechanical aid should be
done using two or more persons.
Failure to observe the above may cause injury due to
dropped equipment, back or waist injury or damage to the
equipment.
Boiler
Mitsubishi
1-16
Chapter 1
Safety
1.4.2.10 Cautions against Sharp Objects
CAUTION
Use leather gloves when handling parts with sharp edges.
1.4.2.11 Cautions using Fork Lift
CAUTION
Do NOT permit anyone to stand below any item being lifted
under any circumstance.
Failure to observe this may cause fatal accidents.
When using a forklift, ALWAYS lift the objects parallel to the

ground while considering the center of gravity.
Otherwise, lifted objects may fall and serious damage could
occur.
A forklift is often used to transfer small machines. Check fork
insertion position for the forklift prior to use. Be careful, as
marks which indicate the fork insertion positions are
sometimes hidden by wraps or packing materials.
Boiler
Mitsubishi
1-17
Chapter 1
Safety
1.4.2.12 Cautions using Crane
CAUTION
A crane is often used to transfer heavy parts. Check for any
possible risks which could occur during hoisting and
transportation before operating the crane.
Check of the equipment:
Check the crane, the crane hook and all related items before
use. Use wire ropes which can withstand the weight of the
parts multiplied by a safety factor.
Inspect the shackles, eyebolts, jigs and wire ropes provided
for the hoisting work prior to the actual hoisting.
Perform periodical inspection (dye penetrant test) of hoisting
tools at least once a year.
Rigging / Slinging work:
Only authorized personnel can perform slinging work and
operation of the crane.
Work area:
Before hoisting, secure a working area around the part to be
lifted and prohibit the entry of unrelated personnel.
Hoisting method:
Hoist the part parallel to the ground while paying attention to
the center of gravity.
Do NOT permit any person to stand under the part being
lifted.
Pay attention to and ensure that all persons are clear of the
equipment being lifted.
Hoisting point:
Do NOT hoist any parts from a position other than the
specified hoisting points.
Unpacking:
Do NOT unpack any part until it is located in the designated
location.
Protection of machine:
Avoid any impact to the unpacked parts.
Boiler
Mitsubishi
1-18
Chapter 1
1.4.2.13
a)
Safety
Disposal
Water disposal including oily drain
The water is disposed to the plant drain system. The water
must be carefully disposed according to the materials
contained in the water. The water drain system is
separated into three categories that are rain water,
chemical water and oily water.
The waste waters are treated and then discharged into the
public drain system.
b)
Chemical disposal
Chemicals must be handled following the instruction of the
MSDS and disposed to the chemical drain system.
c)
Solid disposal made by maintenance work

For disposal from the site, observe the local legal
regulations.
Boiler
Mitsubishi
1-19
Chapter 1
1.5
Safety
Emergency Measure
1.5.1 Evacuation on Emergency Case
1.5.1.1
Evacuation Route
Following items are considered on design and installation
of emergency evacuation.
IMPORTANT
Each building installed in the plant is provided with at least two
exits. A clear indication of the exits can be seen from anywhere
in the building as the exit sign is illuminated using the
emergency power supply.
Evacuation routes are indicated on each floor of the building,
directing personnel to the exits.
Keep the evacuation routes completely free from materials and
tools.
1.5.1.2
Evacuation of Disabled Persons, Who Cannot

Walk by Themselves
The following are necessary items, prepared for emergency
evacuation.
IMPORTANT
It is recommended to keep a stretcher available for emergency
use at a place that is known by all personnel.
If you find this kind of accident, inform the rescue team, and
attempt to bring the collapsed person to the first aid station.
Boiler
Mitsubishi
1-20
Chapter 1
1.5.1.3
Safety
Evacuation from Power House

Following are guidance for the evacuation from the power
house.
IMPORTANT
An evacuation place for personnel to gather in after evacuation
from the power house in an emergency must be predetermined
and explained beforehand in the emergency training.
Evacuation directive must be given by the responsible person
such as Shift Charge Engineer, and all personnel must be
alerted in the power house repeatedly with an available
broadcast facility.
All people working in the power house must stop their work
immediately and leave the power house to the gathering place.
When evacuated to the evacuation place, make sure
that there is no one missing.
Boiler
Mitsubishi
1-21
Chapter 1
Safety
1.5.2 Fire Accident
IMPORTANT
Clearly show the location of the fire alarm push button and the
nearest fire extinguisher to make everybody take the first step
at fire protection.
Inform everyone concerned that a fire has now started if you
discover a fire.
Start fire fighting using the fire extinguisher located near the
fire site.
The operators must check the plant is ready for trip, and wait
for order from the responsible person.
The operator and other personnel must transfer the fire
fighting to the fire fighting team when they arrive at the fire site
and the operators must wait for instruction from the Shift
Charge Engineer. All other personnel must immediately start
evacuation.
If unit trip is decided, the operator must trip the plant manually.
The operators must evacuate from the power house according
to the instruction of the responsible person immediately after
shutdown of the unit.
If the fire is extinguished successfully, the operators should
return to the power house as required by the Shift Charge
Engineer and start inspection of the equipment for restart of
the unit.
Based on the inspection, the responsible person should
decide whether to operate the unit again or shutdown for
repairing.
After the inspection or repair, and then checking the
equipment and/or system, start up the unit again.
Boiler
Mitsubishi
1-22
Chapter 1
Safety
1.5.3 Earthquake
In the case of an earthquake, the shift charge engineer or operator
must judge whether the unit trip is necessary according to the intensity
of the earthquake, and immediately trip the unit manually. If the unit is
tripped, all equipment must be carefully checked on its operation status
and tripped if abnormal phenomena are found.
In the local area, mechanical and/or thermal shocks may be given to
the equipment, piping, instruments and electrical panels. Be sure to
observe the following when completing the inspection.
Check that the lubricating oil pump is running. Bearings of the

equipment will be damaged if lubricating oil is not supplied.
Check the piping and equipment for steam and water leakage. The
steam or high temperature water leakage may cause serious
injury to the personnel and it must be repaired at an early stage of
the leakage.
Check the pulverizers and /or coal silos for signs of a fire. If a coal
fire does start, make sure that CO2 fire fighting system is properly
operated.
Check the position of boiler seismic stopper. Since the boiler
seismic stopper must be anchored at the original position, boiler
cannot be re-started if the slippage is found. If the stopper is not
at the original position, please contact MHI.
CAUTION
Check the piping and equipment for the breaking and the falling
down of insulation. Since the exposure of hot surface may cause
burn injury, it must be repaired by a worker fully dressed in
Personal Protective Equipment.
1.5.4 Explosion Accident
Do not use a fire in a hazardous area where the combustibles

(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or
handled. Use of a fire in a hazardous area could cause serious
injury to personnel and serious damage to equipment due to an
explosion.
Boiler
Mitsubishi
1-23
Chapter 1
1.6
Safety
Qualification and Training

The system must be operated only by authorized operators & maintenance
supervisors.
The customer shall authorize all operators and maintainers, who are involved in
the operation and maintenance of this plant, either by the training course given
by Mitsubishi, or by the customers own personnel assessment.
Operator and maintainer training course {both classroom training and On the
Job Training (OJT)} will be provided by Mitsubishi before the handing over of
this plant. The customer must train and assess new operators and maintainers
who join after the turn-over, according to his own procedure and standard,
(Mitsubishi training course may still be available if required).
As a minimum, operator and maintainer must satisfy the following:
Operator and Maintainer can read and fully understand the description of
this manual.
Operator and Maintainer can understand the related P & ID, logic diagram.
Operator and Maintainer know the location of the system equipment
including pipe routes, valves and instruments.
Operators and Maintainers have fundamental knowledge of the function of
each equipment.
Operator can operate the equipment and the system manually at local
stations.
Operator can operate the system remotely using the DCS system.
Operator can respond suitably for any kind of alarm.
Operator knows the location of emergency exit on the power house and is
available to provide first aid treatment.
Operator knows emergency communication system operation.
Operator and Maintainer, following the Charge Engineers instruction are
aware of the isolation method for mechanical, electrical and instrumental
equipment being prepared for safe maintenance while the unit is in
operation.
Maintainer must also be able to handle the maintenance tools provided by
the owner and those supplied by the manufacturer.
Boiler
Mitsubishi
1-24
Chapter 2
General
C ha pte r
2 General
2.1
Purpose
The purpose of this maintenance manual is to provide specific information to the
Paiton Expansion Project operators and maintaining personnel.
Although this document will convey a good knowledge and direction regarding
maintenance of the boiler, the operator / maintainer must seek assistance or
instruction from the manufacturer when a problem not covered in this document
occurs.
2.2
Boiler
Mitsubishi
References
a)
Boiler P & I Diagram

MHI Dwg. No. P10-0600A
Project Dwg No. P101-74-3-BB-BS-J001
b)
Boiler General Arrangement

MHI Dwg. No. P10-4001A to 4003A Rev.
Project Dwg No. P101-36-BB-LO11 TO LO13
c)
Pressure Part Arrangement

MHI Dwg. No. P10-4101 to 4108
Project Dwg No. P101-36-BB-LO14
d)
Basic Plan for Water Wall Panel

MHI Dwg. No. P12-4001 to 4003
2-1
Chapter 2
2.3
General
Overview of the Boiler and Auxiliaries

Refer to the Figures 2-1 to 2-5.
The boiler facilitates the transfer of heat released during the combustion of the
fuel to the feed water and steam.
This heat transfer produces superheated main steam at a pressure of 25.3
MPa(g) and a temperature of 542oC as required by the HP steam turbine.
This heat transfer also occurs in the reheater section where the temperature of
the cold reheat steam at a pressure of 4.89 MPa (g) is increased from 304oC to
568oC at a pressure of 4.73 MPa(a) as required at the inlet to the IP steam
turbine.
The boiler supplied for the Paiton Expansion Project is of the outdoor, once
through, balanced draft, and reheat type suitable for firing pulverized coal and
generating steam at supercritical conditions.
The following systems/components are associated with the boiler:
Boiler heat transfer banks and insulation
Desuperheaters
Water Separators and Water Separator Drain Tank
Boiler water Circulation Pump
Drafting system
Air Heater
Pulverizer
Burners
Soot Blowers
Electrostatic Precipitators
Flue Gas Desulphurization System
Chimney
The boiler heat transfer banks consist of economizer, furnace water walls,
ceiling (roof) pipes, rear gas (2RY pass) duct water walls, superheaters and
reheaters.
The furnace water walls made of membrane panels minimizes the need for
refractory and ensures gas tightness. Similarly, the water cooled 2RY pass
water walls and roof composed of fin-welded tubes minimizes the need for
refractory and ensures gas tightness.
Boiler
Mitsubishi
2-2
Chapter 2
General
The economizer, superheater and reheater assemblies are housed inside the
box formed by the furnace, roof and 2RY pass water walls.
Each assembly consists of either one or two sections known as tube bank. The
construction of each tube bank is different.
The boiler outer surfaces are provided with thermal insulation to reduce heat
loss and to provide safety to the operator. The outer surface of the insulation
material exposed to the atmosphere is covered with ribbed hot dipped
aluminium coated steel sheets. Setting bars located at the upper and lower ends
of these sheets securely set them in position.
The high pressure (HP) feed water from the outlet of the HP feed water heaters
flows through the economizer banks located at the bottom of the secondary
pass and recovers heat from the outgoing flue gas.
The heated feed water, from the outlet of the economizer, then passes through
the water walls of the boiler to absorb the heat produced by the combustion of
pulverized coal in the furnace.
The water wall tubes in the upper and lower furnace area mainly absorb the
heat by thermal radiation from the fire in the furnace. The roof tubes, passage
side wall tubes, 2RY pass and division wall tubes absorb the heat by convection
from the hot flue gas.
During low load operation (less than 20%), water particles are contained in the
steam at the outlet of the roof and 2RY pass heat transfer banks. Water and
steam mixture from the outlet of the 2RY pass walls/roof tubes is passed
through the two water separators (WS) where mixture is separated. The steam
is passed through other heat transfer banks for superheating. The water is
drained into the water separator drain tank (WSDT) and pumped back to the
economizer by the boiler circulation pump (BCP).
The BCP is of the leak-free glandless type and its bearings are water lubricated.
For full details of the BCP, refer to the Boiler Circulation Pump vendor operation
and maintenance manual (OM-01.01).
Two bypass pipes with motor operated valves (MOV) connect the two roof outlet
headers to the two WS. This bypass arrangement helps to reduce the flow
through the 2RY pass tubes and thus the pressure drop in the boiler is
minimized during normal supercritical operation. The flow stability is very good
at supercritical pressures when the fluid is only in one phase and this property is
used to reduce the flow through the 2RY pass tubes.
The three stage superheater consisting of 1RY, 2RY and 3RY superheater
banks superheat the steam either by radiation or convection heat transfer
depending on their arrangement in the boiler.
The spacer tubes maintain the alignment of the 2RY reheater panels and 3RY
superheater panels. Required spacer tubes for maintaining the alignment of the
panels are drawn from the 1RY superheater inlet headers and connected to the
2RY superheater outlet headers.
Boiler
Mitsubishi
2-3
Chapter 2
General
Similarly girdling tubes are drawn from the 2RY superheater inlet headers and
terminated at the 3RY superheater outlet headers. The girdling tubes maintain
the alignment of tubes of 2RY and 3RY superheater banks which are exposed
to the furnace radiation heat.
Two sets of desuperheaters are placed in between each 1RY and 2RY SH
circuits and 2RY and 3RY SH circuits for steam temperature control.
The two stage reheater consisting of 1RY and 2RY stages of reheater banks are
arranged to provide convective heat transfer surfaces. One set of
desuperheater is placed in between the 1RY and 2RY RH banks for steam
temperature control. During normal operation of the boiler no spray water is
injected. Only under emergency conditions spray water is injected. Hence, a
steam cooling line is provided for the reheater desuperheaters to avoid any
thermal shock during water injection. This cooling line is drawn from the 1RY
RH inlet header and connected to the desuperheater.
The draft system consists of two induced draft fans (IDF), two forced draft fans
(FDF), two primary air fans (PAF) and the associated ducts. For cooling air and
sealing air requirements two sets of AC/DC fans and two sets of AC fans are
provided, respectively.
In order to maintain furnace stability and to obtain the maximum combustion
efficiency, combustion air and additional air are supplied by the FD fans to the
individual burner assemblies.
The PA fans draw air from the atmosphere and its discharge is divided into two
sections, one passing through the air heater to provide hot primary air and the
other bypassing the air heater to provide tempering air.
The hot and the cold primary air are mixed at the pulverizer inlet and the
required inlet air temperature is maintained. This primary air dries the pulverized
coal and then transports the pulverized coal to the coal burners at the desired
temperature.
The two ID fans maintain a balanced draft in the furnace and help to evacuate
the products of combustion in the furnace. The flue gas system is designed to
provide passage for the products of combustion from the boiler to the chimney,
while allowing the gas to transfer its heat energy effectively to the water cooled
tubes and steam cooled tubes installed in the flue gas path.
Two, 50% BMCR duty tri-sector, vertical shaft, counter flow, air heaters are
installed in each stream of air and flue gas path to improve the boiler efficiency.
The air heater recovers a portion of heat from the outgoing flue gas, and imparts
it to the incoming combustion air/primary air from the FD fans / PA fans. Each
air heater is equipped with a power actuated soot blower, and a water washing
device. The air heater has a dual drive arrangement-using an electric AC motor
and an air motor. Bearing lubrication with a water cooling system ensures stable
operation. Fire fighting water is also available. In the case of an emergency both
fire fighting and water wash water are used to put out an air heater fire.
Boiler
Mitsubishi
2-4
Chapter 2
General
Coal is used as the primary fuel and Light oil is the startup fuel in the steam
boiler prepared to provide steam to the steam generators provided for the
Paiton Expansion Project.
Coal delivered to the site is stored, and then it is delivered to the six coal
bunkers serving the six installed coal pulverizers.
Five of the six installed pulverizers are necessary to produce the steam required
to produce the 865900kW of Electric Power required.
From the coal bunker, coal is delivered to the coal feeder then through a coal
feed pipe to the Pulverizer in which the coal is crushed and prepared for firing
into the boiler through the coal burners.
Twenty four sets of tilting type burner assemblies and their accompanying start
up burners are installed on the front and the rear side of the lower furnace walls.
These burners provide efficient and stable combustion of the fuel, formed to
produce two sets of fire balls inside of the furnace.
Oil burners are provided in the burners assemblies only for start up and coal
burner stabilization purposes.
Combustion air to the burners is provided through control dampers located in
the wind boxes connected to each set of burner assembly.
Flame detectors and closed TV cameras are installed in the furnace to monitor
the condition of the flame and to ensure safe operation of the boiler.
Tilting type additional air (AA) port assemblies are provided above the top
burner on the front and rear water wall. The purpose of this additional air is to
cool the furnace outlet gas thereby reducing the NOx emission in the exit flue
gas.
Cooling and sealing air from the Cooling and Sealing Air System is provided to
the flame detectors, furnace TV camera,burners,pulverzers,wind box etc. to
protect this equipment from high temperature and to reduce hot air and dust
leakage.
Thirty long retractable soot blowers, ten half retractable soot blowers and sixty
eight deslaggers are strategically located on the boiler to dislodge any slag or
soot deposited on the heat transfer surfaces.
One swivel type soot blower is provided at the cold end of each air heater for
cleaning the air heater elements.
Superheated steam to the soot blowers is drawn from the 2RY superheater inlet
header.
The auxiliary steam header supplies blowing steam to the air heater soot
blowers to perform soot blowing during a cold startup when superheated steam
from the 2RY superheater inlet header is not available.
Boiler
Mitsubishi
2-5
Chapter 2
General
The Electrostatic Precipitators, installed between the air heaters and the ID fans
collect the fine ash particles present in the flue gas and maintain the particulate
emission within the permitted limits. An opacity measuring instrument is
installed in the flue gas duct ahead of the FGD absorber to measure the
emission level of ash particles in the gas. The SOx level is reduced in the FGD.
The clean flue gas is led to the atmosphere through the chimney. CO2, CO, O2,
SO2 and NOx measuring instruments are installed in the chimney to assist in the
confirmation of the emission level of the gas.
The purpose of this maintenance manual is to describe in detail all pressure
parts of boiler which include heat transfer banks and piping from the economizer
inlet to the 3RY superheater outlet, and the 1RY reheater inlet to the 2RY
reheater outlet.
Maintenance details of Ducts and Boiler Dampers, Forced Draft Fan, Primary
Air Fan, Induced Draft Fan, Pulverizer and Fuel Oil Burner are described in the
mechanical maintenance manuals MM-M-03, MM-M-01.02, MM-M-02.01, and
MM-M-04 respectively. Details of Boiler water Circulation Pump (OM-01.01), Air
Heater (OM-01.02), Soot Blowers (OM-01.03) and Electrostatic Precipitators
(OM-25) are provided in their respective vendor manuals.
Boiler
Mitsubishi
2-6
Chapter 2
BOILER FRONT
General
CEILING GIRDER
HANGER RODS
COAL CONVEYER AREA
LEGEND
RETRACTABLE
SOOT BLOWER
WATER SEPARATOR
WALL DESLAGGER
(T)
2RY SH
3RY SH
(T)
2RY RH
WATER SEPARATOR
DRAIN TANK
BS
COAL BUNKERS
INTERMEDIATE HEADER
& MANIFOLD
1RY RH
1RY SH
T.V
BS
GAS TEMPERATURE
PROBE
HALF RETRACTABLE
SOOT BLOWER
OBSERVATION PORT
100 250
ACCESS DOOR
610
ACCESS DOOR
800 800
ACCESS DOOR
500 800
HEAT EXHAUST DOOR
1000 1000
BUCKSTAY
BOILER STOPPER
ECON.
ECON.
HRSP
FLOWMETER
MSP
CRSP
WDC
FWP
FEEDERS
HIGH & MIDDLE TEMP.

