Total Sheets
PP 067 M B01 0
Document No.
DDC 067
146
BB
SRG
PKC/
ABT
BB
C&I
Civil
QA
First Issue
Status
DEC
THERMAX LTD.
CHOUDWAR, ODISHA
OWNERS
CONSULTANT
KOLKATA
PROJECT
Appd
Elec.
Description of
Revisions
PKC/
ABT
Mech.
Date
SRG
Ppd
Rev
Client Submission
PM
05.12.09
Approval
Appd
Revised as marked
Ckd
20.01.09
Ppd
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
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Sheet
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POWER PLANT, IMFA,
ORISSA
PP 067 M B01 0
INTRODUCTION ...............................................................................................9
2.
3.
4.
4.3.1.
4.3.2.
Coal Analysis..................................................................................................... 18
4.3.3.
4.3.4.
4.3.5.
4.3.6.
5.
5.1.
5.1.1.
Power House..................................................................................................... 24
5.1.2.
Boiler Area......................................................................................................... 25
5.1.3.
5.2.
5.3.
5.3.1.
5.3.2.
5.4.
5.5.
5.6.
6.
POWER DIVISION
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Document Title
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POWER PLANT, IMFA,
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PP 067 M B01 0
6.1.
6.2.
6.3.
6.4.
6.5.
GENERAL .....................................................................................................28
TURBINE ......................................................................................................29
GLAND STEAM SYSTEM.................................................................................30
TURBINE DRAIN SYSTEM ...............................................................................31
TURBINE LUBE OIL SYSTEM...........................................................................32
6.5.1.
6.5.2.
Oil Coolers......................................................................................................... 32
6.5.3.
Oil Pumps.......................................................................................................... 33
6.5.3.1.
6.5.3.2.
6.5.3.3.
Overhead Tank........................................................................................................33
6.5.4.
6.5.5.
6.5.6.
6.6.
6.7.
6.8.
6.9.
7.
7.1.
7.2.
7.2.1.
7.2.2.
7.2.3.
7.2.3.1.
Furnace ....................................................................................................................41
7.2.3.2.
7.2.3.3.
Headers ....................................................................................................................42
7.2.4.
Superheaters..................................................................................................... 42
7.2.5.
7.2.6.
Economiser ....................................................................................................... 43
7.3.
7.3.1.
7.3.2.
7.3.3.
POWER DIVISION
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PP 067 M B01 0
7.3.4.
7.3.5.
Velocity Profile................................................................................................... 47
7.3.6.
7.3.6.1.
7.3.6.2.
7.3.7.
7.4.
7.4.1.
7.4.2.
7.4.3.
7.4.4.
Superheater....................................................................................................... 50
7.4.5.
7.4.6.
Economiser ....................................................................................................... 50
7.5.
7.5.1.
7.5.2.
7.5.3.
Fluidized Bed..................................................................................................... 52
7.6.
7.7.
7.7.1.
Draft System...................................................................................................... 52
7.7.2.
7.7.3.
7.7.4.
7.7.5.
7.8.
7.8.1.
Structural Steel.................................................................................................. 58
7.8.2.
7.9.
7.9.1.
General.............................................................................................................. 58
7.9.2.
7.9.3.
External Insulation............................................................................................. 59
7.9.4.
7.9.5.
7.10.
7.11.
7.12.
POWER DIVISION
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7.13.
7.14.
7.14.1.
7.14.2.
7.14.3.
8.
8.1.1.
8.2.
8.2.1.
Deaerator .......................................................................................................... 66
8.2.2.
8.2.3.
8.2.4.
8.2.5.
8.3.
8.3.1.
8.3.2.
8.3.3.
8.3.4.
8.3.5.
8.3.6.
Make-up Water................................................................................................. 79
8.3.7.
9.
9.1.1.
9.1.2.
9.1.3.
9.1.4.
9.1.5.
9.1.6.
9.1.7.
9.1.8.
9.2.
9.2.1.
9.2.1.1.
POWER DIVISION
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9.2.1.2.
9.2.2.
9.2.2.1.
9.2.2.2.
9.2.3.
10.
11.
11.1.
11.2.
12.
12.1.
13.
13.1.1.
13.1.2.
13.1.3.
13.2.
13.2.1.
13.2.2.
13.2.3.
14.1.
14.2.
14.2.1.
14.2.2.
14.3.
15.
13.1.
14.
15.1.
15.1.1.
Air Conditioning System for Central Control Room & Associated Areas ..... 113
15.1.2.
15.2.
POWER DIVISION
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16.
16.1.
16.1.1.
Ventilation System for Power House Building & associated Areas.............. 117
16.1.2.
16.2.
17.
17.1.
17.1.1.
17.1.2.
17.1.3.
17.1.4.
17.1.5.
18.
19.
ELEVATORS.................................................................................................127
20.
ENVIRONMENTAL CONSIDERATION.........................................................127
20.1.
20.2.
21.
21.1.
21.2.
21.3.
21.4.
21.5.
21.6.
21.7.
21.7.1.
21.7.2.
21.7.3.
POWER DIVISION
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21.12.
21.13.
21.14.
21.15.
21.16.
21.17.
EFFLUENT ...............................................................................................137
SERVICE AND POTABLE WATER PIPE LINE ...................................................138
CONDENSER COOLING WATER PIPING ........................................................138
AUXILIARY COOLING WATER PIPING ...........................................................138
FIRE WATER PIPING .................................................................................138
VALVES...................................................................................................138
21.17.1.
21.17.2.
21.18.
22.
ANNEXURES ................................................................................................142
22.1.
22.2.
22.3.
22.4.
POWER DIVISION
1.
THERMAX LIMITED
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INTRODUCTION
This document aims at establishing the criteria for basic and detail
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10
Degree Celsius
kg/cm2 (g)
kV
Kilo Volt
kW
Kilo Watt
MLC
MW
Mega Watt
MWC
No.
Number
Nos.
Numbers
TPH
2.2. ABBREVIATIONS
ACW
AHP
CEP
CHP
CV
Control Valve
DBR
DM
De-Mineralised
HP
High Pressure
IPP
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11
3.
LP
Low Pressure
MB
Mixed Bed
MCW
MOC
Material of Construction
MSL
PRDS
PRV
Re
Reynolds Number
RL
Reference Level
RO
Reverse Osmosis
SAC
SBA
SHP
STG
TDH
UF
Ultra Filtration
BFP
regulations of the Central / State Government and relevant Statutory bodies of the
government.
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12
DIN Standards
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13
Petroleum Act
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14
reliability.
4.
5oC temperature at the Main Steam Stop Valve using fuel as per Coal
Analysis mentioned elsewhere in this document. The boiler envisage desulphuring using lime stone as per lime stone analysis mentioned
elsewhere in this document.
Two (2) number Electro Static Precipitator (ESP), one each per
boiler, each ESP will have single stream of 100% gas path, designed for
dust concentration at ESP outlet of 50 mg/Nm3 with one field out of
operation.
Two (2) number single-flue Steel Chimney one for each boiler. The
height of the chimney will be restricted to 44 m.
Two (2) number STG: Multi-stage, single flow, condensing type Steam
Turbine Generator, with five uncontrolled extraction for regenerative
heating, generating 60 MW at 11 kV voltage level with an inlet steam at
98 kg/cm2 (a) pressure and 535oC temperature before emergency stop
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Boiler feed water pumping system with 3 x 100 % Motor driven boiler
feed water pumps. Out of these three pumps, one will be operating
normally for each boiler unit while the third pump shall remain as a
common standby and will come into operation automatically in case one
of the working pump fails.
One Main Cooling Tower for both units with 7 cells (6 working & 1
standby) induced draft counter flow design and RCC / Pultruded FRP
One Auxiliary Cooling Tower for both units with 2 cells (1 working & 1
standby) induced draft counter flow design and FRP / Pultruded FRP
construction and auxiliary cooling water pumping system.
Note : Both for main and auxiliary cooling tower as an alternative to RCC,
pultruded FRP structure as part CTI USA may be used. In either
case, cooling tower basin & fore bay etc. will remain as RCC only.
Water system consists of raw water supply pumps pumping raw water
from raw water reservoir, water pre-treatment plant & DM water system,
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16
Fire protection system for the power plant, transformer area, fuel oil
area, switch yard area, coal handling area and ash handling area.
Item
Description
POWER DIVISION
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17
Sr.
No.
Item
Description
1.
Project Title
2.
Location
3.
Nearest Town
4.
Nearest City
Cuttack 12 KMs.
5.
Nearest Port
Paradeep
6.
Charbatia 12 km away
7.
Nearest Airport
8.
Fuel Availability
9.
Coal Transportation
By Coal Conveyors
10.
Water Source
11.
Meteorological Data
a.
Site elevation
b.
Ambient Temperature
50 Deg.C.
c.
1475 mm
d.
Average
humidity
relative
62%
e.
84%
f.
46%
Mean
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Sr.
No.
Item
Description
g.
Type of atmosphere
h.
Annual
Velocity
i.
j.
k.
l.
Wind Direction
South to North.
Seismic Data
m.
Mean
Wind
6.4 Km/hr
RANGE
BLENDED COAL
(DESIGN BASIS)
Performance Coal
(%) (50% ROM 50% Reject)
Carbon
33.73
19.50
26.62
Hydrogen
2.35
1.90
2.13
Oxygen
5.77
4.50
5.14
Sulphur
0.37
0.30
0.34
Nitrogen
0.78
0.80
0.79
Ash
42.00
60.00
51.00
Moisture
15.00
13.00
14.00
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TOTAL
100.00
100.00
100.00
GCV (Kcal/Kg)
3280.00
2010.00
2645.00
PROXIMATE ANALYSIS
Ash
42.00
60.00
51.00
Volatile matter
21.00
14.00
17.50
Moisture
15.00
13.00
14.00
Fixed carbon
22.00
13.00
17.50
Total
100.00
100.00
100.00
COAL SIZE
Feed Coal size at Grizzly of Ground
90 % below 100 mm.
Hopper by Customer
4.3.3. ASH ANALYSIS :
ELEMENTS
Alumina as Al2O3
28-30
20.65
Calcium as CaO
0.5-0.7
1.44
Chlorides as Cl
0.12
Iron as Fe2O3
3-5
6.21
Magnesium as MgO
0.2-0.4
0.41
Phosphorus as P2O5
0.4-0.5
0.24
Potassium as K2O
0.5-0.7
0.59
Silica sa SiO2
60-65
64.2
Sodium as Na2O
0.05-0.1
0.8
Sulphur as SO3
0.2-0.4
0.18
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Titanium as TiO2
1-2
2.32
< 0.01
0.02-0.04
0.12
Zinc as ZnO
0.02
Loss on ignition
2.11
oxide
as
% BY WT. (RANGE)
MgCO3
0.5 1.0
SiO2
1.0 1.5
Inert
3.5 4.5
> 3.3
Attrition Index
< 2.6
Nature
Soft, Powdery
Unit
Range
Silica
65 68
Al2O3
25 28
FeO
0.95 1.1
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TiO2
1.5 1.7
MnO
Traces
CaO
0.5 0.6
MgO
0.2 0.25
P2O5
Na2O
K2O
Unit
% Passing
< 500
100
< 400
90
< 300
50
< 250
10
Unit
Range
1.
Source
Mahanadi River
2.
Calcium
mg/l as CaCO3
31 35
3.
Magnesium
mg/l as CaCO3
13 15
4.
Sodium
mg/l as CaCO3
28 32
5.
Total Cations
mg/l as CaCO3
72 82
6.
Sulphate
mg/l as CaCO3
9 14
7.
Chlorides
mg/l as CaCO3
11 15
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8.
Bi- Carbonates
mg/l as CaCO3
52 60
9.
Total Anions
mg/l
72 89
10.
Iron as Fe
mg/l as CaCO3
0.8 1.0
11.
Silica (Reactive)
mg/l as SiO2
8.0 10
12.
M- Alkalinity
mg/l as CaCO3
52 60
13.
Turbidity
NTU
184 200
14.
mg/l
170 190
15.
mg/l
70 80
16.
pH value at 25oC
17.
Conductivity at 25oC
18.
Colloidal Silica
19.
COD
mg/l
Traces
20.
BOD
mg/l
Traces
7.6 7.8
S/cm
mg/l as SiO2
137 150
NIL
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POWER DIVISION
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c) Cooling tower
d) Compressor room
f) DG room
5.1.1. POWER HOUSE
The Power House will include:
Steam Turbine Generator & auxiliaries which includes condenser, CEPs,
LP & HP heaters, Deaerator, BFPs, steam jet ejectors, gland steam condenser etc.
located in the Steam Turbine Hall.
