Power Plant Eng. Lect. Akeel M. A.

Morad
Fuel and Energy 4th Year

Below is a list of power stations in Iraq

Thermal

Name Location Capacity (MW)

Al-Mussaib Babil 1280

Doura Baghdad 640

Bayji Salahuddin 1320

South Baghdad Baghdad 355

Al-Shemal Mosul 2100

Al-Hartha Basra Governorate 400

An Nassiriyah Dhiqar 840

Renewable
Hydroelectric
Name Location Capacity (MW) Type

Adhaim Dam Saladin Province 27 Conventional

Darbandikhan Dam Sulaymaniyah Governorate 248 Conventional

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Name Location Capacity (MW) Type

Dukan Dam Sulaymaniyah Governorate 400 Conventional

Haditha Dam Al Anbar Governorate 660 Conventional

Hemrin Dam Diyala Governorate 50 Conventional

Samarra Barrage Salah ad Din Governorate 84 Conventional

Mosul Dam Ninawa Governorate 1052 Conventional

Mosul Dam Regulator Ninawa Governorate 62 Run-of-the-river

Natural Gas
Name Location Capacity (MW) Type

Mulla Abdulla (New) Kirkuk Governorate 222 Open-cycle

Khor Al Zubayr Basra Governorate 252 Open-cycle

Al-Mansurya Diyala Governorate 728 Open-cycle

Al-Anbar Al-Anbar Governorate 1,642.6 Combined-cycle

Shatt Al-Basra Basra Governorate 1250 Open-cycle

Erbil Erbil Governorate 1500 Combined-cycle

South Baghdad 1 Baghdad Governorate 246 Open-cycle

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Name Location Capacity (MW) Type

South Baghdad 2 Baghdad Governorate 400 Open-cycle

Daura 1 Baghdad Governorate 146 Open-cycle

Daura 2 Baghdad Governorate 750 Open-cycle

Al-Rasheed 1 Baghdad Governorate 94 Open-cycle

Taji 1 Baghdad Governorate 156 Open-cycle

Taji 2 Baghdad Governorate 160 Open-cycle

Sadr Baghdad Governorate 160 Open-cycle

Al-Quds 1 Baghdad Governorate 450 Open-cycle

Al-Quds 2 Baghdad Governorate 450 Open-cycle

Al-Quds 3 Baghdad Governorate 500 Open-cycle

Al-Najybia Basra Governorate 500 Open-cycle

Sulaymaniyah Sulaymaniyah Governorate 1500 Combined-cycle

Duhok Duhok Governorate 500 Open-cycle

Rumaila Basra Governorate 1460 Open-cycle

Taza Kirkuk Governorate 292 Open-cycle

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Name Location Capacity (MW) Type

Hilla Babil Governorate 250 Open-cycle

Karbala Karbala Governorate 250 Open-cycle

Al-Najaf Najaf Governorate 250 Open-cycle

Yusufiyah Location: Salahuddin 8 X 210 MW construction halted?

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year

Boiler Materials

Introduction
A core boiler, excluding the firing equipment, is mainly built with several high-
temperature materials, namely steels and refractories, with structural steels used for
support and sheet materials for air and gas transport.
Refractories, heat-facing materials, are steadily being replaced by more steel for easier.
There is, however, a comeback of sorts for the refractory materials, with the rise of
circulating fluidize bed combustion (CFBC) boilers where they are required in large
quantities for furnace and cyclone lining.

1- Boiler Parts
A wide variety of both raw materials and components, besides auxiliary plant and
equipment, are required to construct a boiler plant. Materials employed in boiler making
can be broadly classified as shown in Table 1.
Depending on the type of boiler and its scope, each of the three items in Table 1
contributes to ∼30 to 40% of the cost of the boiler plant. In a typical industrial plant, the
common bought-outs (BOs) are often included in the scope of boilers, whereas in larger
boilers, item 3c is excluded

TABLE 1

2-Boiler Steels
Boiler steels are of high-quality characterized by low carbon and high weldability,
high consistency, definite high-temperature properties, and a long history of satisfactory
usage. They are manufactured and tested to the specified codes.

