AMARDEEP .M.

JADEJA
B.E. MECHANICAL (THIRD YEAR)

INDUS INSTITUTE OF ENGINEERING

& TECCHNOLOGY,AHMEDABAD.
 CONTENTS
2) INTRODUCTION OF BOILER
3) AIR PREHEATER
4) ASH HANDLING PLANT
5) FUEL OIL SYSTEM
6) COAL MILL
7) ID, FD & PA FAN
8) COOLING TOWER
9) FIRE FIGHTING SYSTEM
10)COAL HANDLING PLANT
11) TURBINE
12) SEA WATER SYSTEM
13) DM PLANT
14) TDBFP & MDBFP SYSTEM
CLASSIFICATION OF POWER
PLANTS:
Thermal Power Plant Installed capacity

Diesel Power Plant 2% 3%

10%

Nuclear Power Plant

Hydro Power Plant 26% 59%

Gas turbine Power Plant

Geothermal Power Plant Coal Hydro Gas Nuclear Others
THERMAL POWER PLANT:
A thermal power station is a power plant in which the prime
mover is steam driven. Water is heated, turns into steam and
spins a steam turbine which either drives an electrical generator
or does some other work, like ship propulsion. After it passes
through the turbine, the steam is condensed in a condenser and
recycled to where it was heated; this is known as a Rankine cycle
Thermal power stations produce electricity by burning fuel in a
boiler to heat water to produce steam. The steam, at tremendous
pressure, flows into a turbine, which spins a generator to
produce electricity. The steam is cooled, condensed back into
water, and returned to the boiler to start the process over.
Power generated by this power plant covers nearly 60% of all
power. They work with the help of coal, oil, natural gases, waste
heat etc.
INTRODUCTION OF
BOILER
INTRODUCTION OF BOILER
What is Boiler?
A boiler is defined as "a
closed vessel in which
water or other liquid is
heated, steam or vapor is
generated, steam is
superheated, or any
combination thereof,
Boiler under pressure or
vacuum, for use external
to itself, by the direct
application of energy from
the combustion of fuels,
from electricity or nuclear
energy."
Boiler According to Indian Boiler
Regulations.
IBR Steam Boilers means any closed vessel
exceeding 22.75 liters in capacity and which is
used expressively for generating steam under
pressure and includes any mounting or other
fitting attached to such vessel, which is wholly,
or partly under pressure when the steam is shut
off.
Introduction to Adani Power 660
MW Boiler
Description Unit Value
Type Supercritical, Once Through Type,
Sliding Pressure, Single Furnace, New
Tangential Type, Single Reheat,
Balanced Draft, Dryed Slag Discharge,
Complete Steel Structure, Complete
Hanging Construction, Double Gas
Passes.
Manufacturer HARBIN BOILER COMPANY,
CHINA
Design Code ASME, GB9222-88, IBR
For Pressure
Parts
 Overall View Of Adani Boiler

2. Spirally wounded
evaporators for safe
Large Single Funace
and reliable evaporator

4. High Strength material

3. Proven and economic
application
heating surface
arrangement
5. Economic and safe
low load and startup
system by circulating 6. Burner tilting for
pump reheater steam
temperature control

8. Long life and high 7. Low Nox Tangential

Performance mills Burner
 CRITICAL CONDITION
Definition
CRITICAL is a thermodynamic expression
describing the state of a substance beyond which
there is no clear distinction between the liquid
and gaseous phase.
The critical pressure & temperature for water are
Pressure = 225.56 Kg / cm2
Temperature = 374.15 C
TEMP
540C 568C
600
m2
/ c
Kg
500 6
25 SUPER CRITICAL
400 BOILER CYCLE
WITH SH, RH &
300 Regeneration
200
of ADANI 5 x 660 MW
Steam flow :2225 T/Hr
Steam temp : 540 c
100 Steam Pres : 256 kg/cm2
RH pre : 51.6 Kg/cm2
RH Temp : 568c
Feed water Temp : 291c
0

ENTROPY
 WHY SUPERCRITICAL PRESSURE
The purpose of having high inlet steam pressure for
turbine can be inferred from Previous deliberations.
A Boiler operating at a pressure above critical point is
called SUPERCRITICAL BOILER
A point where boiling water and dry saturated lines meet
so that associated latent heat is zero, this point is called
Critical Point and occurs at 225 kg/cm2 (abs) 374.15 C
temperature.
 SH

DRUM
RISERS
BFP HTR ECO
DOWN COMER

Natural Circulation W/WALL

Boiler

SH
SEPERATOR

W/WALL

BFP HTR ECO

ONCE THROUGH SYSTEM

FLOW DIAGRAM OF SIPAT SUPER-CRITICAL BOILER

BP & EXT,d
ECONOMIZE FURNACE WALL FUR. ROOF
WALL
R WALL
S/H S/H S/H
SEPARAT
OR.