Power house building size shall be 87 m x 31.5 m devided into AB bay
(20.5 m wide) & BC bay (11 m wide). AB bay shall have 3 floor elevations i.e.
ground floor at 0 m, mezzanine floor at 4.5 m & operating floor at 10 m. BC bay
shall have 4 floor elevations i.e. cable spreader floor at 0 m, swithgear floor at 4.0
1
Two (2) nos. Steam Turbine Generator will be located in the turbine hall of
78 m length and 20.5 m span (width) at operating floor (10 m).
2.
3.
The STG unloading and maintenance area has been provided on the
turbine side of Unit No 1.
4.
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5.
The crane rails elevation of the turbine hall shall be selected based on
turbine height and crane clearance required above turbine.
6.
The vertical can type Condensate Extraction Pump will be located adjacent
to the Condenser on the ground floor.
7.
The Lube Oil System will be located at mezzanine floor (4.5 m) level on
turbine side.
8.
The Deaerator will be mounted on the roof of the control building i.e. at
Deaerator floor level (15 m). The Deaerator foundation design will take into
consideration any possible vibration due to steam chugging.
9.
The boiler feed pumps shall be located within the power house at ground
floor (0 m). Vertical HP & LP heaters are also located on ground floor.
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POWER DIVISION
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POWER DIVISION
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STEAM TURBINE
6.1. GENERAL
The steam turbine generator (STG) unit is designed to operate as at a base
load and in parallel with grid. During disturbances in the electrical grid, the unit is
capable of operating in an island mode catering to its own house load (about 10%)
with bypass system in operation. These disturbances will not cause tripping of
steam generator.
The steam turbine has designed to meet the requirements of the latest IEC
Standard Publication No. 45. The steam turbine is designed for quick start-up
rates and to withstand rapid load fluctuations without causing undue thermal
stresses and strains in the components of steam turbine.
The various components of the STG are described below.
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6.2. TURBINE
The Steam Turbine will be of horizontal, single casing impulse-reaction with
axial flow multistage construction. The Turbine will be designed with five bleeds,
for the regenerative heating requirement in LP Heater, Deaerator and HP Heater.
Steam Turbine Casings & Admission Valves
The turbine casing is horizontally split. The upper and lower casing halves
are flanged and assembled by bolts. Steam flow through the turbine is in the axial
direction. After leaving the body of the emergency stop valve, the live steam
enters the valve chest with the control valves which forms an integral casting with
the upper half of the outer casing. The valve chest is designed as a transverse
tube with openings at both ends for assembly.
The turbine casing is divided into an admission and an exhaust section.
Depending on the initial steam conditions, the admission sections of comparable
size are designed with castings of different wall thickness. The admission section
will be completed by an exhaust section of adequate size. The overall length is
adjusted by cylindrical or conical spacer rings.
A hydraulically Operated Emergency stop valve shall be provided for
closing the supply to the Turbine under emergency condition.
Steam Turbine Rotor & Blading
The turbine rotor is integral with the disk of the control-stage wheel and is
forged from a solid blank. Except for the control stage, the blading is of the
reaction type. The moving blades have their root, shaft and shrouding milled from
the same solid forging. Only exception to this rule are the twisted blades of the
low-pressure end rows. Because of their wide spacing and thin shaft section it is
impossible to design them with integrally milled shrouding. The moving blades in
the drum stages have roots of the inverted-T type. Normally, only the roots of the
control-stage blades are forked. But occasionally the last row of low-pressure
blades, depending on the centrifugal stress to which they are subjected, may be
designed with forked roots, too.
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The guide blades are manufactured from drawn bar material and have
pronged roots. The guide blade tips are fitted with riveted shroud strips.
Bearings
By its brackets, the outer casing is supported on the two bearing pedestals
independently from the bearing housings. The vertical position of the outer casing
is determined by adjustable positioning elements located between the brackets
and the supporting plane of the pedestals. The clearance left between the
underside of the assembly-bolt head and the bracket allows for both axial and
lateral expansion of the outer casing with respect to the pedestal. The central
position is ensured by guideways in the bottom half of the casing. They leave the
casing free to expand also in the vertical direction. The fixed reference position of
the casing is at the rear end support brackets. The casing is thus free to yield to
thermal expansion by moving forward on special slide elements between the frontend brackets and the front bearing pedestal. The turbine rotor is supported in the
bearing housings and is radially independent from the outer casing. The radial
journal bearings are of the multi-wedge type. Two or four oil wedges uniformly
spaced on the circumference hold the rotor in a stable position. The bearings are
babbitt-lined.
The correct axial position of the turbine rotor is ensured by a thrust bearing
incorporated in the front bearing housing. It is intended also for taking up the
residual axial thrust. For this reason it is designed as double-acting bearing of the
segment type. The tiltable bearing segments are likewise babbitt-lined. The
heated rotor expands in the direction towards the exhaust hood. As the turbine
casing with its fixed reference position at the rear pedestal expands into the
opposite direction, the resulting differential expansion will be only small on
condition that rotor and casing are heated to approximately the same temperature.
6.3. GLAND STEAM SYSTEM
Shaft outer and interstage glands shall be of the contactless labyrinth type.
The labyrinth rings with the machined sealing collars and recesses shall be split in
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multiple segments that would be pushed in the working position by the flat springs
and by the steam pressure. The stator labyrinth rings segments can be pushed
away from the rotor in case of accidental contact and the rubbing of rotating and
stationary parts can be minimised. The shaft shall have in the gland sections
caulked sheet fins that together with the stator collars form the small chambers of
the labyrinth gland.
During normal operation, the source of sealing steam is from the turbine
itself. During start-up and low loads, an alternative source of sealing steam is
provided from the main steam.The front outer gland shall be fed from a pressurecontrol valve, which shall receive the steam from the main steam line. The rear
outer gland seals during the normal operation permanently face the vacuum inside
of the turbine casing and must be therefore continuously fed by the steam. The
feeding steam shall be taken from the front gland leakage. The leakage steam
from outer labyrinths shall go to the Gland Steam Condenser (GSC). The gland
sealing supply control valve shall be controlled by a pressure transmitter located
on gland steam supply header.
Last sections of both front and rear outer glands shall be slightly below
atmospheric pressure. The gland steam condenser shall keep the pressure in the
last sections lower than atmospheric and to ensure that there is no leak of steam
from the glands in the machine room.
The condensate collected from the Gland steam Condenser shall be sent to
the main condenser and the non-condensable gases shall be vented to the
atmosphere.
6.4. TURBINE DRAIN SYSTEM
During every start-up, it shall be ensured that the drain valves provided on
1
the turbine HP & LP casing, balancing line, gland sealing steam header and
extraction steam line are opened to drain the entrapped condensate to avoid
damage due to high-energy water accumulation or ingress.
Drains are provided at the lowest end of the steam lines. Drains from the
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extraction steam lines before the QCNRV connection are connected to condenser.
The downstream of QCNRV, the drains are connected to atmospheric flash tank
and taken out. Vacuum drains are connected to a manifold in the flash tank whose
top nozzle is connected to steam space of the Condenser and bottom nozzle
connected to the hotwell. The high pressure drain is connected farthest from the
condenser, where as the low pressure drains are connected closer to the
condenser. The drain manifold connection will be above the maximum level in the
condenser hotwell.
6.5. TURBINE LUBE OIL SYSTEM
6.5.1. OIL STORAGE TANKS
Each turbine will have one (1) main oil tank designed considering the
complete drain oil from lube oil system & control oil system. The capacity of the
main oil tank is about 14 m3. The main oil tank will be provided with necessary
level indicator, inlet and outlet oil connections and exhaust fan to evacuate oil
vapour from the tanks. Main oil tank is also provided with necessary connections
for oil centrifuge.
The drain oil tank is provided for handling oil during drain of oil cooler, oil
filter etc. The capacity of the drain oil tank is about 1 m3. The drain oil pump will
deliver the oil back to the main oil tank through oil purifier.
6.5.2. OIL COOLERS
Two (2) oil coolers, each designed with adequate margin, horizontally
mounted will be provided with one (1) running and the other stand-by. The lube oil
coolers shall be interchangeable during service without interruption to oil flow. The
oil cooler tube will be of admiralty brass material. The shell and water boxes will
be made out of carbon steel plates of material specification conforming to IS2062.
POWER DIVISION
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Total three (3) pumps of identical capacity i.e. 3 x 100 % have been
provided, each one capable of meeting the total lube oil requirement. One of these
pumps is designated as Main Oil Pump (MOP) and other two as Auxiliary Oil
Pump (AOP). All the three pumps are AC motor driven.
6.5.3.2. Emergency Oil Pump
The turbine will be provided with an emergency oil pump, mounted on top
of oil tank, driven by an AC & DC motor. It will cater to the needs of bearings of
turbine, gearbox and alternator in case of failure of AC motor driven auxiliary lube
oil pump.
6.5.3.3. Overhead Tank
In the event of a turbine trip when A/C power is not available, the
emergency oil pump, driven by DC power will ensure that necessary lubrication oil
is supplied to the turbine bearings for safe coast down. In the unlikely event of
non-availability of DC power also, the oil pressure in the header may tend to go
down. An overhead tank of adequate capacity is provided for each turbine for
supplying oil to the bearing under such events. The oil from the tank will flow by
gravity. The tank capacity will be suitable for safe coasting down of the turbine.
6.5.4. OIL FILTERS
One (1) duplex lube oil filter and one (1) duplex control oil filter will be
provided each with change over device. The lube oil filter & control oil filter will be
capable of filtering oil to a required quality.
6.5.5. OIL MIST FAN
Two (2x100%) oil mist fan will be provided for evacuating oil vapour from
the oil tank.
The fan will be mounted on top of the tank and the discharge to
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escaping oil.
6.5.6. LUBE OIL PURIFIER
An oil purifier will be provided with necessary filters and heater, including
the pump and motors of the purifier system. The purifier is an off-line equipment
meant to clean the oil in the system by partial recirculation (operated for one shift
per day). Desludging of the purifier shall be done manually periodically. The
system will purify the re-circulating lubricating oil from entrained moisture &
suspended solids. The purifier capacity will be 2000 LPM.
6.6. JACKING OIL PUMP
The turbine will have a 1 x 100 % AC motor driven and 1 x 100 % DC motor
driven jacking oil pump for turbine and generator shaft lifting during starting,
designed so as to lift the rotor from standstill condition.
6.7. TURNING GEAR
When the unit is under shutdown for a long period, due to its inherent
weight, the rotor shaft sags. Rolling of the unit with this condition will result in
contact of the moving parts with the stationary parts. Following tripping of the
machine, due to condensation of the locked up steam, the rotor shaft tends to
hog. In order to prevent sagging and hogging of the rotor shaft, a barring gear
shall be provided. The barring device shall be provided with manual engagement
1
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516 Gr.70) construction. The condenser will be designed with 85% cleanliness
factor. The hot well storage capacity will be minimum 3 minutes between normal
and low level at MCR condition.
6.9. MAIN TECHNICAL PARAMETERS OF STEAM TURBINE
(A) At 100 % TMCR Condition
Parameter
Unit
Value
kW
60,000
Ata
98
535
TPH
224
TPH
0.5
Ata
0.1
Exhaust flow
TPH
158.27
Unit
Value
kW
63,000
Ata
98
535
TPH
240
TPH
0.5
Ata
0.1
Exhaust flow
TPH
169.95
Unit
Value
kW
60,000
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Ata
98
535
TPH
219
TPH
0.5
Ata
0.1
Exhaust flow
TPH
166.33
Unit
Value
kW
60,000
Ata
98
535
TPH
210.6
TPH
0.5
Ata
0.1
Exhaust flow
TPH
172.16
Unit
Value
kW
60,000
Ata
98
535
TPH
232.7
TPH
0.5
Ata
0.1
Exhaust flow
TPH
166.8
POWER DIVISION
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Unit
Value
kW
48,000
Ata
98
535
TPH
180.8
TPH
0.5
Ata
0.1
Exhaust flow
TPH
132
Unit
Value
kW
30,000
Ata
98
7.
535
TPH
113.6
TPH
0.5
Ata
0.1
Exhaust flow
TPH
87.1
CFBC) type Natural Circulation, Single Drum, Top Supported, Water tube,
Balanced Draft with Over-Bed fuel feeding system, Suitable for semi-outdoor
installation.
The following is the basis for the design of the CFBC Boiler:
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38
Sl.
No.
Parameters
1.0
Capacity
1.1
2.0
Pressure
2.1
3.0
Temperature
3.1
Unit
Value
TPH
240
Kg/cm2(a)
101
540 5
3.2
% MCR
3.3
158
3.4
225
4.0
Ambient Conditions
4.1
Ambient temperature
35
4.2
Relative humidity
60
5.0
Fuel
5.1
Main fuel
As mentioned below
5.2
Startup fuel
LDO
The boiler is designed for firing following fuels (Refer to coal analysis as
mentioned elsewhere in this document):
1
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POWER DIVISION
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pressure. The boiler is provided with necessary access platform, galleries and
stair case to approach all equipments and pressure part. The boiler top is well
enclosed by canopy with side sheeting / lovers up to drum level. The required
structural supporting steelwork for the boiler, galleries, staircases and outer casing
will be provided for the boiler, auxiliaries, ducting etc.