BASKET ELEMENT
REMOVAL DOOR
FURNACE
PIPE &
CABLE SPACE
AIR HEATERS
SILENCER SILENCER
SILENCERS
LOW TEMP. BASKET

ELEMENT REMOVAL DOOR
BCP
FLUE GAS
TO EP, FGD& ID FAN
MM-M01.01
Rev.004
FORCED DRAFT FANS

MILLS
DCC
PRIMARY AIR FANS
MPTD-3-0080
FIGURE 2-1
Boiler
Mitsubishi
OVERVIEW OF BOILER & AUXILIARIES
2-7
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-2
Boiler
Mitsubishi
CUTAWAY VIEW OF BOILER
2-8
Chapter 2
REAR WALL HANGER TUBE
OUTLET HEADER
REAR WALL HANGER

TUBE INLET MANIFOLD
PASSAGE SIDE WALL

INLET MANIFOLD
REAR WALL OUTLET HEADER

PASSAGE SIDE WALL
INLET HEADER
1RY SH INLET HEADER
REAR WALL 2ND INTERMEDIATE HEADER

PASSAGE SIDE WALL
OUTLET HEADER
REAR WALL
INTERMEDIATE HEADER
PASSAGE SIDE WALL

INLET HEADER
REAR WALL INLET HEADER

PASSAGE SIDE WALL
OUTLET HEADER
FURNACE INLET MANIFOLD

SIDE WALL INLET HEADER
SIDE WALL
INTERMEDIATE HEADER
REAR WALL
INTERMEDIATE MANIFOLD
VENT
VENT
2RY PASS REAR WALL

INLET HEADER
2RY PASS INLET MANIFOLD

2RY PASS DIVISION WALL
OUTLET HEADER
SIDE WALL 2ND

INTERMEDIATE HEADER
SIDE WALL
INTERMEDIATE MANIFOLD
VENT
SIDE WALL
INLET HEADER
2RY PASS REAR WALL

OUTLET HEADER
VENT
N2
2RY PASS INLET MANIFOLD

SIDE WALL
OUTLET HEADER
VENT
1RY SH INLET HEADER

INLET HEADER
2RY PASS SIDE WALL

INLET HEADER
2RY PASS DIVISION WALL
INLET HEADER
2RY PASS SIDE WALL

INLET HEADER
SIDE WALL 2ND

INTERMEDIATE
HEADER
TO REHEATER STEAM TEST
2RY PASS SIDE WALL

OUTLET HEADER
SIDE WALL
OUTLET HEADER
General
TO SILENCER
VENT
VENT
VENT
FOR CHEMICAL CLEANING
FRONT WALL INLET HEADER
FRONT WALL
INTERMEDIATE HEADER
VENT
FRONT WALL INTERMEDIATE

MANIFOLD
VENT
WATER
SEPARATOR
VENT
N2
ROOF INLET HEADER
VENT
N2
BCP WARMING
TO BCP
VENT
ROOF OUTLET HEADER
VENT
WATER
SEPARATOR
2RY PASS SIDE WALL

OUTLET HEADER
N2
N2
2RY PASS FRONT WALL

OUTLET HEADER
ROOF INLET MANIFOLD

VENT
N2
2RY PASS FRONT WALL

INLET HEADER
WATER SEPARATOR
DRAIN TANK
SH SPRAY LINE
M
N2
VENT
M
ECONOMIZER OUTLET HEADER

M
TO BOILER FLASH PIPE
MM-M01.01
Rev.004
FROM H.P. HEATERS

ECONOMIZER INTERMEDIATE HEADER
ECONOMIZER INLET HEADER
MPTD-3-0082
FIGURE 2-3
Boiler
Mitsubishi
FLOW PATH UP TO THE WATER SEPARATOR
2-9
Chapter 2
General
3 R Y S H O U T L ET H E A D E R
3R Y S U P E R H EA T E R
G IR D L IN G TU B E S
3R Y S H IN LE T H E A D E R
3R Y SU P E R H EA T E R
M A IN S T E A M P IP E 3A
T O H P T U R B IN E
G IR D L IN G T U B E S
M A IN S T E A M P IP E 3B
F O R S O O T B LO W E R
T O H P T U R B IN E
T O S ILE N C E R
VENT
T O S ILE N C E R
T O S ILE N C E R
N2
M
S
2ry S H D S H
2ry S H D S H
S
T O B O ILE R F LA S H P IP E
2R Y S H O U T L ET H E AD E R
2 R Y S U P E R H E A TE R
B C P W A R M IN G LIN E
T O A U X ILIA R Y S T E A M
VENT
TO REHEATER STEAM TEST

M
N2
1ry S H D S H
1ry S H D S H
T O B O ILE R F LA S H P IP E
1R Y S H O U T LE T H E AD E R
1R Y SH O U T LE T H E AD E R
N2
1R Y S U P E R H E A TE R
MM-M01.01
Rev.004
M P TD -3-0083
VENT
S P A C E R TU B E S
W ATER
S E P A R A TO R
FROM ECONOMIZER OUTLET HEADER
S P A C E R TU B E S
W ATER
SEPARATOR
F R O M 2R Y P A S S R E A R W A L L O U T LE T H E A D E R
FIGURE 2-4
Boiler
Mitsubishi
W ATER SEPARATOR
D R A IN T A N K
TO BCP
FLOW PATH OF SUPERHEATED STEAM
2-10
Chapter 2
TO SILENCER
General
TO SILENCER
TE
TE
TE
TE
2RY RH OUTLET HEADER
2RY REHEATER
2RY REHEATER
VENT
2RY RH INLET HEADER
TE
TE
TE
TE
RH DSH
FROM BFP INTERMEDIATE STAGE
N2
RH DSH
TE
FROM BFP INTERMEDIATE STAGE
TE
1RY RH OUTLET HEADER

DSH COOLING LINE
DSH COOLING LINE
1RY REHEATER
1RY REHEATER
TO
SILENCER
TO
SILENCER
1RY RH INLET HEADER

FROM HP TURBINE EXHAUST
FROM WATER SEPARATOR

TEMP. PIPE
MPTD-3-0084
FIGURE 2-5
Boiler
Mitsubishi
FLOW PATH OF REHEATER STEAM
2-11
Chapter 2
2.4
General
Boiler Components
The boiler consists of the following major components:
Furnace pass wall, passage side wall and 2RY pass wall tubes and roof
tubes
Water separator and water separator drain tank
Superheaters
Reheaters
Desuperheaters
Economizer
Boiler supports
Casing and insulation
Safety valves
2.4.1 Furnace Pass Wall, Passage Side Wall and 2RY Pass
Wall Tubes and Roof Tubes
Refer to the Figures 2-6 to 2-17, 2-22 to 2-28, 2-31 to 2-36.
The purpose of the wall tubes and roof tubes is to absorb radiant /
convection heat produced in the furnace by the combustion of
pulverized coal and to convert water in the tubes into steam.
The furnace pass walls, passage side walls, 2RY pass walls and roof
tubes together provide the furnace area and the flue gas path.
The furnace space is formed by the furnace pass walls which are in the
form of a large vertical box. The four water wall sides of the furnace
pass, namely the front, rear, right and left, together form the furnace.
The furnace can be divided into two halves; lower furnace and upper
furnace. The burners and the additional air compartments are mounted
on the outer surface of the lower half. The upper half inside is filled with
the 2RY and 3RYsuperheater banks which absorb mostly radiant heat.
Each side water wall has an inlet header at the bottom and terminates
at an outlet header in the roof housing.
Each furnace wall side of the boiler is formed by welding together gas
tight membrane wall panels and each panel is formed by welding
several tubes together.
A nose section is formed at a height of 46.2235m for the flue gas flow
diversion. This is provided by bending the rear wall tube panels as
shown in Figure 2-6. This nose section is extended to the width of the
passage wall and connected to the rear wall outlet header and thus
provide a gas tight area for the passage wall bottom area.
Boiler
Mitsubishi
2-12
Chapter 2
General
This large vertical box has a narrow opening at the bottom side through
which the ash is removed.
Another short vertical box is formed by the 2RY pass walls which
provide a flue gas outlet path. The 2RY pass walls are generally
formed by welding together the fins of individual tubes to provide a gas
tight finned wall except for the portion of the front wall where gas flow is
to be allowed from the furnace pass to the 2RY pass. Thus the
secondary pass front wall for the length of 10.650m is provided with
screen tubes to allow gas flow from furnace pass to 2RY pass between
passage walls.
The secondary pass is divided into two paths by a division wall formed
by tubes originating from the 2RY pass division panel inlet header.
Similar to the 2RY pass front wall screen tubes are provided on the
division wall for a length of 10.210m from the division wall outlet header
to allow the gas flow through both sections. The lower portion of the
division wall is provided with finned tubes similar to other wall sections
and provides a gas tight finned wall.
Two manifolds are provided in the 2RY pass flow path between roof
outlet header and the 2RY pass wall inlet headers. These manifolds
make a homogeneous mixture of steam and make the heat transfer
uniform in the water/steam cooled walls of the 2RY pass.
The flue gas outlet is connected to a duct at the top of the air heater.
The space inside this box is filled with 1RY SH, 1RY RH and
economizer.
The short vertical box has a full width opening at the bottom through
which the hot flue gas exits.
These two vertical boxes are joined together by a small horizontal pass
formed partly by the passage side walls and partly by nose formation of
the rear furnace pass wall. These walls are extended from the furnace
rear wall outlet header. The passage walls also have the finned wall
construction. The outlet header is connected to a manifold.
This manifold is connected to different inlet headers which supplies
tubes necessary for the passage walls and the hanger pipes.
The outlet headers of hanger pipes and passage walls are suitably
supported in the roof beams. The space between the passage walls is
occupied by the 2RY RH.
Water from the hanger pipes, the furnace walls and the passage walls
enter the roof inlet header and then to the roof outlet header. The
connecting pipes of the roof headers at the front side with reference to
the hanger pipes towards the inlet header are of size 45.0mm whereas
on the rear side towards the outlet header are of size 57.1mm. The
tubes are welded with fins to form a gas tight top cover.
Boiler
Mitsubishi
2-13
Chapter 2
General
Where tubes are spaced out to allow for burner openings, manholes,
observation ports or for other tube exit through roof panel, the
additional space between the tubes is closed with split pins and sealed
with castable refractory and/or sheet casing to present a completely
sealed surface. This arrangement prevents the hot furnace gases from
leaking through these gaps.
The water walls and roof tubes are of the drainable type.
The outside surfaces of the boiler walls are insulated and covered with
a casing to reduce radiation heat loss from the system.
Some of the special features in the construction of the boiler walls are
detailed below.
Water from the economizer outlet header to the furnace inlet headers is
admitted through furnace inlet manifolds. These manifolds assist in
equalizing the flow through the furnace wall tubes.
For the final equal distribution of the flow through each tube, all the
tubes in the four furnace walls are fitted with flow equalizing orifices at
a point 270mm away from the geometric centre of the corresponding
inlet header pipes.
Due to the high flux density and unequal distribution of heat, the
enthalpy of water in the furnace wall tubes is large on the middle tubes
of walls and reduces almost parabolically along the sides of walls. The
equalization of the enthalpy in the furnace wall tubes along the breadth
and width of the upper furnace is achieved by installing distribution
manifolds and intermediate headers.
In between the inlet and outlet header of the water walls on each side
there are two intermediate headers, at a height of 42.380m and
44.310m respectively, which are placed outside of the water wall
surfaces and suitably supported to the nearby buckstays.
Alternate tubes of the water walls are extended out of the water wall
outer surfaces at two different levels (44.310m and 44.971m) and
connected to the intermediate headers without affecting the continuous
formation of the waterwall.
The water supply from the first intermediate header to the second
intermediate header is distributed through a manifold positioned in
between the two intermediate headers. There are two manifolds each
on the front and rear side and one manifold each on the left and right
side.
The furnace water walls are exposed to high temperature radiation,
and are provided with rifled tubes covering the entire furnace length
from a height of 16.500m up to the top of the intermediate outlet header
height of 45.120m. In all the other locations smooth tubes are used.
Boiler
Mitsubishi
2-14
Chapter 2
General
The rifled tubes cause the water, or steam and water mixture to spin
within the tube to provide a greater heat transfer.
Manifolds are also provided between the front wall outlet header and
the roof inlet header, rear wall outlet header and passage side wall inlet
header/rear wall intermediate inlet header. These manifolds equalize
the flow through the tubes in the roof tubes, passage wall tubes and
rear wall hanger pipes.
The entire weight of water walls is supported from the top of the roof
housing by rigid hangers provided on the water wall outlet headers.
These tubes expand downwards in the vertical direction during hot
condition with the hanger support as the zero expansion point.
The four sides of the boiler walls are surrounded by buckstay beams
which avoid the possible buckling and deformation of the tubes due to
forces applied by the furnace pressure and temperature variations. The
buckstays equalize the force around the walls through the corner plates
and corner links. The buckstays have provision to allow the walls to
expand in the traverse direction during hot condition along the boiler
stoppers provided on the buckstay beams as the zero expansion points
in the traverse direction.
Buckstay positioners installed between two adjacent elevation
buckstays guide their vertical movement during operating conditions.
Boiler stoppers are provided at different elevations as required. The
purpose of these stoppers is to arrest the horizontal movement of the
buckstay beams.
2.4.2 Water Separator and Water Separator Drain Tank

Refer to the Figures 2-29 & 2-30.
The water separator and the water separator drain tank are high
pressure vessels.
The function of the water separator is to separate the water and steam
from the wet steam. The separated steam flows upward to the 1RY
superheater. The separated water flows downward to the water
separator drain tank through a vortex breaker installed at the bottom of
each water separator.
Four outlet pipes from the 2RY pass rear wall outlet header are welded
to the upper half of each water separator with an offset as shown in
Figure 2-28. This offset provides the tangential entry of the steam. The
resultant swirling action separates any remaining water from the steam.
Each 2RY superheater bypass pipe from the two roof outlet headers
are connected to an individual MOV. The outlet of each MOV is further
divided into two pipes and each pipe joins the regular inlet pipe of each
water separator.
Boiler
Mitsubishi
2-15
Chapter 2
General
Inspection stubs are provided on the water separator to provide access

for inspection during outage. Each water separator is supported on four
lugs with spring hangers connected to the hanger beams.
The two water separators are located adjacent to the 2RY pass rear
wall near the 64.550m elevation to receive the steam from the 2RY
pass outlet header.
The drain pipe of each water separator is welded to the bottom half of
the water separator drain tank. Guide supports are provided for the
drain tank.
A nozzle at the bottom end of the water separator drain tank directs any
water to the BCP and a nozzle at the top directs the steam to the three
stage superheaters.
Provision is made in the water separator drain tank for level
transmitters which provide remote level indications in the control room
and level signals for the auto control loop.
2.4.3 Superheaters
The function of the superheater is to raise the steam temperature
above the saturation level, thus increasing the potential energy within
the steam.
The superheater consists of three basic sections.
Primary superheater(1RY SH)
Secondary superheater (2RY SH)
Tertiary superheater (3RY SH)
All the superheater assemblies are of the nondrainable type except the
1RY superheater, because of the vertical arrangement of the coils.
a)
Primary Superheater
Refer to the Figures 2-2, 2-6, 5-15 & 5-16.
The steam from the water separators enter the 1RY superheater
inlet header and then into the tube banks that make up the 1RY
superheater assembly.
The 1RY superheater tube banks are located in the 2RY pass
between the 2RY pass rear wall and the division wall and above
the economizer bank. They absorb heat from the flowing flue
gases by convection.
Constructionally the 1RY superheater is divided into two tube
banks-horizontal type and a terminal type. The banks consist of
prepared bends and straight lengths of alloy steel tubes of
45mmxt6.9mm, welded together to form large flat surfaces.
Boiler
Mitsubishi
2-16
Chapter 2
General
The horizontal type tube bank consists of bent tubes (coiled)

located above the economizer rear section of the 2RY pass and
is supported by the economizer hanger tubes. This bank consists
of 220 panels with 6 tubes in each panel.
The terminal type tube bank consists of straight tubes connecting
the horizontal type bank to the outlet header inside the roof
housing. This bank consists of 110 panels with 12 tubes in each
panel.
The 1RY SH tube banks are supported by the economizer
hanger tubes. Due to the different mediums handled by the two
sets of tubes, there is a differential expansion between the 1RY
SH terminal tubes and the economizer hanger tubes.
In order to avoid the mechanical strain due to the differential
expansion, the terminal type bank is provided with cold springs
(12mm) near the tube joints between the terminal and the
horizontal type banks (Refer to the Figure 2-6).
Fixed spacers, sliding spacers and band spacers are provided on
the1RY superheater banks at specific locations to maintain
alignment between the adjacent tubes.
At locations where the 1RY superheater tubes penetrate the roof
panel, sealing is provided to prevent the leakage of the flue gas
and fly ash into the roof.
Separate outlet pipes from the two water separators join the two
individual 1RY superheater inlet headers of 431.8mm located in
the secondary pass. The steam passes through the lower and
upper banks and enters the outlet header of 482.6mm.
The 1RY superheater banks are of the drainable type.
The entire assembly is supported at the outlet header. The outlet
header is connected to the collector beams through rigid hangers
and then the collector beams are connected to the hanger beams
with spring hangers.
b)
Secondary Superheater
Refer to the Figures 2-2, 2-6, 5-17 & 5-18.
Steam from the 1RY superheater outlet header enters the 2RY
superheater inlet header via the 1RY superheater desuperheater.
There are four sets of 2RY superheater assemblies each set
consisting of an inlet /outlet header.
The 2RY superheater is of the non drainable type.
Boiler
Mitsubishi
2-17
Chapter 2
General
Steam from the 2RYsuperheater bank tubes exits through the