- Horizontal - FUR.
- SIDE (SPIRAL & VERT.) - B/P. ROOF - - PLATEN - FINAL
- Pendant - FRONT & REAR (SPIRAL & ROOF - B/P. FRONT & REAR
DIVISION

STORAGE TK
VERT.) - B/P SDIDE (R.L)
- EXT. FLOOR &
SIDE(R.L)

LT R/H HT R/H
(Coil)

BY OT H ER
BLR WTR fill in from F/W HTR
No.8
- PLATEN - FINAL

BY OT H ER D S
BY OT H ER D S
HP IP GENERATO
TB TB R
LP
TB

BY OT H ER
DS

BY OT H ER
BWR
P

CW in
CONDENSO
R CW
Evaporator Wall Construction (1/3)

Upper Part
Vertical Wall

Lower Part
Spiral Wall
 Supercritical Boiler Technology
Spiral Wall Evaporator

Configuration of Evaporator panel

Spiral wall outlet temp at BMCR (front wall)
Spiral wall : Vertical wall = 3 : 1
 WALL OF BOILER

spiral wall spiral wall and windbox

660 MW PLANT BOILER
 LTSH COILS

ECONOMISER COILS
ECONOMISER
O/L HEADER

ECONOMISER I/L HEADER

AIR PREHEATER
The Air Preheater absorbs waste heat from flue gas,
and then transfers this heat to incoming cold air by
means of continuously rotating heat transfer elements
of specially formed metal plates.

Air Preheater is in general divided into two

types:

Regenerative

2. Recuperative
 1) Regenerative APH are also known as
storage type heat exchangers, have an energy
storage medium, called the matrix, which is
alternately exposed to the hot and cold fluids.
When the hot flue gases flow through the matrix
in the first half of the cycle, the matrix is heated
and the gas is cooled. In the next half of the
cycle when air flows through the matrix, air gets
heated and the matrix is cooled. The cycle
repeats itself.
 2) Recuperative APH, heat is directly
transferred from the hot gases to the air across
the heat exchanging surface. They are commonly
tubular, although some plate types are still in
use. Tubular units are essentially counter-flow
shell-and-tube heat exchangers in which the hot
gases flow inside the vertical straight tubes and
air flows outside. Baffles are provided to
maximize air contact with the hot tubes.
Regenerative Type Air Pre Heater

Nos. 2
Speed of Rotation 0.9rpm
Cooling water Consumption
18t/h
Air temperature at
Regenerative APH outlet -
 General Arrangement of Airpreheater

TG House

SA
SA
PA PA

FG FG

Chimney
Air Preheater, main technical specifications and list
of master drawings
 List of master drawing
1 General arrangement of Air Preheater.
2. Rotor assembly
3. Rotor radial seal assembly
4. Rotor module assembly.
5. Rotor post and trunnion assembly.
6. Hot end and hot intermediate layer elements and element baskets.
7. Cold end element and element basket.
8. Rotor housing assembly.
9. Hot end primary center section assembly.
10. Cold end primary center section assembly.
11. Hot end connecting plate assembly.
12. Cold end connecting plate assembly.
13. Guide bearing assembly.
14. Support bearing assembly.
15. Static seal assembly (hot end and cold end).
16. Axial and by-pass seal assembly.
17. Rotor drive assembly.
18. Sector plate assembly (hot end and cold end).
19. Air seal pipe, observation port and vapor or dust proof light assembly.
20. Stationary water washing device (hot end and cold end) and fire fighting device
21. Special tools and spare parts.
Isometric view of Air Preheater
 AIR PRE-HEATER OPERATION
PRE START CHECKS

Support bearing/ guide bearing lubricating oil pumps

RUNNING and lubricating oil coolers are CHARGED.
Bearing temperature NOT HIGH (less than 60oC)
Electrical supply to APH motor is AVAILABLE.
Local operation - Isolating valves of air motors are 'OPEN'
and bypass valves of air motor solenoids are 'CLOSED'.
'Air motors' lubricating oil level ADEQUATE
Service air pressure is ADEQUATE (> 5 Kg/cm2)
AIR PRE-HEATER OPERATION
APH STARTING PROCEDURE

WHEN BOTH APHS ARE OFF

START air motor of APH.
Air motors ON indications come on
Isolating dampers of APHs start opening.
INSTRUCT local operator to check, locally for any abnormal
sounds from bearings/seals.
START air heater electrical motor.
Breaker CLOSED & its indication comes on UCB
Associated air motor stops.
Starting current shoots up and comes down to normal load
current.
AIR PRE-HEATER OPERATION
Isolating dampers of the air heater remain open.
Isolating dampers of the other air heater, not in service, start
closing if its air motor is not ON.
INSTRUCT local operator to check, locally for any abnormal
sounds from bearings/seals.
There should be no abnormal hunting in air heater amperes
meter readings.
There should be no abnormal sounds from air pre-heater
seals or bearings.
Bearing temperatures must be within the normal range (65
0
C -75 0C)
 Parameters related to APH
Make : Ljungstorm
Type : Trisector
Oil used : TC 680 cyndol (Bearing)
EP 320 Parthan (Gear Box)
Motor Drive :
Main Motor (Electric driven, AC)
Stand by motor (Electric driven, AC)
Motor: N=970rpm , Speed Reducer Assembly O/P: N=0.89
rpm
ASH HANDLING PLANT
 INTRODUCTION
Ash is a waste product of coal and solid fuel combustion. It contains
many harmful elements which can contaminate sub-soil water of water is
allowed to seep through ash into soil. Further, percentage of ash present
in Indian coals is large. As a result, disposal of ash also uses up
considerable area of land, which could otherwise be put to better use.
Therefore, it is desirable to put ash to use so that the problem of
providing land area for its disposal is solved. All out efforts are being
made for finding uses of ash. Presently, only negligible amount of total
ash produced in the country is put to use. However, ash being a good
landfill material can be used in bulk in projects like highway
construction. This is being done to as large an extent as possible.
Pollution Control Regulations have made it mandatory to dispose ash in
dry form only so that harmful elements do not find ingress in the sub-
soil water
 ASH HANDLING SYSTEM
In modern boilers ash is collected in two locations
namely (i) Bottom of the furnace and (ii) in
Electrostatic Precipitators (or Dust Collection
Systems). Out of these two fractions generally the
quantity of ash collected in Electrostatic Precipitators
(or Dust Collection Systems) is larger. Ash collected in
the Bottom of Furnace is generally small in quantity
and is handled wet, whereas that collected in
Electrostatic Precipitators (or Dust Collection
Systems) is now collected by means of dry handling
systems.
Silos for
collection
of FLY-ASH
 FLY ASH HANDLING SYSTEM