The boiler has been provided with three storage bunkers for application of
coal (as a main fuel), lime stone (an additive) and bed material.
The fuel feeding system will consist of drag chain feeders and fuel feed
lines. The fluidised bed is located at the bottom most part of the furnace.
The boiler will be provided with two nos. (2 x 60% MCR) ID, SA and PA
fans and the complete air and gas ducting with required dampers and expansion
joints. All the fans will be provided with variable speed fluid coupling.
The feed water system will consist of three (3) nos. (3 x 100 %) motor
driven boiler feed pumps (with variable speed fluid coupling) of which one (1)
1
pump will be working for each boiler unit with third pump as a common standby,
together with complete piping, valves and other fittings.
All required actuators and controls and instrumentation will be supplied.
A brief outline of the various sections of the proposed boiler and auxiliaries
are presented in the following paragraphs.
7.2. BOILER PRESSURE PARTS
7.2.1. ARRANGEMENT OF PRESSURE PARTS
Boiler will have steam drum and be designed for natural circulation with
single pass design. Boiler will be top supported on supporting structure. The
furnace will be formed by fusion welded membrane wall panel on the top of the
furnace & with refractory on bottom of the furnace.
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Furnace
The boiler furnace is in membrane wall construction. The furnace tubes will
be manufactured from carbon steel tubes.
suitably bent for providing peepholes, access doors, and will be welded at top and
bottom to respective side wall top and bottom headers. The furnace tubes will be
suitably sized to allow superheater coils to pass through. The headers shall be
manufactured from seamless pipes. The headers shall be provided with drain
connections, air vent connection and hand holes for inspection as required.
Furnace will have U-Beams for internal primary solid re-circulation. U-
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Divisional Wall
Headers
The headers will be of adequate size and design in accordance with Indian
Boiler Regulations, and the material specification will conform to SA 106
Gr. B / SA 335 Gr. P11 / SA 335 Gr. P22 depending on the fluid temperature. The
necessary drain connections and hand-holes will be provided as required.
The connections to the steam drum and the connections to the headers will
be designed so as to form an integral circuit providing adequate natural circulation
under all operating conditions.
All headers will be provided with extended pipes and end caps welded.
7.2.4. SUPERHEATERS
The superheaters are provided in three sections i.e. wing wall, primary,
secondary superheater. The wing wall superheater receives saturated steam from
drum and is positioned in the radiation zone of the furnace.
Primary and secondary superheaters are convection zone. The super
heater assembly is designed to meet the steam temperature as specified. The
main outlet is from secondary super heater.
7.2.5. DE-SUPERHEATERS (ATTEMPERATORS)
Two (2) nos. of spray type interstage attemperators are provided. The first
stage is between the Primary 1st stage and 2nd stage of superheater, the second
stage is between the primary superheater and secondary superheater. The final
steam temperature shall be maintained within 5oC over specified load range.
The spray water for the de-superheater will be tapped off from the feed
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Unit
Value
Inside diameter
mm
1500
Material specification
SA 516 Gr 70
Shell thick
1
mm
90
Hemispherical
SA 516 Gr 70
(Tangent
to
mm
90
mm
10000
Unit
Value
Primary Superheater
Description
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Tube OD
mm
44.45
Tube thickness
mm
Tube material
Header size
NB
200 / 250
Header thickness
mm
Header material
Secondary Superheater
Description
Unit
Value
Tube OD
mm
44.45
Tube thickness
mm
Tube material
Header size
NB
200 / 250
Header thickness
mm
Header material
Unit
Value
Tube OD
mm
Tube thickness
mm
POWER DIVISION
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Tube material
SA210 GR. A1
Header size
NB
200
Header thickness
mm
Header material
SA 106 GR.B
Attemperator
Description
Unit
Value
Header size
NB
200 / 250
Header thickness
mm
Header material
SA106 GR.B
Risers
Description
Unit
Value
Riser OD
mm
101.6
Riser thickness
mm
Riser material
SA 210 GR.A1
Main downcomers
Description
Unit
Value
Downcomer size
NB
250
Downcomer thickness
mm
Downcomer material
SA 106 GR.B
Superehater
Unit
Value
m2
3027
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Economiser
m2
3561
Airpreheater ( PA + SA )
m2
10003
m2
1441
Unit
Value
Deg. C
35
1.2
Deg. C
140-150
2.1
Super heater In
Deg. C
800-820
2.2
Economizer In
Deg. C
445-465
2.3
Deg. C
290-310
2.4
Deg. C
140-150
2.5
At Chimney
Deg. C
140-150
Steam temperatures
3.1
Steam drum
Deg. C
315-330
3.2
Wing wall in
Deg. C
330-350
3.3
Deg. C
350-370
3.4
De super heater - I In
Deg. C
400-420
3.5
Deg. C
360-380
3.6
Deg. C
445-465
3.7
Deg. C
420-440
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3.8
Deg. C
535-555
3.9
Deg. C
220-230
4.1
Economizer In
Deg. C
220-230
4.2
Economizer out
Deg. C
290-310
Unit
Value
1.1
Sec superheater
Kg/cm2
4.6
1.2
Pri superheater
Kg/cm2
0.95
1.3
Economiser
Kg/cm2
1.19
2.1
Sec superheater
mmwc
2.2
Pri superheater
mmwc
10
2.3
Economiser
mmwc
20
2.4
Airpreheater
mmwc
40
Unit
Value
Flue gas
1.1
Sec. superheater
m/s
6-8
1.2
Pri. superheater
m/s
6-8
1.3
Economiser
m/s
6-8
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1.4
m/s
11-13
m/s
10-12
Unit
Value
Kg/cm2 (g)
119
Kg/cm2 (g)
120
Kg/cm2 (g)
108
Kg/cm2 (g)
105
2
2.1
Airpreheater
Air
Airpreheater
7.3.6.2.
Sl. No.
Description
Quantity
(Nos.)
Value (TPH)
96
48
36
Description
Unit
Value
Kg/hr
64420
Fuel
Performance fuel (50% ROM coal +
50% Washery rejects)
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1.2
ROM coal
Kg/hr
51564
1.3
Washery rejects
Kg/hr
88746
Limestone
2.1
Kg/hr
4030
2.2
ROM coal
Kg/hr
3430
2.3
Washery rejects
Kg/hr
4780
Bed material
Kg/hr
Nil
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7.4.4. SUPERHEATER
-Safety valve (secondary outlet)
-Motor operated main steam stop valve with integral by-pass valve
-Steam outlet check valve
-Start-up vent will be sized for 30% of BMCR capacity.
-Pressure gauges with isolation valves and drain valves
-Sampling valves
-Drain valves
-Air vent valves
-Valves for pressure transmitters and flow transmitters
-Main steam flow nozzle
-Thermocouples
7.4.5. SPRAY WATER LINE
-Spray water regulating valve
-Spray water regulator isolating valves
-Spray water by-pass valve
-Spray water check valve
-Main isolation valve for de-superheater inlet
-Drain valves
7.4.6. ECONOMISER
-Drain valves
-Pressure gauge with isolation valves
-Air vent valves
7.5. SOLID FUEL FIRING SYSTEM
The boiler will adopt circulating fluidised bed combustion system and the
fuel firing system will be designed for `over bed feeding' system. The boiler is
capable of firing the following fuels:
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Description
Basis of
Design
Consumption
of Material per
Boiler, TPH
a)
Fuel bunker
50 % Washery
Rejects + 50
% ROM Coal
(Performance
Fuel) for 16
hrs storage
with 800
kg/m3 fuel
density & 0.9
filling factor
Consumption of
fuel at 100%
BMCR : 64.42
TPH
Bunker
Capacity
Required,
m3
64.42 TPH
x 16 Hrs /
0.8 T/m3 =
1288 m3
(Effective
volume)
Bunker
Volume
Provided,
m3
1600 m3
(Bunker
Capacity
provided
per boiler)
1288 m3 /
0.85 =
1515 m3
(Water
volume)
Note : 1. Bulk density of fuel is 800 kg/m3 & filling factor is considered as 0.85.
2. The bunker will be adequately stiffened and covered at the top, leaving
necessary opening for conveyor chutes.
3. The bunker will be provided with necessary support steelwork from firing floor
level. The design of the bunker should take care of free flow of fuel.
7.5.2. FUEL FIRING SYSTEM
The fuel firing system will be designed to burn maximum particle size of 6
mm with a fine content (less than 1 mm size) not exceeding 35 %.
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For each boiler there are separate bunkers. Fuel is fed into drag chain
feeder. The drag chain feeder speed is controlled through VFD. The outlet of drag
chain feeder is connected to the furnace.
7.5.3. FLUIDIZED BED
The fluidised bed will consist of compartments (sections). Each
compartment will be provided with stainless steel fuel feeding nozzles and
adequate number of stainless steel fluidizing air nozzles fitted on to the distributor
plate.
7.6. OIL FIRING SYSTEM
Three (3) nos. of burners will be installed in the front side of the furnace
panel. Burner will be used for start-up of the boiler. Burner support will be required
till 20% of boiler loading. Each Burner will be 1500 litre capacity and combined
firing capacity will be 25% MCR.
7.7. AIR AND FLUE GAS SYSTEMS
7.7.1. DRAFT SYSTEM
The boiler is designed for balanced draft operation and adequately rated
ID, SA and PA fans are provided. The boiler is equipped with ID, SA and PA fan
along with necessary interconnecting air and gas ducting, dampers etc. Fans
offered will be of simply supported design on bearing pedestal on both sides and
1
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guard.
provided with silencer to meet the noise level. The control shall be
through Inlet Guide vane. SA fan shall be with variable speed fluid
coupling.
Two (2) Primary Air (PA) fan of 60% boiler MCR capacity, boosting hot
air pressure from air heater outlet. The PA fan is centrifugal type with
suitably sized impeller. The fan impeller shall be dynamically balanced
and is complete with inspection door, foundation bolts and guard. The
PA fan shall be provided with silencer to meet the noise level. The
control shall be through Inlet Guide vane. PA fan shall be with variable
speed fluid coupling.
Sizing of ID, SA & PA fan are as follows:
A) ID Fan ( 2 X 60 % MCR)
Unit
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
Capacity of each
fan
60
60
60
60
Altitude
47.38
47.38
47.38
47.38
Sl.
No.
Description
I)
Capacity Details
a)
No. of fan
b)
c)
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d)
Ambient temp.
50
35
35
35
e)
160
140
140
140
f)
kg/s
56.42
52.27
56.42
49.46
g)
Margin on
Capacity
20
h)
ID fan Capacity
kg/s
67.7
II)
Head Details
a)
dP SH
mmWC
15
12
15
12
b)
dP economiser
mmWC
20
17
20
15
c)
dP APH
mmWC
60
50
60
44
d)
dP ESP + MDC
+ U Beam
mmWC
140
117
140
101
e)
dP Ducts +
Dampers
mmWC
25
21
25
20
f)
Chimney
mmWC
10
10
g)
Total dP
mmWC
270
225
270
200
h)
Margin on head
40
i)
ID fan Head
mmWC
380
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
B) SA Fan ( 2 X 60 % MCR)
Sl.
No.
Description
Unit
I)
Capacity Details
a)
No. of fan
b)
Capacity of each
fan
60
60
60
60
c)
Altitude
47.38
47.38
47.38
47.38
d)
Ambient temp.
50
35
35
35
e)
Relative humidity
60
60
60
60
f)
kg/s
16.49
16.06
16.49
15.88
g)
Margin on
Capacity
20
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h)
SA fan Capacity
II)
Head Details
a)
kg/s
19.78
dP Bed
mmWC
430
430
388
421
b)
dP flow
measuring +
OFA + Duct and
Damper +
Silencer
mmWC
560
533
560
522
c)
dP APH
mmWC
50
47
50
47
d)
Total dP
mmWC
1040
1010
1000
990
e)
Margin on head
%
45
mmWC
1375
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
(only on variable
head)
f)
SA fan Head
C) PA Fan ( 2 X 60 % MCR)
Sl.
No.
Description
Unit
I)
Capacity Details
a)
No. of fan
b)
Capacity of each
fan
60
60
60
60
c)
Altitude
47.38
47.38
47.38
47.38
d)
Ambient temp.