2RY superheater outlet header.
The 2RY superheater assembly is located in the upper furnace
and most of the heat absorption takes place from radiant heat.
The 2RY superheater bank is a panel type and is fabricated from
48.6mm alloy steel and stainless steel tubes. The tubes
connecting the panels to the header in the roof are of size
31.8mm and have the thickness of t5.9mm, t6.4mm, t6.9mm
and t7.4mm depending on their locations in the header.
Since the panel spacing is of the order of 2403.0mm the
convection heat transfer is quite less in this superheater.
There are 12 panels arranged along the width and depth of the
furnace. Each panel consists of 160 tubes. Spool pieces have
been provided for insertion and welding between the tubes of
dissimilar materials.
To provide rigidity to the 2RY superheater bank tubes and to
prevent side movement due to turbulent gas flow inside the
furnace, girdling loop arrangements are provided around the tube
assemblies.
These girdling loops originate from each 2RY superheater inlet
header, bifurcate into two tubes forming a girdling loop around
both the 2RY and 3RY superheater assemblies at the bottom and
then terminate at each 3RY superheater outlet header after
combining as a single tube. Necessary sleeves, protectors and
supports are provided to avoid damages to the tubes.
Rod spacers and support plates are also provided on the 2RY
superheater assembly at specific locations to maintain alignment
between adjacent tubes.
Adjacent tubes of the 2RY superheater bank are interlocked with
sliding spacers which allow relative expansion between the
adjacent tubes to maintain alignment.
The locations where the 2RY superheater tubes penetrate the
furnace roof panel are provided with sealing arrangements to
prevent the leakage of flue gas.
The 2RY superheater panels and the 2RY superheater inlet and
outlet headers are supported by rigid hanger supports connected
to the hanger beams. The inlet pipes and the outlet pipes to these
headers are connected to the collector beams through rigid
hangers and then the collector beams are connected to the
hanger beams with spring hangers.
Boiler
Mitsubishi
2-18
Chapter 2
c)
General
Tertiary Superheater
Refer to Figures 2-2, 2-32, 5-19 & 5-20.
Steam from the 2RY superheater outlet header enters the 3RY
superheater inlet header via the 2RY superheater desuperheater.
They are of platen type and consist of fifty four panels.
The 3RY superheater bank is of the non drainable type.
Steam from the 3RY superheater exits through the 3RY
superheater outlet header which is connected to the main steam
pipe.
The 3RY superheater bank is located above the nose portion in
the upper furnace and is sandwiched by the 2RY superheater
and the 2RY reheater. This superheater absorbs heat, mostly, by
convection process from the hot flue gas. Some heat is also
absorbed by radiation from the furnace.
The 3RY superheater bank is fabricated from 45mm alloy steel
tubes and stainless steel tubes. The tubes connecting the inlet
header have a thickness of 5.9mm whereas the tubes connecting
the outlet header are of thickness 6.9mm.
There are 54 panels and each panel is formed by a group of 32
tubes. Spool pieces have been provided for insertion and welding
between the tubes of dissimilar materials.
Girdling loop arrangements as provided for the 2RY superheater
are extended to this superheater also to provide rigidity to the
3RY superheater banks and to prevent side movement due to
turbulent gas flow inside the furnace.
Steam cooled spacer tubes are provided for the 3RY superheater
to prevent the sidewise movement of the panel across the gas
flow path. Two steam cooled spacer tubes of 45.0mm are
tapped from each 1RY superheater inlet header at the bottom of
the 2RY pass.
The spacer tubes enter through the nose section of the furnace at
the centre line of the boiler. Each tube is drawn in between two
tubes at the front and rear end of 3RY superheater bank. The
tube runs through the entire width of the bank. Necessary
protectors are provided on the SH tubes to avoid tube damages
due to rubbing.
The spacer tubes are rigidly supported to the side wall tube with
support plates before exiting to the roof and are terminated to
each 2RY superheater outlet header on the extreme ends of both
sides respectively.
Boiler
Mitsubishi
2-19
Chapter 2
General
The locations where the spacer tubes penetrate the roof wall
panel are provided with sealing arrangements to prevent leakage
of flue gas.
A section of the spacer tube which is located outside of the boiler
and not exposed to the flue gas is insulated to reduce heat loss.
Alloy steel fasteners such as U rods and flats are used to hold
the spacer tube in position with the adjacent beams, wherever
the tube is passing through the boiler.
superheater assembly at specific locations to maintain alignment
Adjacent tubes of the 3RY superheater bank are interlocked with
sliding spacers, which allow relative expansion between the
adjacent tubes and maintain alignment.
The locations where the 3RY superheater tubes penetrate the
roof wall panel are provided with sealing arrangements to prevent
leakage of flue gas.
The 3RY superheater bank and the 3RY superheater inlet and
outlet headers are supported by rigid hangers to the collector
beams which are in turn connected to the hanger beams through
spring hangers.
The outlet header is connected to the main steam pipe.
2.4.4 Reheaters
The exhaust steam from the HP turbine (having spent energy to rotate
the HP turbine) is at a pressure of 4.7 MPa(a) and a temperature of
304oC when the plant is operating at BMCR. In practice, it is not
possible to increase the pressure of this steam; but more useful work
can be obtained from the steam if its enthalpy is increased. This is
achieved within the reheater section of the boiler, where the HP turbine
exhaust steam (referred to as cold reheat steam) is reheated up to
566oC.
The reheater consists of two sections known as 1RY and 2RY reheater.
Cold reheat steam from the exhaust of the HP turbine flows to the 1RY
and then to the 2RY section of the reheater.
a)
Primary Reheater
Refer to Figures 2-2, 2-6, 5-21 & 5-22.
The 1RY reheater assembly consists of two banks known as
horizontal type and terminal type. The horizontal type bank
basically consists of three sections of bent tube assemblies
stacked one above the other with short vertical connecting pipes.
Boiler
Mitsubishi
2-20
Chapter 2
General
The terminal type consists of straight long pipes. This type of

construction makes the 1RY reheater drainable.
The 1RY RH tube banks are supported by the economizer
hanger tubes. Due to the different mediums handled by the two
sets of tubes, there is a differential expansion between the 1RY
RH terminal tubes and the economizer hanger tubes. In order to
avoid the mechanical strain due to the differential expansion, the
terminal type bank is provided with cold springs (21mm) near the
tube joints between the terminal and the horizontal type banks
(Refer to the Figure 2-6).
The 1RY reheater bank is made of 57.1mm steel tubes.
Depending on the temperature of the flue gas each section is
made of carbon steel for low temperature areas and alloy steel
for high temperature areas. The upper most section is made of
alloy steel only.
The lower horizontal bank occupies the space just above the
economizer assemblies in the front section of the 2RY pass. The
terminal type bank is located above the horizontal bank and
connects the 1RY reheater bank to the reheat inlet/outlet header.
Both banks absorb convection heat from the flue gas.
The cold reheat steam enters the horizontal 1RY reheater inlet
header located above the economizer in the 2RY pass section
and adjacent to the front wall tubes. The cold reheat steam flows
through the 1RY reheater tubes in an upward direction.
To provide rigidity to the 1RY reheater bank and to prevent side
movement due to turbulent gas flow, each element is supported
by economizer hanger tubes at two locations. There are two
hundred and twenty hanger tubes supporting the 1RY reheater
assembly.
Fixed spacers, sliding spacers and band spacers are provided on
the 1RY reheater banks at specific locations to maintain the
alignment between the adjacent tubes.
Ash erosion protectors are provided on the 1RY reheater tubes
and bends at specific erosion prone locations and also at the
front and rear water cooled walls to prevent erosion of tubes due
to ash flow.
At locations where the 1RY reheater tubes penetrate the roof,
sealing is provided to prevent the entry of flue gas and fly ash
from the flue gas.
The 1RY reheater banks are supported at the1RY reheater outlet
header by spring hangers located above the roof housing.
Boiler
Mitsubishi
2-21
Chapter 2
b)
General
Secondary Reheater
Refer to Figures 2-2, 5-23 & 5-24.
The 2RY reheater is of the non drainable type and is located in
the passage pass between the 3RY superheater and the 1RY
reheater banks. The heat transfer takes place by convection
process.
The cold reheat steam after passing through the 1RY reheater
enters the 2RY reheater section. The 2RY reheater bank is of
alloy steel and stainless steel tube material ( 57.1mm).
Steam cooled spacer tubes are provided for the 2RY reheater to
prevent the sidewise movement of the panel across the gas flow
path. Two steam cooled spacer tubes of 45.0mm are tapped
from each 1RY superheater inlet header at the bottom of the 2RY
pass.
The spacer tubes enter through the nose section of the furnace at
the centre line of the boiler. Each tube is drawn in between two
tubes at the front and rear end of 2RY reheater bank. The tube
runs through the entire width of the bank. Necessary protectors
are provided on the RH tubes to avoid tube damages due to
rubbing.
They are rigidly supported to the side wall tube with support
plates before exiting to the roof and are terminated to each 2RY
superheater outlet header on the extreme ends of both sides
respectively.
A section of the spacer tube which is located outside of the boiler
and not exposed to the flue gas is insulated to reduce heat loss.
Alloy steel fasteners such as U rods and flats are used to hold
the spacer tube in position with the adjacent beams, wherever
the tube is passing through the boiler.
reheater assembly at specific locations to maintain the alignment
Adjacent tubes of the 2RY reheater bank are interlocked with
sliding spacers, which allow relative expansion between the
adjacent tubes to maintain alignment.
At locations where the 2RY reheater tubes penetrate the roof,
sealing arrangements are provided to prevent the entry of flue
gas and fly ash into the roof housing.
The secondary reheater inlet and outlet headers are located
inside the roof housing and are supported by spring hangers
located above the roof housing.
Boiler
Mitsubishi
2-22
Chapter 2
General
2.4.5 Desuperheaters
Refer to the Figures 5-25 & 5-26.
To control the final steam temperature at the 3RY superheater outlet,
spray type desuperheaters are provided between the 1RY and the 2RY
superheaters and 2RY and the 3RY superheaters.
Similarly, to control the reheat temperature under emergency
conditions desuperheaters are provided between 1RY reheater and
2RY reheater banks.
All desuperheaters have similar internal construction. As the reheater
desuperheater spray is not continuously used, it has been provided
with a steam warming / cooling pipe connection to avoid any thermal
stress to the internal parts due to sudden application of spray water.
The desuperheaters consist of a circular pipe body having the same
inner diameter as the respective outlet pipes emerging from the
superheater outlet header.
The inside surface of the body is protected with a liner pipe, which is
positioned and supported by positioning and supporting bolts that are
welded to the body. At the four locations of positioning bolts, the liner
pipe is reinforced by 9.27mm thick reinforcing pads on the inner
surface at the inlet end of steam water mixture.
The spray water pipe enters horizontally into the desuperheater body at
right angle and extends to the opposite side through the diameter of the
body. This pipe is made of cast steel and alloy steel materials as per
the temperature contour in the various sections of the pipe.
The pipe assembly consisting of positioning rod, reinforcement ring and
lugs is welded to the body. The positioning rod remains inserted into
the positioning ring in the protection nozzle welded in the opposite side
of the body. The protection nozzle is closed by the protection nozzle
end plate.
The protection nozzle side chamber (formed as above) pressure is
equalized by the two 7mm internal holes drilled at the top and bottom of
the protection nozzle as shown in the Figures 5-22&23. For the proper
functioning of the desuperheater, the fixing arrangement of the spray
pipe is very important.
The clearance between the positioning rod and the positioning ring play
an important role in this regard and need to be inspected during
maintenance.
The spray pipe is fitted with two spray nozzles. The spray nozzles are
fixed on the spray water pipe on the side opposite to the steam inlet in
a horizontal plane and supported by a spray nozzle support.
Boiler
Mitsubishi
2-23
Chapter 2
General
Thus the spray nozzles are fixed in such a way that the sprayed water
is directed along the path of the incoming superheated steam.
Inspection nozzles are provided at the steam inlet and exit end of the
desuperheater body. This facilitates the inspection of the
desuperheater during annual overhaul. The direction of steam flow is
engraved on the body.
2.4.6 Economizer
Refer to the Figures 2-2, 2-6, 5-11, & 5-12.
The function of the economizer is to raise the feed water temperature
by absorbing heat from the exiting flue gas before the feed water enters
the furnace wall inlet headers.
The feed water enters the economizer via the inlet header and then
flows upward through the economizer banks in counter flow to the
downward flue gas path. This counter flow increases the heat transfer
efficiency between the flue gas and the feed water.
The economizer is of the drainable type. The economizer consists of
tubes placed across the width of the secondary pass in four banks.
There are two horizontal tube banks with spiral fin tubes. One tube
bank consisting of only one horizontal section is placed in the front side
of the 2RY pass whereas the second bank consisting of two horizontal
assemblies is placed in the rear side. Each horizontal element has
spirally wound fins to increase the heating surface area for more
efficient heat transfer. The 19mm high, 1.4mm thick fins are mounted
with a spacing of 12.7mm on the 45.0mm OD x 4.1mm thick
economizer tubes. The tube material is carbon steel (SA-210 Gr.C).
The bends at the tube ends are not finned.
The outlets from the two horizontal banks are welded to the other two
tube banks, known as hanger type, through economizer intermediate
headers. There are two intermediate headers between each set of
horizontal and hanger type banks. The 57.1/50.8 mm or 63.5/50.8mm
OD hanger pipes support the economizer tube banks, 1RY superheater
tube bank and the 1RY reheater tube bank.
The hanger pipes passing through the 1RY superheater and 1RY
reheater tube bank support them using fixed and sliding supports. The
hanger pipes are fitted with anti vibration bands at fixed locations.
Support lugs, support plates, stoppers and lugs are used at appropriate
locations to support the economizer tube bank. These support plates
are secured to the intermediate headers by welding, thus providing
support to the economizer assemblies.
Anti-vibration plates are provided over the top tubes of the element to
prevent damage to tubes and fins due to vibration.
Boiler
Mitsubishi
2-24
Chapter 2
General
The pitch of the economizer bank is maintained by the economizer

supports. These supports are welded to the respective economizer
intermediate headers located above the economizer assemblies.
Ash erosion protectors are provided on the economizer tubes and
bends at specific locations and also at the front and rear walls to
prevent erosion of tubes due to ash flow.
At locations where the economizer hanger tubes penetrate the roof,
sealing arrangements are provided to prevent the entry of flue gas into
the roof housing.
The economizer outlet header is supported by rigid hangers from the
top of the roof housing.
2.4.7 Boiler Supports

Refer to the Figures 2-2, 2-33 & 2-34.
The boiler pressure parts are supported and hung from the boiler
structure in the roof housing.
The outlet tubes from each side of the furnace water walls, 2RY pass
walls, passage walls; 1RYsuperheater, 1RY reheater, economizer, etc.
are welded to their respective outlet headers located inside the roof
housing. The outlet headers are supported on the boiler structural
beams using rigid and spring hangers.
The inlet headers of the 1RYsuperheater, 1RY reheater and the
economizer inlet and intermediate headers are supported from the 2RY
pass walls inside the 2RY pass.
The 2RY superheater, 3RY superheater and the 2RY reheater inlet and
outlet headers are located in the roof housing and supported on the
boiler structure.
Feed water and steam pipes connected to the boiler and feed water are
routed outside of the furnace and are supported on the boiler structure.
Water separator, water separator drain tank, boiler circulation pump etc.
are the equipment located external to the boiler. Such equipment is
supported on prepared structures.
For Details of the type and the location of the various supports, please
refer to Appendix G.
Boiler
Mitsubishi
2-25
Chapter 2
General
2.4.8 Casing and Insulation

Refer to the Figures 2-2, 2-35 to 2-37, 2-39 and Appendix E.
Thermal insulation is provided in the boiler for the following reasons.
To prevent burns to personnel.
To improve efficiency by reducing heat loss from steam and hot
water systems.
To protect the boiler internal components from damage.
The thermal insulation used in the boiler is mainly in the form of
refractory, mineral fiber materials, calcium silicate blocks and insulating
plastics.
Refractory materials are provided in the form of bricks, mortar and
castable refractory mainly in access doors, roof tube penetrations,
finned tubes and burner panels. Mineral fiber materials are used in the
form of mattress, board or blanket in boiler furnace, steam cooled walls,
air and flue gas ducts and expansion joints. Calcium silicate and
insulating plastics are also used in certain locations in the boiler.
For more details refer to the vendor manual OM-01.08.
2.4.9 Safety Valves

Refer to the Figures 2-4, 2-5 & 2-40.
To relieve the excess pressure and to protect the boiler pressure parts
in the event of over pressurization, safety valves are provided.
There are six spring loaded safety valves at the common steam outlet
header of the water separator and the water separator drain tank.
There is also a spring loaded safety valve in the main steam pipe 3B
connected to the outlet from the 3RY superheater outlet header.
The reheat steam system is provided with eight spring loaded safety
valves, six on the cold reheat lines and two on the hot reheat header, to
relieve the excessive pressure and protect boiler pressure parts in the
reheat steam flow path during accidental over pressurization.
Each spring loaded safety valve opens at a fixed set pressure and
closes at a lower reset pressure automatically after relieving the excess
steam to atmosphere. The valve has provisions to adjust the lifting and
reseating pressures.
The boiler is also provided with three solenoid operated pressure relief
valve at the outlet from the 3RY superheater header.
Boiler
Mitsubishi
2-26
Chapter 2
General
The solenoid operated safety valve opens at a fixed set pressure and
closes at lower reset pressure automatically after relieving the
excessive steam to the atmosphere.
The solenoid valve has provisions to adjust the lifting and reseating
pressures, in addition to automatic operation.
The solenoid operated relief valve can be manually opened and closed
at any operating pressure. For further details of the boiler safety valves
refer to the respective vendor operation and maintenance manual
(OM-15.01).
Boiler
Mitsubishi
2-27
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-6
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE)
2-28
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-7
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE A-A OF FIGURE 2-6)
2-29
Chapter 2
General
B O IL E R F R O N T
O P E N IN G F O R
L IF T IN G P L A T F O R M
FRONT W ALL
OUTLET HDR.
+ 6 47 5 0
+ 6 46 00
SECONDARY PASS REAR WALL TUBE (219-O38.1)
ROOF TUBE (REAR) (220-O57.1)
1RY SH TUBE (110-O45.0)
ECO. HANGER TUBE (110-O50.8)
SECONDARY PASS DIVISION WALL (147-O45.0)
1RY RH TUBE (110-O57.1)
2 R Y P A S S D IV IS IO N
W ALL OUTLET HDR.
2RY PASS FRONT

W ALL OUTLET HDR.
REAR W ALL HANG ER

O U T LE T H D R .
+ 6 45 0 0
ECO. HANGER TUBE (110-O50.8)
SECONDARY PASS FRONT WALL

(110-O45.0)
2RY RH TUBE (108-O57.1)

(109-O48.6)
2RY SH TUBE
(12-O45.0)
ROOF TUBE (FRONT)

(440-O45.0)
+ 6 42 00
3RY SH TUBE (54-O45.0)
SPACER TUBE
O 4 5.0
FRONT WALL TUBE (660-O28.6)

R O O F IN LE T H D R .
S E C O N D A R Y P A S S S ID E W A LL T U B E
(2 -105 -O 38 .1 )
P A S S A G E S ID E W A L L T U B E
(2 -67-O 3 8 .1)
S ID E W A L L T U B E ( 2-32 2 -O 28 .6)
C A B L E O P E N IN G
2RY PASS REAR

W ALL OUTLET HDR.
+ 6 4 50 0
+ 6 4 75 0
ROO F OUTLET HDR.
+ 6 32 00
R O O F TU B E
CL O F F R O N T W A LL T U B E
2R Y SH TU BE
3R Y SH TU BE
2RY RH TUBE
C
L OF REAR W ALL
HANGER TUBE
1RY RH TUBE
C
L O F 2R Y P A S S F R O N T
W ALL TU B E
1R Y SH TU B E
C
L O F 2 R Y P A S S D IV IS IO N
W A LL T U B E
C
L O F 2R Y P A S S R E A R
W ALL TUBE
SPACER TUBE
O 4 5.0
MM-M01.01
Rev.004
O P E N IN G F O R
L IF T IN G P L A T F O R M
C A B L E O P E N IN G
+ 6 47 50
M P T D -3 -00 87
FIGURE 2-8
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE B-B OF FIGURE 2-6)
2-30
Chapter 2
General
REAR WALL HANGER

OUTLET PIPES
HANGER ROD
+67100
CL OF BOILER
2RY PASS FRONT

WALL OUTLET HDR.
1-O219.1
C
L OF BOILER
HANGER ROD
+64200
+63200
ROOF TUBE
+64200
REAR WALL HANGER

OUTLET PIPES
ROOF TUBE (REAR)
.
(220-O57.1)
1RY SH TUBE
. (110-O45.0)
1RY RH TUBE (110-O63.5)

.
g-g
2RY PASS REAR. WALL TUBE (219-O38.1)
SECONDARY PASS SIDE WALL

TUBE (2x105-O38.1)
.
ECO. HANGER TUBE

.
(110-O50.8)
2RY PASS FRONT

WALL
.
(110-O45.0)
.
REAR WALL HANGER
TUBE
(109-O48.6)
2RY SH. TUBE

(12-O45.0)
HANGER ROD
PASSAGE SIDE
WALL TUBE
.
(2x67-O38.1)
3RY SH TUBE .(54-O45.0)
FRONT WALL TUBE

.
(660-O28.6)
SIDE WALL TUBE

(2x322-O28.6)
.
2RY PASS DIVISION

. WALL (147-O45.0)
ECO. HANGER TUBE
(110-O50.8)
.
2RY RH TUBE. (108-O57.1)
+62690
F
+64200
FRONT WALL
OUTLET HDR.
1-O323.8
B-B
BOILER FRONT
+65900
HANGER ROD
A-A
HANGER ROD
+63200
ROOF TUBE
2RY PASS REAR

WALL OUTLET HDR.
1-O323.8
+64750
+63200
ROOF TUBE
2RY PASS REAR WALL . TUBE (2219-O38.1)
+64200
BOILER FRONT
+64750
+64750
+64200
REAR W ALL
HANGER OUTLET HDR.
1-O219.1
+64600
+65900
REAR WALL HANGER

OUTLET HDR.
FRONT WALL OUTLET HDR.