The fly ash handling plant will remove fly ash from Electro
static precipitator (ESP) hoppers and transport it to the
storage silos. This will be carried out by pressure pneumatic
conveying system on a continuous, cyclic basis. One boiler
unit will be provided with one pneumatic conveying system
for handling fly ash collected in the ESP hopper. The system
layout and the conveying pipeline configuration will be
designed and constructed to enable evacuation of fly ash at
maximum design rate. The output of the system will be not
less than 200% of actual ash amount. The capacity of each set
of system will be 30t/h.
 ELECTROSTATIC PRECIPATATOR

It is a device which captures the dust particles from

the flue gas thereby reducing the chimney emission.

Precipitators function by electrostatically charging the dust

particles in the gas stream. The charged particles are then
attracted to and deposited on plates or other collection
devices. When enough dust has accumulated, the
collectors are shaken to dislodge the dust, causing it to fall
with the force of gravity to hoppers below. The dust is then
removed by a conveyor system for disposal or recycling
 LOCATION OF ESP

ECO

APH ESP CHIMNEY

Electro Static Precipitator
Basic Principle
 ESP PROCESS STEPS
1.Electron emission
Dust layer
1

2.Dust particle charging Collecting

2
electrode,
grounded
3

3.Migration
5.Rapping

4 5

4.dust collection

Discharge electrode with

Negative high tension (20-60kV) Rapping mechanism
 ESP

Collector plate Emitter coil

Flue gas

Gas distribution plate

ESP TECHNICAL SPECIFICATIONS

Description Unit Value

Nos. of Gas Stream / ESP Double

Nos. of Parallel Path per Stream Nos. 38

Nos. of electrical fields in series Nos. 5

Total active treatment length per m 3.5
stream
Treatment Time Seconds 15
Description Unit Value

Total Number of Electrode Nos. 3192 x 2

Total numbers of Rappers per Unit Nos. 7

Total Nos. of Transformer Rectifier Unit Nos. 20

Capacity of Transformer Rectifier Unit KVA 1.6A/72

Each KV
Total No. of Dust Hoppers Nos. 40
FUEL OIL SYSTEM
 There are two types of fuels are used
for ignition in combustion chamber.

1) Heavy fuel oil(HFO).

2) Light diesel oil (LDO).

 HEAVY FUEL OIL
The density of HFO is higher.
Cost is low compare to the LDO.
The viscosity is high.
The auxilary steam is mixed for easely flowing
through pipe.
The storage tank of HFO is 2000 m3
 BOILER LIGHT-UP
"HFO" inlet and re-circulation flow start increasing
"HFO header pressure very low" alarms clear off.
HFO temperature in the HFO header increases up to 110 oC.
OPEN Ignitor oil trip valve
Ignitor oil trip valve opens up.
Ignitor air fans A & B, start automatically.
Ignitor oil and ignitor air pressure increase up to 23 Kg/cm2 and 400
mm wcl, respectively.
"Ignitor air to furnace DP low & "Ignitor oil/Atomising air pressure
low" & "Ignitor oil/HFO trip valve closed" alarms clear off.
CHECK these parameters are within their operation limits.
Drum level normal (-60 mm. to 0, preferably on lower side).
 BOILER LIGHT-UP
HFO temp. 110 oC . (Min. temp. required is 95 oC).
HFO atomising steam pressure 8.75 Kg/cm2
Light oil pressure more than 15 Kg/cm2.
Ignitor atomising air pressure 5 to 7 Kg/cm2
Wind box pressure between 35 to 40 mm wcl
ADJUST HFO header pressure set point to 50%(13 Kg/cm2) and
TRANSFER its control to auto.
HFO pressure controller transfers to auto and modulates to maintain
the set HFO header pressure.
CLOSE heavy fuel oil re-circulation valve.
HFO re-circulation flow valve closes.
HFO re-circulation flow comes to minimum position
 LIGHT DIESEL OIL
The density of LDO is low.
Cost is high compare to the HFO.
The viscosity is low.
The fuel is easely flowing through pipe.
The storage tank of LDO is 300 m3
COAL MILL
 INTODUCTION
As coal powder is the most important fuel in the power
plant, the plant owners need coal mill or coal pulverizer
to grind the coal to micro powders.
Raw coal (crushed) is fed through hopper at the top
of the coal pulverizer and falls down to grinder ring to
be pressed, crushed and milled into pieces by rollers.
After the first crush, coal powder fall into the second
and third layer. The pumping of the high-pressure
centrifugal blower put the outside air into the coal mill.
The coarse coal powder will be brought into the
classifier.
 TYPES OF MILLS
1) Ball mill