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year
All the boiler steels should be procured only from code-approved manufacturers, and
code recognition comes only after stringent and periodic verification regarding
compliance to the set standards for manufacturing processes, stage inspections, and
documentation. The machines, the work procedures, the inspection stages, and even
workmen such as welders must be qualified individually. Thus, all the pressure part (PP)
materials in a boiler must come from fully recognized sources and meet minimum set
patterns conforming to a defined quality.
All boiler PP materials are invariably provided with material test certificates (TCs) in
which the material source and all appropriate tests at various manufacturing stages of
steel, as outlined in the code are detailed. Usually, the TCs, so prepared by the steel
maker, are further certified by an independent third-party agency to confirm the
reliability of the reports supplied by the manufacturer.
Various PP assemblies and the raw steels required are given in Table 2. Thus, the PP
material requirements are as follows:
1. Plates
2. Tubes
3. Pipes
4. Forgings
5. Castings (occasionally)
The mean metal temperature range of 450–480ºC is the rough dividing line for carbon
steels (CS) and alloy steels (AS).
TABLE 2

Boilers require a variety of steels, starting from low-strength low-carbon steels to high-
strength high-alloy steels and even stainless steel (ss) for various parts. However, with
the success of 9Cr–1Mo–V steels, the use of ss has considerably reduced. The limiting
temperature and the strength required are the main factors that decide the appropriate
metallurgy. The pattern of a steady progression from carbon to ss is as follows.

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A- Boiler Quality (BQ) Plates

Boiler quality plates are required to withstand high pressure and temperature: high pres-
sure in drums, high temperature in RH outlet headers, and both high pressure and
temperature in superheater (SH) headers made from plates. The most important
requirements of BQ plates are as follows:
# Consistency and uniformity of properties across the length, width, and thickness
of the plate
# High purity of steel
# No inclusions or air pockets

These requirements make BQ plates not easy to roll by all mills, particularly in higher
thicknesses. Boiler quality plates are characterized by the following:
* Low carbon content for good weldability
* High tensile strength to limit drum thicknesses
* Fully killed (deoxidized)
* High thicknesses
There are three categories of plates available with progressively increasing tensile
strength:
1. Carbon steel (low, medium, and high carbon)
2. Low-alloy steel
3. High-alloy steel

* In the American boiler-making practice, CS is favored, even with increasing carbon

(∼0.35%), resulting in thicker drums, as opposed to the European practice of adopting
low-carbon low-alloy plates (∼0.25%) of higher strength, which yield thinner drums that
are more conducive to faster boiler dynamics.
* High-carbon steel plates of both SA 515 and SA 516 are extensively used in the
industry. For lower thicknesses up to 40 mm, coarse-grained steel of SA 515 of
suitable grade is used, whereas for thicknesses up to 100 mm, i ne-grained steel of
SA 516 is generally preferred.
* For even higher-pressure applications, SA 299 in CS and SA 302 in AS are popular
to contain the thickness.
Table 3 lists various American and European plate materials in common use.

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year
TABLE 3

Notes: Brief details of popular drum plates to American standards are provided here and are compared
with the other popular equivalent British and German plates.
For accurate and current details, the readers must refer to the latest specifications.
Tensile strength reduces as the plate thickness increases. Tensility given here refers to higher
thicknesses. Tensile and yield strength values given are the minimum values. Figures in MPa are
rounded off.
The equivalent plate indicated is not an identical material. It is the closest by tensile strength but
differs in almost all other major parameters.
Plates of high-alloy steels are popular in Europe. The values given in the table against this item are not
for American plates but of Ducol and WB36, respectively.
NA, not available

B-Boiler Tubes
In case of drums, the diameter is large, but as the temperature is low, the higher stress
values of the plate manage to contain the thickness. For tubes, the case is reversed with
metals experiencing the highest temperatures in SH and RH and, consequently, having
the lowest stress values. The range of tube materials required in a boiler is therefore far
higher than the range for plate materials.
B.1- Tubes versus Pipes
Tubes and pipes are not identical. The most important difference is that pipes do not
transfer heat. Further differences are mentioned in Table 4. Tubes and pipes are
manufactured to different specifications and are not interchangeable even in the narrow
overlapping range up to 125 mm.

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year
TABLE 4

B.2 Seamless and Electric Resistance–Welded (ERW) Tubes

Boiler tubes are manufactured by two processes, and are classified as follows:
1. Seamless tubes—produced by piercing a red-hot billet with a plunger
2. Electric resistance-welded tubes produced by folding and welding steel strip,
called skelp.
In terms of weldability, bending, and physical and chemical properties, the seamless and
the ERW tubes are nearly the same. In fact the ERW tubes are superior and preferred for
lower thicknesses, as they are made from plate materials, which render the
* Inside tube surface smooth resulting in lower inside-pressure drop
* Bore concentric to OD, unlike in seamless tubes, and thus better suited for tube
expansion
* Lower costs
B.3 Hot-Finished and Cold-Drawn Seamless Tubes (HFS and CDS)
As the tubes come out of the tube mill, they are hot finished and their tolerance levels
are high. For furnace, boiler bank (BB), and economizer (ECON) sections, the slightly
higher pressure drop in HFS tubes makes no significant difference. Even in SHs of
smaller boilers, the higher pressure drop is of no consequence. Cold-drawn seamless
tubes have closer tolerance, and for SH and RH duties in large boilers, tolerance makes
a large difference. CDS tubes are produced from HFS tubes by reheating them to the
appropriate temperature and re-rolling to a closer finish.