50
35
35
35
e)
Relative humidity
60
60
60
60
f)
kg/s
24.76
23.59
24.76
23.20
g)
Margin on
Capacity
20
h)
SA fan Capacity
kg/s
29.71
II)
Head Details
a)
dP Bed
mmWC
1000
912
875
906
b)
dP flow
measuring +
mmWC
125
114
125
110
POWER DIVISION
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Project
Document Title
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POWER PLANT, IMFA,
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PP 067 M B01 0
56
Silencer + Duct
and Damper
1
c)
dP APH
mmWC
60
54
60
53
d)
dP bubble cap
mmWC
400
360
400
351
e)
Total dP
mmWC
1585
1440
1460
1420
f)
Margin on head
%
45
mmWC
1920
(only on variable
head)
g)
SA fan Head
12 m/sec upto Air Pre-heater & 16 m/sec after Air Pre-heater for flue gas
applications. The ducts will be rectangular in cross section and will be of welded
construction, properly stiffened and reinforced. All ducts handling air and flue gas
will be fabricated with carbon steel plates of thickness not less than 5 mm for air
and for flue gases, 6 mm upto Air Pre-heater & 8 mm from Air Pre-heater outlet to
stack. The carbon steel plates will be as per IS:2062. Alloy steel ducts will be
provided, at regions where flue gas temperature exceeds 450C. Duct corners will
have stitch weld internal and external full weld.
Internal struts will be provided for ducts if required, these will be generally
of tubular truss work, at load transferring points heavier truss work will be
provided. Internal struts will be of ERW tubing. The ducts will be provided with
necessary supporting either from the ground or from the boiler supporting steel
work depending on the locations.
Expansion joints will be provided as applicable and will be made of carbon
steel / alloy steel sheets / fabric (non metallic) as applicable.
Necessary dampers will be provided, complete with actuators, visual
position indicators and means of securing as required by the design.
POWER DIVISION
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57
tubes.
The clean air passes through tubes and those tubes are surrounded by hot
flue gases which help to increase the temperature of air. This hot air is used in
boiler to help combustion process.
7.7.4. ASH RECYCLE SYSTEM
Mechanical Dust Collector (MDC) is positioned in the exit of Economiser.
The ash collected in the MDC will be recycled through three
(3) sets of air slides inside the furnace. The ash recycle quantity will be based on
boiler load, operating bed temperature and type of fuel fired.
A fraction of ash will be taken out of the system and disposed by ash
handling system.
7.7.5. ASH DISCHARGE SYSTEM
Bed ash will be periodically drained through the discharge pipes. Bed drain
pipes is provided to drain ash through ash cooler and to maintain the correct bed
height. In addition to this, drain points are provided in the distributor level to drain
out the entire material, if required.
The fly ash collected in the boiler bank / economiser hoppers, air heater
hoppers and ESP hopper shall be delivered to the ash conveying system. One (1)
bypass line will be given in each hopper upto the ground level to discharge the
ash collected, manually.
POWER DIVISION
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POWER PLANT, IMFA,
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58
All structural steel will be designed for horizontal seismic forces as applicable
under the latest Revision of IS 1893 and wind forces as per latest revision of IS
875, whichever governs the design. All structural steel work will be designed as
per IS 800 and material specification conforming to IS 2062. The structure will
incorporate necessary lifting beams and hoist blocks required for maintenance of
fans, pumps etc.
7.8.2. PLATFORM, STAIRWAYS AND GRATING
A complete system of platforms around boiler at feed water control station,
at fuel feeder floor etc. will be provided and stairways will be provided to enable
access to various parts of the boiler. The stairways will be provided on one side
of the boiler upto drum floor (37.8 m) and other side of boiler upto working
platform floor (5.2 m). Handrails will be provided for all stairways and platforms as
per relevant engineering standard and also as required by Inspector of Factories.
Boiler platform & stair case width will be minimum 900 mm.
7.9. REFRACTORY AND INSULATION
7.9.1. GENERAL
The boiler will be complete with all the necessary castable refractory and
refractory bricks and blocks as required for the furnace and generator bank areas,
together with all the necessary insulating blocks, bricks and mattresses and all the
requisite fixings, holders and other attachments. The refractory and insulation
materials will comply with the relevant Indian standards.
POWER DIVISION
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59
POWER DIVISION
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Project
Document Title
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60
etc.
7.11.SAMPLING LINES
The sampling lines and sample coolers will be provided for feed water,
1
Unit
Performance
Fuel
Washery
Rejetcs
ROM Coal
POWER DIVISION
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Document Title
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POWER PLANT, IMFA,
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PP 067 M B01 0
61
m3/sec
124
134
117
140
140
140
CO2
% v./v.
13.31
12.62
13.70
H2O
% v./v.
14.07
16.16
12.87
N2
% v./v.
69.54
68.20
70.32
O2
% v./v.
3.06
3.00
3.1
SO2
% v./v.
0.0064
0.0074
0.0056
Kg/Nm3
1.2875
1.2732
1.2957
Dust concentration at
ESP inlet (wet)
gm/Nm3
70
70
70
Dust concentration at
ESP outlet with one
field out of service
mg/Nm3
50
50
50
Suction pressure at
MCR
mmWC
- 310
- 310
- 310
Maximum suction
mmWC
- 400
- 400
- 400
Number of fields
10
Number of sections
(flue gas path)
THERMAX LIMITED
25 m/sec exit gas velocity at TMCR operation of the plant. The bottom of chimney
will be provided with a manhole for removal of ash and approach to chimney. For
the purpose of maintenance / repair of the chimney, necessary access ladders,
hand rails (with protection cage for cat ladder), platforms, etc will be provided.
POWER DIVISION
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POWER PLANT, IMFA,
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PP 067 M B01 0
62
Particulars
Units
Value
Kg/Hr
64420
Sulphur Percentage
0.34
Kg/Hr
219.0
89.6
Sulphur at Stack
Kg/Hr
22.7
Kg/Hr
45.5
44.0
Particulars
Units
Value
Kg/hr
344400
Gas Temperature
Deg. C
140
m /Kg
1.18
m /hr
407257
m2
7.1
Calculated
portion
m/s
16
2.4
m2
4.5
10
Velocity
m/s
25.0
Gas
velocity
for
Straight
Note : Height of the Bottom Conical portion & base diameter of chimney will
be decided from Structural Stability
POWER DIVISION
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63
7.14.3.SKETCH OF CHIMNEY
8.
Steam from each boiler with steam parameter 101 kg/cm2 (a) pressure
1
POWER DIVISION
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64
POWER DIVISION
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Project
Document Title
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65
POWER DIVISION
THERMAX LIMITED
Project
Document Title
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66
POWER DIVISION
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Document Title
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67
1)
Deaerator
a)
Type
b)
264 TPH
c)
Operating temperature
158 deg C
d)
Operating pressure
6 ata
e)
Deaerator operation
Sliding pressure
2)
a)
Diameter
b)
Length
c)
Storage capacity
44 m3
POWER DIVISION
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68
non-return valves and automatic minimum flow recirculation (ARC) valves to cater
for start-up and low flow conditions, gland sealing and bearing cooling pipe work,
valves, pressure and temperature indicators.
The feed pumps will be provided with minimum flow automatic recirculation
lines and will discharge to deaerator via isolating and non-return valves. The
pumps will be supplied with necessary suction and discharge lines.
Motorised valves will be provided at the discharge of the boiler feed water
pumps. The suction lines for the feed pumps will be tapped from a nozzle of the
deaerator, at a suitable elevation. Isolating valves will be provided at both suction
and discharge ends with pressure gauges. A check valve will be provided at the
discharge line. Inline strainer with facility for removal for cleaning will be provided
on the suction line. The pump and motor will be mounted on a common base
frame and provided with a flexible coupling and guard. Coupling halves will be
properly balanced.
Boiler Feed Pump Sizing
For boiler feed pump sizing, 10% margin will be provided on flow and 5%
POWER DIVISION
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margin will be provided on head calculated based on 2nd drum safety valve set
pressure. With such margin, it shall be checked and ensured that even at 47.5 Hz
frequency the boiler feed water pump is capable of delivering 100 % TMCR flow
rate and required head during TMCR operation of unit. The BFP sizing basis is as
follows.
a) Pump Capacity Calculation
Feed water flow at BMCR
240 TPH
909.4 kg/m3
As per HBD
263.9 m3/hr
271.8 m3/hr
Margin 10%
27.2 m3/hr
Calculated flow
299 m3/hr
300 m3/hr
2.5 kg/cm2
As per prelim.
piping layout
1.6 kg/cm2
As confirmed by
boiler supplier
As per prelim.
equipment layout
Required
discharge
(G=A+B+C+D+E+F)
3.5 kg/cm2
pressure
POWER DIVISION
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70
Head
(including
1444 mWC
1495 mWC
POWER DIVISION
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system, exhaust hood spray water and auxiliary PRDS station for deaerator
pegging steam etc.
The exhaust steam from the steam turbine is condensed in the water-
POWER DIVISION
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cooled surface condenser. Drain condensate from LP heaters, GSC and interafter ejector condensers are taken to the flash pipe of the condenser.
8.3.1. SURFACE CONDENSER
The condenser shall condense all the steam at the steam turbine exhaust,
and shall receive all the condensate from the steam jet ejector condensers, gland
steam condenser and LP heaters. At an emergency condition of very high level in
HP heater, the condensate drain will be diverted to condenser through HP flash
tank instead of the deaerator.
receive all the drains. The vent and drain from the HP flash tank and flash pipe will
be connected to the shell and hotwell of the condenser respectively.
The condenser shall be designed as per Heat Exchanger Institute (HEI)
standard for surface condensers.
The condenser shall be of horizontal two-pass type and shall be so
designed that it can operate satisfactorily under normal operating conditions of the
turbine.
The condenser shall be designed such that steam received from the turbine
exhaust during turbine VWO operation with 0% make-up, all heaters in service,
can be condensed along with other heat rejections like all LP heater drains &
vents diverted to the condenser etc. maintaining the condenser pressure of 0.1
ata with inlet cooling water temperature of 33C with all tubes working having a
tube cleanliness factor of 85%. Cooling water temperature rise will be 9C.
The condenser shall also be adequately designed to meet turbine bypass
condition without any problem.
The divided water boxes shall be designed and guaranteed to operate
under shut-off head of the main circulating water pumps. The cover plates of the
water boxes shall have hinged connection in order to enable periodic manual
cleaning of the condenser tubes. A sufficient number of openings shall be
provided at each end of condenser of suitable size and location for inspection and
POWER DIVISION
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material. Condenser tube sheet shall be of carbon steel (SA 516 Gr. 70) material.
Suitable drain and vent connections complete with necessary valve shall be
provided for all the water boxes to obtain a smooth flow path in the water boxes
and even water distribution to the tubes and to avoid any unvented air pockets.
The condenser shall be provided with a hotwell made of carbon steel (SA
516 Gr. 70) having a total storage capacity of at least three (3) minutes of the total
design condensate flow (between normal and low level) at maximum steam load
condition. The hotwell shall be provided with suitable access doors. Drain valves
with blind flanges shall be provided on hotwell.
A rupture disc, designed as per manufacturers standard, shall be provided
on the condenser to prevent over-pressurisation of the condenser.
The following are the brief details & design basis of the condenser:
Type
Design code
HEI
Service
Continuous
Location
Indoor
Shell Side
Tube Side
Fluid circulated
No. of passes
One
Design pressure
Design temperature
150 C
Condenser pressure
0.1 ata
45.44 C
Two
60 C
POWER DIVISION
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74
Cooling water
(inlet / outlet)
temperature 33 C / 42 C
Cleanliness factor
85 %
Plugging margin
3%
87142367 Kcal/hr
Surface area
4900 m2
Hotwell capacity
Material of Construction :
1
Shell
Tube sheet
Hot-well
Tubes
POWER DIVISION
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condenser are provided. Each service air ejector is of two stages with an intercondenser between the Ist and IInd stage and an after-condenser located after
the IInd stage. The condensate from the inter-condenser and after-condenser is
led to the main condenser through a loop seal and trap station respectively.
Condensate from the CEP discharge passes through the tube side of the inter and
after-condensers.
The following are the brief details of the Ejectors: 1
No. of ejectors
Service - Two (1 W + 1 S)
Start up One (1)
Design Calculations
Standard
HEI
Location
Indoor
Medium to be handled
Cooling Medium
Condensate
Material of construction
Body / Diffuser
Carbon Steel
Nozzles
Stainless Steel
Heat Exchanger
Shell
IS 2062 or equivalent
Tubes
Stainless Steel
Tube sheet
IS 2062 or equivalent
POWER DIVISION
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196 TPH
As per HBD
990 kg/m3
As per HBD
Volumetric flow
198 m3/hr
204 m3/hr
Margin 10%
20.4 m3/hr
Calculated flow
224.4 m3/hr
238 m3/hr
POWER DIVISION
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77
set
8 kg/cm2 (a)
As per deaerator
data sheet
0.75 kg/cm2
As per deaerator
data sheet
0.4 kg/cm2
As per prelim.
piping layout
flow
0.2 kg/cm2
Estimated
1.6 kg/cm2
As per LP heater
data sheet
Pressure drop
condenser (F)
0.5 kg/cm2
0.5 kg/cm2
0.5 kg/cm2
Estimated
2.5 kg/cm2
As per prelim.
equipment layout
Pressure drop
nozzle (D)
valve
across
in
ejector
(J=A+B+C+D+E+F+G+H+I)
150 mWC
(J-K / density)
157.5 mWC
159.6 mWC
POWER DIVISION
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78
Indoor
Designed capacity
No. of cooler
One
1 (W) + 1 (S)
POWER DIVISION
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Cooling media
Condensate
POWER DIVISION
9.