ROOF INLET HDR.
+64200
+64600
+64500
2RY PASS FRONT

WALL OUTLET HDR.
+64750
2RY PASS REAR

WALL OUTLET HDR.
+64750
2RY PASS DIVISION

WALL OUTLET HDR.
+64500
MM-M01.01
Rev.004
COLD SIDE
b-b
COLD SIDE
c-c
COLD SIDE
d-d
COLD SIDE
COLD SIDE
e-e
+64500
+62630
ROOF OUTLET HDR.
f-f
FIGURE 2-9
Boiler
Mitsubishi
C-C
+64200
+63200
ROOF TUBE
M PTD-3-0088
D-D
j
C
L OF BOILER
2RY PASS
DIVISION WALL OUTLET HDR.
1-O219.1
BOILER FRONT
F-F
+63200
ROOF
TUBE
BOILER FRONT
+63200
+64500
BOILER FRONT
C
L OF BOILER
C
L OF BOILER
PRESSURE PARTS ARRANGEMENT (UPPER SIDE C-C OF FIGURE 2-6 )
2-31
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-10
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE D1-D1, D2-D2 OF FIGURE 2-6)
2-32
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-11
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE E-E OF FIGURE 2-6)
2-33
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-12
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE F-F OF FIGURE 2-6)
2-34
Partitioning
plate
Drain Nozzle
Eoc. Inlet HDR.
1-O610.0
DETAIL OF "A"
2ry Pass Front
Wall Inlet HDR.
1-O219.1
Eco. Inlet HDR.

1-O610.0
+38865
Partitioning
plate
Eco. Inlet HDR.

1-O610.0
Sleeve
2ry Pass Division

Wall Inlet HDR.
1-O219.1
2ry Pass Division

Wall Inlet HDR.
1-O219.1
Eco. Inlet HDR.

1-O610.0
DETAIL OF "B"
+37565
a
CL OF BOILER
2ry Pass
Supply Pipe
O114.3
DETAIL OF "D"
Partitioning
plate
2ry Pass Division

Wall Inlet HDR.
1-O219.1
2ry Pass
Supply Pipe
O168.3
a-a
b-b
2ry Pass
Supply Pipe
O168.3
+37565
+38015
2ry Pass Rear

Wall Inlet HDR.
1-O219.1
General
+38015
+38865
Chapter 2
DETAIL OF "E"
2ry Pass
Supply Pipe
O168.3
+38865
Drain Nozzle
2ry Pass Front

Wall Inlet HDR.
1-O219.1
2ry Pass Rear Wall

Tube (219-O38.1)
.
2ry Pass Inlet Pipe

2-O660.0
DETAIL OF "C"
2ry Pass Rear

Wall Inlet HDR
1-O219.1
DRAIN NOZZLE
"A"
2ry Pass Inlet

Manifold Air Vent Pipe
(25A)
"D"
Eco. Inlet Pipe
O610.0
MM-M01.01
"E"
"B"
2ry Pass Division
Wall Tube (294-O38.1)
.
BOILER FRONT
Rev.004
2ry Pass Side Wall .Tube (105-O38.1)
2ry Pass Inlet Manifold

2-O1230.0
"C"
Eco. Inlet HDR.

1-O610.0
2ry Pass Division

Wall Inlet HDR
1-O219.1
2ry Pass Side

Wall Inlet HDR
2-O219.1
Economizer
(194-O45.0)
.
CL OF BOILER
2ry Pass
Supply Pipe
38-O168.3
DRAIN NOZZLE
2ry Pass Front

Wall Inlet HDR
1-O219.1
2ry Pass
Supply Pipe
76-O114.3
2ry Pass Front Wall

Tube (220-O38.1)
.
MPTD-3-0092
FIGURE 2-13
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT (UPPER SIDE G-G OF FIGURE 2-6)
2-35
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-14
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT LOWER SIDE
2-36
Chapter 2
BS FL+45500
A
E
E
D
C
L BOILER
"d"
Front Wall Intermediate
Manifold Outlet Pipe
2x34-O114.3
FL+45120
FL+44971.8
Rear Wall
2nd Intermediate HDR
1-O323.8
F
F
D
FL+44310
BS FL+44000
BOILER FRONT
Front Wall
Intermediate Manifold
2-O762.0
S1
FL+43750
D-D
Rear Wall
2-O762.0
CL BOILER
Rear Wall Intermediate

34-O114.3
FL+44971.8
H
CL FURNACE
H
BS FL+42650
FL+42380
a-a
Rear Wall Tube

660-O28.6
Furnace Intermediate
HDR (Rear Wall)
1-O323.8
BS FL+41750
Front Wall
2-O762.0
BOILER FRONT
BS FL+45500
DETAIL "C"
C
L BOILER
7FL +46300
Side Wall
2-O323.8
Side Wall
2-O762.0
Side Wall Intermediate
17-O114.3
Front Wall
1-O323.8
General
KEY PLAN
DETAIL "d"
FL+44310
a
CL BOILER
BS FL+42650
FL+42380
FL+42380
BS FL+41750
HDR (Side Wall)
2-O323.8
HDR (Front Wall)
1-O323.8
Front Wall Tube 660-O28.6
.
Side Wall Tube

2x322-O28.6
Rear Wall
1-O323.8

2x34-O114.3
A-A
S5
S5
S5
S5
S5
S5
S3
S3
S3
S3
S3
S3
S3
S5
S5
S5
S5
S5
S5
S5
S5
S5
S3
S3
S3
e
S2
S2
S2
S2
S2
S2
S2
Rear Wall
2-O762.0
Rear Wall
Rear Wall
Manifold
2-O762.0

2x16-O114.3

34-O114.3
HDR (Rear Wall)
2-O323.8
BOILER FRONT
b-b
7FL +46300
Front Wall
1-O323.8
Front Wall
2-O762.0
34-O114.3
FL+42380
Side Wall
2-O762.0
E-E
"C"
FL+46223.5
BS FL+45500
FL+44310
b
BS FL+42650
FL+42380
C
L FURNACE
Rev.004
MM-M01.01
HDR (Side Wall)
2-O323.8
G-G
H-H
S4
S4
S5
S5
S2
S3
S4
S5
S2
S3
S4
S5
FL+42380
BS FL+41750
HDR (Front Wall)
1-O323.8
Front Wall Tube
660-O28.6
F-F
Rear Wall
1-O323.8
Rear Wall
2-O762.0
34-O114.3
HDR (Rear Wall)
1-O323.8
2x16-O114.3
Side Wall Tube. 2x322-O28.6
B-B
Rear Wall Tube

660-O28.6
FL+42380
FL+42380
HDR (Rear Wall)
2-O323.8
HDR (Rear Wall)
2-O323.8
e-e
f-f
MPTD-3-0094
FIGURE 2-15
Boiler
Mitsubishi
S4
S4
S4
S4
S4
S4
S4
S4
S4
S1
34-O114.3
Side Wall
2-O323.8
S4
S4
S4
S4
S4
S1
Air Vent
Nozzle
CL FURNACE
Side Wall
2-O762.0
Rear Wall
1-O323.8
Rear Wall
1-O323.8
S2
S2
S2
S4
ARRANGEMENT OF INTERMEDIATE HEADERS
2-37
Chapter 2
General
Rifled Tube
MPTD-4-0095
MSD-4-0041
FIGURE 2-16
Boiler
Mitsubishi
SECTIONAL VIEW OF RIFLE TUBE
2-38
Chapter 2
General
BO ILE R FR ON T
FR ON T W ALL
O UTLET H DR .
1-O 323.8
R O OF IN LET H D R .
1-O 219.1
+64500
S1
S2
+63200
R OO F TU BE
S6
BS+61700
BS+60200
BS+60200
BS+58700
Left Side O nly
+61100
R O OF O U TLET HD R .
1-O 610.0
D D D D
+58900
BS+58700
+58100
BS+57200
BS+57200
BS+55700
+55100
BS+54200
S7
+53700
BS+52700
BS+51200
BS+51200
BS+49700
BS+49700
+54700
+55100
+54500
+53600
+53223.4
+52250
BS+48200
BS+48200
BS+46700
BS+46700
BS+45500
+45120
+47600
BS+45500
+45120
BS+40350
BS+35850
BS+3585
BS+34350
BS+29744
E
C
L OF C O AL BU RN ER S
C
L O F OIL BUR N ERS
C
E
C
C
L O F OIL BUR N ERS
C
+30729
BS+40100
+39465
+38865
S3
S4
S5
SECO ND AR Y PASS SID E
W ALL IN LET H DR .
2-O2 19.1
SEC O N D AR Y PASS SID E W ALL
U
B
BS+28260
BS+26776
BS+26776
BS+24806
BS+24806
BS+23322
BS+23322
BS+21838
BS+21838
BS+19868
BS+19868
BS+18384
BS+18384
BS+16800
BS+16800
+16500
A
R
E
A
+15686
R igh t Side Only

an
BS+10400
+12200
+12000
br
Left Side Only
FUR NAC E INLET PIPE

2-O 457.0
+13507.7
em
BS+13000
+12200
+13507.7
SIDE W ALL IN LET H D R .

1-O 219.1
BS+10400
BS+14600
C
L OF FURNACE
Membrane
C
L OF BO ILER
BS+13000
Membrane
BS+41400
BS+29744
BS+28260
BS+14600
Smooth Tube
Rev.004
+39315
S10
+7833.3
MM-M01.01
+42300
+42420
+20828
+16500
B.L+15686
+7133.3
+7133.3
S1-S1
FR O N T W ALL
FRO N T W ALL INLET H DR .

1-O 219.1
S1
S2
SID E W ALL
FIGURE 2-17
Boiler
Mitsubishi
BS+44800
+25791
M PTD -3-0096
BS+46350
BS+43200
BS+31714
RifleTube
C
C
L O F OIL BUR N ERS
C
S10
BS+31714
+21515
+20828
+34950
BS+34350
+33600
BS+33385
Smooth Tube
RifleTube
BS+33385
+47050
I
F
+33600
+26453
+25791
+25129
BS+48200
+38150
BS+37350
BS+50000
+47300
BS+37350
+50450
+42580
+42400
S9
S8
BS+53600
PR IM AR Y SH
IN LET H D R.
2-O 457.0
BS+51800
+50050
+42840
BS+38850
BS+38850
CL OF A.A
S9
CL OF A.A
T.V
BS+41750
+41150
BS+40350
BS+41750
+41150
S11
S11
PASSAG E SID E
+50650
W ALL IN TLET H D R .
2-O 219.1
C ABLE O PEN IN G
+47300
+47000
PR IM AR Y R H
IN LET H D R.
2-O 559.0
BS+42650
BS+42650
47100
+54400
+50800
+50500
O PEN IN G FOR
LIFTIN G PLATFO RM
+47600
+54700
S7
Membrane
S8
Smooth Tube
+56300
BS+52700
+31391
+30729
+30067
+64750
S6
Both Side
BS+54200
+34950
S5
+64500
+62630
+60850
+54900
+37733
S4
+64750
+63200
R OO F TU BE
BS+61700
BS+55700
+39061
SECO N D ARY PASS

SID E W ALL O UTLET H D R .
2-O2 19.1
S3
+64600
+64200
Hanger Tube
(Except For Bend Tube)
Smooth Tube
PASSAG E SID E
W ALL O U TLET H D R.
2-O 219.1
SID E W ALL
O U TLET H D R.
2-O 323.8
RIFLE TUBE LOCATION IN FURNACE WALLS
2-39
Chapter 2
General
SPACER SPECIFICATION
Material
Thickness
(t)
3ry Superheater (Front)
65
SA240-310S
3ry Superheater (Rear)
65
SA240-310S
2ry Reheater (Front)
65
SA240-310S
2ry Reheater (Rear)
65
SA240-310S
Pipe Position
1
2
"E"
"E"
Height (H)
Tube No.
1ry SH Outlet HDR

2-O431.8
7
ROUND TO EDGE
PROTECTOR
2ry SH Outlet HDR

2-O355.6
ROUND TO EDGE
END TUBE OF SH/RH BANK
SPACER TUBE
+66200
+65900
+65300
+64750
+54038.8
+65700
+54900
"B" O45.0 7 "B"
BS+54200
"B"
2ry Pass
Rear Wall Tube
219-O38.1
(T)
"B"
3ry SH Tube
ST=2136
STN=54
+56485
O45.0
O45.0
+56050
1
+55220
+54220
+54100
+56300 +56485
4 O45.0
3 O45.0
+55485
+55485
"B" +55100
+55100
2 O45.0
Support from
Buckstay (+55700)
+53600
+53400
+52400
+50863.3
+50400
Protector
t4
Protector
t4
a
+54900
b
DETAIL "G"
DETAIL "F"
Plate(t5)
Protector
t6
Protector
t6
Support(t5)
Protector
t4
Protector
t6
+61700
1ry RH Tube
ST=133.5
STN=220
O57.1
+50800
clearance
(O54.88)
+56000
+62630
2ry Pass Wall. Tube (Side)
2x105-O38.1
+58100
Girdling
Tube Support
O45.0
DETAIL "D"
DETAIL "E"
COLD
SIDE
Passage Side
Wall Tube
.
2x67-O38.1
+61700
+61100
7 O45.02ry RH Tube
ST=267
STN=108
+59800
O57.1
+59500
+59500
+59800
+58900
2ry SH Tube
ST=2136
STN=12
O45.0
BS+55700 "A"
O28.6
+56485
+56050
+55220
Girdling Tube
24-O45.0
DETAIL "B"
Side Wall. Tube

2x322-O28.6
"C"
Sleeve
O42.0xt5.0
SPACER TUBE
(O45.0)
+54161.2
+64500
Roof Tube (Rear)

220-O57.1
clearance
(O54.88)
2ry Pass Rear

Wall Outlet HDR
1-O457.0
Roof Outlet HDR
2-O610.0
1ry SH Outlet HDR

2-O482.6
Economizer
Outlet HDR
1-O457.0
2ry Pass Division

Wall Outlet HDR
1-O219.1
2nd SH Tube O45.0

(3rd SH Tube O45.0)
+63600
Roof Tube (Front)

440-O45.0
O45.0 7
Rev.004
1ry SH
Inlet Pipe
2-O482.6
COLD
SIDE
+66600
+65800
+64750
+63200
MM-M01.01
1ry RH Outlet HDR

2-O711.0
2ry RH
Outlet HDR
2-O864.0
+66300
2ry Pass Front

Wall Outlet HDR
1-O219.1
2ry SH Inlet HDR

4-O323.8
+65800
2ry RH Inlet HDR

2-O660.0
Front Wall Outlet HDR

2-O323.8
Rear Wall Hanger

Outlet HDR
1-O219.1
3ry SH Inlet HDR

2-O431.8
Roof Inlet HDR

1-O219.1
BOILER FRONT
3ry SH Outlet HDR

2-O482.6
DETAIL "I"
1ry SH Tube
ST=133.5
Support from
Buckstay (51800) STN=220
O45.0
+51500
+50650
+49700
+54100
+54100
O45.0
BS+51800
DETAIL "C"
+50450
+50050
Sleeve
O42.0xt5.0
Girdling Tube
(Y-Piece)
O54.0
O45.0
Girdling Tube
O54.0
O45.0
+53900
+54100
a-a
b-b
DETAIL "A"
Support from Rear Wall

Upper Support Beam
MPTD-3-0097
Boiler
Mitsubishi
1st SH Inlet HDR

2-O431.8
FIGURE 2-18
ARRANGEMENT OF SPACER TUBE & GIRDLING TUBE
2-40
Chapter 2
General
Silencer
RFL +73632
Air Vent Nozzle

Water Separator Equalizer Pipe
1-O323.8
Pressure Gauge Nozzle

BOILER FRONT
Water Separator
Inlet Pipe
4-O406.4
FL+69400
FL+69850
FL+67750
FL+66600
1st SH Inlet Pipe

2-O482.6
FL+63200
Roof Outlet HDR

2-O610.0
FL+61100
FL+66700
FL+64750 FL+64900
FL+64050
FL+64650
FL+62630
2ry Pass
Rear Wall FL+64100
Outlet HDR
1-O355.0
FL+62800
FL+65300
FL+64550
FL+63750
PIT
Water Separator
2-O760id
Steam Vent Pipe
1-O219.1
Level Transmitter Pipe Nozzle
FL+61450
FL+60800
Air Vent Nozzle
9FL +60400
Secondary Pass Bypass Pipe

2-O457.0
FL+58900
FL+58100
Water Separator
Outlet Pipe
2-O610.0
2ry Pass Bypass Pipe
4-O323.8
FL+69450
FL+68800
FL+68000
FL+68750
10FL +68600
(T)
FL+56700
FL+56300
PIT
TE
FL+55100
FL+54600
FL+55100
Support from 9FL
FL+54700
8FL +53600

1-O760id
FL+54200
FL+27800
FL+53000
FL+52900
RH Safety Valve
Test Nozzle
(Left Side Only)
FL+50800
FL+50050
FL+49700

Inlet Pipe
2-O559.0
FL+50450
FL+26346
1st SH Inlet HDR

2-O431.8
FL+47300
FL+47300
FL+47300
Level Transmtter Pipe Nozzle
7FL +46300
FL+45350
FL+45350
FL+43600
FL+42420
FL+42300
2ry Pass Inlet Pipe