2) Ball and Race mill

3) Impact or Hammer mill

4) Bowl mill
COAL
MILL
 MILL LOCATION
PA-A FD-A
MILL

A
ECO I/L 493C CHIMNEY

134C

129C
351C
B ESP
PASS A

ESP O/L X OVER DUCT

APH PA
1165C

126C
WIND BOX
SA X-OVER DUCT

136C
SA FG

ESP I/L X OVER DUCT

ESP
C PASS B
ID-A
SCAPH
FURNACE
SCAPH

324C D ESP
PASS C
ID-B
WIND BOX SA FG
APH
PA ESP
PASS D
E
320C

F COLD SA
HOT SA
27C COLD PA
HOT PA
PA-B FD-B FLUE GAS
 Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) Local
Ensure R.C. Bunker level satisfactory.
R.C. feeder and mill properly boxed up and no maintenance staff working.
Gear box oil level normal. lubricating oil coolers charged.
Pulveriser START PERMIT is AVAILABLE. (Boiler total airflow is <
40% and all burners are HORIZONTAL). Alternatively, if anyone coal
feeder is proven then start permit will come from the proven feeder.
Tramp iron gate open.
Cold air gate 100 % open. Hot air gate closed.
Mill outlet valve open.
Seal air valve 100 % open.
"No unsuccessful start" permissive for pulveriser is ON.
Mill fire fighting system ready.
 Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) UCB
Ensure no PTW pending.
Ensure at least one P.A. fan and a seal air fan is in service. Check the
header pressure for both primary and seal air is normal.
Check that mill ignition energy is O.K. (Minimum 3 out of 4 gun
nozzle valves in adjacent elevation are open and elevation oil flow is
more than 30% OR adjacent feeder speed is more than 50% and
boiler load is more than 30%.
Check that mill start permissive as per FSSS are satisfied
Ensure E.P. zones have been charged (for first mill).
Get the electrical supply for the mill.
Inform the local operator to be near mill for start up.
Start the mill
 Milling System
POST START CHECKS
Local -Check there is no abnormal sound from mill. Check return
oil flow from upper bearing is satisfactory. Check all the rollers are
rotating and the rate of reject is normal (after the mill is loaded).
U.C.B.-Check mill starting time and current. Ensure that they are
normal. Open hot air gate. Warm up the mill.
Start the RC feeder and load the mill gradually.
Keep the air flow through mill - 54 T/hr.
Keep watch on mill differential to avoid mill choking.
Maintain mill outlet temperature between 75C to 80C.
As the pressure, temperature of main steam shoots up with coal
firing proper check should be kept on these parameters. (Especially
for first mill).
 Milling System
MILL SHUTDOWN PROCEDURE
TRANSFER mill feeder and fuel master controller to manual.
Fuel master and feeder control transfer to manual.
REDUCE feeder speed to minimum, gradually.
Coal flow to mill starts coming down.
Other running feeders start loading up, to maintain boiler loading, if on
auto.
STOP the mill feeder.
Hot air gate closes with a time delay of 30 sec approx.
Mill current and differential pressure start reducing as the mill becomes
empty, gradually.
EVACUATE the mill reject chamber locally and STOP the mill.
Mill temperature comes down to less than 500C.
Mill CAD goes to <5% open
Airflow to furnace drops slightly.
 Coal Pulverisers
Description Unit Value
Type of Design & Construction Medium Speed Mill
Number (Each Unit) Nos. 6
Capacity of each pulveriser for TPH 70
the design coal
Min. load of Pulverisers % 25
Mill Speed Rpm 33
Driver Speed Rpm 982
Rated Power Kw 900
Avg. life of Rollers/Grind Roll Hrs. 12000
& Bottom Race Liners before
Replacement
ID, FD & PA FAN
 FURNACE

CHIMNEY MILLS
SECONDRY AIR HEATER

PRIMERY AIR HEATER

FD FAN A FD FAN B

ID FAN A Atmospheric air

ESP PA FAN A PA FAN B

ID FAN B Atmospheric air

 I.D.FANS (Induced Draught Fan)
The induced draft fans are generally of axial
impulse type. The fan consists of the following
sub assemblies,
(a) Suction Chamber,
(b) Inlet valve Control,
(c) Impeller,
(d) Outlet Guide Vane Assembly.
Induced Draught
Fan
 The outlet guides are fixed in between the case of the
diffuser and the casing. These guide vanes serve to
direct flow axially and to stabilize the draft-flow
caused in the impeller. These outlet blades are
removable type from outside. During operation of the
fan itself
These blades can be replaced one by one. Periodically
the outlet blades can be removed one at a time to find
out the extent of wear on the blade.
 F.D Fan: (Forced Draught Fan)

The fan normally of the same type as ID fan

consists of the following components:
1) Silencer,
2) Inlet bend,
3) Fan housing,
4) Impeller with blades and setting mechanism,
5) Guide wheel casing with guide vanes and
diffuser.
Forced Draught
Fan
 The centrifugal and setting forces of the blades
are taken up by blade bearing. The blade shaft is
placed in combined radial and axial antifriction
bearing which are sealed off to the outside
The rotor is accommodated in cylindrical roller
bearing and an inclined ball bearing at the drive
side absorbs the axial thrust.
Lubrication and cooling of these bearing is
assured by a combined oil level and circulating
lubrication system.
 PA Fan (primary air fan)
P.A fan if flange mounted design, single stage
suction, NDFV type backward curved bladed
radial fan operating on the principle of energy
transformation due to centrifugal forces. Some
amount of the velocity energy is converted to
pressure energy in the spiral casing. The fan is
driven at a constant speed and the flow is
controlled by varying the angle of the inlet vane
control.
primary air

fan
 The special feature of the fan is that it is
provided with inlet guide vane control with a
positive and precise link mechanism.