THERMAX LIMITED
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80
WATER SYSTEM
9.1. PLANT WATER SYSTEM
9.1.1. RAW WATER SYSTEM & RAW WATER RESERVOIR
Water from Mahanadi river will be pumped by means of raw water intake
pumps to the raw water reservoir. The raw intake pumps and piping upto raw
water reservoir are in Owners scope. The EPC contractors scope starts from the
raw water reservoir.
Raw Water Reservoir, for collection and storage of raw water, of total
capacity 10,000 m3 in two (2) compartments along with gates and accessories
shall be provided. Inside and bottom surface shall be lined with impermeable
HDPE lining of thickness 1 mm. Design and construction of the reservoir shall be
done in such a fashion that no water can escape from the reservoir through
seepage.
The raw water analysis as mentioned elsewhere in this document has been
considered as the design raw water analysis.
Raw water pump house will be adjacent to the raw water reservoir which
will house 2 x 100 % horizontal raw water supply pumps (1 W + 1 S - common for
120 MW) to draw required water from the reservoir. The raw water supply pumps
shall primarily supply water to the water treatment plant through one raw water
header pipe.
Description of Raw water supply pumps is as follows.
Number of pumps: 2 x 100 % for 120 MW (1W + 1S)
Capacity of pumps with 10% Margin: 450 m3/hr
The
water
system
consists
of
raw
water
pre-treatment
plant,
POWER DIVISION
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81
:
:
60 ppm
1 ppm
Sodium
Hypochlorite
b) DM feed-cum-Auxiliary CT
make up pumps
All the pumps will be sized based on system requirement with 10 % margin
on flow and 5 % margin on head.
POWER DIVISION
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Clarified water pump house will also house fire water pumps. A dead
capacity, as per the requirement of TAC, to supply firewater in case of emergency,
will be kept below the minimum submergence level of clarified water storage tank.
The clarified water storage tank shall meet the entire water requirement of
the various power plant consumers like DM water, cooling tower make-up water,
service water, potable water, fire water etc. The water balance diagram showing
the water requirement by various consumers is attached in Annexure-II.
9.1.3. MAIN COOLING TOWER MAKE-UP SYSTEM
Make-up water needs to be supplied to the main cooling tower to recover
1
the water lost in CT blowdown, evaporation & drift losses and SSF backwashing.
This make-up water to main cooling tower is supplied by 2 x 100 % main CT make
up pumps from the clarified water storage tank.
The main cooling water make-up requirement has been calculated as
follows:
:
17,931 m3/hr
9 deg C
Cycles of Concentration
Evaporation loss
283 m3/hr
Blowdown + Drift
57 m3/hr
SSF backwash
3 m3/hr
343 m3/hr
POWER DIVISION
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Document Title
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83
1,976 m3/hr
7 deg C
Cycles of Concentration
Evaporation loss
24 m3/hr
Blowdown + Drift
5 m3/hr
29 m3/hr
potable water, one will be working for auxiliary cooling tower make-up and one
common standby. (please refer water balance diagram).
Description of DM feed-cum-auxiliary pumps & DMF is as follows :
Total filtered water required = Make-up to auxiliary CT + DM Plant +
POWER DIVISION
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84
: 3 x 50 %
: 30 m3/hr
filtered water in a filtered water storage tank of capacity 40 m3. Potable water (3
m3/hr) and backwashing water for DMF (1.25 m3/hr) will be fed from this filtered
water storage tank.
The capacity of the DM water plant has been arrived as follows:
240 TPH
3%
7.2 m3/hr
14.4 m3/hr
0.5 m3/hr
0.5 m3/hr
15.4 m3/hr
Regeneration water
1.5 m3/hr
22.5 m3/hr
2 x 25 m3/hr
(1 W + 1 S)
Each stream of the DM Plant shall broadly comprise Activated Carbon Filter
(ACF), Strong Acidic Cation (SAC) exchanger, Degasser tower & storage tank
(common for both the streams), Strong Basic Anion (SBA) exchanger and Mixed
POWER DIVISION
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Bed (MB) exchanger. Acid and alkali measuring tanks (common to both streams)
with ejectors shall form part of the system to provide these chemicals for
regeneration. Hydrochloric acid and sodium hydroxide shall be the chemicals
used for this purpose.
The DM Plant shall be designed to operate continuously for 18 hours
before regeneration of the exhausted resin in the ion exchangers. The
regeneration of the exchangers shall be completed in a maximum period of 6
hours. Regeneration water heater for regeneration of anion resins will be
provided.
The waste from the regenerated waste of DM plant shall be collected in
drain pits near the vessels and routed through acid/alkali proof lined trenches to a
neutralizing pit. Acid or alkali as required shall be dosed in this pit and the effluent
shall be neutralized by recirculation before being pumped to the guard pond.
Bulk acid and alkali storage tanks (one each) shall be provided to store acid
and alkali of commercially available strengths. The capacity of each tank shall be
sufficient to unload one tanker load of chemical. As the standard capacity of a
normal tanker is 10 m3, the tanks shall be sized for 10 m3 capacity. Two (2) nos.
acid unloading pumps and two (2) nos. alkali unloading pumps shall be provided.
The capacity of each pump shall be sufficient to unload each tanker in about one
hour. The acid and alkali shall be transferred to the respective measuring tanks by
gravity.
The operation of the DM Plant will be semi-automatic through a dedicated
1
PLC called water system PLC. DM plant will be located in a RCC building along
with DM plant control cum MCC room.
The DM water generated by the DM plant shall be stored in two (2) nos.
vertical cylindrical MS with epoxy coated DM water storage tanks of capacity 250
m3 each. The tank shall be designed as per IS:803 and provided with inlet, outlet,
drain, overflow, vent and recirculation connections. Tank shall be provided with
suitable access manholes. Level instruments for monitoring the level in the tanks
POWER DIVISION
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86
Qty
2 nos.
POWER DIVISION
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Type of pump
Horizontal centrifugal
Location of pumps
1 or 2 (as required)
m/hr
Location of tank
By gravity
comprises of dosing with sodium hypochlorite for chlorination. Two (2) nos. pumps
of capacity 3 m3/hr each shall be provided to cater potable water requirement at
various locations of plant. Potable water tank of suitable capacity will be provided
in various building as listed below. The capacity of the tank shall be sufficient for
one days requirement of potable water.
The capacity of the potable water system has been worked out as below:
15 litres
No. of persons
(assumed)
Plant
500
0.3125 m3
3.0 m3/hr
Location of tank
in
Power
POWER DIVISION
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88
house, Administrative
building, Medical building,
canteen, store, workshop
etc.
1
Distribution of potable water from potable
water tank
By gravity
System Description
The main cooling water system will be used to cool the circulating water
used for condensing steam in the surface condenser.
Main cooling water system for surface condenser will be closed cycle
cooling system employing a cooling tower common for two units, cooling water
pumping system, CW treatment system and associated piping & valves.
The cooling tower will be of mechanical, induced draft, multi-cell, counterflow type. The material of construction of the cooling tower will be of RCC /
Pultruded FRP. Common cooling tower is provided for two units which consist of
seven cells (6 Working + 1 Standby) out of which three (3) cells will be working for
one unit with one (1) common standby. Cooling tower shall cool the hot return
water and discharge it into an RCC fore bay.
The tower will be designed in such a way that any cell can be operated,
repaired or maintained independent of the other cells. Cooling tower basin along
with fore bay shall be provided with storage capacity equivalent to 10 minutes
cooling water flow rate. The make up water will be added in the cooling tower
basin and will be suitably treated. Dosing of chemicals to prevent biological
growth, corrosion and scaling in the cooling water shall be provided on the
forebay. Drains from the sumps located behind the towers shall be provided for
each cell which shall be routed to the storm water drains.
The cold water will be transferred to the condenser water box by means of
MCW pumps and the return will be taken back to the cooling tower. MCW pumps
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will be vertical turbine type pumps located in a pump house at the end of the fore
bay. There will be a total of three (3) number of CW pumps, one will be working
for each unit and the third will remain as common stand by. Overhead EOT crane
of suitable capacity will be provided in the MCW pump house for maintenance of
the pumps.
Motor operated isolation valves will be provided at the discharge of the
main cooling water pumps. Manual isolation valves shall be provided at individual
inlets and outlets to the condenser. Manual isolation valves are provided in the
return line inlet to individual cells of cooling tower. A pneumatically operated
control valve is provided in the CT makeup water line to regulate inflow based on
level in the cooling water sump.
For maintaining the level of TSS in the circulating cooling water a side
stream filter (SSF) has been envisaged. Six (6) numbers of Automatic Valveless
Gravity Filters (AVGF) type SSF are provided. The SSF is designed for 5 % of the
total cooling water flow rate. Considering five (5) nos. of SSF working, the
1
capacity of the each filter works out to be 200 m3/hr. However, each filter of 225
m3/hr capacity will be provided.
9.2.1.2.
The following criteria are considered for the main cooling water system
sizing.
Design ambient wet bulb temperature : 28C
Design approach temperature : 5C
Cooling water inlet temperature to condenser is 33C
Cooling water outlet temperature from condenser is limited to 42C
Calculation for Main Cooling Water Flow:
Description
Condenser heat load
Unit
Value (100
% TMCR)
Value
(VWO)
Kcal/hr
80,686,468
87,142,366
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Document Title
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POWER PLANT, IMFA,
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PP 067 M B01 0
90
m/hr
8,965
9,683
m/hr
17,930
19,366
10
m/hr
19,723
20,334
m/hr
10
m/hr
9,862
10,167
m/hr
20,400
10,200
During steam dump operation also, the selected capacity of the cooling
tower shall suffice with increased cooling water outlet temperature.
Main cooling water flow capacity of each pump shall be 10,200 m3/hr as
1
calculated above. MCW pump head will be established considering Hazen William formula for pressure drop calculation across the pipe line.
The main cooling tower has been sized at 20,400 m3/hr flow rate (total),
3,400 m3/hr per cell. The cooling range of the tower is specified as 9C.
Summary of Main Cooling Tower technical Parameters :
1
Type
: Mechanical,
Flow
Induced
Draft,
Counter
Construction
No. of cells
Flow rate
: 28C
: 33C
Range
: 9C
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91
Water quality
: Circulating water
Cycles of concentration
: 6
10
: 0.05%
System Description
cooling water flow rate. The make up water (filtered water after duel media filters)
will be added in the cooling tower basin and will be suitably treated. Dosing of
chemicals to prevent biological growth, corrosion and scaling in the cooling water
shall be provided on the forebay. Drains from the sumps located behind the
towers shall be provided for each cell which shall be routed to the storm water
drains.
The cold water will be transferred to various plant auxiliaries of boiler, STG
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92
and compressors by means of ACW pumps and the return will be taken back to
the cooling tower. ACW pumps will be vertical turbine type pumps located in a
pump house at the end of the fore bay. There will be a total of three (3) number of
ACW pumps, one will be working for each unit and the third will remain as
common stand by. Monorail with manual hoist of suitable capacity will be provided
in the ACW pump house for maintenance of the pumps.
Motor operated isolation valves will be provided at the discharge of the
auxiliary cooling water pumps. Manual isolation valves are provided in the return
line inlet to individual cells of cooling tower. A pneumatically operated control
valve is provided in the CT makeup water line to regulate inflow based on level in
the cooling water sump. Alternatively, an ON-OFF type air operated valve can be
used for make-up.
Auxiliary cooling water system is provided with vertical type pressure sand
filter online for make-up water line to maintain the quality of water.
9.2.2.2.
The following criteria are considered for the auxiliary cooling water system
sizing.
Design ambient wet bulb temperature : 28C
Design approach temperature : 5C
Cooling water inlet temperature to condenser is 33C
Cooling water outlet temperature from condenser is limited to 42C
Calculation for Auxiliary Cooling Water Flow:
Description
Unit
Value
m/hr
350
m/hr
240
m/hr
80
m/hr
100
Fuel feeders
m/hr
48
CBD quenching
m/hr
20
POWER DIVISION
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Document Title
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PP 067 M B01 0
93
BFP cooler
m/hr
Sample coolers
m/hr
10
SWAS system
m/hr
15
m/hr
50
AC system
m/hr
40
m/hr
10
Miscellaneous
Total auxiliary cooling water flow
required for one unit
m/hr
20
m/hr
988
m/hr
1976
10
m/hr
2174
m/hr
2200
10
m/hr
1087
m/hr
1100
Auxiliary cooling water flow capacity of each pump shall be 1,100 m3/hr as
calculated above. ACW pump head will be established considering Hazen William formula for pressure drop calculation across the pipe line.