2-O660.0

2-O1174
6FL +40300
3FL +24200
Boiler Circulation Pump

Inlet Pipe
1-O508.0
FL+39465
FL+39315
FL+38865
TE
FL+38000
FL+37700
FL+37400
FL+37565
5FL +36500
DETAIL "A"
FL+35865
FL+34800
WDS
Drain Pipe Nozzle

Furnace Inlet Pipe
2-O457.0
FWP
FL+29848
4FL +29000
"A"
FL+28500
FL+27800
FL+27700
BCP. Warming Pipe Nozzle

(Left Side Only)
FL+25200
FL+25700
FL+26800
FL+26346
FL+25296
FL+24840
3FL +24200
Boiler Circulation
Pump Outlet Pipe
1-O406.4
ORIFICE
Flow Transmitter
Nozzle
FL+19600
Strainer
Insp.Hole
Chemical Cleaning
Nozzle
Insp.Hole
FL+18500
FL+17800
FL+17500
FL+16800
FL+16100
FL+14950
FL+13650
FL+12750
FL+12250
FL+12200
2FL +11000
Support from Furnace

Bottom Buckstay
Drain Pipe Nozzle
Rev.004
FL+7833.3
Outlet
Valve
Outlet Flow Control Valve
Drain Pipe Nozzle
Minmum Flow Pipe Nozzle
PIT
Furnace Inlet Manifold

2-O813.0
MM-M01.01
CL FORCED DRAFT FANS
MPTD-3-0098
FL+- 0
FIGURE 2-19
Boiler
Mitsubishi
PRESSURE PARTS ARRANGEMENT AROUND BOILER (1/3)

2-41
Chapter 2
General
BOILER FRONT

Outlet Flow Control Valve
3FL +24200
+11000
BCP.Floor
Outlet Valve
Drain Pipe Nozzle

HPFW

Outlet Pipe
1-O406.4
Flow Transmitter
Nozzle
Minmum Flow Pipe Nozzle

Insp.Hole
PIT

Inlet Pipe
1-O508.0
ORIFICE
Drain Pipe Nozzle
FL+16800
2FL +11000
PIT
BCP Warming Pipe Nozzle
RH Safety Valve
Test Nozzle
(Left Side Only)
5FL
Chemical Cleaning
Nozzle
Air Vent Nozzle

(Left Side Only)
Furnace Inlet Pipe

2-O457.0
9FL +60400
2RY PASS BYPASS VALVE
7FL +46300

Bottom Buckstay
+60800
W S.Floor
Support from 6FL
Drain Pipe
Nozzle
Air Vent Nozzle

Water Separator
Equalizer Pipe
1-O323.8
Pressure Gauge
Nozzle

2-O813.0
PIT

1-O760id
+60400
W SDT.Floor
CL FURNACE

Bottom Buckstay
Chemical Cleaning
Nozzle
TE
Level Transmitter Pipe Nozzle

Insp.Nipple
C
L BOILER

Bottom Buckstay
+46300
W SDT.Floor
Silencer
WSD
2ry Pass Inlet Pipe

2-O660.0
2ry Pass
Bypass Pipe
4-O323.8
Water Separator
Inlet Pipe
4-O406.4
2ry Pass Rear Wall
Outlet HDR
1-O355.6
Economizer Inlet HDR
2-O457.0
Roof Outlet HDR
Furnace Inlet Pipe
2-O610.0
2-O457.0
Air Vent Nozzle
Level Transmtter
Pipe Nozzle

Steam Vent Pipe
1-O219.1
Water Separator Drain Tank Inlet Pipe
2-O559.0
Air Vent Nozzle
+60800
2-O1174
W S.Floor
Water Separator
2-O760id
Water Separator Outlet Pipe
2-O610.0
Insp.Nipple
CL BOILER
2ry Pass Inlet Pipe

2-O660.0

Inlet Pipe
1-O508.0
TE
Drain Pipe
Nozzle
Water Separator Drain

Tank Inlet Pipe
2-O559.0
1st SH Inlet HDR

2-O431.8

2-O457.0
1st SH Inlet Pipe
2-O482.6
1st SH Inlet Pipe
2-O482.6
MM-M01.01
Rev.004
TE PIT
+46300
MPTD-3-0099
FIGURE 2-20
Boiler
Mitsubishi
2-42
Chapter 2
General
S ile ncer
W ater S eparator
E qu alizer P ipe
1 -O 32 3.8 A ir V ent N ozzle
P ressure G auge N oz zle

RFL+73632
W ater S epara tor D rain Tank

S team V en t Pipe
1-O 219.1
A ir V ent N ozzle
W ater S epara tor

O utle t P ipe
2-O 61 0.0
W ater S eparator
2-O 7 60id
FL+69 450
W ater S eparator
Inlet P ipe
4-O 40 6.4
FL+68800
10F L +68600
FL+68000
FL+67750
2R Y P A S S B Y P A S S V A LV E
2ry P as s B ypass P ipe

4-O 32 3.8
A ir V ent N ozzle
2ry P as s B ypass P ipe
2-O 45 7.0
FL+66 600
A ir V ent N ozzle
FL+64750
FL+64050
FL+64550
FL+65300
FL+64650
FL+64100
FL+63750
P IT
FL+62 800
FL+62630
FL+6 1450
W ater Lev el
G auge N oz zle
2ry P ass R ear W all

O utlet H D R
1-O 355.6
9FL+60400
R oo f O utlet H D R
2-O 610.0
FL +60800
FL+56700
P IT
S up port from 6FL
FL+55100
FL+54600
FL+54 200
TE
8FL +53600
FL+53000
FL+52900
R H S afety V alve Tes t No zzle

(Left S ide O nly)
P IT
W ater S eparator
D rain Tank
1-O 7 60id
TE
TE
TE
W ater S eparator D rain Tank
Inlet P ipe
2-O 55 9.0
1st S H Inlet H D R
2-O 43 1.8
FL+50050
1st S H Inlet P ipe

2-O 482.6
FL+47 300
7FL+46300
FL+45350
2ry P ass Inlet Pipe

FL+43500
2 -O 66 0.0
B o iler C irculation P um p
Inlet P ipe
1-O 50 8.0
Level Tra nsm tter

P ipe N o zz le
6FL +40300
Furnac e Inlet P ipe

2 -O 45 7.0
FL+38865
FL+38000
FL+37700
FL+37400
5FL+36500
TE
2 ry P ass In let M anifold

2-O 11 74
FL+35865
D rain P ip e N oz zle
FL+34800
W DS
D rain P ip e N ozzle
FW P
FL+29848
4FL +29000
FL+28750
FL+28500
FL+25700
FL+25296
FL+24840
3FL+24200
FL+26800
FL+26 346
FL+25200
B C P . W arm ing P ipe N oz zle

(Le ft S ide O nly)
Insp.H ole
S trainer
Insp.H ole
FL+27800
FL+27700
B oiler C irculation P um p
O utle t P ipe
1-O 406.4
Flow Transm itter

N oz zle
FL+18500
FL+17 800
FL+17500
FL+19 600
FL+19600
C hem ica l Cleaning

N oz zle
C h em ical C leaning
N ozzle
FL+16800
FL+16100
M in m u m Flo w Pipe N ozzle

FL+12250
2FL+11000
S up port fro m Furnace

B ottom B uc ks tay
FL+15850
P IT
FL+14950
B oile r C irculation P um p
O utlet P ipe
1-O 406.4
B C P W arm ing
P ipe N o zz le
S up port from Furnace

B ottom B uckstay
FL+13650
FL+12750
FL+12200
D rain P ip e N ozzle
B oile r C irculation P um p
Fu rnac e In let M anifold

2-O 81 3.0
MM-M01.01
Rev.004
FL+7833.3
FL +- 0
M PT D -3-0100
FIGURE 2-21
Boiler
Mitsubishi
2-43
Chapter 2
General
BO ILE R FR ON T
FR O NT W ALL
O UT LET HD R .
1-O 323.8
R OO F IN LET H DR .
1-O 219.1
+64500
S1
S2
Hanger Tube
(Except For Bend Tube)
S6
BS+61700
BS+60200
BS+60200
BS+58700
Left Side O nly
+61100
R O OF O U TLET H DR .
1-O 610.0
D D D D
+58900
BS+58700
+58100
BS+57200
BS+57200
BS+55700
+55100
BS+54200
S7
+53700
BS+52700
BS+51200
BS+51200
BS+49700
BS+49700
+54700
+55100
+54500
+53600
+53223.4
+52250
BS+48200
BS+48200
+47600
BS+46700
BS+46700
BS+45500
+45120
BS+45500
+45120
BS+42650
BS+40350
BS+37350
BS+37350
BS+35850
BS+3585
BS+50000
BS+48200
+47300
+47050
BS+46350
BS+44800
BS+43200
+42580
+42300
+39315
BS+33385
S 10
BS+31714
+42420
BS+41400
BS+40100
+39465
+38865
BS+29744
C
L OF C OAL BU RN ER S
C
L O F OIL BU R N ERS
C
S4
S5
SEC O N DAR Y PAS S SID E
W ALL IN LET HD R.
2-O 219.1
S 10
SE C O N DA RY PA SS SIDE W ALL
BS+31714
RifleTube
C
C
C
S3
+34950
BS+34350
+33600
BS+33385
BS+34350
+30729
BS+29744
BS+28260
BS+28260
BS+26776
BS+26776
BS+24806
BS+24806
BS+23322
BS+23322
BS+21838
BS+21838
BS+19868
BS+19868
BS+18384
BS+18384
BS+16800
BS+16800
+16500
+25791
C
C
C
+20828
+16500
B.L+15686
BS+10400
BS+14600
BS+13000
+12200
+13507.7
Left Side Only

BS+10400
FU R N ACE IN LET PIPE

2-O 457.0
+13507.7
C
L OF FURNACE
C
L OF BOILER
Membrane
BS+13000
Smooth Tube
+15686
BS+14600
Membrane
+50450
+38150
+33600
+21515
+20828
S8
BS+53600
PR IM ARY SH
IN LET H DR .
2-O 457.0 BS+51800
+50050
+42840
+42400
BS+38850
+34950
+26453
+25791
+25129
T.V
S9
BS+38850
CL O F A.A
+31391
+30729
+30067
S9
CL O F A.A
+38150
BS+41750
+41150
BS+40350
+41150
S 11
S 11
PASSAG E SID E
+50650
W ALL IN TLET H DR .
2-O 219.1
C ABLE O PEN IN G
+47300
+47000
PR IM ARY R H
IN LET H DR .
2-O 559.0
BS+42650
BS+41750
+39061
47100
+54400
+50800
+50500
O PENIN G FO R
LIFTIN G PLATFOR M
+47600
+54700
S7
Membrane
S8
Smooth Tube
+56300
BS+52700
+64750
S6
Both Side
BS+54200
RifleTube
S5
+64500
+62630
+60850
+54900
Smooth Tube
S4
+64750
+63200
R OO F TUBE
BS+61700
BS+55700
+37733
SEC ON D AR Y PASS
SID E W A LL O U TLET H D R.
2-O 219.1
S3
+64600
+64200
+63200
R OO F TUBE
Smooth Tube
PASSAG E SID E
W ALL O U TLET HD R .
2-O 219.1
SID E W ALL
O UT LE T H D R .
2-O 323.8
+12000
+12200
R ight Side O nly
SIDE W ALL INLET HD R.
1-O 219.1
+7833.3
MM-M01.01
Rev.004
+7133.3
+7133.3
S1-S1
M P TD -3-01 01
FR O NT W A LL
FR O NT W ALL IN LET H DR .
1-O 219.1
S1
S2
SID E W ALL
FIGURE 2-22
Boiler
Mitsubishi
BASIC PLAN OF WATER WALL PANELS (1/3)
2-44
Chapter 2
General
B OILER FRONT
ROOF TUBE
.
(FRONT)
ROOF TUBE
.
(REAR)
ROOF TUBE (FRONT)
REAR W ALL OUTLET HDR.

1-O273.0
L CABLE OPENING
+53600
OPENING FOR
LIFTING PLATFORM
+52250
M em brane
M em brane
OPE NING FOR

LIFTING PLATFORM
C O F SIDE W ALL
CL OF 2RY P ASS SIDE W ALL
CL O F PA SSAG E SIDE W ALL
S11-S11
REA R W ALL
HANGER OUTLET HDR.
1-O219.1
+64600
+64200
+63200
RO OF TUBE
ROOF INLET HDR.

1-O219.1
REAR W ALL HANGER
.
TUBE
CL OF BOILER
ROOF OUTLET HDR.
+53700
REA R W ALL
HANGER OUTLET HDR.
1-O219.1
Smooth. Tube
+50500
OPENING FOR
LIFTING PLATFORM
S6-S6
CABLE OPENING
+45120
B OILER FRONT
BS+45500
+44971.8
+44310
FIN t9
FIN t9
BS+42650
BS+41750
+41150
BS+40350
C
L O F A.A
+38150
+39061
REAR W ALL
HANGER INLE T HDR.
2-O219.1
BS+38850
C
L O F A.A
BS+37350
BS+35850
REAR W ALL OUTLET HDR.

1-O273.0
+34950
BS+34350
+33600
B S+33385
Rifle Tube
.
CL O F BOILER
+31391
+30729
+30067
BS+31714
CL O F CO A L BURNERS
CL O F O IL BURNERS
+30729
BS+29744
BS+28260
+26453
+25791
+25129
+25791
CL O F O IL BURNERS
BS+26776
CL O F O IL BURNERS
B S+21838
BS+24806
BS+23322
+21515
+20828
+20191
+20828
S7-S7
B S+19868
REAR W ALL
HANGER TUBE
B S+18385
FRO NT W ALL TUBE

BS+16800
+16500
B.L+15686
PASSAGE SIDE
W ALL TUBE
2RY PASS
FRO NT W ALL TUBE
SIDE W ALL TUBE

CL O F SIDE W ALL
CL O F PASSAG E SIDE W ALL
2RY PASS
SIDE W ALL TUBE
2RY PASS
REAR W ALL TUBE
CL O F 2RY PASS S IDE W ALL
Smooth Tube
.
BS+14600
2RY PASS
DIVISION W ALL TUBE
Membrane
Membrane
BS+13000
CL O F BOILER
BS+10400
+7833.3
Rev.004
+7133.3
S2-S2
REAR W A LL INLET HDR.

1-O219.1
BO ILER FRONT
MM-M01.01
REAR W ALL
M PT D-3-0102
CL OF BOILER
S8-S8
FIGURE 2-23
Boiler
Mitsubishi
2-45
Chapter 2
SECON DARY PASS
FRO NT W ALL OUTLET HD R.
1-O219.1
+64750
SEC OND ARY PASS

D IV ISION WALL OUTLET HDR .
1-O219.1
+64500
+64200
General
+64200
+63200
RO OF TU BE
+63200
R OOF TU BE
CL OF BOILER
SEC ON DAR Y PASS FR ON T WALL TUBE

.
+54590
+54290
+54300
+54100
+54825
BS+51800
BS+50000
BS+48200
BS+46350
BS+44800
BS+43200
BS+41400
BS+40100
+38865
+38865
CL OF BO ILER
SEC OND ARY PASS

FRO NT W ALL IN LET H DR.
1-O 219.1
S3-S3
S4-S4
SECO NDARY PASS FRONT W ALL
SEC OND AR Y PASS

D IVISION W ALL IN LET HD R.
1-O 219.1
SECONDARY PASS DIVISIO N W ALL

SEC ON DARY PASS
REAR W ALL O UTLET HD R.
1-O 355.6
+64750
+64200
+63200
RO OF TU BE
BS+61700
BS+60200
BOILER FRON T
BOILER FR ONT
C
L OF BO ILER
BS+58700
BS+57200
BS+55700
BS+53600
BS+51800
CL OF BOILER
CL OF BO ILER
BS+50000
BS+48200
BS+46350
BS+44800
BS+43200
BS+41400
BS+40100
+38865
Rev.004
SECON D ARY PASS

REAR W ALL INLET HD R.
1-O 219.1
S5-S5
MM-M01.01
M PTD-3 -0103
SECONDARY PASS REAR W ALL
S9-S9
S10-S10
FIGURE 2-24
Boiler
Mitsubishi
2-46
General
Chapter 2
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DESCRIPTION
WATER WALL TUBES
BLOCK INSULATION (MINERAL FIBER BOARD)
INSULATION PINS
PIN CLIPS
OUTER CASING
LOOSE MINERAL FIBER
BUCKSTAY
TIE PLATE
HOLDER
CORNER LINK
CORNER LINK BRACKET
STOPPER BEAM
BOILER STRUCTURE COLUMN
STIFFENER
1
3
2
14
12
13
6
7
11
10
9
MPTD-4-0106
FIGURE 2-25
TYPICAL ARRANGEMENT OF FURNACE BUCKSTAY & BOILER