B. 4 Tubes and Comparison

Carbon, alloy, and occasionally ss tubes are employed in boiler making as shown in
Table 5. Tubes to American specifications are listed along with the BS and DIN
equivalents, which are the other popular globally accepted specifications.
Tubes are rolled in sizes from 12.7 to 127 mm (0.5–5 in.) OD, and almost all sizes from
31.8 mm OD onward are used in boilers. Tubes are always designated by their outside
diameters.

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year

TABLE 5

Notes: Safe maximum outside tube wall metal temperatures given here are on the basis of oxidation
resistance. Design codes decide the permissible temperature limits.
For CS usage beyond 454ºC when permitted by the code, special inspection is required for 100% weld
efficiency.
In the column pertaining to use, 1 refers to furnace walls exposed to high heat, 2 refers to ECON and
other enclosures not exposed to high heat, and 3 refers to SH
and RH.
$ refers to DIN 17456, which is the specification for ss tubes. The equivalents are for basic steels
without suffix H. Steels with suffix H are modified to suit high-
temperature duties of SH and RH by increasing the carbon content by 0.02%.
Thickness as per SA standards is usually the minimum thickness with no negative tolerance, whereas
with BS and DIN, it is the nominal thickness with appropriate
negative tolerance.

B.5 Selection of Tube Materials

Temperature limits, based on accelerated oxidation, determine the basic applicability of

any material. Thereafter, the strength of the material at the operating temperature
governs the selection. As shown in Figure 1.7, the permissible stresses, particularly at
the low temperatures, do not vary much (<250° C approx.); but at the elevated
temperature, they deteriorate sharply beyond 450°C. Each incremental improvement in
metallurgy is costlier by 20–40%. A good boiler design has the following features:
1- Maximum use is made of low-carbon steels due to their ease of manufacture and

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year
repair.
2- The thicknesses are kept to a minimum by using superior metals to lower the thermal
inertia.
3- The use of ss is minimized due to the expense, much higher elongation, susceptibility
to stress corrosion, and possible problems arising from welding dissimilar metals.
Table 6 lists various commonly used carbon, alloy, and ss tubes and pipes as per
different codes with their areas of application in different parts of the boiler.

FIGURE 1 Allowable high-temperature stresses for selective pressure part materials as per
ASME BPVC 2007

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year

TABLE 6

Table 7 lists the commonly used tubes with their diameters and thicknesses and provides
the tube weight in kilograms per meter. Tube thickness is normally expressed in wire
gauge. There are two popular designations, namely, standard wire gauge (SWG) as per
British practice and Birmingham wire gauge (BWG) as per American practice. They are
similar as can be seen in the comparison in Table 8. Note that the thicknesses are in
steps of 10%.

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year

TABLE 7

TABLE 8

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Power Plant Eng. Lect. Akeel M. A. Morad
Fuel and Energy 4th Year

C-Pipes
Pipes are designated by nominal bore (NB) for sizes up to 304.8 mm (12 in.) and by OD
beyond that size. In boilers, pipe materials are used in the following three areas:
1. Headers and downcomers placed inside or outside the gas stream
2. Integral piping, namely, drain, vent, blowdown, soot blower (SB), attemperator,
and interconnecting piping
3. Piping for feed water (FW), main steam, and reheated steam
Table 9 lists the popularly used BQ pipes to American specifications and their
equivalents in BS and DIN. Table10 lists the pipes by NB and thicknesses
(mm) and unit weights (kg/m) as per ANSI.

TABLE 9

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Fuel and Energy 4th Year

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Power Plant Eng. Lect. Akeel M. A. Morad
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D- Insulation
Some of the important aspects of the insulating materials are as follows:
Unlike the refractory materials, which are substantially mineral-based and therefore
capable of withstanding the highest temperatures and erosion, the insulation materials
are non-mineral (except for ceramic fibers), can stand up to temperature no higher than
∼1650ºC, and do not have any abrasion resistance.
1- The insulating materials possess much lower heat conductivity, several times lower
than those of the refractory materials.
2-The insulating materials are fluffy and hold lot of air, which contributes to the
reduced heat flow.
3-Thermal conductivity for insulating materials rises steeply with temperature.
Insulation materials in boiler practice are available in mainly four forms:
1. Reformed shapes and slabs
2. Mattresses
3. Plastic cement
4. Loose fill
The insulating materials used in boilers are as follows:
1. Calcium silicate in block forms
2. Mineral/slag wool
3. Ceramic fiber
4. High-temperature plastic

Table 11 lists the properties of various common insulating materials used in boilers.

TABLE 11

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