UPGRADE OF PIONEER MILL BOILER NO. 2

PIONEER BOILER No 2 was upgraded as part of the co-generation project undertaken by CSR at their Pioneer Sugar Mill during 2005. The steam supply from this boiler now supplies a single 30.8 MW(e) turbo-generator with the exhaust steam supplying the sugar processing needs of the factory. The 1976 Babcock and Wilcox boiler had a minor upgrade in 1989 and was producing 200 t/h of steam at 17.5 bar and 270°C. The 2005 upgrade increased steam output to 241 t/h at 31 bar (g) and 383° C. Clyde Babcock-Hitachi Australia Pty Ltd were contracted to undertake the design and carry out the modifications required on the boiler to meet the new design output steam conditions. This paper covers the major component replacements and upgrades undertaken on the boiler to meet its new demand. It also covers the repairs undertaken on the original pressure parts.