STOPPER
Boiler
Mitsubishi
2-47
Chapter 2
11267
14335
RFL +73400
BOILER FRONT
6022
7167.5
11570
8106.2
LONGITUDINAL
BUCKSTAY SIZE
7167.5
General
1 2VFR/L-1
CL OF FURNACE
1872
H294x200x8/12
2 2VFR/L-2
H294x200x8/12
EXP.=0
FL+68600
833
4000
8200
3 7VCR/L-1
2000
1302
3785
3785
H294x200x8/12
2000
4 7VCR/L-2
4585
6200
2717
H294x200x8/12
51
5 8VFR/L-1
H294x200x8/12
2545
2500
2500
1006.5
2545
13FR/L
5607
2545
1040.5
FL+24806
EXP. 259.22
1500
20VFR/L-2
H400x200x9/12
1500
C11
3000
H500x200x9/12
3000
H400x200x9/12
FL+26776
EXP. 247.60
3000
22FR/L
3000
3000
23FR/L
H800x250x14/22
24FR/L
H500x200x9/12
H500x200x9/12
26FR/L
H800x250x14/22
26VFR/L-2
H400x200x9/12
H400x200x9/12
C03
FL+18384
EXP. 297.11
10
13CR/L
H800x250x14/22
14CR/L
H800x250x14/22
FL+39315
1500
1500
1500
1500
1500
2100
FL+44800
EXP. 139.42
B06
A13
12CR/L-B
H500x200x9/19
FL+42420
FL+42580
FL+42300
FL+46350
EXP. 130.43
A09
FL+43200
EXP. 148.70
A12
FL+41400
EXP. 159.14
A04
FL+40100
EXP. 166.68
FL+39465
EXP.
45.8
EXP.
112.9
EXP.
173.8
D02
FL+35490
D07
750
C02
27FR/L
H500x200x9/12
C11
28FR/L
H500x200x9/12
29FR/L
H800x250x14/22
BOILER
FRONT
C02
5607
5607
1560.5
FL+14600
EXP. 319.44
4167.5
C12
D06 250
32FR/L
FL+13000
EXP. 328.88
H800x250x14/22
3000
3000
FL+12200
31FR/L
2750
C09
EXP.
313.03
H800x250x14/22
250
2750
D06
H800x250x14/22
D08
FL+12000
2600
EXP.
11.0
1220.8
FL+15686
EXP.
313.03
1302.3
EXP.
73.50
96.1
1302
FL+16800
EXP. 306.46
1964.7
1134.5 1865.5
33FR/L
FL+10400
EXP. 344.22
CL OF FURNACE FRONT WALL
C
L OF FURNACE REAR WALL
FL+15686
C08
30FR/L
4167.5
817.5
7167.5
CL OF FURNACE
EXP.0
C03
1560.5
14335
7167.5
C03
393
FL+19868
EXP. 288.36
A19
FL+47050
H800x250x14/22
817.5
307
FL+23322
EXP. 267.98
FL+48200
EXP. 119.70
FL+47300
7365.6
H800x250x14/22
FL+42400
B07
1560.5
2607
C11
25FR/L
2300
FL+50000
EXP. 109.26
H500x200x9/16
158.1
1455.5 1072.4
1167.5
FL+28260
EXP. 238.85
FL+21838
EXP. 276.74
2107.5
3110
S2-R/L
C05
18FR/L
H800x350x16/32
3865.5
3302
7167.5
FL+34950
C04
19FR/L
H800x350x16/36
3167.5
4000
4000
3167.5
H800x250x14/22
20FR/L
3317.5
3100
3100
3317.5
1917.5
C10
1917.5
21FR/L
H500x200x9/12
750
C03
H600x200x9/12
1950
1950
23VFR/L-2
H400x200x9/12
C01
D07
FL+38150
17FR/L
3110
H400x200x9/12
20VFR/L-1
FL+35850
EXP. 194.07
3467.5
H500x200x9/12
16FR/L
23VFR/L-1
2107.5
D02
18VFR/L-1 H400x200x9/12
D03
H600x200x9/12
3700
10CR/L
2350
11CR/L
12CR/L-A
H500x250x9/19
H800x250x14/22
FL+41150
15FR/L
3700
1854.4
B05
1560.5
5607
2545
1071
H800x250x14/22
14FR/L
3467.5
FL+47000
FL+46223.5
FL+42380
E02
9CR/L
H800x250x14/22
FL+47300
H800x250x14/22
2500
2500
8CR/L-B
A16
H800x250x14/22
FL+14613.6
31FF
FL+13000
33FF
FL+14613.6
31FB
FL+13158.1
32FF
FL+13158.1
32FB
33FB
FL+11779.2
34FF
FL+10400
36FF
2686
1560.5
1037
A02
FL+51800
EXP. 98.82
A17
FL+50450
H500x200x9/16
H294x200x8/12
FL+47600
FL+53600
EXP. 88.38
A17
1246.9
H800x300x16/28
FL+50650
8CR/L-A
B08
10FR/L-B
3000
7CR/L
H294x200x8/12
3807.75
FL+49700
FL+55700
EXP. 76.20
250
H294x200x8/12
FL+11779.2
34FB
FL+10476.9
35FF
FL+10476.9
35FB
FL+9098
37FF
37FB
FL+7833.3
2600
1283
12FR/L
2500
7323.1
FL+50800
FL+50863.3
9FR/L-C
H294x200x8/12
B02
FL+40350
EXP. 167.52
B09
6467.5
H800x250x14/22 7
FL+47100
T.V
11FR/L
250
SEE DWG.NO.
FL+29744
EXP. 230.09
9FR/L-B
6CR/L
1400
PH FL+47600 10FR/L-A
C 16300-0421
FL+34350
EXP. 202.92
FL+33385
EXP. 208.61
1400
H294x200x8/12
FL+45500
EXP. 137.13
FL+37350
EXP. 185.22
1800
1800
S1-R/L-5
H800x250x14/22
250
FL+54700
FL+54400
H800x350x16/36
FL+54700
10 11VCR/L-2
36FB
3266.7
9FR/L-A
H294x200x8/12
FL+46700
EXP. 130.05
FL+38850
EXP. 176.37
1800
A07
FL+48200
EXP. 121.20
FL+42650
EXP. 153.95
FL+41750
EXP. 159.26
1800
3450.5
H800x250x14/22
1400
1617
8FR/L
FL+51200
EXP. 103.50
1800
H800x350x16/36
18VFR/L-2 H400x200x9/12
B04
1800
7FR/L
5FR/L-C
FL+57200
EXP. 67.50
A06
250
FL+55100
FL+54500
FL+58700
EXP. 58.80
H294x200x8/12
50??
1200
383
H800x250x14/22
A21
552
A07
FL+49700
EXP. 112.35
H294x200x8/12
FL+56300
H294x200x8/12
S1-R/L-4
H800x350x16/36
H800x250x14/22
4FR/L-C
H400x200x12/22
9 11VCR/L-1
1800
6FR/L
FL+52700
EXP. 94.65
5FR/L-B
3FR/L-D
B04
FL+55100
A07
FL+54200
EXP. 85.80
4FR/L-B
FL+60200
EXP. 50.10
H800x250x14/22
H400x200x12/22
8 8VFR/L-4
1800
S1-R/L-3
H800x350x16/36
iT j 1
1VFR/L-2
A07
5FR/L-A
2FR/L-C
H294x200x8/12
FL+58900
3FR/L-C
3FR/L-B
H294x200x8/12
H294x200x8/12
FL+58100
FL+55700
EXP. 76.95
A06
1800
S1-R/L-2
FL+61700
EXP. 41.40
H800x250x14/22
1850
H800x350x16/36
2FR/L-B
1FR/L-C
1550
4FR/L-A
H400x200x9/12
1400
2370.5
1600
S1-R/L-1
1FR/L-B
2251.5
H294x200x8/12
7 8VFR/L-3
1800
1VFR/L-1
FL+57200
EXP. 68.10
1970
1484
1484
6100
H800x350x16/36
1970
1484
1484
H800x250x14/22
2933
3FR/L-A
1970
1484
2FR/L-A
A07
2200
1584
FL+61100
FL+63200
EXP. 32.70
1300
FL+58700
EXP. 59.25
FL+31714
EXP. 218.47
1600
H800x250x14/22
FL+60850
A06
FL+60200
EXP. 50.40
2717
H1000 3
~50 1
~9/36
1FR/L-A
FL+61700
EXP. 41.55
4585
6200
BH1200x300x25/50
833
26VFR/L-1
1671
965 1500
1500
1500
1500
1400 900
2850
1200
1500
1500
1500
1500
1500
1500
1500
1500
1500
1500
1500
6 8VFR/L-2
FL+63200
EXP. 32.70
FL+7133.3
2000
4000
4000
FL+7833.3
FURNACE BOTTOM TRUSS BUCKSTAY
FL+7133.3
FL +0
4000
7900
6534.5
11900
10400
G17300-0002
D-9
B
G17300-0003
D-9
10400
C
G17300-0004
F-3
8200
G17300-0004
F-7
RIGHT SIDE WALL

MPTD-3-0105-1
MM-M01.01
Rev.004
G A
3865.5
10400
FIGURE 2-26
Boiler
Mitsubishi
GENERAL ARRANGEMENT OF BUCKSTAY 1/3
2-48
Chapter 2
29414
RFL+73400
LONGITUDINAL
BUCKSTAY SIZE
29414
14707
RFL+73400
14707
14707
FL+69400
14707
FL+69400
11 18VFF-3
FL+68600
5700
5700
5700
H500x250x12/25
FL+68600
EXP.=0
457
5700
12 18VFF-4
EXP.=0
457
5700
H500x250x12/25
1000
13 20VFF-1
CL BOILER
H300x300x10/15
H800x250x14/25
15 20VFF-3
1500
A05
1850
4FF-B
F1-2
2667
3700
9FF-B
3700
3700
FL+47600
SEE DWG. NO.

16300-0401
6759
2545 2047
13FF-A
2074
833.5
2545
FL+42650
EXP. 153.95 FL+42380
FL+41750
EXP. 159.26
5000
2417
2417
5000
5000
BH1500x200x25/25
12FF-A
1600
690
5429
2545
2545
BH800x350x25/50
445
1646.5
1646.5
5429
2545
6759
2047 2545
13FF-B
2545
1807
H294x200x8/12
17FF-A
H294x200x8/12
18FF-A
BH1500x300x25/25
1800
1800
1600
1400
15FF-B
H294x200x8/12
16FF-B
H294x200x8/12
FL+37700
1800
17FF-B
H294x200x8/12
4050
F2
2000
900
1200
14FF-B
FL+41150
H294x200x8/12
15FF-C
H294x200x8/12
16FF-C
FL+38150
H294x200x8/12
17FF-C
18FF-B
5100
2350
1800
1807
FL+34950
13
21FF-A
H294x200x8/12
FL+29744
EXP. 230.09
22FF-A
H294x200x8/12
23FF-A
FL+24806
EXP. 259.22
25FF-A
H294x200x8/12
3600
3600
3850
16
2350
17
18
2057
C01
4157
20
21FF-E
H294x200x8/12
21FF-D
H294x200x8/12
21FF-C
H294x200x8/12
15
19FF-B
3100
20FF-B
3100
4500
D01
19
22FF-B
H294x200x8/12
H294x200x8/12
22FF-C
H294x200x8/12
24FF-B
H294x200x8/12
24FF-C
H294x200x8/12
24FF-D
H294x200x8/12
25FF-B
H294x200x8/12
H294x200x8/12
25FF-C
H294x200x8/12
25FF-D
H294x200x8/12
27FF-B
H294x200x8/12
27FF-C
H294x200x8/12
27FF-D
H294x200x8/12
28FF-B
H294x200x8/12
28FF-C
H294x200x8/12
28FF-D
H294x200x8/12
PH
FL+47600
22FF-E
H294x200x8/12
22FF-D
H294x200x8/12
23FF-B
23FF-C
24FF-E
H294x200x8/12
27 20VFB-4
H700x200x12/22
BH1800x300x25/50
12FB-B
H800x250x14/25
29 20VFB-2
833.5
2545
2047
2545
2545
BH800x350x25/50
2545
13FB-B
1646.5 1646.5
2545
13FB-A
2047
2545
2545
H800x250x14/25
833.5
2545
30 20VFB-1
H300x300x10/15
FL+42380
1878
14FB-B
15FB-C
16FB-C
H294x200x8/12
17FB-C
H294x200x8/12
6955
307
FL+35850
EXP. 194.07
1500
1800
557
FL+34350
EXP. 202.92
FL+33385
EXP. 208.61
C01
H294x200x8/12
1500
607
3750
21FB-E
H294x200x8/12
FL+29744
EXP. 230.09
22FB-E
H294x200x8/12
FL+28260
EXP. 238.85
FL+26776
EXP. 247.60
24FB-E
H294x200x8/12
FL+24806
EXP. 259.22
25FB-E
H294x200x8/12
16FB-B
H294x200x8/12
5429
17FB-B
H294x200x8/12
R2
1800
H1000x250x16/28
5200
BH1500x450x25/50
6750
19FB-B
5000
20FB-B
5429
900 900
3600
1800
1800
1800
5100
4000
15FB-A
H294x200x8/12
16FB-A
H294x200x8/12
17FB-A
H294x200x8/12
FL+38150
6955
26
1500
1800
FL+34950
19FB-A
5100
20FB-A
6350
27
28
E01
1878
307
18FB-A
1500
1800
1500
D02 C04
1500
557
4357
30
21FB-B
H294x200x8/12
21FB-C
H294x200x8/12
25
FL+41150
445
4900
21FB-D
H294x200x8/12
23FB-C
14FB-A
22
15FB-B
18FB-B
24
21
H294x200x8/12
BH1500x300x25/25
8400
23
FL+31714
EXP. 218.47
BH1300x250x25/50
D01
21FB-A
H294x200x8/12
29
22FB-D
H294x200x8/12
H294x200x8/12
22FB-C
H294x200x8/12
24FB-D
H294x200x8/12
24FB-C
H294x200x8/12
24FB-B
H294x200x8/12
25FB-D
H294x200x8/12
H294x200x8/12
25FB-C
H294x200x8/12
25FB-B
H294x200x8/12
27FB-D
H294x200x8/12
27FB-C
H294x200x8/12
27FB-B
H294x200x8/12
28FB-D
H294x200x8/12
29FB-B
28FB-C
H294x200x8/12
28FB-B
H294x200x8/12
29FB-A
22FB-A
H294x200x8/12
22FB-B
H294x200x8/12
23FB-B
23FB-A
24FB-A
H294x200x8/12
1484
1484
4583.5
3382
250
890 890
4984
28FB-A
H294x200x8/12
250
3382
4583.5
867.5
D05
C07
FL+16800
EXP. 306.46
30FB-B
3700
30FB-A
7400
3700
FL+16800
EXP. 306.46
3607
FL+13158.1
EXP. 327.95
FL+11779.2
EXP. 336.08
FL+10476.9
EXP. 343.76
FL+9098
EXP. 351.89
H200x200x8/12
H200x200x8/12
H200x200x8/12
BH200x200x12/25
31FB-B
31FB-A
32FB-B
34FB-B
35FB-B
37FB-B
R3
32FB-A
34FB-A
35FB-A
37FB-A
FL+14600
EXP. 319.44
FL+13000
EXP. 328.88
2600
H200x200x8/12
FL+14613.6
EXP. 319.36
1600
2200
3607
BH1000x300x25/36
7400
31VFB-1 BH400x300x12/25
FL+10400
EXP. 344.22
27FB-A
H294x200x8/12
31VFB-2 BH400x300x12/25
2200
FL+13000
EXP. 328.88
867.5
BH1500x450x25/50
250
4984
31VFB-3 BH400x300x12/25
37FF-B
26FB-A
31VFB-4 BH400x300x12/25
35FF-B
FL+14600
EXP. 319.44
250
FL+18384
EXP. 297.11
BH400x300x12/25
F3
34FF-B
28FB-E
H294x200x8/12
31VFB-5
BH200x200x12/25
867.5
31VFF-8 BH400x300x12/25
37FF-A
H200x200x8/12
3607
4583.5
31VFF-7 BH400x300x12/25
FL+9098
EXP. 351.89
35FF-A
32FF-B
31VFF-6 BH400x300x12/25
FL+12000
FL+10476.9
EXP. 343.76
H200x200x8/12
31VFF-5 BH400x300x12/25
34FF-A
H200x200x8/12
7400
3382
4984
FL+16800
EXP. 306.46
31FF-B
BH400x300x12/25
FL+11779.2
EXP. 336.08
3700
890 890
H200x200x8/12
31FF-A
32FF-A
3700
4984
31VFF-4
FL+13158.1
EXP. 327.95
30FF-B
31VFF-3 BH400x300x12/25
FL+14613.6
EXP. 319.36
31VFF-2 BH400x300x12/25
BH400x300x12/25
867.5
31VFF-1
1302.28
1455.48 2186.46
1378.88
1378.88
D04
BH1500x300x25/36
7400
3382
30FF-A
3607
4583.5
FL+19868
EXP. 288.36
31VFB-6 BH400x300x12/25
250
C06
FL+16800
EXP. 306.46
27FB-E
H294x200x8/12
25FB-A
H294x200x8/12
26FB-B
FL+20350
1584
250
29FF-B
250
1600
1584
BH1500x450x25/50
250
29FF-A
28FF-E
H294x200x8/12
2600
1484
FL+20350
FL+18384
EXP. 297.11
FL+21838
EXP. 276.74
31VFB-7 BH400x300x12/25
28FF-A
H294x200x8/12
27FF-E
H294x200x8/12
26FB-C
31VFB-8 BH400x300x12/25
FL+19868
EXP. 288.36
FL+23322
EXP. 267.98
1484
27FF-A
H294x200x8/12
26FF-C
1970
FL+21838
EXP. 276.74
25FF-E
H294x200x8/12
26FF-B
1302.28
1455.48 2186.46
1378.88
1378.88
1484
26FF-A
1970
1484
FL+23322
EXP. 267.98
FL+10400
EXP. 344.22
FL+7833.3
FL+7133.3
FL+7133.3
Rev.004
28 20VFB-3
12FB-A
FL+7833.3
FL +0
-
FL +0
18800
3B
MM-M01.01
H700x200x12/22
PH
1970
24FF-A
H294x200x8/12
3850
2700
1970
FL+26776
EXP. 247.60
H1000x250x16/28
3850
21FF-B
H294x200x8/12
14
FL+28260
EXP. 238.85
3600
H800x250x14/25
1970
FL+31714
EXP. 218.47
5100
BH1500x450x25/50
3100
26 20VFB-5
FL+37350
EXP. 185.22
1484
20FF-A
4157
FL+48200
EXP. 121.20
H800x250x14/25
FL+38850
EXP. 176.37
1484
19FF-A
2157
1970
1671
FL+34350
EXP. 202.92
FL+33385
EXP. 208.61
D02 C04
25 20VFB-6
FL+40350
EXP. 167.52
1500
16FF-A
12
FL+49700
EXP. 112.35
FL+42650
EXP. 153.95
FL+41750
EXP. 159.26
1500
H294x200x8/12
11
24 20VFB-7
SEE DWG.NO.
1500
FL+35850
EXP. 194.07
15FF-A
BH1300x250x25/50
H300x300x10/15
FL+51200
EXP. 103.50
C 16300-0411
965 1500
FL+37350
EXP. 185.22
14FF-A
H500x250x12/25
23 20VFB-8
FL+45500
EXP. 137.13
1671
18VFF-1 H500x250x12/25
FL+38850
EXP. 176.37
1484
1500
2074
833.5
2545
EXP.
86.8
FL+46700
EXP. 130.05
12FF-B
E01
FL+40350
EXP. 167.52
1484
B01
2850
5000
1600
FL+45500
EXP. 137.13
A01
11FF-B
1400 900
690
22 18VFB-3
EXP.
86.8
FL+52700
EXP. 94.65
1200 1500
A05
H300x300x10/15
21 18VFB-4
H500x250x12/25
1500
10FF-B
BH1500x200x25/25
11FF-A
FL+46700
EXP. 130.05
A05
BH1500x200x25/25
10FF-A
FL+47100
T.V
H800x250x14/25
20 20VFF-8
FL+54200
EXP. 85.80
1500
A05
940
H800x250x14/25
19 20VFF-7
FL+55700
EXP. 76.95
1500
2667
FL+57200
EXP. 68.10
1500
3700
18VFF-6 H500x250x12/25
1500
3700
18VFF-5 H500x250x12/25
1500
1500
1500
3700
9FF-A
8FF-B
BH1500x200x25/25
FL+48200
EXP. 121.20
1400 900
7FF-B
BH1500x200x25/25
8FF-A
940
1500
EXP.
86.8
A05
FL+49700
EXP. 112.35
1500
6FF-B
F1-5
BH1500x200x25/25
7FF-A
FL+51200
EXP. 103.50
1500
F1-4
BH1500x200x25/25
6FF-A
EXP.
86.8
FL+52700
EXP. 94.65
965 1500
5FF-B
A05
FL+54200
EXP. 85.80
F1-3
BH1500x200x25/25
5FF-A
18VFF-2 H500x250x12/25
1500
FL+55700
EXP. 76.95
H700x200x12/22
18 20VFF-6
FL+58700
EXP. 59.25
1500
3850
BH1500x200x25/25
3FF-B
H700x200x12/22
17 20VFF-5
FL+60200
EXP. 50.40
18VFB-1 H500x250x12/25
4FF-A
F1-1
BH1500x200x25/25
FL+61700
EXP. 41.55
18VFB-2 H500x250x12/25
FL+57200
EXP. 68.10
A05
C
L BOILER
3FF-A
2FF-B
18VFB-5 H500x250x12/25
FL+58700
EXP. 59.25
1FF-B
H800x250x14/25
16 20VFF-4
18VFB-6 H500x250x12/25
BH1500x200x25/25
1500
2FF-A
1500
1FF-A
FL+60200
EXP. 50.40
FL+63200
EXP. 32.70
1500
1500
1500
1500
1500
1500
FL+61700
EXP. 41.55
A05
1200 1500
2850
14 20VFF-2
FL+63200
EXP. 32.70
BH1500x200x25/25
General
MPTD-3-0105-2
18800
18800
5A
7A
7A
18800
5A
SECTION A-A
SECTION B-B
FURNACE FRONT WALL