Fan can develop high pressures at low and

medium volumes and can handle hot air laden
with dust particles.
 Fans
Description Unit FD PA ID

Fan Model Axial Fan Axial Fan Axial Fan

Rated Power of Motor kW 2000 3150 4500

Rotational Speed of Fan r/min 990 1490 990

Volume flow of fan inlet m^3/s 230.1 112.9 538.4

Temperature of fan inlet C 47.8 47.8 137

Fan total pressure Pa 3871 12671 3989

Total efficiency % 87 88 85.5

External Diameter of Blade mm 2880 2100 3349

Diameter of Impeller mm 1600 1400 1884

Blade No. of Each Grade Nos. 26 22 18

COOLING TOWER
 INTRODUCTION
Cooling towers cool the warm water discharged
from the condenser and feed the cooled water
back to the condenser. They, thus, reduce the
cooling water demand in the power plant.
Cooling tower may classify as:
1) Induced draft cooling tower
2) Forced draft cooling tower
3) Balanced draft cooling tower
Cooling towers can be either mechanical
draught or natural draught.
In mechanical draught cooling towers, air is
moved through the fill by one or more fans
driven by motors.
The fans could be of the forced draught (FD)
type or induced draught (ID) type.
COOLING TOWER
 Cooling tower Detail
There are 20 sets cooling tower for one unit.
The design meteorological parameter;
Relative humidity: 60 percentage
Main air pressure: 1013.25 hpa A
Inlet water temperature: 42C
B
outlet water temperature: 33C C

Type: counter flow mechanical draft cooling tower

Type of fill: PVC fill D
Cooling tower stack material: fiber glass reinforced
plastics
Depth of fill: 1.5m
E
Water basin depth: 2m
Tower overall height : about 16.4m F
Cooling water capacity: 5256 m3/hr
Fan specification: A=Mechanical equipment
Fan dia: 9750 mm B=Drift eliminator
Blade of each fan: 6 pieces C=Water distribution
D=Fill packing
Motor power: 220Kw E=Air in late louvers
Voltage:6600 v F=Cold water basin
 Principle of cooling Tower operation

In COOLING TOWER

- Water is split up into small droplets & brought into intimate contact with air.

- In doing so a small quantity of water is evaporated.

- The EVAPORATION brings about the 75 % of the cooling effect.

- Balance 25 % of the cooling is due to sensible heat transfer.

 Blowdown
Evaporation

Cooling Heat
Tower Load

Recirculating Pump
 Wet cooling towers have a hot water distribution system that
showers or sprays water evenly over a lattice of horizontal
slats or bars called fill or packing.
The fill thoroughly mixes the falling water with air moving
through the fill as the water splashes down from one fill level
to another by gravity. Outside air enter the tower through
louvers on the side of the tower. Intimate mixing of water and
air enhances heat and mass transfer (evaporation), which cools
the water. More the water evaporates; more will be the cooling
since the latent heat of evaporation is taken from the water
itself (evaporation cooling). Cold water is collected in a
concrete basin at the bottom of the tower, from where it is
pumped back to the condenser. Hot and moist air leaves the
tower from the top.
FIRE FIGHTING SYSTEM
 Water spray fire fighting system
HVWS System & Automatic alarming ,Automatic/Manual startup
Generator transformers, category-A
2000 m3 2000 m3
Unit auxiliary transformers, category-A
fresh water fresh water
Station transformers, category-A reservoir reservoir

outdoor oil storage tanks, category-B

Diesel generator room, category-B
Boiler burner, category-B
1 4 3 3
2 2
Air pre-heater, category-B
Mill lube oil system, category-B
Medium layer oil device, category-B
To spray fire hydro
Turbine lube oil tank, category-B fighting pneumatic
Hydrogen seal oil device, category-B system(300 nb) tank(80nb)
Steam driven pump lube oil system, category-B'

Steam driven pump lube oil system, category-B' No Description

MVW -Bunker bay Automatic sprinkler driven F.F
1 Q-410,H=115,N=220,1nos
-10.4 m cable mezzanine
Automatic sprinkler F.F jockey
-switch yard control building 10.40m cable spreader room 2 pump,Q-18,H-115,N-13.5-2nos
- Crusher room Air compressor-2nosX100%Type-
3 ww-0.7/25V=170LN=11kw
- 1#juction house
Automatic sprinkler motor drive
- 2#juction house 4 F.F pump,Q-410,H-115,N-220
- 3#juction house
- Coal conveyor
 Hydrant fire fighting system
Main turbine house-5 unit
2000 m3 2000 m3
Main turbine house-6 unit fresh water fresh water
Dearetor & bunker bay reservoir reservoir
Boiler house-5 unit
Boiler house-6 unit
Central control building 5 6 9 10 7 7 8 8
ESP& stack area
D.M water treatment plant area
To fire hydrant fire hydro pneumatic
Waste water treatment building area fighting system tank(80nb)
fuel oil storage area
Water clarifiers area
No Description
Cooling tower area of Unit-5& 6
Hydrants Diesel- drive F.F
Coal yard area 5,6 pump,Q-273,H-125,N-160
Junction house-1nos
Hydrants Motor- drive F.F
Junction house-2nos
9,10 pump,Q-273,H-125,N-160

Junction house-3nos
7 Hydrants F..F jockey pump
Crusher room
Air
compressor-2nosX100%Ty
8 pe-
ww-0.7/25V=170LN=11kw
COAL HANDLING PLANT
 INTRODUCTIO
Coal Handling System and plant shall comprise of
following:

(a) Track Hopper and paddle Feeders

(b) Roller Screens with Single Drive
(c) Crushers
(d) Stacker & Reclaimer
(e) Conveying System
(f) Transfer Tower
LAYOUT OF COAL HANDLING PLANT
CRUSHER
HOUSE
TT-3
TT-4

TT-1
TT-2
BUNKER
 General:
The track hopper together with coal handling
facility (to supply coal for units), capable of
continuous, efficient, and reliable operation with
minimum maintenance under the environmental
and operating conditions pertaining to area
adjacent to power plant site. Track hopper
complex together with Coal Handling System
shall be designed for continuous duty of 24
hour/day.
 The entire coal handling plant (CHP) facility shall comply
with currently applicable statutes, regulation & safety codes
related to design, construction & operation of the CHP.

The CHP will supply coal from the track hopper up to and
including the bunker fill system.

The conveying and handling of coal from the above ground

coal stockyard to the main plant boiler bunkers;

The plant will be designed to handle with the whole

range and condition of coal that may be delivered to
the site in a safe, reliable, economic and
environmentally acceptable manner
 Conveyor System:
(a) Each conveyor will be fitted with a
centrifugal speed switch for use in the
sequential starting and tripping interlock scheme
and for ensuring that the driving motor will be
shut down automatically in the event of the belt
slipping or breaking. Start-up and shutdown of
each conveyor will be by remote control with
provision for local control.
(b) Plant will be designed for ease and flexibility of operation
including.
All conveyors and transfer towers will be totally enclosed with
a central access walkway, maintenance walkways at each
side of conveyors. Adequate access will be provided for
cleaning all conveyors.
Transfer points will be designed to give good material flow
and central loading of conveyors without spillage. Access will
be provided for chute cleaning.
High quality belt scrapers will be provided. They will be
positioned and chutes designed such that all scrapings fall into
the main chute, to merge with the main flow of material.
All operational areas will be well-lit with special lighting
provided where the interiors of chutes, hoppers and bunkers
must be inspected frequently.
Coal conveyor
 Coal Receiving System:

Coal will be discharged from wagons

to coal gap for train and be fed to 1AB
belt conveyor by paddle feeder, then
pass through 2# belt conveyor,
ultimately be stacked in coal yard by
the bucket wheel stacker & reclaimer.
 Coal Reclaim System:
Coal reclaim system will involve the operating flow
from the stacker & reclaimer to the coal bunker in main
block.
Coal will be reclaimed by the stacker & reclaimer, and
pass through 2#,3AB belt conveyor, then be injected
into the crusher, which could crush coal into smaller
pieces. The crushed coal will be conveyed through 5AB
belt conveyor, ultimately be discharged into the coal
bunker by the plough trippers.
Stacker &
Reclaimer
TURBINE
TURBINE MAKE:- Dong Fang Steam Turbine Works

Nominal Capacity- 660 MW

Type- N660-24.2/566/566
 IMPULSE TURBINES

REACTION TURBINES
IMPULSE TURBINE REACTION TURBINE
 TURBINE SPECIFICATION
TYPE
Impulse Type
Tandem Compounded
3 Cylinders (HP & IP Combined, two LP Cylinders)
Four Flow Exhausts
Reheat
Condensing Turbine
 From Reheater
Boiler

Economiser

8 6 2x7 2x7
FCS

HPT IPT LPT A LPT B

5 6 5 6
7 7 7 7
3 8 8 8 8
1 LPH -7A
LPH -7B
HPH - 1

LPH -8A
LPH -8B

Condensor
(HP) Condenser
Deaerator
HPH - 2

EXT From (LP)

CRH

(MD BFBP 1x35%) BFBP

2x50%
LPH-5 Extr from 16th stage
HPH -3

LPH-6 From 17th stage

TDBFP 2x50%
LPH-7 From 18th stage
(MD BFP 1x35%) CEP
LPH-8 From 19th stage
3x50%
1994 TPH
GSC
HPH-1 Extr from 6th stage
HPH-2 From CRH CPP
HPH-3 From 11 stageth
1482 TPH
Deaerator From 14th stage LPH -6
LPH -5
 TURBINE SPECIFICATION

Steam Admission Parameters at Turbine Inlet

HPT IPT LPT

Pressure (bar) 242 44.9 11.6
Temp (Deg C) 566 566 383.5
Steam Flow (tph) 1994.25

No of Stop valves 2 2
No of Control valves 4 2
TURBINE CONSTRUCTION
TB
HPT IPT
No. of Journal bearings
Type
Thrust Bearing Type
Max shaft vibration &
bearing housing
Type of Coupling
LPT A LPT B
- 6
- HIP Tilting Pad
LP Elliptical Type
- Tapered-land type
- 125 microns
- Rigid Coupled with bolts
 TURBINE CONSTRUCTION

FEATURES OF 660 MW TURBINE

Combined HP & IP Section

Shorter Turbine Length

Reduced No.of Bearings thereby Mech losses

Reduced No. of Packing segments thereby reduced leakage loss & maintenance

Smooth Distribution of Temp Gradient

Thrust force balanced Easier.