The auxiliary cooling tower has been sized at 2,200 m3/hr flow rate (total),
2,200 m3/hr per cell. The cooling range of the tower is specified as 7C.
Summary of Auxiliary Cooling Tower technical Parameters :
1
Type
: Mechanical,
Flow
Induced
Draft,
Construction
No. of cells
Flow rate
Counter
POWER DIVISION
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94
: 28C
: 33C
Range
: 7C
Water quality
: Circulating water
Cycles of concentration
: 6
10
: 0.05%
fuel firing system will be designed for `Over bed feeding system. The circulating
fluidised bed will consist of three (3) feeding points.
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95
11.1.SYSTEM SIZING
Material Handling System to be supplied will handle ROM Coal, Washery
rejects mixed together or one at a time. Owner will arrange to feed these materials
into specified underground hoppers as per requirement. This system will convey
the material to bunker compartments of boilers after crushing and grading. The
coal handling plant will be controlled by a dedicated PLC located near the coal
handling plant. The PLC will be connected to central DCS for monitoring purpose.
The basic scheme for handling shall be as per the attached scheme
(Drawing No. PP 067 M 132 3).
To arrive at the Coal Handling system sizing, the coal consumption per
Boiler is calculated as indicated in the table below. The Fuel handling plant will be
designed for 12 hrs of operation based on Performance Fuel (50% ROM and 50%
Washery Rejects) as per the specification requirement.
Capacity Calculation for Coal Handling System
Particulars
Calculation
Fuel
Consumption
per
Boiler
(Considering Performance Coal)
64.42 TPH
12 Hrs.
Hrs.
Hours
of
downtime
operation
excluding
Fuel
Handling
Plant
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Particulars
Fuel
Consumption
(Washery Rejects)
Calculation
per
Boiler
88.746 TPH
Hrs.
Based on the above and with 12 hours operation the capacity of the
handling system has been sized at 300 TPH.
Each boiler will be provided with fuel bunkers.
Bunker sizing basis is discussed in section covering boilers of this
document.
11.2.SYSTEM DESCRIPTION
1
The conveyor below the feeder will run through the tunnel with
required slope to feed the crusher/ screen in the crusher house. The Tunnel will
be provided with 2 x 100% Sump pump.
Coal Crushing, Screening & Bunker Feeding System
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The coal will be available at the terminal point at (-) 100 mm size minimum
90%.
CFBC boilers requires coal at (-) 6 mm. Hence, a coal Crushing and
screening plant will be installed. The coal crushing, screening and boiler feeding
system will be designed for 2 x 300 TPH capacity as per the basis outlined above.
From the grizzly hoppers, the Coal shall be fed to the crushers in the
crusher house. This belt shall be routed through an underground tunnel. All
above ground belts shall be provided central walkway of 1000 mm and both side
walkways of 800 mm. The conveyor will be covered from top as well as from sides
with permanent colour coated zincalume steel sheet.
The RCC crusher house shall house two crushers, one working and one
standby of 300 TPH capacity each. The Crusher will open bottom type non
reversible crushers appropriate for feed and product size of 100 mm and 6 mm
respectively. It shall also house four (4) nos. flip flow type screens for Screening
the Crushed Coal.
Input Coal size distribution and properties has been considered as follows
for sizing screen and Crusher.
Total Moisture - 20 %
Hard Grove Index - 45 - 77
Sieve-analysis:
Maximum lump-size - 100 mm
Sieve-opening size passing through :
100 mm
100 %
50 mm
55 %
25 mm
32 %
12 mm
18 %
6 mm
12 %
1 mm
8%
Bunker feed system:
Two numbers travelling tripper shall be provided in the belt beside the
bunker of the boilers. From the travelling tripper, coal shall be fed to the Coal
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98
Bunkers.
Dust extraction & ventilation system
Dust extraction systems will be provided for the crusher house and other
dust generation points. Dust Extraction system for material-handling plant will
ensure minimum leakage. Dust Extraction system bag filter outlet will be designed
for 100 mg/Nm3 SPM level.
Grizzly hopper tunnel ventilation system will be provided. Ventilation
system will be provided for all the boiler bunkers.
Dust suppression system with sprinkler nozzles will be provided in coal
storage area and grizzly hopper area. Treated effluent water will be used for the
same purpose.
Other design criteria/ standards followed:
The following is a list of other features that are being followed. However,
this may vary slightly based on manufacturers std.
(a) Conveyor design standards
: IS/CEMA
: 0.8 T/m3
: 1.04 T/m3
: 14 to horizontal
Note: Due to layout constraint in few cases, the inclination angle may be
slightly higher to horizontal.
(e) Speed of belt conveyor
: 35
: Nylon Nylon
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99
: 2% of idler spacing
belt
tension
running
should
of
allowable
condition
not
the
belt
exceed
maximum
tension
(m) Idlers
(1) Idlers to be Designed as per IS: 8598, IS: 4776, IS:11592 or
Equivalent
(2) Idlers below magnetic separator and metal detectors should be nonmagnetic type. Maximum 3 nos. of such idlers to be provided under
each above mentioned equipment
(3) Minimum 5 impact idlers shall be provided at every feeding point.
1
(4) Suitable no. of adjustable transition idlers at head end and tail end
at slope of maximum 10 shall be provided for all conveyors.
Maximum gap of transmission idler shall be 700mm.
(5) Adequate no. of idler pulley shall be provided for each conveyor
where change of belt direction takes place and for installation of
scrapper.
(6) Minimum bearing life shall be 30000 hours.
(n) Pulley
(1) To be Designed as per IS per IS-8531, IS 4776, Part-1, IS 1891 &
BS 2890 or Equivalent.
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(2) Service: For head and drive, head snub, bend take-up, tail and tail
snub pulleys (if required)
(3) Minimum pulley width: As per IS
(4) Pulley construction: Welded steel as per IS 8531.
Pulley below magnetic separators and metal detectors shall be nonmagnetic stainless steel.
(5) Pulley diameter: As per IS 1891 or belt manufacturer standards
(6) Bearing life: 50000 hours
(o) Gear box
(1) Type of high-speed coupling: Pin-Bush
(2) Type of low speed coupling: Gear
(3) Type of gear box: upto 20kW :- Worm type
More than 20kW :- Helical
(4) Type of bearing: Antifriction / Roller
(5) Bearing life: 30000 hours
(6) Hold backs: Hold back will be provided for inclined conveyors
except for reversible ones.
(7) Material of construction: Casing: - Cast Steel, FG -260 of IS -210
Worm, Gear pinion: - Alloy Steel
Shaft: - Forged / Alloy Steel
1
Type of cooling: - Natural / Fan cooler
(p) Magnetic Seperator : Two numbers over-band type magnetic separator
before the belt entering crusher house
(q) Hoppers and chutes
(1) Material: MS IS 2062
In magnetic zone, chutes will be SS 409M / non-magnetic
(2) Chute thickness: 10mm (minimum)
(3) Hopper material; MS
POWER DIVISION
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101
The circulating fluidized bed boiler uses Lime stone to capture the sulphur
present in the fuel. The lime stone quality to be used as per the specification
elsewhere mentioned in the DBR. To restrict the chimney height to 44m, 90%
sulphur capture is required. To achieve this Ca/S ratio of 5.3 is being employed for
performance fuel.
12.1.SYSTEM DESCRIPTION & SYSTEM SIZING
Lime stone less than 20 mm size will be received at ground grizzly hopper
and will be fed to the conveying system through vibratory feeder and conveyor.
Lime stone will be crushed and screened and will be conveyed pneumatically to
the boiler bunkers.
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102
Calculation
Boiler
4.03 TPH
2 x 4.03 = 8.06 TPH
12 Hrs.
Required
Capacity
Lime
Stone
handling
Plant
Selected
Capacity
Lime
Stone
Handling
Plant
18 TPH*
The ash handling system for two number CFBC boilers operating on
various types of coals as mentioned in Boiler Design Basis Report shall be
designed for the maximum ash generation from Washery Rejects
The ash handling system consists of three basic schemes:
Bed ash handling system - Ash removal from the bed ash coolers.
Ash generation details as worked out from boiler operation with highest ash
content coal are provided in Table-1 below. Ash handling system is designed on
the basis of this data. Details of the system are provided in subsequent sections.
Below each ash hopper outlet, suitable MS surge chutes with 1 no.
expansion joint shall be provided. Level probes will be provided in the surge
hoppers for automatic operation of the system. The ash vessel (transporter) will
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103
be placed below each surge hopper. The level probe in the hopper senses the
pressure of material to initiate the conveying cycle. The valve will open and allow
the material to gravitate in to the vessel till it is closed automatically by the timer
present as per process parameters. On closure of dome valve, valve seal gets
inflated and signals the conveying air injection into the transporter.
13.1.1.BED ASH CONVEYING SYSTEM
Bed ash from the boilers will be discharged through the bed ash coolers at
about 200 oC. Each boiler will have 3 nos. water cooled type bed ash cooler. Ash
from each bed ash cooler outlet will be transported to a Ash vessel through a
conveyor located below the Boiler.
Though normal ash temperature is expected to be around 200 Deg C ,
design temp for the bed ash conveying system will be 400 Deg C. Bed Ash from
the Ash vessel will be transported to an Intermediate Silo.
1
Bed ash conveying scheme is presented in Flow Diagram for Bed Ash Handling
System, drawing number: - PP 067 M 131 2.
13.1.2.FLY ASH CONVEYING SYSTEM
Dense phase pneumatic handling system shall be used for conveying fly
ash from the MDC at boiler, air preheater and ESP to two fly ash silos.
Ash from six numbers of hoppers at each boiler MDC is transported back to
furnace for recycling. Ash level controllers at the hoppers will discharge excess
ash out of boiler system. This excess fly ash is pneumatically conveyed to ash
silos through one number ash vessels. In addition, two lines of two fly ash
collection points each at air preheater hoppers will also be provided. Ash handling
system at these locations will be designed for 300 Deg C temperatures.
Major fly ash collection is from ESP hoppers. Each boiler ESP has 6 fields
from where fly ash is collected and conveyed pneumatically to ash silos. Ash
collection estimate from various fields under all fields working condition and under
first field failed condition are provided in Table-1 below. Capacities of ash
POWER DIVISION
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104
conveying lines will be decided based on the worst condition at these locations.
Fly ash conveying scheme is presented in Flow Diagram for Fly Ash
Handling System drawing number: - PP 067 M 131 1.
Table-1 : Ash Generation Details
Sl.
No.
Locatio
n
Number
of Ash
Discharg
e point
Numbe
r of Ash
Vessel
Design
capacity per
Ash vessel
Kg/Hr
Total Design
Ash quantity
Kg/hr
Normal
Operating
Temperatur
e Deg. C
Design
Temperatur
e Deg. C
1.0
Bed Ash
2W + 1S
7500
15000
200
400
2.0
MDC
76570
76570
270
350
3.0
AHP
2960
5920
180
280
4.0
ESP- 1st
field
11970/(1330)
*
23940/(2660)
*
140
160
5.0
ESP2nd field
1200/(10775)
*
2400/(21550)
*
140
160
6.0
ESP3rd field
120/(1080)*
240/(2160)*
140
160
7.0
ESP4th field
12/(110)*
24/(220)*
140
160
8.0
ESP5th field
1.5/(15)*
3.0/(30)*
140
160
9.0
ESP6th field
1/(1.5)*
2/(3.0)*
140
160
Notes :
1.0 Based on specification requirement of 8hrs Ash being evacuated in 5hrs the
conveying Air compressor shall be sized for a total Ash generation of 92660
Kg/Hr per Boiler.
2.0
Figures marked with * is collection of Ash quantity with First field out
condition.
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3.0 Design Capacity of vessels have been arrived based on uncertainties of ash
collection rates at different point with adequate margin based on Boiler
Manufacturers experience
13.1.3.ASH SILOS
Ash Silos have designed based on worst fuel i.e. Washery rejects having
maximum Ash content. The maximum fuel consumption has been determined
based on boiler evaporation of 240 TPH. The Ash distribution for sizing Bed Ash
and Fly Ash Silos have been considered as 20% for Bed Ash and 80% for Fly
Ash.
Bed ash from Ash vessels will be transported to one number Intermediate
bed ash Silo located close to the Boiler area. The Ash from the Intermediate Bed
Ash Silo will be transported to one number Bed ash silo, common for two boilers.