G17300-0001
F-9
FURNACE REAR WALL

G17300-0001
D-9
FIGURE 2-27
Boiler
Mitsubishi
3B

2-49
Chapter 2
General
29404.5
14702.25
14702.25
14702.25
FL+69400
14702.25
FL+69400
FL+68600
FL+68600
EXP.=0
EXP.=0
1897.25
2805
5000
5000
2500
2500
5000
FL+63200
EXP. 32.70
FL+63200
EXP. 32.70
FL+61700
EXP. 41.40
FL+61700
EXP. 41.40
FL+60200
EXP. 50.10
FL+60200
EXP. 50.10
FL+58700
EXP. 58.80
FL+58700
EXP. 58.80
BH1500x200x25/25
3CB-B
R1-1
3CB-A
FL+57200
EXP. 67.50
FL+57200
EXP. 67.50
BH1500x200x25/25
4CB-B
R1-2
4CB-A
FL+55700
EXP. 76.20
FL+55700
EXP. 76.20
BH1500x200x25/25
5CB-B
R1-3
5CB-A
FL+53600
EXP. 88.38
FL+53600
EXP. 88.38
BH1500200x25/25
6CB-B
R1-4
6CB-A
FL+51800
EXP. 98.82
BH1500x200x25/25
7CB-B
R1-5
7CB-A
FL+50000
EXP. 109.26
BH1500x200x25/25
8CB-B
8CB-A
FL+48200
EXP. 119.70
BH1500x200x25/25
9CB-B
9CB-A
FL+46350
EXP. 130.43
BH1500x200x25/25
10CB-B
10CB-A
FL+44800
EXP. 139.42
BH1500x200x25/25
11CB-B
11CB-A
FL+43200
EXP. 148.70
BH1500x200x25/25
12CB-B
12CB-A
FL+41400
EXP. 159.14
BH1500x200x25/25
5000
13CB-B
5000
1897.25
3430
BH1500x250x25/25
6250
1CB-B
3125
BH1500x200x25/25
2CB-B
1897.25
2805
1CB-A
3125
6250
1897.25
3430
A05
2CB-A
A05
A05
A20
EXP.
86.8
EXP.
86.8
FL+51800
EXP. 98.82
EXP.
86.8
EXP.
86.8
A15
FL+50000
EXP. 109.26
5000
5000
1102.2
3600
A15
FL+48200
EXP. 119.70
9CF-A
BH1400x200x25/25
9CF-B
3300
FL+46350
EXP. 130.43
10CF-A
FL+44800
EXP. 139.42
11CF-A
H1000x250x16/28
3300
3300
3300
750 752.2
10CF-B
A18
A18
A10
A08
11CF-B
H1000x250x16/28
3900
3900
3900
2100
902.2
A11
FL+43200
EXP. 148.70
12CF-A BH1000x350x25/50
FL+41400
EXP. 159.14
13CF-A
FL+40100
EXP. 166.68
14CF-A
12CF-B
A14
7600
13CF-B
BH250x300x9/25
13CF-E
A15
14CF-B
BH250x300x9/25
14CF-D
14CF-C
2147.25
FL+38865
2680
7252
3491
3491
Rev.004
MM-M01.01
18800
7252
3959.25
3959.25
7252
1647.25
A03
B03
3491
3491
18800
5A
7252
3959.25
FL+35240
18800
7A
7A
18800
5A
SECTION C-C
SECTION D-D
BACK PASS FRONT WALL

G17300-0001
C-9
BACK PASS REAR WALL

G17300-0001
B-9
FIGURE 2-28
Boiler
Mitsubishi
2930
14CB-A
FL+35240
MPTD-3-0105-3
13CB-A
5000
FL+38865
3959.25
3B
A15
5000
14CB-B
BH1500x200x25/25
FL+40100
EXP. 166.68
14CF-E
125
125
6200
13CF-D
13CF-C
3B

2-50
Chapter 2
General
SUPPORT PLATE
LIFTING LUG
SHELL
STEAM
OUTLET
WATER
OUTLET
INSPECTION NOZZLE
BOILER FRONT
BOILER FRONT
SHELL
INSPECTION
NOZZLE
INSPECTION
NOZZLE
SHELL
SHELL
INSPECTION
NOZZLE
INSPECTION
NOZZLE
C-C
A-A
B-B
MPTD-4-0107
FIGURE 2-29
Boiler
Mitsubishi
SECTIONAL VIEW OF WATER SEPARATOR
2-51
Chapter 2
WATER INLET
Boiler
Mitsubishi
WATER INLET
FIGURE 2-30
General
SECTIONAL VIEW OF WATER SEPARATOR DRAIN TANK
2-52
Chapter 2
B
1880
2145
1872
EXP.=0
S17
FL+68600
2553.625
FL+67750
4.5
94.0
15.4
74.8
112.9
25.4
23.9
45.8
24.8
27.3
FL+68800
R8
S21
57.4
FL+58100
14335 FD
E9
E10
28.7
FL+58900
52.7
S14
14.6
S7
R3
8106
(T)
6022
11570
FL+56700
EXP.=0
68.0
FL+56300
42.3
58.8 FL+54700
FL+54400
S6
CL ADDITIONAL AIR
3382
4561
1691
5073
4FL +36500
102.5
11.3
FL+39315
FURNACE
FL+42420
FL+38015
88.6
FL+39465
99.0
FL+38865
180.2
51.2
31.2 FL+38150
CL ADDITIONAL AIR FL+37733
FL+38150
179.0
39.9
168.2
59.9
E5
45.8
175.1
CL ADDITIONAL AIR FL+39419
177.6
CL ADDITIONAL AIR
167.6
734
FL+48650
173.8
109.0
FL+42300
6.8
149.9
1.3
167.3
FL+41250
149.0
21.3
127.3
19.0
41.2
153.9
69.3 61.2
150.6
10.0
151.1
29.9 FL+41250
49.9
155.1
FL+42480
81.5
69.8
50.6
FL+42840
70.1 FL+42220
60.3
FL+42580
67.1
FL+35865
E4
FL+34950
194.0
1691
CL COAL BURNERS FL+26453

CL O IL BURNERS FL+25791
CL CO AL BURNERS
CL OIL BURNERS
CL CO AL BURNERS
3FL +24200
W9
W7
215.0
715
W1
244.1

715
CL CO AL BURNERS
OIL BURNERS
CL
CL CO AL BURNERS
11.0
218.9
73.5
248.0
3382
W8
W9
CL FURNACE
281.1

CL CO AL BURNERS
OIL BURNERS
CL
CL CO AL BURNERS
273.2
3382
277.1
3382
222.8
2870
FL+34950
251.9
86.8
135.7
E8
104.4
R1
E7
82.6
95.4
FL+50450
FL+50050
E6
D
94.2
FL+47300
121.1
FL+47300
FL+47050
FL+47000
83.5
94.0
106.1
101.3
R2
FL+47600
122.6
5FL +46300
103.1
S5
122.9
2403
107.6
107.0
BOILER
C
L
4539
FL+47400
T.V
119.3
4539
FL+47600
120.5
3226
14.2
119.3
40.7
18.1
27.9 FL+49700
59.8
1500
FL+50650
60.0 FL+50800
FL+50500
FL+50400
3138
87.7
1200
39.4
97.3
FL+52250
79.8
89.3
FL+53600
77.5
FL+54300
92.4
75.1
FL+55100
FL+47600
FL+64200
118.4
37.0
39.7
1.3 FL+61100
66.1
1500
S1
6FL +60400
29414 FW
ITEM
1750
79.5
11.3
15.4
13.2
15.0
20.5
26.5
S15
S13
22.3
1750
S4
60.3
11.0
2106
32.7
FL+63200
73.5
25.4
27.3
78.9
6.8
1000
S9
S10
34.4
7.5
9.8
28.7
41.2
3281.875
C
R4
R6
S19 S11
2681.875
400
59.5
FL+67400
2452.625 600
S2
24.2
S16 S12
1997
S3
W79
W78
W77
W76
W75
W74
W73
W72
W71
W70
W69
W68
W67
W66
W65
W64
W63
W62
W61
W60
W59
W58
W57
W56
W55
W54
W53
W52
W51
W50
W49
W48
W47
W46
W45
W44
W43
W42
W41
W40
W39
W38
W37
W36
W35
W34
W33
W32
W31
W30
W29
W28
W27
W26
W25
W24
W23
W22
W21
W20
W19
W18
W17
W16
W15
W14
W13
W12
W11
W10
W9
W8
W7
W6
W5
W4
W3
W3
W3
W2
W1
NAME
W ater Separator Drain Tank Outlet Pipe
W ater Separator Drain Tank
W ater Separator Drain Tank Inlet Pipe
W ater Separator
W ater Separator Inlet Pipe
Secondary Pass Rear Wall Outlet Header
Secondary Pass Division W all Outlet Pipe
Secondary Pass Side Wall Outlet Pipe
Secondary Pass Front Wall Outlet Pipe
Secondary Pass Division W all Outlet Header
Secondary Pass Side W all Outlet Header
Secondary Pass Front Wall Outlet Header
Secondary Pass Division W all (Screen)
Secondary Pass Division Wall
Secondary Pass Side W all
Secondary Pass Rear Wall
Secondary Pass Front Wall (Screen)
Secondary Pass Front Wall
Secondary Pass Division W all Inlet Header
Secondary Pass Side W all Inlet Header
Secondary Pass Rear Wall Inlet Header
Secondary Pass Front Wall Inlet Header
Secondary Pass Division W all Supply Pipe
Secondary Pass Side Wall Supply Pipe
Secondary Pass Rear Wall Supply Pipe
Secondary Pass Front Wall Supply Pipe
Secondary Pass Inlet Manifold
Secondary Pass Inlet Pipe
Roof Outlet Header
Passage Side Wall Outlet Pipe
Rear Wall Hanger Outlet Pipe
Roof (Rear)
Roof (Front)
Roof Inlet Header
Roof Inlet Supply Pipe
Roof Inlet Manifold
Roof Inlet Pipe
Roof Inlet Pipe (Side)
Roof Inlet Pipe (Front)
Passage Side Wall Outlet Header
Passage Side Wall
Side Wall Outlet Header
Rear Wall Hanger Outlet Header
Rear Wall Hanger
Front W all Outlet Header
Rear Wall Hanger Inlet Header
Rear Wall Hanger Supply Pipe
Rear Wall Hanger Inlet Manifold
Rear Wall Hanger Inlet Pipe
Passage Side Wall Inlet Header
Passage Side Wall Supply Pipe
Passage Side Wall Inlet Manifold
Passage Side Wall Inlet Pipe
Rear Wall Outlet Header
Furnace Side Wall (Upper)
Furnace Rear Wall (Upper)
Furnace Front W all (Upper)
Side Wall Intermediate Outlet Header
Rear Wall Intermediate Outlet Header
Front Wall Intermediate Outlet Header
Side Wall Intermediate Manifold Outlet Pipe
Rear Wall Intermediate Manifold Outlet Pipe
Front W all Intermediate Manifold Outlet Pipe
Side Wall Intermediate Manifold
Rear Wall Intermediate Manifold
Front W all Intermediate Manifold
Furnace Intermediate Header (Side Wall)
Furnace Intermediate Header (Rear Wall)
Furnace Intermediate Header (Front Wall)
Furnace Side Wall (Lower)
Furnace Rear Wall (Lower)
Furnace Front W all (Lower)
Side Wall Inlet Header
Rear Wall Inlet Header
Front W all Inlet Header
Furnace Supply Pipe (Side Wall)
Furnace Supply Pipe (Rear Wall)
Furnace Supply Pipe (Front Wall)
Furnace Inlet Pipe
ITEM
REHEATER
1170
S8
SUPERHEATER
1903.5
E11
41.3
4297
R3
66.6
1650
R9
17.9
2714.5
R7
17.7
2600
S22
MS
1000
S20
HTRH
S18
ECONOMIZER
FL+47600
General
NAME
R10
R9
R8
R7
R6
R5
R4
R3
R2
R1
Reheater Desuperheater W arming Pipe

Secondary Reheater Outlet Header
Secondary Reheater
Secondary Reheater Intlet Header
Reheater Desuperheater Outlet Pipe
Reheater Desuperheater
Reheater Desuperheater Inlet Pipe
Primary Reheater Outlet Header
Primary Reheater
Primary Reheater Inlet Header
S22
S21
S20
S19
S18
S17
S16
S15
S14
S13
S12
S11
S10
S9
S8
S7
S6
S5
S4
S3
S2
S1
Tertiary Superheater Outlet Header

Tertiary Superheater
Tertiary Superheater Intlet Header
Superheater Secondary Desuperheater Outlet Pipe
Superheater Secondary Desuperheater
Superheater Secondary Desuperheater Intlet Pipe
Superheater Secondary Desuperheater Intlet Pipe
Secondary Superheater Outlet Header
Secondary Superheater
Secondary Superheater Intlet Header
Superheater Primary Desuperheater Outlet Pipe
Superheater Primary Desuperheater Outlet Pipe
Superheater Primary Desuperheater
Superheater Primary Desuperheater Intlet Pipe
Primary Superheater Outlet Header
Primary Superheater (pendant)
Primary Superheater
Primary Superheater Intlet Header
Primary Superheater Inlet Pipe
W ater Separator Outlet Pipe
W ater Separator Outlet Equalizer Pipe
W ater Separator Drain Tank Steam Vent
E11
E10
E9
E8
E7
E6
E5
E4
E3
E2
E1
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Economizer
Outlet Header
Hanger (SH pass)
Hanger (RH pass)
Intermediate Header (SH pass)
Intermediate Header (RH pass)
(SH pass)
(RH pass)
Inlet Header
Inlet Pipe
Inlet Pipe
Inlet Pipe
329.4
FL+12000
2FL +11000
Rev.004
W2
94.5
MM-M01.01
W6
3865.5
10400
W2
W5
6534.5
Boiler
Mitsubishi
FL+7833.3
5.7
40.9
W4
SECTION A-A
4.0
W3
W3
10400
10400
8200
FIGURE 2-31
BOILER EXPANSION MOVEMENT DIAGRAM 1/2
2-53
Chapter 2
BOILER
C
L
S4
S18
S2
1000
2600
2714.5
S20
1650
4297
S22
1903.5 1170
R7
1880
R9
2145
14335 FD
R3
1997
2553.625
E11
S8
2452.625 600 2681.875
S3
3281.875
1000
2106
General
S2
1750
1750
1500
11570
6022
EXP.=0
86.8
99.6
78.9
4.3
22.3
77.9
60.3
57.6
FL+64200
100.4
102.9
97.9
3B
3B
97.9
44.9
74.8
118.4
34.4
112.9
FL+63200
11570
67.7
55.1
45.8
11.0
74.8
FL+56700
37.6
34.5
44.1
44.1
73.5
EXP.=0
59.5
86.8
18800
6.8
28.7
8106
18800
S1
44.9
37.6
14.2
26.8
135.7
1872
29414 FW
EXP.=0
BOILER
C
L
S2
26.8
S12 S15
S1
R1
S16
18800
44.9
44.1
55.1
E4
S10
S11
34.5
S17
18800
14.2
S13
S18
67.7
FL+38865
5A
5A
EXP.=0
44.6
FL+48650
37.6
FL+50050
FL+35865
100.4
77.9
S9
102.9
SECTION B-B
99.6
86.8
S19
10400
R5
R4
10400
W1
S4
97.9
R6
10400
10400
8200
SECTION C-C
8200
SECTION D-D
Rev.004
MM-M01.01
7A
7A
MPTD-3-0109-2
FIGURE 2-32
Boiler
Mitsubishi
BOILER EXPANSION MOVEMENT DIAGRAM 2/2
2-54
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-33
Boiler
Mitsubishi
ARRANGEMENT OF BOILER HEADER SUPPORTS
2-55
General
MM-M01.01
Rev.004
Chapter 2
FIGURE 2-34
Boiler
Mitsubishi
TYPICAL ARRANGEMENT OF BOILER ELEMENT SUPPORTS
2-56
Chapter 2
General
INSPECTION ITEMS
* SCALES (THICKNESS, AMOUNT, COMPOSITION)
* O.D., THICKNESS OF TUBE
* MECHANICAL PROPERTIES, COMPOSITION OF
TUBE.
ITEM
1
2
3
4
5
DESCRIPTION
FINNED TUBE WALL PANEL
BLOCK INSULATION (MINERAL FIBER BOARD)
OUTER CASING
PIN CLIPS
INSULATION PINS
MPTD-3-0112
FIGURE 2-35
Boiler
Mitsubishi
INSULATION OF FINNED TUBE WALLS
2-57
Chapter 2
PLAN VIEW OF
STEAM GENERATOR
CORNER
TUBES
MINERAL FIBER
General
WELD
PIN
SPEED WASHER
JOINTS
SIDE WALLS
RIBBED LAGGING
SPEED WASHER
MPTD-4-0113
FIGURE 2-36
Boiler
Mitsubishi
INSULATION OF MEMBRANE TUBE WALLS
2-58
General
MM-M01.01
Rev.004
Chapter 2
MPTD-3-0114
FIGURE 2-37
Boiler
Mitsubishi
INSULATION OF BOILER MOUNTINGS
2-59
Chapter 2
OUTER CASING
General
STEAM GENERATOR TUBES
CLASS 4 CASTABLE
ACCESS DOOR OPENING
CLASS 4 CASTABLE
REFRACTORY ACCESS DOOR
(IN 3 PARTS)
EXTERNAL STEEL DOOR
BLANKET TYPE INSULATION
CASTABLE BLOCK SUPPORT
PLAN VIEW OF
ACCESS DOOR
MINERAL FIBER BOARD

CASTABLE CLASS 4 REFRACTORY
CERAMIC FIBER BLANKET
MPTD-4-0115
FIGURE 2-38
Boiler
Mitsubishi
BOILER ACCESS DOOR INSULATION
2-60
Chapter 2
General
INSULATION SUPPORT
SUS WIRE
OD
PIPE
BOLT NUT
JOINTS
BOILER-FRONT
FRONT WALL TUBE
SIDE WALL TUBE
REAR WALL TUBE
INSULATION SUPPORT
INSULATING PIPE
COVER
FOR ALL SINGLE PIPES WITH AN O.D. LARGER THAN 89.1 MM

AND A SLOPE OF 60 OR MORE, THE INSULATION SHALL BE
FASTENED WITH SUPPORTING BANDS AS SHOWN ABOVE.
HORIZONTAL PIPE
+7833.3
INSULATION
t100
INSULATION
t100
SEAL PLATE
REFRACTORY
t130
REFRACTORY
t130
GLASS TAPE
BUCKSTAY
OD
GLASS TAPE
"A"
50
SCREW
AND WASHER
0.9
100
INSULATION SUPPORT
CL FURNACE
ANCHOR ROD
ANCHOR ROD
POSITIONER
METAL LAGGING
DETAIL "A"
INSULATION SHALL BE
CAREFULLY AND TIGHTLY
APPLIED IN THIS AREA.
INCLINED PIPE
BUCKSTAY
OUTER METAL LAGGING