Impulse type Turbine

Little Steam Leak around the blades

Greater axial clearance, thus capable of withstanding transient conditions

Requirement:

To lift Turbine Rotor During Turning Gear Operation

System Envisaged to Fulfill The Above Requirement:

1X100 % AC Driven Jacking Oil Pump

1X100 % DC Driven Jacking Oil Pump
SEA WATER SYSTEM
 Water balance diagram

3/ hr Sea water
m Sea water
8 06
8 reservoir

S 661

Effl
wa ea 1m
ter
tak in 3/h

uen
pum e
r
hou p

t
se 43m

p
3/hr

l ant
D.M plant
8806

waste
r water(43m3/hr

r
3/h
m

3/h
m )
440
3/hr

m
21
61
er
acc Mec tow
ele han g
rat i o lin 2200
ed cal Co
cl a m3/h
rifi
er r
8366m3/hr 156
m3 Evaporative
losses
/h
124 cum/hr from fresh
r
water sys.
Drift losses
 Over view of water system of phase-III
Intake Water Reservoir (sea water)

8806 m3/hr

Desalination plant (PMC scope)

Make water system
381 m3/hr

service water system

Recirculation water
system
D.M water system

Water spray fire fighting system

Hydrant fire fighting system

Potable water supply system

 Make up water system

Sea water intake

reservoir

Vertical turbine pump,

Q=5285m3/hr,H=18m,P=400Kw,3-nos

8806m3/hr

Mechanical accelerated clarifier (Q=1800m3/hr-6nos)

According to the sea water quality ,chemical dose such as aluminum sulfate &
polyacry lamide (PAM) will be added to the clarifier in order to effectually
remove the suspended solids.
The chlorinator equipment will be used for disinfection.

8366m3/hr
440m3/hr

Mechanical draft Blow down water 6121m3/hr

Effluent pit
cooling tower
 service water system
2000 m3 fresh water reservoir 2000 m3 fresh water reservoir

Service water pump,Q-150m3/

hr,H-60Mtr,N-40Kw

To service Water(198m3/hr,250nb)

Consume & stand by water(30m3/hr)

Industrial waste water
treatment system(1m3hr Wash water for car & floor(2m3/hr)
loss)
Ash handling air compressor cooling
Make up water water(60m3/hr)
to cooling tower
basin128m3/hr) Mechanical air compressor cooling
water(100m3/hr)

Wash Moisten Wash

Bottom For Coal Coal storage area
ASH
SSC water for ing water for spray water(6m3/hr)
Seal HAVAC clinker water
hopper coal water
seal
water( system- floor(2m3/ treatment
3m3/h handling for dry Spray water for bunker
water(3 (8m3/hr hr loss) system(6 wheel
r) system(2 ash(9m
m3/hr) ) m3/hr) machine(3m3/hr)
m3/hr) 3/hr)
 TOTAL WATER REQUIREMENT
FOR Ph-III & Ph-IV

Sea water make up : 8608+13804 = 22412 cum/hr

Back to sea through ETP: 6611+10104= 16715 cum/hr

Fresh water reqmt.(from De-sal. Plant) : 371 +548= 919 cum/hr

 Waste water treatment System

1. Sanitary sewage treatment system

This system function is to send the sewage to the sewage treatment
equipment, in which the sewage is treated to remove the suspended
solid, colloidal substance, soluble organic matter and to eliminate the
pathogenic bacteria

2. Coal wastewater treatment system

Storm water runoff from the coal handling area and Coal Handling Plant
is collected in a set of coal settling pond. Coal fines, which accumulate in
the basin over time, must be periodically removed. These are stacked-
out adjacent to the pond for dewatering, and returned to the coal pile.
The rain water will be pumped into the coal wastewater treatment
system and will be reused in the plant.

3. Industrial wastewater treatment system

Industrial wastewater system collects variety of wastewater, which is
produced in the course of daily life and production activities. The water
will be treated by the Industrial wastewater treatment system and then
be reused.
 Sea water
Sea water

Sea water in

43
take reservoir

38
0m
6611m3/hr

3/
Vertical turbine pump,
Sea water in

hr
Q=5285m3/hr,H=18m,P=400K
w,3-nos take reservoir

8806m3/hr
Mechanical C.W
accelerated clarifier 440m3/hr pump,Q-43380m3/
(Q=1800m3/hr-6nos)
Effluent pit hr,H-29.82mP-4800
kw,3nos

8366m3/hr
Auxiliary equipment Condenser cooling
Blow down water 6121m3/hr cooling water water
Mechanical draft
cooling tower 43380m3/hr

C.W pump,Q-43380m3/hr,
H-29.82mP-4800kw,3nos

Auxiliary equipment Condenser cooling

cooling water water
DM PLANT
 What is DM Water?

Demineralization of water is removal of

cautions & anions known as TDS( Total
dissolved solids ) of all minerals.
 Outlet water quality
Inlet water quality PH= 8 to 7.2
PH- 5-6 D.M plant flow diagram Turbidity<1NTU
T.D.S - <500ppm Free chlorine Nil
T.S.S=Nil Conductivity
Sodium+ <0.1Micromhos/cm
potassium=<150ppm Sodium as Na= <1ppm
Sulphate=<20ppm Free CO2<5ppm
Chloride<250ppm Total silica <0.02ppm
Silica=<1ppm

Reducing agent dosing D.M water tank Condenser

Caustic & acid dosing
storage
tank
precision filter Mixed ion exchanger ,V=300m3
Q=110m3/hr 2200,Hcation-500mm,
Hanion-500mm
High pressure pump DM water pump
Q=110m3/hr,H=1.35Mpa Q=120m3/hr,H=0.4Mpa-2nos
Q=300m3/hr,H=0.5Mpa-1nos
Cleaning agent dosing caustic dosing
Anion exchanger
Reverse osmosis
Q=80m3/hr

Intermediate water pump

Decarbonator Q=90m3/hr,H=0.4Mpa

Fresh water tank Acid dosing

V=300m3 Cation exchanger

Fresh water pump

Q=90m3/hr,H=0.3Mpa
 Chemical Reactions in SAC
Operation
CaCO3 + 2 R-H+ R2-Ca+2 + H2CO3
Na2CO3 + 2 R-H+ 2R-Na+ + H2CO3
Regeneration
2HCl + R-Ca+2 2 R-H+ + CaCl2
R-Na+ + HCl 2 R-H+ + NaCl
 Chemical Reactions in SBA
Operation
Cl- + R-OH- H2O + R-Cl-
2(HSiO3) + 2R-OH- 2(HSiO3)R +2H2O
Regeneration
2Cl--R + 2NaOH 2 R-OH- +2NaCl
2(HCO3-)R + 2NaOH 2R-OH- + 2NaHCO3
 Process Flow Diagram for Conventional DM Plant for Adani Power Ltd. , Mundra SEZ

Bulk Acid
Filter water B/W Storage
Water Tank
Storage Tank
Tank
DM Water Supply
Pumps (3W+1S) Acid Unloading &
Strong Acid Transfer Pump
(1W+1S)
60 m3/hr
Cation 30% HCl for
60m3 /hr 60m3 /hr Activated Exchanger
Pressure regeneration Acid
Sand Filter Carbon Filter Measuring
Sodium Hypochlorite (2W+1S) (2W+1S) Tank for SAC
Degasser Blower
Dosing Pump-I
(1W+1S)
(1W+1S)
Air Scouring Blower (1W+1S)

Degasser Degasser Tower Acid

Storage tank Measuring
Degassed Water
Sodium Hypochlorite Tank for MB
Transfer Pump
Dosing Pump-II
(3W+1S) [
(1W+1S)
Neutralization
Mixed Bed Blower
(1W+1S)
Pit (2)
Sodium Service
Hypochlorite Water Caustic
Effluent Transfer
Dosing Tank Overhead Measuring Pumps (1W+1S)
Weak Base 60m3 /hr Strong Base Mixed bed
Tank Tank for MB
Anion Anion 60m3 /hr Exchanger
Exchanger Exchanger ETP

45% NaOH for

regeneration Caustic
Measuring
Tank for SBA Caustic Unloading
Pump (1W+1S)

DM Regeneration Pumps
(1W+1S) DM Water Storage
Tank
Bulk Caustic
Condensate Storage Tank
Storage
Tank Condensate Water
Transfer Pumps
(1W+1S)
DM PLANT
TDBFP & MDBFP
SYSTEM
Requirement
To pump feed water from deaerator to
Boiler
Type of BFP
Horizontal
Barrel type outer casing
Multistage

Configuration of BFP
For 500MW
2x50% TDBFP & 1x50% MDBFP
For 200MW
3x50% MDBFP
Requirement:

To pump feed water from Deaerator to boiler through HP Feed water

heaters.

Options Available

1X100% TDBFP 2X50% TDBFP 3X33% TDBFP

& & &
1X100% MDBFP 1X50% MDBFP 1X33% MDBFP
 Meets IBR requirements of two independent
source
Incase one running TDBFP is out, full unit
load can be maintained with 50% MDBFP.
Can facilitate cold as well as hot unit start ups
Unit Start up is faster.
Better availability and Operational flexibility.
THE BOILER FEED WATER PUMP
Efficiency of generator = 98% (Say)
Efficiency of UAT= 97% (Say)
Efficiency of Elect. system = 98% (Say)
Efficiency of BFP Motor = 97% (Say)
Efficiency of Hyd. coupling = 87% (Say)
Total percentage utilisation when MDBFP used= 78.6%
(0.98 X 0.97 X 0.98 X0.97 X 0.87 = 0.786)
Power consumed by two TDBFP = 15 MW (approx.) ??
Saving in MW when TDBFP used = 3.21 MW
(15 X (1-0.786) = 3.21 MW)
 TD BFP

TD BFP Turbine Parameters

TDBFP NOS 2X50%

STEAM PRESSURE Mpa 1.018
STEAM TEMP. Deg C 353.9
STEAM FLOW TPH 108.4
 TD BFP

Numbers Nos 2x50%

Rated Capacity Cum/Hr 1150

Suction Pressure Kg/Cm2 12(a)

Discharge Pressure Kg/Cm2 250(a)

NPSH Required mlc 36

Pump Efficeincy % 82
 TD BFPs BOOSTER PUMP

Numbers Nos 2x50%

Rated Capacity Cum/Hr 1150

Suction Pressure Kg/Cm2(a) 0.8

Discharge Pressure Kg/Cm2 (a) 12

NPSH Required mlc 3.8

Pump Efficeincy % 80

Motor Rating kw 540

 Gain in Heat Rate When TDBFP Used
When TDBFP used
Heat rate (as per EPDC) for 660 MW TG 1900 Kcal/kwhr
When MDBFP used
Additional power required to be generated = 3.21MW
Net Generator output =(660 + 3.21) MW
= 663.21 MW
Total Heat addition in the system 663.21 X 1900 M cal
Saving in HR with TDBFP = {(663.21 X 1900)/660} - 1900
= 9.24 kcal / kwhr
~ 9 - 10 kcal / kwhr
TDBFP
 MD BFP

MDBFP NOS 1X35%

Motor Capacity Kw 12000

MDBFP