Capacity calculation for the Bed Ash intermediate Silo and Bed Ash Silo is
included in subsequent paragraph.
Fly ash from MDC hoppers, AHP Hoppers and ESP hoppers will be
conveyed to Fly Ash silo. Provision will be made for discharging Ash to any one of
the Silo.
1
Each fly ash silo will be provided with RF type level measurement and four
outlets as below.
One for unloading fly ash into closed trucks in dry form through rotary
feeder and retractable telescopic chute.
One for unloading fly ash in conditioned form through rotary feeder and ash
conditioner to open trucks.
Other two with blind flange with plate valves for future use.
The minimum unloading rate of bed ash & fly ash in the open trucks as well
POWER DIVISION
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13.2.SYSTEM SIZING
Quality of clean air from bag filter of dust extraction system shall be 50
mg/nm3
Silos will be equipped with Fluidising Air blower and Fluidising Air Heaters.
13.2.1.DESIGN CALCULATION FOR INTERMEDIATE ASH SILO:
Sl. No.
Particulars
Calculation
1.0
88746 Kg/Hr
2.0
60%
3.0
Ash Quantity
53247.6 Kg/Hr
4.0
6501 Kg/Hr
5.0
59748.6 Kg/Hr
6.0
7.0
8.0
9.0
10.0
650 Kg/M3
11.0
0.85
12.0
Volumetric Capacity
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107
13.0
37 M3
Sl. No.
Particulars
Calculation
1.0
88746 Kg/Hr
2.0
60%
3.0
Ash Quantity
53247.6 Kg/Hr
4.0
6501 Kg/Hr
5.0
59748.6 Kg/Hr
6.0
7.0
8.0
9.0
573585.6 Tons
10.0
650 Kg/M3
11.0
0.88
12.0
Volumetric Capacity
573585.6/(0.88
1002.77 M3
13.0
1005 M3
Sl. No.
Particulars
Calculation
1.0
88746 Kg/Hr
2.0
60%
3.0
Ash Quantity
53247.6 Kg/Hr
650)
M3
POWER DIVISION
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108
4.0
6501 Kg/Hr
5.0
59748.6 Kg/Hr
6.0
7.0
8.0
9.0
10.0
11.0
750 Kg/M3
11.0
0.92
12.0
Volumetric Capacity
1147173.6/(0.92
1662.6 M3
13.0
1665 M3
750)
M3
* Note : Filling factor have been arrived based on number of feed points in the Silo
and Silo geometry.
14. COMPRESSED AIR SYSTEM
14.1.SYSTEM DESCRIPTION
The power plant will require instrument air for operation of I/P converters,
purge instruments, pneumatic actuation of control valves, dampers etc. for
different systems. Service air will be required for cleaning of filters, strainers, fuel
oil atomization, igniters cooling and other general purposes.
Compressed air
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The compressed air system shall consist of Instrument Air Compressors &
Air-Drying Plants (ADP), Service Air Compressors, Air Receivers, interconnecting
compressed air piping. It will also include control panels, Instrumentation &
control.
Instrument air is dehumidified & dried to requisite level before use. Oil free
air is required form the compressors for instrument air service. Three (3) nos.
(normally 2 working + 1 standby) oil free screw type instrument air compressors
and two (2) nos. (1 working + 1 standby) driers will be provided to cater for the
instrument air requirement of the entire plant. Instrument air is taken from the
compressed air header after air driers and will be supplied to one (1) no. air
receiver dedicated to instrument air.
Two (2) nos. (1 working + 1 standby) oil filled screw type service air
compressors will be provided to supply service air requirement of the entire plant.
Service air is taken from the compressed air header after service air compressors
& is supplied to one (1) no air receiver dedicated to service air.
The instrument air and service air headers will be connected by a
pneumatic operated on-off valve, so that in case of emergency, the service air
compressors can supply compressed air to the instrument air header.
Compressors shall deliver air at a pressure of 8.0 kg/cm2 (g). Each
compressor to include suction filter, silencer intercooler with moisture separators,
automatic drain traps, instruments, control panel, base plate, coupling guard and
other necessary accessories. Noise level should not exceed 95 dBA when
measured at distance of 1.0 meter from compressor and at a height of 1.5 m
above the floor.
Each air receiver will have a capacity of 10 m3 and will be designed for a
pressure of 10 kg/cm2 (g) and temperature of 50C.
The air drying plant will be drying the air by adsorption method and will be
of Heat of compression type. The quality of instrument air at the outlet of
instrument air receiver shall conform to ISA S7.3 standard (-40C dew point at
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atmospheric pressure).
Air piping shall conform to IS: 1239, Heavy Grade, or IS: 3589 Gr. 410.
14.2.SYSTEM SIZING
14.2.1.INSTRUMENT AIR SYSTEM
Instrument air system is sized considering followings consumers:
Boiler
Balance of plant
c) Purge loss -
d) Considering margin -
1.2 x (A + B + C)
Boiler area
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Based on above areas, total thirty (30) tapping points have been
considered for various applications of service air for the entire plant. Assuming 25
% of the tappings will be in operation simultaneously and considering 0.6 Nm3/
min/tapping, the total service air requirements works out to be 270 Nm3/hr.
Considering spare and leakage losses at 10 %, the total service air quantity
required for service air stations work out to 300 Nm3/hr i.e. 5 Nm3/min.
Based on above calculations, service air compressor is sized for 2 x 5
Nm3/min (1 W + 1 S).
14.3.EQUIPMENT DESCRIPTIONS
Following are salient technical parameters of the equipment selected in the
compressed air system:
Air Compressors:
Parameter
UOM
Value
Fluid to be Compressed
Air
Application
Type of Compressor
Type of drive
Duty
Continuous
Location
Indoor
Quantity required
Nos.
PERFORMANCE DATA
Design
Conditions
Compressors;
- Pressure
for
kg/cm (a)
Atmospheric pressure
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Temperature
Humidity
C
%
Nm3/min
50
62
IA 10 Nm3/min
SA 5 Nm3/min
kg/cm (g)
8.0
33
Deg C
< 40
dB(A)
< 95
ppm
0.0
Air Driers:
Parameter
UOM
Value
Type of Dryer
Application
Instrument Air
Duty
Continuous
Design Code
IS 2825
Location
Indoor
Design Temperature
Quantity required
Net drier capacity required
C
Nos.
3
Nm /min
Desiccant
Compressed air at Drier inlet:
Pressure
50
Two (2) nos. (1 W + 1 S)
20
Alumina / Silica gel
kg/cm (g)
Max. Temperature
45
44
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Outlet
45 (max)
(-) 40 (at
pressure)
Maximum
oil
content
exclusive
of
noncondensable
shall
not
exceed 1 ppm
atmospheric
dB
< 85
Air Receiver:
Parameter
UOM
Value
Design standard
IS 7398 / IS 2825
Type
Vertical, Cylindrical
No. of units
Nos.
IA - One (1)
SA - One (1)
Working pressure
kg/cm2 (g)
8.0
Design pressure
kg/cm2 (g)
10
kg/cm2 (g)
15
m3
10
Capacity
Minimum shell thickness
6 mm
MOC Shell
IS 2062
IS 2002
Tolerance / allowance
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AREAS
For the Power House Building, one common Central Chilled Water Plant for
both the units shall be provided with individual Air Handling Units and Fan-Coil Units
for the Central Control Room (common for both the units), Control Equipment
Rooms, Computer Room, UPS & Battery Charger Rooms, SWAS Rooms (dry panel
1
area) and Shift Charge Engineers Rooms / Office and Technical Building.
3 x 50% water cooled chilling units will be provided to cater cooling
requirement of Central Control Room & associated areas. Two (2) units will be
working while one (1) unit will be kept as stand-by. The plant will be located on
ground floor of STG Building. Each Chiller unit will have microprocessor based
control panel for operational & safety control of the chiller. Separate Control panel
will be provided in the plant room for automatic operation of the plant. Expansion
tank for the system will be located on B-C bay roof. Cooling water required for the
chiller units will be made available from the Auxiliary Cooling Water system of the
plant.
Air Handling Units (AHUs) with chilled water coil will be provided for Air
Conditioning of Central Control Room & associated areas. Two (2) nos (both
working) AHUs of 50% capacity are provided for this purpose.
The AHUs will be complete with pre filter (90% efficiency down to 10
microns), chilled water coil, 3-way mixing valve in chilled water line, centrifugal
fan, motor operated dampers etc. Dehumidified cool air from AHUs will be
supplied to the air conditioned areas through insulated ducts. The return air from
A/C area will also be taken back to AHUs through insulated ducts. The ducts will
be routed through false ceiling void. High efficiency filters (99 % efficiency down to
5 microns) will be provided in supply air ducts.
Motor operated fire dampers (de-energised to close) shall be provided in
the A/C supply air duct in order to isolate the respective AHU A/C room area in the
event of fire.
Required amount of fresh air will be supplied to AHUs by fresh air supply
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unit consisting of pre filter, fine filter & Damper. Duct mounted heaters and pan
type humidifier with sensors will be provided to maintain desired DB & RH in A/C
area. Supply air duct up to a distance of 5 m from AHU will be acoustically lined
from in side. Ducts will be fabricated from GI sheets as per IS 277 with Zinc
coating of 120 gsm. Duct thickness & fabrication will be as per IS 655.
Piping for Chilled water, Condenser, cooling water system shall be Heavy
grade-IS: 1239 or equivalent upto150 NB and IS: 3589 or equivalent beyond 200
NB with a minimum thickness of 6 mm.
Chilled water system consisting of refrigerant circuit, chilled water circuit
and cooling water circuit for refrigerant condenser, will have a dedicated
Microprocessor based control system for automatic operation and safety
interlocks.
Air Handling Unit shall take the chilled water for cooling the air which will be
circulated for the air-conditioning system. AHU shall have dedicated control
system for start/stop and automatic control operation of the AHU.
15.1.2.AIR CONDITIONING SYSTEM FOR OTHER AREAS
Following areas will be provided with 2 x 100% or 3 x 50% capacity
(depending on the cooling load) non-ductable air cooled window / split type air
conditioners:
Administrative Building
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15.2.SYSTEM SIZING
Air conditioning system shall be designed based on parameters described
below :
Sl.
Parameter
No.
1
Values
DBT (C)
WBT (C)
Summer
41.5
27.8
Monsoon
35.0
28.3
Winter
13.3
8.3
Relative
Humidity %)
24.4 2
50 5
24.4 2
< 60 %
Equipment load
At actual
Lighting Load
At actual
Occupancy
Fresh air
At actual
1.5 air change / hr or 34 m3/hr per person
whichever is more
Main Duct
8 m/s
Branch Duct
6 m/s
Diffusers
3 m/s
85 dB(A)
Cooling Water
CW inlet Temp
33 C
CW outlet Temp
38 C Max.
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FOR
ASSOCIATED
AREAS
The ventilation system will be provided in the following locations within the
Power House :
a) TG bay (Ground, Mezzanine and Operating floor) including HP/LP heater
area, Condenser area, Boiler feed pump area, Oil cooler area etc.
b) Battery Rooms
c)
1
d) Cable Spreader Rooms
e) Elevator M/C Rooms
f)
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of TG building. Such division and location area is decided to achieve effective air
distribution with less amount of duct work and less pressure drop in fans with no
cross-over of ducting across A-B bay.
The Air Washer Units will primarily serve TG hall and the electrical areas
1
b)
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HDPE filter.
c)
Raw Water & Clarified Water Supply air by wall mounted Axial
Pump House
Flow fans (without filter) and
exhaust through louvers.
d)
e)
Store Building
f)
g)
Administrative
AC area)
h)
Building
DG plant building
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j)
k)
j)
Unitary Air Filtration Unit shall consists of Air intake Louvers, HDPE wire
mesh Filter with water spray, PVC moisture eliminator, Centrifugal/ Tube Axial
Fan set, GI casing with water sump.
Dry type Fresh Air Unit shall consists of Wall mounted type Fan Filter Unit.
16.2.SYSTEM SIZING
Ventilation system shall be designed based on parameters described below
:
Sl.
Parameter
No.
1
Values
Relative
Humidity (%)
DBT (C)
WBT (C)
Summer
41.5
27.8
Monsoon
35.0
28.3
Winter
13.3
8.3
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TG hall
15
20
15
15
20
15
15
Pump Houses
10
Battery Room
20
Toilet
20
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The system will be design as per the norms laid down by Tariff Advisory
Committee (TAC), India. NFPA norms will be followed where-ever TAC norms are
not available / not clear. Equipments approved by IS / Statutory Authority / UL
and/or bearing IS mark will be used.