SCREW
DRIP PLATE SUPPORT
DRIP PLATE
DRIP PLATE
CIRCUMFERENTIAL JOINT
METAL LAGGING
LONGITUDINAL JOINT
METAL LAGGING
FRONT & REAR WALL
FURNACE BOTTOM ARRANGEMENT
DETAIL OF METAL LAGGING JOINT
MPTD-3-0116
MM-M01.01
Rev.004
SIDE WALL
FIGURE 2-39
Boiler
Mitsubishi
APPLICATION OF REFRACTORY AND INSULATION FOR BOILER & PIPES
2-61
Chapter 2
MARK
DESCRIPTION
BASE
COVER PLATE ASSEMBLY
2A
COVER PLATE
2B
WASHER RETAINER
2C
FLOATING WASHER
2D
PIN
General
TOP PLATE ASSEMBLY
3A
TOP PLATE
3B
WASHER RETAINER
3C
FLOATING WASHER
3D
SCREW
3E
PIN
SPINDLE
SEAT BUSHING
COMPRESSION SCREW
UPPER ADJUSTMENT RING
UPPER ADJUSTMENT RING PIN
LOWER ADJUSTMENT RING
10
LOWER ADJUSTMENT RING PIN
12
YOKE
14
DISC
15
GUIDE
16
SPRING
17
LIFTING GEAR
18
DISC HOLDER
19
DISC COLLAR
20
LIFT STOP
21
OVERLAP COLLAR
23
LOCK NUT
`A'
VENT
STEAM
EXHAUST
DRAIN
DETAIL `A'
STEAM INLET
MPTD-4-0048
FIGURE 2-40
Boiler
Mitsubishi
SECTIONAL VIEW OF A TYPICAL BOILER SAFETY VALVE
2-62
Chapter 3
Specifications
C ha pte r
3 Specifications
Applicable Standard
ASME Boiler Pressure Vessel Code Section I without stamp
TABLE 3-1
BOILER SPECIFICATIONS
Subject
Specifications
Boiler Type
Supercritical, sliding pressure operation, once

through boiler, single reheat cycle
Evaporation (BMCR)
2,695t/hr
Main steam pressure at BMCR
25.78MPag (3ry SH outlet)
Main steam temperature at BMCR
542C (3ry SH outlet)
Feed water temperature at Economizer inlet
290.0C
Steam pressure at Reheater outlet
4.84MPag
Reheat steam temperature at BMCR
568C (2ry RH outlet)
Excess air at BMCR
15%
Superheater
27.05MPag
Reheater
5.90MPag
Superheater
550C
Reheater
582C
Design pressure
Design temperature
Drafting system
Balance draft
Average
25.5C
Summer
33C
Ambient temperature
Changing point between Wet and Dry Operation
Approx.25% load
Fuel
Coal (diesel oil startup and support)
Grade of automatic operation
Fully automated on boiler operation
Boiler
Mitsubishi
3-1
Chapter 3
Specifications
TABLE 3-2 WATERWALL TUBES

Subject
Specifications
Manufacturer
MHI
Type
Membrane wall
Furnace width
29.414m
Furnace depth
14.335m
Furnace height (Furnace lower header

to roof)
56.067m
Furnace volume
21369m3
Effective Projected Radiation Surface

(EPRS)
5405m2
Operating pressure (WS outlet)
27.36MPag (BMCR)
Tube outside diameter
28.6mm
Tube material
SA-213T12
Pitch
44.5mm
Fluid
Steam/water
TABLE 3-3 WATER SEPARATOR

Subject
Specifications
Manufacturer
MHI
Outside diameter
1000mm
Thickness
120mm
Height (Shell end to end)
3.31m
Design pressure
28.77MPa
Design temperature
450C
Operating medium
Steam/water
Shell material
SA387-11-2
Boiler
Mitsubishi
3-2
Chapter 3
Specifications
TABLE 3-4 WATER SEPARATOR DRAIN TANK

Subject
Specifications
Manufacturer
MHI
Outside Diameter
1000mm
Thickness
120mm
Height
16.4m
Design Pressure
28.77MPa
Design Temperature
450C
Operating medium
Water
Shell material
SA387-11-2
TABLE 3-5 ROOF TUBES

Type:
Fin welded panel
Design pressure:
30.11MPag
Heating surface:
1170m2
Tube Size (mm)
No. of
Tubes
Material
Roof front
440
Roof rear
220
Tube
Outside Diameter
Thickness
Tube Pitch
(mm)
SA213-T12
45.0
9.4
66.75
SA213-T12
57.1
8.9
133.5
TABLE 3-6 BACK PASS AND PASSAGE WALL TUBES

Type:
Fin welded panels
Design pressure:
29.8MPag
Heating surface:
3680m
Tube Size (mm)

No. of
Tubes
Material
Outside
Diameter
Thickness
Tube Pitch
(mm)
Back pass front wall

-Lower
-Screen
220
110
SA213-T12
SA213-T12
38.1
45.0
8.9
7.4
133.5
267.0
Back pass rear wall
219
SA213-T12
38.1
8.9
133.5
Back pass side wall
2 105
SA213-T12
38.1
8.9
111.25
Screen
146
SA213-T12
45.0
7.4
200.25
Lower
292
SA213-T12
38.1
8.9
100.125
2 67
SA213-T12
38.1
8.9
89
Tube
Back pass division

wall
Passage side wall
Boiler
Mitsubishi
3-3
Chapter 3
Specifications
TABLE 3-7 PRIMARY SUPERHEATER

Type:
Horizontal, drainable
Design pressure:
28.61MPag
Heating surface:
7830m
Tube Size (mm)

Panel Pitch (mm)
Number
of Panels
Material
Outside
Diameter
Thickness
Tube Pitch
(mm)
133.5
220
SA213-T12
45.0
6.9
80.0
267
110
SA213-T12
45.0
6.9
80.0
TABLE 3-8 SECONDARY SUPERHEATER

Type :
Panel, non-drainable
Design pressure:
28.0MPag
Heating surface:
3470 m
Tube Size (mm)

Panel Pitch (mm)
2403
Girdling Tube
Boiler
Mitsubishi
Number
of Panels
12
Outside
Diameter
Thickness
Tube Pitch
(mm)
SA213-T12
45.0
9.4
54.5
ASME Code Case 2199-3
45.0
5.9
54.5
45.0
5.4
54.5
45.0
6.9
54.5
SA213-T12
38.1
6.4
54.5
SA213-T12
31.8
5.9
54.5
SA213-T12
31.8
6.4
54.5
SA213-T12
31.8
7.4
54.5
SA213-T91
45.0
6.9
54.5
45.0
5.4
SA213T12
45.0
6.9
SA213-T91
45.0
6.9
Material
3-4
Chapter 3
Specifications
TABLE 3-9 TERTIARY SUPERHEATER

Type:
Platen, non-drainable
Design pressure:
27.56MPag
Heating surface:
2800m
Tube Size (mm)

Panel Pitch (mm)
534
Number
of Panels
54
Cooling Spacer Tube
Outside
Diameter
Thickness
Tube Pitch
(mm)
45.0
4.9
54.5
45.0
5.4
54.5
SA213-T91
45.0
5.9
54.5
SA213-T91
45.0
6.9
54.5
45.0
5.4
SA213-T12
45.0
6.9
SA213-T12
31.8
5.9
SA213-T91
45.0
6.9
Material
TABLE 3-10 PRIMARY REHEATER

Type:
Horizontal, Drainable
Design pressure:
5.90MPag
Heating surface:
15540m
Tube Size (mm)

Number
of Panels
Material
Outside
Diameter
Thickness
Tube Pitch
(mm)
133.5
220
SA213-T12
57.1
3.5
115,140,160
267
110
SA213-T22
57.1
4.0
115
267
110
Code Case 2328-1
57.1
3.5
115
267
110
SA213-T12
63.5
7.2
115
Panel Pitch (mm)
Boiler
Mitsubishi
3-5
Chapter 3
Specifications
TABLE 3-11 SECONDARY REHEATER

Type:
Pendant, non-drainable
Design pressure:
5.90 MPag
Heating surface:
4180 m
Tube Size (mm)

Panel Pitch (mm)
Number
of Panels
267
108
Outside
Diameter
Thickness
Tube Pitch
(mm)
57.1
3.5
115
SA213-T22
57.1
4.5
115
SA213-T12
57.1
3.5
115
SA213-T12
38.1
3.5
115
SA213-T91
57.1
4.5
115
Material
TABLE 3-12 DESUPERHEATERS

Material
OD
(mm)
ID
(mm)
Thickness
(mm)
Design P
MPa(g)
Design T
(C)
Spray
Cap.t/h
Qty
(Nos.)
Primary SH
De-superheater
SA335-P12
482.6
332.6
75
28.0
467
269.5
Secondary SH
De-superheater
SA335-P91
482.6
352.6
65
27.56
533
269.5
Reheat
De-superheater
SA335-P12
711.0
653.0
29
5.90
496
89.0
Description
TABLE 3-13 ECONOMIZER (SPIRAL FINNED TUBE)

Design pressure:
31.49MPag
Heating surface:
44120m
Tube Size (mm)

Panel Pitch
(mm)
Number of
Panels
Material
Reheater pass (Front

section)
150.0
194
Superheater pass
(Rear section)
150.0
194
Location
Tube Pitch
Outside
Diameter
Thickness
(mm)
SA210-C
45.0
6.9
115
SA210-C
45.0
6.9
115
TABLE 3-14 ECONOMIZER (HANGER TUBE)

Design pressure:
31.49MPag
Tube Size (mm)
Panel Pitch
(mm)
Number of
Panels
Material
Reheater pass (Front

section)
267
110
110
Superheater pass
(Rear section)
267
110
110
Location
Boiler
Mitsubishi
Tube Pitch
(mm)
Outside
Diameter
Thickness
SA210-C
SA210-C
50.8
57.1
7.4
8.4
SA210-C
SA210-C
63.5
50.8
9.4
7.4
3-6
Chapter 3
Specifications
TABLE 3-15 SPECIFICATION OF HEADERS

No.
Description
Material
OD &
Thickness
(mm)
Design
Pressure
(MPa)
Design
Temp. C
Furnace Inlet Header (Front)
SA-106C
219.4 40
31.49
362
Furnace Inlet Header (Rear)
SA-106C
219.4 40
31.49
362
Furnace Inlet Header (Side)
SA-106C
219.4 40
31.49
362
Furnace Intermediate Header (Front)
SA-335P12
323.8 63
31.49
450
Furnace Intermediate Header (Rear)
SA-335P12
323.8 63
31.49
450
Furnace Intermediate Header (Side)
SA-335P12
323.8 63
31.49
450
Furnace 2nd Intermediate Header (Front)
SA-335P12
323.8 63
31.49
450
Furnace 2nd Intermediate Header (Rear)
SA-335P12
323.8 63
31.49
450
Furnace 2nd Intermediate Header (Side)
SA-335P12
323.8 63
31.49
450
10
Furnace Outlet Header (Front)
SA-335P12
323.8 60
30.11
450
11
Furnace Outlet Header (Rear)
SA-335P12
323.8 65
30.11
450
12
Furnace Outlet Header (Side)
SA-335P12
323.8 65
30.11
450
13
Rear Wall Hanger Inlet Header
SA-335P12
219.1 44
30.11
450
14
Rear Wall Hanger Outlet Header
SA-335P12
219.1 44
30.11
450
15
Passage Side Wall Inlet Header
SA-335P12
219.1 44
30.11
450
16
Passage Side Wall Outlet Header
SA-335P12
219.1 44
30.11
450
17
Roof Inlet Header
SA-335P12
219.1 44
30.11
450
18
Roof Outlet Header
SA-335P12
610 123
29.8
450
19
Back Pass Inlet Header (Front)
SA-335P12
219.1 44
29.8
450
20
Back Pass Inlet Header (Rear)
SA-335P12
219.1 44
29.8
450
21
Back Pass Inlet Header (Side)
SA-335P12
219.1 44
29.8
450
22
Back Pass Outlet Header (Front)
SA-335P12
219.1 44
28.77
450
23
Back Pass Outlet Header (Rear)
SA-335P12
355.6 61
28.77
450
24
Back Pass Outlet Header (Side)
SA-335P12
219.1 44
28.77
450
25
Back Pass Inlet Header (Division wall)
SA-335P12
219.1 44
29.8
450
26
Back Pass Outlet Header (Division wall)
SA-335P12
219.1 44
28.77
450
27
Primary SH Inlet Header
SA-335P12
431.8 84
28.61
461
28
Primary SH Outlet Header
SA-335P12
482.6 80
28.0
467
29
Secondary SH Inlet Header
SA-335P12
323.8 60
28.0
454
30
Secondary SH Outlet Header
SA-335P91
355.6 56
27.56
533
31
Tertiary SH Inlet Header
SA-335P91
406.4 52
27.56
513
Boiler
Mitsubishi
3-7
Chapter 3
Specifications
Continued from previous page
No.
Description
Material
OD &
Thickness
(mm)
Design
Pressure
(MPa)
Design
Temp. C
32
Tertiary SH Outlet Header
SA-335P91
482.6 70
27.05
550
33
Primary RH Inlet Header
SA-106C
559.0 28
5.9
350
34
Primary RH Outlet Header
SA-335P12
711.0 39
5.9
496
35
Secondary RH Inlet Header
SA-335P12
660.0 39
5.9
496
36
Secondary RH Outlet Header
SA-335P91
762.0 50
5.9
582
37
Economizer Inlet Header
SA-106C
610.0 98
31.49
350
38
Economizer Intermediate Header

(Reheater pass)
SA-106C
219.1 44
31.49
391
39
Economizer Intermediate Header

(Superheater pass)
SA-106C
219.1 44
31.49
391
40
Economizer Outlet Header
SA-106C
457.0 67
31.49
362
Boiler
Mitsubishi
3-8
Chapter 4
C ha pte r
4 Preventive Maintenance
Preventive maintenance is carried out to avoid or reduce the possibility of failure or
deterioration of boiler performance. This requires a constant effort from operators and
maintainers to make sure that the Unit is available on demand.
There are two categories of preventive maintenance; Routine Maintenance and Outage
Maintenance.
Routine maintenance helps to reduce the possibility of outage and hence the downtime
of machinery.
Outage maintenance is required to maintain the internal components of the installed
equipment.
The vendor/manufacturers recommendations provide a good basis for the provision of a
preventive maintenance schedule. However, the frequency and other details must be
updated from time to time. It must be based on practical experience and actual feedback
gathered during inspection and normal operation of the boiler.
Consideration of these site related specific issues will make the preventive maintenance
more effective.
4.1
Prerequisites
The necessary prerequisites for the preventive maintenance of the boiler and
associated tube banks are as follows:
4.1.1 Scheduling
Scheduling is the first activity in the preparation of a preventive
maintenance program. The schedule must include planning to perform
inspections on all operating equipment on a fixed regular basis.
Initially, schedules will be prepared based on vendor/manufacturers
generic instructions. The schedules, however, must be updated
(frequency, nature of inspection, etc.) so that the latest site data can
always be available.
Preventive maintenance must be coordinated with other concerned
departments.
In case of a major scheduled outage, maintainer and other concerned
departments must jointly prepare a plan of activities, well in advance.
Boiler
Mitsubishi
4-1
Chapter 4
The plan must include the inspection activities and other logistics (such
as the availability and supply of required equipment, spare parts, and
tools, etc.).
The schedule must clearly identify the critical path. Priority must be given
to specific tasks that also involve parallel activities to reduce the
equipment downtime and to complete the work within the scheduled
time.
4.1.2 Interdepartmental Cooperation and Communication

Interdepartmental cooperation and communication is essential to reduce
a risk of failure in routine or annual outage maintenance.
Prior to starting preventive maintenance, all concerned persons (shift
supervisors, operators, etc.) must be made aware of the schedule and
the nature of the activities.
If there is any problem or discrepancy found in the schedule, it must be
solved mutually and agreed upon by the parties concerned.
4.1.3 Isolation of Equipment

It is important that isolations are agreed and valid clearances and work
permits are obtained before any maintenance work is performed.
The isolation boundaries of the particular equipment to be taken under
maintenance must be clearly identified.
In the case of an electrical isolation, the power supply must be
disconnected and/or the fuses removed.
In the case of a mechanical isolation, close the valves or other
mechanical means of isolation at the isolation boundaries, and if possible
they must be locked closed and a Do not operate tag should be
attached.
The boiler system within the isolation boundaries must be depressurized.
4.1.4 Safety Precautions

Before the start of any maintenance work, the person in charge of the
work site must perform a risk assessment and method statement for the
safe execution of the job, as per the work permit.
Risk assessment includes identifying, recognizing and understanding the
potential hazards associated with the work.
The method statement must illustrate the safe working practices in
accordance with the safety manual and the manufacturers instruction
manual to prevent personal injury and/or equipment damage.
Boiler
Mitsubishi
4-2

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Project Dwg. No: G101-25-1723.

Be sure to read this manual.

Disassembly and Reassembly

Water Washing Method

Feature of Boiler Safety 1-1

Warnings Description 1-2

Definitions of Serious Injury, Minor Injury, Serious

Hazards Warning Label 1-5

Hazard Area 1-7

Risk Assessment Standard 1-8

Safety Measures 1-10

Work Permit System (Lockout/Tagout) 1-10

General Cautions on Personnel in Working Area 1-11

1.4.2.1 Cautions against Rotating Equipment 1-11

Safety (Continued from previous page)

Emergency Measure 1-20

Evacuation on Emergency Case 1-20

1.5.1.1 Evacuation Route 1-20

Fire Accident 1-22

Explosion Accident 1-23

Qualification and Training 1-24

Overview of the Boiler and Auxiliaries 2-2

Boiler Components 2-12

Furnace Pass Wall, Passage Side Wall and 2RY Pass

Water Separator and Water Separator Drain Tank 2-15

Boiler Supports 2-25

Casing and Insulation 2-26

Safety Valves 2-26

Preventive Maintenance _____________

Interdepartmental Cooperation and Communication 4-2

Isolation of Equipment 4-2

Safety Precautions 4-2

Routine Maintenance 4-4

Inspection and Maintenance 4-5

Outage Maintenance 4-14

Inspection and Maintenance 4-15

Disassembly and Reassembly ________

Water Wall Tubes, Roof Tubes, Headers and Manifolds 5-1

Superheater Headers, Tubes and Desuperheaters 5-9

Recommended 10 Year Inspection 5-12

Reheater Headers, Tubes and Desuperheater 5-15

Recommended 10 Year Inspection 5-3

Recommended 10 Year Inspection 5-17

Economizer Headers and Tubes 5-19

Recommended 10 Year Inspection 5-20

Sample Tube Removal 5-22

Corrective Maintenance _____________

Boiler Tube Repair 6-2

Torque Chart A-1

Recommended Spare Parts B-1

Special Tools C-1

Applicable Vendor Drawings D-1

Details of Refractory, Insulation, etc. E-1

Reference Drawings F-1

Types of Hazard Warning Labels 1-6

Boiler Mapping for Hazard Areas 1-9

Overview of Boiler & Auxiliaries 2-7

Cutaway View of Boiler 2-8

Flow Path up to the Water Separator 2-9

Flow Path of Superheated Steam 2-10

Flow Path of Reheat Steam 2-11

Pressure Parts Arrangement (Upper side) 2-28