17.1.1.FIRE WATER SYSTEM
The fire water system will consist of:
One (1) no. Motor Driven Fire Water Pump of Capacity 273 Cum/Hr at 88
mWC head for Hydrant System
One (1) no. Motor Driven Fire Water Pump of Capacity 273 Cum/Hr at 88
mWC head for Spray System
One (1) no. Diesel Engine Driven Fire Water Pump of Capacity 273 Cum/Hr
at 88 mWC head. The pump will be connected to Hydrant & Spray system & will
act as Common Stand-by.
One (1) no. Jockey Pump of Capacity 11 Cum/Hr at 88 mwc Head.
One (1) no. Hydro-pneumatic Tank
One (1) no. Air Compressor
All the pumps will be connected to a common ring header which will supply
fire water to both hydrant and spray water system.
17.1.2.HYDRANT SYSTEM
The hydrant system will consist of complete hydrant system, including
hydrant mains in ring, both external and internal hydrant / landing valves, monitors
and hose houses / hose boxes etc with all accessories. Hydrants will be located
through out the plant as per guidelines of TAC. Hydrants will also be provided for
coal conveyors. Monitors will be provided in place of hydrant for protecting tall
structure exceeding 15 m height.
Hydrant Mains will be kept pressurized at all times. Minor leakages will be
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taken care of by the Jockey pump. System operation will be automatic. The pump
will also be connected to spray system header to keep the pressurized at all
times.
The fire water piping will be laid in ring mains around all areas to ensure
multidirectional flow. The fire water mains will be buried minimum 1 m below the
FGL and will be coated and wrapped to take care of soil corrosion. Isolation
valves will be provided in the network to enable isolation of any section of the
network without affecting the flow in the rest.
17.1.3.SPRAY WATER SYSTEM
Entire spray water system shall be designed generally as per the guidelines
given in the relevant sections of NFPA / TAC. Spray water supply piping will be
provided up to the spray nozzle of each spray system. Spray water header will be
connected to Hydrant header through NRV & cut-off valve so that Hydrant system
can supply water to spray system as and when required. Spray water header will
1
MV spray nozzle
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Type
TG Building
Boiler Area
DG House
CO2 Type
Pre-Treatment Plant
DCP Type
DM Plant
CO2 Type
CW Pump House
Control Rooms
Battery Rooms
Compressor House
Store / Office
Cable Galleries
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Turbine Building,
Boiler Area
Turbine
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provided in the CW Pump House. The same will be adequate to handle the CW
Pump Motor and Pump components.
Miscellaneous Hoists and Trolleys
Miscellaneous Hoists and Trolleys with suitable monorails will be provided,
wherever required, for the handling of equipment and other items of more than
500 Kg weight.
Wherever by the use of a manual hoist the hoisting operation requires an
effort more than 25 Kg, an electrical hoist will be used instead.
Following buildings will be provided with suitable hoist and trolleys. The
capacity of individual hoist will be decided depending on the maximum weight of
component to be handled, once vendor data is received.
Compressor Room
DM plant building
DG house
Unit
Application
Value
STG
CW Pump
Building
House
No. of crane:
Nos.
One (1)
One (1)
Tons
80 / 5
10
IS 3177-1977
IS 807-1976
Class
II
Location
Operation
Indoor
Cabin
Pendant
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operated
operated
Speed
Long Travel
m/min
30
Cross travel
m/min
15
m/min
1.5
m/min
Creep
m/min
10 % of main speed
19. ELEVATORS
Boiler Goods cum Passenger Elevator
One (1) goods cum passenger elevator of capacity ten (10) Tonnes will be
provided common for two boilers. All major boiler floors including the working
platform, fuel feeder floor, fuel bunker floor will be approached by the elevator with
suitable interconnecting platforms at the required levels.
Turbine Building & Service Building Passenger Elevator
One (1) passenger elevator of capacity 650 kg, suitable to carry 8
passengers at a time, will be provided to serve different floors of the TG Building
as well as of the adjacent technical building, which will include major offices of the
plant.
20. ENVIRONMENTAL CONSIDERATION
Both gaseous emission & liquid effluent are discharged from the plant
taking into consideration, the environmental norms & emission standards.
20.1.GASEOUS EMISSION
Being a coal fired plant, the gaseous emission is from the chimney exhaust.
Particulate emission is taken care by providing electrostatic precipitator
(ESP). ESP will be designed to limit dust concentration at ESP outlet to 50
mg/Nm3 with one field out of operation.
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As per the contract requirement, 44 meter high single flue self supported
steel stack is provided to restrict the ground level concentrations within acceptable
limits. Sufficient exit velocity from chimney is considered to limit GLC within limit.
Stack monitoring equipments to measure particulate matter and exhaust
gases has been provided.
20.2.LIQUID EFFLUENT
Liquid effluent from the Power Plant is generated from the following
sources.
Boiler blowdown
Oily waste from fuel oil area, power house area and transformer area
All the above streams are of a quality that can be directly discharged to the
guard pond except Sludge from raw water pre-treatment plant and oily waste from
fuel oil area, power house area & transformer area.
The oily water run off during rains and regular washing/cleaning, leakage,
draining from Fuel Oil Unloading Area shall be collected in a Retention Pit. Oily
waste from the Retention Pit shall be directed to a Common Oily Waste Retention
Pit, which also receives oily effluent from Power House area and Transformer
Yard area and. From the Common Oily Waste Retention Pit the oil contaminated
effluent shall be pumped to Oil Water Separator for removal of oil and suspended
solids.
The treated water from OWS may be discharged in another collection pit
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from where treated water shall be sent finally to Guard Pond. Separated oil shall
be collected in a Slope Oil Storage Tank.
Oily effluent from the Transformer Yard Area & Power House Area will be
led to a Retention Pit from where waste shall be transferred to the Common Oily
Waste Retention Pit as addressed above.
For the various effluents in the plant, a guard pond is being provided where
the effluents will be collected. The guard pond is provided with 2 x 100 % pumps
for evacuating the pond. A buffer volume of Guard Pond is provided to allow
containing any sudden upset flow conditions. With this consideration, the pond is
1
Quantity (m3/hr)
52
Boiler Blowdown
14.4
1.5
SSF Backwash
79
20
conditioning
Capacity of the Guard Pond (24 hours basis) = 79 x 24 = 1896 m3.
1
Selected Capacity of the Guard pond = 2000 m3.
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Steam lines
50 to 150
200 mm
50 mm
mm NB
NB & up
15-20
20-35
25-45
15-25
20-35
30-50
20-30
25-40
30-50
NB
1.
2.
3.
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4.
5.
6.
7.
steam
over
70
kg/cm2 (g)
Exhaust steam line from turbine to
20-35
30-45
30-55
20-35
30-50
40-60
20-35
35-61
50-75
20
60
atmosphere
8.
Vacuum lines
9.
75
150
Maximum Velocity (m/s)
2.0
6.0
1.5
3.5
3.5
5.0
1.5
1.2
2.2
0.6
2.0
3. Air lines
Pipe Size below 50mm
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15-30
25-35
Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
101
540
Flow
Pipe
TPH Size NB
224
300
Pipe
Thick.
mm
Velocity
m/s.
21.44
38.06
Value
101
540
3476
12
100
0.281
62.22
0.03540
35.5
1.0828E-06
9.22E+06
Estimated
0.05
5619
0.01340
100.0
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10
1
0
1
0.3
7.31
1.30
Overall
Pressure loss as per 100 % TMCR HBD:
3.00
Margin dp on design dp ( % )
56.5%
Operating Operating
Pressure
Temp.
2
Kg/cm (a) Deg. C
Flow
Pipe
TPH Size NB
Pipe
Thick.
mm
Velocity
m/s.
1st extraction to
HPH-1
30
374
15
150
7.11
21.6
2nd extraction to
HPH-2
16.3
301
14.1
150
7.11
33.4
3rd extraction to
Deaerator
6.6
202
12.75
200
6.35
34.6
extraction to
LPH-1
2.5
127.5
12.3
300
6.35
32.9
5th extraction to
LPH-2
0.735
90.7
11.5
450
9.53
49.0
4th
The dumping steam (TG bypass) line will be sized for 60 % of TMCR. The
material for the dumping steam line shall be alloy steel conforming to ASTM A 335
Gr. P22 upstream the TG bypass valve. The material for dumping steam line
downstream of the TG bypass valve shall be carbon steel conforming to ASTM
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A106 Gr. B.
21.7.BOILER FEEDWATER PIPING
21.7.1.BOILER FEED WATER SUCTION & DISCHARGE LINES
The piping material shall be carbon steel conforming to ASTM A 106 Gr.B.
For sizing of the lines, the velocity will be maintained as indicated in the table
elsewhere in this document.
Line Description
1
BFP suction
BFP discharge
Operating Operating
Pressure
Temp.
2
Kg/cm (a) Deg. C
6.6
158
110
225
250
Pipe
Thick.
mm
6.35
225
150
14.27
Flow
Pipe
TPH Size NB
160
Velocity
m/s.
1.3
4.9
Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
10
160
Flow
Pipe
TPH Size NB
67.5
80
Pipe
Thick.
mm
Velocity
m/s.
7.62
4.85
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Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
0.15
45.5
184
300
Pipe
Thick.
mm
6.35
Flow
Pipe
TPH Size NB
Velocity
m/s.
0.68
CEP discharge
13
46
184
150
7.11
2.77
15
46
70
80
5.49
4.16
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valves and specialities will comply with all currently applicable standards,
regulations and codes.
All drain and vent connections for 40 kg/cm2(a) rating will be made up of
two (2) valves in series, both of isolating type.
All valves and specialities will be located so that they are readily accessible
for both operation and maintenance. Wherever necessary, the valve spindles will
be extended and an approved type of pedestal hand-wheel will be provided at the
next higher floor level or a necessary platform will be provided.
21.17.1.INSULATION
All piping systems having working temperature equal to or more than 60 C
will be normally insulated for conserving enthalpy and for personnel protection.
The insulating material is selected suitably based on the working
temperature of the pipe.
chlorides, oil, Sulphur and other impurities and retains its density and thermal
conductivity over a reasonably long period.
Insulation thickness will be so selected that the temperature of its outside
jacket remains 65C with ambient temperature of 35C considering 1 m/s air
velocity, since it is expected that such temperature does not produce burns on
human skin within a contact period of 3 seconds.
21.17.2.PIPE SUPPORTS AND HANGERS
Pipe supports shall be designed according to the layout requirements.
Wherever the load variation is limited, variable spring hangers and constant spring
hangers are used.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
PP 067 M B01 0
140
Rod hangers are used in those cases where lateral movement is allowable.
21.17.2.4. Pipe Clamps and Shoe / Saddle supports
This shall be used in those cases where restraint supports are used.
Minimum thickness of pipe clamps shall be 5-mm.
21.17.2.5. Materials of Construction
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
PP 067 M B01 0
141
While providing openings in floor/walls for pipe crossing due care shall
be taken for the pipe thermal movement and insulation thickness.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
PP 067 M B01 0
142
22. ANNEXURES
22.1.ANNEXURE I : HEAT AND MASS BALANCE DIAGRAM
22.2.ANNEXURE II : WATER BALANCE DIAGRAM
22.3.ANNEXURE III : FLOW DIAGRAM FOR ASH HANDLING SYSTEM
1
22.4.ANNEXURE IV : FLOW DIAGRAM FOR FUEL HANDLING SYSTEM
PP
PP
PG
PG
PG
TG
TG
PP
PG
TG
PP
TG
BV
BV
PRESSURE RELIEF
VALVE
LEVEL TRANSMITTER
PG
TG
TG
BV
BV
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH
PP C
BV
PNEUMATIC
PLATE VALVE
PSL
PNEUMATIC
PLATE VALVE
A
PNEUMATIC
PLATE VALVE
PSL
ASH COND.
PNEUMATIC
PLATE VALVE
ASH COND.
M
M
FROM TREATED WATER
REF.DRG.PP 067 M XXX 1
TO TRUCK
UNLOADING
TO TRUCK
UNLOADING
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH
PP C
PP
BV
BV
PP
BV
PP
PP C
PP C
PP C
PP C
BV
PP
PP
PP
PP
BYPASS WITH
GATE
(ONLY FOR BED ASH)
PLATE VALVE
BV
EXPANSION JOINT
PP C
BV
PP C
PP
BV
BV
PP C
PP C
PP C
PP C
BV
PP
PP
PP
PP
PP
TO TRUCK
UNLOADING
SERVICE AIR
PG
AIR HEATER
2 Nos (1W+ 1S)
SURGE HOPPER
SURGE HOPPER
WATER JACKET
M
LEGEND :-
PLATE VALVE
PLATE VALVE
EXPANSION JOINT
DOME VALVE
EXPANSION JOINT
DOME VALVE
TOP PLATE
TOP PLATE
TOP PLATE
BV
BV
FROM CONVEYING
AIR COMPRESSOR
DOME VALVE
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH